SEN06284-06

ARTICULATED HM400 -3M0

DUMP TRUCK SERIAL NUMBERS 5001 and up
SHOP MANUAL

ARTICULATED DUMP TRUCK

HM400-3M0
Model Serial Number

HM400-3M0 5001 and up

00 Index and foreword

1 00 Index and foreword

HM400-3M0 00-1
00 Index and foreword
Index

Index (ALL-0310-001-A-00-A)
00 Index and foreword ....................................................................................................................... 00-1
Index ......................................................................................................................................... 00-2
Foreword, safety and general information ................................................................................... 00-16
Important safety notice ....................................................................................................... 00-16
How to read the shop manual.............................................................................................. 00-23
Explanation of terms for maintenance standard .................................................................... 00-25
Handling equipment of fuel system devices .......................................................................... 00-27
Handling of intake system parts........................................................................................... 00-28
Handling of hydraulic equipment.......................................................................................... 00-29
Method of disconnecting and connecting of push-pull type coupler ......................................... 00-31
Handling of electrical equipment.......................................................................................... 00-34
How to read electric wire code............................................................................................. 00-42
Precautions when performing operation ............................................................................... 00-45
Practical use of KOMTRAX ................................................................................................. 00-50
Standard tightening torque table.......................................................................................... 00-51
List of abbreviation ............................................................................................................. 00-57
Conversion table ................................................................................................................ 00-62
01 Specification................................................................................................................................. 01-1
Table of contents ........................................................................................................................ 01-2
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Specifications ...................................................................................................................... 01-5
Weight table ...................................................................................................................... 01-11
Table of fuel, coolant, and lubricants .................................................................................... 01-12
10 Structure and function ................................................................................................................... 10-1
Table of contents ........................................................................................................................ 10-2
Engine and cooling system .......................................................................................................... 10-4
Engine related parts ............................................................................................................. 10-4
Output shaft......................................................................................................................... 10-5
Turbocharger ....................................................................................................................... 10-6
EGR system layout drawing .................................................................................................. 10-8
EGR system circuit diagram .................................................................................................. 10-9
EGR valve......................................................................................................................... 10-11
Bypass valve ..................................................................................................................... 10-13
Venturi system ................................................................................................................... 10-15
EGR cooler........................................................................................................................ 10-17
Muffler............................................................................................................................... 10-19
Cooling system .................................................................................................................. 10-20
Radiator fan pump.............................................................................................................. 10-22
Aftercooler fan motor .......................................................................................................... 10-30
Radiator fan motor ............................................................................................................. 10-41
Oil cooler bypass valve....................................................................................................... 10-50
Power train............................................................................................................................... 10-51
Power train system............................................................................................................. 10-51
Drive shaft ......................................................................................................................... 10-53
Torque converter and transmission hydraulic piping .............................................................. 10-54
Torque converter ................................................................................................................ 10-55
Transmission ..................................................................................................................... 10-61
Transmission control valve.................................................................................................. 10-86
Forward and reverse clutch ECMV and gear speed clutch ECMV ........................................... 10-89
Lockup clutch ECMV .......................................................................................................... 10-96
Differential lock clutch ECMV ............................................................................................ 10-100
Main relief valve, torque converter relief valve, and main flow selector valve.......................... 10-104
Axle ................................................................................................................................ 10-110
Differential ....................................................................................................................... 10-113
Final drive ....................................................................................................................... 10-117
Steering system...................................................................................................................... 10-120

00-2 HM400-3M0
 00 Index and foreword
Index

Layout of steering devices ................................................................................................ 10-120

Steering column............................................................................................................... 10-121
Flow amplifier valve.......................................................................................................... 10-122
Steering valve.................................................................................................................. 10-126
Emergency steering pump ................................................................................................ 10-132
Emergency steering motor ................................................................................................ 10-133
Brake system ......................................................................................................................... 10-134
Layout of brake parts........................................................................................................ 10-134
Parking brake solenoid and accumulator charge valve ........................................................ 10-136
Accumulator .................................................................................................................... 10-142
Shut off solenoid valve...................................................................................................... 10-143
Brake valve ..................................................................................................................... 10-144
Proportional pressure reducing valve ................................................................................. 10-149
Slack adjuster .................................................................................................................. 10-151
Brake .............................................................................................................................. 10-155
Brake system tank ........................................................................................................... 10-158
Parking brake .................................................................................................................. 10-159
Undercarriage and frame......................................................................................................... 10-162
Suspension ..................................................................................................................... 10-162
Suspension cylinder ......................................................................................................... 10-166
Oscillation hitch ............................................................................................................... 10-169
Hydraulic system .................................................................................................................... 10-170
Hydraulic component layout .............................................................................................. 10-170
Dump body control ........................................................................................................... 10-172
Hydraulic tank.................................................................................................................. 10-173
Steering and hoist pump ................................................................................................... 10-174
Hoist valve ...................................................................................................................... 10-185
Steering pump selector solenoid valve ............................................................................... 10-191
Dump EPC valve ............................................................................................................. 10-192
Center brake cooling remote motor .................................................................................... 10-194
Front brake cooling relief valve .......................................................................................... 10-203
Center brake cooling relief valve........................................................................................ 10-204
Cab and its attachments .......................................................................................................... 10-205
ROPS cab ....................................................................................................................... 10-205
Cab tilt ............................................................................................................................ 10-206
Electrical system .................................................................................................................... 10-207
Electrical control system ................................................................................................... 10-207
Machine monitor system ................................................................................................... 10-236
Rear view monitor system................................................................................................. 10-259
KOMTRAX system ........................................................................................................... 10-263
System component parts .................................................................................................. 10-266
Sensor ............................................................................................................................ 10-292
20 Standard value tables.................................................................................................................... 20-1
Table of contents ........................................................................................................................ 20-2
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-5
30 Testing and adjusting .................................................................................................................... 30-1
Table of contents ........................................................................................................................ 30-2
Related information on testing and adjusting ................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-8
Engine and cooling system .......................................................................................................... 30-9
Testing engine speed ........................................................................................................... 30-9
Testing boost pressure ....................................................................................................... 30-10
Testing exhaust gas temperature ......................................................................................... 30-12
Testing exhaust gas color ................................................................................................... 30-14
Adjusting valve clearance ................................................................................................... 30-16
Testing compression pressure............................................................................................. 30-18

HM400-3M0 00-3
00 Index and foreword
Index

Testing blowby pressure ..................................................................................................... 30-20

Testing engine oil pressure ................................................................................................. 30-21
Testing drive pressure of EGR valve and bypass valve .......................................................... 30-23
Testing fuel pressure .......................................................................................................... 30-24
Handling cylinder cutout mode operation.............................................................................. 30-25
Handling no‐injection cranking operation.............................................................................. 30-26
Testing fuel return rate and leakage ..................................................................................... 30-27
Bleeding air from fuel system .............................................................................................. 30-29
Testing fuel circuit for leakage ............................................................................................. 30-31
Testing radiator fan and aftercooler fan speed....................................................................... 30-32
Testing and adjusting alternator belt tension ......................................................................... 30-33
Testing and adjusting air conditioner compressor belt tension ................................................ 30-34
Power train............................................................................................................................... 30-35
Testing torque converter stall speed..................................................................................... 30-35
Testing power train oil pressure ........................................................................................... 30-37
Adjusting transmission speed sensor ................................................................................... 30-48
Adjusting transmission controller ......................................................................................... 30-51
Retrieval of disabled machine that resulted from a trouble in electrical system ......................... 30-52
Retrieval of disabled machine due to traction control system (KTCS) failure ............................ 30-56
Steering system........................................................................................................................ 30-58
Testing and adjusting steering circuit oil pressure.................................................................. 30-58
Brake system ........................................................................................................................... 30-60
Testing and adjusting brake oil pressure............................................................................... 30-60
Testing accumulator nitrogen gas pressure and charging procedure for accumulator nitrogen
gas ...................................................................................................................... 30-64
Testing braking performance ............................................................................................... 30-68
Bleeding air from brake circuit ............................................................................................. 30-69
Testing wear of wheel brake disc ......................................................................................... 30-70
Parking brake emergency releasing procedure ..................................................................... 30-71
Testing wear of parking brake pad and adjusting clearance.................................................... 30-72
Hydraulic system ...................................................................................................................... 30-74
Testing and adjusting suspension cylinder............................................................................ 30-74
Testing and adjusting dump circuit oil pressure ..................................................................... 30-79
Work equipment ....................................................................................................................... 30-82
Adjusting dump body positioner sensor ................................................................................ 30-82
Cab and its attachments ............................................................................................................ 30-83
Cab tilt up procedure .......................................................................................................... 30-83
Electrical system ...................................................................................................................... 30-87
Setting and adjusting each equipment.................................................................................. 30-87
Special functions of machine monitor ................................................................................... 30-98
KOMTRAX terminal start-up procedure .............................................................................. 30-169
Handling voltage circuit of engine controller........................................................................ 30-173
Handling battery disconnect switch .................................................................................... 30-174
Pm clinic ................................................................................................................................ 30-175
Pm Clinic service ............................................................................................................. 30-175
40 Troubleshooting............................................................................................................................ 40-1
Table of contents ........................................................................................................................ 40-2
Related information on troubleshooting....................................................................................... 40-10
Troubleshooting points ....................................................................................................... 40-10
Sequence of events in troubleshooting................................................................................. 40-12
Check before troubleshooting.............................................................................................. 40-14
Inspection procedure before troubleshooting ........................................................................ 40-16
Preparation for troubleshooting of electrical system............................................................... 40-25
Classification and procedures for troubleshooting ................................................................. 40-31
Symptom and troubleshooting numbers ............................................................................... 40-34
Information in troubleshooting table ..................................................................................... 40-36
Procedure for troubleshooting wiring harness of pressure sensor system for open
circuit................................................................................................................... 40-38
Connector list and layout .................................................................................................... 40-40

00-4 HM400-3M0
 00 Index and foreword
Index

Connector contact identification........................................................................................... 40-56

T-branch box and T-branch adapter table ............................................................................. 40-92
Fuse location table ............................................................................................................. 40-97
Precautions on troubleshooting of machine monitor ............................................................ 40-101
Processing procedure of harness checker for troubleshooting of machine monitor LCD
unit .................................................................................................................... 40-103
Failure codes table........................................................................................................... 40-108
Troubleshooting by failure code (Display of code) ...................................................................... 40-121
Failure code [1500L0] Double Engagement of T/M Clutches ................................................ 40-121
Failure code [15B0NX] Transmission Oil Filter Clogging ...................................................... 40-122
Failure code [15F0KM] Abuse 1 of Gear Shifting from R to F................................................ 40-123
Failure code [15F0MB] Abuse 2 of Gear Shifting from R to F................................................ 40-124
Failure code [15F7KM] Abuse of TM Forward Clutch Disk ................................................... 40-125
Failure code [15G0MW] Failure of Clutch (Reverse)............................................................ 40-126
Failure code [15G7KM] Abuse of TM Reverse Clutch Disk................................................... 40-129
Failure code [15H0MW] Failure of Clutch (High) ................................................................. 40-130
Failure code [15J0MW] Failure of Clutch (Low) ................................................................... 40-133
Failure code [15K0MW] Failure of Clutch (1st) .................................................................... 40-136
Failure code [15L0MW] Failure of Clutch (2nd) ................................................................... 40-139
Failure code [15M0MW] Failure of Clutch (3rd) ................................................................... 40-142
Failure code [15SBL1] Release Trouble of ECMV (Reverse)................................................ 40-145
Failure code [15SBMA] Malfunction of ECMV (Reverse)...................................................... 40-148
Failure code [15SCL1] Release Trouble of ECMV (High) ..................................................... 40-149
Failure code [15SCMA] Malfunction of ECMV (High) ........................................................... 40-152
Failure code [15SDL1] Release Trouble of ECMV (Low)...................................................... 40-153
Failure code [15SDMA] Malfunction of ECMV (Low)............................................................ 40-156
Failure code [15SEL1] Release Trouble of ECMV (1st)........................................................ 40-157
Failure code [15SEMA] Malfunction of ECMV (1st).............................................................. 40-160
Failure code [15SFL1] Release Trouble of ECMV (2nd)....................................................... 40-161
Failure code [15SFMA] Malfunction of ECMV (2nd)............................................................. 40-164
Failure code [15SGL1] Release Trouble of ECMV (3rd) ....................................................... 40-165
Failure code [15SGMA] Malfunction of ECMV (3rd) ............................................................. 40-168
Failure code [15SJMA] Malfunction of ECMV (Lockup) ........................................................ 40-169
Failure code [15SKMA] Malfunction of ECMV (Inter-Axle Diff.) ............................................. 40-171
Failure code [2F00KM] Dragging of Parking Brake .............................................................. 40-173
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ............................................. 40-175
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) .............................................. 40-176
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-177
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-178
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-179
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-180
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-181
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-182
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-183
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-184
Failure code [879GKX] Refrigerant Abnormality .................................................................. 40-185
Failure code [989D00] Tilt Caution ..................................................................................... 40-186
Failure code [989L00] Engine Controller Lock Caution1....................................................... 40-187
Failure code [989M00] Engine Controller Lock Caution2...................................................... 40-188
Failure code [989N00] Engine Controller Lock Caution3 ...................................................... 40-189
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-190
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-192
Failure code [AB00KY] Hot Short of Alternator R Terminal ................................................... 40-193
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-194
Failure code [B@BAZK] Engine Oil Level Low.................................................................... 40-195
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-196
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-197
Failure code [B@C6NS] Retarder Oil Overheat (Front)........................................................ 40-199
Failure code [B@C8NS] Retarder Oil Overheat (Center) ..................................................... 40-200

HM400-3M0 00-5
00 Index and foreword
Index

Failure code [B@CENS] T/C Oil Temp. Overheat................................................................ 40-201

Failure code [B@JANS] Steering Oil Overheat ................................................................... 40-202
Failure code [CA111] ECM Critical Internal Failure .............................................................. 40-203
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-204
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-205
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-207
Failure code [CA131] Throttle Sensor High Error................................................................. 40-209
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-211
Failure code [CA135] Eng Oil Press Sensor High Error........................................................ 40-213
Failure code [CA141] Eng Oil Press Sensor Low Error ........................................................ 40-215
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-217
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-219
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-221
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-223
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-225
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-227
Failure code [CA222] Ambient Press Sens Low Error .......................................................... 40-229
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-231
Failure code [CA234] Eng Overspeed ................................................................................ 40-232
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-233
Failure code [CA263] Fuel Temp Sensor High Error ............................................................ 40-234
Failure code [CA265] Fuel Temp Sensor Low Error ............................................................. 40-236
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-238
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-239
Failure code [CA273] PCV2 Short Error ............................................................................. 40-240
Failure code [CA274] PCV2 Open Error ............................................................................. 40-241
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-242
Failure code [CA323] Inj #5(L#5) Open/Short Error ............................................................. 40-244
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................. 40-246
Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................. 40-248
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................. 40-250
Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................. 40-252
Failure code [CA342] Calibration Code Incompatibility......................................................... 40-254
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-255
Failure code [CA352] Sensor 1 Supply Volt Low Error ......................................................... 40-256
Failure code [CA386] Sensor 1 Supply Volt High Error......................................................... 40-258
Failure code [CA431] Idle Validation Sw Error..................................................................... 40-259
Failure code [CA432] Idle Validation Process Error ............................................................. 40-262
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-265
Failure code [CA442] Battery Voltage High Error................................................................. 40-267
Failure code [CA449] Rail Press Very High Error................................................................. 40-268
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-269
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-271
Failure code [CA553] Rail Press High Error ........................................................................ 40-273
Failure code [CA554] Rail Press Sensor In Range Error ...................................................... 40-274
Failure code [CA559] Rail Press Low Error......................................................................... 40-275
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-279
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-281
Failure code [CA757] All Continuous Data Lost Error .......................................................... 40-282
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-283
Failure code [CA1228] EGR valve servo error 1 .................................................................. 40-285
Failure code [CA1625] EGR Valve Servo Error 2................................................................. 40-286
Failure code [CA1626] Bypass Valve Solenoid Current High Error........................................ 40-287
Failure code [CA1627] Bypass Valve Solenoid Current Low Error......................................... 40-289
Failure code [CA1628] Bypass Valve Servo Error 1 ............................................................. 40-291
Failure code [CA1629] Bypass Valve Servo Error 2 ............................................................. 40-292
Failure code [CA1631] BP valve Lift Position Sensor High Error ........................................... 40-293
Failure code [CA1632] BP valve Lift Position Sensor Low Error............................................ 40-295
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-297

00-6 HM400-3M0
 00 Index and foreword
Index

Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-299
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-301
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-302
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-304
Failure code [CA2351] EGR Valve Solenoid Short Error ...................................................... 40-306
Failure code [CA2352] EGR Valve Solenoid Open Error ...................................................... 40-308
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-310
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-312
Failure code [D150KB] Ground Fault of Emerg. Steering Relay ............................................ 40-314
Failure code [D150KZ] Failure of Emerg. Steering Relay ..................................................... 40-315
Failure code [D151KB] Ground Fault of Emerg. Steering Relay 2 ......................................... 40-316
Failure code [D151KZ] Failure of Emerg. Steering Relay 2................................................... 40-317
Failure code [D164KY] Hot Short of Head Light High Selector.............................................. 40-318
Failure code [D19HKZ] Failure of Stop Lamp (R&L) ............................................................ 40-319
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-321
Failure code [D1EHKA] Disconnection of Engine Start Relay ............................................... 40-322
Failure code [D1EHKB] Ground Fault of Engine Start Relay................................................. 40-323
Failure code [D1EHKY] Hot Short of Engine Start Relay ...................................................... 40-324
Failure code [D1EMKA] Disconnection of Parking Interlock Relay ........................................ 40-325
Failure code [D1EMKB] Ground Fault of Parking Interlock Relay .......................................... 40-326
Failure code [D1EMKY] Hot Short of Parking Interlock Relay ............................................... 40-327
Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay........................................... 40-328
Failure code [D5ZHL6] Disconnection of Key SW C ............................................................ 40-329
Failure code [D811MC] KOMTRAX Error............................................................................ 40-331
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-332
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...................................... 40-333
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-335
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 .......................................................... 40-337
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-338
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ..................................... 40-339
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-340
Failure code [DAF0MC] Monitor Error ................................................................................ 40-341
Failure code [DAF3KK] Controller Power Source Low (MON)............................................... 40-342
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-344
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit .......................................... 40-345
Failure code [DAFGMC] GPS Module Error........................................................................ 40-347
Failure code [DAFLKA] Operating Lamp Open Circuit (MON)............................................... 40-348
Failure code [DAFLKB] Operating Lamp Short Circuit (MON)............................................... 40-350
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-352
Failure code [DAQ0KK] Controller Power Source Low (T/M) ................................................ 40-353
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ....................................... 40-355
Failure code [DAQ0MC] T/M Con Error .............................................................................. 40-356
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) .............................................. 40-357
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ................................................. 40-359
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) .......................................... 40-361
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) ................................................ 40-362
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) ................................................ 40-364
Failure code [DAQQKR] CAN2 Discon (Transmission Con) ................................................. 40-366
Failure code [DAQRKR] CAN1 Discon (Transmission Con) ................................................. 40-367
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ......................................... 40-371
Failure code [DAQV00] Neutral Coast Caution ................................................................... 40-372
Failure code [DAQW00] Neutral Over Speed Caution.......................................................... 40-373
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-374
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-375
Failure code [DB10KT] Abnormality of Non-volatile Memory (RHC) ...................................... 40-376
Failure code [DB10MC] RHC Error .................................................................................... 40-377
Failure code [DB11KA] Disconnection of Key SW ACC (RHC) ............................................. 40-378
Failure code [DB12KK] Solenoid Power Source Low (RHC)................................................. 40-380
Failure code [DB13KK] Controller Power Source Low (RHC) ............................................... 40-382

HM400-3M0 00-7
00 Index and foreword
Index

Failure code [DB19KQ] Inconsistency of Model Selection (RHC).......................................... 40-384

Failure code [DB1LKA] Disconnection of System Ope. Lamp (RHC)..................................... 40-385
Failure code [DB1LKB] Short Circuit of System Ope. Lamp (RHC) ....................................... 40-387
Failure code [DB1QKR] CAN2 Discon (Retarder Hoist Con) ................................................ 40-389
Failure code [DB1QMA] Inconsistency of Option Selection (RHC) ........................................ 40-390
Failure code [DB1RKR] CAN1 Discon (Retarder Hoist Con)................................................. 40-391
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-392
Failure code [DBSQKR] CAN2 Discon (PLM) ..................................................................... 40-397
Failure code [DBSQKQ] Inconsistency of Model Selection (PLM) ......................................... 40-401
Failure code [DD1ML4] Failure of ARAC SW ...................................................................... 40-402
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ................................ 40-404
Failure code [DDTHKA] Disconnection of Fill Switch (High) ................................................. 40-406
Failure code [DDTJKA] Disconnection of Fill Switch (Low) ................................................... 40-408
Failure code [DDTKKA] Disconnection of Fill Switch (1st) .................................................... 40-410
Failure code [DDTLKA] Disconnection of Fill Switch (2nd) ................................................... 40-412
Failure code [DDTMKA] Disconnection of Fill Switch (3rd) ................................................... 40-414
Failure code [DDTNKA] Disconnection of Fill Switch (Reverse) ............................................ 40-416
Failure code [DF10KA] Disconnection of Shift Lever Input ................................................... 40-418
Failure code [DF10KB] Ground Fault of Shift Lever Input ..................................................... 40-421
Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor ............................................ 40-425
Failure code [DGR3KB] Ground Fault of Retarder Oil Temp. S.(C)........................................ 40-427
Failure code [DGR3L8] Failure of Retarder Oil Temp. Sensor (C) ......................................... 40-428
Failure code [DGR4KB] Ground Fault of Retarder Oil Temp. S.(F) ........................................ 40-429
Failure code [DGR4L8] Failure of Retarder Oil Temp. Sensor (F).......................................... 40-430
Failure code [DGR6KB] Ground Fault of Steering Oil Temp. S.............................................. 40-432
Failure code [DGR6L8] Failure of Steering Oil Temp. Sensor ............................................... 40-433
Failure code [DGR7KX] Out of Range of Piston Pump Oil Temp. S. ...................................... 40-435
Failure code [DGR8KX] Out of Range of CAC Output Temp. S............................................. 40-437
Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor ............................................ 40-439
Failure code [DHP4KY] Hot Short of Suspension Press. S. (FR) .......................................... 40-441
Failure code [DHP4KZ] Failure of Suspension Press. S. (FR) .............................................. 40-443
Failure code [DHP5KY] Hot Short of Suspension Press. S. (FL) ........................................... 40-445
Failure code [DHP5KZ] Failure of Suspension Press. S. (FL) ............................................... 40-447
Failure code [DHP6KY] Hot Short of Suspension Press. S. (RR) .......................................... 40-449
Failure code [DHP6KZ] Failure of Suspension Press. S. (RR) .............................................. 40-451
Failure code [DHP7KY] Hot Short of Suspension Press. S. (RL)........................................... 40-453
Failure code [DHP7KZ] Failure of Suspension Press. S. (RL)............................................... 40-455
Failure code [DHQ2KX] Out of Range of Main Flow Sel. Valve S. ......................................... 40-457
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor ..................................... 40-459
Failure code [DHT5L6] Failure of T/C Oil Press Sensor ....................................................... 40-461
Failure code [DHT8KX] Out of Range of Steering Oil Press. S.............................................. 40-463
Failure code [DHT8ZG] Steering Oil Pressure Low.............................................................. 40-465
Failure code [DHU2KX] Out of Range of Acc. Oil Press. S. (F) ............................................. 40-466
Failure code [DHU3KX] Out of Range of Acc. Oil Press. S. (R)............................................. 40-468
Failure code [DHUAKX] Out of Range of Retarder Press. S. (CR) ........................................ 40-470
Failure code [DHUBKX] Out of Range of Retarder Press. S. (FR)......................................... 40-472
Failure code [DHUCKX] Out of Range of Parking Brake Press. S. ........................................ 40-474
Failure code [DHUDKX] Out of Range of Emerg. Steering Press. S.1 ................................... 40-476
Failure code [DHUEKX] Out of Range of Emerg. Steering Press. S.2 ................................... 40-478
Failure code [DHUQKX] Out of Range of Retarder Press. S. (FL) ......................................... 40-480
Failure code [DHURKX] Out of Range of Retarder Press. S. (CL)......................................... 40-482
Failure code [DJF1KA] Disconnection of Fuel Level Sensor ................................................. 40-484
Failure code [DK30KX] Out of Range of Steering Angle Pot. ................................................ 40-486
Failure code [DK51L5] Failure of Retarder Lever Pot. and RVS............................................ 40-488
Failure code [DK52KX] Out of Range of Hoist Lever Potentio............................................... 40-491
Failure code [DK53L8] Failure of Hoist Lever Potentio. ........................................................ 40-493
Failure code [DK54KX] Out of Range of Body Potentio. ....................................................... 40-494
Failure code [DK60KX] Out of Range of Acceleration Sensor............................................... 40-496
Failure code [DKH0KX] Out of Range of Inclination Angle Sensor ........................................ 40-498

00-8 HM400-3M0
 00 Index and foreword
Index

Failure code [DKH1KX] Out of Range of Long. Inclination Angle S. ...................................... 40-500
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor........................................ 40-502
Failure code [DLF1LC] Failure of T/M Input Speed Sensor................................................... 40-504
Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor........................................ 40-506
Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor........................................ 40-508
Failure code [DLF400] T/M Diff. Overrun Prevention Activated ............................................. 40-510
Failure code [DLF4KA] Disconnection of T/M Diff. Speed Sensor ......................................... 40-511
Failure code [DLF4LC] Failure of T/M Diff. Speed Sensor .................................................... 40-513
Failure code [DLF6LC] Failure of Wheel Speed Sensor (FR)................................................ 40-515
Failure code [DLF7LC] Failure of Wheel Speed Sensor (FL) ................................................ 40-517
Failure code [DLFDLC] Failure of Wheel Speed Sensor (CR)............................................... 40-519
Failure code [DLFELC] Failure of Wheel Speed Sensor (CL) ............................................... 40-521
Failure code [DLFFLC] Failure of Wheel Speed Sensor (Front) ............................................ 40-523
Failure code [DLFGLC] Failure of Wheel Speed Sensor (Center) ......................................... 40-524
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor.................................. 40-525
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor............................................. 40-527
Failure code [DLM3MB] Radiator Fan Control Mismatch...................................................... 40-529
Failure code [DLM4KA] Disconnection of CAC Fan Speed Sensor ....................................... 40-530
Failure code [DLM4LC] Failure of CAC Fan Speed Sensor .................................................. 40-532
Failure code [DLM4MB] CAC Fan Control Mismatch ........................................................... 40-534
Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main).................................... 40-535
Failure code [DLT3LC] Failure of Output Speed Sensor (Main)............................................. 40-537
Failure code [DPQ1KR] LIN Discon (Switch Panel) ............................................................. 40-539
Failure code [DPQ2KR] LIN Discon (LED Unit) ................................................................... 40-542
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ..................................................... 40-545
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) .............................................................. 40-548
Failure code [DV00KB] Ground Fault of Buzzer Output........................................................ 40-549
Failure code [DW2BKA] Disconnection of Main Flow Selector Sol. ....................................... 40-551
Failure code [DW2BKB] Ground Fault of Main Flow Selector Sol. ......................................... 40-552
Failure code [DW2BKY] Hot Short of Main Flow Selector Sol. .............................................. 40-553
Failure code [DW2BL1] Release Trouble of Main Flow Sel. Valve......................................... 40-554
Failure code [DW2BLH] Malfunction of Main Flow Selector Valve ......................................... 40-555
Failure code [DW4BK4] Release Trouble of Parking Brake Valve ......................................... 40-556
Failure code [DW4BMA] Malfunction of Parking Brake Valve ............................................... 40-558
Failure code [DW72KZ] Failure of Kick out Solenoid............................................................ 40-559
Failure code [DW73KA] Disconnection of Hoist Selector Sol. ............................................... 40-561
Failure code [DW73KB] Ground Fault of Hoist Selector Sol.................................................. 40-563
Failure code [DW73KY] Hot Short of Hoist Selector Sol. ...................................................... 40-565
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. .......................................... 40-567
Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol................................................. 40-569
Failure code [DW7BKZ] Failure of Radiator Fan Rev. Sol..................................................... 40-570
Failure code [DW7LKB] Ground Fault of CAC Fan Rev. Sol. ................................................ 40-572
Failure code [DW7LKY] Hot Short of CAC Fan Rev. Sol....................................................... 40-573
Failure code [DW7LKZ] Failure of CAC Fan Rev. Sol........................................................... 40-574
Failure code [DW7NKZ] Failure of Steering Pump Selector Sol. ........................................... 40-575
Failure code [DWNJKZ] Failure of TCS Shut off Sol. (Front)................................................. 40-577
Failure code [DWNKKZ] Failure of TCS Shut off Sol. (Center) .............................................. 40-579
Failure code [DX13KA] Disconnection of Hoist EPC Solenoid .............................................. 40-581
Failure code [DX13KB] Ground Fault of Hoist EPC Solenoid................................................ 40-583
Failure code [DX13KY] Hot Short of Hoist EPC Solenoid ..................................................... 40-585
Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol....................................... 40-587
Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. ....................................... 40-588
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ....................................... 40-590
Failure code [DX29KA] Disconnection of CAC Fan Pump EPC Sol....................................... 40-591
Failure code [DX29KB] Ground Fault of CAC Fan Pump EPC Sol. ....................................... 40-592
Failure code [DX29KY] Hot Short of CAC Fan Pump EPC Sol.............................................. 40-593
Failure code [DX30K4] Release Trouble of Retarder EPC Valve(FL)..................................... 40-594
Failure code [DX30KA] Disconnection of Retarder EPC Sol. (FL) ......................................... 40-596
Failure code [DX30KB] Ground Fault of Retarder EPC Sol. (FL)........................................... 40-598

HM400-3M0 00-9
00 Index and foreword
Index

Failure code [DX30KY] Hot Short of Retarder EPC Sol. (FL) ................................................ 40-600
Failure code [DX30MA] Malfunction of Retarder EPC Valve (FL) .......................................... 40-602
Failure code [DX31K4] Release Trouble of Retarder EPC Valve(CR).................................... 40-604
Failure code [DX31KA] Disconnection of Retarder EPC Sol. (CR) ........................................ 40-606
Failure code [DX31KB] Ground Fault of Retarder EPC Sol. (CR).......................................... 40-608
Failure code [DX31KY] Hot Short of Retarder EPC Sol. (CR) ............................................... 40-610
Failure code [DX31MA] Malfunction of Retarder Valve (CR) ................................................. 40-612
Failure code [DX32K4] Release Trouble of Retarder EPC Valve(CL) .................................... 40-614
Failure code [DX32KA] Disconnection of Retarder EPC Sol. (CL)......................................... 40-616
Failure code [DX32KB] Ground Fault of Retarder EPC Sol. (CL) .......................................... 40-618
Failure code [DX32KY] Hot Short of Retarder EPC Sol. (CL)................................................ 40-620
Failure code [DX32MA] Malfunction of Retarder EPC Valve (CL).......................................... 40-622
Failure code [DX33K4] Release Trouble of Retarder EPC Valve (FR) ................................... 40-624
Failure code [DX33KA] Disconnection of Retarder EPC Sol. (FR)......................................... 40-626
Failure code [DX33KB] Ground Fault of Retarder EPC Sol. (FR) .......................................... 40-628
Failure code [DX33KY] Hot Short of Retarder EPC Sol. (FR) ............................................... 40-630
Failure code [DX33MA] Malfunction of Retarder EPC Valve (FR).......................................... 40-632
Failure code [DX34KA] Disconnection of Remote Cooling EPC Sol. ..................................... 40-634
Failure code [DX34KB] Ground Fault of Remote Cooling EPC Sol........................................ 40-635
Failure code [DX34KY] Hot Short of Remote Cooling EPC Sol. ............................................ 40-637
Failure code [DXH0KA] Disconnection of ECMV (Inter-Axle Diff.) ......................................... 40-638
Failure code [DXH0KB] Ground Fault of ECMV (Inter-Axle Diff.)........................................... 40-640
Failure code [DXH0KY] Hot Short of ECMV (Inter-Axle Diff.) ................................................ 40-642
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ..................................... 40-644
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) ....................................... 40-646
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) ............................................ 40-648
Failure code [DXH2KA] Disconnection of ECMV Solenoid (High) ......................................... 40-650
Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High) ........................................... 40-652
Failure code [DXH2KY] Hot Short of ECMV Solenoid (High) ................................................ 40-654
Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low) .......................................... 40-655
Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low)............................................ 40-657
Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low) ................................................. 40-659
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)............................................ 40-662
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) ............................................. 40-664
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st)................................................... 40-666
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)........................................... 40-669
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) ............................................ 40-671
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd).................................................. 40-673
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ........................................... 40-676
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) ............................................. 40-678
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) .................................................. 40-680
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse).................................... 40-683
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ..................................... 40-685
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)........................................... 40-687
Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor........................................... 40-690
Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor .......................................... 40-693
Failure code [DY30ME] Emerg. Steering Long-Time Activated ............................................. 40-696
Failure code [DY32MC] Malfunction 2 of Emerg. Steering Motor 2........................................ 40-698
Troubleshooting of electrical system (E-mode) .......................................................................... 40-701
E-1 Engine does not start (Engine does not crank) .............................................................. 40-701
E-2 Manual preheating system does not work..................................................................... 40-706
E-3 Automatic preheating system does not work................................................................. 40-709
E-4 While preheating is working, preheating monitor does not light up .................................. 40-711
E-5 All of LCD unit, LED unit and meter unit on machine monitor display nothing ................... 40-713
E-6 LCD unit on machine monitor displays nothing.............................................................. 40-716
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or
flickers) .............................................................................................................. 40-718
E-8 LCD on machine monitor does not display properly ....................................................... 40-720
E-9 Meter unit display on machine monitor is abnormal ....................................................... 40-722

00-10 HM400-3M0
 00 Index and foreword
Index

E-10 Night lighting lamp of meter unit on machine monitor is abnormal ................................. 40-725
E-11 LED unit lamp on machine monitor is abnormal ........................................................... 40-728
E-12 Night lighting lamp of switch panel on machine monitor is abnormal or switches does not
operate properly ................................................................................................. 40-730
E-13 2 switches operation of switch panel on machine monitor does not function................... 40-732
E-14 Switch panel buzzer of machine monitor is abnormal................................................... 40-734
E-15 Rear view monitor does not light up or backlight flickers............................................... 40-736
E-16 Rear view monitor images are not displayed clearly..................................................... 40-738
E-17 Rear view monitor brightness cannot be adjusted........................................................ 40-741
E-18 Night lighting lamp of rear view monitor is abnormal .................................................... 40-744
E-19 Rearview monitor does not display images while reverse linked display function is
enabled ............................................................................................................. 40-746
E-20 Guide line on rear view monitor is not displayed while guide line is set .......................... 40-749
E-21 Some items of gauges and caution lamps on machine monitor are not displayed
properly ............................................................................................................. 40-751
E-22 Fuel level gauge does not indicate correct level .......................................................... 40-752
E-23 Seat belt caution lamp indication is abnormal.............................................................. 40-754
E-24 Machine monitor cannot be operated when starting switch is in OFF position ................ 40-755
E-25 Alarm buzzer does not sound .................................................................................... 40-756
E-26 Alarm buzzer does not stop sounding......................................................................... 40-758
E-27 Engine mode selector function does not operate properly ............................................ 40-760
E-28 AISS function does not operate properly..................................................................... 40-761
E-29 Hoist lever does not operate properly ......................................................................... 40-762
E-30 Turn signal lamp and winker lamp (hazard lamp) do not operate properly ...................... 40-764
E-31 None of headlamp, clearance lamp, and tail lamp lights ............................................... 40-768
E-32 Clearance lamp does not light up............................................................................... 40-770
E-33 Tail lamp does not light up ......................................................................................... 40-772
E-34 Low beam of headlamp does not light up.................................................................... 40-774
E-35 High beam of headlamp does not light up ................................................................... 40-776
E-36 Neither Low beam nor High beam of headlamp lights up.............................................. 40-778
E-37 High beams do not light up while passing switch is operated ........................................ 40-780
E-38 KOMTRAX does not operate properly ........................................................................ 40-782
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-783
Information described in troubleshooting table (H-mode) ..................................................... 40-783
System chart of hydraulic and mechanical systems............................................................. 40-784
Failure mode and cause table ........................................................................................... 40-786
H-1 Machine does not start ............................................................................................... 40-790
H-2 Machine does not travel smoothly (engine hunts).......................................................... 40-792
H-3 Lockup clutch is not disengaged.................................................................................. 40-793
H-4 Abnormally large shocks result from starting of machine and gear shifting ...................... 40-794
H-5 Machine does not upshift ............................................................................................ 40-795
H-6 Machine lacks travel speed or power during travel in lockup drive mode through all gear
speeds............................................................................................................... 40-797
H-7 Machine lacks travel speed or power during travel in torque converter drive
mode ................................................................................................................. 40-798
H-8 Machine lacks travel speed or power during travel in specific gear speed........................ 40-799
H-9 Machine starts or gear speed shifts with long time lag ................................................... 40-800
H-10 Torque converter oil temperature is high..................................................................... 40-802
H-11 Torque converter oil pressure is low ........................................................................... 40-803
H-12 Front brake does not work sufficiently ........................................................................ 40-804
H-13 Center brake does not work sufficiently ...................................................................... 40-805
H-14 Steering wheel is heavy to turn.................................................................................. 40-806
H-15 Steering wheel does not move .................................................................................. 40-807
H-16 Steering wheel swings.............................................................................................. 40-808
H-17 Dump body raise speed or power is slow.................................................................... 40-809
H-18 Dump body does not move ....................................................................................... 40-811
H-19 Hydraulic drift of dump body is large .......................................................................... 40-812
H-20 Radiator fan speed is abnormal (high, low, or stationary) ............................................. 40-813
H-21 Aftercooler fan speed is abnormal (high, low, or stationary) .......................................... 40-814

HM400-3M0 00-11
00 Index and foreword
Index

H-22 Unusual noise is heard from around radiator fan ......................................................... 40-815
H-23 Unusual noise is heard from around aftercooler fan..................................................... 40-816
Troubleshooting of engine (S-mode)......................................................................................... 40-817
Information mentioned in troubleshooting table (S mode)..................................................... 40-817
S-1 When starting switch is turned to START position, engine is not cranked......................... 40-818
S-2 The engine cranks but exhaust smoke does not come out ............................................. 40-819
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start
but does not) ...................................................................................................... 40-820
S-4 Engine startability is poor ............................................................................................ 40-821
S-5 Engine does not pick up smoothly ............................................................................... 40-823
S-6 Engine stops during operation ..................................................................................... 40-825
S-7 Engine runs rough or is unstable ................................................................................. 40-827
S-8 Engine lacks power .................................................................................................... 40-828
S-9 Exhaust smoke is black .............................................................................................. 40-830
S-10 Engine oil consumption is excessive .......................................................................... 40-832
S-11 Oil becomes contaminated quickly ............................................................................. 40-833
S-12 Fuel consumption is excessive .................................................................................. 40-834
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-835
S-14 Oil pressure drops .................................................................................................... 40-836
S-15 Fuel mixes into engine oil.......................................................................................... 40-837
S-16 Water mixes into engine oil (milky) ............................................................................. 40-838
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-839
S-18 Unusual noise is heard ............................................................................................. 40-840
S-19 Vibration is excessive ............................................................................................... 40-841
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-842
50 Disassembly and assembly ........................................................................................................... 50-1
Table of contents ........................................................................................................................ 50-2
Related information on disassembly and assembly ........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-19
Engine and cooling system ........................................................................................................ 50-37
Removal and installation of supply pump assembly............................................................... 50-37
Removal and installation of injector assembly....................................................................... 50-41
Removal and installation of cylinder head assembly.............................................................. 50-48
Removal and installation of radiator assembly ...................................................................... 50-60
Removal and installation of radiator core assembly ............................................................... 50-65
Removal and installation of cooling fan and fan motor assembly for radiator............................ 50-67
Removal and installation of aftercooler assembly .................................................................. 50-69
Removal and installation of cooling fan and fan motor assembly for aftercooler ....................... 50-73
Removal and installation of engine assembly ....................................................................... 50-75
Removal and installation of engine front oil seal .................................................................... 50-84
Removal and installation of engine rear oil seal..................................................................... 50-88
Removal and installation of output shaft assembly ................................................................ 50-94
Disassembly and assembly of output shaft assembly ............................................................ 50-99
Removal and installation of air cleaner assembly ................................................................ 50-102
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly...................... 50-104
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly..................... 50-106
Removal and installation of fire prevention cover on exhaust pipe ........................................ 50-109
Power train............................................................................................................................. 50-113
Removal and installation of transmission and front differential assembly ............................... 50-113
Disconnection and connection of front differential assembly and transmission
assembly ........................................................................................................... 50-125
Disassembly and assembly of front differential assembly..................................................... 50-127
Disassembly and assembly of torque converter assembly ................................................... 50-142
Disassembly and assembly of transmission assembly......................................................... 50-149
Removal and installation of center differential assembly ...................................................... 50-189
Disassembly and assembly of center differential assembly .................................................. 50-193

00-12 HM400-3M0
 00 Index and foreword
Index

Removal and installation of rear differential assembly.......................................................... 50-207

Disassembly and assembly of rear differential assembly ..................................................... 50-209
Removal and installation of front final drive and brake assembly........................................... 50-219
Disassembly and assembly of front final drive and brake assembly ...................................... 50-221
Removal and installation of center final drive and brake assembly ........................................ 50-233
Disassembly and assembly of center final drive and brake assembly.................................... 50-235
Removal and installation of rear final drive assembly........................................................... 50-245
Disassembly and assembly of rear final drive assembly....................................................... 50-246
Removal and installation of center axle assembly ............................................................... 50-251
Removal and installation of rear axle assembly................................................................... 50-255
Steering system...................................................................................................................... 50-258
Disassembly and assembly of steering cylinder assembly ................................................... 50-258
Undercarriage and frame......................................................................................................... 50-264
Removal and installation of front suspension cylinder assembly ........................................... 50-264
Removal and installation of rear suspension cylinder assembly............................................ 50-266
Disassembly and assembly of suspension cylinder assembly .............................................. 50-268
Removal and installation of equalizer bar assembly ............................................................ 50-270
Removal and installation of front wheel assembly ............................................................... 50-272
Removal and installation of rear (front side) wheel assembly................................................ 50-276
Removal and installation of rear (back side) wheel assembly ............................................... 50-277
Removal and installation of hitch frame assembly ............................................................... 50-278
Disassembly and assembly of hitch frame assembly ........................................................... 50-285
Hydraulic system .................................................................................................................... 50-290
Removal and installation of flow amplifier valve assembly.................................................... 50-290
Removal and installation of hoist valve assembly ................................................................ 50-293
Disassembly and assembly of hoist valve assembly............................................................ 50-297
Disassembly and assembly of hoist cylinder assembly ........................................................ 50-301
Body...................................................................................................................................... 50-307
Removal and installation of dump body assembly ............................................................... 50-307
Cab and its attachments .......................................................................................................... 50-310
Removal and installation of operator's cab assembly........................................................... 50-310
Removal and installation of operator's cab glass (adhered glass) ......................................... 50-315
Removal and installation of operator's seat assembly.......................................................... 50-321
Removal and installation of seat belt .................................................................................. 50-323
Electrical system .................................................................................................................... 50-324
Removal and installation of machine monitor assembly ....................................................... 50-324
Removal and installation of engine controller assembly ....................................................... 50-326
Removal and installation of retarder and hoist controller assembly ....................................... 50-328
Removal and installation of transmission controller assembly .............................................. 50-329
Removal and installation of KOMTRAX terminal assembly .................................................. 50-330
Air conditioner unit .................................................................................................................. 50-331
Removal and installation of air conditioner unit assembly..................................................... 50-331
Removal and installation of air conditioner compressor assembly......................................... 50-336
Removal and installation of air conditioner condenser ......................................................... 50-338
60 Maintenance standard................................................................................................................... 60-1
Table of contents ........................................................................................................................ 60-2
Engine and cooling system .......................................................................................................... 60-3
Engine mount ...................................................................................................................... 60-3
Output shaft......................................................................................................................... 60-4
Radiator fan pump................................................................................................................ 60-5
Radiator fan motor ............................................................................................................... 60-7
Aftercooler fan motor ............................................................................................................ 60-8
Power train............................................................................................................................... 60-10
Drive shaft ......................................................................................................................... 60-10
Torque converter and transmission mount ............................................................................ 60-12
Torque converter ................................................................................................................ 60-13
Transmission ..................................................................................................................... 60-16
Transmission control valve.................................................................................................. 60-24
Forward and reverse clutch ECMV and gear speed clutch ECMV ........................................... 60-25

HM400-3M0 00-13
00 Index and foreword
Index

Lockup clutch ECMV .......................................................................................................... 60-26

Differential lock clutch ECMV .............................................................................................. 60-27
Main relief valve, torque converter relief valve, and main flow selector valve............................ 60-28
Differential ......................................................................................................................... 60-30
Axle .................................................................................................................................. 60-33
Final drive ......................................................................................................................... 60-35
Steering system........................................................................................................................ 60-40
Steering column................................................................................................................. 60-40
Steering cylinder ................................................................................................................ 60-41
Emergency steering pump .................................................................................................. 60-42
Brake system ........................................................................................................................... 60-43
Slack adjuster .................................................................................................................... 60-43
Brake ................................................................................................................................ 60-45
Parking brake .................................................................................................................... 60-48
Undercarriage and frame........................................................................................................... 60-50
Suspension ....................................................................................................................... 60-50
Suspension cylinder ........................................................................................................... 60-54
Oscillation hitch ................................................................................................................. 60-56
Hydraulic system ...................................................................................................................... 60-58
Steering and hoist pump ..................................................................................................... 60-58
Pump for driving torque converter, transmission, aftercooler fan, and center brake cooling
motors ................................................................................................................. 60-61
Center brake cooling pump ................................................................................................. 60-63
Brake charge pump ............................................................................................................ 60-64
Center brake cooling remote pump ...................................................................................... 60-65
Center brake cooling remote motor ...................................................................................... 60-66
Hoist valve ........................................................................................................................ 60-68
Hoist cylinder..................................................................................................................... 60-70
80 Appendix...................................................................................................................................... 80-1
Table of contents ........................................................................................................................ 80-2
Air conditioner components ......................................................................................................... 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-7
Outline of refrigeration cycle.................................................................................................. 80-8
Air conditioner unit ............................................................................................................. 80-10
Dual pressure switch .......................................................................................................... 80-15
Air conditioner controller ..................................................................................................... 80-16
Compressor....................................................................................................................... 80-17
Condenser ........................................................................................................................ 80-18
Receiver drier .................................................................................................................... 80-19
Outer temperature sensor (outside air temperature sensor) ................................................... 80-20
Procedure for testing and troubleshooting ............................................................................ 80-21
Circuit diagram and arrangement of connector pins............................................................... 80-23
System diagram................................................................................................................. 80-25
Input and output signals of the air conditioner controller ......................................................... 80-26
Parts and connectors layout................................................................................................ 80-28
Testing air leakage (duct) .................................................................................................... 80-33
Testing with self-diagnosis function ...................................................................................... 80-36
How to open the electrical system abnormality record screen in service mode of the machine
monitor ................................................................................................................ 80-37
Testing vent (mode) changeover.......................................................................................... 80-39
Testing FRESH/RECIRC air changeover.............................................................................. 80-40
Testing (dual) pressure switch for refrigerant......................................................................... 80-41
Testing relays .................................................................................................................... 80-43
Troubleshooting chart 1 ...................................................................................................... 80-45
Troubleshooting chart 2 ...................................................................................................... 80-46
Information in troubleshooting table ..................................................................................... 80-49
Failure code list related to air conditioner.............................................................................. 80-50

00-14 HM400-3M0
 00 Index and foreword
Index

Failure code [879AKA] A/C Inner sensor Open Circuit ........................................................... 80-51
Failure code [879AKB] A/C Inner sensor Short Circuit ........................................................... 80-52
Failure code [879BKA] A/C Outer sensor Open Circuit .......................................................... 80-53
Failure code [879BKB] A/C Outer sensor Short Circuit .......................................................... 80-55
Failure code [879CKA] Ventilating sensor Open Circuit ......................................................... 80-57
Failure code [879CKB] Ventilating sensor Short Circuit.......................................................... 80-58
Failure code [879EMC] Ventilating Damper Abnormality ........................................................ 80-59
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-60
Failure code [879GKX] Refrigerant Abnormality .................................................................... 80-61
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-63
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-65
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-68
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-70
Troubleshooting with gauge pressure................................................................................... 80-72
Connection of service tool................................................................................................... 80-75
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-77
Handling of compressor oil.................................................................................................. 80-79
90 Diagrams and drawings................................................................................................................. 90-1
Table of contents ........................................................................................................................ 90-2
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Power train hydraulic circuit diagram...................................................................................... 90-7
Hydraulic circuit diagram....................................................................................................... 90-9
Electric circuit diagram .............................................................................................................. 90-13
Symbols in electric circuit diagram ....................................................................................... 90-13
Inside cab electrical circuit diagram ..................................................................................... 90-17
Outside cab electrical circuit diagram ................................................................................... 90-33
Electrical circuit diagram of engine....................................................................................... 90-57
Index.................................................................................................................................................................... 1

HM400-3M0 00-15
00 Index and foreword
Foreword, safety and general information
Foreword, safety and general information
Important safety notice (ALL-1120-012-A-01-A)
• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
• The symbol mark k is used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.
Safety points
• Good arrangement
• Correct work clothes
• Observance of work standard
• Practice of making and checking signals
• Prohibition of operation and handling by
unlicensed workers
• Safety check before starting work
• Wearing protective goggles (for cleaning or
grinding work)
• Wearing shielding goggles and protectors (for
welding work)
• Good physical condition and preparation
• Precautions against work which you are not
used to or you are used to too much
General precautions
k Inappropriate handling causes an extreme
danger. Read and understand what is
described in the operation and maintenance
manual before operating the machine. Read
and understand what is described in this
manual before starting the work.
• Before performing any greasing or repairs, read
all the safety labels stuck to the machine. For
the locations of the safety labels and detailed
explanation of precautions, see the operation
and maintenance manual.
• Locate a place in the repair workshop to keep
the tools and removed parts. Always keep the
tools and parts in their correct places. Always
keep the work area clean and make sure that
there is no dirt, water or oil on the floor. Smoke
only in the areas provided for smoking. Never
smoke while working.
• When performing any work, always wear the
safety shoes and helmet. Do not wear loose
work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when
hitting parts with a hammer.
2. Always wear the protective eyeglasses when
grinding parts with a grinder, etc.
• When performing any work with 2 or more
workers, always agree on the working procedure
00-16
(ALL-0370-001-A-00-A)
(Rev. 2014/08)
before starting. While working, always keep
conversations of the work between your fellow
workers and your self on any step of the work.
During the work, hang the warning tag of
"UNDER WORKING" in the operator's
compartment.
• Only qualified workers must perform the work
and operation which require license or
qualification.
• Keep the tools in good condition. And learn the
correct way to use the tools, and use the proper
ones among them. Before starting the work,
thoroughly check the tools, lift truck, service
vehicle, etc.
• If welding repairs is required, always have a
trained and experienced welder with good
knowledge of welding perform the work. When
performing welding work, always wear welding
gloves, apron, shielding goggles, cap, etc.
• Before starting work, warm up your body
thoroughly to start work under good condition.
• Avoid continuing work for long hours and take
rests with proper intervals to keep your body in
good condition. Take a rest in a specified safe
place.
Preparation
• Before adding oil or making any repairs, place
the machine on a firm and level ground, and
apply the parking brake and chock the wheels or
tracks to prevent the machine from moving.
• Before starting work, lower the work equipment
(blade, ripper, bucket, etc.) to the ground. If it is
not possible to lower the equipment to the
ground, insert the lock pin or use blocks to
prevent the work equipment from falling. And be
sure to lock all the work equipment control levers
and hang a warning tag on them.
• When performing the disassembling or
assembling work, support the machine securely
with blocks, jacks, or stands before starting the
work.
• Remove all of mud and oil from the steps or
other places used to get on and off the machine
completely. Always use the handrails, ladders of
steps when getting on or off the machine. Never
HM400-3M0

jump on or off the machine. When the scaffold is
not provided, use steps or stepladder to secure
your footing.
Precautions during work
• For the machine equipped with the battery
disconnect switch, check that the system
operating lamp is turned off before starting the
work. Then, turn the battery disconnect switch to
OFF (Q) position and remove the switch key. For
the machine not equipped with the battery
disconnect switch, remove the cable from the
battery before starting the work. Be sure to
remove the negative end (-) of the battery cable
first.
• Release the remaining pressure in the circuits
completely before the work when the parts in the
circuits of oil, fuel, coolant and air are
disconnected or removed. When the cap of the
oil filter, drain plug or oil pressure pickup plug is
removed, loose them slowly to prevent the oil
from spurting out.
• When removing or installing the checking plug or
the piping in the fuel circuit, wait 30 seconds or
longer after the engine is shut down and start
the work after the remaining pressure is
released from the fuel circuit.
• Immediately after the engine is shut down, the
coolant and oil in the circuits are hot. Be careful
not to get scalded by the hot coolant and oil.
Start the work after checking that the coolant
and oil are cooled down sufficiently.
• Start the work after the engine is shut down. Be
sure to shut down the engine when working on
or around the rotating parts in particular. When
checking the machine without shutting down the
engine (measuring oil pressure, rotational speed,
oil or coolant temperature), take extreme care
not to get caught in the rotating parts or the
working equipment.
• The hoist or crane must be used to sling the
components weighing 25 kg or heavier. Check
the slings (wire rope, nylon sling, chain and
hook) for damage before the work. Use the
slings with ample capacity and install them to
the proper places. Operate the hoist or crane
slowly to prevent the component from hitting any
other part. Do not work with any part still raised
by the hoist or crane.
• When removing the part which is under internal
pressure or reaction force of the spring, always
leave 2 bolts in diagonal positions. Loosen those
2 bolts gradually and alternately and release the
pressure, then, remove the part.
• When removing the part, be careful not to break
or damage the electrical wiring. The damaged
wiring may cause electrical fires.
• When removing piping, prevent the fuel or oil
from spilling out. If any fuel or oil drips onto the
HM400-3M0
00 Index and foreword
Foreword, safety and general information
floor, wipe it off immediately. Fuel or oil on the
floor can cause you to slip and can even cause
fires.
• As a general rule, do not use gasoline to wash
parts. Do not use gasoline to clean the electrical
parts, in particular.
• Reinstall the parts removed to their original
places. Replace the damaged parts and the
parts which must not be used with new ones.
When installing the hoses and wiring harnesses,
be careful that they are not damaged by
contacting with other parts when the machine is
operated.
• When connecting the high pressure hoses and
tubes, make sure that they are not twisted. The
damaged high pressure hoses and tubes are
very dangerous when they are installed. So, be
extremely careful when connecting the high
pressure pipings. In addition, check that their
connections are correct.
• When assembling or installing the parts, be sure
to tighten the bolts to the specified torque. When
installing the protective parts such as guards, or
the parts which vibrate violently or rotate at high
speeds, be sure to check that they are installed
correctly.
• When aligning 2 holes, never insert your fingers
or hand into the holes. Align the holes with care
so that your fingers are not caught in the hole.
• When measuring hydraulic pressure, check that
the measuring tools are correctly installed.
• Pay attention to safety when removing and
installing the tracks of the track type machines.
When removing the track, it separates suddenly.
The workers should not stand at either end of
the track.
• If the engine is operated for a long time in a
closed place which is not ventilated well, you
may suffer from gas poisoning. Accordingly,
open the windows and doors to ventilate the
place well.
Precautions for slinging work and making
signals
• Only one appointed worker must make signals
and co-worker must communicate with each
other frequently. The appointed signaler must
make specified signals clearly at the place
where the signaler is well seen from the
operator's seat and where the signaler can see
the working condition easily. The signaler must
always stand in front of the load and guide the
operator safely.
1. Do not stand under the load.
2. Do not step on the load.
• Check the slings before starting sling work.
• Keep putting on the gloves during sling work.
(Put on the leather gloves, if available.)
00-17
00 Index and foreword
Foreword, safety and general information
• Measure the weight of the load by the eye and
check its center of gravity.
• Use the proper sling according to the weight of
the load and method of slinging. If too thick wire
ropes are used to sling a light load, the load may
slip and fall.
• Do not sling a load with 1 wire rope only. If do so,
the load may rotate or the sling gets loose and
the sling may slip off. Install 2 or more wire ropes
symmetrically.
k Slinging with one rope may cause turning
of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original slinging position on the load,
which can result in a dangerous accident.
• Hanging angle must be 60 deg. or smaller as a
rule.
• When hanging a heavy load (25kg or heavier),
the hanging angle of the rope must be narrower
than that of the hook.
a When slinging a load with 2 ropes or more,
the larger the hanging angle is, the larger the
tension of each rope. The figure bellow
shows the variation of allowable load in kg
when hoisting is made with 2 ropes, each of
which is allowed to sling up to 9.8 kN
{1,000kg} a load vertically, at various
hanging angles. When the 2 ropes sling a
load vertically, up to 2,000 kg of total weight
can be suspended. This weight is reduced to
1,000 kg when the 2 ropes make a hanging
angle of 120 deg.. If the 2 ropes sling a 2,000
kg load at a hanging angle of 150 deg., each
rope is subjected to a force as large as 4,000
kg.
• When installing wire ropes to an angular load,
apply pads to protect the wire ropes. If the load
is slippery, apply proper material to prevent the
wire rope from slipping.
• Use the specified eye bolts and fix wire ropes,
chains, etc. to them with shackles, etc.
• Apply wire ropes to the middle part of the hook.
00-18
a Slinging near the tip of the hook may cause
the rope to slip off the hook during hoisting.
The strength of the hook is maximum at its
central part.
• Do not use twisted or kinked wire ropes.
• When slinging up a load, observe the following.
1. Wind up the rope slowly until the wire rope
tensions. When putting your hands on the
wire ropes, do not grasp them but press them
down from above. If you grasp them, your
fingers may be caught.
2. After the wire ropes are stretched, stop the
crane and check the condition of the slung
load, wire ropes, and pads.
3. If the load is unstable or the wire rope or
chains are twisted, lower the load and lift it
up again.
4. Do not lift up the load at an angle.
• When lowering a load, pay attention to the
following.
1. When lifting down a load, stop it temporarily
at 30 cm above the floor, and then lower it
slowly.
2. Check that the load is stable, and then
remove the sling.
3. Remove kinks and dirt from the wire ropes
and chains used for the sling work, and put
them in the specified place.
Precautions for using mobile crane
a Read the Operation and Maintenance Manual of
the crane carefully in advance and operate the
crane safely.
Precautions for using overhead traveling crane
k The hoist or crane must be used to sling the
components weighing 25 kg or heavier. A
part weighing 25 kg or heavier in
"disassembly and assembly" section is
indicated with the symbol of 4 .
• Before starting work, check the wire ropes,
brake, clutch, controller, rails, over winding
prevention device, ground fault circuit interrupter
HM400-3M0
 00 Index and foreword
Foreword, safety and general information

for electric shock prevention, crane collision a The allowable load is calculated as one sixth of
prevention device, and energizing warning lamp, the breaking load of the rope to be used (safety
and check the following safety items. coefficient: 6).
• Observe the signals for sling work.
• Operate the hoist at a safe place. Precautions for disconnecting and connecting
• Be sure to check the directions of the direction hoses and tubes in air conditioner circuit
indication plate (north, south, east and west) and Disconnection
the operating button.
• Do not sling a load at an angle. Do not move the k When replacing the air conditioner unit, air
crane while the slung load is swinging. conditioner compressor, condenser or
• Do not raise or lower a load while the crane is receiver drier, etc., collect the refrigerant (air
moving longitudinally or laterally. conditioner gas: R134a) from the air
• Do not drag a sling. conditioner circuit before disconnecting the
• When lifting up a load, stop it just after it leaves air conditioner hoses.
the ground and check safety, and then lift it up.
a Ask a qualified person for collecting, adding and
• Consider the travel route in advance and lift up a
filling operations of the refrigerant (air
load to a safe height.
conditioner gas: R134a). (Only registered
• Place the control switch in a position where it will
persons can work.)
not be an obstacle to work and passage.
• After operating the hoist, do not swing the a Never release the refrigerant (air conditioner
control switch. gas: R134a) to the atmosphere.
• Remember the position of the main switch so
that you can turn off the power immediately in an k If refrigerant gas (air conditioner gas: R134a)
emergency. gets in your eyes, you may lose your sight.
• Shut down the main switch when the hoist stops And if it touches your skin, you may suffer
because of a blackout. When turning on a switch from frostbite. Put on protective eyeglasses,
which is turned OFF by the ground fault circuit gloves and working clothes with long
interrupter for electric shock prevention, check sleeves while collecting the refrigerant or
that the devices related to that switch are not in filling the air conditioner circuit with the
operating condition. refrigerant.
• If you find an obstacle around the hoist, stop the
• When loosening the nuts fixing air conditioner
operation.
hoses and tubes, be sure to use 2 wrenches;
• After finishing the work, stop the hoist at the
use one wrench to fix and use the other one to
specified position and raise the hook to at least 2
loosen the nut.
meters above the floor. Do not leave the sling
attached to the hook. Connection
• When installing the hose for the air conditioner
Selecting wire ropes
circuit, take care not to allow invasion of dirt,
• Select adequate ropes depending on the weight
dusts and water into the hose.
of the parts to be hoisted, referring to the table
• Check that the O-rings are fitted to the joints
below
when connecting the air conditioner piping.
Wire rope (JIS G3525, 6 x 37 - Type A)
• Once an O-ring is used, it is deformed and
(Standard Z twist wire ropes without galvanizing) deteriorated. Accordingly, do not reuse it.
Nominal • When removing the O-rings, use a soft tool so
diameter of rope Allowable load that the piping is not damaged.
mm kN ton • Check that the O-ring is not damaged or
10 8.8 0.9 deteriorated.
12 12.7 1.3 • Apply compressor oil for refrigerant (R134a) to
the O-ring.
14 17.3 1.7
16 22.6 2.3 a However, do not apply oil to the threaded
18 28.6 2.9 part of a bolt, nut or union.
20 35.3 3.6 Manufacturer Part name
25 55.3 5.6 DENSO ND-OIL8
30 79.6 8.1 VALEO THERMAL ZXL100PG (equivalent to
40 141.6 14.4 SYSTEMS PAG46)
50 221.6 22.6 SANDEN SP-10
60 318.3 32.4

HM400-3M0 00-19
00 Index and foreword
Foreword, safety and general information

• When tightening nuts of the air conditioner

hoses and tubes, be sure to use 2 wrenches.
Use one wrench to fix and tighten the nut with
the other wrench to the specified torque (Use a
torque wrench for tightening).
a Example of fitting of O-ring
• An O-ring is fitted to every joint of the air
conditioner piping.

For tightening torques, see "Others",

"Precautions for disconnection and connection
of air conditioner piping".

00-20 HM400-3M0

Precautions to prevent fire (ALL-0000-17B-K-03-A)
• Fire caused by fuel, oil, coolant or window
washer fluid
Do not bring any flame or fire close to flammable
substances such as fuel, oil, coolant or window
washer fluid.There is danger that they may catch
fire. Always observe the following.
• Do not smoke or use any flame near fuel or
other flammable substances.
• Shut down the engine before adding fuel.
• Do not leave the machine when adding fuel
or oil.
• Tighten all the fuel and oil caps securely.
• Be careful not to spill fuel on overheated
surfaces or on parts of the electrical system.
• After adding fuel or oil, wipe up any spilled
fuel or oil.
• Put greasy rags and other flammable
materials into a safe container to maintain
safety at the workplace.
• When washing parts with oil, use a non-
flammable oil. Do not use diesel oil or
gasoline.There is danger that they may catch
fire.
• Do not weld or use a cutting torch to cut any
pipes or tubes that contain flammable liquids.
• Determine well-ventilated areas for storing oil
and fuel. Keep the oil and fuel in the
specified place and do not allow
unauthorized persons to enter.
• When performing grinding or welding work
on the machine, move any flammable
materials to a safe place before starting.
9 J D 0 1 7 2 0
9 J D 0 1 7 2 1
• Fire caused by accumulation or attachment
of flammable material
HM400-3M0
00 Index and foreword
Foreword, safety and general information
• Remove any dry leaves, chips, pieces of
paper, coal dust, or any other flammable
materials accumulated or attached to or
around the engine exhaust manifold, muffler,
or battery, or on the undercovers.
• To prevent fires from being caught, remove
any flammable materials such as dry leaves,
chips, pieces of paper, coal dust, or any
other flammable materials accumulated
around the cooling system (radiator, oil
cooler) or on the undercover.
• Fire coming from electric wiring
Short circuits in the electrical system can cause
fire. Always observe the following.
• Keep all the electric wiring connections clean
and securely tightened.
• Check the wiring every day for looseness or
damage. Reconnect any loose connectors or
refasten wiring clamps. Repair or replace any
damaged wiring.
• Fire caused by piping
Check that all the clamps for the hoses and
tubes, guards, and cushions are securely fixed
in position.
If they are loose, they may vibrate during
operation and rub against other parts. There is
danger that this may lead to damage to the
hoses and cause high-pressure oil to spurt out,
leading to fire and serious personal injury or
death.
• Fire around the machine due to highly heated
exhaust gas
Some machines are equipped with KDPF
(Komatsu Diesel Particulate Filter).
KDPF is a system for purifying soot in exhaust
gas. Its exhaust gas discharged during
purification process (regeneration) can be at
higher temperature than that from existing
models. Do not bring any flammable material
close to the outlet of the exhaust pipe.
• When there are thatched houses, dry leaves
or pieces of paper near the work site, set the
system to disable the regeneration before
starting work to prevent fire hazards due to
highly heated exhaust gas.
See the operation and maintenance manual
for the setting procedure.
• Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte,
or coolant, always use lighting equipment
with anti-explosion specifications.
• When taking the electrical power for the
lighting equipment from the machine itself,
follow the instructions in the operation and
maintenance manual.
00-21
00 Index and foreword
Foreword, safety and general information

Actions if fire occurs (ALL-0000-17A-K-01-A)

• Turn the starting switch to OFF position to stop

the engine.
• Use the handrails and steps to get off the
machine.
• Do not jump off the machine. You may fall or
suffer serious injury.
• The fume generated by a fire contains harmful
materials which have a bad influence on a
human body when they are sucked.
Don't breathe a fume.
• After a fire, there may be harmful compounds
left. If it touches your skin it may have a bad
influence on your body.
Be sure to wear rubber gloves when handle the
materials left after the fire.
The material of the gloves, which is
recommended is polychloroprene (Neoprene) or
polyvinyl chloride (in the lower temperature
environment).
When wearing cotton-work-gloves, wear rubber
gloves under them.
Dispose of waste materials (ALL-0000-99A-K-02-A)

To prevent pollution, pay full attention to the way to

dispose of waste materials.
• Always put the oil and coolant drained from the
machine in containers. Never drain the oil and
coolant directly onto the ground or dump into the
sewage system, rivers, the sea, or lakes.
• Observe the related laws and regulations when
disposing of harmful objects such as oil, fuel,
coolant, solvent, filters, and batteries.

Some kinds of rubber and plastics may produce

poisonous gas harmful to human body when they
are burned.
• As for rubber, plastics, or parts (hoses, cables,
and wiring harnesses, etc.) which contain those
materials, ask the industrial waste treatment
firms for their disposals in accordance with the
local regulations.

00-22 HM400-3M0
 00 Index and foreword
Foreword, safety and general information

How to read the shop manual (ALL-0320-010-A-01-A)

(Rev. 2012/10)
• Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
• Materials and specifications are subject to change without notice.
• The shop manuals are available for "Machine part" and "Engine part". For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.

Composition of shop manual

• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of "Structure and function"
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.

HM400-3M0 00-23
00 Index and foreword
Foreword, safety and general information

Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual is used
practically.
Symbol Item Remarks
Safety The special safety precautions required for performing work are
k described.
The special technical precautions or other precautions for preserving
a Caution standards required when performing work are described.
The weight of part or component and the cautions required when
4 Weight selecting hoisting wire or when working posture is important are
indicated.
Tightening The tightening torques that require special attention during assembly
3 torque work are indicated.
The places to be coated with adhesives, grease, etc. during assembling
2 Coat
are indicated.
Oil, coolant The places where oil, coolant, etc. must be added and the quantity to be
5 added are indicated.
Places where oil, coolant, etc. must be drained and the quantity to be
6 Drain
drained are indicated.

Unit
• In this shop manual, the units are indicated with International System of units (SI).
• For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }.

00-24 HM400-3M0
 00 Index and foreword
Foreword, safety and general information

Explanation of terms for maintenance standard (ALL-0330-006-A-01-A)

(Rev. 2012/10)
• The chapter of maintenance standard shows judgement criteria to determine the products to be replaced
or to be reused. The judgement criteria are described by using the following terms.

Standard dimension and tolerance • When some parts are repaired, the value of
• To be accurate, the finished dimension of a part performance/function is set to the standard
is slightly different from one to another. value.
• The finished dimension of a part specifies the
allowable difference from the standard
dimension which is set first.
• The dimension set as the standard is called the
standard dimension and the range of difference
from this standard dimension is called the
"tolerance".
• An indication example of a standard dimension
and tolerance is shown in the following table.
(The standard dimension is entered on the left
side and the tolerance is entered with a positive
or negative symbol on the right side)
Example:
Standard dimension Tolerance
-0.022
120
-0.126
• The tolerance may be indicated in the text and a
table as "standard dimension (upper limit of
tolerance/lower limit of tolerance)."
Example: 120(-0.022/-0.126)
• Usually, the dimension of a hole and the
dimension of a shaft to be inserted into the hole
are indicated by the same standard dimension
and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
• An indication example of a shaft and hole is
shown in the following table.
Standard interference
(The standard dimension is entered on the left
• When the diameter of a hole of a part shown in
side and the tolerance of the shaft is entered
with a positive or negative symbol at the center the given standard dimension and tolerance
table is smaller than that of the shaft to be
and that of the hole on the right side)
inserted, the difference between those
Standard Tolerance diameters is called the "interference".
dimension Shaft Hole • Subtract the maximum dimension of the hole
-0.030 +0.046 from the minimum dimension of the shaft and
60
-0.076 0 call it (A). Subtract the minimum dimension of
the hole from the maximum dimension of the
Standard clearance and standard value shaft and call it (B). The range between (A) and
• The clearance made when new parts are (B) is the "standard interference".
assembled is called the standard clearance, • After repairing or replacing some parts, measure
which is indicated by the range from the the dimension of their hole and shaft and check
minimum clearance to the maximum clearance. that the interference is in the standard range.
• When some parts are repaired, the clearance is
generally adjusted to the standard clearance. Repair limit and allowable value or allowable
• The values indicating performance and function dimension
of new products or equivalent are called the • The dimensions of parts change because of the
"standard value", which is indicated by a range wear or deformation while they are used. When
or a target value. the dimension changes exceeding certain value,

HM400-3M0 00-25
00 Index and foreword
Foreword, safety and general information

the parts can not be used any longer. This value

is called "repair limit".
• If a part is worn to the repair limit, it must be
replaced or repaired.
• The performance and function of the products
lower while they are used. When the value of the
performance and function lowers exceeding a
certain limit and it influences the operation etc.,
this value is called the allowable value or
allowable dimension.
• A product whose dimension is out of the
allowable value, must be repaired. However,
since the allowable values are generally
estimated through various tests or experiences
in most cases, the judgement must be made in
consideration of the operating condition and
customer's requirement.

Allowable clearance
• Parts can be used until the clearance between
them is increased to a certain limit. The limit at
which those parts cannot be used is called the
"allowable clearance".
• If the clearance between the parts exceeds the
allowable clearance, they must be replaced or
repaired.

Allowable interference
• The allowable maximum interference between
the hole of a part and the shaft of another part to
be assembled is called the "allowable
interference".
• The allowable interference shows the repair limit
of the part of smaller tolerance.
• The parts whose interferences are out of the
allowable interference must be replaced or
repaired.

00-26 HM400-3M0
 00 Index and foreword
Foreword, safety and general information

Handling equipment of fuel system devices (PC-AD00-2A4-K-00-A)

(Rev. 2012/01)
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. If foreign material enters this system, it
may cause a failure. Use special care to prevent
entry of the foreign material when servicing the
fuel system.

Use care for working environment

• Avoid filter change or repairing the machine in
rain or high winds, or at places where there is a
lot of dust.
Sealing openings
• Plug the pipes and the openings of the
components which are removed with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never perform repair works under
the condition that the openings are left as they
are or plugged with cloths as foreign material
may enter or environment may be polluted by
the oil leaked. Do not discard the waste oil
somewhere or other. Hand it over to your
customer for disposal, or dispose it by yourself.

How to clean parts when dirt is stuck

• If any dirt or dust sticks the parts of the fuel
system, clean it off thoroughly with clean fuel.

Precautions for replacing fuel filter cartridge

• Be sure to use the Komatsu genuine fuel filter
cartridge.
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. In order to prevent foreign material from
entering this system, the filter employs a
specially high performance of filter element. If a
filter element other than the genuine one is used,
the fuel system may have a failure. Accordingly,
never use such a filter element.

HM400-3M0 00-27
00 Index and foreword
Foreword, safety and general information

Handling of intake system parts (PC220-A900-2A4-K-00-A)

(Rev.2013/10)
• The Komatsu Variable Geometry Turbocharger
consists of more precise parts (variable
mechanism) than the parts used in the
conventional turbocharger. If foreign material
enters this system, it may cause a failure. Use
special care to prevent entry of the foreign
material when servicing the air intake system.

Be careful of working environment

• Avoid the repair work of the machine in rain or
strong wind or at the places where there is a lot
of dust.
Sealing openings
• Plug the pipes and the openings of the
components which are removed, with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never perform repair works under
the condition that the openings are left open or
plugged with rag since foreign material may
enter.

00-28 HM400-3M0
 00 Index and foreword
Foreword, safety and general information

Handling of hydraulic equipment (ALL-C000-2A4-P-01-A)

(Rev. 2012/10)
• With the increase in pressure and precision of the hydraulic components, the most common cause of a
failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when
adding hydraulic oil,or when disassembling or assembling the hydraulic components.

Be careful of working environment

• Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or at
places where there is a lot of dust.

Disassembly and maintenance work in the field

• When disassembly or maintenance work of the
hydraulic is performed in the field, there is
danger of dust entering the components. It is
also difficult to check the performance of the
components after repairs, so it is desirable to
use the component exchange service. The
disassembly and assembly of the hydraulic
components must be performed in the specially
arranged dustproof workshop and the Preventing intrusion of foreign materials during
performance test of the components must be refilling operations.
performed with the special testing equipment. • Care must be taken when adding hydraulic oil so
that foreign material does not enter. Keep the oil
filler port and the area around it, oil supply pump
and oil container clean. If an oil cleaning device
is used, it is possible to remove the dirt that is
collected during storage. It is a surer means.

Plugging of opening (prevention of flowing out

of oil)
• Plug the pipes and the openings of the
components which are removed (when plugs
are not prepared, seal with caps, tapes, vinyl
bags, etc.) to prevent entry of foreign material
and flowing out of oil. Never leave the openings
of the pipes and hoses without being covered or
plugged with cloth as foreign material may enter
them or environment may be polluted by the oil
leaked. Do not discard the waste oil somewhere
or other. Hand it over to your customer for
disposal, or dispose it by yourself.
Replacing hydraulic oil while its temperature is
high
• When the hydraulic oil is warm, it flows easily. In
addition, sludge can also be drained from the
circuit together with the oil. So, it is better to
change the hydraulic oil while it is warm. When
changing the hydraulic oil, the old oil must be
drained as much as possible. (Drain the oil not
only from the hydraulic tank, but also from the
filter housing and the drain plug hole in the
circuit.) If the old oil is left in the system, the
contaminant and sludge in the oil mix with the
new oil and shorten the life of the new hydraulic
oil.

HM400-3M0 00-29
00 Index and foreword
Foreword, safety and general information

Flushing operations
• After disassembling the equipment or when
changing the hydraulic oil with new one, flush
the system to remove the contaminant and
sludge left in the hydraulic circuit as well as the
oil which includes them. Normally, flushing is
performed twice. Primary flushing is performed
by use of the flushing oil and the secondary
flushing is performed by use of the specified
hydraulic oil.

Cleaning operations
• After repairing the hydraulic equipment (pump,
control valve, etc.) or when the machine is in
operation, perform oil cleaning to remove the
sludge or contaminant in the hydraulic oil circuit.
The oil cleaning equipment can remove the ultra
fine (approximately 3 μm) particles that the filter
built in the hydraulic equipment can not remove.
So, it is an extremely effective device.

00-30 HM400-3M0
 00 Index and foreword
Foreword, safety and general information

Method of disconnecting and connecting of push-pull type coupler (ALL-

C930-001-P-00-A)
(Rev. 2012/01)

k Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the
hydraulic tank.

k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.

Type 1 (ALL-C930-925-P-01-A)

Disconnection
1. Hold adapter (1) and push hose joint (2) into
mating adapter (3). (Fig. 1)
a It can be pushed in by approximately 3.5mm.
a Do not hold rubber cap portion (4).
2. While pushing hose joint (2) into adapter (3),
push rubber cap (4) against adapter (3) until
"click" is heard. (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 container.
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 part (4).
2. After inserting the hose fitting in the adapter on
the other side perfectly, pull it back to check the
connecting condition. (Fig. 4)
a When the hose fitting is pulled back, the
rubber cap will move approximately 3.5mm
toward the hose, however, it is not a problem.

HM400-3M0 00-31
00 Index and foreword
Foreword, safety and general information

Type 2 (ALL-C930-925-P-02-A)

Disconnection Connection
1. While holding the fitting, push body (7) in straight 1. While holding the fitting, push body (7) in straight
until sliding prevention ring (6) hits contact until sliding prevention ring (6) hits contact
surface (a) at the hexagonal part on the male surface (a) at the hexagonal part on the male
side. (Fig. 6) side to connect it. (Fig. 9)
2. While keeping the condition of Step 1, turn lever
(8) to the right (clockwise). (Fig. 7)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (7) to disconnect it. (Fig. 8)

00-32 HM400-3M0
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Foreword, safety and general information

Type 3 (ALL-C930-925-P-03-A)

Disconnection Connection
1. While holding the fitting, push body (9) in straight 1. While holding the fitting, push body (9) in straight
until sliding prevention ring (8) hits contact until sliding prevention ring (8) hits contact
surface (b) at the hexagonal portion on the male surface (a) at the hexagonal portion on the male
side. (Fig. 10) side to connect them. (Fig. 13)
2. While keeping the condition of Step 1, push
cover (10) straight until it hits contact surface (b)
of the hexagonal portion on the male side. (Fig.
11)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (9) to disconnect it. (Fig. 12)

HM400-3M0 00-33
00 Index and foreword
Foreword, safety and general information

Handling of electrical equipment (ALL-E000-2A4-P-01-A)

(Rev. 2012/11)

• To maintain the performance of the machine over a long period, and to prevent failures or troubles before
they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics components
and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in
"Handling of electrical equipment".

Precautions for handling electric equipment

Handling wiring harnesses and connectors

• Wiring harnesses consist of wires connecting
one component to another component,
connectors used for connecting and
disconnecting one wire from another wire, and
protectors or tubes used for protecting the wires.
• Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they Defective crimping or soldering of connectors
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely • The pins of the male and female connectors are
careful when handling the wiring harnesses. attached to wires by crimping or soldering. If
excessive force is applied to the wire, the joining
area may become loose, which may result in a
defective connection or breakage.

Main failures occurring in wiring harness

Defective contact of connectors (defective
contact between male and female connectors)
• Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,or
because one or both of connectors are
deformed or the position is not correctly aligned,
or because there is corrosion or oxidization of
the contact surfaces. The corroded or oxidized
contact surfaces may become shiny again (and
contact may become normal) by connecting and
disconnecting the connectors approximately 10
times.
Disconnections in wiring
• If the wiring harness is pulled to disconnect the
connector, or the components are lifted with a
crane while the wiring harness is still connected,
or a heavy object hits the wiring harness, the
crimping of the connector may separate, or the
soldering may be damaged, or the wiring
harness may be broken.

00-34 HM400-3M0
 00 Index and foreword
Foreword, safety and general information

blow it with compressed air and spray it with

electrical contact restorer.
a When wiping the joint portion of the
connector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed air, it
causes the contacts to become dirtier. So,
remove the oil and water from the
compressed air completely before cleaning
the connector with the compressed air.

High-pressure water entering connector

• The connector is designed to make it difficult for
water to enter (drip-proof structure), but if high-
pressure water is sprayed directly on the
connector, water may enter the connector,
depending on the direction of the water jet.
Accordingly, take care not to spray water over
the connector.
The connector is designed to prevent water from
entering, but once water does enter, it is difficult
to drain it. If water should get into the connector,
the pins will be short-circuited by the water. So if
any water gets in, immediately dry the connector Removing, installing, and drying connectors
and wiring harnesses
or take other appropriate action before passing
Disconnecting connectors
electricity through it.
1. Hold the connectors when disconnecting.
• Disconnect connectors by holding the
connector bodies. For the connectors held by
a screw, loosen the screw fully, then hold the
male and female connectors with each hand
respectively and pull them apart horizontally.
For the connectors with lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a Never pull the connector with one hand.

Entry of water, mud or dirt when disconnecting a

connector
• If any water, mud or dirt is stuck to the outside
surface of a connector, it can enter inside the
connector when the connector is disconnected.
Before disconnecting the connector, wipe off any
stuck water or dirt by using a piece of dry cloth
or blow it with compressed air.
Oil, mud or dirt stuck to connector
• If any oil or grease is stuck to the connector and
an oil film is formed on the mating surface of the 2. When removing from clips
male and female pins, the oil prevents electricity • Both of the connector and clip have stoppers,
from passing through, resulting in defective which are engaged with each other when the
contact. If any oil or grease, mud or dirt is stuck connector is connected.
to the connector, wipe it off with a dry cloth or

HM400-3M0 00-35
00 Index and foreword
Foreword, safety and general information
• When removing a connector from a clip, pull
the connector in a parallel direction to the clip
for removing stoppers.
a If the connector is pried up and down or
to the right and left, the housing may
break.
3. Action to take after removing connectors
• After removing the connector, cover it with
the vinyl bag to prevent entry of dust, dirt,oil
or water in the contact portion.
a If the machine is left disassembled for a
long time, it is particularly easy for
improper contact to occur, so always
cover the connector.
Connecting connectors
1. Check the connector visually.
00-36
• Check that there is no oil, dirt or water stick
to the connector pins (joint portion).
• Check that the connector pins are free from
deformation, defective contact, corrosion, or
damage.
• Check that external surfaces of the
connectors are free from damage or
breakage.
a If any oil, water or dirt is stuck to the
connector, wipe it off with a dry cloth. If any
water is inside the connector, warm the
connector and the inside of the wiring
harness with a dryer. But be careful not to
make it too hot as it causes short circuit.
a If there is any damage or breakage, replace
the connector.
2. Fix the connector securely.
• Align the connectors correctly, and fit them
securely. For the connectors with the lock
stopper, push in the connectors until "click" is
heard.
3. Correct the protrusion of the boot and
misalignment of the wiring harness
• For connectors fitted with the boot, correct
any extrusion of the boot. In addition, if the
wiring harness or the clamp is out of the
position, put it in its original position.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
HM400-3M0

• If the connector clamp is removed, be sure to
return it to its original position. And check
that it is securely installed.
Handling of Deutsch connector (DT8-pin, DT12-
pin)
Disconnection
1. While pressing locks (a) and (b) from each side
respectively, pull out female connector (2).
Connection
1. Push in female connector (2) horizontally until
the lock clicks. (Arrow: x)
2. Since locks (a) and (b) may not be set
completely, push in female connector (2) with
curving movement until the locks are set
normally. (Arrow: x, y, and z)
a Lock (a) in the figure is pulled down (not set
completely), and lock (b) is set completely.
HM400-3M0
00 Index and foreword
Foreword, safety and general information
Drying wiring harness
• If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing by
using steam. If the wire harness must be
washed in water, do not apply high pressure
water or steam directly to the wiring harness. If
water gets directly on the connector, do as
follows.
1. Disconnect the connector and wipe off the water
with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is a risk that oil in the
air may cause defective contact of the
conditioner, remove oil and water in the air
before starting air blow.
2. Dry the inside of the connector with a dryer.
If water gets inside the connector, use a dryer to
dry the connector.
a Hot air from the dryer can be used, but
regulate the time to use hot air in order to
prevent the connector or related parts from
becoming too hot, as it causes deformation
or damage to the connector.
3. Perform a continuity test on the connector.
After drying, leave the wiring harness
disconnected and perform a continuity test to
check for any short circuits between pins caused
by water.
a After the connector is completely dried, blow
the contact restorer and reassemble them.
00-37
00 Index and foreword
Foreword, safety and general information

2. While pressing lock (L2), pull out connector (1).

Handling of connectors used on engine

Slide, lock type

(FRAMATOME-3, FRAMATOME-2)
Disconnection
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1)
toward you.
a In the case that even if lock (L2) is pressed,
connector (1) cannot be pulled out toward
you unless part A floats, float part A with a
small flat-head screwdriver while pressing
lock (L2), and then pull out connector (1)
toward you.
a Lock (L2) is located in the back of connector
(1).

Connection
1. Insert the connector securely until a click is Connection
heard.
1. Insert the connector securely until a click is
(FRAMATOME-24)
heard.
Disconnection
1. Slide down lock (red) (L1). Pull lock type
(PACKARD-2)
Disconnection
1. Disconnect the connector (2) by pulling lock (B)
(on the wiring harness side) of connector (2)
outward.

00-38 HM400-3M0
 00 Index and foreword
Foreword, safety and general information

Connection Connection
1. Insert the connector securely until a click is 1. Insert the connector securely until a click is
heard. heard.
(AMP-3)
Push lock type
(BOSCH-3) Disconnection
Disconnection 1. While pressing lock (E), pull out connector (5) in
the direction of the arrow.
1. While pressing lock (C), pull out connector (3) in
the direction of the arrow.
• 114 series

Connection
1. Insert the connector securely until a click is
heard.
• 107 series (SUMITOMO-2)
Disconnection
1. While pressing lock (E), pull out connector (5) in
the direction of the arrow.

a If the lock is located on the underside, use

flat-head screwdriver [1] since you cannot
insert your fingers.
While pushing up lock (C) of the connector Connection
with flat-head screwdriver [1], pull out 1. Insert the connector securely until a click is
connector (3) in the direction of the arrow. heard.

HM400-3M0 00-39
00 Index and foreword
Foreword, safety and general information

(SUMITOMO-3)
Disconnection
1. While pressing lock (E), pull out connector (5) in
the direction of the arrow.
a Pull the connector straight up.

Connection
1. Insert the connector to the end while aligning its
grove to the other.
2. Turn housing (H1) in the direction of the arrow
until it "clicks".

Connection
1. Insert the connector securely until a click is
heard.
(SUMITOMO-4)
Disconnection
1. While pressing lock (D), pull out connector (4) in
the direction of the arrow.

Handling controller
• The electronic circuits for control including the
microcomputers are assembled in the controller.
These electronic circuits in the controller must
be handled with care as they control the
machine.
• Do not place objects on top of the controller.

Connection
1. Insert the connector securely until a click is
heard.
Turn-housing type (Round green connector)
(CANNON-4)
Disconnection
1. Turn housing (H1) in the direction of the arrow.
a Unlock the connector by turning housing (H1).
When the lock is release the housing is felt
tight to turn.
2. Pull out housing (H1) in the direction of the • Cover the control connectors with tape or a vinyl
arrow. bag. Never touch the connector contacts.
a Housing (H1) is left on the wiring harness • During rainy weather, do not leave the controller
side. in a place where it is exposed to rain.
• Do not place the controller on oil, water, or soil,
or in a place that can be heated to a high

00-40 HM400-3M0
 00 Index and foreword
Foreword, safety and general information

temperature even for a short period of time.

(Place it on a suitable dry stand.)

• Precautions when performing arc welding

When performing arc welding on the machine
body, disconnect all the wiring harness
connectors connected to the controller. Put the
arc welding ground to the place close to the
welding point.

Precautions for troubleshooting electrical

circuits
• Be sure to turn the starting switch to "OFF"
position before disconnecting or connecting the
connectors.
• Before performing troubleshooting, check all the
related connectors for loose connection.
a Check the related connectors for their
performance by disconnecting and
connecting them several times.
• Be sure to connect all the disconnected
connectors before proceeding to the next step.
a If the starting switch is turned to "ON"
position with the connectors disconnected,
the failure which is not related to the part
which is actually failed.
• When performing the troubleshooting for the
circuit (measurement of voltage, resistance,
continuity, current, etc.), shake the related wiring
harnesses and connectors several times and
check that the multimeter reading does not
change.
a If there is any value change on the
multimeter, there may be a defective contact
in the circuit.

HM400-3M0 00-41
00 Index and foreword
Foreword, safety and general information

How to read electric wire code (ALL-E500-030-P-00-A)

(Rev. 2012/10)
• In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by
symbols. The wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of
0.85
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not
indicated on the diagram.)
Indicates size of wire by nominal No.
0.85
Size (Nominal No.) is shown in Table 2.
Indicates color of wire by color code.
L
Color codes are shown in Table 3.

Type, symbol, and material

• AV and AVS are different in thickness and outside diameter of the coating. CAVC has a circular
compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of
the coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV
and AVS in material of the coating.
(Table 1)
Temperature
Type Sym- Conductor Example of use
Insulator material range (°C) in
bol material
use
Low-voltage For large current wiring
wire for AV
automobile (nominal No. 5 and above)
Thin-cover
low-voltage
General wiring
wire for AVS
automobile (nominal No. 3 and lower)
Soft polyvinyl chloride -30 to +60
(Type 1) Annealed
Thin-cover copper for
low-voltage electric For mid- to small-size
wire for CAVS appliance excavators
automobile (nominal No. 1.25 and lower)
(Type 2)
Heat- General wiring for extremely
resistant low- Heat-resistant cross cold weather specification
voltage wire AEX linked polyethylene -50 to +110
for Wiring at high ambient
automobile temperature place

00-42 HM400-3M0
 00 Index and foreword
Foreword, safety and general information

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/ 20/ 30/ 11/ 50/ 16/ 37/ 26/ 58/ 41/ 65/
7/0.32
Diameter of 0.18 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
strand
Conductor Cross-
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 —
Coating D

AV Standard — — — — — — — 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 — 3.8 4.6

Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/ 108/ 127/ 169/ 217/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80
Diameter of 0.80 0.80 0.80 0.80
strand
Conductor Cross-
sectional 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard — — — — — — — — —
Coating D

AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of
strands/ 7/round 11/round 16/round
— — —
Diameter of compression compression compression
strand
Conductor Cross-
sectional — 0.56 — 0.88 — 1.29
area (mm2)
d (approx.) — 0.9 — 1.1 — 1.4
Coating D

CAVS Standard — 1.6 — 1.8 — 2.1

a "f" of nominal No. denotes "flexible".

HM400-3M0 00-43
00 Index and foreword
Foreword, safety and general information

Color codes table

(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White

a 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.
Examples)
GW means that the background is "Green" and marking is "White".

Types of circuits and color codes

Type of wire AVS, AV, CAVS 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 — — — — — — —

00-44 HM400-3M0
 00 Index and foreword
Foreword, safety and general information

Precautions when performing operation (ALL-1160-927-A-00-A)

(Rev. 2012/11)
• When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and
assembly" of the components, observe the following general cautions.

Precautions for removal and disassembly work

• If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage
rashly.
• After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering.
• When draining oil, prepare a container with sufficient capacity.
• Check the match marks which indicate the installing position, and put match marks on the places where
they seem necessary before removal of the components to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses to show their installing positions to prevent any mistake when
installing.
• Check the number and thickness of the shims, and keep them in a safe place.
• When hoisting the components, prepare the slings with sufficient strength.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and
alternately.
• Before removing any component, clean the surrounding area and cover the component to prevent any
foreign material from entering after removal.
• After disconnecting the piping or removing a pipe joint, install the following plugs.
a The O-rings in the table are emergency parts used for disassembly or transportation of the machine.
When assembling, confirm the part numbers in the parts book and use the parts conforming to the
using condition.
Disconnection of face seal type hoses and tubes

Hose side Pipe joint side

Nominal No. O-ring (3)
Plug (1) Nut (2)
02 07376-70210 02789-00210 02896-11008
03 07376-70315 02789-00315 02896-11009
04 07376-70422 02789-00422 02896-11012
05 07376-70522 02789-00522 02896-11015
06 07376-70628 02789-00628 02896-11018

HM400-3M0 00-45
00 Index and foreword
Foreword, safety and general information

Disconnection of taper seal type hoses and tubes

Hose side Pipe joint side

Nominal No.
Plug (1) Nut (2)
02 07376-50210 07222-00210
03 07376-50315 07222-00312
04 07376-50422 07222-00414
05 07376-50522 07222-00515
06 07376-50628 07222-00616
10 07376-51034 07222-01018
12 07376-51234 07222-01219
14 07376-51443 07222-01422

Disconnection of split flange type hoses and tubes

No- Bolt pitch (mm) Hose side Tube side

minal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
a b Flange (1)
No. (2) (3)
07379- 01010-
04 38.1 17.5 07371-30400 07378-10400 07000-12021 01643-50823
00400 80825
07379- 01010-
05 42.9 19.8 07371-30500 07378-10500 07000-13022 01643-50823
00500 80830
07379- 07372-
06 47.6 22.2 07371-30640 07378-10600 07000-13025 01643-51032
00640 51035
07379- 07372-
10 52.4 26.2 07371-31049 07378-11000 07000-13032 01643-51032
01044 51035
07379- 07372-
58.7 30.2 07371-31255 07378-11200 07000-13038 01643-51032
01250 51035
12
07379- 01010-
66.7 31.8 07371-51260 07378-11210 07000-13038 01643-51232
01260 81245
07379- 07372-
14 69.9 35.8 07371-31465 07378-11400 07000-13048 01643-51232
01460 51240

00-46 HM400-3M0
 00 Index and foreword
Foreword, safety and general information

No- Bolt pitch (mm) Hose side Tube side

minal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
a b Flange (1)
No. (2) (3)
07379- 01010-
79.4 36.5 07371-51470 07378-11410 07000-13048 01643-31445
01470 81455
07379- 07372-
77.8 42.8 07371-32076 07378-12000 07000-12060 01643-51232
02071 51240
20
07379- 01010-
96.8 44.5 07371-52080 07378-12010 07000-12060 01643-31845
02080 81865
07379- 07372-
24 88.9 50.8 07371-12484 07378-12400 07000-12070 01643-51232
02484 51240
07379- 07372-
30 106.4 62 07371-13010 07378-13000 07000-12085 01643-51645
03010 51650
07372-
34 120.6 69.8 07379-03411 07371-13411 07378-13400 07000-12100 01643-51645
51650
07379- 07372-
40 130.2 77.8 07371-14012 07378-14000 07000-12110 01643-51645
04012 51650
07372-
50 152.4 92 07379-05011 07371-15011 07378-15000 07000-12135 01643-51645
51655

Removal of pipe joints of O-ring boss type

Nominal No. Plug (1) O-ring (2)

08 07040-10807 07002-10823
10 07040-11007 07002-11023
12 07040-11209 07002-11223
14 07040-11409 07002-11423
16 07040-11612 07002-11623
18 07040-11812 07002-11823
20 07040-12012 07002-12034
24 07040-12412 07002-12434
30 07041-13012 07002-13034
33 07040-13316 07002-13334
36 07041-13612 07002-13634
42 07040-14220 07002-14234
52 07040-15223 07002-15234

Removal of pipe joints of taper pipe thread type

HM400-3M0 00-47
00 Index and foreword
Foreword, safety and general information

Nominal Plug (1)

Nominal No.
thread size Square head type (A) Hexagonal socket head (B)
01 R 1/ 8 07042-00108 07043-00108
02 R 1/ 4 07042-00211 07043-00211
03 R 3/ 8 07042-00312 07043-00312
04 R 1/ 2 07042-00415 07043-00415
06 R 3/ 4 07042-00617 07043-00617
10 R1 07042-01019 07043-01019
12 R1 1/4 07042-01222 07043-01222
14 R1 1/2 07042-01422 07043-01422
20 R2 07042-02026 07043-02026

Precautions for installation and assembly work

• Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES), unless otherwise specified.
• Install the hoses without twist and interference, and securely fasten the clamps located in-between if they
are.
• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the part, and apply 2 to 3 drops of adhesive to the threaded
part.
• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that
the surface is free from dirt or damage.
• Clean all of the parts, and repair any damage, dents, burrs, or rust found on them.
• Coat the rotating parts and sliding parts with engine oil.
• Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P).
• After installing the snap ring, check that the snap ring is settled in the ring groove completely.
• When connecting wiring harness connectors, clean the connectors to remove oil, dirt, or water, then
connect them securely.
• Use the eye bolts with no fatigue and deformation and screw them in securely. Match the directions of the
eyes and the hook.
• When installing split flanges, tighten the bolts uniformly and alternately to prevent excessive tightening on
one side.
• As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded part of each taper male
screws which receives pressure.
However, if the threaded part is difficult to degrease, you may use a seal tape.
• When winding a seal tape onto a right-handed taper male screw, wind it clockwise in the advancing
direction of the threads, seeing from the screw end and starting at the third thread.
a If you wind the seal tape in the opposite direction, it becomes loose and comes off or its end part is
pushed out, and that can cause oil leakage.

00-48 HM400-3M0
 00 Index and foreword
Foreword, safety and general information

a When the hydraulic cylinder is used for the first time after reassembly of the hydraulic equipment such as
the hydraulic cylinder, pump, etc. and piping after removing them for repair, be sure to perform air bleeding
of the hydraulic circuit according to the following procedure.
1. Start the engine, and run it at low idle.
2. Repeat the operation to extend and retract each cylinder of the work equipment to approximately 100
mm before the stroke end 4 to 5 times.
3. Operate the hydraulic cylinder 3 to 4 times to the end of its stroke.
a After the completion of repair and when operating the machine which is stored long term, perform the air
bleeding with the same procedure as the one described above.

Precautions at the time of completing work

Refilling of coolant, oil and grease
• When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the
coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping,
and add the coolant to the specified level again.
• When the hydraulic components are removed and installed, refill the oil reservoir with the oil Komatsu
recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the
specified level again.
• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after
rebuilding the parts, by referring to "Testing and adjusting".
• Supply the specified amount of grease to the work equipment parts.
Testing installed condition of cylinder heads and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If any bolt is loose, retighten it.
a For the tightening torques, see the "Disassembly and assembly".
Testing of engine piping for damage and looseness
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints
Intake and exhaust for air suction and exhaust gas leakage.
system
If any part is loosely installed or damaged, retighten the bolts or repair the parts.
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints
Cooling system for water leakage.
If any part is loosely installed or damaged, retighten the bolts or repair the parts.
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints
Fuel system for fuel leakage.
If any part is loosely installed or damaged, retighten the bolts or repair the parts.
Check of KDPF or muffler and exhaust pipe for damage and looseness
• Visually check the KDPF or muffler, exhaust pipe and their mounting parts for a crack and damage. If any
part is damaged, replace it.
• Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting parts
for looseness.
If any part is loosely installed, retighten the bolts.
Check of KDPF or muffler function
• Check the KDPF or the muffler for unusual noise comparing to the noise when they are new.
If any unusual noise is heard, repair KDPF or muffler, referring to "Troubleshooting" and "Disassembly and
assembly".

HM400-3M0 00-49
00 Index and foreword
Foreword, safety and general information

Practical use of KOMTRAX (ALL-Q210-13V-K-00-A)

(Rev. 2012/10)
KOMTRAX system transmits various machine information by use of the radio communication and KOMTRAX
operator can refer this information in the office and provide various services to the customers.
When KOMTRAX is installed on the machine, the machine information can be checked through the
KOMTRAX system and the testing and troubleshooting can be performed efficiently.
(KOMTRAX may not be installed on the machine in some countries or areas.)

Merit of using KOMTRAX

• The working place of the machine can be checked in the map on PC.
• Operation information such as service meter reading, operating hours, fuel consumption, occurred caution
and failure code can be checked.
• The hours used and replacement time of consumable parts of the machine such as fuel filter, hydraulic oil
filter, hydraulic oil and engine oil can be checked.
• The information of machine working condition (idling time, traveling time, digging time, relieving time, etc.)
can be checked and the machine operating condition can be presumed with these information.
• Various reports such as "Fuel saving operation support", "Summary of operation", etc. can be generated
and utilized as an advice as well for the user and operator.

How to use KOMTRAX practically

With KOMTRAX, following support activities will be available.
1. Quick response to sudden request of repair
1) When receiving a repair request from a user, check the displayed caution and failure code, etc. through
KOMTRAX.
2) Arrange the necessary tools, replacement parts, etc, immediately in accordance with the displayed
failure code.
3) By using the map of KOMTRAX, find the location of the failed machine and visit the customer there.
2. Proactive maintenance
1) Check the service summary screen of KOMTRAX, and find the machine which has high priority failure
code indicated by a red or yellow flag.
2) Check the condition of the machine with the customer and make a plan to visit.
3) Arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure
code.
3. Practice of periodic maintenance and periodic inspection service
1) Check the service summary screen of KOMTRAX, and find the machine of which the usage limits for
the consumable parts indicated by red flags are over.
2) Submit an estimate sheet for the consumable parts to be replaced and the labor cost for the
replacement work to the customer.
3) Propose the periodic inspection (PM clinic, etc.) according to the service meter reading.

How to operate KOMTRAX

For the operating method of each screen of KOMTRAX, see "Global KOMTRAX Web Reference Manual (For
Key Person)".

00-50 HM400-3M0
 00 Index and foreword
Foreword, safety and general information

Standard tightening torque table (ALL-M140-03B-P-01-A)

(Rev. 2012/10)

Table of tightening torque for bolts and nuts

Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below.

Thread diameter Width across flats

Tightening torque (Nm {kgm})
(mm) (mm)
10
6 11.8 to 14.7 {1.2 to 1.5}
(*2) 10
13
8 27 to 34 {2.8 to 3.5}
(*2) 12
17
10 59 to 74 {6.0 to 7.5}
(*1, *2) 14
19
12 98 to 123 {10.0 to 12.5}
(*1, *2) 17
14 22 157 to 196 {16 to 20}
24
16 245 to 309 {25 to 31.5}
(*1) 22
18 27 343 to 427 {35 to 43.5}
20 30 490 to 608 {50 to 62}
22 32 662 to 829 {67.5 to 84.5}
24 36 824 to 1,030 {84 to 105}
27 41 1,180 to 1,470 {120 to 150}
30 46 1,520 to 1,910 {155 to 195}
33 50 1,960 to 2,450 {200 to 250}
36 55 2,450 to 3,040 {250 to 310}
39 60 2,890 to 3,630 {295 to 370}
*1: Split flange bolt.
*2: Flanged bolt.

HM400-3M0 00-51
00 Index and foreword
Foreword, safety and general information

a Tighten the following flanged bolt on which "7" is stamped on its top to the tightening torque shown in the
following table.

Thread diameter Width across flats

Tightening torque (Nm {kgm})
(mm) (mm)
6 10 5.9 to 9.8 {0.6 to 1.0}
8 12 13.7 to 23.5 {1.4 to 2.4}
10 14 34.3 to 46.1 {3.5 to 4.7}
12 17 74.5 to 90.2 {7.6 to 9.2}

Unless otherwise specified, tighten the unified coarse threaded bolts and nuts to the torque shown in the table
below.

Type of bolt A B
Nominal No. - Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
threads per inch,
type of thread Range Target Range Target
1/4-20UNC 9.8 to 14.7 {1 to 1.5} 12.7 {1.3} 2.9 to 3.9 {0.3 to 0.4} 3.43 {0.35}
5/16-18UNC 24.5 to 34.3 {2.5 to 3.5} 29.4 {3} 6.9 to 8.8 {0.7 to 0.9} 7.8 {0.8}
3/8-16UNC 44.1 to 58.8 {4.5 to 6} 52.0 {5.3} 9.8 to 14.7 {1 to 1.5} 11.8 {1.2}
7/16-14UNC 73.5 to 98.1 {7.5 to 10} 86.3 {8.8} 19.6 to 24.5 {2 to 2.5} 21.6 {2.2}
1/2-13UNC 108 to 147 {11 to 15} 127 {13} 29.4 to 39.2 {3 to 4} 34.3 {3.5}
9/16-12UNC 157 to 216 {16 to 22} 186 {19} 44.1 to 58.8 {4.5 to 6} 51.0 {5.2}
5/8-11UNC 226 to 294 {23 to 30} 265 {27} 63.7 to 83.4 {6.5 to 8.5} 68.6 {7}
3/4-10UNC 392 to 530 {40 to 54} 461 {47} 108 to 147 {11 to 15} 127 {13}
7/8-9UNC 637 to 853 {65 to 87} 745 {76} 177 to 235 {18 to 24} 206 {21}
1-8UNC 883 to 1,196 {90 to 122} 1,040 {106} 245 to 333 {25 to 34} 284 {29}
1 1/8-7UNC 1,187 to 1,608 {121 to 164} 1,393 {142} 333 to 451 {34 to 46} 392 {40}
1 1/4-7UNC 1,598 to 2,157 {163 to 220} 1,873 {191} 451 to 608 {46 to 62} 530 {54}
1 1/2-6UNC 2,354 to 3,177 {240 to 324} 2,765 {282} 657 to 892 {67 to 91} 775 {79}

00-52 HM400-3M0
 00 Index and foreword
Foreword, safety and general information

Unless otherwise specified, tighten the unified fine threaded bolts and nuts to the torque shown in the table
below.

Type of bolt A B
Nominal No. - Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
threads per inch,
type of thread Range Target Range Target
1/4-28UNF 14.7 to 19.6 {1.5 to 2} 17.7 {1.8} 3.9 to 4.9 {0.4 to 0.5} 4.41 {0.45}
5/16-24UNF 34.3 to 39.2 {3.5 to 4} 37.3 {3.8} 7.8 to 9.8 {0.8 to 1} 8.8 {0.9}
3/8-24UNF 53.9 to 68.6 {5.5 to 7} 61.8 {6.3} 14.7 to 19.6 {1.5 to 2} 16.7 {1.7}
7/16-20UNF 83.4 to 108 {8.5 to 11} 96.1 {9.8} 24.5 to 29.4 {2.5 to 3} 26.5 {2.7}
1/2-20UNF 127 to 167 {13 to 17} 147 {15} 34.3 to 49.0 {3.5 to 5} 41.2 {4.2}
9/16-18UNF 186 to 245 {19 to 25} 216 {22} 49.0 to 68.6 {5 to 7} 58.6 {6}
5/8-18UNF 255 to 343 {26 to 35} 294 {30} 73.5 to 98.1 {7.5 to 10} 83.4 {8.5}
3/4-16UNF 441 to 598 {45 to 61} 520 {53} 127 to 167 {13 to 17} 147 {15}
7/8-14UNF 716 to 961 {73 to 98} 843 {86} 196 to 265 {20 to 27} 226 {23}
1-14UNF 1,020 to 1,373 {104 to 140} 1,196 {122} 284 to 382 {29 to 39} 333 {34}
1 1/8-12UNF 1,353 to 1,844 {138 to 188} 1,598 {163} 382 to 520 {39 to 53} 451 {46}
1 1/4-12UNF 1,804 to 2,432 {184 to 248} 2,118 {216} 510 to 686 {52 to 70} 598 {61}
1 1/2-12UNF 2,707 to 3,658 {276 to 373} 3,177 {324} 765 to 1,030 {78 to 105} 892 {91}

Table of tightening torque for O-ring boss piping joints

a Unless otherwise specified, tighten the pipe joint for O-ring boss to the torque shown in the table below.

Thread Width Tightening torque (Nm {kgm})

Nominal No. diameter across flats
(mm) (mm) Range Target
02 14 Varies 35 to 63 {3.5 to 6.5} 44 {4.5}
— 18 depending 59 to 98 {6.0 to 10.0} 78 {8.0}
03, 04 20 on type of 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 connector. 128 to 186 {13.0 to 19.0} 157 {16.0}

HM400-3M0 00-53
00 Index and foreword
Foreword, safety and general information

Thread Width Tightening torque (Nm {kgm})

Nominal No. diameter across flats
(mm) (mm) Range Target
10, 12 33 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1,010 {76.0 to 103} 883 {90.0}

Table of tightening torque for O-ring boss plugs

a Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below.

Thread Width Tightening torque (Nm {kgm})

Nominal No. diameter across flats
(mm) (mm) Range Target
08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 — 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 — 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 — 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}

Table of tightening torque for hose (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the table below.
a The table is applied to the threads coated with engine oil (wet threads)

00-54 HM400-3M0
 00 Index and foreword
Foreword, safety and general information

Tightening torque (Nm {kgm}) Taper seal Face seal

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

Table of tightening torque for face seal joints

a The tightening torque table below applies to the seal joint (sleeve nut type)
a The table is applied to the threads coated with engine oil (wet threads).

Tightening torque (Nm {kgm}) Face seal

Outside Width
diameter of across flats Nominal No. - Thread root
pipe (mm) (mm) Range Target threads per inch, diameter (mm)
type of thread (reference)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 {27} 43 to 47 {4.4 to 4.8} 45 {4.6} 13/16-16UN 20.6
15 {16} 30 {32} 60 to 68 {6.1 to 6.8} 64 {6.5} 1 -14UNS 25.4
22 {20} 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 1 3/16-12UN 30.2
Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification.

Tightening torque table for bolts and nuts on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series
engines to the torques shown in the table below.
Thread diameter (mm) Tightening torque (Nm {kgm})
6 10 ± 2 {1.02 ± 0.20}
8 24 ± 4 {2.45 ± 0.41}
10 43 ± 6 {4.38 ± 0.61}
12 77 ± 12 {7.85 ± 1.22}
14 —

HM400-3M0 00-55
00 Index and foreword
Foreword, safety and general information

Tightening torque table for 102, 107, and 114 series engines (joint bolts)
a Unless otherwise specified, tighten the metric joint bolts used on the 102, 107, and 114 series engines to
the torque shown in the table below.

Thread diameter (mm) Tightening torque (Nm {kgm})

6 8 ± 2 {0.81 ± 0.20}
8 10 ± 2 {1.02 ± 0.20}
10 12 ± 2 {1.22 ± 0.20}
12 24 ± 4 {2.45 ± 0.41}
14 36 ± 5 {3.67 ± 0.51}

Tightening torque table for tapered screws on 102,107, and 114 series engines (National taper pipe
thread (NPT))
a Unless otherwise specified, tighten the National taper pipe threaded (NPT) screws used on the 102, 107,
and 114 series engines to the torques shown in the table below.
Material of female screw In cast iron or steel In aluminum
Nominal thread size Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
1/16 15 ± 2 {1.53 ± 0.20} 5 ± 1 {0.51 ± 0.10}
1/ 8 20 ± 2 {2.04 ± 0.20 15 ± 2 {1.53 ± 0.20}
1/ 4 25 ± 3 {2.55 ± 0.31} 20 ± 2 {2.04 ± 0.20}
3/ 8 35 ± 4 {3.57 ± 0.41} 25 ± 3 {2.55 ± 0.31}
1/ 2 55 ± 6 {5.61 ± 0.61} 35 ± 4 {3.57 ± 0.41}
3/ 4 75 ± 8 {7.65 ± 0.82} 45 ± 5 {4.59 ± 0.51}

00-56 HM400-3M0
 00 Index and foreword
Foreword, safety and general information

List of abbreviation (ALL-0360-005-A-00-A)

(Rev. 2015/01)
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts,
components, and functions whose meaning is not immediately clear. The spelling is given in full with an
outline of the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text (marked with a).
• This list of abbreviations consists of 2 parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.

List of abbreviations used in the shop manual

Purpose of use (major
Abbrevia- Actual word spelled applicable machine (*), or Explanation
tion out equipment/device)
With this function, when the tires skid (wheels
Anti-skid Brake Travel and brake stop rotating), the brakes are released, and
ABS System when the wheels start to rotate, the brakes are
(HD, HM)
applied again.
Automatic Idling This function automatically sets the idle
AISS Engine
Setting System speed.
A lever is used to perform the steering
Advanced Joystick Steering operations instead of a steering wheel.
AJSS Steering System Moreover, it shifts gear and changes direction
(WA)
(FORWARD or REVERSE).
When the accelerator pedal is released while
Automatic Retarder Travel and brake the machine is traveling downhill, this function
ARAC automatically applies the retarder with a
Accelerator Control (HD, HM)
constant braking force.
When the accelerator pedal is released while
Travel and brake the machine is traveling downhill, this function
Automatic Retarder
ARSC automatically applies the retarder to ensure
Speed Control (HD, HM) that the machine speed does not accelerate
above the speed set by the operator.
Travel and brake When the tires spin on soft ground surfaces,
Automatic Spin
ASR this function automatically uses the optimum
Regulator (HD, HM) braking force to drive both wheels.
A device that can be fixed onto a machine in
ATT Attachment Work equipment
order to enable it to do different jobs.
Brake When the retarder is not being used, this
Brake cooling oil valve bypasses part of the brake cooling oil to
BCV
control valve (HD) reduce the load on the hydraulic pump.
Controller Area Communication and One of communication standards that is used
CAN
Network electronic control in the network on the machine.
A regulator valve which is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and it is
Regulator
not used independently.
This system can simultaneously actuate
Closed-center Load multiple actuators regardless of the load
CLSS Hydraulic system
Sensing System (provides better combined operation than O.L.
S.S.).
Engine controller electronically controls
supply pump, common rail, and injector. This
CRI Common Rail Injection Engine
function maintains optimum fuel injection
amount and fuel injection timing.
Electronic control device uses the signals
Electronic Control from the sensors on the machine. This signal
ECM Electronic control system
Module indicates the optimum actuation to the
actuators. (Same as E.C.U.)

HM400-3M0 00-57
00 Index and foreword
Foreword, safety and general information

Purpose of use (major

Abbrevia- Actual word spelled applicable machine (*), or Explanation
tion out equipment/device)
Transmission Proportional electromagnetic valve that
Electronic Control
ECMV gradually increases oil pressure to engage
Modulation Valve (D, HD, WA, etc.)
clutch and reduces transmission shock.
Electronically This system ensures smooth high-speed
Travel travel by absorbing vibration of machine
ECSS Controlled Suspension
System (WA) during travel with hydraulic spring effect of
accumulator.
Electronic control device uses the signals
from the sensors on the machine. This signal
ECU Electronic Control Unit Electronic control system indicates the optimum actuation to the
actuators. (Same as E.C.M.)
This function recirculates part of exhaust gas
Exhaust Gas Engine to combustion chamber in order to reduce
EGR
Recirculation combustion temperature, controls emission of
NOx.
Equipment This system allows data (filter, oil replacement
Management interval, malfunctions on machine, failure
EMMS Machine monitor
Monitoring System code, and failure history) from each sensor on
the machine to be checked on the monitor.
Electromagnetic This mechanism allows actuators to be
EPC Hydraulic system
Proportional Control operated in proportion to the current supplied.
This structure protects the operator's head
from falling objects. (Falling Object Protective
Falling Object Cab and canopy Structure)
FOPS
Protective Structure
This performance is standardized as ISO
3449.
Forward-Neutral- Operation
F-N-R Forward-Neutral-Reverse
Reverse
Global Navigation A general term for positioning system using
GNSS Satellite System Communication satellites such as GPS, GALILEO, etc.
Communication
Global Positioning This system uses satellites to determine the
GPS System (KOMTRAX, KOMTRAX current location on the earth.
Plus)
This function uses a combination of hydraulic
Steering motor and bevel shaft to control difference in
Hydrostatic Steering
HSS travel speed of right and left tracks.
System (D) Accordingly machine can turn without using
steering clutch.
Transmission This function uses a combination of hydraulic
Hydro Static pump and hydraulic motor to shift the speed
HST
Transmission (D, WA) range steplessly without using gears.
Information and A general term for the engineering and its
Communication Intelligent Machine socially applied technology of information
ICT
Technology Control processing and communication.
This valve is installed at inlet port of pump,
Inlet Metering Actuator Engine and it adjusts fuel intake amount in order to
IMA
control fuel discharge of supply pump. Same
as I.M.V.
This is a device to detect the angular velocity
Inertial Measurement Intelligent Machine
IMU and acceleration of the 3 axes that control
Unit Control
motions.
This valve is installed at inlet port of pump,
and it adjusts fuel intake amount in order to
IMV Inlet Metering Valve Engine
control fuel discharge of supply pump. Same
as I.M.V. (I.M.A.)
This mechanism separates oil in blowby gas
Komatsu Closed Engine and returns it to the intake side to afterburn it
KCCV
Crankcase Ventilation there. It primarily consists of filters.

00-58 HM400-3M0
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Purpose of use (major

Abbrevia- Actual word spelled applicable machine (*), or Explanation
tion out equipment/device)
Komatsu Catalyzed This filter captures soot in exhaust gas.
KCSF Engine
Soot Filter It is built in to KDPF.
The catalyst used for purifying exhaust gas.
Komatsu Diesel
KDOC Engine This is built in KDPF or assembled with the
Oxidation Catalyst
muffler.
This component is used to purify the exhaust
gas. KDOC (catalyst) and KCSF (filter to
Komatsu Diesel Engine capture soot) are built-in it.
KDPF
Particulate Filter
It is installed in place of the conventional
muffler.
This function recovers the drive force of the
wheels by braking automatically with the
Komatsu Traction Travel and brake optimum force and at the same time activates
KTCS Control System the inter-axle differential lock when the wheels
(HM system)
idle while the machine travels on the soft
ground road.
Komatsu Variable
The turbocharger on which the cross-section
KVGT Geometry Engine
area of the exhaust passage is made variable.
Turbocharger
Image display equipment such as a monitor
LCD Liquid Crystal Display Machine monitor which assembles in the liquid crystal element.
It refers to semiconductor element that emits
LED Light Emitting Diode Electronic parts light when the voltage is applied in forward
direction.
Local Interconnect Communication and One of communication standards that is used
LIN
Network electronic control in the network on the machine
Function that detects differential pressure of
LS Load Sensing Hydraulic system pump and controls discharge amount
corresponding to load.
Low Voltage Communication and One of communication standards that is used
LVDS Differential Signaling electronic control in the network on the machine
This indicates engine intake air flow.It is not
Engine used independently but it is used as combined
MAF Mass Air Flow
with sensor.Mass air flow sensor can be called
as MAF sensor.
Service that allows transmission and
Multimedia Messaging reception of short messages consisting of
MMS Communication characters or voice or images between cell
Service
phones.
Electric and hydraulic Device actuated to open electric or hydraulic
NC Normally Closed circuits that are normally closed if not
systems
actuated.
Electric and hydraulic Device actuated to close electric or hydraulic
NO Normally Open
systems circuits that are normally open if not actuated.
Open-center Load Hydraulic system that can operate multiple
OLSS Hydraulic system actuators at the same time, regardless of the
Sensing System
load.
Pressure
PC Hydraulic system A function used to correct oil pressure.
Compensation
System in which a controller instantly
Palm command control Steering analyses data from each lever, pedal, and
PCCS system dial, and performs optimum electronic control
(D)
of the engine and transmission.
This valve is installed at inlet port of pump and
Pre-stroke Control Engine it adjusts fuel intake amount in order to control
PCV
Valve fuel discharge amount of supply pump.

HM400-3M0 00-59
00 Index and foreword
Foreword, safety and general information

Purpose of use (major

Abbrevia- Actual word spelled applicable machine (*), or Explanation
tion out equipment/device)
Used for controlling proportional pressure.
Proportional Pressure Hydraulic system This system moves actuators in proportion to
PPC
Control the oil pressure.
Piston Pump and Hydraulic system
PPM Piston pump and motor.
Motor (D, PC, etc.)
PTO Power Take Off Power transmission Power take-off mechanism
Power Tilt and power Work equipment This function performs hydraulic control of the
PTP tilt and pitch of the bulldozer blade.
Pitch dozer (D)
If a machine tips over, this structure protects
the operator with the seat belt fastened from
Roll-Over Protective being crushed. (Operator Protective Structure
ROPS Cab and canopy When Tipping)
Structure
This performance is standardized as ISO
3471.
Le Systeme Abbreviation for the "International System of
International d’ Unites Units". It is the universal unit system and "a
SI (International unit Unit single unit for a single quantity" is the basic
system) principle applied.
It refers to an actuator consisting of a solenoid
and an iron core that is moved by the
SOL Solenoid Electric system
magnetic force when the solenoid is
energized.
Hydraulic and electric Solenoid valve that switches over direction of
TWV 2-Way Valve
systems flow.
*1: Code for applicable machine family
D: Bulldozer
HD: Dump truck
HM: Articulated dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG

00-60 HM400-3M0
 00 Index and foreword
Foreword, safety and general information

Abbreviation Actual word spelled out

SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

HM400-3M0 00-61
00 Index and foreword
Foreword, safety and general information

Conversion table (ALL-2150-931-A-00-A)

(Rev. 2012/10)

Method of using the conversion table

• The unit conversion table enables the simple conversion in the figures between the different units. For
further details of the method of use of the conversion table, see the examples given below.
Example: Method of using the conversion table to convert a unit from millimeters to inches
Conversion of 55 mm into inches
1. Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2. Locate the number 5 in the row across the top, take this as (B), then draw a vertical line down from (B).
3. Take the point where the 2 lines cross as (C). This point (C) gives the value when converting the unit from
millimeters to inches. Therefore, 55 mm = 2.165 in.
Conversion of 550 mm into inches
1. The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the
left) to get 55 mm.
2. Then convert 55 mm to 2.165 in by the same procedure as above.
3. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to get the original value. This gives 550 mm = 21.65 in. Therefore, 550 mm = 21.65
in.
Millimeters to inches
(B)
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 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

00-62 HM400-3M0
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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 2.847 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

Kilograms to pounds
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

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

HM400-3M0 00-63
00 Index and foreword
Foreword, safety and general information

l to U.K. Gallons
1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1,005
140 1,013 1,020 1,027 1,034 1,042 1,049 1,056 1,063 1,071 1,078
150 1,085 1,092 1,099 1,107 1,114 1,121 1,128 1,136 1,143 1,150
160 1,157 1,165 1,172 1,179 1,186 1,193 1,201 1,208 1,215 1,222
170 1,130 1,237 1,244 1,251 1,259 1,266 1,273 1,280 1,288 1,295
180 1,302 1,309 1,316 1,324 1,331 1,338 1,345 1,353 1,360 1,367
190 1,374 1,382 1,389 1,396 1,403 1,410 1,418 1,425 1,432 1,439

00-64 HM400-3M0
 00 Index and foreword
Foreword, safety and general information

kg/cm2 to lb/in22
1 kg/cm2 = 14.2233 lb/in22
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

HM400-3M0 00-65
00 Index and foreword
Foreword, safety and general information

Temperature
Conversion of Fahrenheit to Celsius
• A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice
versa is to see the number in the center column of the following table. The figures on the following table
show the temperatures in both Fahrenheit and Celsius.
• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.
• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

00-66 HM400-3M0
SHOP MANUAL

ARTICULATED DUMP TRUCK

HM400-3M0
Model Serial Number

HM400-3M0 5001 and up

01 Specification
2 01 Specification

HM400-3M0 01-1
01 Specification
Table of contents

Table of contents (ALL-0310-002-A-00-A)

01 Specification................................................................................................................................. 01-1
Table of contents ........................................................................................................................ 01-2
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Specifications ...................................................................................................................... 01-5
Weight table ...................................................................................................................... 01-11
Table of fuel, coolant, and lubricants .................................................................................... 01-12

01-2 HM400-3M0
 01 Specification
Specification drawing

Specifications (ALL-2111-001-A-00-A)

Specification drawing (ALL-2110-001-A-00-A)

HM400-3M0 (HM400_3M0-2110-931-A-00-A)

Item Unit HM400-3M0

Gross weight (machine weight +
74,125
max. payload + 1 operator (80 kg))
kg
Machine weight 34,045
Max. payload 40,000
Dump body capacity
Struck 18.2
m3
Heaped (2:1) 24.0
Dumping speed (raise)
(at engine speed of 1,800 min-1 sec 12.0
{1,800 rpm})
Engine model — Komatsu SAA6D140E-5 diesel engine
Engine rated horsepower
• SAE J1995 (gross) (*1) 338 {453}/2,000 {2,000}
kW {HP}/min-1
• ISO 14396 338 {453}/2,000 {2,000}
{rpm}
• ISO 9249/SAE J1349 (net) (*2) 334 {448}/2,000 {2,000}
Nm {kgm}/min-1
Engine max. torque (*2) 2,062 {210}/1,400 {1,400}
{rpm}
A Overall length mm 11,105
B Overall height mm 3,735
Overall height when dump body is mm 7,171
C
raised
D Overall width mm 3,450
Min. ground clearance (bottom of
E rear axle) mm 615
Min. turning radius (wall to wall) mm 8,800

HM400-3M0 01-3
01 Specification
Specification drawing

Item Unit HM400-3M0

Travel speed
• Forward
1st 6.6
2nd 10.1
3rd 15.5
4th 23.8
km/h
5th 36.5
6th 56.0
• Reverse
1st 6.8
2nd 16.0
Operating temperature range °C -20 to 45
*1: Indicates the value of the basic engine (without cooling fan).
*2: Indicates the value at the minimum cooling fan speed.
a The engine rated horsepower is indicated in the net value and gross value. The gross denotes the
flywheel horsepower measured on the basic engine unit, while the net denotes the value measured of an
engine under the condition essentially the same as that when it is installed on a machine.
a Following shows the rated horsepower (net) at the maximum cooling fan speed.
307 kW {411 HP}/2,000 min-1 {2,000 rpm}

01-4 HM400-3M0
 01 Specification
Specifications

Specifications (ALL-2111-001-A-01-A)

HM400-3M0 (HM400_3M0-2111-931-A-00-A)

Machine model HM400-3M0

Unit
Serial No. 5001 and up
Gross weight (machine weight + max.
74,125
payload + 1 operator (80 kg))
Machine weight 34,045
Front wheel 19,325
Center wheel 7,880
Rear wheel kg 6,840
Max. payload 40,000
Weight distribution (with max.
payload)
Front wheel 21,725
Center wheel 26,200
Rear wheel 26,120

Performance
Dump body capacity
Struck 18.2
m3
Heaped (2:1) 24.0
Max. travel speed km/h 56.0
Gradeability (sin θ) — 0.51
Min. turning radius
Front wheel (wall to wall) 8,800
mm
Center wheel/ Rear wheel 4,170
Dumping angle (angle to ground) deg. 70

HM400-3M0 01-5
01 Specification
Specifications

Machine model HM400-3M0

Unit
Serial No. 5001 and up

Dimensions
Overall length mm 11,105
Overall width mm 3,450
Overall height mm 3,735
Dump body width mm 3,450
Front overhang mm 2,985
Wheelbase (front wheel to center
mm 4,350
wheel)
Wheelbase (center wheel to rear wheel) mm 1,970
Articulation center to front wheel mm 1,350
Tread
Front wheel 2,690
Center wheel mm 2,690
Rear wheel 2,690
Distance between outside of tires
Front wheel 3,450
Center wheel mm 3,450
Rear wheel 3,450
Approach angle deg. 25
Min. ground clearance
Front wheel 655
Center wheel 615
Rear wheel mm 615
Articulate part 710
Lower end of raised dump body 770
Loading height of dump body mm 3,164
Dump body height (when dump body is
7,171
raised) mm
Distance between rear axle to shaft pin 620
Cab width mm 1,675
Dump body length mm 5,667

01-6 HM400-3M0
 01 Specification
Specifications

Machine model HM400-3M0

Unit
Serial No. 5001 and up

Engine
Model — SAA6D140E-5
4-cycle, water-cooled, in-line, vertical, direct
Type — injection, with turbocharger and air-cooled
aftercooler
No. of cylinders - bore x stroke mm 6 - 140 x 165
Total piston displacement l {cc} 15.24 {15,240}
Performance
Rated horsepower
• SAE J1995 (gross) (*1) 338 {453}/2,000 {2,000}
kW {HP}/min-1
• ISO 14396 338 {453}/2,000 {2,000}
{rpm}
• ISO 9249/SAE J1349 (net) (*2) 334 {448}/2,000 {2,000}
Nm {kgm}/min-1
Max. torque (*2) 2,062 {210}/1,400 {1,400}
{rpm}
Fuel consumption ratio at rated
g/kWh {g/HPh} 213 {159}
horsepower
Starting motor — 24 V, 11 kW
Alternator — 24 V, 60 A
Battery (*3) — 12 V, 136 Ah x 2 pieces
Radiator model — CF79-4
Type of aftercooler core — Corrugated aluminum
*1: Indicates the value of the basic engine (without cooling fan).
*2: Indicates the value at the minimum cooling fan speed.
*3: The battery capacity (Ah) is indicated in the 5-hour rate.
a The engine rated horsepower is indicated in the net value and gross value. The gross denotes the
flywheel horsepower measured on the basic engine unit, while the net denotes the value measured of an
engine under the condition essentially the same as that when it is installed on a machine.
a Following shows the rated horsepower (net) at the maximum cooling fan speed.
307 kW {411 HP}/2,000 min-1 {2,000 rpm}

Power train
Torque converter
Type 3-element, 1-stage, 2-phase
— Hydraulically actuated, wet-type, single disc
Lockup clutch
clutch
Transmission
TORQFLOW, counter-shaft type, full automatic,
Type electrically/hydraulically actuated, pump force
— lubrication type
No. of speed ranges Forward 6-speed, reverse 2-speed
Reduction gear system
Type Spiral bevel gear, splash lubrication type
Reduction ratio — 3.727
Differential type Straight bevel gear, splash lubrication type
Final reduction gear
Type Planetary gear, splash lubrication type
—
Reduction ratio 4.941

HM400-3M0 01-7
01 Specification
Specifications

Machine model HM400-3M0

Unit
Serial No. 5001 and up

Steering
Steering method — Articulation type
Actuating method — Full hydraulic

Suspension
Axle type
Front axle Full floating type
Center axle — Full floating type
Rear axle Full floating type
Suspension method
Front axle Axle suspension type (De Dion type)
—
Rear axle Axle suspension type

Tire
Size x number
Front wheel 29.5R25 x 2
Center wheel — 29.5R25 x 2
Rear wheel 29.5R25 x 2
Inflation pressure
Front wheel 380 {3.8}
Center wheel kPa {kg/cm2} 400 {4.0}
Rear wheel 400 {4.0}

Brake
Main brake
Independent front and center wheel brake,
Front wheel sealed, wet- type, multiple disc,
Hydraulically operated type
—
Independent front and center wheel brake,
Center wheel sealed, wet- type, multiple disc,
Hydraulically operated type
Parking brake — Spring-boosted caliper disc type
Independent front and center wheel brake,
Retarder — sealed, wet- type, multiple disc,
Hydraulically operated type

01-8 HM400-3M0
 01 Specification
Specifications

Machine model HM400-3M0

Unit
Serial No. 5001 and up

Hydraulic system
Steering and hoist pump
Type — Variable displacement swash plate piston type
Discharge
At steering operation
(at engine speed of 2,000 min-1 197.5 x 2
{2,000 rpm})
l/min
At hoist operation
(at engine speed of 1,800 min-1 178 x 2
{1,800 rpm})
Radiator fan pump
Type — Variable displacement swash plate piston type
Discharge
(at engine speed of 2,000 min-1 l/min 105
{2,000 rpm})
Aftercooler fan pump
Type — Gear pump
Discharge
(at engine speed of 2,000 min-1 l/min 26.4
{2,000 rpm})
Transmission pump
Type — Gear pump
Discharge
(at engine speed of 2,000 min-1 l/min 126
{2,000 rpm})
Torque converter and front brake
cooling pump
Type — Gear pump
Discharge
(at engine speed of 2,000 min-1 l/min 65
{2,000 rpm})
Center brake cooling pump
Type — Gear pump
Discharge
(at engine speed of 2,000 min-1 l/min 142.3
{2,000 rpm})
Center brake cooling remote motor
drive pump
Type — Gear pump
Discharge
(at engine speed of 2,000 min-1 l/min 27.3
{2,000 rpm})
Center brake cooling remote pump
Type — Gear pump
Discharge
(at engine speed of 2,000 min-1 l/min 111.7
{2,000 rpm})

HM400-3M0 01-9
01 Specification
Specifications

Machine model HM400-3M0

Unit
Serial No. 5001 and up
Brake charge pump
Type — Gear pump
Discharge
(at engine speed of 2,000 min-1 l/min 40.6
{2,000 rpm})
Emergency steering pump
Type — Gear pump
Discharge l/min 40 x 2
Radiator fan motor
Type — Fixed displacement, swash plate, piston type
Motor capacity cc/rev 55
Aftercooler fan motor
Type — Fixed displacement, swash plate, piston type
Motor capacity cc/rev 10
Center brake cooling remote motor
Type — Fixed displacement, swash plate, piston type
Motor capacity cc/rev 10
Emergency steering motor
Type — DC motor
Hoist cylinder
Type — Piston type, double-acting
Cylinder bore mm 135
Piston rod diameter mm 95
Stroke mm 2,486
Max. distance between pins mm 5,517
Min. distance between pins mm 3,031
Steering cylinder
Type — Piston type, double-acting
Cylinder bore mm 120
Piston rod diameter mm 70
Stroke mm 525
Max. distance between pins mm 1,466
Min. distance between pins mm 941
Hydraulic tank — Box-shaped sealed type
Hydraulic oil filter — Tank return side
Hydraulic oil cooler — Water cooled

01-10 HM400-3M0
 01 Specification
Weight table

Weight table (ALL-2120-001-A-00-A)

HM400-3M0 (HM400_3M0-2120-931-A-00-A)

k This weight table is a guide for use when handling or transporting the components.
Unit: kg
Machine model HM400-3M0
Serial No. 5001 and up
Engine assembly (including mounting bracket, exhaust piping, 1,937
etc.)
• Output shaft assembly 88
Cooling system assembly 586
• Radiator 126
• Aftercooler 94
• Oil cooler 138
Fuel tank (tank only) 309
Transmission assembly 1,518
Front drive shaft 31
Center drive shaft 47
Rear drive shaft (front) 81
Rear drive shaft (rear) 40
Front differential 443
Front final drive 1,126
Drive shaft (1 piece) 47
Center axle assembly 2,047
• Differential 382
• Final drive 1,274
Rear axle assembly 1,385
• Differential 260
• Final drive 683
Tire and rim assembly (29.5R25AAE-2) (1 piece) 777
• Tire and rim assembly (29.5R25AAE-2) (1 piece) 520
• Rim (25.00-25WTB) (1 piece) 257
Front suspension cylinder (left) 93
Front suspension cylinder (right) 94
Rear suspension cylinder 62
Oscillation hitch assembly 846
Front frame 2,086
Rear frame 2,398
Operator's cab (including interior parts) 1,050
Operator's seat 48
Steering cylinder (1 piece) 70
Hoist cylinder (1 piece 300
Flow amplifier valve 29
Hoist valve 34
Hydraulic tank 175
Steering and hoist control pump 91
Pump for driving torque converter, transmission, aftercooler fan,
and center brake cooling motors 29
Center brake cooling pump, radiator fan pump and brake charge
pump 117
Center brake cooling remote pump 7
Dump body assembly 4,523

HM400-3M0 01-11
01 Specification
Table of fuel, coolant, and lubricants

Table of fuel, coolant, and lubricants (HM400_3R-RA19-05A-K-00-A)

a For details of notes (Note 1, Note 2...) in the table, see the Operation and Maintenance Manual.

01-12 HM400-3M0
 01 Specification
Table of fuel, coolant, and lubricants

Unit: l
Applicable portion Specified capacity Refill capacity
Engine oil pan 58 50
Transmission case (including brake oil tank) 260 125
Hydraulic tank 245 167
Front suspension (each of right and left) 7.8 7.8
Rear suspension (each of right and left) 2.4 2.4
Front differential case 26.0 26.0
Front final drive case (each of right and left) 6 5.5
Center differential case 43 43
Center final drive case (each of right and left) 5.5 5.0
Rear differential case 39 39
Rear final drive case (each of right and left) 6 5.5
Fuel tank 525.0 —
Cooling system 120 114

HM400-3M0 01-13
01 Specification
Table of fuel, coolant, and lubricants

01-14 HM400-3M0
SHOP MANUAL

ARTICULATED DUMP TRUCK

HM400-3M0
Model Serial Number

HM400-3M0 5001 and up

10 Structure and function

3 10 Structure and function

HM400-3M0 10-1
10 Structure and function
Table of contents

Table of contents (ALL-0310-002-A-00-A)

10 Structure and function ................................................................................................................... 10-1
Table of contents ........................................................................................................................ 10-2
Engine and cooling system .......................................................................................................... 10-4
Engine related parts ............................................................................................................. 10-4
Output shaft......................................................................................................................... 10-5
Turbocharger ....................................................................................................................... 10-6
EGR system layout drawing .................................................................................................. 10-8
EGR system circuit diagram .................................................................................................. 10-9
EGR valve......................................................................................................................... 10-11
Bypass valve ..................................................................................................................... 10-13
Venturi system ................................................................................................................... 10-15
EGR cooler........................................................................................................................ 10-17
Muffler............................................................................................................................... 10-19
Cooling system .................................................................................................................. 10-20
Radiator fan pump.............................................................................................................. 10-22
Aftercooler fan motor .......................................................................................................... 10-30
Radiator fan motor ............................................................................................................. 10-41
Oil cooler bypass valve....................................................................................................... 10-50
Power train............................................................................................................................... 10-51
Power train system............................................................................................................. 10-51
Drive shaft ......................................................................................................................... 10-53
Torque converter and transmission hydraulic piping .............................................................. 10-54
Torque converter ................................................................................................................ 10-55
Transmission ..................................................................................................................... 10-61
Transmission control valve.................................................................................................. 10-86
Forward and reverse clutch ECMV and gear speed clutch ECMV ........................................... 10-89
Lockup clutch ECMV .......................................................................................................... 10-96
Differential lock clutch ECMV ............................................................................................ 10-100
Main relief valve, torque converter relief valve, and main flow selector valve.......................... 10-104
Axle ................................................................................................................................ 10-110
Differential ....................................................................................................................... 10-113
Final drive ....................................................................................................................... 10-117
Steering system...................................................................................................................... 10-120
Layout of steering devices ................................................................................................ 10-120
Steering column............................................................................................................... 10-121
Flow amplifier valve.......................................................................................................... 10-122
Steering valve.................................................................................................................. 10-126
Emergency steering pump ................................................................................................ 10-132
Emergency steering motor ................................................................................................ 10-133
Brake system ......................................................................................................................... 10-134
Layout of brake parts........................................................................................................ 10-134
Parking brake solenoid and accumulator charge valve ........................................................ 10-136
Accumulator .................................................................................................................... 10-142
Shut off solenoid valve...................................................................................................... 10-143
Brake valve ..................................................................................................................... 10-144
Proportional pressure reducing valve ................................................................................. 10-149
Slack adjuster .................................................................................................................. 10-151
Brake .............................................................................................................................. 10-155
Brake system tank ........................................................................................................... 10-158
Parking brake .................................................................................................................. 10-159
Undercarriage and frame......................................................................................................... 10-162
Suspension ..................................................................................................................... 10-162
Suspension cylinder ......................................................................................................... 10-166
Oscillation hitch ............................................................................................................... 10-169
Hydraulic system .................................................................................................................... 10-170
Hydraulic component layout .............................................................................................. 10-170
Dump body control ........................................................................................................... 10-172

10-2 HM400-3M0
 10 Structure and function
Table of contents

Hydraulic tank.................................................................................................................. 10-173

Steering and hoist pump ................................................................................................... 10-174
Hoist valve ...................................................................................................................... 10-185
Steering pump selector solenoid valve ............................................................................... 10-191
Dump EPC valve ............................................................................................................. 10-192
Center brake cooling remote motor .................................................................................... 10-194
Front brake cooling relief valve .......................................................................................... 10-203
Center brake cooling relief valve........................................................................................ 10-204
Cab and its attachments .......................................................................................................... 10-205
ROPS cab ....................................................................................................................... 10-205
Cab tilt ............................................................................................................................ 10-206
Electrical system .................................................................................................................... 10-207
Electrical control system ................................................................................................... 10-207
Machine monitor system ................................................................................................... 10-236
Rear view monitor system................................................................................................. 10-259
KOMTRAX system ........................................................................................................... 10-263
System component parts .................................................................................................. 10-266
Sensor ............................................................................................................................ 10-292

HM400-3M0 10-3
10 Structure and function
Engine related parts

Engine and cooling system (ALL-R401-001-K-00-A)

Engine related parts (HM400_3M0-A001-041-K-00-A)

1. Air cleaner
2. Muffler
3. Rear engine mount
4. Engine oil filter
5. Fuel main filter
6. Front engine mount
7. Vibration damper
8. Vacuator valve
9. EGR cooler
10.Turbocharger
11.Drain plug

10-4 HM400-3M0
 10 Structure and function
Output shaft

Output shaft (HM400-CB30-041-K-00-A)

1. Rubber cushion (large)

2. Rubber cushion (small)
3. Outer body
4. Flange
5. Shaft
6. Coupling
7. Inner body
8. Cover
Function (HM300-CB30-042-K-00-A)

• The output shaft is installed to the engine flywheel, and absorbs the torsional vibration caused by
fluctuation of the engine torque.

HM400-3M0 10-5
10 Structure and function
Turbocharger

Turbocharger (HM400_3R-AA10-041-K-00-A)

10-6 HM400-3M0
 10 Structure and function
Turbocharger

A: Air intake inlet

B: Air intake outlet
C: Exhaust inlet
D: Exhaust outlet
E: Oil inlet
F: Oil outlet

1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10.Journal bearing
11.Seal ring
12.Turbine impeller
Specifications (HM400_3R-AA10-030-K-00-A)

Model KTR110L
Type Air cooled
Overall length (mm) 308
Overall width (mm) 305
Overall height (mm) 287
Weight (kg) 24

HM400-3M0 10-7
10 Structure and function
EGR system layout drawing

EGR system layout drawing (HM400_3M0-A9J0-04D-K-00-A)

a EGR: Abbreviation for Exhaust Gas Recirculation

1. EGR valve
2. EGR valve position sensor
3. Bypass valve
4. Bypass valve position sensor
5. Venturi system
6. EGR oil pump
7. EGR cooler

10-8 HM400-3M0
 10 Structure and function
EGR system circuit diagram

EGR system circuit diagram (HM400_3M0-A9J0-051-K-00-A)

a EGR: Abbreviation for Exhaust Gas Recirculation

1. EGR valve
2. Bypass valve
3. EGR cooler
4. Venturi system
5. Sensors

HM400-3M0 10-9
10 Structure and function
EGR system circuit diagram

Function (HM400_3M0-A9J0-042-K-00-A)

• EGR valve (driven hydraulically)

Controls the gas flow from exhaust side to intake side.
Since the exhaust pressure is higher than the boost pressure, the exhaust gas flows into the intake side.
• Bypass valve
Supply air flows into exhaust side to boost exhaust gas pressure so that EGR gas returns to air intake side
easier.
• EGR cooler
It cools down exhaust gas and returns it to air intake side.
The engine coolant is used for cooling.
• Venturi system
Negative pressure is generated by Venturi effect to suck the exhaust gas.
• Sensors
Monitorings operation state of each part
Troubleshoots the EGR system.

Advantages
• Controls each part of the EGR circuit and controls the EGR rate in accordance with the operating
condition to clean the exhaust gas constantly.
• Monitors the condition of the EGR circuit and perform troubleshooting to prevent a serious failure.
Operation (HM400_3M0-A9J0-044-K-00-A)

• The engine controller outputs signals so that EGR valve (1) opens properly in accordiance with the engine
load to realize both clean exhaust gas and low fuel consumption.
• When EGR valve (1) opens, a part of the exhaust gas (EGR gas) flows from the exhaust manifold into
EGR cooler (3) through the EGR piping.
• The exhaust gas cooled by EGR cooler (3) flows through EGR valve (1), merges with the supply air in the
mixing connector, and flows into the air intake manifold.
• When the boost pressure is higher than the exhaust pressure, engine controller gives the command to
open bypass valve (2).

10-10 HM400-3M0
 10 Structure and function
EGR valve

EGR valve (HM400_3M0-A9K1-041-K-00-A)

a EGR: Abbreviation for Exhaust Gas Recirculation

A: Oil inlet
B: Oil outlet
C: EGR gas

1. Stick prevention device

2. Hydraulic control valve
3. Solenoid valve
4. Position sensor
5. Hydreulic piston
6. Spring
7. Valve

HM400-3M0 10-11
10 Structure and function
EGR valve

Function (HM400_3M0-A9K1-042-K-00-A)

• EGR valve is electronically controlled and hydraulically driven.

• EGR valve controls the gas flow from exhaust side to intake side.
Operation (HM400_3M0-A9K1-044-K-00-A)

• Valve (7) is closed by reaction force of spring (6).

• Hydraulic control valve (2) is controlled by solenoid valve (3), and reduces the oil pressure (engine oil)
supplied from oil inlet (A).
• Press force is generated to hydraulic piston (5) by reduced oil pressure by hydraulic control valve (2).
• When the press force of hydraulic piston (5) is higher than the reaction force of spring (6), valve (7) opens
and valve opening in proportion to pilot pressure can be obtained.
• Engine controller controls the drive current of solenoid valve (3) to obtain specified valve opening.
• Engine controller detects the position of hydraulic piston (5) by using position detecting sensor (4).

10-12 HM400-3M0
 10 Structure and function
Bypass valve

Bypass valve (HM400_3M0-A9K2-041-K-00-A)

A: Oil inlet
B: Oil outlet
C: Supply air

1. Stick prevention device

2. Hydraulic control valve
3. Solenoid valve
4. Position sensor
5. Hydraulic piston
6. Spring
7. Valve

HM400-3M0 10-13
10 Structure and function
Bypass valve

Function (HM400_3M0-A9K2-042-K-00-A)

• Bypass valve is electronically controlled and hydraulically driven.

• Bypass valve boosts exhaust gas pressure so that EGR gas returns to air intake side easier.
Operation (HM400_3M0-A9K2-044-K-00-A)

• Valve (7) is closed by reaction force of spring (6).

• Hydraulic control valve (2) is controlled by solenoid valve (3), and reduces the oil pressure (engine oil)
supplied from oil inlet (A).
• Press force is generated to hydraulic piston (5) by reduced oil pressure by hydraulic control valve (2).
• When the press force of hydraulic piston (5) is higher than the reaction force of spring (6), valve (7) opens
and valve opening in proportion to pilot pressure can be obtained.
• When valve (7) opens, exhaust pressure increases so that the exhaust gas returns to air intake side
easier.
• Engine controller controls the drive current of solenoid valve (3) to obtain specified valve opening.
• Engine controller detects the position of hydraulic piston (5) by using position detecting sensor (4).

10-14 HM400-3M0
 10 Structure and function
Venturi system

Venturi system (HM400_3M0-A9M0-041-K-00-A)

A: Supply air inlet

B: EGR gas inlet

1. Venturi nozzle
2. Throttle
3. Diffuser
Structure
• Venturi system is adopted at the place where EGR gas merges with supply air.
• Venturi system consists of venturi nozzle (1), throttle (2) and diffuser (3).

HM400-3M0 10-15
10 Structure and function
Venturi system

Function (HM400_3M0-A9M0-042-K-00-A)

• Venturi system sucks EGR gas to supply side by Venturi effect and mixes it with supply air.
Operation (HM400_3M0-A9M0-044-K-00-A)

• Boost pressure supercharged by turbocharger is changed to the negative pressure temporarily by Venturi
effect of throttle (2).
• EGR gas is sucked into supply air side from Venturi nozzle (1) and merges to supply air.
• Mixed supply air with EGR gas flows into air intake manifold through diffuser (3).
• Diffuser (3) returns the supply air pressure mixed with EGR gas to the proper value.

10-16 HM400-3M0
 10 Structure and function
EGR cooler

EGR cooler (HM400_3M0-A9L0-041-K-00-A)

A: EGR gas inlet

B: EGR gas outlet
C: Coolant inlet
D: Coolant outlet
E: Air vent

1. Heat exchanger tube (wave tube)

Structure
• Multi-tube type heat exchanger
• Heat exchanger tube (1) is formed to wave shape so that high cooling efficiency can be obtained.
• Heat exchanger tube (1) is made of corrosion resistant stainless steel.

HM400-3M0 10-17
10 Structure and function
EGR cooler

Function (HM400_3M0-A9L0-042-K-00-A)

• EGR cooler cools down high temperature EGR gas taken out from exhaust gas, and increases gas
density to improve EGR efficiency.
Operation (HM400_3M0-A9L0-044-K-00-A)

• The EGR gas enters from EGR gas inlet (A) and flows through heat transfer tubes (1).
• Coolant enters from coolant inlet (C) and flows around heat transfer tubes (1) in the shell and then goes
out from coolant outlet (D).
• EGR gas is effectively cooled by heat transfer tubes (1) and flows out from EGR gas outlet (B).

10-18 HM400-3M0
 10 Structure and function
Muffler

Muffler (HM400_3R-A9H0-041-K-00-A)

A: Exhaust inlet
B: Exhaust outlet

HM400-3M0 10-19
10 Structure and function
Cooling system

Cooling system (HM400_3R-B000-041-K-00-A)

10-20 HM400-3M0
 10 Structure and function
Cooling system

A: From thermostat
B: To water pump
C: From brake
D: To oil filter
E: To hydraulic tank
F: From thermostat

1. Radiator
2. Radiator inlet hose
3. Aftercooler
4. Aftercooler outlet hose
5. Aftercooler inlet hose
6. Reservoir tank
7. Water filler port
8. Sub-tank
9. Torque converter and steering oil cooler
10.Radiator outlet hose
11.Aftercooler fan motor
12.Radiator fan motor
13.Oil cooler bypass valve
Specifications (HM400-B000-030-K-00-A)

Torque converter oil Steering oil cooler

Radiator Aftercooler
cooler
Core model CF79 PTO-LS PTO-LS —
Cracking pressure of 90 ± 15
pressure valve (kPa — — —
{kg/cm2}) {0.9 ± 0.15}

HM400-3M0 10-21
10 Structure and function
Radiator fan pump

Radiator fan pump (HM400_3R-B450-041-K-00-A)

P1: Pump discharge port

PAEPC: EPC output pressure pickup plug
PEPC: EPC valve source pressure input port
PS: Pump suction port
TO: Drain port

1. Servo valve
2. Bleeder
3. EPC valve

10-22 HM400-3M0
 10 Structure and function
Radiator fan pump

1. Shaft
2. Servo piston
3. Spring
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Case
10.Oil seal
11.Ball retainer

HM400-3M0 10-23
10 Structure and function
Radiator fan pump

Structure
• Cylinder block (7) is supported to shaft (1) by spline (11).
• Shaft (1) is supported by each bearing (12) at the front and rear.
• The tip of piston (6) is shaped as a concave sphere and crimped together with shoe (5).
• Piston (6) and shoe (5) form a spherical bearing.
• Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
• Rocker cam (4) pivots on ball retainer (13).
• Piston (6) moves relatively in the axial direction in each cylinder chamber of cylinder block (7).
• Cylinder block (7) rotates relatively to valve plate (8) while sealing the pressurized oil.
• The oil pressure is balanced properly on the contact face between cylinder block and valve plate.
• The pressurized oil is sucked in and discharged from each cylinder chamber in cylinder block (7) through
valve plate (8).
Specifications (HM400_3R-B450-030-K-00-A)

Model LPV45
Type Variable displacement swash plate type piston pump
Theoretical discharge (cm3/rev) 45
Fan drive pressure (MPa {kg/cm2}) 17.3 {177}
Rated speed (rpm) 2,374

Function (HM300-B450-042-K-00-A)

• This pump converts the rotation and torque of the engine transmitted to its shaft into hydraulic energy and
discharges hydraulic oil according to the load.
• The discharge can be changed by changing the swash plate angle.

10-24 HM400-3M0
 10 Structure and function
Radiator fan pump

Operation (HM400_3R-B450-044-K-00-A)

• Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A).
• Rocker cam (4) pivots on ball retainer (13), and accordingly angle (a) between center line (X) of rocker
cam (4) and the axial direction of cylinder block (7) changes.
• Angle (a) is called the swash plate angle.

• While angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7), plane
(A) works as a cam for shoe (5).
• Pistons (6) slide inside cylinder block (7) and a difference is made between volumes (E) and (F) in cylinder
block (7).
• Oil in amount of (F) - (E) is sucked in and discharged from each piston (6).
• Oil is discharged while cylinder block (7) rotates and the volume of chamber (E) decreases.
• Oil is sucked in when the volume of chamber (F) increases.

• When center line (X) of rocker cam (4) matches the axis of cylinder block (7) (the swash plate angle is
zero), the difference between volumes (E) and (F) inside cylinder block (7) is zero.
• Pressurized oil is not sucked or discharged, namely pumping action is not performed. (Actually, however,
the swash plate angle does not become 0 deg.)
• The pump discharge is in proportion to swash plate angle (a).

HM400-3M0 10-25
10 Structure and function
Radiator fan pump

Control of discharge

• When swash plate angle (a) is increased, the difference between volumes (E) and (F) is increased, then
discharge (Q) is increased.
• Swash plate angle (a) is changed by servo piston (10).
• Servo piston (10) reciprocates linearly according to the signal pressure of the servo valve.
• This linear motion is transmitted to rocker cam (4).
• Rocker cam (4) supported with ball retainer (13) pivots on ball retainer (13).

10-26 HM400-3M0
 10 Structure and function
Radiator fan pump

Servo valve (HM400_3R-B4H0-041-K-00-A)

HM400-3M0 10-27
10 Structure and function
Radiator fan pump

P: EPC valve source pressure port

PE: Control piston pressure port
PH: Pump discharge pressure port
T: Drain port

1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
8. Spring
9. EPC valve

Function (PC400-B4H0-042-K-00-A)
• The servo valve controls the pump so that the input current (i) to the EPC valve relates to pump discharge
(Q) as shown in the figure below.

10-28 HM400-3M0
 10 Structure and function
Radiator fan pump

Operation (HM400_3R-B4H0-044-K-00-A)

• The output pressure of the EPC valve enters piston chamber (C) and pushes piston (6).
• Piston (6) pushes spool (5) and moves to a position where it is balanced with the spring.
• Land (PE) of the servo piston pressure passage is connected to pump discharge pressure passage (PH)
through the notch of spool (5), so the pump discharge pressure is transmitted to servo piston (10).
• Rocker cam (9) is pushed up by servo piston (10), and then its position is fed back and lever (2) moves to
compress spring (8).
• When spool (5) is pushed back, the pump discharge circuit and the servo piston circuit are disconnected.
• The pressure in the servo piston chamber decreases and rocker cam (9) moves toward the maximum
swash plate angle.
• These processes are repeated until the swash plate is fixed to an angle where the EPC output pressure is
balanced with the force of spring (8).
• As the EPC output pressure increases, the swash plate angle decreases. As the EPC output pressure
decreases, the swash plate angle increases.

HM400-3M0 10-29
10 Structure and function
Aftercooler fan motor

Aftercooler fan motor (HM400-B5L0-041-K-00-A)

P: From pump through charge valve

T: To hydraulic tank through return filter
TC: To hydraulic tank

1. Terminal ER
2. Terminal EF
3. Terminal EN
4. EPC valve
5. Aftercooler fan reverse solenoid valve

10-30 HM400-3M0
 10 Structure and function
Aftercooler fan motor

1. Output shaft
2. Case
3. thrust plate
4. Piston assembly
5. Cylinder block
6. Valve plate
7. End cover
8. Bearing
9. Spring
10.Retainer shoe
11.Retainer guide

HM400-3M0 10-31
10 Structure and function
Aftercooler fan motor

12.Bearing
13.Oil seal
14.Flow control spool
15.Suction safety valve
16.Reversible spool
17.Speed sensor

Structure
• This fan motor is installed within the blade width as shown in the figure.

Specifications (HM300-B5L0-030-K-00-A)

Model LMF10
Type Swash plate type piston motor
Motor capacity (cc/rev) 10
Rated speed (rpm) 2,600
Rated flow rate (l/min) 26
Cracking pressure of check valve (MPa {kg/cm2}) 0.013 {0.13}

Hydraulic motor (HM300-B5N0-042-K-00-A)

Function
• This hydraulic motor is called a swash plate axial piston motor. It converts the energy of the pressurized oil
sent from the hydraulic pump into rotary motion.

Principle of operation (HM300-B5N0-04B-K-01-A)

• The pressurized oil sent from the pump flows through valve plate (6) into cylinder block (5).
• This oil can flow to only one side of the (Y-Y) line connecting the top dead center and bottom dead center
of the stroke of piston (4).
• The pressurized oil sent to one side of cylinder block (5) pushes each piston (4) (2 or 3 pistons).
• Each piston (4) generates force (F1) [F1 (kg) = P (kg/cm2) x x D2 / 4 (cm2)].
• This force acts on thrust plate (2).
• Since thrust plate (2) is fixed at specific angle (a) to output shaft (1), the force is divided into components
(F2) and (F3).
• Radial component (F3) generates each torque [T = F3 x ri] against the (Y - Y) line connecting the top dead
center and bottom dead center.
• The total of these torque [T = Σ(F3 x ri)] rotates cylinder block (5) through piston (4).
• Cylinder block (5) is connected to output shaft (1) with spline.
• Output shaft (1) rotates to transmit the torque.

10-32 HM400-3M0
 10 Structure and function
Aftercooler fan motor

HM400-3M0 10-33
10 Structure and function
Aftercooler fan motor

Suction safety valve (HM300-B6D6-001-K-00-A)

Function as suction valve (HM300-B6D6-042-K-00-A)

• When the pump stops, the pressurized oil does not flow into the motor any more.
• Since the motor continues to rotate with the force of inertia, the pressure on the outlet side of the motor
increases.
• When the oil stops flowing in from inlet port (P), suction safety valve (1) sucks in the oil on the outlet side
and supplies it to port (MA), compensating for the lack of oil on that side to prevent cavitation.

Operation (HM400-B6D6-044-K-00-A)

When started

• The pressurized oil from the pump is supplied to port (P), increasing the (MA) side pressure.
• The starting torque is generated in the motor, and the motor starts rotating.
• The pressurized oil on the motor outlet (MB) side returns to the tank through port (T).

10-34 HM400-3M0
 10 Structure and function
Aftercooler fan motor

When stopped

• When the engine stops, the pump input speed becomes 0 rpm.
• The pressurized oil from the pump is not supplied to port (P).
• As the pressurized oil is not supplied to (MA) side of the motor, the motor speed decreases gradually to
stop.
• When the motor shaft is rotated by the force of inertia while the oil flow in the port (P) is decreasing, the oil
in port (T) on the outlet side is sent by suction safety valve (1) to the (MA) side to prevent cavitation.

HM400-3M0 10-35
10 Structure and function
Aftercooler fan motor

Function as safety valve (HM300-B6D6-042-K-01-A)

• The pressure in port (P) of the motor is increased when the engine is started etc.
• Suction safety valve (1) is installed to protect the fan system circuit in such a case.

Operation (HM400-B6D6-044-K-01-A)

• If the pressure in port (P) rises above the cracking pressure of suction safety valve (1), valve (2) of suction
safety valve (1) opens to release the pressurized oil into port (T).
• This operation prevents generation of the abnormally high pressure in port (P).

10-36 HM400-3M0
 10 Structure and function
Aftercooler fan motor

Reversible valve (HM400-B6E0-041-K-00-A)

Operation

When aftercooler fan reverse solenoid is "de-energized"

• When coil (1) is "de-energized", the pressurized oil from the pump is blocked by valve (2), and port (C) is
connected to the tank circuit.
• Spool (3) is pushed to the right by spring (4) to open motor port (MA), and then the pressurized oil flows in
to rotate the motor forward (clockwise).

HM400-3M0 10-37
10 Structure and function
Aftercooler fan motor

When aftercooler fan reverse solenoid is "energized"

• When coil (1) is "energized", valve (2) switches to allow the pressurized oil from the pump to flow through
port (C) to spool chamber (D).
• The pressurized oil in chamber (D) pushes spool (3) to the left against spring (4).
• Motor port (MB) opens and the pressurized oil flows in to rotate the motor in reverse (counterclockwise).

10-38 HM400-3M0
 10 Structure and function
Aftercooler fan motor

Flow control valve (steplessly-variable type) (HM300-B6D5-001-K-00-A)

Function (HM300-B6D5-042-K-00-A)
This valve supplies the pump discharge to the motor by the necessary quantity, and returns the excess oil to
the hydraulic tank.
• The motor speed increases in proportion to motor flow (Q) as shown in Fig 1.
• When the motor flow is (Q1), motor speed is (B) rpm.
• In order to reduce noise and performance loss of the motor, this valve keeps the fan speed constant at
necessary level regardless of the motor flow.
• Even if the motor flow is increased from (Q0) to (Q1), this valve maintains the motor speed constant at (A)
rpm and (C) rpm.

Operation (HM400-B6D5-044-K-00-A)
• In the flow control valve, the upstream pressure of the orifice is applied to the right side of spool (1) and
the downstream pressure is applied to the left side.
• The differential pressure caused by the motor flow over orifice (E) acts on spring (2).
• In Fig. 1, if the motor flow exceeds (Q0), the differential pressure across spool (1) exceeds the load at
installed length of spring (2).
• Spool (1) moves to the left and port (P) and port (T) are interconnected.
• The excessive oil of (Z) portion in Fig. 1 flows to the hydraulic tank through the flow control valve, and the
motor speed is kept constant in the range from (A) to (C).
• This flow control valve can be adjusted steplessly.
• As shown in Fig. 2, the flow control valve can be adjusted steplessly while maintaining the motor speed
constant between (A') to (C') by changing the command current between the motor speed (A) and (C).

HM400-3M0 10-39
10 Structure and function
Aftercooler fan motor

10-40 HM400-3M0
 10 Structure and function
Radiator fan motor

Radiator fan motor (HM400-B5L0-041-K-01-A)

P: From fan pump

T: To hydraulic tank via cooler
TC: To hydraulic tank

HM400-3M0 10-41
10 Structure and function
Radiator fan motor

1. Output shaft
2. Case
3. thrust plate
4. Piston assembly
5. Cylinder block
6. Valve plate
7. End cover
8. Center spring
9. Check valve
10.Pilot valve
11.Reversible valve spool
12.Safety valve
13.Speed sensor

10-42 HM400-3M0
 10 Structure and function
Radiator fan motor

Structure
• This fan motor is installed within the blade width as shown in the figure.

Specifications (HM400-B5L0-030-K-00-A)

Model LMF55
Type Swash plate type piston motor
Motor capacity (cc/rev) 55.0
Rated speed (rpm) 1,430
Rated flow rate (l/min) 78.7
Cracking pressure of check valve (kPa {kg/cm2}) 78.5 {0.8}

Hydraulic motor (HM300-B5N0-042-K-00-A)

Function
• This hydraulic motor is called a swash plate axial piston motor. It converts the energy of the pressurized oil
sent from the hydraulic pump into rotary motion.

Principle of operation (HM300-B5N0-04B-K-01-A)

• The pressurized oil sent from the pump flows through valve plate (6) into cylinder block (5).
• This oil can flow to only one side of the (Y-Y) line connecting the top dead center and bottom dead center
of the stroke of piston (4).
• The pressurized oil sent to one side of cylinder block (5) pushes each piston (4) (2 or 3 pistons).
• Each piston (4) generates force (F1) [F1 (kg) = P (kg/cm2) x x D2 / 4 (cm2)].
• This force acts on thrust plate (2).
• Since thrust plate (2) is fixed at specific angle (a) to output shaft (1), the force is divided into components
(F2) and (F3).
• Radial component (F3) generates each torque [T = F3 x ri] against the (Y - Y) line connecting the top dead
center and bottom dead center.
• The total of these torque [T = Σ(F3 x ri)] rotates cylinder block (5) through piston (4).
• Cylinder block (5) is connected to output shaft (1) with spline.
• Output shaft (1) rotates to transmit the torque.

HM400-3M0 10-43
10 Structure and function
Radiator fan motor

10-44 HM400-3M0
 10 Structure and function
Radiator fan motor

Suction valve (HM300-B6D0-001-K-00-A)

Function (HM300-B6D0-042-K-00-A)
• When the pump stops, the pressurized oil does not flow into the motor any more.
• Since the motor continues to rotate with the force of inertia, the pressure on the outlet side of the motor
increases.
• When the oil stops flowing in from inlet port (P), suction valve (1) sucks in the oil on the outlet side and
supplies it to port (MA), compensating for the lack of oil on that side to prevent cavitation.

Operation (HM400-B6D0-044-K-00-A)

When started

• The pressurized oil from the pump is supplied to port (P), increasing the (MA) side pressure.
• The starting torque is generated in the motor, and the motor starts rotating.
• The pressurized oil on the motor outlet (MB) side returns to the tank through port (T).

HM400-3M0 10-45
10 Structure and function
Radiator fan motor

When stopped

• When the engine stops, the pump input speed becomes 0 rpm.
• The pressurized oil from the pump is not supplied to port (P).
• As the pressurized oil is not supplied to (MA) side of the motor, the motor speed decreases gradually to
stop.
• When the motor shaft is rotated by the force of inertia while the oil flow in port (P) is decreasing, the oil in
port (T) on the outlet side is sent by suction safety valve (1) to the (MA) side to prevent cavitation.

10-46 HM400-3M0
 10 Structure and function
Radiator fan motor

Reversible valve (HM400-B6E0-041-K-01-A)

Operation

When radiator fan reverse solenoid is "de-energized"

• When coil (1) is "de-energized", the pressurized oil from the pump is blocked by spool (2).
• Port (C) connects to the tank circuit.
• Spool (3) is pushed to the right by spring (4).
• Port (MA) opens and the pressurized oil flows in to rotate the motor in normal direction (clockwise).

HM400-3M0 10-47
10 Structure and function
Radiator fan motor

When radiator fan reverse solenoid is "energized"

• When coil (1) is "energized", spool (2) switches.

• The pressurized oil from the pump enters port (C) and flows into spool chamber (D).
• The pressurized oil in chamber (D) compresses spring (4).
• Spool (3) moves to the left.
• Port (MB) opens and the pressurized oil flows in to rotate the motor in reverse (counterclockwise).

10-48 HM400-3M0
 10 Structure and function
Radiator fan motor

Safety valve (ALL-B6G0-001-K-00-A)

Function (PC400-B6G0-042-K-00-A)
• When the engine is started, the pressure in port (P) of the fan motor is increased in some cases.
• Safety valve (1) is provided in order to protect the fan system circuit.

Operation (HM400-B6G0-044-K-00-A)

• When the pressure in port (P) rises above the cracking pressure of safety valve (1), valve (2) of safety
valve (1) opens to release the pressurized oil into port (T).
• This operation prevents generation of the abnormally high pressure in port (P).

HM400-3M0 10-49
10 Structure and function
Oil cooler bypass valve

Oil cooler bypass valve (HM400_3R-B8PB-041-K-00-A)

1. Case
2. Valve plate
3. Spring
4. Pin
Function (HM400_3R-B8PB-042-K-00-A)

• This valve controls the maximum pressure in the oil cooler to protect it.

10-50 HM400-3M0
 10 Structure and function
Power train system

Power train (ALL-C100-001-K-00-A)

Power train system (HM400-C100-041-K-00-A)

HM400-3M0 10-51
10 Structure and function
Power train system

1. Engine
2. Output shaft
3. Front drive shaft
4. Pump for driving torque converter, transmission, aftercooler fan, and center brake cooling motors
5. Center brake, radiator fan, and brake charge pump
6. PTO
7. Torque converter
8. Steering and hoist pump
9. Transmission
10.Center drive shaft
11.Oscillation hitch
12.Drive shaft (hitch)
13.Differential (front)
14.Front drive shaft
15.Tire
16.Final drive (front)
17.Brake (front)
18.Rear drive shaft (front)
19.Differential (center)
20.Tire
21.Final drive (center)
22.Brake (center)
23.Rear drive shaft (rear)
24.Differential (rear)
25.Tire
26.Final drive (rear)
27.Inter-axle differential lock

10-52 HM400-3M0
 10 Structure and function
Drive shaft

Drive shaft (HM400-D510-041-K-00-A)

1. Drive shaft (right)

2. Front drive shaft
3. Center drive shaft
4. Rear drive shaft (front)
5. Rear drive shaft (rear)
6. Drive shaft (left)
Function (HM400-D510-042-K-00-A)

• The power from the engine output shaft is transmitted through front drive shaft (2), the transmission, the
front differential, and further transmitted through right and left drive shafts (1) and (6) to the final drives.
• The engine power is also transmitted through center drive shaft (3), the oscillation hitch, and further
transmitted through rear drive shafts (4) and (5) to the center and rear differentials.
• The relative positions of the engine, transmission and axles change due to articulation of the machine
body, or impacts received from the road surface during traveling, or impacts during operations, etc.
The drive shafts absorb the fluctuation of their angle and length by the universal joints and sliding joints so
that the power will be transmitted without damaging the parts even when the machine receives the above
impacts and when the positions of the components change. Thus, they have other purposes than
transmitting power.

HM400-3M0 10-53
10 Structure and function
Torque converter and transmission hydraulic piping

Torque converter and transmission hydraulic piping (HM400-C151-041-K-00-A)

1. Oil cooler
2. Torque converter
3. Center brake cooling remote pump
4. Power train and brake cooling return filter
5. Transmission oil filter
6. Transmission
7. Brake system tank

10-54 HM400-3M0
 10 Structure and function
Torque converter

Torque converter (HM400-CD00-041-K-00-A)

1. Mounting location of pump for driving torque converter, transmission, aftercooler fan, and center brake
cooling motors
2. Mounting location of center brake, radiator fan, and brake charge pump
3. Mounting location of steering and hoist pump
4. PTO gear (number of teeth: 91)
a PTO gears at 3 places are the same and the number of spline teeth of them is 14 each.

HM400-3M0 10-55
10 Structure and function
Torque converter

1. Coupling
2. Input shaft (number of teeth: 108)
3. Case
4. Drive case
5. Turbine
6. Outer race
7. Pump
8. Retainer
9. Stator shaft
10.Sleeve
11.Inner race
12.Free wheel
13.Stator
14.Lockup clutch disc
15.Lockup clutch piston
16.Lockup clutch housing
17.Retainer

10-56 HM400-3M0
 10 Structure and function
Torque converter

Specifications (HM400-CD00-030-K-00-A)

3-element, 1-stage, 2-phase

Type with modulation mechanism
with lockup clutch
Wet type single disc clutch
Lockup clutch Hydraulic control
(with modulation mechanism)
Stall torque ratio 2.63

HM400-3M0 10-57
10 Structure and function
Torque converter

Power transmitting route (HM400-CD00-052-K-00-A)

When lockup clutch is "disengaged"

Drive case (4) is disconnected from boss (8) and turbine (7) and the torque converter works as an ordinary
torque converter.
The power from engine
O
Drive shaft
O
Coupling (1)
O
Input shaft (2), clutch housing (3), drive case (4) and pump (5) rotate as a unit
O
Oil is used as a medium
O
Turbine (7) and boss (8)
O
Transmission input shaft (9)
• The power transmitted to the input shaft (2) is then transmitted through the PTO gear to drive the pump.

10-58 HM400-3M0
 10 Structure and function
Torque converter

When lockup clutch is "engaged"

Drive case (4) is connected to boss (8) and turbine (7) and the torque converter is locked up.
The power from engine
O
Drive shaft
O
Coupling (1)
O
Input shaft (2), clutch housing (3), drive case (4) and pump (5) rotate as a unit
O
Lockup clutch (6)
O
Boss (8)
O
Transmission input shaft (9)
• The power transmitted to the input shaft (2) is then transmitted through the PTO gear to drive the pump.

HM400-3M0 10-59
10 Structure and function
Torque converter

Oil flow (HM400-CD00-044-K-00-A)

• 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 through inlet port (A) and oil passages of stator shaft (1) into
pump (2).
• The oil is given centrifugal force by pump (2) and flows into turbine (3) to transfer its energy to turbine (3).
• The oil from turbine (3) is sent to stator (4) and flows into pump (2) again. However, a part of the oil flows
between turbine (3) and stator (4) and through outlet port (B) and oil cooler to be cooled, and then
lubricates the transmission.

10-60 HM400-3M0
 10 Structure and function
Transmission

Transmission (HM400-CF00-041-K-00-A)

HM400-3M0 10-61
10 Structure and function
Transmission

A: To front brake
B: From return filter
C: Pump for driving torque converter, transmission, aftercooler fan, and center brake cooling motors
D: Center brake, radiator fan, and brake charge pump

1. Transmission case (front)

2. Transmission case (rear)
3. Transmission intermediate shaft speed sensor
4. Transmission output shaft speed sensor
5. Oil filler pipe mounting location
6. Power train lubricating oil temperature sensor
7. Drain plug
8. Drain valve
9. Interconnection pipe mounting location
10.Transmission input speed sensor
11.Differential input speed sensor

10-62 HM400-3M0
 10 Structure and function
Transmission

A: From transmission oil filter

B: From transmission oil filter (main flow selector valve inlet)

1. Transmission input speed sensor

2. Torque converter outlet oil temperature sensor
3. Transmission control valve
4. Ground cable mounting location
5. Main relief and torque converter relief valve
6. Torque converter intermediate oil pressure sensor
7. R idler gear (number of teeth: 35)
8. Strainer
9. Lubricating oil relief valve
10.Drain plug

HM400-3M0 10-63
10 Structure and function
Transmission

10-64 HM400-3M0
 10 Structure and function
Transmission

1. R clutch
2. 1st clutch
3. 2nd clutch
4. Differential lock clutch
5. Rear output shaft
6. Rear coupling
7. Front output shaft
8. Lower shaft
9. 3rd clutch
10.Upper shaft
11.FH clutch
12.Input shaft
13.FL clutch
14.Torque converter
Lubricating oil relief valve (HM400_3R-CK30-041-K-00-A)

1. Spacer
2. Spring

Structure
In this valve, spacer (1) is green and spring (2) is black.

HM400-3M0 10-65
10 Structure and function
Transmission

FL and R clutches (HM400-CF80-041-K-00-A)

A: R clutch oil port

B: FL clutch oil port
C: Lubricating oil port
D: Lockup clutch oil port

1. Input shaft
2. Input gear (number of teeth: 43)
3. FL clutch gear (number of teeth: 33)
4. FL clutch
5. FL and R cylinders
6. R clutch
7. R clutch gear (number of teeth: 25)

10-66 HM400-3M0
 10 Structure and function
Transmission

FH and 1st clutches (HM400-CF82-041-K-00-A)

A: 1st clutch oil port

B: FH clutch oil port
C: Lubricating oil port

1. FH clutch gear (number of teeth: 57)

2. FH clutch
3. FH and 1st cylinder (number of teeth: 67)
4. 1st clutch
5. 1st clutch gear (number of teeth: 30)
6. Upper gear (number of teeth: 49)
7. Upper shaft

HM400-3M0 10-67
10 Structure and function
Transmission

2nd and 3rd clutches (HM400-CFK0-041-K-00-A)

A: 3rd clutch oil port

B: 2nd clutch oil port
C: Lubricating oil port

1. 3rd clutch gear (number of teeth: 25)

2. 3rd clutch
3. 2nd and 3rd clutch cylinders (number of teeth: 62)
4. 2nd clutch
5. 2nd clutch gear (number of teeth: 43)
6. Lower gear (number of teeth: 54)
7. Lower shaft
8. Lower shaft identification mark (2 places)

10-68 HM400-3M0
 10 Structure and function
Transmission

Differential lockup clutch (HM400-DD30-041-K-00-A)

A: Lubricating oil port

1. Front output shaft

2. Clutch hub
3. Housing
4. Differential lockup clutch
5. Sun gear (number of teeth: 40)
6. Planetary gear (number of teeth: 20)
7. Ring gear (number of teeth: 80)
8. Carrier
9. Output gear (number of teeth: 78)
10.Rear output shaft

HM400-3M0 10-69
10 Structure and function
Transmission

Structure (HM400-CF60-041-K-00-A)

• The transmission consists of the counter-shaft, constant mesh type gear mechanism and the disc clutches
and has "forward 6-speeds and reverse 2-speeds".
• The transmission is set to one rotating direction and one gear speed by fixing the counter-shaft type,
constant mesh gear mechanism and two of the six disc clutches hydraulically by the operation of the
ECMV.
• The transmission receives the power with the input shaft and transfers it to the output shaft while changing
its speed to the forward 1st to 6th or reverse 1st or 2nd by combining the FL, FH, and R clutches and three
speed clutches.
• The transmission gear is shifted automatically by the automatic gear shift system according to the engine
speed.

Number of plates and discs used

Clutch No. Number of plates Number of discs
FL clutch 12 11
R clutch 12 11
FH clutch 10 9
1st clutch 12 11
3rd clutch 8 7
2nd clutch 14 13

Combinations of clutches for each gear speed and reduction ratios

Gear speed Clutches Reduction ratio
Forward 1st FL x 1st 6.061
Forward 2nd FH x 1st 3.957
Forward 3rd FL x 2nd 2.574
Forward 4th FH x 2nd 1.680
Forward 5th FL x 3rd 1.094
Forward 6th FH x 3rd 0.714
Neutral — —
Reverse 1st R x 1st 5.851
Reverse 2nd R x 2nd 2.484

10-70 HM400-3M0
 10 Structure and function
Transmission

Disc clutch (HM300-CF60-001-K-00-A)

Operation (HM300-CF60-044-K-00-A)

When clutch is "engaged" (locked)

• The oil sent from the ECMV is force-fed through the oil passage of shaft (1) to the back of piston (2), and
pushes piston (2) to the right.
• Piston (2) presses plates (3) against discs (4) to stop rotation of discs (4) with the friction force between
them.
• As the internal teeth of discs (4) are meshed with clutch gear (5), shaft (1) and clutch gear (5) transmit the
power in one piece.
• The oil is drained through oil drain hole (6), but it does not affect the operation of the clutch since its
quantity is far less than the quantity of the supplied oil.

When clutch is "disengaged" (released)

• When the oil sent from the ECMV is shut off, the oil pressure applied to the back of piston (2) decreases.
• Piston (2) is pushed back to the left by the reactive force of wave spring (7).
• The friction force between plates (3) and discs (4) is lost and shaft (1) and clutch gear (5) are released.
• When the clutch is disengaged, the oil on the back of the piston is drained by the centrifugal force through
oil drain hole (6) to prevent partial engagement of the clutch.
a Oil drain hole (6) is provided only in the 2nd, 3rd, and differential lock clutches.

HM400-3M0 10-71
10 Structure and function
Transmission

Power transmitting route (HM300-CF60-001-K-01-A)

Forward 1st (HM400-CF60-044-K-00-A)

a The figure shows the route when the differential lock is OFF.

10-72 HM400-3M0
 10 Structure and function
Transmission

FL clutch (4) and 1st clutch (12) are fixed hydraulically.

Power from torque converter
O
Input shaft (1)
O
FL and R cylinders (2)
O
FL clutch (4)
O
FL clutch gear (6)
O
FH and 1st cylinders (9)
O
1st clutch (12)
O
1st clutch gear (13)
O
2nd and 3rd cylinders (15)
O
Lower gear (20)
O
Output gear (21)
(The following is the route when the differential lock is OFF.)
O
Carrier (22)
O
Planetary gear (26) o O
O O
Sun gear (27) Ring gear (28)
O O
Front output shaft (29) Rear output shaft (30)

a For the route when the differential lock is in ON, see "Forward 2nd speed".

HM400-3M0 10-73
10 Structure and function
Transmission

Forward 2nd (HM400-CF60-044-K-01-A)

a The figure shows the route when the differential lock is ON.

10-74 HM400-3M0
 10 Structure and function
Transmission

FH clutch (11) and 1st clutch (12) are fixed hydraulically.

Power from torque converter
O
Input shaft (1)
O
Input gear (3)
O
FH clutch gear (10)
O
FH clutch (11)
O
FH and 1st cylinders (9)
O
1st clutch (12)
O
1st clutch gear (13)
O
2nd and 3rd cylinders (15)
O
Lower gear (20)
O
Output gear (21)
(The following is the route when the differential lock is ON.)
O
Carrier (22) o O
O O
Front housing (23) O
O O
Differential lock clutch (24) Planetary gear (26)
O O
Clutch hub (25) Ring gear (28)
O O
Front output shaft (29) Rear output shaft (30)

a For the route when the differential lock is OFF, see "Forward 1st speed".

HM400-3M0 10-75
10 Structure and function
Transmission

Forward 3rd (HM400-CF60-044-K-02-A)

a The figure shows the route when the differential lock is OFF.

10-76 HM400-3M0
 10 Structure and function
Transmission

FL clutch (4) and 2nd clutch (18) are fixed hydraulically.

Power from torque converter
O
Input shaft (1)
O
FL and R cylinders (2)
O
FL clutch (4)
O
FL clutch gear (6)
O
FH and 1st cylinders (9)
O
Upper gear (14)
O
2nd clutch gear (16)
O
2nd clutch (18)
O
2nd and 3rd cylinders (15)
O
Lower gear (20)
O
Output gear (21)
(The following is the route when the differential lock is OFF.)
O
Carrier (22)
O
Planetary gear (26) o O
O O
Sun gear (27) Ring gear (28)
O O
Front output shaft (29) Rear output shaft (30)

a For the route when the differential lock is ON, see "Forward 2nd speed".

HM400-3M0 10-77
10 Structure and function
Transmission

Forward 4th (HM400-CF60-044-K-03-A)

a The figure shows the route when the differential lock ON.

10-78 HM400-3M0
 10 Structure and function
Transmission

FH clutch (11) and 2nd clutch (18) are fixed hydraulically.

Power from torque converter
O
Input shaft (1)
O
Input gear (3)
O
FH clutch gear (10)
O
FH clutch (11)
O
FH and 1st cylinders (9)
O
Upper gear (14)
O
2nd clutch gear (16)
O
2nd clutch (18)
O
2nd and 3rd cylinders (15)
O
Lower gear (20)
O
Output gear (21)
(The following is the route when the differential lock is ON.)
O
Carrier (22) o O
O O
Front housing (23) O
O O
Differential lock clutch (24) Planetary gear (26)
O O
Clutch hub (25) Ring gear (28)
O O
Front output shaft (29) Rear output shaft (30)

a For the route when the differential lock is OFF, see "Forward 1st speed".

HM400-3M0 10-79
10 Structure and function
Transmission

Forward 5th (HM400-CF60-044-K-04-A)

a The figure shows the route when the differential lock is OFF.

10-80 HM400-3M0
 10 Structure and function
Transmission

FL clutch (4) and 3rd clutch (19) are fixed hydraulically.

Power from torque converter
O
Input shaft (1)
O
FL and R cylinders (2)
O
FL clutch (4)
O
FL clutch gear (6)
O
FH and 1st cylinders (9)
O
3rd clutch gear (17)
O
3rd clutch (19)
O
2nd and 3rd cylinders (15)
O
Lower gear (20)
O
Output gear (21)
(The following is the route when the differential lock is OFF.)
O
Carrier (22)
O
Planetary gear (26) o O
O O
Sun gear (27) Ring gear (28)
O O
Front output shaft (29) Rear output shaft (30)

a For the route when the differential lock is ON, see "Forward 2nd speed".

HM400-3M0 10-81
10 Structure and function
Transmission

Forward 6th (HM400-CF60-044-K-05-A)

a The figure shows the route when the differential lock ON.

10-82 HM400-3M0
 10 Structure and function
Transmission

FH clutch (11) and 3rd clutch (19) are fixed hydraulically.

Power from torque converter
O
Input shaft (1)
O
Input gear (3)
O
FH clutch gear (10)
O
FH clutch (11)
O
FH and 1st cylinders (9)
O
3rd clutch gear (17)
O
3rd clutch (19)
O
2nd and 3rd cylinders (15)
O
Lower gear (20)
O
Output gear (21)
(The following is the route when the differential lock is ON.)
O
Carrier (22) o O
O O
Front housing (23) O
O O
Differential lock clutch (24) Planetary gear (26)
O O
Clutch hub (25) Ring gear (28)
O O
Front output shaft (29) Rear output shaft (30)

a For the route when the differential lock is OFF, see "Forward 1st speed".

HM400-3M0 10-83
10 Structure and function
Transmission

Reverse 1st (HM400-CF60-044-K-06-A)

a The figure shows the route when the differential lock is "OFF".

10-84 HM400-3M0
 10 Structure and function
Transmission

R clutch (5) and 1st clutch (12) are fixed hydraulically.

Power from torque converter
O
Input shaft (1)
O
FL and R cylinders (2)
O
R clutch (5)
O
R clutch gear (7)
O
R idler gear (8)
(Output rotation is reversed through R idler gear (8).)
O
Upper gear (14)
O
FH and 1st cylinders (9)
O
1st clutch (12)
O
1st clutch gear (13)
O
2nd and 3rd cylinders (15)
O
Lower gear (20)
O
Output gear (21)
(The following is the route when the differential lock
is "OFF".)
O
Carrier (22)
O
Planetary gear (26) o O
O O
Sun gear (27) Ring gear (28)
O O
Front output shaft (29) Rear output shaft (30)

a For the route when the differential lock clutch is in ON position, see "Forward 2nd speed".

HM400-3M0 10-85
10 Structure and function
Transmission control valve

Transmission control valve (HM400-CJA0-041-K-00-A)

10-86 HM400-3M0
 10 Structure and function
Transmission control valve

A: Lockup clutch oil pressure pickup port

B: 2nd clutch oil pressure pickup port
C: 3rd clutch oil pressure pickup port
D: R clutch oil pressure pickup port
E: FL clutch oil pressure pickup port
F: 1st clutch oil pressure pickup port
G: FH clutch oil pressure pickup port
H: Differential lock clutch oil pressure pickup port

1. Lockup clutch ECMV

2. 2nd clutch ECMV
3. 3rd clutch ECMV
4. R clutch ECMV
5. FL clutch ECMV
6. Breather
7. 1st clutch ECMV
8. FH clutch ECMV
9. Differential lock clutch ECMV
10.Seat
11.Last chance filter

HM400-3M0 10-87
10 Structure and function
Transmission control valve

Function (HM400-CJA0-042-K-00-A)

• The lockup clutch ECMV operates when the machine travels forward at speed above the travel speed set
by the transmission controller.
• The differential lockup clutch ECMV operates in the 3rd or lower gear speed.

Table of ECMV operation

ECMV
FL FH R 1st 2nd 3rd L/U D/L
F1 Q Q Q Q
F2 Q Q Q Q
F3 Q Q Q Q
F4 Q Q Q
Gear
speed F5 Q Q Q
F6 Q Q Q
R1 Q Q Q
R2 Q Q Q
N Q
L/U: Indicates lockup clutch ECMV.
D/L: Indicates differential lockup clutch ECMV.

Identification of ECMVs and difference between them

Identifica- Fill switch
Stamp on name plate Pressure control
tion color (operating pressure: Clutches
(A) valve
(B) MPa {kg/cm2})
Installed
0A****** Yellow Without slit FL, FH, R, and 1st
(0.26 {2.7})
Installed
0E****** Pink With slit 2nd and 3rd
(0.26 {2.7})
Lockup and differential
K******* — With slit Not installed lockup

10-88 HM400-3M0
 10 Structure and function
Forward and reverse clutch ECMV and gear speed clutch
ECMV

Forward and reverse clutch ECMV and gear speed clutch ECMV (HM300-CJJ0-
041-K-00-A)

a ECMV: Abbreviation for Electronic Control Modulation Valve

a Do not disassemble this since it needs to be adjusted for maintaining the performance after reassembly.

A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pickup port

1. Fill switch connector

2. Proportional solenoid connector
3. Oil pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Name plate

HM400-3M0 10-89
10 Structure and function
Forward and reverse clutch ECMV and gear speed clutch
ECMV

Function (HM300-CJJ0-042-K-00-A)

• The ECMV consists of a pressure control valve and a fill switch.

• Pressure control valve
The proportional solenoid receives the current from the transmission controller, and this valve converts it
into oil pressure.
• Fill switch
This switch detects that the clutch is filled with oil and has the following functions.
1. Outputs a signal (a fill signal) to the controller to notify that filling is completed when the clutch is filled with
oil.
2. Keeps outputting the signals (fill signals) to the controller to notify that the oil pressure is applied while oil
pressure is applied to the clutch.

Range A: Before shifting gear (oil is drained)

Range B: Clutch is being filled
Range C: Pressure is being adjusted
Range D: Clutch is being filled (triggering period)
Point E: Filling is started
Point F: Filling is finished
a The logic is designed so that the controller does not recognize completion of filling even if the fill switch is
turned "ON" during the triggering period (Range D).

ECMV and proportional solenoid

• Each ECMV is equipped with one proportional solenoid.
The proportional solenoid generates thrust shown below according to the command current from the
controller.
Oil pressure is generated as shown below by applying the thrust generated by the proportional solenoid to
the pressure control valve spool.
Accordingly, the thrust is changed by controlling the command current to operate the pressure control
valve and control the flow and pressure of the oil.

10-90 HM400-3M0
 10 Structure and function
Forward and reverse clutch ECMV and gear speed clutch
ECMV

Proportional solenoid current - thrust characteristics

Proportional solenoid thrust - oil pressure characteristics

ECMV and fill switch

• Each ECMV is equipped with one fill switch.
When the clutch is filled with oil, the fill switch is turned "ON" by the pressure of the clutch. This signal
allows the oil pressure to build up.

HM400-3M0 10-91
10 Structure and function
Forward and reverse clutch ECMV and gear speed clutch
ECMV

Operation of ECMV (HM300-CJJ0-044-K-00-A)

a ECMV: Abbreviation for Electronic Control Modulation Valve

• ECMV is controlled by the command current sent from the controller to the proportional solenoid and the
fill switch output signal.
The relationship among the proportional solenoid command current for ECMV, clutch input pressure, and
fill switch output signal is shown below.

Range A: Before shifting gear (oil is drained)

Range B: Clutch is being filled
Range C: Pressure is being adjusted
Range D: Clutch is being filled (triggering period)
Point E: Filling is started
Point F: Filling is finished
a The logic is designed so that the controller does not recognize completion of filling even if the fill switch is
turned "ON" during the triggering period (Range D).

10-92 HM400-3M0
 10 Structure and function
Forward and reverse clutch ECMV and gear speed clutch
ECMV

Before shifting gear [when oil is drained] (range A in chart)

• While no current is flowing to the proportional solenoid (1), pressure control valve (3) drains the oil from
clutch port (A) through drain port (T).
Fill switch (5) is turned OFF at this time since the oil pressure is not applied to pressure sensing valve (4).

HM400-3M0 10-93
10 Structure and function
Forward and reverse clutch ECMV and gear speed clutch
ECMV

Filling phase (range B in chart)

• When the current flows to proportional solenoid (1) while there is no oil in the clutch, the hydraulic force
balanced with the solenoid force is applied to chamber (B) to push pressure control valve (3) to the left. As
a result, pump port (P) is connected with clutch port (A) and the oil starts filling the clutch. When the clutch
is filled with the oil, oil pressure sensing valve (4) operates and fill switch (5) is turned "ON".

10-94 HM400-3M0
 10 Structure and function
Forward and reverse clutch ECMV and gear speed clutch
ECMV

Pressure build-up (range C in chart)

• When a current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current.
The pressure builds up until the thrust of the solenoid is balanced with the sum of the thrust generated by
the oil pressure in clutch port and the reaction force of pressure control valve spring (2).

HM400-3M0 10-95
10 Structure and function
Lockup clutch ECMV

Lockup clutch ECMV (HM400-CDT8-041-K-00-A)

a ECMV: Abbreviation for Electronic Control Modulation Valve

a Do not disassemble this since it needs to be adjusted for maintaining the performance after reassembly.

A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pickup port

1. Proportional solenoid connector

2. Sleeve
3. Proportional solenoid
4. Pressure control valve
5. Name plate

10-96 HM400-3M0
 10 Structure and function
Lockup clutch ECMV

Function (HM300-CDT8-042-K-00-A)

• This valve is used for building up the clutch oil pressure to the set pressure and selecting a clutch.
Since the modulation waveform is used for the pressure application characteristics to the clutch, the
lockup clutch is engaged smoothly and the gear shift shocks are reduced. In addition, occurrence of a
peak torque in the power train is prevented. As a result, the operator comfort improves and the power train
durability increases.

When torque converter drive mode changes to direct drive mode

When gear is shifted (traveling in direct drive mode)

HM400-3M0 10-97
10 Structure and function
Lockup clutch ECMV

Operation (HM300-DD31-044-K-00-A)
When clutch is "disengaged" (released)

• While no current is flowing to the proportional solenoid (1), pressure control valve (3) drains the oil from
clutch port (A) through drain port (T).

10-98 HM400-3M0
 10 Structure and function
Lockup clutch ECMV

When clutch is "engaged" (locked)

• When the current flows to proportional solenoid (1), the hydraulic force balanced with the solenoid force is
applied to chamber (B) to push pressure control valve (3) to the left. As a result, pump port (P) is
connected to clutch port (A) and the oil starts filling the clutch.
• When the clutch is filled with oil, the thrust of the solenoid is balanced with the sum of the thrust generated
by the oil pressure in clutch port and the reaction force of pressure control valve spring (2), thus the
pressure is adjusted.

HM400-3M0 10-99
10 Structure and function
Differential lock clutch ECMV

Differential lock clutch ECMV (HM400-DD31-041-K-00-A)

a ECMV: Abbreviation for Electronic Control Modulation Valve

a Do not disassemble this since it needs to be adjusted for maintaining the performance after reassembly.

A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pickup port

1. Proportional solenoid connector

2. Sleeve
3. Proportional solenoid
4. Pressure control valve
5. Name plate

10-100 HM400-3M0
 10 Structure and function
Differential lock clutch ECMV

Function (HM300-DD31-042-K-00-A)

• The proportional solenoid generates thrust shown below according to the command current from the
controller.
• Oil pressure is generated as shown below by applying the thrust generated by the proportional solenoid to
the pressure control valve spool.
• Accordingly, the thrust is changed by controlling the command current to operate the pressure control
valve and control the flow and pressure of the oil.

Proportional solenoid current - thrust characteristics

Proportional solenoid thrust - oil pressure characteristics

HM400-3M0 10-101
10 Structure and function
Differential lock clutch ECMV

Operation (HM300-DD31-044-K-00-A)
When clutch is "disengaged" (released)

• While no current is flowing to the proportional solenoid (1), pressure control valve (3) drains the oil from
clutch port (A) through drain port (T).

10-102 HM400-3M0
 10 Structure and function
Differential lock clutch ECMV

When clutch is "engaged" (locked)

• When the current flows to proportional solenoid (1), the hydraulic force balanced with the solenoid force is
applied to chamber (B) to push pressure control valve (3) to the left. As a result, pump port (P) is
connected to clutch port (A) and the oil starts filling the clutch.
• When the clutch is filled with oil, the thrust of the solenoid is balanced with the sum of the thrust generated
by the oil pressure in clutch port and the reaction force of pressure control valve spring (2), thus the
pressure is adjusted.

HM400-3M0 10-103
10 Structure and function
Main relief valve, torque converter relief valve, and main
flow selector valve

Main relief valve, torque converter relief valve, and main flow selector
valve (HM300-C156-041-K-00-A)

10-104 HM400-3M0
 10 Structure and function
Main relief valve, torque converter relief valve, and main
flow selector valve

A: Drain (torque converter relief)

B: Drain
C: From pump
D: Drain
E: To torque converter
F: Drain
G: Drain
P1: Torque converter relief oil pressure pickup port
P4: Main relief oil pressure pickup port
P9: Main flow selector valve inlet pressure pickup port

1. Body
2. Piston
3. Torque converter relief valve
4. Piston
5. Main relief valve
6. Solenoid valve for main flow selector valve
7. Pressure sensor for main flow selector valve

HM400-3M0 10-105
10 Structure and function
Main relief valve, torque converter relief valve, and main
flow selector valve

Main relief valve (HM300-CJ10-001-K-00-A)

Function (HM400_3R-CJ10-042-K-00-A)
• The main relief valve regulates the oil pressure in the transmission and brake to the set pressure.
Set pressure: 2.56 MPa {26.1 kg/cm2} (when main flow selector valve operates at engine rated speed)

Operation (HM300-CJ10-044-K-00-A)

• The oil from the hydraulic pump flows to port (C) through the filter. Then it flows to chamber (H) through
orifice (a) in main relief valve (1).

• When the oil pressure in the circuit exceeds the set pressure, the oil in chamber (H) pushes piston (2) and
the reaction force of the piston pushes main relief valve (1) leftward to connect ports (C) and (E).
Then, the oil from the pump flows through port (E) into the torque converter.

10-106 HM400-3M0
 10 Structure and function
Main relief valve, torque converter relief valve, and main
flow selector valve

Torque converter relief valve (HM300-CDC0-001-K-00-A)

Function (HM300-CDC0-042-K-00-A)
• The torque converter relief valve maintains the torque converter inlet pressure below the set pressure to
protect the torque converter from abnormally high pressure.
Set pressure: 1.02 MPa {10.4 kg/cm2} (cracking pressure)

Operation (HM300-CDC0-044-K-00-A)

• The oil from the main relief valve flows through port (E) into the torque converter. It also flows through
orifice (b) in torque converter relief valve (3) into chamber (J).
• When the oil pressure to the torque converter exceeds the set pressure, the oil in chamber (J) pushes
piston (4) and the reaction force of the piston pushes torque converter relief valve (3) rightward to connect
ports (E) and (A). Then, the oil in port (E) is drained through port (A).

HM400-3M0 10-107
10 Structure and function
Main relief valve, torque converter relief valve, and main
flow selector valve

Main flow selector valve (HM300-CJ30-001-K-00-A)

Function (HM300-CJ30-042-K-00-A)
• The main flow selector valve is used for selecting the flow to the main relief valve.
When the main pressure can be maintained by only one of the two charge pumps, the oil from the other
pump flows to the torque converter without through the main relief valve. With this system, the pump load
is reduced and the fuel efficiency is improved.

Operation (HM300-CJ30-044-K-00-A)
• This valve operates automatically according to the engine speed set for each gear speed.

Operating condition
Engine speed (rpm)
Gear speed
ON o OFF OFF o ON
F2 1500 1600
N 1450 1550
Does not operate with gear speed in F1, R1, and R2.
Operates normally with gear speed in F3 to F6.

When solenoid is "de-energized" (pump flows are merged)

• While no current is flowing in solenoid (1), no hydraulic force is applied to chamber (K) and accordingly
main flow selector valve (2) is pushed leftward by spring (3). At this time, the oil delivered by pumps (L)
and (M) flows from chamber (N) through the main relief valve to the torque converter.

10-108 HM400-3M0
 10 Structure and function
Main relief valve, torque converter relief valve, and main
flow selector valve

When solenoid is "energized" (pump flows are divided)

• When the current flows in solenoid (1), hydraulic force is applied to chamber (K) and accordingly main flow
selector valve (2) is pushed rightward. At this time, only the oil delivered by pump (L) flows from chamber
(N) through the main relief valve to the torque converter.
The oil delivered by pump (M) flows from chamber (P) to the torque converter without through the main
relief valve.

HM400-3M0 10-109
10 Structure and function
Axle

Axle (HM300-DA00-001-K-00-A)

Front axle (HM400-DA20-041-K-00-A)

1. Drive shaft
2. Front differential
3. TCS speed sensor (wheel speed sensor)
4. Brake
5. Final drive

10-110 HM400-3M0
 10 Structure and function
Axle

Center axle (HM400-DAK5-041-K-00-A)

1. Center axle
2. TCS speed sensor (wheel speed sensor)
3. Brake
4. Final drive
5. Oil filler port/oil level plug
6. Drain plug
7. Center differential

HM400-3M0 10-111
10 Structure and function
Axle

Rear axle (HM400-DAC0-041-K-00-A)

1. Drain plug
2. Oil filler port/oil level plug
3. Rear axle housing
4. Final drive
5. Rear differential

10-112 HM400-3M0
 10 Structure and function
Differential

Differential (HM300-DC10-001-K-00-A)

Front differential (HM400-DC70-041-K-00-A)

1. Differential case
2. Side gear (number of teeth: 24)
3. Pinion (number of teeth: 14)
4. Shaft
5. Bevel gear (number of teeth: 41)
6. Bevel pinion (number of teeth: 11)

HM400-3M0 10-113
10 Structure and function
Differential

Center differential (HM400-DCH1-041-K-00-A)

1. Bevel gear (number of teeth: 41)

2. Bevel pinion (number of teeth: 11)
3. Pinion (number of teeth: 14)
4. Differential case
5. Shaft
6. Side gear (number of teeth: 24)

10-114 HM400-3M0
 10 Structure and function
Differential

Rear differential (HM400-DCD0-041-K-00-A)

1. Bevel gear (number of teeth: 41)

2. Bevel pinion (number of teeth: 11)
3. Pinion (number of teeth: 14)
4. Shaft
5. Differential case
6. Side gear (number of teeth: 24)

HM400-3M0 10-115
10 Structure and function
Differential

Operation (HM300-DC10-044-K-00-A)

• The power from the engine is transmitted to each axle through the output shaft, front drive shaft, torque
converter and transmission.
• Inside the axle, the power is transmitted through pinion gear (5) to bevel gear (1) and changed in direction
by 90 deg. and reduced in speed, and then transmitted to the axle shaft through pinion gear (6) and side
gear (3).
• The power transmitted to the axle shaft is further reduced in speed by the planetary gear type final drives,
and then transmitted to the wheels.

When machine is traveling straight

• When the machine is traveling straight, the right and left wheels rotate at the same speed. Accordingly,
pinion gears (6) in the differential assembly do not rotate and the power of differential case (2) is
transmitted through pinion gears (6) and side gears (3) to the right and left axle shafts evenly.

When machine is turning

• When the machine is turning, the right and left wheels rotate at different speed. Accordingly, pinion gears
(6) and side gears (3) in the differential rotate and transmit the power of differential case (2) to the right
and left axle shafts, depending on the difference in rotation speed between the right and left wheels.

10-116 HM400-3M0
 10 Structure and function
Final drive

Final drive (HM300-DF10-001-K-00-A)

Front final drive (HM400-DFD0-041-K-00-A)

1. Shaft
2. Ring gear (number of teeth: 67)
3. Planetary gear (number of teeth: 24)
4. Planetary carrier
5. Sun gear (number of teeth: 17)
6. Drain plug
7. Brake

HM400-3M0 10-117
10 Structure and function
Final drive

Center final drive (HM400-DFJ6-041-K-00-A)

1. Shaft
2. Ring gear (number of teeth: 67)
3. Planetary gear (number of teeth: 24)
4. Planetary carrier
5. Sun gear (number of teeth: 17)
6. Drain plug
7. Brake

10-118 HM400-3M0
 10 Structure and function
Final drive

Rear final drive (HM400-DFH0-041-K-00-A)

1. Shaft
2. Ring gear (number of teeth: 67)
3. Planetary gear (number of teeth: 24)
4. Planetary carrier
5. Sun gear (number of teeth: 17)
6. Drain plug
Function (HM300-DF10-042-K-00-A)

• The final drive reduces the power in speed to obtain large driving force by using a planetary gear
mechanism and transmits that driving force to the tire.
Operation (HM300-DF10-044-K-00-A)

• The power transmitted from the differential to sun gear (5) through shaft (1) is transmitted to planetary
gears (3).
As the planetary gears rotate inside ring gear (2) which is fixed, reduced rotation is transmitted to
planetary carrier (4) and consequently transmitted to the wheel mounted on the planetary carrier.

HM400-3M0 10-119
10 Structure and function
Layout of steering devices

Steering system (ALL-F000-001-K-00-A)

Layout of steering devices (HM400-DT00-04D-K-00-A)

1. Steering valve
2. Steering column
3. Steering cylinder (right)
4. Flow amplifier valve
5. Emergency steering motor
6. Emergency steering pump
7. Steering cylinder (left)
8. Steering and hoist pump

10-120 HM400-3M0
 10 Structure and function
Steering column

Steering column (HM300-F171-041-K-00-A)

1. Steering shaft
2. Steering column
3. Lock lever
4. Yoke
5. Joint shaft
6. Steering valve

HM400-3M0 10-121
10 Structure and function
Flow amplifier valve

Flow amplifier valve (HM300-F5D7-041-K-00-A)

10-122 HM400-3M0
 10 Structure and function
Flow amplifier valve

CL: To steering cylinder

CR: To steering cylinder
EF: To hoist valve
HP: From hydraulic pump
HT: From hoist valve
L: From steering valve
LS: From steering valve
P: To steering valve
PP: Plug
R: From steering valve
T: To steering valve

1. Priority valve
2. Relief valve
3. Spring
4. Pressure control valve
5. Directional valve
6. Suction relief valve
7. Suction relief valve
8. Check valve
Function (HM300-F5D7-042-K-00-A)

• The flow amplifier valve consists of the directional valve, amplifier stage, priority valve, relief valve,
pressure control valve, and suction valve.
• The flow from ports (L) and (R) of the steering unit is amplified at the specified ratio. The amplified oil flows
through ports (CL) and (CR) of the flow amplifier valve to the steering cylinder. The amplified flow is in
proportion to the rotation of the steering wheel.

HM400-3M0 10-123
10 Structure and function
Flow amplifier valve

Operation (HM400-F5D7-044-K-00-A)
When in neutral

• Port (P) of steering unit (9) is closed and the flow amplifier valve is also closed at chamber (M) of pressure
control valve (4).
• Ports (L), (R), and (T) of steering unit (9) are connected to each other and the oil in them is drained into the
hydraulic tank through port (T) of the flow amplifier valve.
Because of the above connection, directional valve (5) is kept in neutral by the springs on both sides.
Consequently, reactions or shocks from the steering cylinder are not transmitted to steering unit (9) while
the steering is in neutral.
• The oil is also drained through relief valve (2) of priority valve (1). Before the engine is started, priority
valve (1) is pushed leftward strongly by spring (3) to almost fully close port (EF) of the flow amplifier valve.
• When the engine is started, the oil flows to port (HP) of the flow amplifier valve and to port (P) of steering
unit (9). Since the pilot pressure connected to port (PP) increases sharply, the spool moves rightward to
balance with the spring, and consequently port (EF) opens and the oil flows to the hoist piping.

10-124 HM400-3M0
 10 Structure and function
Flow amplifier valve

When machine is steered

• When steering unit (9) operates, the oil sent from port (P) of priority valve (1) flows through ports (P) and
(L) of steering unit (9) to port (L) of directional valve (5).
At the same time, the oil also flows from priority valve (1) to chamber (M) of pressure control valve (4).
• When the oil pressure in directional valve (5) exceeds the force of the spring, it pushes the spool rightward
and enters chamber (C) of pressure control valve (4), where it also pushes the spool leftward against the
spring.
• The oil which has been in chamber (M) of pressure control valve (4) flows in chamber (N) because the
spool is pushed leftward by the action on steering unit (9), and then flows through port (CL) of directional
valve (5) to the left chamber of steering cylinder.
• The oil on the right chamber of steering cylinder is drained through port (CR) of directional valve (5), check
valve (8), and port (HT) of the flow amplifier valve into the hydraulic tank.
• If the abnormal external force is applied to tires or steering cylinder due to bad road surface or rocks etc.,
suction relief valves (6) and (7) open at 29.1 ± 1.0 MPa {285.5 ± 10 kg/cm 2}, and drain the oil to the
hydraulic tank through directional valve (5).

HM400-3M0 10-125
10 Structure and function
Steering valve

Steering valve (HM300-F570-041-K-00-A)

L: To flow amplifier valve

LS: To flow amplifier valve
P: From flow amplifier valve
R: To flow amplifier valve
T: To flow amplifier valve

1. Cover
2. Drive shaft
3. Valve body
4. Center pin
5. Bearing
6. Spool
7. Centering spring
8. Sleeve
9. Stator

10-126 HM400-3M0
 10 Structure and function
Steering valve

10.Rotor
11.Lower cover
Structure

A: Drive shaft connecting part of steering column

B: Groove meshed with center pin

• Top (A) of spool (6) is connected to the drive shaft of the steering wheel and further connected to sleeve
(8) by center pin (4) (which does not touch spool when the steering wheel is in "neutral") and centering
spring (7).
• Drive shaft (2) is meshed at its top (B) with center pin (7) and forms one unit with sleeve (8). Its bottom is
meshed with the spline of rotor (10) of the gerotor set.
• Valve body (3) has ports (P), (L), (LS), (R), and (T). All ports are connected to the flow amplifier valve.
Port (P) is connected to the pump circuit via flow amplifier valve.
Ports (L) and (R) are connected to the steering cylinder circuit via pilot side of flow amplifier valve.
Port (LS) is connected to the pilot side of flow amplifier valve.
Port (T) is connected to the tank circuit via flow amplifier valve.
• The ports on the pump side (P) and tank side (T) are connected through the check valve inside the valve
body. If the pump or the engine has trouble, the oil can be sucked in directly from the tank through this
check valve.

HM400-3M0 10-127
10 Structure and function
Steering valve

Function (HM300-F570-042-K-00-A)

• The steering valve sends the oil from the steering pump via flow amplifier valve to the right or left steering
cylinder to change the travel direction of the machine.
• During ordinal steering operation, It functions as a hydraulic motor.
• When oil supply is blocked due to a failure of steering pump or engine, it functions as a hand pump to
supply oil to steering cylinder. (However, it cannot be operated actually since its operating effort is too
high)
Operation (HM300-F570-044-K-00-A)
Connection of hand pump and sleeve
Fig. 1

Fig. 2

• Above figure 1 shows suction and discharge ports (C) of the gerotor. Above figure 2 shows the
connections of (C) and the sleeve ports.
• When the steering wheel is turned to the right, ports (a), (c), (e), (g), (i) and (k) are connected by the
vertical grooves in the spool to the pump. At the same time, ports (b), (d), (f), (h), (j) and (l) are connected
to the head side of the right steering cylinder in the same way.

10-128 HM400-3M0
 10 Structure and function
Steering valve

In above figure 1, ports (1), (2) and (3) are the discharge ports of the gerotor set and connected to ports (l),
(b) and (d) to send the oil to the cylinder.
Ports (5), (6) and (7) are also connected and the oil flows in from the pump.
Figure 3 shows the state after the steering wheel is turned 90 deg. from the above state. Under this state,
ports (1), (2) and (3) are in the suction state and connected to ports (i), (k) and (c). Ports (5), (6) and (7) are
in the discharge state and connected to ports (d), (f) and (h).

HM400-3M0 10-129
10 Structure and function
Steering valve

Fig. 3

• In this way, the ports of the gerotor in the discharge state are connected to the ports connected to the
steering cylinder. The ports in the suction state are connected to the pump circuit.
• Discharge adjusting gerotor in accordance with angle of steering wheel: For every 1/7 turn of the steering
wheel, the inner teeth of the gerotor gear advance one position to discharge oil from the pump by the
quantity for this operation.
Accordingly, the quantity of the oil discharged from the pump is directly proportional to the turning angle of
the steering wheel.

10-130 HM400-3M0
 10 Structure and function
Steering valve

Role of centering spring

• Centering spring (2) is composed of layers of 2 flat springs and 4 X-shaped leaf springs and installed
between spool (9) and sleeve (8) as shown in the figure below. When the steering wheel is turned, the
spool compresses the spring and angular difference (angular displacement) is generated between the
spool and sleeve.
As a result, the ports in the spool and sleeve are connected and the oil is sent to the cylinder. When the
steering wheel is stopped turning, the gerotor also stops turning, and accordingly no more oil is sent to the
cylinder and the oil pressure rises.
To prevent this, when the steering wheel is stopped turning, the centering spring rotates the sleeve by the
turning angle difference (angular displacement (D)) from the spool to return the steering wheel to the
"neutral" state.

HM400-3M0 10-131
10 Structure and function
Emergency steering pump

Emergency steering pump (HM400-F940-041-K-00-A)

A: From hydraulic tank

B: To flow amplifier valve
Specifications (HM400-F940-030-K-00-A)

Type Gear pump

Theoretical discharge (cc/rev) 21.0
Rated pressure: (MPa {kg/cm2}) 20.6 {210}
Max. speed (rpm) 3,500

Function (HM300-F940-042-K-00-A)

• The emergency steering pump is installed under the hydraulic tank together with the emergency steering
motor. It supplies oil to the steering circuit if the steering circuit pressure decreases below the specified
value.

10-132 HM400-3M0
 10 Structure and function
Emergency steering motor

Emergency steering motor (HM300-F9R0-041-K-00-A)

1. Terminal E
2. Terminal M
Specifications (HM300-F9R0-030-K-00-A)

Type DC motor
Rated voltage (V) 24
Rated horsepower (kW) 0.9
Function (HM400-F9R0-042-K-00-A)

• The emergency steering motor drives the emergency steering pump by the signals from the retarder and
hoist controller when the manual switch is operated or the steering circuit pressure decreases abnormally.
• 2 parts are installed to compose 2 emergency steering systems.

HM400-3M0 10-133
10 Structure and function
Layout of brake parts

Brake system (ALL-G000-001-K-00-A)

Layout of brake parts (HM400-G000-04D-K-00-A)

10-134 HM400-3M0
 10 Structure and function
Layout of brake parts

1. Pump for driving torque converter, transmission, aftercooler fan, and center brake cooling motors
2. Brake valve
3. Center brake cooling, radiator fan, and brake charge pump
4. Shut off solenoid valve
5. Shuttle valve (rear)
6. Proportional pressure reducing vlave (rear)
7. Slack adjuster (center)
8. Parking brake
9. Shuttle valve (front)
10.Slack adjuster (front)
11.Brake system tank
12.Proportional pressure reducing valve (front)
13.Parking brake solenoid and accumulator charge valve
14.Accumulator (front brake)
15.Accumulator (parking brake)
16.Accumulator (center brake)
17.Brake filter

HM400-3M0 10-135
10 Structure and function
Parking brake solenoid and accumulator charge valve

Parking brake solenoid and accumulator charge valve (HM400_3R-GJB0-041-K-00-A)

10-136 HM400-3M0
 10 Structure and function
Parking brake solenoid and accumulator charge valve

ACC1: Plug
ACC2: To center brake accumulator
D: To brake system tank
E: To parking brake
P: From hydraulic pump
T: To brake system tank

1. Accumulator charge valve

2. Parking brake solenoid valve
3. Filter
4. Relief valve (R1)
5. Relief valve (H1)
6. Main relief valve (R3)
7. Valve body
8. Relief valve (R4)
9. Solenoid assembly
10.Check valve (C1)
11.Check valve (C3)
12.Piston
13.Valve seal
14.Ball
15.Check valve (C2)
16.Filter
17.Spool
18.Ball
19.Filter
Function (HM300-GJB0-042-K-00-A)

• Parking brake solenoid and accumulator charge valve serves not only as parking brake solenoid valve but
also as accumulator charge valve.
Parking brake solenoid valve (HM300-GJD0-041-K-00-A)

Function (HM300-GJD0-042-K-00-A)
• When the parking brake switch is set to the TRAVEL position, the solenoid valve is energized to lead the
brake oil pressure to the parking brake spring cylinder, and set the parking brake in the travel state.
• When the parking brake switch is set to the PARK position, the solenoid valve is de-energized to eliminate
the brake oil pressure from the parking brake spring cylinder, and apply the parking brake to park the
machine.
Accumulator charge valve (HM300-G2H0-041-K-00-A)

Specifications (HM300-G2H0-030-K-00-A)
Cut-in pressure: 11.8 MPa {120 kg/cm2}
Cut-out pressure: 20.6 MPa {210 kg/cm2}

Function (HM300-G2H0-042-K-00-A)
• The accumulator charge valve maintains the oil pressure from the pump at the specified pressure and
increases the pressure in the accumulator.
• When the oil pressure rises above the specified pressure, the oil from the pump is led to the drain circuit to
reduce the load on the pump.

HM400-3M0 10-137
10 Structure and function
Parking brake solenoid and accumulator charge valve

Operation (HM300-G2H0-044-K-00-A)

When oil is not supplied to accumulator

(Cut-out state)
• Since the pressure at port (A) is higher than the set pressure of relief valve (R1), piston (8) is moved up
forcibly by the oil pressure of port (A). As a result, poppet (6) opens and port (B) is connected to port (C).
• Since the spring chamber at the top of spool (13) is connected to port (B) of relief valve (R1), the pressure
in it becomes the tank pressure.
The oil from the pump enters port (P), pushes spool (13) up at low pressure equivalent to the load on
spring (12), and flows through orifices (19), (20), and (21) to the tank.

10-138 HM400-3M0
 10 Structure and function
Parking brake solenoid and accumulator charge valve

When oil is supplied to accumulator

(Cut-in state)
• When the pressure at port (A) decreases below the set pressure of relief valve (R1), piston (8) is returned
downward by spring (5). As a result, poppet (6) contacts valve seat (7) to disconnect port (B) from port (C).
• The upper spring chamber of spool (13) is also disconnected from port (C) and the pressure in it increases.
The pressure in port (P) also increases.
• When the pressure in port (P) exceeds the pressure in port (A) (accumulator pressure), supply of oil to the
accumulator starts. In this case, oil of a certain quantity decided by the size (area) of orifice (19) and the
pressure difference across that orifice (equivalent to the load of spring (12)) is supplied regardless of the
engine speed.

HM400-3M0 10-139
10 Structure and function
Parking brake solenoid and accumulator charge valve

(When pressure reaches cut-out pressure)

• When pressure at port (A) (accumulator pressure) reaches the set pressure of relief valve (R1), poppet (6)
leaves valve seat (7). As a result, oil flows and is relieved.
• As the oil is relieved, pressure difference is generated across piston (8). As a result, piston (8) moves up
to open poppet (6) forcibly and connect port (B) to port (C).
• Since the spring chamber at the top of spool (13) is also connected to port (B) of relief valve (R1), the
pressure in it becomes the tank pressure.
• Since the pressure at port (P) also drops to the level equivalent to the load of spring (12), oil supply to the
accumulator is stopped as well.

10-140 HM400-3M0
 10 Structure and function
Parking brake solenoid and accumulator charge valve

Main relief valve (R3)

• If the pressure at port (P) (pump pressure) exceeds the set pressure of relief valve (R3), the oil from the
pump pushes ball (11) upward against spring (10) to drain the oil to the tank circuit, thus the maximum
pressure in the brake circuit is limited to protect the circuit.

HM400-3M0 10-141
10 Structure and function
Accumulator

Accumulator (HM300-G2G0-041-K-00-A)

1. Gas valve
2. Top cover
3. Cylinder
4. Piston
5. End cover
Specifications (HM300-G2G0-030-K-00-A)

Gas to be used Nitrogen gas

Filled quantity 4,000 cc
4.4 ± 0.15 MPa {45 ± 1.5 kg/cm2}
Charge pressure
(at 20 ± 5 °C)

Function (HM300-G2G0-042-K-00-A)

• The accumulator is installed between the accumulator charge valve and brake valve. The space between
cylinder (3) and free piston (4) is filled with nitrogen gas. The nitrogen gas absorbs the hydraulic pulses
generated by the hydraulic pump by utilizing its compressibility, and secures the braking force and
operability when the engine is stopped.

10-142 HM400-3M0
 10 Structure and function
Shut off solenoid valve

Shut off solenoid valve (HM400_3M0-GT4A-041-K-00-A)

A: To proportional pressure reducing valve

P: From brake valve
T: To brake system tank

1. Connector
2. Solenoid valve
Function (HM400_3M0-GT4A-042-K-00-A)

• This valve cuts off the circuit to the brake corresponding to the command of retarder and hoist controller.

HM400-3M0 10-143
10 Structure and function
Brake valve

Brake valve (HM300-G2B0-041-K-00-A)

10-144 HM400-3M0
 10 Structure and function
Brake valve

A: To center brake
B: To front brake
T: To brake system tank
PA: From center accumulator
PB: From front accumulator

1. Pilot piston
2. Rod
3. Lower cylinder
4. Spool
5. Upper cylinder
6. Spool
Operation (HM300-G2B0-044-K-00-A)
Upper section
• When pedal (1) is depressed, the depressing force is transmitted to spool (3) through rod (2) and spring
(4). When spool (3) lowers, drain port (a) is closed and the oil from the pump and accumulator flows
through ports (PA) and (A) to operate the center brake cylinder.

Lower section
• When pedal (1) is depressed, the depressing force is transmitted to spool (3) through rod (2) and spring
(4). When spool (3) lowers, spool (5) lowers through plunger (6). As a result, drain port (b) is closed and
the oil from the pump and accumulator flows through ports (PB) and (B) to operate the front brake cylinder.

HM400-3M0 10-145
10 Structure and function
Brake valve

Operation of brake when upper section of valve is failed

• Even if oil leaks from the piping at upper section of valve, when pedal (1) is depressed, spool (5) is moved
down mechanically and the lower section of valve operates normally. The brake connected to the upper
section of valve does not operate.

Operation of brake when lower section of valve is failed

• Even if the oil leaks from the piping at lower section of valve, the brake connected to the upper section of
valve operates normally.

10-146 HM400-3M0
 10 Structure and function
Brake valve

Balancing operation

Upper section
• When oil fills the center brake cylinder and the pressure between ports (PA) and (A) increases, the oil
flowing in port (H) through orifice (e) of spool (3) pushes spool (3) up against spring (4) to disconnect port
(PA) from port (A). At this time, drain port (a) is kept closed to maintain the oil in the brake cylinder and
leave the brake applied.

Lower section
• When spool (3) in the upper section moves up and port (PA) is disconnected from port (A), oil also fills the
front brake cylinder to increase the pressure between ports (PB) and (B). The oil flowing in port (J) through
orifice (f) of spool (5) pushes up spool (5) by the same amount that spool (3) moves, and disconnects port
(PB) from port (B).
Since drain port (b) is closed, the oil flowing in the brake cylinder is held and the brake is kept applied.
• The pressure in the space of the upper section is balanced with the depressing force of the pedal and the
pressure in the space of the lower section is balanced with the pressure in the space of the upper section.
When spools (3) and (5) move to the stroke end, ports (PA) and (A), and ports (PB) and (B) are connected
completely. Thus, the pressures in the spaces of the upper and lower sections and in the right and left
brake cylinders become equal to the oil pressure from the pump.
Therefore, the braking effect can be adjusted by adjusting the depressing force of the pedal until the piston
moves to the stroke end.

HM400-3M0 10-147
10 Structure and function
Brake valve

When brake is released

Upper section
• When pedal (1) is released and the operating force is removed from the top of the spool, the back
pressure from the brake cylinder and the force of the spool return spring move spool (3) up. Drain port (a)
is opened and the oil from the brake cylinder flows to the brake system tank return circuit to release the
center brake.
Lower section
• When the pedal is released, spool (3) of the upper section moves upward and the back pressure from the
brake cylinder and the spool return spring move spool (5) to open drain port (b). Then, the oil from the
brake cylinder flows to the brake system tank return circuit to release the front brake.

10-148 HM400-3M0
 10 Structure and function
Proportional pressure reducing valve

Proportional pressure reducing valve (HM300-GTQ1-041-K-00-A)

A: To slack adjuster
B: To slack adjuster
P: From accumulator
T: To brake system tank

1. Filter
2. Connector
3. Solenoid assembly

HM400-3M0 10-149
10 Structure and function
Proportional pressure reducing valve

Function (HM300-GTQ1-042-K-00-A)

• The proportional pressure reducing valve is used for retarder control and KTCS and installed between the
brake system tank and brake valve in the brake circuit.
It changes the discharge pressure according to the turning angle of the retarder control lever or command
of the KTCS, and control the retarder freely.

10-150 HM400-3M0
 10 Structure and function
Slack adjuster

Slack adjuster (HM300-G310-001-K-00-A)

Front slack adjuster (HM400-G320-041-K-00-A)

A: Inlet port
B: Outlet port

1. Bleeder
2. Cylinder
3. Check valve
4. Spring
5. Piston

HM400-3M0 10-151
10 Structure and function
Slack adjuster

Center slack adjuster (HM400-G322-041-K-00-A)

A: Inlet port
B: Outlet port

1. Breather
2. Cylinder
3. Check valve
4. Piston
5. Spring
Specifications (HM300-G310-030-K-00-A)

Piston operating pressure kPa {kg/cm2} 9.8 to 19.6 {0.1 to 0.2}

Check valve cracking pressure (when cooling
1.74 ± 0.05 {17.8 ± 0.5}
pressure is zero) (MPa {kg/cm2})
Check valve closing pressure (MPa {kg/cm2}) 1.09 ± 0.05 {11.1 ± 0.5}

Function (HM300-G310-042-K-00-A)

• The slack adjuster is installed in the brake oil line going to the brake piston from the brake valve, and
keeps the time lag in braking operation at a constant value.

10-152 HM400-3M0
 10 Structure and function
Slack adjuster

Operation (HM300-G310-044-K-00-A)
When brake pedal is depressed
• Before the brake pedal is depressed, pistons (4) are returned by the distance corresponding to stoke (S)
(full stroke). When the brake pedal is depressed, the oil from the brake valve is divided at slack adjuster
port (P) and flows to the right and left cylinders (2) to move pistons (4) rightward and leftward by stroke
(S).

• As a result, brake piston (7) moves by stroke (S). At this time, the clearance between the brake piston and
disc becomes zero, but no braking force is applied.

• When the brake pedal is depressed further and the oil pressure from the brake valve exceeds the
specified pressure, check valve (3) opens and pressure is applied to port (C) to generate braking force.
Thus, the time lag when the brake is applied is maintained constant.

HM400-3M0 10-153
10 Structure and function
Slack adjuster

When brake pedal is released

• When the brake pedal is released, piston (4) is returned by the brake cooling oil pressure by the amount
equivalent to stroke (S), and the brake is released.
That is, return stroke (T) of brake pistons (7) is decided by the oil volume for stroke (S) of the slack
adjuster and the time lag in braking is kept constant, regardless of wear of the brake disc.

10-154 HM400-3M0
 10 Structure and function
Brake

Brake (HM300-G160-001-K-00-A)

Front brake (HM400-G16H-041-K-00-A)

1. Stud bolt
2. Cylinder
3. Brake piston
4. Disc
5. Plate
6. Hub gear (number of teeth: 112)
7. Outer gear (number of teeth: 164)

HM400-3M0 10-155
10 Structure and function
Brake

Center brake (HM400-G16J-041-K-01-A)

1. Bolt
2. Cylinder
3. Brake piston
4. Disc
5. Plate
6. Hub gear (number of teeth: 112)
7. Outer gear (number of teeth: 164)
Function (HM300-G160-042-K-00-A)

• The wet type multiple disc brakes are installed to the front and center axles.

10-156 HM400-3M0
 10 Structure and function
Brake

Operation (HM300-G160-044-K-00-A)

• When the brake pedal is depressed, the pressurized oil from the brake valve moves brake piston (3) in the
direction of the arrow to press discs (7) against plates (6) and generate friction force between them. Since
the wheel is rotating together with the discs, the friction decelerates the machine to stop.

A: From slack adjuster

• When the brake pedal is released, back pressure on brake piston (3) is released and internal pressure
moves the piston in the direction shown by the arrow to release the brake.

B: To slack adjuster

HM400-3M0 10-157
10 Structure and function
Brake system tank

Brake system tank (HM400-G246-041-K-00-A)

A: From accumulator charge valve, brake valve, and proportional pressure reducing valve
B: To transmission
C: To hydraulic pump

1. Outlet tube
2. Inlet tube
3. valve
4. Oil level gauge

10-158 HM400-3M0
 10 Structure and function
Parking brake

Parking brake (HM400-GJ00-041-K-00-A)

1. Parking brake caliper

2. Spring cylinder
3. Parking brake disc
Function (HM300-GJ00-042-K-00-A)

• The disc type parking brake is installed to the rear of the oscillation hitch.
• The parking brake is applied mechanically by the force of the spring in the spring cylinder and released
hydraulically.
• The parking brake caliper is installed to the oscillation hitch.
• The disc is installed to the hitch shaft output coupling and rotates together with the coupling.

HM400-3M0 10-159
10 Structure and function
Parking brake

Spring cylinder (HM300-GJ62-041-K-00-A)

1. Spring (outside)
2. Spring (inside)
3. Piston
4. Cylinder
5. Boot
6. Rod

Function (HM300-GJ62-042-K-00-A)
• The oil pressure from the parking brake solenoid valve pushes springs (1) and (2) to release the parking
brake.
When the engine is stopped, the parking brake is applied by springs (1) and (2) to hold the machine.

10-160 HM400-3M0
 10 Structure and function
Parking brake

Parking brake caliper (HM400-GJ30-041-K-00-A)

1. Adjuster
2. Piston
3. Piston shaft
4. Pad
5. Caliper

Function (HM300-GJ30-042-K-00-A)
• Caliper (5) has the piston guide, to which piston (2) and piston shaft (3) are fitted. When piston shaft (3)
rotates, piston (2) moves axially to lock the disc with pad (4) and apply the parking brake.
• The spline side of piston shaft (3) is coupled with adjuster (1) by spline. Pad (4) is fitted and held together
with calipers (5) to the caliper mounting plates.

HM400-3M0 10-161
10 Structure and function
Suspension

Undercarriage and frame (ALL-DT00-001-K-00-A)

Suspension (HM300-E000-001-K-00-A)

Function (HM300-E000-042-K-00-A)

• The suspension system supports the weight of the machine, absorbs the shocks received from the
uneven road surface, improves the operator comfort, and has the wheels contact to the road surface
constantly to attain high motion performance including the acceleration, braking, and turning even during
high-speed travel.
• The suspension cylinder which absorbs shocks is of the hydro-pneumatic type and charged (sealed up)
with oil and nitrogen gas, which are compressed and expanded by the load applied from the road surface
and work as a shock absorber (a spring and a damper).
Front suspension (HM400-E140-041-K-00-A)

1. Front suspension cylinder

2. Lateral rod
3. Dust cover
4. Arm

10-162 HM400-3M0
 10 Structure and function
Suspension

Function (HM400-E140-042-K-00-A)
• The front suspension cylinder has functions of a shock absorber and a spring. It is connected to the arm
and main frame by the spherical bearing. As it is extended or retracted, the arm rocks.
The main frame and arm are connected to each other by the lateral rod to receive lateral loads.

HM400-3M0 10-163
10 Structure and function
Suspension

Center and rear suspensions (HM400-E141-041-K-00-A)

1. Arm
2. Equalizer bar
3. Lateral rod (rear)
4. Rear suspension cylinder
5. Spring
6. Lateral rod (center)

10-164 HM400-3M0
 10 Structure and function
Suspension

Function (HM400-E141-042-K-00-A)
• The center axle and rear axle are respectively fixed to the arms. The center axle is connected to the
equalizer bar through the spring. The rear axle is connected to the equalizer bar through the rear
suspension cylinder. The arms and equalizer bar rock to have the wheels contact to the road surface
according to the road surface condition.
The main frame and arm are connected to each other by the lateral rod to receive lateral loads.

HM400-3M0 10-165
10 Structure and function
Suspension cylinder

Suspension cylinder (HM400-E139-001-K-00-A)

Front suspension cylinder (HM400-E150-041-K-00-A)

a This figure shows the front left suspension cylinder.

1. Air supply valve

2. Oil level valve
3. Retainer
4. Rod
5. Flange
6. Cylinder

10-166 HM400-3M0
 10 Structure and function
Suspension cylinder

Rear suspension cylinder (HM400-E170-041-K-00-A)

a This figure shows the rear left suspension cylinder.

1. Air supply valve

2. Oil level valve
3. Retainer
4. Rod
5. Flange
6. Cylinder
Function (HM300-E139-042-K-00-A)

• The suspension cylinder has functions of a shock absorber and a spring.

• When oil of a certain quantity is sent from oil chamber (1) through orifices (4) and (5) to cavity (3), the oil is
reduced by the orifices to give damping effect.

HM400-3M0 10-167
10 Structure and function
Suspension cylinder

Operation (HM400-E139-044-K-00-A)

a The figure show the front left suspension cylinder.

1. Oil chamber
2. Nitrogen gas chamber
3. Cavity
4. Orifice
5. Orifice
6. Check ball
Retract action
• When a wheel encounters a projection or an obstacle on the road during travel, it is lifted up and the
cylinder rod is pushed into the cylinder.
As a result, the nitrogen gas in chamber (2) is compressed and the oil in chamber (1) is sent to cavity (3)
through 2 orifices (4) and (5), thus cavity (3) is filled more quickly than in the extract action.

Extract action
• When a wheel passes over a projection or an obstacle on the road, the cylinder rod is extracted upward by
the weight of the wheel and axle and the nitrogen gas pressure in chamber (2).
As a result, the quantity of oil in cavity (3) reduces and pressure is applied to the oil remaining in cavity (3).
Since this pressurized oil closes orifice (4) with check ball (6) and the oil is sent through only orifice (5) to
chamber (1), the oil flow through the orifice is less than in the retract action and the quantity of the oil
returning to chamber (1) is adjusted to give damping effect.

10-168 HM400-3M0
 10 Structure and function
Oscillation hitch

Oscillation hitch (HM400_3R-H1P0-041-K-00-A)

1. Pin
2. Hitch frame
3. Shaft
4. Rear drive shaft
5. Coupling
6. Coupling
7. Center drive shaft
8. Pin
Function (HM400-H1P0-042-K-00-A)

• The front frame and rear frame are connected by the oscillation hitch.
• The front frame is connected to the hitch frame by the bearings and pins (1) and (8), and the rear frame is
connected to the hitch frame by the spacer, retainer, and bearing so that those frames can articulate and
rock.
• The output of the transmission is transmitted through center drive shaft (7) to coupling (6), and then
transmitted through coupling (5) and rear drive shaft (4) to the rear axle.

HM400-3M0 10-169
10 Structure and function
Hydraulic component layout

Hydraulic system (D65-PM10-001-K-00-A)

Hydraulic component layout (HM400-M5J0-04D-K-00-A)

10-170 HM400-3M0
 10 Structure and function
Hydraulic component layout

1. Front brake cooling relief valve

2. Brake charge pump
3. Dump EPC valve
4. Pump for driving torque converter, transmission, aftercooler fan, and center brake cooling motors
5. Center brake cooling remote motor
6. Center brake cooling remote pump
7. Brake Cooling Filter
8. Center brake cooling relief valve
9. Hoist cylinder (right)
10.Hoist cylinder (left)
11.Hydraulic tank
12.Hoist valve
13.Flow amplifier valve
14.Strainer
15.Steering pump selector solenoid valve
16.Steering and hoist pump
17.Center brake cooling pump
18.Radiator fan pump

HM400-3M0 10-171
10 Structure and function
Dump body control

Dump body control (HM400-PM10-041-K-00-A)

1. EPC valve
2. Dump lever
3. Retarder controller
4. Dump body position sensor
5. Hoist valve
6. Steering and hoist pump
Function (HM300-PM10-042-K-00-A)

• When dump body is raised and dump body position sensor (4) comes to set position, this control sets
dump body lever (2) to "HOLD" position to stop raising the dump body.
• The signal from dump lever (2) is controlled by retarder controller (3) to operate EPC valve (1). The pilot
pressure generated in EPC valve (1) moves the spool of hoist valve (5) to control the hoist cylinder.

10-172 HM400-3M0
 10 Structure and function
Hydraulic tank

Hydraulic tank (HM400-PM30-041-K-00-A)

1. Breather
2. Oil level gauge
3. Drain plug
4. Bypass valve
5. Strainer
6. Element

HM400-3M0 10-173
10 Structure and function
Steering and hoist pump

Steering and hoist pump (HM400-C200-041-K-00-A)

P1F: Pump discharge port

P1LF: Pump pressure input port
P1LR: Pump pressure input port
P1R: Pump discharge port
PD2F: Drain plug
PD2R: Drain plug
PDF: Drain port
PDR: Drain port
PENF: Control pressure pickup plug
PENR: Control pressure pickup plug
PLSF: Load pressure input port
PLSR: Load pressure input port
POPF: Control source pressure input port
POPR: Control source pressure input port
PSF: Pump suction port
PSR: Pump suction port

1. Pump body
2. Servo valve
3. Bleeder

10-174 HM400-3M0
 10 Structure and function
Steering and hoist pump

1. Shaft
2. Oil seal
3. Sleeve
4. Spring
5. Servo piston
6. Shoe retainer
7. End cap
8. Valve plate
9. Cylinder block
10.Piston
11.Shoe
12.Rocker cam
13.Case
14.Bearing
15.Ball retainer

HM400-3M0 10-175
10 Structure and function
Steering and hoist pump

Structure
• Cylinder block (6) is supported on shaft (1) through spline (a). Shaft (1) is supported on the front and rear
bearings.
• The tip of piston (5) is shaped as a concave sphere and is crimped with shoe (4). Piston (5) and shoe (4)
constitute a spherical bearing.
• Rocker cam (3) is supported by case (2) and ball retainer (9) and has plane (A). Shoe (4) is kept pressed
against the plane and slides in a circular pattern. Shoe (4) transmits high-pressure oil to form a static
pressure bearing for its sliding.
• Piston (5) moves relatively in the axial direction in each cylinder chamber of cylinder block (6).
• Cylinder block (6) rotates relatively to valve plate (7) while sealing the pressurized oil.
• The oil pressure is balanced properly on the contact face between cylinder block and valve plate.
• The pressurized oil is sucked in and discharged from each cylinder chamber in cylinder block (6) through
valve plate (7).
Function (HM300-C200-042-K-00-A)

• This pump converts the rotation and torque of the engine transmitted to its shaft into hydraulic pressure
and discharges pressurized oil according to the load.
• The discharge can be changed by changing the swash plate angle.

10-176 HM400-3M0
 10 Structure and function
Steering and hoist pump

Operation (HM400-C200-044-K-00-A)

• Cylinder block (6) rotates together with shaft (1) and shoe (4) slides on plane (A).
• Rocker cam (3) pivots on ball retainer (9), and accordingly angle (a) between center line (X) of rocker cam
(3) and the axis of cylinder block (6) changes.
• Angle (a) is called the swash plate angle.

• While angle (a) is made between center line (X) of rocker cam (3) and the axis of cylinder block (6), plane
(A) works as a cam for shoe (4).
• Piston (5) slides inside cylinder block (6) and a difference is made between volumes (E) and (F) in cylinder
block (6).
• Oil in amount of (F) minus (E) goes in and out of each cylinder.
• Oil is discharged while cylinder block (6) rotates and the volume of chamber (E) decreases.
• Oil is sucked in while the volume of chamber (F) increases.

• When center line (X) of rocker cam (3) matches the axis of cylinder block (6) (the swash plate angle is
zero), the difference between volumes (E) and (F) inside cylinder block (6) is zero.
• Pressurized oil is not sucked or discharged, namely pumping action is not performed. (Actually, however,
the swash plate angle is not set to 0 deg.)
• The pump discharge is in proportion to swash plate angle (a).

HM400-3M0 10-177
10 Structure and function
Steering and hoist pump

Discharge control
• If swash plate angle (a) increases, the difference between volumes (E) and (F) increases, and
consequently discharge (Q) increases.
• Swash plate angle (a) is changed by servo piston (11).
• Servo piston (11) reciprocates linearly according to the signal pressure from the PC and LS valves.
• This linear motion is transmitted to rocker cam (3).
• Rocker cam (3) supported on ball retainer (9) slides around ball retainer (9).

10-178 HM400-3M0
 10 Structure and function
Steering and hoist pump

Servo valve (HM300-C2B0-041-K-00-A)

P1: Pump discharge pressure port

PE: Control pressure output port
T: Drain port

HM400-3M0 10-179
10 Structure and function
Steering and hoist pump

PC valve
T: Drain
PA: Pump pressure input
PPL: PC valve output pressure

LS valve
PA: Pump pressure input
PE: Control piston pressure
PLS: LS pressure input
PPL: PC valve output pressure
PPLS: LS pump pressure input

1. Lever
2. Spring
3. Retainer
4. Seat

10-180 HM400-3M0
 10 Structure and function
Steering and hoist pump

5. Spool
6. Sleeve
7. Piston
8. Seal
9. Piston
10.Nut
11.Plate
12.Plug
13.Spring
14.Seat
15.Spool
16.Plug
LS valve (HM400-C2J0-042-K-00-A)
Function
• The LS valve controls the pump discharge according to the travel of the control lever, or the flow
demanded by the actuator.
• The LS valve detects the flow rate demanded by the actuator from differential pressure (dPLS) between
inlet pressure (PPLS) and outlet pressure (PLS) of the control valve and controls pump discharge (Q).
[(PPLS) is called the LS pump pressure, (PLS) the LS pressure, and (dPLS) the LS differential pressure.]
• In other words, pressure loss [= LS differential pressure (dPLS)], which occurs when the oil flows through
the passage in control valve spool, is detected, and pump discharge (Q) is controlled to maintain the
pressure loss at a constant level. Through this operation, the pump can discharge the proper volume of oil
as demanded by the actuator.
• Pump discharge pressure (PP), LS pump pressure (PPLS), and LS pressure (PLS) are led into the LS
valve. The relationship between LS differential pressure (dPLS) and pump discharge (Q) changes as
shown in the following figure.

HM400-3M0 10-181
10 Structure and function
Steering and hoist pump

PC valve (HM300-C2K0-042-K-00-A)
Function
• The PC valve limits the oil flow to a certain level (depending on the discharge pressure) even if the travel
of the control valve is increased extremely so that the horsepower absorbed by the pump does not exceed
the engine horsepower, when pump discharge pressure (PA) is high.
• In other words, the PC valve decreases the pump discharge when the actuator load is increased and the
pump discharge pressure rises, and increases it when the pump discharge pressure lowers.
• The relationship between the pump pressure and pump discharge is shown below.

Operation (HM400-C2K0-044-K-00-A)

Action of spring
• The spring force of spring (2) in the PC valve is determined by the angle of the swash plate.
• When servo piston (6) moves to the right, spring (2) is compressed through lever (1) and the spring force
changes.

When pump pressure (PA) is low

• The pressing force of piston (5) is decreased and spool (3) is a little closer to the right (Fig. 1). At this time,
port (C) is connected to port (D) and the pressure transmitted to the LS valve becomes drain pressure
(PT).
• When port (F) is connected to port (G) of the LS valve, the pressure in port (J) becomes drain pressure
(PT) and servo piston (6) moves to the left.
• Consequently, the pump discharge is increased.
• As servo piston (6) moves, lever (1) moves to the left and spring (2) expands and the spring force is
decreased. Consequently, spool (3) moves to the left and port (C) is disconnected from port (D) and
connected to pump discharge port (B).
• As a result, the pressure in port (C) rises and the piston pressure is increased and servo piston (6) stops
moving to the left.

10-182 HM400-3M0
 10 Structure and function
Steering and hoist pump

When load is light

(Fig. 1)

When pump pressure (PA) is high

• The pressing force of piston (5) is increased and spool (3) is a little closer to the left (Fig. 2). At this time,
port (C) is connected to port (B) and the pressure transmitted to the LS valve becomes pump pressure
(PA).
• When port (F) is connected to port (G) of the LS valve, the pressure in port (J) becomes pump pressure
(PA) and servo piston (6) moves to the right.
• Consequently, the pump discharge is decreased.
• As servo piston (6) moves, lever (1) moves to the right and spring (2) is compressed and spring force is
increased. Consequently, spool (3) moves to the right and port (C) is disconnected from port (B) and
connected to drain pressure port (D).
• As a result, the pressure in port (C) lowers and the piston pressure is decreased and servo piston (6)
stops moving to the right.
• Accordingly, the stop position (= pump discharge) of servo piston (6) is determined by the position where
the thrust caused by pressure (PA) applied to piston (5) is balanced with the reaction force of spring (2)
acting through spool (3). (Fig. 3)

HM400-3M0 10-183
10 Structure and function
Steering and hoist pump

When load is heavy

(Fig. 2)

When in balance
(Fig. 3)

10-184 HM400-3M0
 10 Structure and function
Hoist valve

Hoist valve (HM400-M5J0-041-K-00-A)

HM400-3M0 10-185
10 Structure and function
Hoist valve

A1: To hoist cylinder bottom

ADT: Adjustment screw
B1: To hoist cylinder head
P: From flow amplifier valve
PA: From EPC valve (LOWER and FLOAT)
PB: From EPC valve (RAISE)
T: To hydraulic tank
T2: Plug

1. Retainer
2. Spool
3. Valve body
4. Retainer
5. Retainer
6. Retainer
7. Relief valve
8. Check valve

10-186 HM400-3M0
 10 Structure and function
Hoist valve

Operation (HM400-M5J0-044-K-00-A)
When hoist valve is in HOLD position

• The pressurized oil from the flow amplifier valve flows in chamber (C). Since the route to the hoist cylinder
is blocked with hoist spool (2), the pressurized oil flows through chamber (D) to the tank.
• Since the port to the hoist cylinder is blocked on both bottom and head sides, the hoist cylinder is fixed at
the current position.

HM400-3M0 10-187
10 Structure and function
Hoist valve

When hoist valve is in RAISE position

• When the dump lever in the cab is set to RAISE position, the pressurized oil from the dump EPC valve
moves hoist spool (2) to the left.
• Accordingly, the pressurized oil flows through chamber (C) to open load check valve (11) and flows in
chamber (A).
• The pressurized oil flows through chamber (A) into the hoist cylinder bottom to extend the hoist cylinder
and raise the dump body.
• On the other hand, the pressurized oil returning from the head side flows through chambers (B) and (D) to
the tank.

10-188 HM400-3M0
 10 Structure and function
Hoist valve

When hoist valve is in FLOAT position

• When the dump lever in the cab is set to FLOAT position, the pressurized oil from the dump EPC valve
moves hoist spool (2) to the right. Then, chambers (C) and (D), and chambers (B), (A), and (D) are
connected respectively.
• The pressurized oil from the flow amplifier valve flows through chambers (C) and (B) to the hoist cylinder.
It also flows through chambers (C) and (D) to the tank.
• Since the bottom end and head end of the hoist cylinder are connected to the tank by the hoist valve, the
hoist cylinder is free.

HM400-3M0 10-189
10 Structure and function
Hoist valve

When hoist valve is in LOWER position

• When the dump lever in the cab is moved from FLOAT position to LOWER position, the pressurized oil
from the dump EPC valve moves hoist spool (2) further to the right from FLOAT position. Accordingly, the
pressurized oil flows through chamber (C) to push load check valve (11) open and flows in chamber (B).
• The pressurized oil flows through chamber (B) into the hoist cylinder head end to retract the hoist cylinder
and lower the dump body.
• On the other hand, the pressurized oil returning from the head end of the hoist cylinder flows through
chambers (A) and (D) to the tank.

10-190 HM400-3M0
 10 Structure and function
Steering pump selector solenoid valve

Steering pump selector solenoid valve (HM400_3R-F5T1-041-K-00-A)

A: From steering valve

B: From flow amplifier valve
P: To steering and hoist pump
T: To hydraulic tank

1. Solenoid assembly
Function (HM400_3R-F5T1-042-K-00-A)

• This valve is controlled by the retarder and hoist controller. It sends the oil from the hydraulic pump to the
steering and hoist pump to change LS pressure, and controls the steering and hoist pump.

HM400-3M0 10-191
10 Structure and function
Dump EPC valve

Dump EPC valve (HM400-M5B5-041-K-00-A)

a EPC: Abbreviation for Electromagnetic Proportional Control

10-192 HM400-3M0
 10 Structure and function
Dump EPC valve

A: To hoist valve (RAISE side)

B: To hoist valve (LOWER side)
C: To aftercooler fan motor
E: To steering and hoist pump, radiator fan pump EPC valve, and brake cooling motor
P1: From aftercooler fan pump
P2: Pressure pickup port
R1: Sequence valve
R2: Pressure reducing valve
T: To hydraulic tank

1. Solenoid assembly (solenoid a)

2. Solenoid assembly (solenoid b)
Function (HM300-M5B5-042-K-00-A)

• The dump EPC valve is controlled by the retarder and hoist controller. It sends the oil from the hydraulic
pump to the hoist valve spool to select and control the pilot pressure and control the hoist valve.

HM400-3M0 10-193
10 Structure and function
Center brake cooling remote motor

Center brake cooling remote motor (HM400_3R-GD7C-041-K-00-A)

P: From pump
PEPC: From dump EPC valve
T: To hydraulic tank through return filter
TC: To hydraulic tank

1. Terminal EF
2. EPC valve
3. Terminal EN

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Center brake cooling remote motor

1. Output shaft
2. Case
3. thrust plate
4. Piston assembly
5. Cylinder block
6. Valve plate
7. End cover
8. Bearing
9. Spring
10.Retainer shoe
11.Retainer guide

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Center brake cooling remote motor

12.Bearing
13.Oil seal
14.Flow control spool
15.Suction-safety valve
16.Reversible spool
17.Speed sensor
Specifications (HM400_3R-GD7C-030-K-00-A)

Model LMF10
Type Swash plate type piston motor
Motor capacity (cc/rev) 10
Rated speed (rpm) 2,567
Rated flow rate (l/min) 30
Check valve cracking pressure (MPa {kg/cm2}) 0.013 {0.13}

Hydraulic motor (HM300-B5N0-042-K-00-A)

Function
• This hydraulic motor is called a swash plate axial piston motor. It converts the energy of the pressurized oil
sent from the hydraulic pump into rotary motion.

Principle of operation (HM300-B5N0-04B-K-01-A)

• The pressurized oil sent from the pump flows through valve plate (6) into cylinder block (5).
• This oil can flow to only one side of the (Y-Y) line connecting the top dead center and bottom dead center
of the stroke of piston (4).
• The pressurized oil sent to one side of cylinder block (5) pushes each piston (4) (2 or 3 pistons).
• Each piston (4) generates force (F1) [F1 (kg) = P (kg/cm2) x x D2 / 4 (cm2)].
• This force acts on thrust plate (2).
• Since thrust plate (2) is fixed at specific angle (a) to output shaft (1), the force is divided into components
(F2) and (F3).
• Radial component (F3) generates each torque [T = F3 x ri] against the (Y - Y) line connecting the top dead
center and bottom dead center.
• The total of these torque [T = Σ(F3 x ri)] rotates cylinder block (5) through piston (4).
• Cylinder block (5) is connected to output shaft (1) with spline.
• Output shaft (1) rotates to transmit the torque.

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Center brake cooling remote motor

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Center brake cooling remote motor

Suction safety valve (HM300-B6D6-001-K-00-A)

Function as suction valve (HM300-B6D6-042-K-00-A)

• When the pump stops, the pressurized oil does not flow into the motor any more.
• Since the motor continues to rotate with the force of inertia, the pressure on the outlet side of the motor
increases.
• When the oil stops flowing in from inlet port (P), suction safety valve (1) sucks in the oil on the outlet side
and supplies it to port (MA), compensating for the lack of oil on that side to prevent cavitation.

Operation (HM400_3R-B6D6-044-K-00-A)

When started

• The pressurized oil from the pump is supplied to port (P), increasing the (MA) side pressure.
• The starting torque is generated in the motor, and the motor starts rotating.
• The pressurized oil on the motor outlet (MB) side returns to the tank through port (T).

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Center brake cooling remote motor

When stopped

• When the engine stops, the pump input speed becomes 0 rpm.
• The pressurized oil from the pump is not supplied to port (P).
• As the pressurized oil is not supplied to (MA) side of the motor, the motor speed decreases gradually to
stop.
• When the motor shaft is rotated by the force of inertia while the oil flow in the port (P) is decreasing, the oil
in port (T) on the outlet side is sent by suction safety valve (1) to the (MA) side to prevent cavitation.

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Center brake cooling remote motor

Function as safety valve (HM300-B6D6-042-K-01-A)

• The pressure in port (P) of the motor is increased when the engine is started etc.
• Suction safety valve (1) is installed to protect the fan system circuit in such a case.

Operation (HM400_3R-B6D6-044-K-01-A)

• If the pressure in port (P) rises above the cracking pressure of suction safety valve (1), valve (2) of suction
safety valve (1) opens to release the pressurized oil into port (T).
• This operation prevents generation of the abnormally high pressure in port (P).

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Center brake cooling remote motor

Flow control valve (steplessly-variable type) (HM400_3R-B6D5-041-K-00-A)

Function (HM400_3R-B6D5-042-K-00-A)
This valve supplies the pump discharge to the motor by the necessary quantity, and returns the excess oil to
the hydraulic tank.
• The motor speed increases in proportion to motor flow (Q) as shown in Fig 1.
• When the motor flow is (Q1), motor speed is (B) rpm.
• In order to reduce noise and performance loss of the motor, this valve keeps the fan speed constant at
necessary level regardless of the motor flow.
• Even if the motor flow is increased from (Q0) to (Q1), this valve maintains the motor speed constant at (A)
rpm and (C) rpm.

Operation (HM400_3R-B6D5-044-K-00-A)
• In the flow control valve, the upstream pressure of the orifice is applied to the right side of spool (1) and
the downstream pressure is applied to the left side.
• The differential pressure caused by the motor flow over orifice (E) acts on spring (2).
• In Fig. 1, if the motor flow exceeds (Q0), the differential pressure across spool (1) exceeds the load at
installed length of spring (2).
• Spool (1) moves to the left and port (P) and port (T) are interconnected.
• The excess oil of (Z) portion in Fig 1 flows to the hydraulic tank through the flow control valve, and the
motor speed is kept constant in the range from (A) to (C).
• This flow control valve can be adjusted in stepless.
• As shown in Fig 2, the flow control valve can be adjusted in stepless while maintaining the motor speed
constant between (A') and (C') by changing the command current between the motor speed (A) and (C).
Fig. 1

Fig. 2

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Center brake cooling remote motor

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Front brake cooling relief valve

Front brake cooling relief valve (HM400_3M0-B8M1-041-K-00-A)

1. Case
2. Valve plate
3. Spring
4. Pin
Function (HM400_3M0-B8M1-042-K-00-A)

• This valve controls maximum pressure of front brake cooling circuit to protect it.
Set pressure: 0.5 ± 0.05 MPa {5.0 ± 0.5 kg/cm2} (cracking pressure)

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10 Structure and function
Center brake cooling relief valve

Center brake cooling relief valve (HM400_3M0-B8M2-041-K-00-A)

1. Case
2. Valve plate
3. Spring
Function (HM400_3M0-B8M2-042-K-00-A)

• This valve controls maximum pressure of center brake cooling circuit to protect it.
Set pressure: 0.6 ± 0.06 MPa {6.1 ± 0.6 kg/cm2} (cracking pressure)

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ROPS cab

Cab and its attachments (ALL-K000-001-K-00-A)

ROPS cab (HM300-K211-041-K-00-A)

a ROPS: Abbreviation for Roll-Over Protective Structure

1. Radio antenna
2. KOMTRAX communication antenna
3. Side window glass (left)
4. Air conditioner fresh air filter
5. Door (left)
6. Window washer tank
7. Front wiper
8. Front window
9. Front working lamp
10.Sash (right)
11.Rear wiper
12.Rear window
Function (HM300-K211-042-K-00-A)

• ROPS cab is a structure which protects the operator fastening a seat belt from being crushed when the
machine tips over.

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Cab tilt

Cab tilt (HM400-K211-27G-K-00-A)

1. Tilt stop bar

2. Tilt cylinder
3. Manual tilting bracket
4. Tilt power switch
5. Tilt power unit
6. Pin

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Electrical control system

Electrical system (HM400_3R-RA1D-001-K-00-A)

Electrical control system (PC220-C050-001-K-00-A)

Transmission control system (HM400_3R-CN20-042-K-00-A)

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Electrical control system

Shift lever positions and automatic gear shift function (HM400_3R-CN10-042-K-00-A)

• The gear is shifted automatically in each shift lever position according to the "Automatic gear shift chart"
shown below.

a When F1 is selected in "F1 Start at D Position Setting" and D range is selected, the lowest gear speed is
set to F1.
(For "F1 Start at D Position Setting", see the User Menu)

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Electrical control system

Gear shift characteristics

• The transmission gear is shifted up and down according to the shift map saved in the memory of the
controller.
There are four shift maps, which are used according to the condition of each input signal.
Each mode is set as shown in the following table.
Mode Setting condition
Brake mode Brake signal ON
When following conditions are satisfied
Coasting mode 1. Brake signal is OFF
2. Accelerator pedal is released
When following conditions are satisfied
Power mode 1. Brake signal is OFF
2. Accelerator pedal is depressed
3. Power mode selector switch is in POWER position
When following conditions are satisfied
Economy mode 1. Brake signal is OFF
2. Accelerator pedal is depressed
3. Power mode selector switch is in ECONOMY position
Other modes Gear is shifted down with engine at full throttle

Brake mode:
Both downshift point and upshift point are increased to keep the engine speed high to secure much retarder
cooling oil flow and improve the engine brake efficiency.

Coasting mode:
The difference between the upshift point and downshift point is increased to reduce the number of
unnecessary gear shifting.

Power mode:
This mode is used to maximize the production by making the most of the machine power.
However, when the machine load is light such as empty (the acceleration is high), the acceleration-sensing
variable gear shift point system is employed. With this system, the machine acceleration is sensed and the
gear is upshifted a little earlier to increase the acceleration and decrease the fuel consumption, noise, and
gear shift shock.
When Lockup is OFF, the engine maximum output is limited for protection of the torque converter. Also, when
the shift lever is in the F1 position, the maximum output at the engine maximum speed is limited for reduction
of noise.
Economy mode:
The upshift point and downshift point are lowered when the machine load is light as in travel with no load or
on a flat road to keep the operating engine speed low and reduce the fuel consumption, noise, and gear shift
shock.
In this mode, the maximum output of the engine is limited.

Other modes:
If the gear is downshifted with engine at full throttle, the upshift point is increased so that sufficient driving
force is secured before upshifting.

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Electrical control system

Automatic gear shift chart (HM400_3R-CN14-050-K-00-A)

• The upshift/downshift points, torque converter lockup ON/OFF points, and automatic brake (for overrun
prevention) ON/OFF points in each mode are as shown in the following figure.

Control in power mode

• The upshift point is set properly in the range of 2,089 to 1,730 rpm according to the throttle position,
acceleration of the machine, and gear speed.
• The downshift point is also set properly in the rage of 1,033 to 1,301 rpm according to the throttle position
and gear speed.

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Electrical control system

Control in economy mode

• The upshift point is set properly in the range of 1,900 to 1,730 rpm according to the throttle position,
acceleration of the machine, and gear speed.
• The downshift point is also set properly in the rage of 1,033 to 1,151 rpm according to the throttle position
and gear speed.

Control in brake (foot brake) mode

• If the travel speed decreases to approximately 9 km/h in the 3rd gear speed or approximately 6 km/h in the
2nd while the foot brake is used, the current gear speed (F3 or F2) is maintained.
• If the machine travels down a slope with the foot brake applied and with the engine speed low for keeping
the current gear speed, the cooling oil becomes insufficient and the engine can overheat easily.
• If the travel speed lowers 1 km/h or below, or the foot brake is released, or the current gear speed is kept
for a long period, the current gear speed is canceled and a proper gear speed is selected according to the
travel speed.

Control in other modes

• The upshift point is set properly in the range of 1,897 to 2,121 rpm according to the selected gear speed
and engine mode.
• The downshift point is also set properly in the range of 1,150 to 1,301 rpm according to the selected gear
speed and engine mode.

Control of lockup clutch

• Lockup ON point is set properly in the range of 1,050 to 1,400 rpm according to the torque converter inlet
speed (engine speed) and outlet speed (transmission input shaft speed), and the throttle position.
• Lockup OFF point is set to 1,000 rpm when the foot brake or retarder brake is applied in R1 or R2, or
1,200 rpm when neither of the foot brake and retarder brake is applied. It is set in the range of 1,000 to
1,200 rpm in F1 or F2 according to the throttle position, or set to 950 rpm when the foot brake or retarder
brake is applied in F3 to F6 or 850 rpm when neither of the foot brake and retarder brake is applied.
• If the machine starts traveling down a slope with the accelerator pedal released, the lockup clutch is not
engaged in F1 or F2 until the accelerator pedal is depressed or the brake is applied.

Control in gear speeds of F2 and F6

• The auto brake ON point is 2,450 rpm.

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Electrical control system

Gear shifting in each shift lever position (HM400_3R-CZ10-05A-K-00-A)

1. When shift lever is in position D
• When upshifting (in POWER mode)
1) When the shift lever is set in the "D" position, the transmission is set in the torque converter range
of "F2". (When "F1" is selected in "F1 Start at D Position Setting", the transmission is set in the
torque converter range of "F1")
2) When the accelerator pedal is depressed, engine speed increases and travel speed increases.
When the transmission input shaft speed reaches 1,050 to 1,400 rpm, the lockup clutch is turned
ON and the torque converter is set in the direct travel mode.
3) If the engine speed increases further to 1,757 to 2,089 rpm, the gear is upshifted to "F3". (The gear
is upshifted from "F1" to "F2" at 1,800 to 2,073 rpm)
The engine speed is decreased (by outputting the command to the engine controller) during the
upshifting process to reduce the gear shift shock.
4) The engine speed decreases just after the upshifting process, but it increases again as travel
speed increases, and the gear is upshifted to "F4" to "F6" similarly to Step 3) above.
• When downshifting (in POWER mode)
1) When the load increases and the engine speed decreases to 1,033 to 1,301 rpm, the gear is
downshifted by one stage (for example, from "F6" to "F5").
The engine speed is increased (by outputting the command to the engine controller) during the
downshifting process to reduce the gear shift shock.
2) When the travel speed decreases further, the gear is downshifted to "F2" in order (to "F1" if "F1" is
selected in "F1 Start at D Position Setting") and the lockup clutch is disengaged and the torque
converter drive starts.
a The set engine speed and operating condition in the above explanation may vary with the travel
condition. For details, see the automatic gear shift chart.
2. When shift lever is in position "F5", "F4", "F3", "F2", or "F1"
The automatic shift method in "F1" to "F5" ("F4", "F3", "F2") is similar to that when "Shift lever is in position
D" explained above.
3. When shift lever is in position "R1" or "R2"
These shift lever positions are for reverse travel.
The safety functions related to reverse travel are the forward-reverse inhibit and reverse safety functions.
If the machine is not operated normally, gear shifting is restricted.
4. When shift lever is in position "N"
This position is NEUTRAL and the transmission does not operate any clutch.

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Shift hold function (HM300-CP11-042-K-00-A)

• When the hold switch on the shift lever is pushed once, the current gear speed is maintained.
When the hold switch is pushed once again or the shift lever is operated, the shift holding function is reset.
If the travel speed decreases extremely in the shift holding mode, the gear is downshifted but returned and
maintained at the set gear speed when the travel speed is increased again.

Disapproved shift time (HM300-CN12-042-K-00-A)

• In the automatic shift range, a disapproved shift time is secured during the gear shifting process to prevent
malfunction caused by a transient speed change during gear shifting. Gear shifting is not accepted during
this time.
The disapproved shift time is controlled finely in each gear shift pattern by the all-gear stage electronic
modulation system.
The gear shifting patterns and rough disapproved shift time values are shown below.

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Electrical control system

Radiator fan control function (HM400_3R-CN1D-042-K-00-A)

• The transmission controller monitors the temperatures of the coolant, transmission lubricating oil,
hydraulic oil, brake oil, and outside air, and controls the fan speed according to them.

Fan speed control

• The transmission controller outputs the maximum value of the fan target speed obtained from the
temperatures of the coolant, transmission lubricating oil, hydraulic oil, and brake oil to the radiator fan
pump as the pump control signal.
• The radiator fan pump changes the swash plate angle to control the discharge of oil to be sent to the
radiator fan motor.
• When the ambient temperature is low, the discharge of oil to be sent to the radiator fan motor is limited to
decrease the fan speed and prevent a loss caused by overcooling.

Selection of fan rotation mode

• When the starting switch is at "ON" position and the engine is stopped, the operator can set the fan
reverse mode by selecting "Radiator Fan Reverse Mode" on the User Menu of machine monitor. There
are 2 fan rotation modes; One is the normal rotation mode and the other is the reverse rotation mode.
The transmission controller operates the reverse solenoid valve of the radiator fan motor to change the fan
rotation direction, according to the selected mode.
1. Normal rotation mode
The reverse solenoid valve does not operate and the fan rotates in normal direction and its speed
varies according to the temperature sensor signal.
2. Reverse rotation mode
The fan can be rotated in reverse at high speed to blow dirt off the radiator fan, regardless of the
temperature sensor signal. The radiator fan cleaning interval can be increased by using this mode
periodically.

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Interlock when mode is changed

• If the fan rotation direction is changed while the fan is rotating, the fan drive circuit is broken.
• Even if "Radiator Fan Reverse Mode" is selected on the User Menu of the machine monitor while the
engine is running, the signal is ignored to protect the fan drive circuit.
Machine monitor (5) displays "Cannot change fan direction." and the fan does not reverse.
• The radiator fan cannot be reversed while the aftercooler fan is set in reverse. Even if the "Radiator fan
reverse mode" is selected, the signal is ignored. Machine monitor (5) displays "Cannot change fan
direction." and the fan does not reverse.
Engine net horsepower constant control
• The net horsepower is kept constant, regardless of the hydraulic fan control condition, by adjusting the
engine gross output for the horsepower consumed by the hydraulic fan.

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10 Structure and function
Electrical control system

Aftercooler fan control function (HM400_3R-CN1E-042-K-00-A)

• The transmission controller controls the speed of the aftercooler cooling fan, installed separately from the
radiator, according to the engine speed, boost temperature, and ambient temperature

Fan speed control

• The transmission controller outputs the maximum value of the fan target speed obtained from the engine
speed and boost temperature as the pump control signal to the flow control valve.
• Fan control valve controls the oil flow rate by the signal from the transmission controller.
• When the ambient temperature is low, the flow control valve limits the oil flow rate to decrease the fan
speed and prevent a loss caused by overcooling.

Selection of fan rotation mode

• When the starting switch is at "ON" position and the engine is stopped, the operator can set the fan
reverse mode by selecting "CAC Fan Reverse Mode" on the User Menu of machine monitor. There are 2
fan rotation modes; One is the normal rotation mode and the other is the reverse rotation mode.
The transmission controller operates the reverse solenoid valve of the aftercooler fan motor to change the
fan rotation direction, according to the selected mode.
1. Normal rotation mode
The reverse solenoid valve does not operate and the fan rotates in normal direction and its speed
varies according to the temperature sensor signal.
2. Reverse rotation mode
The fan can be rotated in reverse at high speed to blow dirt off the aftercooler fan, regardless of the
temperature sensor signal. The aftercooler fan cleaning interval can be increased by using this mode
periodically.

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Interlock when mode is changed

• If the fan rotation direction is changed while the fan is rotating, the fan drive circuit is broken.
• While engine is running, even if "CAC Fan Reverse Mode" is selected on the Use Menu of machine
monitor, "Cannot change fan direction." is displayed in the machine monitor and the fan does not reverse
in order to protect the fan drive circuit.
• Even if "CAC Fan Reverse Mode" is selected while the radiator fan reverse mode is being set, "Cannot
change fan direction." is displayed on the machine monitor and the fan does not reverse.

Engine net horsepower constant control

• The net horsepower is kept constant, regardless of the hydraulic fan control condition, by adjusting the
engine gross output for the horsepower consumed by the hydraulic fan.

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Electrical control system

Safety functions (HM400-CN1F-042-K-01-A)

1. Downshift limiting function
When gear shift lever is operated Do 5 through 1, 5 o 4 through 1, 4 o 3 through 1, 3 o 2 through 1, 2 o
1 while traveling. For example, when traveling in D (F6), even if the gear shift lever is operated to 4, the
transmission does not shift directly from F6 to F4. It shifts down from F6 to F5 to F4 in accordance with the
travel speed.
(Shift change across 2 shifts by mis-operation is prevented. Engine overrun prevention function)
2. Neutral safety function at moving off
To prevent malfunction of the machine, the engine does not start while the shift lever is in the position
other than "N". The power supply voltage is maintained so that the starting motor drive output will not be
turned OFF due to power supply voltage drop during cranking.
3. Directional selection limit function
While the machine is traveling in reverse at a speed of 4.0 km/h or higher, even if the gear shift lever is set
to position D or any one of 5 to 1, the gear is not immediately shifted to the forward gear, but the gear is
set to N and the engine speed is lowered to lower the travel speed. When the travel speed is lowered
below 4.0 km/h, the gear is shifted to the forward gear.
(Prevention of overload on the power train and improvement of durability and reliability)
While the machine is traveling forward at a speed higher than 2.0 km/h, even if the gear shift lever is set to
position R1 or R2, the gear is not immediately shifted to the reverse gear, but the gear is set to N and the
engine speed is lowered to lower the travel speed. When the travel speed is lowered below 2.0 km/h, the
gear is shifted to the reverse gear.
While the machine is traveling in reverse at a speed higher than 7.6 km/h with the gear speed set in R2,
even if the shift lever is moved from R2 to R1, the gear is not shifted to R1. When the travel speed is
lowered below 2.0 km/h, the gear is shifted to R1.
If the machine has started with the shift lever in position "N" and is moving forward or in reverse at a speed
of 4.0 km/h or higher with the shift lever still in position N, the gear is not shifted but kept in N even if the
shift lever is set to a position other than "N". When the travel speed is lowered below 4.0 km/h, a start is
permitted.
(Prevention of overload on the power train and improvement of durability and reliability)
4. Power train overrun prevention retarder brake function
If the engine speed rises above 2,400 rpm (above 2,350 rpm in F2 and F6), the centralized warning lamp
flashes and the alarm buzzer sounds. If the engine speed rises above 2,450 rpm (above 2,400 rpm in F2
and F6), the retarder brake operates automatically.
(Prevent overrun of the engine, torque converter, and transmission, and improve durability and reliability.)
5. Reverse travel safety
The machine does not travel in reverse when the dump lever is in RAISE position and the "dump body is
seated" or when the dump lever is not in FLOAT position and the dump body is not seated. (Prevention of
tipping over) However, if the shift hold switch is pushed when the shift lever is in position R1, the machine
can travel while the switch is held down even if the dump body is not seated.
6. Gear speed limit function when dump body is raised
While the dump body is still not seated after dumping, upshift operation is limited. When the shift lever is in
position D or F5 through F1, the machine starts in F1 but the gear is not upshifted until the dump body is
seated.
7. Neutral coast prevention function
During travel at a speed of 4 km/h or higher, even if the gear shift lever is set in N (NEUTRAL) position, the
gear is not shifted to the neutral. At this time, the centralized warning lamp flashes and the alarm buzzer
sounds. Also, during downhill travel with the gear shift lever in N (NEUTRAL) position, if the travel speed
exceeds 20 km/h, the gear is shifted automatically to a gear speed suitable for the travel speed, and the
centralized warning lamp flashes and the alarm buzzer sounds.
a Do not operate the gear shift lever to N (NEUTRAL) position while traveling on a flat ground or while
traveling downhill. Always set the gear shift lever to any position of D to 1 before starting travel.

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Self-diagnosis function (HM300-CN1G-042-K-00-A)

• The controller performs the self-diagnosis on the system and displays detected abnormality. The contents
of the self-diagnosis is displayed on the monitor. If any abnormality is detected by the self-diagnosis, the
information on it is transmitted to the network and the monitor displays the action level. The transmission
system caution, alarm lamp, and alarm buzzer may operate in this case.

Rim pull limit function for overload prevention (HM400-CN1H-042-K-00-A)

• To prevent overload on the power train, the function to restrict the upper limit of the throttle in gear speeds
F1 and R1 is provided. The details are shown in the figure below.

a The throttle upper limit at the input shaft speed of 0 rpm is set properly in the range of 79 to 89%,
depending on the control condition of the hydraulic fan.

Engine speed restraint function at low temperature (HM300-CN1J-042-K-00-A)

• While the dump body is raised at low temperature, the engine rated speed is lowered to decrease the
pump discharge for protection of the hoist pump.

Throttle limit function at F1 Start at D Position Setting (HM400_3R-CN1K-042-K-00-A)

• After F1 is selected in "F1 Start at D Position Setting" of user menu, if the parking brake or foot brake or
retarder brake is applied while the machine is traveling, the throttle is closed automatically to prevent
damage to the clutch.

Parking brake interlock function (if equipped) (HM300-CN1L-042-K-00-A)

Outline of function
• When the parking brake is applied, the gear is shifted in NEUTRAL regardless of the shift lever position.
This function is works only when it is enabled in the option settings.

Operating condition:
The parking brake is ON.

Conditions for cancellation:

1. The parking brake is OFF and the shift lever is in position N.
2. The parking brake is ON, the engine is running, and the shift lever is operated in the order of N, D, N, D, N,
D, and N within 5 seconds.
a When it is necessary to select a gear speed other than N with the parking brake applied for the check
before starting etc., the parking brake interlock must be canceled by the method in Condition for
cancellation 2.

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ARAC function (if equipped) (HM300-GT81-042-K-00-A)

• When the accelerator pedal is released during travel with the ARAC switch (Auto Retarder, Accelerator
Combination switch) ON, the retarder is operated automatically.
The machine can travel down a slope with only the ARAC function, depending on the travel condition. If
the braking force is insufficient because of the condition, the retarder can be operated additionally with the
retarder lever.
When both of the ARAC function and the retarder lever are applied simultaneously, the one of the larger
braking force is used.
Accordingly, the play of the retarder lever may be felt larger while the ARAC function is applied.
The braking quantity by the ARAC function can be checked with the monitoring function (code: F side:
33807, R side: 33806).
The ARAC function is reset when the ARAC switch is turned OFF, the accelerator pedal is depressed, or
the travel speed decreases.
The ARAC function is reset when an error of a related sensor is detected or the communication has
trouble.
When the ARAC switch is turned OFF while the machine is traveling on a flat road or coasting down on a
gentle slope, the fuel efficiency may be improved.

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Electrical control system

Retarder and hoist control system (HM400_3R-RA1M-042-K-00-A)

HM400-3M0 10-221
10 Structure and function
Electrical control system

Retarder control function (HM300-GT30-042-K-00-A)

Retarder lever control

• The operation angle of the retarder lever is sensed with a potentiometer and a current corresponding to it
is output to the proportional pressure reducing solenoid valve of each wheel to operate the retarder.

Retarder control for overrun prevention and against transmission abuse

• The proportional pressure reducing solenoid valve of each wheel is controlled to operate the retarder by a
certain quantity according to the command (analog) of the transmission controller.

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Relationship between retarder potentiometer and output to proportional pressure reducing solenoid
valve

(1) To improve the initial response of the proportional pressure reducing solenoid valve, the output (trigger
output) is set to a high value.
(2) To make the actuation of the hydraulic pressure smooth in the low pressure range, the output is set to a
high value.
(3) In the range where the retarder is normally used, the output is proportional to the angle of the lever.
(4) To make the opening of the hydraulic pressure smooth in the low pressure range, the output is set to a low
value.

HM400-3M0 10-223
10 Structure and function
Electrical control system

Hoist control function (HM400-M6K0-042-K-00-A)

Hoist control function

This function controls dump EPC valve and steering pump selector valve to operate the dump body in
accordance with the operation of the dump lever while the engine is running.

Lever positioner function

The dump lever has 4 operation positions of RAISE, HOLD, FLOAT, and LOWER.
When the dump lever is set to RAISE position, the dump body is raised. When the dump body top rises to the
set position of the body position sensor, the lever is set to HOLD position.
a The lever has the dump lever potentiometer and lever kick-out solenoid in it.
a The dump lever potentiometer outputs voltage signals to the retarder and hoist controller according to the
lever position.
a The lever kick-out solenoid fixes the lever to RAISE position upon receiving ON signal from the retarder
and hoist controller and returns it to HOLD position upon receiving OFF signal.

Dump body seating speed control

When the dump body is lowered to just before the seating position, the open area of the EPC valve is reduced
to control the lowering speed of the dump body and reduce the seating shock.

Control when key is turned to ON or OFF position and engine is started

• When key is turned to ON position:
The HOLD signal is always output, regardless of the lever position. Even if the dump lever is operated with
the engine stopped, the HOLD state does not change.
• When key is turned to OFF position:
The hoist valve is kept closed and the dump body is held, regardless of the lever position.
• When engine is started:
Immediately after the engine is started, the HOLD signal is output, regardless of the lever position.
Once the lever is set to the HOLD position, the normal operation can be started.

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Float caution function

The float caution lamp on the machine monitor lights up while "FLOAT signal is not output" or "the dump body
is not seated".
"FLOAT signal is output" and "dump body is seated" → Float caution is OFF.
"FLOAT signal is not output" or "dump body is not seated" → Float caution is ON.

Reverse inhibit function

Information on permission and prohibition of reverse travel is judged.
["Lever is not in RAISE position" and "dump body is seated"] or ["lever is in FLOAT position" and "dump body
is not seated"] → Reverse travel is permitted.
["Lever is in RAISE position" and "dump body is seated"] or ["lever is not in FLOAT position" and "dump body
is not seated"] → Reverse travel is prohibited.

Calibration function
To absorb the individual difference of the body potentiometers, calibrate the dump body seating state
recognition and dump body cylinder stopper state.
a After the dump body potentiometer is installed and adjusted or the retarder and hoist controller is replaced,
perform calibration according to the following procedure.
a Dump control calibration procedure
1. Increase the hydraulic oil temperature to 80 to 90°C.
2. Lower the dump body completely and run the engine. Change the lever from HOLD → FLOAT and
check that the float caution lamp goes out.
3. Raise the dump body and raise the lever to the cylinder stopper. Raise the lever for at least 5 seconds
at the cylinder stopper position.
4. Lower the dump body completely and keep the lever at FLOAT for at least 5 seconds.
5. Run the engine at low idle and perform RAISE → FLOAT to raise the dump body to the maximum
height, then lower the dump body completely. Repeat this operation 10 times.
6. Run the engine at high idle and perform RAISE → FLOAT to raise the dump body to the maximum
height, then lower the dump body completely. Repeat this operation 10 times.
a The engine speed is limited to 1,800 rpm (or 1,500 rpm when the steering oil temperature is below 25°C)
or below to protect the pump under the following condition.
• The dump body seating speed is not controlled (except when the dump body is seated).
• "The dump body seating speed is being controlled" and "the lever is not in the HOLD position".

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10 Structure and function
Electrical control system

Automatic emergency steering system (HM400-F900-042-K-00-A)

1. Flow amplifier valve

2. Hydraulic tank
3. Emergency steering motor (*1)
4. Emergency steering pump (*1)
5. Emergency steering oil pressure sensor (*1)
6. Steering oil pressure sensor
*1: These parts are installed 2 each to compose 2 emergency steering systems.

Automatic emergency steering function (HM400-F910-042-K-00-A)

• If the engine stops or the hydraulic pump has trouble and the oil flow in the steering circuit decreases
below the specified value while the machine is traveling, the 2 systems of emergency steering systems
operate the emergency steering pump automatically to secure oil pressure for steering, and steering can
be operated.
This system is designed so that it is also actuated manually.

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Self check function (HM400-F920-042-K-00-A)

• After the key is turned to ON position and the controller starts, the auto emergency steering system
operates to perform the self check automatically to check that the emergency steering system has no
trouble before the machine is operated.
• The self check result of the system is judged by the input value of the emergency steering oil pressure
sensor. If the oil pressure is equal to or above the threshold value when the self check is performed, the
system is judged normal. If the former is less than the threshold value, the latter is judged abnormal.
• The self check is finished within 3 seconds, regardless of the judgment result of the system.
a When the self check result is abnormal, it is notified by the action level, caution symbol, and buzzer.
a Once the system is judged normal, the self check is not performed again until the engine is started o
stopped.
a In the self check, the 2 emergency steering systems operate alternately.

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Electrical control system

KTCS (HM300-GX00-041-K-00-A)

a KTCS: Abbreviation for Komatsu Traction Control System

Function (HM300-GX00-042-K-00-A)
• When the machine travels on soft ground or steep uphill road, if an excessive torque is applied to the tires,
the tires may spin and the machine may not travel. In this case, the KTCS controls the inter-axle
differential lock and applies the brake to the spinning tires automatically to control the torque applied to
those tires, thus the machine can travel.
a Spin of each tire is detected by comparing the tire speed obtained from the wheel speed sensor with the
travel speed obtained from the acceleration sensor.
a The inter-axle differential lock operates under the following condition even if the KTCS does not operate.
• When brake is applied abruptly. (during travel at a speed of 35 km/h or faster)
• When the brake is turned ON. (when the speed difference between the front and rear axles exceeds
the threshold value).
• When the transmission output shaft speed fluctuation caused by gear shifting etc. exceeds the
threshold value.
• When the inter-axle differential lock switch is set to "MANUAL" position.
(When the gear speed is "F3", "F2", "F1", "N", "R1", or "R2")

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Logic of system operation (HM300-GX00-044-K-00-A)

Not in operation
• While no tire is slipping during normal travel, the KTCS does not operate and the brake is not applied.
• When the machine turns, the condition for starting the control varies in accordance with the detected
articulate angle, thus the KTCS does not operate upon detecting the speed difference between the right
and left wheels caused by turning.

During operation
• If slipping of any tire is detected while the accelerator pedal is depressed as shown in the graph, the KTCS
operates to actuate the inter-axle differential lock and apply the brake to the slipping tire. As a result,
slipping of the tire is restricted and the machine can travel.

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10 Structure and function
Electrical control system

Payload meter system (HM400_3M0-M710-041-K-00-A)

(Payload meter setting)

1. Front right suspension cylinder pressure sensor

2. Payload meter controller
3. Download connector
4. R.H. external display lamp
5. L.H. external display lamp
6. Rear right suspension cylinder pressure sensor
7. Rear left suspension cylinder pressure sensor
8. Center inclination angle sensor
9. Front left suspension cylinder pressure sensor

Structure
• Dump truck is supported by suspension cylinders.
• Payload meter controller (2) measures pressure of each suspension cylinder, and calculates weight of
upper part of the machine on the suspension cylinder.
• Load weight is obtained from the difference between the machine weight with load and without load.

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Payload Meter function (HM400_3M0-M710-042-K-00-A)

Function
• Payload meter controller displays the load weight on the machine monitor.
• Payload meter controller indicates the load level to the external display lamp.
• Payload meter controller predicts the load weight with 1 additional loading by loading machine.
• Payload meter controller has a predicted load display function, and flashes the suitable lamp in order to
prevent overload.
• Payload meter controller stores the operation data of carrying load weight etc. for each cycle into the
internal memory.
It statistically calculates data collected from the place of loading to the place of dumping during traveling,
decides carrying load weight, and stores it.
• Stored internal memory can be downloaded by using the exclusive software (optional).
a When introducing or after replacing the payload meter controller, initial setting is required.

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Measuring method (HM400_3M0-M710-04B-K-00-A)

• Machine is supported by suspension cylinders. Accordingly, the weight of upper part of the machine on the
suspension cylinders can be calculated from the load on each suspension cylinder.
• The load on each suspension cylinder can be calculated from internal pressure and cross-sectional area.

W: Load on suspension cylinder

PB: Pressure on bottom side
PT: Pressure on head side
SB: Cross-sectional area of cylinder
ST: Cross-sectional area of rod

• Calculation formula of the load (W) on suspension cylinder is as follows. [W = PB x SB - PT (SB - ST)]
• The pressure on bottom side (PB) is equal to the pressure on head side (PT) due to the structure of
suspension cylinder. [PB ≒ PT]
• Assuming [PB = PT] from above, the load (W) on suspension cylinder can be calculated from [W = PB x
ST].

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Measuring machine weight (calibration)

F: Average load
O: Load
T: Measuring time
V: Sliding resistance
• Travel on flat road for 30 seconds at 10 km/h with empty dump body. Measure average load (F) and
calculate the machine weight.
By measuring while traveling, sliding resistance (V) of each suspension cylinder can be omitted because
average resistance becomes zero due to telescopic motion of cylinder during machine travel.
• Calculated machine weight is stored in the internal memory of payload meter controller as a calibration
data.
Calibration on a slope
• Loading operation on a slope is different from the one on a level ground, so the calibration is performed in
accordance with the longitudinal inclination of the machine.
The longitudinal inclination angle of the machine is detected by center inclination angle sensor.

Measuring of traveling distance and speed

• Traveling distance and speed is measured by travel signal of machine.
Travel signal of machine is detected by transmission speed sensor (output shaft).

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Electrical control system

Battery disconnect switch function and system operating lamp function (HM300-
AW10-051-K-00-A)

1. Battery disconnect switch

2. Battery
3. Circuit breaker
4. Fuse
5. System operating lamp
6. Monitor controller
7. Engine controller
8. Transmission controller
9. Retarder and hoist controller
10.KOMTRAX terminal

Battery disconnect switch function (HM300-AW1P-042-K-00-A)

• When the battery disconnect switch is turned OFF (the contact is opened), all the continuous power
supplies for the components, including the starting switch B terminal and controllers, are all cut out, and
the state is the same as when the battery is not connected. Accordingly, all the electric system of the
machine is disabled.
• Usually, the battery disconnect switch is used instead of disconnecting the cable from the negative
terminal of the battery in the following cases.
1. When storing the machine for a long period (more than one month)
2. When servicing or repairing the electrical system
3. When performing electric welding
a Do not turn OFF the battery disconnect switch while the engine is running or immediately after the engine
is stopped.
If the battery disconnect switch is turned OFF while the alternator is generating power, the generated
current has nowhere to go, leading to overvoltage in the electrical system of the machine, which may
cause serious damage to the electrical system, including the electric devices and controllers.
a Clock of the radio and machine monitor may initialized.
a While the fan is rotating in reverse, the fan reverse solenoid remains energized for a while after the starting
switch is turned to OFF position to protect the hydraulic motor.
Check that the fan stops completely before turning the battery disconnect switch to OFF position.

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System operating lamp function (HM300-AW1Q-042-K-00-A)

• The operating condition of each controller can be checked with the system operating lamp to prevent the
abnormal end of the disconnection of the battery power supply circuit while the controllers are in
operation.
a Before cutting off the battery power supply circuit, turn the starting switch to the "OFF" position, and check
that the system operating lamp goes out, then turn the battery disconnect switch to the "OFF" position.
a If you turn the battery disconnect switch to the "OFF" position (battery power supply circuit is cut off) while
the system operating lamp is lit, Controller Data Lost Error can occur. Do not operate the battery
disconnect switch as long as the system operating lamp is lit.
a The system operating lamp goes out in 2 minutes longest after the starting switch is turned to the "OFF"
position.
a Even if the starting switch is in the OFF position, the system operating lamp may light up since the
KOMTRAX terminal may perform communication.

Lighting up and going off of system operating lamp

• Voltage of 24 V is always applied to the one end of the system operating lamp (LED).
• When any controller is in operation, the output from the controller to the system operating lamp becomes
Low (0 V). This allows electric current to flow through the diode, lighting up the system operating lamp.
• When all controllers are resting, the output from each controller to the system operating lamp becomes Hi
(24 V). This prevents electric current to flow through the diode, going the system operating lamp out.
a The system operating lamp may look slightly luminous in the dark after it is turned off. It is due to the
minute leakage of current and not an abnormal phenomenon.
• The KOMTRAX terminal performs communication periodically even if the starting switch is kept in the OFF
position, thus it starts and stops repeatedly.
• The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the factors including the
communication status and machine stop time. So the lamp can be lit as long as approximately 1 hour.
a When you want to cut off the battery circuit for maintenance but the operating lamp keeps on lighting up,
turn the starting switch to the "ON" position once, then turn it to the "OFF" position. The lamp will go out in
2 minutes maximum.
After the system operating lamp goes out, turn the battery disconnect switch to the OFF position
immediately.

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Machine monitor system

Machine monitor system (HM400_3M0-Q170-041-K-00-A)

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Machine monitor system

Function (HM300-Q170-042-K-00-A)

• The machine monitor system mainly consists of the machine monitor, monitor controller, and switch panel.
1. Machine monitor
Displays the machine condition to the operator.
2. Monitor controller
Obtains the condition data of various sections of the machine monitored with sensors and switches
and processes them. Communicates the network information with each controller.
3. Switch panel
Accepts operations of the operator.

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10 Structure and function
Machine monitor system

Machine monitor (HM300-Q180-042-K-00-A)

Precautions on the machine monitor display

• If there is trouble in the machine monitor, monitor controller, another controller, or network wiring, the
machine monitor does not display normally.
• One of the features of the liquid crystal unit is that there may be black spots (spots that do not light up) or
white spots (spots that stay lighting up) on the screen.
When there are fewer than 10 black or white spots, this is not a failure or a defect.
• When the emergency steering self check is performed or the engine is started, the battery voltage may
drop suddenly, depending on the ambient temperature and the condition of the battery.
In this case, the machine monitor may go out for a moment or may be restarted. However, this
phenomenon is not a trouble.

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Input and output signals of machine monitor (HM300-Q180-03C-K-01-A)

JAE-8P [CN-DPC1] (for LC unit)

Input/output
Pin No. Signal name
signal
1 LC unit LVDS + Input
2 LC unit LVDS - Input
3 GND (LC unit power supply) —
4 LC unit backlight adjustment Input
5 LC unit power supply Input
6 LC unit ON/OFF control Input
7 LC unit backlight ON/OFF control Input
8 LC unit temperature sensor Input

AMP-6P [CN-DPC2] (for LED unit)

Input/output
Pin No. Signal name
signal
1 LED unit power supply (+12 V) Input
2 GND (LED unit power supply) —
3 LIN Input/Output
4 LED unit power supply (+5 V) Input
5 (*1) —
6 (*1) —

AMP-8P [CN-DPC3] (for meter unit)

Input/output
Pin No. Signal name
signal
1 Continuous power supply (24 V) Input
2 Key switch ACC signal Input
3 CAN2_H Input/Output
4 GND (continuous power supply) —
5 Monitor brightness selector switch (night mode signal) Input
6 (*1) —
7 CAN2 terminating resistor Input
8 CAN2_L Input/Output
*1: Never connect these pins. Malfunctions or failures may occur.

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10 Structure and function
Machine monitor system

Display (HM400_3R-Q1LA-042-K-00-A)

LC unit display

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Machine monitor system

α: LC unit
β: LED unit
γ: Meter unit

A: Standard screen

HM400-3M0 10-241
10 Structure and function
Machine monitor system

B: ECO guidance screen

C: Maintenance due time warning screen
D: Warning screen
E: User menu screen
F: Payload meter screen

1. Speedometer
2. Engine tachometer
3. Centralized warning lamp
4. Parking brake pilot lamp
5. Turn signal pilot lamp (left)
6. Headlamp high beam pilot lamp
7. Turn signal pilot lamp (right)
8. Brake oil pressure drop caution icon
9. Clearance lamp pilot lamp
10.ENGINE COOLANT TEMPERATURE GAUGE
11.Engine coolant overheat caution icon
12.Torque converter oil temperature gauge
13.Torque converter oil overheat caution icon
14.Retarder oil temperature gauge
15.Retarder oil overheat caution icon
16.Fuel level gauge
17.Low fuel level caution icon
18.ECO gauge
19.Air conditioner display area
20.Clock
21.L.H. meter (select service meter, odometer, or clock)
22.R.H. meter (select service meter, odometer, clock, or fuel consumption gauge)
23.Shift indicator
24.Shift lever position pilot lamp
25.Message pilot lamp
26.Retarder pilot lamp
27.Inter-axle differential lock pilot lamp
28.KTCS pilot lamp
29.Emergency steering pilot lamp
30.Power mode pilot lamp
31.Shift hold pilot lamp
32.Lockup pilot lamp
33.Fan reverse pilot lamp
34.Engine preheating pilot lamp
35.ECO guidance
36.Maintenance due time caution icon
37.Guidance icon
38.Seat belt caution icon
39.Caution display area
40.Action level
41.Payload meter display area

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Meters and gauges (HM400_3R-Q1LB-043-K-00-A)

Monitor display Item displayed Display Contents Remarks

color
• If communication error occurs
between monitor controller and
Charac- transmission controller, "0" is
Speedometer Display range: 0 to 99 displayed.
ters:
km/h • If communication error occurs
Black
between monitor controller and
meter unit, "00" is displayed.
Charac- • If engine speed increases above
ters: specified level, engine overspeed
White Display range: 0 to 3,500 caution lights up.
Engine rpm (red zone: 2,500 (For details, see engine overrun
tachometer Gradua-
tions: rpm and above) caution.)
White, • If communication error occurs,
red gauge pointer reads "0".
Coolant
tem-
Display Posi-
pera-
Gradua- range: tion • If temperature exceeds 102°C,
ture (°
tions: 50 to engine coolant temperature caution
C)
Engine coolant White, 135°C lights up.
temperature green, (red A1 135 (For details, see engine coolant
gauge red zone: A2 102 temperature caution.)
Pointer: 102°C A3 88 • If communication error occurs,
Red and A4 74 gauge pointer disappears.
above)
A5 59
A6 50
Oil
Display tem-
range: Posi- pera-
Gradua- tion
50 to ture (° • If temperature exceeds 120°C,
Torque tions:
135°C C) torque converter oil temperature
converter oil Green,
(red B1 135 caution lights up.
temperature red
zone: • If communication error occurs,
gauge Pointer: B2 120
120℃ gauge pointer disappears.
Red and B3 97
above) B4 73
B5 50
Oil
Display tem-
range: Posi- pera-
Gradua- tion
50 to ture (° • If temperature exceeds 120°C,
tions:
Retarder oil 135°C C) retarder oil temperature caution
Green,
temperature (red C1 150 lights up.
red
gauge zone: • If communication error occurs,
Pointer: C2 120
102°C gauge pointer disappears.
Red and C3 97
above) C4 73
C5 50

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10 Structure and function
Machine monitor system

Monitor display Item displayed Display Contents Remarks

color
Display Posi- Fuel
range: tion level (l)
Gradua- EMP- D1 505
tions: TY to • If fuel level is 102 l or below, fuel
D2 371
Fuel level Green, FULL level caution lights up.
gauge red (Red D3 237 • If sensor is abnormal, gauge
Pointer: zone: D4 102 pointer disappears.
Red 102 l
and D5 22
below)
• Indicates instantaneous fuel
consumption (average of fuel
consumption by 3 seconds) in 10
steps.
(Display/Non display can be
switched in "ECO Guidance" o
Display range: 0 to 93 l/
Green, "Configurations"o "ECO Gauge"
ECO gauge h (orange zone: 74 l/h
orange on User menu.)
and above)
(Display range can be set in "ECO
Guidance" o "Configurations"o
"ECO Gauge Target Value" on
User menu.)
• If communication error occurs,
gauge reads 0.

Air conditioner Charac- • Set temperature • For details, see Operation &
display area ters: • Air blow rate
Maintenance Manual.
White • Vent

• Displays time.
• 12-hour system
Charac- (12-hours/24-hours display can be
display (AM/PM)
Clock ters: switched in "Monitor
• 24-hour system
White Setting"o"Clock Adjustment" on
display
User menu.)
• Indicates accumulated engine
Charac- operating hours.
Service meter Display range: 0 to
ters: • When engine operating hours
(*1) 999999.9 h
White exceeds 999999.9 h, meter
reading stops at 999999.9 h.
• Indicates integrated travel
Charac- distance.
Odometer (*1) ters: Display range: 0 to • When travel distance exceeds
3999999.9 km 3,999,999.9 km, meter reading
White
stops at 3,999,999.9 km.
• Displays time.
(12-hours/24-hours display can be
switched in "Monitor
Setting"o"Clock Adjustment" on
• 12-hour system User menu.)
Charac- display (AM/PM) • On machine with payload meter
Clock (*1) ters: • 24-hour system specification, time is displayed
White display when payload is below specified
load (15% of max. payload by
default).
When payload exceeds specified
load, payload is displayed.

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Monitor display Item displayed Display Contents Remarks

color
• Indicates average fuel
consumption.
Fuel Charac- • 1 Day display (Display can be switched by
consumption ters: selecting another item in "ECO
• Split display
gauge (*1) White Guidance" o "Configurations"o
"Average Fuel Consumption
Display" on User menu.)
• Displays payload.
• When payload exceeds specified
level (15% of max. payload by
default), clock display section
Payload meter Charac- changes to payload meter display.
• Display range: 0 to
(payload meter ters: • When payload exceeds 99999.9 t,
99999.9 t
setting) White meter reading stops at 99999.9 t.
• For details, see Testing and
Adjusting, "Payload meter" or
Operation and Maintenance
Manual.
*1. Items displayed on R.H. and L.H. meters can be selected from following by "Monitor Setting"o"Meter
Select" on User menu.
L.H. meters: Service meter, odometer, clock
R.H. meters: Service meter, odometer, clock, Fuel consumption gauge

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Machine monitor system

Alarm monitor (HM400_3R-Q1LA-043-K-00-A)

Cen-
tralized
Monitor display Item displayed Display Action warn- Alarm Remarks
color level ing buzzer
lamp
Q
L04 Q (contin-
uous)
Q
(inter- • Appears when trouble is detected
Red L03 Q
mittent) in machine.
Action level
Q
L02 Q (inter-
mittent)
— — • Lights up for 2 seconds, then goes
Yellow L01
out.
Q • Lights up when failure of action
Centralized Red See level L02 or higher occurs or alarm
re- Q (inter-
warning lamp (LED) to warn operator is made. Buzzer
marks. mittent)
sounds, as well.
Q
• Appears when brake oil pressure
L03 Q (inter-
drops while engine is running.
mittent)
Brake oil Red Q
pressure • Appears if brake oil pressure does
(LED) — Q (inter-
caution not increase after engine is started.
mittent)
• Lights up if brake oil pressure
— — —
drops while engine is stopped.
Q
• Appears when engine coolant
Engine coolant L02 Q (inter-
temperature is 105°C or above.
overheat Red mittent)
caution icon • Lights up when engine coolant
— — —
temperature is 102°C or above.
Torque Q
converter oil • Appears when torque converter oil
Red L02 Q (inter-
overheat temperature is 120°C or above.
mittent)
caution icon
Retarder oil Q
• Appears when retarder oil
overheat Red L02 Q (inter-
temperature is 120°C or above.
caution icon mittent)

Low fuel level — — — • Lights up when fuel level is 102 l

Red
caution icon or below.

• Lights up for 30 seconds after

starting switch is turned to ON
Red — — —
position if maintenance due time of
any item is over.
• Lights up for 30 seconds after
Maintenance starting switch is turned to ON
due time position if maintenance reminder
caution due time of any item is over.
Yellow — — — (The notice time is changeable by
selecting "Maintenance Mode
Setting" o "Maintenance Mode
Change" o "Maintenance Notice
Time Setting" in Service Menu.)

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 10 Structure and function
Machine monitor system

Cen-
tralized
Monitor display Item displayed Display Action warn- Alarm
Remarks
color level ing buzzer
lamp

Seat belt — — — • Lights up when seat belt is not

Red
caution fastened.

Q
L04 Q (contin-
Engine system uous)
Red Q • Appears when error is detected in
error caution
(inter- engine system.
icon (*2) L03 Q
mittent)
Yellow L01 — —
Q
• Appears when engine speed is
Red L02 Q (inter-
Engine overrun 2,625 rpm or above.
mittent)
caution icon
Q • Appears when engine speed is
(*2)
Yellow — Q (inter- 2,400 rpm (or 2,350 rpm in F2 and
mittent) F6) or above.
Engine oil
Q
pressure
Red L03 Q (inter- • Appears when engine oil pressure
caution icon is low.
mittent)
(*2)
Q
L04 Q (contin-
Transmission uous)
Red Q • Appears when error is detected in
system caution
(inter- transmission system.
icon (*2) L03 Q
mittent)
Yellow L01 — —
Q
Fan control (inter- • Appears when error is detected in
Red L03 Q
system caution mittent) fan control system.
icon (*2)
Yellow L01 — —
Inter-axle Q
differential Red L03 Q (inter-
lockup system mittent) • Appears when error is detected in
inter-axle differential lock system.
caution icon
(*2) Yellow L01 — —
Wrong • Appears when shift lever is set in a
operation position other than N or dump body
Q
during fan is set in a position other than
— Q (inter-
reverse mode Red seated while radiator fan or
mittent)
caution icon aftercooler fan is rotating in
(*2) reverse.
Q • Appears when error is detected in
L03 Q (inter- charge system for a certain period
Charge voltage mittent) while engine is running.
caution icon Red
(*2) Q • Appears when error is detected in
— Q (inter- charge system while engine is
mittent) running.
Radiator
coolant level • Lights up when radiator coolant
Yellow L01 — —
caution icon level is low.
(*2)

HM400-3M0 10-247
10 Structure and function
Machine monitor system

Cen-
tralized
Monitor display Item displayed Display Action warn- Alarm
Remarks
color level ing buzzer
lamp
Engine oil level
caution icon — — • Lights up when engine oil level is
Yellow L01
(*2) low.

Air cleaner
clogging • Lights up when air cleaner is
Yellow L01 — —
caution icon clogged.
(*2)
Transmission
oil filter
• Lights up when transmission oil
clogging Yellow L01 — —
filter is clogged.
caution icon
(*2)
Q
Retarder (inter- • Appears when error is detected in
Red L03 Q
system caution mittent) retarder system.
icon (*2)
Yellow L01 — —
Q
Parking brake (inter- • Appears when error is detected in
Red L03 Q
system caution mittent) parking brake system.
icon (*2)
Yellow L01 — —
KTCS system
• Appears when error is detected in
caution icon Yellow L01 — —
KTCS system.
(*2)

Steering
• Appears when error is detected in
system caution Yellow L01 — —
steering system.
icon (*2)
Emergency Q
steering Red L03 Q (inter- • Appears when error is detected in
system caution mittent) emergency steering system.
icon (*2) Yellow L01 — —
Q
Hoist control (inter-
Red L03 Q • Appears when error is detected in
system caution mittent) hoist control system.
icon (*2)
Yellow L01 — —
Q
• Appears when steering oil pressure
L03 Q (inter-
drops while engine is running.
mittent)
Steering oil Red Q
pressure • Appears if steering oil pressure
— Q (inter- does not increase after engine is
caution icon mittent)
(*2) started.
• Lights up when steering oil
Yellow — — — pressure drops while engine is
stopped.
Steering oil
Q
overheat • Appears when steering oil
Red L02 Q (inter-
caution icon temperature is 100°C or above.
mittent)
(*2)
Emergency
Q • Appears when emergency steering
steering motor
Red L02 Q (inter- motor is used for 60 seconds or
caution icon
mittent) more.
(*2)

10-248 HM400-3M0
 10 Structure and function
Machine monitor system

Cen-
tralized
Monitor display Item displayed Display Action warn- Alarm
Remarks
color level ing buzzer
lamp
Inclination Q • Appears when hoist lever is in
caution icon Red — Q (inter- RAISE position and lateral
(*2) mittent) inclination angle is excessive.
Q • Appears when hoist lever is not in
Red — Q (inter- FLOAT or when shift lever is not in
Dump body
mittent) N while dump body is raised.
FLOAT caution
icon (*2) • Lights up when hoist lever is not in
Yellow — — — FLOAT or when dump body is
raised.
Q • Appears when error related to
System caution Red L03 Q (inter- machine monitor or rear view
icon (*2) mittent) monitor or error in communication
Yellow L01 — — between controllers is detected.
Air conditioner
• Appears when error is detected in
system caution Yellow L01 — —
air conditioner system.
icon (*2)
payload meter
system caution
icon (*2) • Appears when error is detected in
Yellow L01 — —
payload meter system.
(payload meter
setting)

a *2: If three or more cautions are occurring, the icons are displayed two by two every 2 seconds.

HM400-3M0 10-249
10 Structure and function
Machine monitor system

Pilot monitor (HM400_3R-C7K6-043-K-00-A)

Monitor display Item displayed Display

Contents Remarks
color
• Centralized warning lamp lights
up and alarm buzzer sounds if
Parking brake Lights up when parking
Red (LED) shift lever is not in N while parking
pilot lamp brake is applied.
brake is applied. (Notice alarm for
dragging of parking brake)

Turn signal
Green Lights up when left turn
lamp pilot lamp
(LED) signal is turned on.
(left)

Headlamp Lights up when

(high beam) Blue (LED) headlamp high beam is
pilot lamp turned on.

Turn signal
Green Lights up when right
lamp pilot lamp
(LED) turn signal is turned on.
(right)

Clearance Green Lights up when

lamp pilot lamp (LED) clearance lamp is
turned on.

• "E" and actual gear speed are

displayed alternately in retrieval of
failed machine.
• When the torque converter is
Indicates actual gear
Charac- stalled with the shift lever in D
Shift indicator speed (F1, F2, F3, F4,
ters: White F5, F6, N, R1, or R2). while "F1 Start at D Position
Setting" is enabled, shift indicator
F1 flashes and the centralized
warning lamp and alarm buzzer
operate. (F1 stall alarm)
• When starting switch is turned to
ON position while shift lever is not
Charac- in N, character of current shift
ters: White lever position flashes, centralized
Current shift lever warning lamp lights up and alarm
Shift lever Highligh- position (1, 2, 3, 4, 5, D,
position pilot buzzer sounds. (Neutral safety
ted in: N, R1, or R2) is alarm)
lamp Green highlighted. • When all signals from shift lever
(other than are OFF, character of current shift
N) lever position flashes , centralized
warning lamp lights up and alarm
buzzer sounds.

Message pilot Back- Lights up when there is

lamp (unread) ground: unread message.
Green

Message pilot Back- Lights up when there is

• Goes out when answer is sent or
lamp (read but ground: message read but not
validity of message expires.
unreturned) Black returned yet.

Retarder pilot Lights up when retarder

Orange
lamp operates.

10-250 HM400-3M0
 10 Structure and function
Machine monitor system

Monitor display Item displayed Display

Contents Remarks
color
Inter-axle
Lights up when inter-
differential
Orange axle differential lockup
lockup pilot
operates
lamp

Lights up when KTCS

operates.
KTCS pilot
Orange
lamp
Lights up when KTCS
setting is OFF.

Emergency Lights up when

steering pilot Green emergency steering
lamp operates.

Lights up when
Power mode POWER mode is
pilot lamp selected with power
mode selector switch.
Green
Economy Lights up when
mode pilot ECONOMY mode is
lamp selected with power
mode selector switch.

Shift hold pilot Lights up when shift

lamp Green
hold switch is ON.

Lockup pilot Lights up when lockup

lamp Green is engaged.

Fan reverse Lights up when radiator

Orange fan or aftercooler fan is
pilot lamp
set in reverse.

HM400-3M0 10-251
10 Structure and function
Machine monitor system

Monitor display Item displayed Display

Contents Remarks
color

Preheating Lights up when engine

Orange
pilot lamp preheater operates.

• Guidance on
excessive engine
idling
• Hoist relief
deterrence guidance
Back- • Brake dragging
ground: deterrence guidance
• Upshift • Displayed when machine is
ECO guidance Green operated in manner where more
recommendation
Charac- guidance fuel is consumed.
ters: White • Acceleration
deterrence guidance
while lowering dump
body
• Steering relief
deterrence guidance

10-252 HM400-3M0
 10 Structure and function
Machine monitor system

Guidance icon (HM400_3R-Q1L3-043-K-00-A)

Function (Action that starts when
Monitor display Item Display location
corresponding switch is pressed)
<When maintenance caution lights
User Menu up> • Standard screen (when
selection Moves to "Maintenance" in User maintenance caution lights up)
Menu
Display of • Standard screen (when failure
occurred error Displays occurred error list occurs)
list
<In User Menu or Service Menu>
Move between Moves to upper item • Overall User Menu
items (upper) <When value is input> • Overall Service Menu
Increases value
<In User Menu or Service Menu>
Move between Moves to upper item • Overall User Menu
items (lower) <When value is input> • Overall Service Menu
Decreases value
<In User Menu or Service Menu>
Returns to previous screen or
standard screen • Overall User Menu
Return
• Overall Service Menu
<When Yes/No is selected>
Select "No"
<In User Menu or Service Menu>
Moves to upper item • Overall User Menu
Enter
<When Yes/No is selected> • Overall Service Menu
Selects "Yes"
Moves to right tab • Overall User Menu
Move between
<In service menu> • "Monitoring / Custom" in Service
tabs (right)
Selects monitoring item tab Menu
• Occurred error list
• "ECO Guidance"o "Operation
Record", "ECO Guidance Record"
Moves to upper page in User Menu
Move between
pages (upper) (Moves to bottom page from top • "Monitoring / Pre defined" in
page) Service Menu
• "Abnormality Record" o
"Mechanical Systems" in Service
Menu
• Occurred error list
• "ECO Guidance"o "Operation
Record", "ECO Guidance Record"
Moves to lower item in User Menu
Move between
pages (lower) (Moves to top page from bottom • "Monitoring / Pre defined" in
page) Service Menu
• "Abnormality Record" o
"Mechanical Systems" in Service
Menu
• "ECO Guidance"o "Operation
Record", "ECO Guidance Record"
Start split fuel Starts measurement of split fuel in User Menu
consumption consumption
measurement a Displayed when setting of
"Average fuel consumption
display" is split

HM400-3M0 10-253
10 Structure and function
Machine monitor system

Function (Action that starts when

Monitor display Item Display location
corresponding switch is pressed)
• "ECO Guidance"o "Operation
Record", "ECO Guidance Record"
Stop split fuel Stops measurement of split fuel in User Menu
consumption consumption
measurement a Displayed when setting of
"Average fuel consumption
display" is split
Clear average
fuel Clears average fuel consumption • "ECO Guidance"o "Average Fuel
consumption logs Consumption Logs" in Service
logs Menu
Select average
fuel Selects 1-hour/1-day average fuel • "ECO Guidance"o "Average Fuel
consumption consumption log Consumption Logs" in Service
log Menu

Initialize
Returns to monitor screen • "Monitor Setting"o "Screen
screen
brightness to initial level Adjustment" in User Menu
brightness

Store • "Monitoring / Custom" in Service

Stores monitoring item
monitoring item Menu

Clear saved • "Monitoring / Custom" in Service

Clears monitoring item
monitoring item Menu

• "Monitoring / Pre defined" in

Service Menu
Hold • "Monitoring / Custom" in Service
monitoring Holds value of monitoring item Menu
value • "Diagnostic Tests" o "Cylinder
Cut-out" in Service Menu
• "Adjustment" in Service Menu
• "Monitoring / Pre defined" in
Service Menu
Cancel held • "Monitoring / Custom" in Service
Cancels held value of monitoring Menu
monitoring
item • "Diagnostic Tests" o "Cylinder
value
Cut-out" in Service Menu
• "Adjustment" in Service Menu
<Electrical system abnormality • "Abnormality Record" o
record> "Electrical Systems" in Service
Clears electrical system Menu
abnormality record * For method of clearing
Clear <Phone number entry> abnormality record, see "Testing
and adjusting"
Clears phone number • "Phone Number Entry" in Service
<Adjusting> Menu
Clears input value • "Adjustment" in Service Menu
• "Phone Number Entry" in Service
Menu
Move between
Moves to right item • "Diagnostic Tests" o "Cylinder
items (right)
Cut-out" in Service Menu
Other items (Adjusting screen)
• "Phone Number Entry" in Service
Menu
Move between
Moves to left item • "Diagnostic Tests" o "Cylinder
items (left)
Cut-out" in Service Menu
Other items (Adjusting screen)

10-254 HM400-3M0
 10 Structure and function
Machine monitor system

Function (Action that starts when

Monitor display Item Display location
corresponding switch is pressed)

Select plus or Selects plus or minus of input value • "Adjustment" in Service Menu
minus

Input decimal
Inputs decimal point • "Adjustment" in Service Menu
point

HM400-3M0 10-255
10 Structure and function
Machine monitor system

Operator mode functions (HM400_3R-Q193-042-K-00-A)

• The functions with which the operator can display or set by operating switches in normally displayed
screen.
Display and setting of some functions require special operation of the switch.
• Items available in the operator mode are as follows:
Cate- Display order (*2)
gory Item
(*1) Y Z
Display of KOMATSU logo 1 1
Display of password input 2 -
A Display of standard screen 3 2
Display of end screen
Display of engine shutdown secondary switch screen
Operation of air conditioner
Setting and display of User Menu
• ECO Guidance
B • Machine Setting / Information
• Maintenance
• Monitor Setting
• Display of message (including KOMTRAX messages for user)
Display of ECO guidance
C Display of caution monitor
Display of maintenance due time over
Checking function by LCD (Liquid Crystal Display)
D Function of checking service meter and odometer
Function of usage limitation setting/changing password
*1: The operator mode items are classified as follows.
A: Display from the time when the starting switch is turned to ON position to the time when display changes to
the standard screen, and display after starting switch is turned to OFF position
B: Display when the machine monitor switch is operated
C: Display when condition is satisfied
D: Display that requires special operations of switches
*2: Display sequence from the time when the starting switch is turned to ON position to the time when the
standard screen appears varies depending on the settings and conditions of the machine as follows:
Y: When the engine start lock is set ON
Z: When the engine start lock is set OFF
a For how to operate the operator mode functions, see the Operation and Maintenance Manual or "Operator
mode (Outline)" section in Testing and adjusting.
a For the operating method of the engine start lock function, see Password setting and canceling manual.

10-256 HM400-3M0
 10 Structure and function
Machine monitor system

Service mode functions (HM400_3R-Q194-042-K-00-A)

• These functions are not displayed normally. A technician can display and set them special operation of
switches.
This function is used for special setting, testing, adjusting, or troubleshooting.
• Items available in the service mode are as follows:
Monitoring/Pre-defined
Monitoring/Custom
Mechanical Systems
Abnormality Record
Electrical Systems
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
Machine Model Select
Default Option Select
Unit
Diagnostic Tests Cylinder Cut-out
ECMV Automatic Compensation
T/M Initial Learning
T/M Initial Learning Reset
Engine Mode Fixing
Debug Mode Selection
Adjustment
Fan Mode Fixing
Steering Pump Displacement Fixing
Throttle Limit Check
TCS System Check
Hydraulic Relief Pressure Event
No Injection
Payload to start loading
Travel distance to complete loading
Payload offset
Method of entering saved payload
Correction of payload calculation
Payload meter settings Correction of inclination sensor
Inclination range of external lamps
Stopper-hit threshold
Cycle data deletion
Payload meter initialization
S/N confirmation
Terminal Status
KOMTRAX Settings GPS & Communication Status
Modem Status
Service Message

a For operating method of the service mode functions, see "Service mode" section in Testing and adjusting.

HM400-3M0 10-257
10 Structure and function
Machine monitor system

Switch panel (HM300-Q1C0-042-K-00-A)

Input/output signals of switch panel (HM300-Q1A1-03C-K-00-A)

AMP-6P [CN-OPM]
Input/output
Pin No. Signal name
signal
1 Switch panel power supply (+12 V) Input
2 GND (Switch panel power supply) —
3 LIN Input/Output
4 Switch panel continuous power supply (+5.6 V) Input
5 External starting signal (for switch panel) Output
6 Switch panel built-in buzzer Input

a Never connect pins in the blank columns. Malfunctions or failures may occur.

10-258 HM400-3M0
 10 Structure and function
Rear view monitor system

Rear view monitor system (HM300-Q162-041-K-00-A)

Function (HM300-Q162-042-K-00-A)

• The rear view monitor system mainly consists of the rear view monitor, rear view camera, and monitor
controller.
1. Rearview monitor
Displays the rear view camera image to the operator according to the setting of the rear view monitor
controller (guide lines, display of reverse-interlock, luminance, etc.)
2. Rear view camera
Transmits the taken images to the rear view monitor.
3. Monitor controller
Sends the contents of change of the rear view monitor setting to the monitor.

HM400-3M0 10-259
10 Structure and function
Rear view monitor system

Rear view monitor (HM300-Q16D-042-K-00-A)

Precautions for using rear view monitor

• The reference lines must be re-adjusted in the following cases.
1. When the machine dimensions are changed because of replacement of tires, installation of optional
attachment, etc.
2. When the rear view camera is removed or its direction is changed because of damage etc.

10-260 HM400-3M0
 10 Structure and function
Rear view monitor system

Rear view monitor input/output signals (HM300-Q16D-03C-K-00-A)

AMP-12P [CN-RMN1]
Input/output
Pin No. Signal name
signal
1 Continuous power supply (24 V) Input
2 Power supply return GND —
3 External starting signal Input
4 (*1) —
5 Rear view monitor brightness adjustment switch + Input
6 Rear view monitor brightness adjustment switch - Input
7 Shift lever R signal Input
8 Monitor brightness selector switch (night mode signal) Input
9 LIN Input/Output
10 (*1) —
11 (*1) —
12 Key switch ACC signal Input
*1: Never connect these pins. Malfunctions or failures may occur.

AMP-8P [CN-RMN2]
Input/output
Pin No. Signal name
signal
1 Rear view camera power supply output Output
2 Rear view camera NTSC signal Input
3 (*1) —
4 (*1) —
5 GND (rear view camera power supply) —
6 (*1) —
7 (*1) —
8 GND (rear view camera shield) —
*1: Never connect these pins. Malfunctions or failures may occur.

HM400-3M0 10-261
10 Structure and function
Rear view monitor system

Rear view camera (HM300-Q162-042-K-01-A)

Rear view camera input/output signals (HM300-Q162-03C-K-00-A)

CN1 [CN-BMN]
Input/output
Pin No. Signal name
signal
1 Rear view camera power supply Input
2 Rear view camera NTSC signal Output
3 (*1) —
4 GND (rear view camera power supply) —
*1: Never connect these pins. Malfunctions or failures may occur.

10-262 HM400-3M0
 10 Structure and function
KOMTRAX system

KOMTRAX system (HM300-Q210-042-K-00-A)

• The KOMTRAX system consists of the KOMTRAX terminal, communication antenna, and GPS antenna.
• This system transmits various machine information by use of the radio communication. KOMTRAX
operator can refer this information and provide various services to the customers.
• Following information can be transmitted from the KOMTRAX system.
1. Position information
2. Operation information (service meter, odometer, etc.)
3. Alarm and failure information
4. Fuel consumption information
5. Maintenance information
6. Machine working condition information
a To provide the services, you need to establish radio station for KOMTRAX separately.

HM400-3M0 10-263
10 Structure and function
KOMTRAX system

KOMTRAX terminal (HM300-Q220-042-K-00-A)

Model: TC330

1. LED lamp display

2. GPS antenna connection port
3. Machine wiring harness connection port (CN1A)
4. Machine wiring harness connection port (CN1B)
5. Communication antenna connection port

Input and output signals of KOMTRAX terminal (HM300-Q220-03C-K-00-A)

CN1A[CN-KOM1]
Input/output
Pin No. Signal name
signal
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
10 CAN2_H Input/Output
11 CAN2_L Input/Output
12 (*1) -
13 (*1) -
14 External starting signal Input/Output
15 System operating lamp Output
16 (*1) -
17 (*1) -
18 (*1) -
*1: Never connect these pins. Malfunctions or failures may occur.

CN1B[CN-KOM2]
Input/output
Pin No. Signal name
signal
1 GND (continuous power supply) -
2 GND (continuous power supply) -
3 Starting switch ACC signal Input
4 Alternator R signal Input
5 (*1) -

10-264 HM400-3M0
 10 Structure and function
KOMTRAX system

Input/output
Pin No. Signal name
signal
6 Continuous power supply (24 V) Input
7 Continuous power supply (24 V) Input
8 (*1) -
9 (*1) -
10 (*1) -
11 Starting switch C signal Input
12 (*1) -
*1: Never connect these pins. Malfunctions or failures may occur.

Function (D65-Q220-042-K-01-A)
• This terminal utilizes satellite communications technology.
• The terminal is an equipment which transmits various machine information obtained through network
signals and input signals, as well as GPS positioning data. The terminal can transmit data via the
communication antenna.
• The status of the terminal can be checked by using the menu of "KOMTRAX setting" in the service mode
of the machine monitor .
• Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
• This terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its
display section.
a When commencing operation of the KOMTRAX system or changing the country in which the system is
used, you must give notice about the name of the country to Komatsu Ltd.
a When operating the system in Japan, install a terminal dedicated for use in Japan.

HM400-3M0 10-265
10 Structure and function
System component parts

System component parts (ALL-RA1C-001-K-00-A)

Engine controller (HM400_3R-AP70-041-K-00-A)

10-266 HM400-3M0
 10 Structure and function
System component parts

Transmission controller (HM300-CV10-041-K-00-A)

Function (HM300-CV10-042-K-00-A)
The transmission controller has the following functions.
1. Receive the shift position signal of the shift lever, throttle position information of the accelerator pedal,
speed signal of the transmission, and signals of other switches and sensors, and set the transmission to
the proper gear speed automatically.
2. Control the radiator fan and aftercooler fan according to the temperatures of each oil and coolant.
3. Output the throttle correction command to the engine controller and adjust the engine speed during gear
shifting process to reduce the gear shift shock.
4. Secure transmission oil flow with the large-capacity pump for charging the torque converter only when the
engine speed is low and the transmission is at low temperature and compensate for the pressure with the
additional small-sized pump in other cases to reduce unnecessary loss.
5. Install speed sensors to 3 places, the input shaft, intermediate shaft, and output shaft of the transmission
to detect slipping of the transmission clutch and protect the transmission when the hydraulic system has
trouble.
6. Connect to the network and share the various type of information with the controller.
7. Receive the machine model selection information (on which machine model the transmission controller is
mounted) from the network.
8. Own the self check function divided for each input and output.
9. The self check function is displayed on the machine monitor.
10.When a failure is detected, its contents are transmitted to the network.
11.Whether the failure is occurring now is displayed on the machine monitor.
12.Retrieval function of failed machine due to a failure in the electric system is installed.

HM400-3M0 10-267
10 Structure and function
System component parts

Input/output signal (HM400_3R-CV10-03C-K-00-A)

DEUTSCH-24P [ATC1]
Input/output
Pin No. Signal name
signal
1 Torque converter oil pressure sensor Input
2 (*1) —
3 Transmission oil temperature sensor Input
4 GND (analog) —
5 ARAC switch 2 Input
6 Shift lever position N signal Input
7 (*1) —
8 (*1) —
9 Torque converter oil temperature sensor Input
10 (*1) —
11 Emergency Steering Operation Signal Input
12 Engine mode selector switch Input
13 Transmission flow selector valve operating pressure sensor Input
14 CAC outlet temperature sensor Input
15 Alternator terminal R Input
16 Sensor power supply (24 V) Output
17 Shift hold switch Input
18 AISS switch Input
19 (*1) —
20 Piston pump oil temperature sensor —
21 GND (analog) —
22 Sensor power supply output (5 V) Output
23 Key switch C signal Input
24 ARAC switch 1 Input
*1: Never connect these pins. Malfunctions or failures may occur.

DEUTSCH-40P (1) [ATC2]

Input/output
Pin No. Signal name
signal
1 Sensor power supply output (5 V) —
2 Engine oil level switch Input
3 Emergency retrieval switch Input
4 232C RXD —
5 Shift lever position 5 signal Input
6 Shift lever position 1 signal Input
7 Transmission oil filter switch Input
8 (*1) Output
9 Aftercooler fan reverse solenoid valve Output
10 Transmission differential speed sensor Input
11 (*1) —
12 Coolant level state signal Input
13 (*1) —
14 232C TXD —
15 Shift lever position D signal Input
16 Shift lever position 2 signal Input
17 Air cleaner clogging sensor Input
18 Fan/hoist selector solenoid valve Output
19 Radiator fan reverse solenoid valve Output

10-268 HM400-3M0
 10 Structure and function
System component parts

Input/output
Pin No. Signal name
signal
20 Transmission intermediate shaft speed sensor Input
21 (*1) —
22 CAN0_L Input/Output
23 CAN1_L Input/Output
24 External starting signal Input
25 Shift lever position R1 signal Input
26 Shift lever position 3 signal Input
27 (*1) —
28 Battery relay drive signal Output
29 GND (pulse) —
30 Transmission output shaft speed sensor Input
31 (*1) —
32 CAN0_H Input/Output
33 CAN1_H Input/Output
34 232C GND —
35 Shift lever position R2 signal Input
36 Shift lever position 4 signal Input
37 (*1) —
38 (*1) —
39 GND (pulse) —
40 Transmission input speed sensor Input
*1: Never connect these pins. Malfunctions or failures may occur.

DEUTSCH-40P (2) [ATC3]

Input/output
Pin No. Signal name
signal
1 Continuous power supply (24 V) Input
2 Solenoid power supply (24 V) Input
3 SOL_COM (solenoid common GND) —
4 Solenoid power supply hold relay drive signal Output
5 ECMV Rev (+) Output
6 ECMV High (+) Output
7 Main flow selector solenoid valve Output
8 (*1) —
9 Fill switch 2nd Input
10 (*1) —
11 Continuous power supply (24 V) Input
12 Solenoid power supply (24 V) Input
13 SOL_COM (solenoid common GND) —
14 Key switch ACC signal Input
15 ECMV Diff (+) Output
16 ECMV 1st (+) Input
17 (*1) —
18 Radiator fan pump EPC valve Output
19 Fill switch 3rd Input
20 Fill switch Low Input
21 GND (continuous power supply) Input
22 Solenoid power supply (24 V) Input
23 SOL_COM (solenoid common GND) Input
24 Key switch ACC signal Input
25 Engine start relay Output

HM400-3M0 10-269
10 Structure and function
System component parts

Input/output
Pin No. Signal name
signal
26 ECMV 2nd (+) Output
27 ECMV L/U (+) Output
28 Aftercooler fan pump EPC valve Output
29 Fill switch Rev Input
30 Fill switch High Input
31 GND (continuous power supply) —
32 GND (continuous power supply) —
33 GND (continuous power supply) —
34 System operating lamp Output
35 (*1) —
36 ECMV　3rd (+) Output
37 ECMV　Low (+) Output
38 (*1) —
39 (*1) —
40 Fill switch 1st Input
*1: Never connect these pins. Malfunctions or failures may occur.

10-270 HM400-3M0
 10 Structure and function
System component parts

Shift lever (HM300-CZ10-03C-K-00-A)

1. Lever
2. Lock button
3. Shift hold switch
4. Connector

Function (HM300-CZ10-042-K-00-A)
• Transmit the lever position information signal to the transmission controller and decide the gear shift
possible range according to the position.
• When the shift hold switch is pushed, the current gear speed is set as the maximum gear speed, and gear
is not upshifted any more. When the shift hold switch is pressed again, holding is canceled and the normal
gear shifting mode starts again.

HM400-3M0 10-271
10 Structure and function
System component parts

Retarder and hoist controller (HM300-RA1N-041-K-00-A)

Function (HM300-RA1N-042-K-00-A)
The retarder and hoist controller has the following functions.

Retarder control
Controls the proportional solenoid valves of the front and rear wheels according to the operating angle of the
retarder control lever to operate the retarder.

KTCS (Komatsu Traction Control System)

Controls the retarder and inter-axle differential lock automatically when any tire slips to prevent slipping of the
drive wheels caused by excessive torque and improve the starting and traveling performance on soft ground,
steep uphill slope, etc.

Retarder control for overrun prevention and against transmission abuse

Controls the proportional solenoid valves of the front and rear wheels according to the command (analog) of
the transmission controller to operate the retarder by a certain quantity.

Hoist control
Controls the hoist EPC valve (solenoid valve), hoist selector valve (ON/OFF solenoid valve), and steering
pump selector valve (ON/OFF solenoid valve) according to the dump lever position to operate the dump body.

Automatic emergency steering system

This controller operates the emergency steering pump automatically to make steering operation possible
when the oil flow in the steering circuit decreases below the specified level due to hydraulic pump trouble etc.

Brake cooling control

Outputs the command to the remote cooling valve to decrease the cooling oil flow and decrease the
horsepower loss while the service brake and retarder brake are not in operation.

Brake lamp control

Turns on the brake lamp when the retarder or the service brake is operated.

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 10 Structure and function
System component parts

Communication of network information

Communicates the information and warning on control with other controllers through the network.

Input/output signal (HM400-RA1N-03C-K-00-A)

DEUTSCH-24P [BRC1]
Input/output
Pin No. Signal name
signal
1 Articulate angle sensor Input
2 Retarder oil pressure sensor (front right) Input
3 Retarder oil temperature sensor (front) Input
4 GND (analog) —
5 (*1) —
6 (*1) —
7 Retarder oil pressure sensor (center left) Input
8 Retarder control lever Input
9 Steering oil temperature sensor Input
10 (*1) —
11 (*1) —
12 Hoist lever (sub) Input
13 Retarder oil pressure sensor (center right) Input
14 Dump body position sensor Input
15 Alternator terminal R Input
16 Sensor power supply (24 V) Output
17 (*1) —
18 Acceleration sensor Input
19 Retarder oil pressure sensor (front left) Input
20 Retarder oil temperature sensor (center) Input
21 GND (analog) —
22 Sensor power supply output 0 (5 V) Output
23 (*1) —
24 Hoist lever (main) Input
*1: Never connect these pins. Malfunctions or failures may occur.

DEUTSCH-40P (1) [BRC2]

Input/output
Pin No. Signal name
signal
1 Sensor power supply output 1 (5 V) Output
2 TCS emergency retrieval switch Input
3 Validation switch 2 Input
4 232C_RXD —
5 Emergency steering oil pressure sensor 2 Input
6 Inclination angle sensor Input
7 Wheel speed sensor (center left) Input
8 Shut-off valve (front) Output
9 Auto-emergency steering relay 2 Output
10 (*1) —
11 (*1) —
12 Service brake signal Input
13 Validation switch 1 Input
14 232C TXD —
15 Emergency steering oil pressure sensor 1 Input
16 (*1) —
17 Wheel speed sensor (center right) Input

HM400-3M0 10-273
10 Structure and function
System component parts

Input/output
Pin No. Signal name
signal
18 Steering pump selector valve Output
19 Auto-emergency steering relay 1 Output
20 (*1) —
21 (*1) —
22 CAN0_L Input/Output
23 CAN1_L Input/Output
24 External starting signal Input
25 Steering oil pressure sensor Input
26 Accumulator oil pressure sensor (rear) Input
27 Wheel speed sensor (front left) Input
28 Shut-off valve (center) Output
29 GND (pulse) —
30 Aftercooler fan speed sensor Input
31 (*1) —
32 CAN0_H Input/Output
33 CAN1_H Input/Output
34 (*1) —
35 Parking brake oil pressure sensor Input
36 Accumulator oil pressure sensor (front) Input
37 Wheel speed sensor (front right) Input
38 Memory clear switch Input
39 GND (pulse) —
40 Radiator fan speed sensor Input
*1: Never connect these pins. Malfunctions or failures may occur.

DEUTSCH-40P (2) [BRC3]

Input/output
Pin No. Signal name
signal
1 Continuous power supply (24 V) Input
2 Solenoid power supply (24 V) Input
3 SOL_COM (solenoid common GND) —
4 (*1) —
5 Hoist EPC valve Output
6 Retarder proportional solenoid valve (center right) Output
7 Remote cooling valve solenoid Output
8 Hoist selector valve Output
9 Inter-axle differential lock switch Input
10 Key switch C (engine start) Input
11 Continuous power supply (24 V) Input
12 Solenoid power supply (24 V) Input
13 SOL_COM (solenoid common GND) —
14 Key switch ACC signal Input
15 (*1) —
16 Retarder proportional solenoid valve (center left) Output
17 (*1) —
18 Hoist lever kick-out solenoid valve Output
19 (*1) —
20 Emergency steering switch Input
21 GND (continuous power supply) —
22 Solenoid power supply (24 V) Input
23 SOL_COM (solenoid common GND) —

10-274 HM400-3M0
 10 Structure and function
System component parts

Input/output
Pin No. Signal name
signal
24 Key switch ACC signal Input
25 Brake lamp relay Output
26 (*1) —
27 Retarder proportional solenoid valve (front right) Output
28 (*1) —
29 Parking brake solenoid signal Input
30 (*1) —
31 GND (continuous power supply) —
32 GND (continuous power supply) —
33 GND (continuous power supply) —
34 System operating lamp Output
35 (*1) —
36 (*1) —
37 Retarder proportional solenoid valve (front right) Output
38 (*1) —
39 (*1) —
40 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.

HM400-3M0 10-275
10 Structure and function
System component parts

Retarder control lever (HM300-GT48-041-K-00-A)

1. Lever
2. Potentiometer

Function (HM300-GT48-042-K-00-A)
• The retarder lever has the manual retarder potentiometer and lever validation switches 1 and 2 in it. When
the lever is operated, the potentiometer rotates and outputs a voltage conversion value corresponding to
the lever operation angle to the retarder and hoist controller.
At the same time, the lever validation switches output the ON/OFF information of the lever position to the
retarder and hoist controller.

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 10 Structure and function
System component parts

Monitor controller (HM300-Q180-041-K-00-A)

Input/output signal (HM300-Q180-03C-K-02-A)

AMP-81P [CN-MCM1] (for monitor controller)

Input/output
Pin No. Signal name
signal
1 Continuous power supply (24 V) Input
2 GND (continuous power supply) —
3 GND (continuous power supply) —
4 Continuous power supply (24 V) Input
5 (*1) —
6 Alternator R Input
7 (*1) —
8 Fuel level sensor Input
9 GND (analog) —
10 Dimmer switch Input
11 Key switch C signal Input
12 Seat belt Input
13 GND (digital) —
14 High beam status Input
15 Left turn signal Input
16 Right turn signal Input
17 (*1) —
18 Head lamp (high beam) relay Output
19 Personal code relay Output
20 Buzzer Output
21 (Switch) —
22 Night light power supply output for switch Output

HM400-3M0 10-277
10 Structure and function
System component parts

Input/output
Pin No. Signal name
signal
23 (*1) —
24 Key switch ACC signal Input
25 (*1) —
26 (*1) —
27 (*1) —
28 (*1) —
29 (*1) —
30 Unit selection Input
31 Engine shutdown secondary switch Input
32 (*1) —
33 Monitor brightness selector switch Input
34 Lamp switch Input
35 Engine preheat relay Input
36 (*1) —
37 (*1) —
38 (*1) —
39 (*1) —
40 (*1) —
41 GND (Night light power supply for switch) —
42 (*1) —
43 Key switch ACC signal Input
44 (*1) —
45 (*1) —
46 (*1) —
47 (*1) —
48 (*1) —
49 (*1) —
50 (*1) —
51 (*1) —
52 (*1) —
53 (*1) —
54 Door switch Input
55 (*1) —
56 (*1) —
57 System operating lamp Output
58 Operation lighting for parking brake switch Output
59 (*1) —
60 Night lighting power supply for shift lever Output
61 (*1) —
62 External starting signal Input
63 (*1) —
64 (*1) —
65 (*1) —
66 (*1) —
67 (*1) —
68 (*1) —
69 (*1) —
70 (*1) —
71 (*1) —
72 (*1) —
73 (*1) —

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 10 Structure and function
System component parts

Input/output
Pin No. Signal name
signal
74 (*1) —
75 (*1) —
76 (*1) —
77 (*1) —
78 (*1) —
79 GND (Night light power supply for shift lever) —
80 (*1) —
81 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.

AMP-40P [CN-MCM2] (for monitor controller)

Input/output
Pin No. Signal name
signal
82 Switch panel built-in buzzer Output
83 (*1) —
84 (*1) —
85 (*1) —
86 (*1) —
87 (*1) —
88 (*1) —
89 CAN2_L Input/Output
90 (*1) —
91 LED unit power supply (+5V) Output
92 (*1) —
93 (*1) —
94 (*1) —
95 (*1) —
96 (*1) —
97 CAN2_H Input/Output
98 Switch panel continuous power supply (+5.6V) Output
99 GND (power supply for switch panel and LED unit) —
100 (*1) —
101 (*1) —
102 (*1) —
103 (*1) —
104 (*1) —
105 CAN1_L Input/Output
106 External starting signal (for switch panel) Input
107 Switch panel and LED unit power supply output (+12 V) Output
108 LIN Input/Output
109 (*1) —
110 (*1) —
111 (*1) —
112 CAN1 terminating resistor —
113 CAN1_H Input/Output
114 (*1) —
115 (*1) —
116 (*1) —
117 (*1) —
118 (*1) —
119 (*1) —

HM400-3M0 10-279
10 Structure and function
System component parts

Input/output
Pin No. Signal name
signal
120 (*1) —
121 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.

SAE-8P [CN-MCM3] (for LED unit)

Input/output
Pin No. Signal name
signal
1 LC unit LVDS + Output
2 LC unit LVDS - Output
3 GND (LC unit power supply) —
4 LC unit backlight adjustment Output
5 LC unit power supply Output
6 LC unit ON/OFF control Output
7 LC unit backlight ON/OFF control Output
8 LC unit temperature sensor Output

10-280 HM400-3M0
 10 Structure and function
System component parts

Payload meter controller (HM400_3M0-M715-041-K-00-A)

(Payload meter setting)

Function (HM400_3M0-M715-042-K-00-A)
The payload meter controller has the following functions.

Payload calculation
This controller calculates the weight of upper part of the machine on the suspension from signals of each
suspension pressure sensor and inclination angle sensor.
Payload is calculated from the difference between the machine weight with load and without load.

Cycle data store function

This controller stores the data of payload, traveling distance, time and speed for each cycle.
Stored cycle data can be downloaded by using the exclusive software.

Input/output signal (HM400_3M0-M715-03C-K-00-A)

CN1-20P[CN-HM1]
Input/output
Pin No. Signal name
signal
1 (*1) —
2 External power supply (24 V) Output
3 System operating lamp Output
4 (*1) —
5 (*1) —
6 Continuous power supply (24 V) Input
7 Continuous power supply (24 V) Input
8 Continuous power supply (24 V) Input
9 Continuous power supply (24 V) Input
10 (*1) —

HM400-3M0 10-281
10 Structure and function
System component parts

Input/output
Pin No. Signal name
signal
11 GND (continuous power supply) —
12 GND (continuous power supply) —
13 (*1) —
14 External display lamp (red) Input
15 External display lamp (yellow) Input
16 External display lamp (green) Output
17 Starting switch ACC signal Input
18 (*1) —
19 GND (continuous power supply) —
20 GND (continuous power supply) —
*1: Never connect these pins. Malfunctions or failures may occur.
CN2A-18P[CN-HM2A]
Input/output
Pin No. Signal name
signal
1 (*1) —
2 (*1) —
3 (*1) —
4 (*1) —
5 (*1) —
6 (*1) —
7 (*1) —
8 (*1) —
9 (*1) —
10 (*1) —
11 (*1) —
12 (*1) —
13 (*1) —
14 (*1) —
15 (*1) —
16 (*1) —
17 (*1) —
18 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.

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 10 Structure and function
System component parts

CN2B-12P[CN-HM2B]
Input/output
Pin No. Signal name
signal
1 Suspension pressure sensor (FR) Input
2 Suspension pressure sensor (FL) Input
3 Inclination angle sensor Input
4 (*1) —
5 (*1) —
6 GND —
7 Suspension pressure sensor (RR) Input
8 Suspension pressure sensor (RL) Input
9 GND —
10 (*1) —
11 (*1) —
12 GND —
*1: Never connect these pins. Malfunctions or failures may occur.
CN3A-18P[CN-HM3A]
Input/output
Pin No. Signal name
signal
1 DIS_SWL0 Input
2 (*1) —
3 (*1) —
4 RS232C_TXD2 Output
5 (*1) —
6 (*1) —
7 (*1) —
8 (*1) —
9 (*1) —
10 (*1) —
11 (*1) —
12 RS232C_RXD2 Input
13 GND(RS232C) —
14 (*1) —
15 (*1) —
16 (*1) —
17 (*1) —
18 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.

HM400-3M0 10-283
10 Structure and function
System component parts

CN3B-12P[CN-HM3B]
Input/output
Pin No. Signal name
signal
1 (*1) —
2 (*1) —
3 (*1) —
4 (*1) —
5 DIS_DSWL1 Input
6 (*1) —
7 (*1) —
8 (*1) —
9 GND —
10 (*1) —
11 (*1) —
12 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.
CN4A-14P[CN-HM4A]
Input/output
Pin No. Signal name
signal
1 (*1) —
2 (*1) —
3 (*1) —
4 CAN_H (KOMNET/c) Input/Output
5 (*1) —
6 (*1) —
7 (*1) —
8 (*1) —
9 (*1) —
10 (*1) —
11 (*1) —
12 CAN_L (KOMNET/c) Input/Output
13 (*1) —
14 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.

10-284 HM400-3M0
 10 Structure and function
System component parts

CN4B-10P[CN-HM4B]
Input/output
Pin No. Signal name
signal
1 (*1) —
2 (*1) —
3 (*1) —
4 (*1) —
5 (*1) —
6 (*1) —
7 (*1) —
8 (*1) —
9 (*1) —
10 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.
CN5-12P
Input/output
Pin No. Signal name
signal
1 LAN_TX(+) Output
2 LAN_TX(-) Output
3 LAN_RX(+) Input
4 LAN_RT3 —
5 LAN_RT4 —
6 LAN_RX(-) Input
7 LAN_RT1 —
8 LAN_RT2 —
9 DIS_PWRSEL Input
10 GND —
11 External power supply (5 V) Output
12 GND —
*1: Never connect these pins. Malfunctions or failures may occur.

HM400-3M0 10-285
10 Structure and function
System component parts

Dump lever (HM300-M6K1-041-K-00-A)

10-286 HM400-3M0
 10 Structure and function
System component parts

HM400-3M0 10-287
10 Structure and function
System component parts

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

Function (HM300-M6K1-042-K-00-A)
• When lever (1) is operated, rod (18) moves up and down according to the operating distance of the lever,
and rotates the shaft of potentiometer (16).
• The operating angle (stroke) of the control lever is detected with the potentiometer and signal voltages are
output to the controller.
• One potentiometer is installed and outputs two signal voltages which are opposite to each other as shown
in the "Output voltage characteristics".

10-288 HM400-3M0
 10 Structure and function
System component parts

Operation (HM300-M6K1-044-K-00-A)

When dump lever is in FLOAT position

• When rod (2) on LOWER side is pushed down with lever (1), ball (14) touches projection (a) of rod (11) in
the middle of the stroke. (Before mechanical detent operation starts.)
• When rods (2) and (11) are pushed in, ball (14) pushes up retainer (13) held by detent spring (12) and
escapes out to go over projection (a) of rod (11).
• Rod (18) on the opposite side is pushed up by spring (4) and ball (14) is moved toward the small diameter
side of projection (b) of rod (19) by retainer (13) held by detent spring (20).
• Even if the lever is released, rod (18) is held by projection (b) of rod (19) and the ball pressing force, thus
the lever is maintained in FLOAT position.

HM400-3M0 10-289
10 Structure and function
System component parts

When dump lever is returned from FLOAT position

• When returning lever (1) from FLOAT position, push it down with force larger than the holding force of rod
(19), detent spring (20), retainer (13), and ball (14).

When dump lever is in LOWER position

• When lever (1) is tilted further from FLOAT position, it is set in LOWER position.
• Rod (18) is pushed up by spring (4) corresponding to the operating distance of lever (1).
• Since lever (17) installed to the rotary shaft with which potentiometer (16) detects the displacement is
connected to rod (19), potentiometer (16) outputs voltage corresponding to the vertical stroke of the rod.

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 10 Structure and function
System component parts

When dump lever is in RAISE position

• When rod (18) on RAISE side is pushed down with lever (1), ball (14) touches projection (a) of rod (19) in
the middle of the stroke. (Before electrical detent operation starts.)
• When rods (18) and (19) are pushed further, ball (14) pushes up retainer (13) held by detent spring (20)
and escapes out to go over projection (a) of rod (19).
• At this time, rod (2) on the opposite side is pushed up by spring (4).
• If rod (2) is pushed up while current is flowing in solenoid (9), nut (10) is attracted by bushing (8).
• Since rod (2) is kept pushed up, even if the lever is released, the lever is held in RAISE position.

When dump lever is returned from RAISE position

• When returning lever (1) from RAISE position, push it down with force larger than the pulling force of the
solenoid. Or when the solenoid current is turned "OFF", the lever is returned from RAISE position to HOLD
position.

HM400-3M0 10-291
10 Structure and function
Sensor

Sensor (ALL-E700-001-P-00-A)

Accelerator pedal position sensor (WA380-AG22-041-K-00-A)

1. Pedal
2. Connector
3. Sensor

10-292 HM400-3M0
 10 Structure and function
Sensor

Function (WA380-AG22-042-K-00-A)
• This sensor is installed to the floor top and outputs accelerator signals and idle validation signals
according to the depressing angle of the accelerator pedal.

Accelerator signal
• The potentiometer in the sensor senses displacement of the accelerator pedal and outputs the variable
voltage through pin No. 2.

Idle validation signal

• The switch in the sensor senses the operating condition of the accelerator pedal. It outputs the signal input
to pin No. 5 from pin No. 4 while the accelerator pedal is released, and outputs the signal input to pin No. 6
from pin No. 4 while the accelerator pedal is depressed.

Output characteristics

HM400-3M0 10-293
10 Structure and function
Sensor

Ambient pressure sensor (ENG-AAP2-041-K-00-A)

1. Connector
2. Sensor

Function (ENG-AAP2-042-K-00-A)
• This sensor, installed to the air intake cover at the engine top side, detects the ambient pressure to output
the corresponding variable voltage.

Output characteristics

10-294 HM400-3M0
 10 Structure and function
Sensor

Charge temperature sensor (ENG125-AAM4-041-K-00-A)

Function (ENG125-AAM4-042-K-00-A)
• The charge temperature sensor detects the intake air temperature (boost temperature) and sends it to the
engine controller.
• The thermistor is used as a sensor of which resistance changes according to the temperature. The engine
controller applies voltage to the thermistor and senses the temperature by using the voltage divided by the
resistance in the computer and the resistance of the thermistor.
Coolant temperature sensor (ENG-BA87-041-K-00-A)

1. Connector
2. Sensor
3. O-ring

Function (HM400_3R-BA87-042-K-00-A)
• This sensor, installed on the cylinder block of the engine, converts the temperature variation into the
resistance variation, and outputs the corresponding signals.

HM400-3M0 10-295
10 Structure and function
Sensor

Ne (crankshaft) speed sensor (HM400_3R-AG42-041-K-00-A)

1. O-ring
2. Sensor
3. Connector

Function (HM400_3R-AG42-042-K-00-A)
• This sensor is installed to the flywheel housing of the engine and outputs a pulse voltage according to the
rotation speed of the flywheel.

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 10 Structure and function
Sensor

Bkup (camshaft) speed sensor (ENG125-AG62-041-K-00-A)

Function (HM400_3R-AG62-042-K-00-A)
• Like the Ne speed sensor, it utilizes 0 to 5 V pulses that result from the change in the magnetic lines
passing through the sensor.
• The disc gear installed to the central part of the camshaft of the supply pump has teeth (cut parts) around
it at intervals of 120 deg.
• In addition to the above teeth, one more tooth is installed. Accordingly, 7 pulses are generated every 2
revolutions of the engine.
• The standard pulse of the No. 1 cylinder is recognized by the combination of the Ne speed sensor pulse
and Bkup speed sensor pulse.

HM400-3M0 10-297
10 Structure and function
Sensor

Charge pressure sensor (HM400_3M0-AAM3-041-K-00-A)

1. Sensor
2. O-ring

Function (HM400_3M0-AAM3-042-K-00-A)
• This sensor detects the charge (boost) pressure and output the variable voltage.

Output characteristics

Common rail pressure sensor (ENG-AE28-041-K-00-A)

1. Connector
2. Sensor

Function (ENG-AE28-042-K-00-A)
• This sensor, installed to the common rail in the engine, detects the fuel pressure to output the
corresponding variable voltage.

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 10 Structure and function
Sensor

Engine oil level sensor (ENG-AB45-041-K-00-A)

1. Connector
2. Bracket
3. Float
4. Switch

Function (ENG-AB45-042-K-00-A)
• This sensor, installed on the side face of the oil pan, turns "OFF" by the lowered float, if the oil level
becomes lower than specified.
Air cleaner clogging sensor (PC-A968-041-K-01-A)

1. Adapter
2. Hood
3. Indicator
4. Connector

Function (PC-A968-042-K-00-A)
• This sensor is installed on the air cleaner outlet side. The switch is turned to "ON" position, if the air
cleaner is clogged and the pressure level drops to the specified level (negative pressure).

HM400-3M0 10-299
10 Structure and function
Sensor

Torque converter oil pressure sensor (HM300-CDL4-041-K-00-A)

1. Sensor
2. Wiring harness
3. Connector

Function (HM300-CDL4-042-K-00-A)
• This sensor, installed to the top of the torque converter, detects the oil pressure in the torque converter
and outputs a variable voltage.

10-300 HM400-3M0
 10 Structure and function
Sensor

Piston pump oil temperature sensor (HM400-PMT1-041-K-00-A)

1. Thermistor
2. Plug
3. Wiring harness
4. Connector

Function (HM400-PMT1-042-K-00-A)
• The piston pump oil temperature sensor, installed to the side of the hydraulic tank, measures the hydraulic
oil temperature.
• The output signal is detected by the transmission controller and used as data for limiting and controlling
the engine rated speed when the hydraulic oil temperature is low.
Transmission flow selector valve operating pressure sensor (HM300-CNBC-041-K-00-A)

1. Sensor
2. Connector

Function (HM300-CNBC-042-K-00-A)
• This sensor, installed to the top of the transmission, detects the operating pressure of the flow selector
valve and outputs a variable voltage.

HM400-3M0 10-301
10 Structure and function
Sensor

Transmission oil temperature sensor (HM300-CH18-041-K-00-A)

1. Thermistor
2. Plug
3. Wiring harness
4. Connector

Function (HM300-CH18-042-K-00-A)
• This sensor detects the temperature of oil in the transmission case. The transmission controller uses it for
selecting the temperature table for electronic modulation and performs modulation control matched to the
oil temperature.
Torque converter oil temperature sensor (HM300-CDK4-041-K-00-A)

1. Thermistor
2. Plug
3. Wiring harness
4. Connector

Function (HM300-CDK4-042-K-00-A)
• This sensor detects the temperature of oil in the torque converter. The data are used for controlling the
radiator fan, and at the same time, transmitted to the machine monitor via network and displayed on the
gauge.

10-302 HM400-3M0
 10 Structure and function
Sensor

Transmission speed sensor (input shaft) (HM400-CNB1-041-K-00-A)

1. Magnet
2. Lock nut
3. Wiring harness
4. Connector

Function (HM400-CNB1-042-K-00-A)
• The transmission input shaft speed sensor is installed to the top of the transmission.
• This sensor generates pulse signals according to the gear speed signals and sends them to the
transmission controller.
• The transmission controller converts the pulse signals to the number of rotation (rpm) and transmits it to
the machine monitor via the network. The machine monitor converts the output speed signal into the travel
speed and displays it.

HM400-3M0 10-303
10 Structure and function
Sensor

Transmission speed sensor (intermediate shaft) (HM400-CNBD-041-K-00-A)

1. Magnet
2. Lock nut
3. Wiring harness
4. Connector

Function (HM400-CNBD-042-K-00-A)
• The transmission intermediate shaft speed sensor is installed to the rear left of the transmission.
• This sensor generates pulse signals according to the gear speed signals and sends them to the
transmission controller.
• The transmission controller converts the pulse signals to the number of rotation (rpm) and transmits it to
the machine monitor via the network. The machine monitor converts the output speed signal into the travel
speed and displays it.

10-304 HM400-3M0
 10 Structure and function
Sensor

Transmission speed sensor (output shaft) (HM400-CNA1-041-K-00-A)

1. Magnet
2. Lock nut
3. Wiring harness
4. Connector

Function (HM400-CNA1-042-K-00-A)
• The transmission output shaft speed sensor is installed to the rear bottom of the transmission.
• This sensor generates pulse signals according to the gear speed signals and sends them to the
transmission controller.
• The transmission controller converts the pulse signals to the number of rotation (rpm) and transmits it to
the machine monitor via the network. The machine monitor converts the output speed signal into the travel
speed and displays it.

HM400-3M0 10-305
10 Structure and function
Sensor

Transmission speed sensor (differential) (HM400-CNBH-041-K-00-A)

1. Magnet
2. Lock nut
3. Wiring harness
4. Connector

Function (HM400-CNBH-042-K-00-A)
• The transmission (differential input shaft) speed sensor is installed to the rear right of the transmission.
• This sensor generates pulse signals according to the gear speed signals and sends them to the
transmission controller.
• The transmission controller converts the pulse signals to the number of rotation (rpm) and transmits it to
the machine monitor via the network. The machine monitor converts the output speed signal into the travel
speed and displays it.

10-306 HM400-3M0
 10 Structure and function
Sensor

Radiator fan speed sensor (HM300-B750-041-K-00-A)

1. Sensor
2. Wiring harness
3. Connector

Function (HM300-B750-042-K-00-A)
• This sensor, installed to the radiator fan motor, generates pulse signals according to the gear speed
signals and sends them to the retarder controller.
• The pulse signals are converted into the number of rotation (rpm) in the retarder controller and sent to the
transmission controller through the network and used for fan speed control by feedback method.

HM400-3M0 10-307
10 Structure and function
Sensor

Aftercooler fan speed sensor (HM300-B750-041-K-01-A)

1. Sensor
2. Wiring harness
3. Connector

Function (HM300-B750-042-K-01-A)
• This sensor, installed to the radiator fan motor, generates pulse signals according to the gear speed
signals and sends them to the retarder controller.
• The pulse signals are converted into the number of rotation (rpm) in the retarder controller and sent to the
transmission controller through the network and used for fan speed control by feedback method.
Aftercooler outlet temperature sensor (HM400_3R-B754-041-K-00-A)

1. Thermistor
2. Plug
3. Connector

Function (HM400_3R-B754-042-K-00-A)
• This sensor, installed to the aftercooler outlet piping, detects the temperature change and outputs signal
as a resistance change of the thermistor to the retarder and hoist controller.
• If the aftercooler outlet temperature increases above the specified level, it is notified by the action level,
caution icon, and buzzer.

10-308 HM400-3M0
 10 Structure and function
Sensor

Front left retarder pressure sensor (HM400-GT61-041-K-00-A)

1. Sensors
2. Connector

Function (HM400-GT61-042-K-00-A)
• This sensor, installed to the retarder hydraulic piping between the shuttle valve on the front axle side and
the proportional pressure reducing valve, converts the retarder drive pressure of the front left axle into
voltage and outputs it to the retarder and hoist controller.
Front right retarder pressure sensor (HM400-GT61-041-K-01-A)

1. Sensors
2. Connector

Function (HM400-GT61-042-K-01-A)
• This sensor, installed to the retarder hydraulic piping between the shuttle valve on the front axle side and
the proportional pressure reducing valve, converts the retarder drive pressure of the front right axle into
voltage and outputs it to the retarder and hoist controller.

HM400-3M0 10-309
10 Structure and function
Sensor

Center left retarder pressure sensor (HM400-GT66-041-K-00-A)

1. Sensors
2. Connector

Function (HM400-GT66-042-K-00-A)
• This sensor, installed to the retarder hydraulic piping between the shuttle valve on the center axle side and
the proportional pressure reducing valve, converts the retarder drive pressure of the center left axle into
voltage and outputs it to the retarder and hoist controller.
Center right retarder pressure sensor (HM400-GT66-041-K-01-A)

1. Sensors
2. Connector

Function (HM400-GT66-042-K-01-A)
• This sensor, installed to the retarder hydraulic piping between the shuttle valve on the center axle side and
the proportional pressure reducing valve, converts the retarder drive pressure of the center right axle into
voltage and outputs it to the retarder and hoist controller.

10-310 HM400-3M0
 10 Structure and function
Sensor

Parking brake pressure sensor (HM300-GP2M-041-K-00-A)

1. Sensor
2. Connector

Function (HM300-GP2M-042-K-00-A)
• This sensor, installed to the parking brake hydraulic piping, converts the parking brake release pressure
into voltage and outputs it to the retarder and hoist controller.
Steering oil pressure sensor (HM300-F7C1-041-K-00-A)

1. Sensor
2. Connector

Function (HM300-F7C1-042-K-00-A)
• This sensor, installed to the steering and hoist piping, converts the steering circuit pressure into voltage
and outputs it to the retarder and hoist controller.
• If the steering circuit pressure lowers below the specified level, the electric pump operates to secure oil
pressure for steering.

HM400-3M0 10-311
10 Structure and function
Sensor

Emergency steering pressure sensor (HM300-F9SA-041-K-00-A)

1. Sensor
2. Connector

Function (HM400-F9SA-042-K-00-A)
• This sensor is installed to the emergency steering pump piping and converts the emergency steering
pressure into voltage and outputs it to the retarder and hoist controller.
• 2 parts are installed to compose 2 emergency steering systems.
Front accumulator oil pressure sensor (HM400-G41N-041-K-00-A)

1. Sensors
2. Connector

Function (HM400-G41N-042-K-00-A)
• This sensor, installed to the front brake accumulator piping, converts the accumulator oil pressure into
voltage and outputs it to the retarder and hoist controller.
• If the oil pressure lowers below the specified level, it is notified by the action level, caution icon, and
buzzer.

10-312 HM400-3M0
 10 Structure and function
Sensor

Rear accumulator oil pressure sensor (HM400-G41R-041-K-00-A)

1. Sensors
2. Connector

Function (HM400-G41R-042-K-00-A)
• This sensor, installed to the rear brake accumulator piping, converts the accumulator oil pressure into
voltage and outputs it to the retarder and hoist controller.
• If the oil pressure lowers below the specified level, it is notified by the action level, caution icon, and
buzzer.

HM400-3M0 10-313
10 Structure and function
Sensor

Front left suspension pressure sensor (HM400_3M0-E313-041-K-00-A)

(Payload meter setting)

1. Sensor
2. Wiring harness
3. Connector

Function (HM400_3M0-E313-042-K-00-A)
• This sensor, installed to the bottom side of the front left suspension cylinder, converts the pressure of
cylinder bottom into voltage and output it to the payload meter controller.

Output characteristics

10-314 HM400-3M0
 10 Structure and function
Sensor

Sensor

1.Sensor part
2.Valve
3.Valve core
• When replacing sensor part (1) of this sensor, take out only sensor part (1) with valve (2) installed to the
bottom side of suspension cylinder.
• When taking out sensor part (1) of this sensor, the suspension cylinder pressure does not decrease due to
valve core (3).
a When taking out sensor part (1), do not rotate valve (2) together.

HM400-3M0 10-315
10 Structure and function
Sensor

Front right suspension pressure sensor (HM400_3M0-E312-041-K-00-A)

(Payload meter setting)

1. Sensor
2. Wiring harness
3. Connector

Function (HM400_3M0-E312-042-K-00-A)
• This sensor, installed to the bottom side of the front right suspension cylinder, converts the pressure of
cylinder bottom into voltage and output it to the payload meter controller.

Output characteristics

10-316 HM400-3M0
 10 Structure and function
Sensor

Sensor

1.Sensor part
2.Valve
3.Valve core
• When replacing sensor part (1) of this sensor, take out only sensor part (1) with valve (2) installed to the
bottom side of suspension cylinder.
• When taking out sensor part (1) of this sensor, the suspension cylinder pressure does not decrease due to
valve core (3).
a When taking out sensor part (1), do not rotate valve (2) together.

HM400-3M0 10-317
10 Structure and function
Sensor

Rear left suspension pressure sensor (HM400_3M0-E315-041-K-00-A)

(Payload meter setting)

1. Sensor
2. Wiring harness
3. Connector

Function (HM400_3M0-E315-042-K-00-A)
• This sensor, installed to the bottom side of the rear left suspension cylinder, converts the pressure of
cylinder bottom into voltage and output it to the payload meter controller.

Output characteristics

10-318 HM400-3M0
 10 Structure and function
Sensor

Sensor

1.Sensor part
2.Valve
3.Valve core
• When replacing sensor part (1) of this sensor, take out only sensor part (1) with valve (2) installed to the
bottom side of suspension cylinder.
• When taking out sensor part (1) of this sensor, the suspension cylinder pressure does not decrease due to
valve core (3).
a When taking out sensor part (1), do not rotate valve (2) together.

HM400-3M0 10-319
10 Structure and function
Sensor

Rear right suspension pressure sensor (HM400_3M0-E314-041-K-00-A)

(Payload meter setting)

1. Sensor
2. Wiring harness
3. Connector

Function (HM400_3M0-E314-042-K-00-A)
• This sensor, installed to the bottom side of the rear right suspension cylinder, converts the pressure of
cylinder bottom into voltage and output it to the payload meter controller.

Output characteristics

10-320 HM400-3M0
 10 Structure and function
Sensor

Sensor

1.Sensor part
2.Valve
3.Valve core
• When replacing sensor part (1) of this sensor, take out only sensor part (1) with valve (2) installed to the
bottom side of suspension cylinder.
• When taking out sensor part (1) of this sensor, the suspension cylinder pressure does not decrease due to
valve core (3).
a When taking out sensor part (1), do not rotate valve (2) together.
Front retarder oil temperature sensor (HM400-GTB4-041-K-00-A)

1. Thermistor
2. Plug
3. Wiring harness
4. Connector

Function (HM400-GTB4-042-K-00-A)
• This sensor, installed to the front axle retarder piping, detects the temperature change and outputs signal
as a resistance change of the thermistor to the retarder and hoist controller.
• The retarder and hoist controller sends the signal through the network to the machine monitor to display
the temperature level.
• If the level displayed on the machine monitor reaches the specified level, it is notified by the action level,
caution icon, and buzzer.

HM400-3M0 10-321
10 Structure and function
Sensor

Center retarder oil temperature sensor (HM400-GTB6-041-K-00-A)

1. Thermistor
2. Plug
3. Wiring harness
4. Connector

Function (HM400-GTB6-042-K-00-A)
• This sensor, installed to the center axle retarder piping, detects the temperature change and outputs
signal as a resistance change of the thermistor to the retarder and hoist controller.
• The retarder and hoist controller sends the signal through the network to the machine monitor to display
the temperature level.
• If the level displayed on the machine monitor reaches the specified level, it is notified by the action level,
caution icon, and buzzer.
Steering oil temperature sensor (HM300-F7D1-041-K-00-A)

1. Thermistor
2. Plug
3. Wiring harness
4. Connector

Function (HM300-F7D1-042-K-00-A)
• This sensor, installed to the steering and hoist piping, detects the temperature change and outputs signal
as a resistance change of the thermistor to the retarder and hoist controller.
• If the steering oil temperature increases above the specified level, it is notified by the action level, caution
icon, and buzzer.

10-322 HM400-3M0
 10 Structure and function
Sensor

Front left wheel speed sensor (HM400-G41J-041-K-00-A)

1. Sensors
2. Hose
3. Connector

Function (HM400-G41J-042-K-00-A)
• This sensor, installed to the left side of the front differential, generates pulse voltages from rotation of the
gear teeth made on the periphery of the pulse wheel on the front left side and outputs them to the retarder
and hoist controller.

HM400-3M0 10-323
10 Structure and function
Sensor

Front right wheel speed sensor (HM400-G41J-041-K-01-A)

1. Sensors
2. Hose
3. Connector

Function (HM400-G41J-042-K-01-A)
• This sensor, installed to the right side of the front differential, generates pulse voltages from rotation of the
gear teeth made on the periphery of the pulse wheel on the front right side and outputs them to the
retarder and hoist controller.

10-324 HM400-3M0
 10 Structure and function
Sensor

Center left wheel speed sensor (HM400-G41L-041-K-00-A)

1. Sensors
2. Hose
3. Connector

Function (HM400-G41L-042-K-00-A)
• This sensor, installed to the left side of the center axle, generates pulse voltages from rotation of the gear
teeth made on the periphery of the pulse wheel on the left side of the center axle and outputs them to the
retarder and hoist controller.

HM400-3M0 10-325
10 Structure and function
Sensor

Center right wheel speed sensor (HM400-G41L-041-K-01-A)

1. Sensors
2. Hose
3. Connector

Function (HM400-G41L-042-K-01-A)
• This sensor, installed to the right side of the center axle, generates pulse voltages from rotation of the gear
teeth made on the periphery of the pulse wheel on the right side of the center axle and outputs them to the
retarder and hoist controller.

10-326 HM400-3M0
 10 Structure and function
Sensor

Dump body position sensor (HM300-M5D2-041-K-00-A)

1. Bearing
2. Brush assembly
3. Connector

Function (HM300-M5D2-042-K-00-A)
• This sensor is installed to the rear of the machine. When the dump body angle changes, the shaft of this
sensor is rotated through the link installed to the dump body to sense the dump angle of the dump body.

HM400-3M0 10-327
10 Structure and function
Sensor

Articulate angle sensor (HM300-FV8J-041-K-00-A)

1. Bearing
2. Brush assembly
3. Connector

Function (HM300-FV8J-042-K-00-A)
• This sensor is installed to the hitch portion. When the machine articulates to turn, the shaft of this sensor
rotates to sense the articulate angle.

10-328 HM400-3M0
 10 Structure and function
Sensor

Center inclination angle sensor (HM400_3M0-M5D3-041-K-00-A)

(Payload meter setting)

1. Body
2. Connector

Function (HM400_3M0-M5D3-042-K-00-A)
• This sensor, installed to the center of the machine, converts the longitudinal inclination angle of the
machine into voltage by sensing the relative position change between the magnet and magnetic resistor
element in the case, and outputs it to the retarder and hoist controller.
a The lateral inclination of the machine is not sensed.

HM400-3M0 10-329
10 Structure and function
Sensor

Rear inclination angle sensor (HM400_3M0-CZTK-041-K-00-A)

1. Body
2. Connector

Function (HM300-CZTK-042-K-00-A)
• This sensor, installed to the rear of the machine, converts the lateral inclination angle of the rear part of the
machine into voltage by sensing the relative position change between the magnet and magnetic resistor
element in the case and outputs it to the retarder and hoist controller.
• If the dump lever is set to RAISE position while the machine inclines more than the sideways fall danger
angle, the danger is notified by the action level, caution icon, and buzzer.
a The lengthwise inclination of the machine is not sensed.
Acceleration sensor (HM300-AF2E-041-K-00-A)

1. Sensor
2. Wire
3. Connector

Function (HM300-AF2E-042-K-00-A)
• This sensor, installed in the cab, converts the acceleration in fore-aft directions into voltage by sensing the
change of the ball position in it, and outputs it to the retarder and hoist controller.

10-330 HM400-3M0
 10 Structure and function
Sensor

Fuel level sensor (HM300-AD41-041-K-00-A)

1. Float
2. Arm
3. Variable resistor
4. Connector

Function (HM300-AD41-042-K-00-A)
• This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level. The movement of the float moves the variable resistor through the arm and outputs the signal
voltage to the monitor controller. The monitor controller displays the fuel level on the machine monitor and
outputs the fuel level low caution icon when the fuel level lowers below the specified level.

HM400-3M0 10-331
10-332 HM400-3M0
SHOP MANUAL

ARTICULATED DUMP TRUCK

HM400-3M0
Model Serial Number

HM400-3M0 5001 and up

20 Standard value tables

4 20 Standard value tables

HM400-3M0 20-1
20 Standard value tables
Table of contents

Table of contents (ALL-0310-002-A-00-A)

20 Standard value tables.................................................................................................................... 20-1
Table of contents ........................................................................................................................ 20-2
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-5

20-2 HM400-3M0
 20 Standard value tables
Standard value table for engine

Standard service value table (ALL-A000-001-K-00-A)

Standard value table for engine (HM400_3M0-A000-033-K-00-A)

Machine model HM400-3M0

Engine SAA6D140E-5
Standard value
Item Measurement condition Unit for new Repair limit
machine
• Coolant At high Power mode 2,200(+50/0) 2,200(+50/0)
temperature: 60 idle Economy mode 2,000(+50/0) 2,000(+50/0)
to 100°C
Power mode
• Transmission oil At low 725 ± 25 725 ± 25
temperature: 70 idle Economy mode
to 90°C Power mode 2,000 2,000
speed • Hydraulic oil rpm
temperature: 45
to 55°C At rated
• Torque speed Economy mode 1,700 1,700
converter oil
temperature: 60
to 80°C
• Coolant temperature: 60 to
100°C
• Hydraulic oil temperature: kPa Min. 163 Min. 139
Boost pressure Power mode
45 to 55°C {mmHg} {1,220} {1,040}
• With torque converter
stalled
• Coolant temperature: 60 to
100°C
• Hydraulic oil temperature:
Exhaust
45 to 55°C Power mode °C Max. 650 Max. 700
temperature
• Whole speed range
(ambient temperature: 20°
C)
At high idle Max. 10 Max. 10
Exhaust gas • Coolant temperature: 60 to Bosch
color 100°C At sudden index Max. 40 Max. 40
acceleration
Valve Intake valve (when engine is cold) 0.35 —
mm
clearance Exhaust valve (when engine is cold) 0.57 —
Compression • Engine oil temperature: 40 to 60°C MPa
Min. 4.1 {42} 2.8 {29}
pressure • Engine speed: 200 to 250 rpm {kg/cm2}
• Coolant temperature: 60 to
100°C
Blowby • Hydraulic oil temperature: kPa Max. 2.94 Max. 3.92
pressure Power mode {mmH2O} {300} {400}
45 to 55°C
• With torque converter
stalled
• With torque converter
SAE0W30OS
stalled Min. 0.34 {3.5} Min. 0.21 {2.1}
• Coolant temperature: Min. SAE5W40LEOS MPa
Oil pressure 80°C SAE10W30DH
{kg/cm2}
• At low idle SAE15W40DH
• Coolant temperature: Min. Min. 0.10 {1.0} Min. 0.08 {0.8}
SAE30DH
80°C

HM400-3M0 20-3
20 Standard value tables
Standard value table for engine

Machine model HM400-3M0

Engine SAA6D140E-5
Standard value
Item Measurement condition Unit for new Repair limit
machine
EGR valve and Min. 1.18 Min. 1.18
At high idle
bypass valve • Coolant temperature: 60 to MPa {12.0} {12.0}
driving oil 100°C {kg/cm }
2 Min. 1.43 Min. 1.43
pressure At low idle {14.6} {14.6}
Oil
Whole speed range (inside oil pan) °C 90 to 110 120
temperature
• Coolant temperature: 60 to At high idle MPa 0.15 to 0.3 0.15 to 0.3
Fuel pressure
100°C {kg/cm2} {1.5 to 3} {1.5 to 3}
Engine speed:
At 1,600 rpm Max. 960 Max. 960
Engine speed:
Max. 1,020 Max. 1,020
At 1,700 rpm
Fuel return rate Engine speed:
• Coolant temperature: 60 to At 1,800 rpm Max. 1,080 Max. 1,080
from injector
100°C Engine speed:
• Return rate for 1 minute ml Max. 1,140 Max. 1,140
At 1,900 rpm
• With torque converter
stalled Engine speed:
Max. 1,200 Max. 1,200
At 2,000 rpm
At high idle
Leakage from At cranking
pressure limiter Max. 10 Max. 10
(engine speed:
Min. 150 rpm)

20-4 HM400-3M0
 20 Standard value tables
Standard value table for machine

Standard value table for machine (HM400_3M0-0000-033-K-00-A)

Engine
Machine model HM400-3M0
Standard value
Item Measurement condition Unit for new Repair limit
machine
Torque converter F1, F2, R1 or R2 1,200 ± 50 1,200 ± 50
lockup actuated • Coolant 1,050 ± 50 1,050 ± 50
F3 to F6
temperature: 60 to
100°C Service brake
• Transmission oil applied 1,000 ± 50 1,000 ± 50
temperature: 70 to F1, F2, R1 or R2
90°C Service brake
• Hydraulic oil applied 950 ± 50 950 ± 50
Torque converter temperature: 45 to F3 to F6
lockup released 55°C Service brake
• Torque converter oil not applied 1,200 ± 50 1,200 ± 50
temperature: 60 to F1, F2, R1 or R2
80°C
Service brake
• Accelerator pedal:
not applied 850 ± 50 850 ± 50
Full stroke
F3 to F6
• Coolant Power mode 1,858 ± 100 —
temperature: 60 to
100°C
• Transmission oil
temperature: 70 to
With torque 90°C
converter stalled • Hydraulic oil Economy mode 1,742 ± 100 —
temperature: 45 to
55°C
Engine speed

• Torque converter oil

temperature: 60 to
80°C rpm
Power mode
Accelerator 2,000 ± 100 2,000 ± 100
• Coolant pedal: Full
Transmission at temperature: 60 to stroke
upshift 100°C Economy mode
• Transmission oil Accelerator 1,850 ± 50 1,850 ± 50
temperature: 70 to pedal: Full
90°C stroke
• Hydraulic oil Accelerator
Transmission at temperature: 45 to pedal: not 1,050 ± 50 1,050 ± 50
downshift 55°C applied
Transmission at • Torque converter oil
temperature: 60 to 2,200 ± 50 2,200 ± 50
upshift
80°C Brake mode
Transmission at 1,360 ± 50 1,360 ± 50
downshift • Brake mode: Brake
Transmission at ON
downshift — 1,360 ± 50 1,360 ± 50
inhibited
Overrun
prevention F2, F6 2,400 ± 50 2,400 ± 50
actuated
Upshift is not operated (at top speed
1,850 ± 50 1,850 ± 50
Overrun determined with shift lever)
prevention not Upshift is operated (at NEUTRAL or
actuated other than top speed determined with 2,200 ± 50 2,200 ± 50
shift lever)

HM400-3M0 20-5
20 Standard value tables
Standard value table for machine

Power train
Machine model HM400-3M0
Standard value
Item Measurement condition Unit for new Repair limit
machine
21.6 ± 3.9
Operating effort N {kg} Max. 19.6 {2.0}
Shift lever

• At center of lever knob {2.2 ± 0.4}

• Between each position
Stroke mm 24.5 ± 1 24.5 ± 2

Engine speed: 2.56 ± 0.20 2.56 ± 0.20

Main relief • Torque converter oil 2,000 rpm {26.1 ± 2.0} {26.1 ± 2.0}
pressure temperature: 60 to Engine speed: 2.45 ± 0.20 2.45 ± 0.20
80°C At low idle {25.0 ± 2.0} {25.0 ± 2.0}
• Transmission oil
0.96 ± 0.10 0.96 ± 0.10
Main flow rate temperature: 70 to Engine speed:
90°C 2,000 rpm {9.8 ± 1.0} {9.8 ± 1.0}
selector valve
Oil pressure

inlet pressure • Shift lever: N Engine speed: 2.45 ± 0.20 2.45 ± 0.20
At low idle {25.0 ± 2.0} {25.0 ± 2.0}
Torque converter • Torque converter oil Service brake 0.86 ± 0.10 0.86 ± 0.10
inlet pressure temperature: 60 to not applied {8.8 ± 1.0} {8.8 ± 1.0}
80°C
Service brake 0.49 ± 0.10 0.49 ± 0.10
• Transmission oil
temperature: 70 to not applied {5.0 ± 1.0} {5.0 ± 1.0}
Torque converter 90°C
outlet pressure • Shift lever: N Service brake 0.62 ± 0.10 0.62 ± 0.10
• Engine speed: applied {6.3 ± 1.0} {6.3 ± 1.0}
2,000 rpm
Torque converter
lockup clutch 2.01 ± 0.20 2.01 ± 0.20
operating Shift Lever: 1
{20.5 ± 2.0} {20.5 ± 2.0}
pressure
Transmission Lo MPa 2.55 ± 0.25 2.55 ± 0.25
clutch operation Shift Lever: 1
pressure {kg/cm }
2 {26.0 ± 2.5} {26.0 ± 2.5}
Transmission Hi 2.50 ± 0.25 2.50 ± 0.25
clutch operation Shift Lever: 2
pressure {25.5 ± 2.5} {25.5 ± 2.5}
Transmission 1st 2.55 ± 0.25 2.55 ± 0.25
clutch operation • Torque converter oil Shift Lever: 1
pressure temperature: 60 to {26.0 ± 2.5} {26.0 ± 2.5}
Oil pressure

80°C
Transmission 2nd 2.38 ± 0.22 2.38 ± 0.22
• Transmission oil
clutch operation
temperature: 70 to Shift Lever: 3 {24.25 ± 2.25} {24.25 ± 2.25}
pressure
90°C
Transmission 3rd • Engine speed: 2.43 ± 0.22 2.43 ± 0.22
clutch operation 2,000 rpm Shift Lever: 5
pressure {24.75 ± 2.25} {24.75 ± 2.25}
Transmission R 2.55 ± 0.25 2.55 ± 0.25
clutch operation Shift lever: R1
pressure {26.0 ± 2.5} {26.0 ± 2.5}
Inter-axle
At inter-axle 2.43 ± 0.22 2.43 ± 0.22
differential lock
differential lock
clutch operation {24.75 ± 2.25} {24.75 ± 2.25}
operated
pressure
Transmission 0.20 ± 0.05 0.20 ± 0.05
Service brake
lubricating oil
not applied {2.0 ± 0.5} {2.0 ± 0.5}
pressure (*1)
(*1) Check of the transmission lubricating oil pressure may be omitted since it can be substituted with the
torque converter outlet pressure.

20-6 HM400-3M0
 20 Standard value tables
Standard value table for machine

Machine model HM400-3M0

Standard value
Item Measurement condition Unit for new Repair limit
machine
F1 6.6 ± 10% 6.6 ± 10%
F2 10.1 ± 10% 10.1 ± 10%
F3 15.5 ± 5% 15.5 ± 5%
F4 • Standard tire: 23.8 ± 5% 23.8 ± 5%
Power mode
F5 29.5R25 36.5 ± 5% 36.5 ± 5%
F6 • Level ground 56.0 ± 5% 56.0 ± 5%
Travel speed

R1 • Coolant 6.8 ± 10% 6.8 ± 10%

R2 temperature: 60 to 16.0 ± 5% 16.0 ± 5%
100°C km/h
F1 • Transmission oil 6.0 ± 10% 6.0 ± 10%
F2 temperature: 70 to 9.2 ± 10% 9.2 ± 10%
F3 90°C 14.1 ± 5% 14.1 ± 5%
F4 • Dump body: 21.6 ± 5% 21.6 ± 5%
Unloaded Economy mode
F5 33.2 ± 5% 33.2 ± 5%
F6 50.9 ± 5% 50.9 ± 5%
R1 6.2 ± 10% 6.2 ± 10%
R2 14.6 ± 5% 14.6 ± 5%
• Standard tire: Front 0.375 {3.8} 0.375 {3.8}
29.5R25 MPa
Tire inflation pressure
• Dump body: Center, rear {kg/cm2} 0.39 {4.0} 0.39 {4.0}
Unloaded

HM400-3M0 20-7
20 Standard value tables
Standard value table for machine

Brake
Machine model HM400-3M0
Standard value
Item Measurement condition Unit for new Repair limit
machine
Depressing effort of
N {kg} Max. 294 {30.0} Max. 294 {30.0}
brake pedal • At 150 mm away from pedal fulcrum
Travel of brake pedal mm 44.5 ± 5 44.5 ± 5
Operating effort of 5.9 to 9.8 3.0 to 14.7
N {kg}
retarder lever • At 10 mm away from top of lever {0.6 to 1.0} {0.3 to 1.5}
Travel of retarder deg. 78 ± 1 78 ± 2
lever
Nitrogen gas
pressure (charge
Gas pressure

pressure) of
accumulator for 4.41 4.41
• Gas temperature (ambient MPa
front service {45} {45}
temperature): 20 °C {kg/cm2}
brake, rear (*2)
service brake,
and parking
brake
Charge valve cut- 11.77(+1.18/0) 11.77(+1.18/0)
in pressure • Engine: At high idle {120(+12/0)} {120(+12/0)}
Charge valve cut- • Hydraulic oil temperature: 45 to 55 °C 20.6(+1.47/0) 20.6(+1.47/0)
out pressure {210(+15/0)} {210(+15/0)}
• Actuating pressure in the 1st
Wheel brake 4.9 ± 0.49 4.9 ± 0.49
operation after charging the
operating
accumulator and stopping the {50 ± 5} {50 ± 5}
pressure
engine.
Oil pressure

Lowering of
• Drop in pressure 5 minutes after MPa
wheel brake
specified oil pressure (4.9 MPa {50 {kg/cm 2} Max. 0.49 {5} Max. 0.49 {5}
operating
kg/cm2}) is applied
pressure
Retarder brake • Actuating pressure in the 1st
operation operation after charging the 4.22 ± 0.42 4.22 ± 0.42
pressure (front, accumulator and stopping the {43.0 ± 4.3} {43.0 ± 4.3}
rear) engine.
Parking brake
operating 3.92 ± 0.39 3.92 ± 0.39
• Parking brake switch: ON
(releasing) {40 ± 4.0} {40 ± 4.0}
pressure
Braking • The machine must not move when Must not move Must not move
performance of the engine speed is gradually at 1,100 at 1,100
service brake increased at gear shift lever D rpm
Braking (indicated as "F2" in shift indicator)
Must not move Must not move
performance of until the torque converter stalls while
at 1,090 at 1,090
retarder brake the brake is applied.
Wheel brake

• Level and dry road

Service brake • Dump body loaded with 40.0 ton
Braking distance m Max. 16.7 Max. 22.3
cargo
of service brake • Travel speed: 32 km/h
Must be within Must be within
• Brake pedal: stroke end the range the range
Wear of disc • Measure with disc wear measuring — indicated on the indicated on the
gauge disc wear disc wear
gauge gauge

20-8 HM400-3M0
 20 Standard value tables
Standard value table for machine

Machine model HM400-3M0

Standard value
Item Measurement condition Unit for new Repair limit
machine
• The machine must not move when
the engine speed is gradually
Braking increased at gear shift lever D rpm Must not move Must not move
Parking brake

performance (indicated as "F2" in shift indicator) at 1,100 at 1,100

until the torque converter stalls while
the brake is applied.
• Dump body loaded with 40.0 ton
Braking slope
cargo % Min. 25 Min. 25
angle
• Slope angle (sin θ)
Amount of wear
• Limit thickness of pad mm — 1.5
of pad
• 9(+1/0)% downhill slope
Service brake Braking • Dump body loaded with 40.0 ton
distance of service m Max. 59.0 Max. 59.0
cargo
brake • Travel speed: 25 ± 2 km/h
*2: Accumulator gas pressure gradually decreases while using, the gas is to be adjusted into the standard
range at testing every 2,000 hour. (even if it is not within the standard value, it is not faulty or defective.)
For the gas pressure and temperature, see of "Testing of accumulator nitrogen gas pressure and charging
procedure for accumulator nitrogen gas".

HM400-3M0 20-9
20 Standard value tables
Standard value table for machine

Steering
Machine model HM400-3M0
Standard value
Item Measurement condition Unit for new Repair limit
machine
Operating effort • Engine: At low idle N {kg} Max. 29.4 {3.0} Max. 35.3 {3.6}
Play • Dump body: Unloaded mm 20 to 50 20 to 50
Steering wheel

speed • Gear shift lever: N (stopped) position

Turns 4.1 ± 0.5 4.1 ± 0.5
• At circumference of steering wheel
• Operating speed: When operated at
10 rpm speed
Turning time • Play: Until the tires start to move sec. Max. 7 Max. 7
• No. of turns: From lock to lock
• Turning time: From lock to lock
• Hydraulic oil temperature: 45 to 55°C MPa 20.59 ± 0.98 20.59 ± 0.98
Steering relief
• Engine: At high idle
pressure {kg/cm 2} {210 ± 10} {210 ± 10}
• At maximum swash plate angle
Suspension cylinder
Machine model HM400-3M0
Standard value
Item Measurement condition Unit for new Repair limit
machine
Installed length (a) of
mm 176 ± 10 176 ± 10
front cylinder
• On horizontal road
Front cylinder MPa 3.59 ± 0.15 3.59 ± 0.15
• Engine: Stopped
pressure • Dump body: Unloaded {kg/cm2} {36.6 ± 1.5} {36.6 ± 1.5}
Installed length (b) of • For installation lengths (a) and (b),
mm 106 ± 5 106 ± 5
rear cylinder see the illustration at the end of this
Rear cylinder section. MPa 1.9 ± 0.15 1.9 ± 0.15
pressure {kg/cm2} {19.4 ± 1.5} {19.4 ± 1.5}
Dump
Machine model HM400-3M0
Standard value
Item Measurement condition Unit for new Repair limit
machine
HOLD o RAISE Max. 29.4 {3.0} Max. 35.3 {3.6}
RAISE o HOLD Must return smoothly
Dump lever operating • Engine: Stopped HOLD o FLOAT Max. 29.4 {3.0} Max. 35.3 {3.6}
N {kg}
effort • At center of grip FLOAT o HOLD Max. 29.4 {3.0} Max. 35.3 {3.6}
FLOAT o LOWER Max. 29.4 {3.0} Max. 35.3 {3.6}
LOWER o FLOAT Must return smoothly
Dump body raise time • Hydraulic oil temperature: 70 to 90°C 12.0 ± 1.5 12.0 ± 1.5
• At high idle sec.
Dump body lower • Measure lower time with operating 9.0 ± 1.5 9.0 ± 1.5
time FLOAT
• Hydraulic oil temperature: 70 to 90°C
• Retraction amount of hoist cylinder 5
Hydraulic drift of mm/
minutes after setting dump body Max. 85 Max. 170
dump body 5 min.
angle 50 deg. (hoist cylinder stroke:
1,750 mm) and stopping the engine.
• Hydraulic oil temperature: 45 to 55°C
Main relief pressure • Engine: At high idle (Engine speed: 28.4 ± 0.49 28.4 ± 0.49
(RAISE) 1,800 rpm) {290 ± 5} {290 ± 5}
MPa
• Hoist cylinder: Stroke end
{kg/cm2}
• Hydraulic oil temperature: 45 to 55°C 3.8 ± 0.49 3.8 ± 0.49
Pilot relief pressure • Engine: At high idle (Engine speed:
2,000 rpm) {39.0 ± 5} {39.0 ± 5}

20-10 HM400-3M0
 20 Standard value tables
Standard value table for machine

Hydraulic fan
Machine model HM400-3M0
Standard value
Item Measurement condition Unit for new Repair limit
machine
• Hydraulic oil Fan mode: MAX 1,230(+100/-50) 1,230(+100/-50)
Radiator fan speed temperature: 45 to Fan mode:
rpm 1,503(+100/-50) 1,503(+100/-50)
55°C Brake
Aftercooler (CAC) fan • Engine speed:
2,000 rpm Fan mode: MAX 2,108 ± 250 2,108 ± 250
speed

a Installed length of suspension cylinder

HM400-3M0 20-11
20 Standard value tables
Standard value table for machine

20-12 HM400-3M0
SHOP MANUAL

ARTICULATED DUMP TRUCK

HM400-3M0
Model Serial Number

HM400-3M0 5001 and up

30 Testing and adjusting

5 30 Testing and adjusting

HM400-3M0 30-1
30 Testing and adjusting
Table of contents

Table of contents (ALL-0310-002-A-00-A)

30 Testing and adjusting .................................................................................................................... 30-1
Table of contents ........................................................................................................................ 30-2
Related information on testing and adjusting ................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-8
Engine and cooling system .......................................................................................................... 30-9
Testing engine speed ........................................................................................................... 30-9
Testing boost pressure ....................................................................................................... 30-10
Testing exhaust gas temperature ......................................................................................... 30-12
Testing exhaust gas color ................................................................................................... 30-14
Adjusting valve clearance ................................................................................................... 30-16
Testing compression pressure............................................................................................. 30-18
Testing blowby pressure ..................................................................................................... 30-20
Testing engine oil pressure ................................................................................................. 30-21
Testing drive pressure of EGR valve and bypass valve .......................................................... 30-23
Testing fuel pressure .......................................................................................................... 30-24
Handling cylinder cutout mode operation.............................................................................. 30-25
Handling no‐injection cranking operation.............................................................................. 30-26
Testing fuel return rate and leakage ..................................................................................... 30-27
Bleeding air from fuel system .............................................................................................. 30-29
Testing fuel circuit for leakage ............................................................................................. 30-31
Testing radiator fan and aftercooler fan speed....................................................................... 30-32
Testing and adjusting alternator belt tension ......................................................................... 30-33
Testing and adjusting air conditioner compressor belt tension ................................................ 30-34
Power train............................................................................................................................... 30-35
Testing torque converter stall speed..................................................................................... 30-35
Testing power train oil pressure ........................................................................................... 30-37
Adjusting transmission speed sensor ................................................................................... 30-48
Adjusting transmission controller ......................................................................................... 30-51
Retrieval of disabled machine that resulted from a trouble in electrical system ......................... 30-52
Retrieval of disabled machine due to traction control system (KTCS) failure ............................ 30-56
Steering system........................................................................................................................ 30-58
Testing and adjusting steering circuit oil pressure.................................................................. 30-58
Brake system ........................................................................................................................... 30-60
Testing and adjusting brake oil pressure............................................................................... 30-60
Testing accumulator nitrogen gas pressure and charging procedure for accumulator nitrogen
gas ...................................................................................................................... 30-64
Testing braking performance ............................................................................................... 30-68
Bleeding air from brake circuit ............................................................................................. 30-69
Testing wear of wheel brake disc ......................................................................................... 30-70
Parking brake emergency releasing procedure ..................................................................... 30-71
Testing wear of parking brake pad and adjusting clearance.................................................... 30-72
Hydraulic system ...................................................................................................................... 30-74
Testing and adjusting suspension cylinder............................................................................ 30-74
Testing and adjusting dump circuit oil pressure ..................................................................... 30-79
Work equipment ....................................................................................................................... 30-82
Adjusting dump body positioner sensor ................................................................................ 30-82
Cab and its attachments ............................................................................................................ 30-83
Cab tilt up procedure .......................................................................................................... 30-83
Electrical system ...................................................................................................................... 30-87
Setting and adjusting each equipment.................................................................................. 30-87
Special functions of machine monitor ................................................................................... 30-98
KOMTRAX terminal start-up procedure .............................................................................. 30-169
Handling voltage circuit of engine controller........................................................................ 30-173
Handling battery disconnect switch .................................................................................... 30-174
Pm clinic ................................................................................................................................ 30-175
Pm Clinic service ............................................................................................................. 30-175

30-2 HM400-3M0
 30 Testing and adjusting
Related information on testing and adjusting

Related information on testing and adjusting (ALL-3831-001-A-00-A)

Tools for testing and adjusting (HM400_3M0-5320-304-A-00-A)

Testing/Adjusting Symbol Q'ty

Part No. Part name Remarks
item
Testing boost -101 to 200 kPa
pressure A 799-201-2202 Boost gauge kit 1
{-760 to 1,500 mmHg}
Testing exhaust
gas temperature B 799-101-1502 Digital thermometer 1 -99.9 to 1,299°C
1 799-201-9002 Handy smoke checker 1
Testing exhaust
gas color C Commercially Bosch index: 0 to 9
2 Smoke meter 1
available
Adjusting valve Commercially Feeler gauge
D 1
clearance available
1 795-502-1590 Compression gauge 1 0 to 7 MPa {0 to 70 kg/cm2}
Testing 795-471-1330 Adapter 1
compression 2
E 6261-71-6150 Gasket 1
pressure Commercially Inner diameter: 14 mm,
3 Hose 1 length: approx. 2 m
available
Testing blowby
pressure F 799-201-1504 Blowby checker 1 0 to 5 kPa {0 to 500 mmH2O}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
1
799-301-1190 • Adapter 1 R1/4 o Rc1/8
Testing engine oil 799-101-5160 • Nipple 1 R1/8
pressure G
799-101-5150 • Hose 1
Pressure gauge:
2 790-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm2}
Pressure gauge:
3 799-401-2320 Gauge 1
1.0 MPa {10 kg/cm2}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge:
Testing fuel 790-261-1204 Digital hydraulic tester 1
pressure H 60 MPa {600 kg/cm2}
795-790-5120 Screw 1
2
07005-01412 Gasket 1
Pressure gauge:
3 799-401-2320 Gauge 1
1.0 MPa {10 kg/cm2}
Pressure gauge:
Testing drive 799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
pressure of EGR {25, 60, 400, 600 kg/cm2}
T
valve and dypass Pressure gauge:
valve 790-261-1204 Digital hydraulic tester 1 60 MPa {600 kg/cm2}

HM400-3M0 30-3
30 Testing and adjusting
Related information on testing and adjusting

Testing/Adjusting Symbol Q'ty

Part No. Part name Remarks
item
1 6151-51-8490 Spacer 1
2 6206-71-1770 Joint 1
Commercially Inside diameter approx. 6.5
3 Hose 1
available mm
Testing fuel return Commercially Inside diameter approx. 17.5
rate and leakage J 4 Hose 1
available mm
Commercially Measuring cylinder
5 1
available
Commercially Stopwatch
6 1
available
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm2}
Pressure gauge:
799-401-2320 Hydraulic gauge 1
Testing power train 1 MPa {10 kg/cm2}
oil pressure K 799-101-5220 Nipple 1
M10 x P1.25
07002-11023 O-ring 1
799-101-5260 Nipple 1
M12 x P1.5
07002-11223 O-ring 1
799-101-5230 Nipple 1
M14 x P1.5
07002-11423 O-ring 1
Pressure gauge: 1.0 MPa {10
799-401-2320 Gauge 1 kg/cm2}
Pressure gauge:
Testing and 799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
adjusting steering M {25, 60, 400, 600 kg/cm2}
circuit oil pressure Pressure gauge:
790-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm2}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
Testing and 1 {25, 60, 400, 600 kg/cm2}
adjusting brake oil L Pressure gauge:
pressure 709-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm2}
2 793-520-1805 Brake test kit 1
3 799-401-3200 Adapter assembly 1 #3
1 792-610-1702 Gas charge tool 1
Testing 792-610-1310 Nipple (for Russia) 1 GOST
accumulator 792-610-1320 Nipple (for US) 1 CGA No. 351
nitrogen gas 792-610-1330 Nipple (for US) 1 ASA B-571-1965
pressure and P DIN 477-1963
charging procedure 2
792-610-1350 Nipple (for Germany) 1 NEN 3268-1966
for accumulator
nitrogen gas SIS-SMS2235/2238
BS 341Part1-1962
792-610-1360 Nipple (for UK) 1

30-4 HM400-3M0
 30 Testing and adjusting
Related information on testing and adjusting

Testing/Adjusting Symbol Q'ty

Part No. Part name Remarks
item
Suspension tool
— 792-610-1000 assembly 1
— 792-610-1100 Pump assembly 1
1 792-610-1130 • Pump 1
2 792-610-1110 • Hose 1 • N1 to N3 are components
3 792-610-2200 • Joint of 792-610-1100
1
• N4 to N10 are
Testing and — 792-610-1200 Charging tool assembly 1 components of 792-610-
adjusting 4 07020-21732 • Fitting 1 1200
suspension N
5 792-610-1140 • Joint 1 • 792-610-1100 and 792-
cylinder 6 792-610-1250 • Valve assembly 1 610-1200 are components
7 792-610-1260 • Nipple 1 of 792-610-1000
• 792-610-1000 includes
8 792-610-1270 • Hose 1
storage case 792-610-
9 792-610-1280 • Valve 1 1290
10 792-610-1400 • Regulator 1
11 792-610-1430 Gauge 1
12 792-610-1440 Gauge 1
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
Testing and
1 {25, 60, 400, 600 kg/cm2}
adjusting dump S
circuit oil pressure Pressure gauge:
790-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm2}
2 790-301-1720 Adapter 1 M20 x P1.5
Testing coolant
temperature and oil — 799-101-1502 Digital thermometer 1 -99.9 to 1,299°C
temperature
799-601-4101
or T-adapter assembly 1
799-601-4201
799-601-4330 • Socket 1 For Bkup sensor
799-601-4130 • T-adapter 1 For Ne sensor
• T-adapter For common rail pressure
799-601-9420 1
sensor
799-601-4240 • Socket 1 For ambient pressure sensor
799-601-4250 • Socket 1 For boost pressure sensor
799-601-4150 • T-adapter 1 For oil pressure sensor
795-799-5540 • Socket 1 For boost temperature sensor
Troubleshooting of For coolant temperature
controller sensors 795-799-5530 • Socket 1 sensor and fuel temperature
—
and actuators sensor
related to engine 799-601-4260 • T-adapter 1 For controller (4 poles)
For controller (50 poles)
799-601-4211 • T-adapter 1
(only 799-601-4101)
For controller (60 poles)
799-601-4220 • T-adapter 1
(only 799-601-4101)
For 60 poles
799-601-4350 • T-adapter 1
(only 799-601-4101)
799-601-9020 • T-adapter 1 For injector
799-601-9430 • Socket 1 For supply pump
799-601-9030 • T-adapter 1
799-601-9120 • T-adapter 1

HM400-3M0 30-5
30 Testing and adjusting
Related information on testing and adjusting

Testing/Adjusting Symbol Q'ty

Part No. Part name Remarks
item
799-601-9000
or T-adapter assembly 1
799-601-9100
799-601-9320 • T-box (for ECONO) 1 For HD and DT
799-601-9250 • Adapter for HD 1 For 9P
799-601-7000
or
799-601-7100
or T-adapter assembly 1
799-601-7400
or
799-601-8000
799-601-7040 • Adapter for X 1 For X4P
For SW6P (not including 799-
799-601-7050 • Adapter for SWP 1 601-8000)
799-601-7090 • Adapter for M 1 For M2P
799-601-7130 • Adapter for M 1 For M6P
799-601-7140 • Adapter for S 1 For S8P
799-601-7320 • Adapter for SWP 1 For SW16P
799-601-7360 T-adapter for relay 1 For REL-5P
799-601-7370 T-adapter for relay 1 For REL-6P
799-601-7500 T-adapter assembly 1
799-601-7510 • Adapter for 070 1 For 070-8P
Troubleshooting of
— 799-601-7520 • Adapter for 070 1 For 070-12P
machine wiring
harness 799-601-7540 • Adapter for 070 1 For 070-18P
799-601-9000
or T-adapter assembly 1
799-601-9200
799-601-9020 • Adapter for DT 1 For DT2P
799-601-9030 • Adapter for DT 1 For DT3P
799-601-9040 • Adapter for DT 1 For DT4P
799-601-9050 • Adapter for DT 1 For DT6P
• Adapter for DT
799-601-9060 (Gray) 1 For DT8PGR
• Adapter for DT
799-601-9070 (Black) 1 For DT8PB
• Adapter for DT
799-601-9080 (Green) 1 For DT8PG
• Adapter for DT
799-601-9110 (Gray) 1 For DT12PGR
• Adapter for DT
799-601-9120 (Black) 1 For DT12PB
• Adapter for DT
799-601-9130 (Green) 1 For DT12PG
• Adapter for DT
799-601-9140 (Brown) 1 For DT12P
799-601-9300 T-adapter assembly 1
799-601-9350 • Adapter for DRC 1 For DRC-40
799-601-9360 • Adapter for DRC 1 For DRC-24
Testing operating — 79A-264-0021 Push-pull scale 1 0 to 294 N {0 to 30 kg}
effort and
depressing effort — 79A-264-0091 Push-pull scale 1 0 to 490 N {0 to 50 kg}
Testing stroke and Commercially
— Ruler 1
hydraulic drift available

30-6 HM400-3M0
 30 Testing and adjusting
Related information on testing and adjusting

Testing/Adjusting Symbol Q'ty

Part No. Part name Remarks
item
Testing work Commercially
— Stopwatch 1
equipment speed available
Testing voltage and — Commercially
Multimeter 1
resistance available
Removal and
installation of
Commercially 3.26 mm TORX wrench (KTC
charge (boost) — Torx wrench 1
available Q4T15 or equivalent)
pressure and
temperature sensor
Removal and
installation of — 27 mm deep socket
795-799-6210 Socket 1
engine oil pressure
switch
Removal and
19 mm deep socket
installation of
— 795T-981-1010 Socket 1 (MITOLOY 4ML-19 or
engine coolant
equivalent)
temperature sensor

HM400-3M0 30-7
30 Testing and adjusting
Related information on testing and adjusting

Sketch of tools for testing and adjusting (HM400_3R-3531-061-A-00-A)

-: Socket

30-8 HM400-3M0
 30 Testing and adjusting
Engine and cooling system

Engine and cooling system (ALL-R401-001-K-00-A)

Testing engine speed (HM300-A000-001-K-02-A)

k Place the machine on a level ground, set the
parking brake switch to P (parking), and
chock the wheels.
a Check the engine speed on "Monitoring/Pre-
defined" or "Monitoring" screen of the machine
monitor.
a Check the engine speed under the following
conditions.
• Coolant temperature: 60 to 100°C
• Transmission oil temperature: 70 to 90°C
• Hydraulic oil temperature: 45 to 55°C
• Torque converter oil temperature: 60 to 80°C
Testing engine speeds at torque converter
lockup actuation and cancel
Testing engine speed at transmission upshift
and downshift
Testing engine speed at transmission downshift
inhibit
Testing engine speeds at overrun prevention
actuation and cancel
Start the engine and measure the engine speed for
each condition while traveling and following the
automatic gear shift chart (see Structure and
function).

Testing (HM400-A000-388-K-00-A) a The engine speed is normal if it is within the

standard value range. For the standard values,
Preparation see "Standard value table", "Standard value for
Set the machine monitor to monitor the engine engine" and "Standard value table for machine".
speed.
a For the machine monitor operating method, see
the section of "Special functions of machine
monitor".
• Monitoring code: 01002 "Engine speed"

Testing low idle speed

Start the engine and measure the engine speed
with the dump body seated, control levers in
NEUTRAL, output mode in "Power" or "Economy"
mode, and the accelerator pedal in the low idle
position.

Testing high idle speed

Start the engine and measure the engine speed
with the dump body seated, control levers in
NEUTRAL, output mode in "Power" or "Economy"
mode, and the accelerator pedal in the full throttle
position.

Testing torque converter stall speed

a See "Testing torque converter stall speed".

HM400-3M0 30-9
30 Testing and adjusting
Engine and cooling system

Testing boost pressure (HM300-A900-001-K-00-A)

a Testing tools
Sym-
Part No. Part name
bol
A 799-201-2202 Boost gauge kit

k Place the machine on a level ground, set the

parking brake switch to P (parking), and
chock the wheels.

k Be careful not to touch any hot part when

installing or removing the testing tools.

a Boost pressure can be checked on "Monitoring/

Pre-defined" or "Monitoring" screen of the 3. Install the nipple and hose [1] of the boost gauge
machine monitor. kit and connect gauge [2] to the hose.

a Test the boost pressure under the following

conditions.
• Coolant temperature: 60 to 100°C
• Hydraulic oil temperature: 45 to 55°C
Testing (HM400_3R-A900-362-K-00-A)
Testing with machine monitor
Select power mode "1" (Power) on "Engine Mode
Fixing" screen of special functions of the machine
monitor and test the boost pressure when the
torque converter is stalled.
a For the operation method of the machine monitor,
see "Testing torque converter stall speed".
a The boost pressure is normal when it is within
the standard value range. For standard values,
see "Standard value table", "Standard value for
engine".
Testing by use of testing tools
1. Open the engine hood.
2. Remove boost pressure pickup plug (1).
3 Nipple:
2.0 to 3.9 Nm {0.2 to 0.4 kgm}
4. Run the engine at medium speed or above and
drain oil in the hose.
a Repeat opening the self-sealing portion on
the hose by inserting approximately half of
the connection part of the gauge into the
hose to drain oil.
a When Pm kit (799-401-2301) is available,
you can use air bleeding coupling (790-261-
1130) in the kit.
a Air bleeding is indispensable since the gauge
becomes immovable if oil is in the hose.
5. After confirming that F2 (gear speed at start) is
selected in "F1 Start at D Position Setting" menu
of special functions of the machine monitor, set
the parking brake switch to P position, then set
the shift lever to D position while depressing the
brake pedal. (The shift indicator changes to F2
when the shift lever is moved to the D position)

30-10 HM400-3M0
 30 Testing and adjusting
Engine and cooling system

k If the gear speed at start is set to any

position other than F2, machine may start
even if the brake pedal is depressed. So
you must confirm that "F2" (gear speed at
start) is selected in "F1 Start at D Position
Setting" menu of special functions of the
machine monitor before moving the shift
lever to D position for testing.
6. Depress the accelerator pedal gradually, then
measure the boost pressure when the torque
converter stalls with the engine at high idle.

k Do not set the shift lever to any position

other than D. Otherwise internal damage
may be induced in the transmission.
a After the checking is completed, set the
engine speed to low idle and return the shift
lever to "N" position.
a The boost pressure is normal when it is
within the standard value range. For
standard values, see "Standard value table",
"Standard value for engine".

7. After finishing the test, remove the testing tools,

and restore the machine.
3 Pickup port plug (1):
2.0 to 3.9 Nm {0.2 to 0.4 kgm}

HM400-3M0 30-11
30 Testing and adjusting
Engine and cooling system
Testing exhaust gas temperature
a Testing tools
Sym-
Part No. Part name
bol
B 799-101-1502 Digital thermometer
k Place the machine on a level ground, set the
parking brake switch to P (parking), and
chock the wheels.
k Installand remove the testing tool after the
exhaust manifold temperature lowers.
a Measure the exhaust temperature according to
the following procedure.
• Coolant temperature: 60 to 100°C
• Hydraulic oil temperature: 45 to 55°C
Testing (HM400_3R-A900-386-K-00-A)
1. Open the engine hood and remove exhaust
temperature pickup plug (1).
2. Install sensor [1] of digital thermometer B and
connect it to meter [2].
a Clamp the wiring harness of the digital
thermometer so that it does not touch a hot
part.
3 Sensor [1]:
2.9 to 5.9 Nm {0.3 to 0.6 kgm}
3. Start the engine and increase the coolant
temperature to 60 to 100°C and the hydraulic oil
temperature to 45 to 55°C.
30-12
(HM300-A900-001-K-01-A)
4. Procedure for measuring maximum value in
troubleshooting
Measure the maximum exhaust gas temperature
when the actual operations are performed.
a Use the digital temperature gauge in the
PEAK mode.
5. Procedure for measuring exhaust gas
temperature periodically in preventive
maintenance services (Pm clinic)
Run the engine at high idle and measure the
exhaust gas temperature when the torque
converter stalls.
6. Perform the following procedure when
measuring the exhaust gas temperature by
stalling the torque converter.
a In order to prevent overheating of the torque
converter, stabilize exhaust gas temperature
with full stall (torque converter stall +
hydraulic relief) once. Then stall the torque
converter only for the measurement.
1) Start the engine, and increase the coolant
temperature to 60 to 100°C.
2) After confirming that F2 (gear speed at start)
is selected in F1 Start at D Position Setting,
set the parking brake switch to P position,
then set the shift lever to D position while
depressing the brake pedal. (The shift
indicator changes to F2 when the shift lever
is moved to the D position)
k If the gear speed at start is set to any
position other than F2, machine may
start even if the brake pedal is
depressed. So you must confirm that
"F2" (gear speed at start) is selected in
"F1 Start at D Position Setting" menu
of special functions of the machine
monitor before moving the shift lever
to D position for testing.
3) Depress the accelerator pedal gradually to
stall the torque converter at high idle of the
engine and at the same time, induce
hydraulic relief (full stall) by operating the
dump lever to LOWER position.
a Continue to the stall until the exhaust gas
temperature stabilizes.
k Do not set the shift lever to any
position other than D. Otherwise
internal damage may be induced in the
transmission.
4) After the exhaust gas temperature is
stabilized, check the exhaust gas
HM400-3M0
 30 Testing and adjusting
Engine and cooling system

temperature when the torque converter alone

is stalled.
a Since the exhaust gas temperature starts
to drop after the full stall condition is
induced, record the temperature when it
stabilizes.
a If the exhaust gas temperature does not
drop but rises, set the temperature at full
stall higher.
a After the checking is completed, set the
engine speed to low idle and return the
shift lever to "N" position.
a The exhaust temperature is normal when
it is within the standard value range. For
standard values, see "Standard value
table", "Standard value for engine".
7. After finishing the test, remove the testing tools,
and restore the machine.
a Clean the threaded part of the removed plug,
apply seizure prevention compound to the
plug and install it again.
3 Plug:
2.9 to 5.9 Nm {0.3 to 0.6 kgm}
2 Plug:
Seizure prevention compound (LC-G)

HM400-3M0 30-13
30 Testing and adjusting
Engine and cooling system

Testing exhaust gas color (HM400_3R-A900-360-K-00-A)

a Testing tools Testing with smoke meter C2

Sym- 1. Connect the probe hose, accelerator switch
Part No. Part name outlet and air hose to smoke meter C2.
bol
1 799-201-9002 Handy smoke checker a The supplied air pressure must be 1.5 MPa
C Commercially {15 kg/cm2} or below.
2 Smoke meter
available 2. Connect the power cable to an AC 100 V
k Place the machine on a level ground, set the receptacle.
parking brake switch to P (parking), and a Before connecting the power cable, make
chock the wheels. sure that the power switch of the smoke
meter is turned OFF.
k Be careful not to touch any hot part when 3. Insert probe [1] of smoke meter C2 into exhaust
installing or removing the testing tools. pipe (1).
a Measure the exhaust gas color under the a Set the probe end so that it is in parallel with
following conditions. the direction of the pipe at its center.
• Sample the exhaust gas after maintaining
the steady condition for 5 seconds.
• Coolant temperature: 60 to 100°C
a If an air source and a electric power source are
not available in the field, use handy smoke
checker C1. When recording official data, etc.,
use smoke meter C2.
Testing (HM400_3R-A900-385-K-00-A)
Checking with handy smoke checker C1
1. Fit a sheet of filter paper to handy smoke
checker C1.
2. Insert the exhaust gas intake pipe into exhaust
4. Loosen the cap nut of the suction pump and
pipe (1).
place the filter paper.
a Set the probe end so that it is in parallel with
a Fit the filter paper securely so that the
the direction of the pipe at its center.
exhaust gas does not leak.
3. Start the engine, and increase the coolant
5. Turn the power switch of smoke meter C2 ON.
temperature to 60 to 100°C.
4. Accelerate the engine suddenly or run it at high
idle and operate the handle of smoke checker
C1 to collect exhaust gas on the filter paper.
a Collecting time: 1.4 ± 0.2 second

6. Accelerate the engine rapidly or run it at high

idle and depress the accelerator pedal of the
smoke meter C2 to collect exhaust gas on the
filter paper.
7. Place the contaminated filter paper on the clean
5. Remove the filter paper and compare it with the filter paper (at least 10 sheets) in the filter paper
attached scale for judgment. holder and read the indicated value.
6. After finishing the test, remove the testing tools,
and restore the machine.

30-14 HM400-3M0
 30 Testing and adjusting
Engine and cooling system

a The exhaust gas color is normal when it is

within the standard value range. For
standard values, see "Standard value table",
"Standard value for engine".
8. After finishing the test, remove the testing tools,
and restore the machine.

HM400-3M0 30-15
30 Testing and adjusting
Engine and cooling system

Adjusting valve clearance (HM400-A700-001-K-00-A)

a Adjusting tools
Sym-
Part No. Part name
bol
Commercially Feeler gauge
D
available

k Place the machine on a level ground, set the

parking brake switch to P (parking), and
chock the wheels.

k Turn the battery disconnect switch to OFF

position, and remove the key.

a Adjust the valve clearance under the following
conditions.
• When engine is cold
Adjusting (HM400_3R-A700-27D-K-00-A)
1. Open the engine hood.
2. Remove all cylinder head covers (1). For details,
see "Disassembly and assembly".
3. Rotate the crankshaft in the normal direction to
set No. 1 cylinder to the compression top dead
center by matching "1.6 TOP" stamping mark (a)
of the damper to pointer (2).
a Crank the crankshaft at hexagonal part of
water pump drive shaft tip.
a At the compression top dead center, the
rocker arm of No. 1 cylinder can be moved
by hand by the distance equivalent to the
valve clearance. If the rocker arm cannot be
moved, the No. 1 cylinder is not at its
compression top dead center. In that case,
rotate the crankshaft one more turn.
4. With adjustment screw (3) fixed, loosen lock nut
(4).
a After setting the No. 1 cylinder at the
compression top dead center, adjust valve
clearance of No. 1 cylinder.
5. Insert feeler gauge D into the clearance between
rocker arm (5) and crosshead (6), and adjust the
valve clearance with adjustment screw (3).
a With the feeler gauge inserted, turn the
adjustment screw until the feeler gauge can
move lightly.
a The valve clearance is normal when it is
within the standard value range. For
standard values, see "Standard value table",
"Standard value for engine".
6. While fixing adjustment screw (3), tighten lock
nut (4).
3 Lock nut:
45.1 to 51.0 Nm {4.6 to 5.2 kgm}
a After tightening the lock nut, check the valve
clearance again.

7. After finishing the adjustment of No. 1 cylinder,

rotate the crankshaft forward by 120 deg. at one
time to align "TOP" stamp line of each cylinder
number to pointer (2), and adjust the valve
clearance of each cylinder in the firing order.
• Firing order: 1 — 5 — 3 — 6 — 2 — 4

30-16 HM400-3M0
 30 Testing and adjusting
Engine and cooling system

8. After finishing the adjustment, restore the

machine.
3 Cylinder head cover (1) mounting
bolt:
29.4 to 34.3 Nm {3.0 to 3.5 kgm}

HM400-3M0 30-17
30 Testing and adjusting
Engine and cooling system

Testing compression pressure (HM400_3R-A000-360-K-00-A)

a Testing tools a Disconnect the terminal of the injector

Sym- harness on the injector side and the bracket
Part No. Part name on the rocker housing side, and then remove
bol
1 795-502-1590 Compression gauge the injector harness from the injector (loosen
795-471-1330 Adapter the 2 terminal nuts alternately).
2
E 6217-71-6150 Gasket a Lift up the injector by pulling a wire passed
Hose (inside diameter 14 under the fuel passage that is protruding
Commercially mm, length approximately
3 sideways. (Do not pry open the injector top.)
available 2 m)

k Place the machine on a level ground, set the

parking brake switch to P (parking), and
chock the wheels.

k Turn the battery disconnect switch to OFF

position, and remove the key.

k When measuring the compression pressure,

take care not to get yourself burned by
touching the exhaust manifold or exhaust
pipe, or not to get caught in a rotating part.

a Measure the compression pressure while the
engine is warmed up.
• Engine oil temperature: 40 to 60°C
• Engine speed: 200 to 250 rpm
Testing (HM400_3R-A000-36B-K-00-A)
1. Open the engine hood.
2. Remove head cover (1) of the cylinder to be
measured for the compression pressure. For
details, see "Disassembly and assembly".
5. Install adapter E2 to the injector mounting hole
and connect compression gauge E1.
a Be sure to fit the gasket to the end of the
adapter.
a Fix the adapter with the injector holder.
3 Holder mounting bolt:
58.8 to 73.5 Nm {6 to 7.5 kgm}
a Apply a small amount of engine oil to the
connecting portion of the adapter and gauge
to prevent air leakage.
6. Install rocker arm assembly (2) and adjust the
valve clearance.
3 Rocker arm assembly mounting bolt:
93 to 103 Nm {9.5 to 10.5 kgm}
a See "Adjusting valve clearance".

3. Set the cylinder to be tested to the compression

top dead center and remove rocker arm
assembly (2).
a For the procedure of setting each cylinder to
the compression top dead center, see
"Adjusting valve clearance."
4. Disconnect fuel high-pressure tube (3) and
injector harness, then remove injector (4) and
wiring harness. 7. Select the "No Injection cranking" by operating
the machine monitor.

30-18 HM400-3M0
 30 Testing and adjusting
Engine and cooling system

a Turn the battery disconnect switch to ON 3 Sleeve nut:

position, then turn the starting switch to ON 39.2 to 44.1 Nm {4 to 4.5 kgm}
position.
a For "No Injection cranking" setup procedure,
see the section of "Special functions of
machine monitor".

k If the engine is not set to the "No Injection

cranking", it may start during
measurement and cause personal injury.
Accordingly, be sure to set the engine in
this mode.

a Install the injector harness according to the

following procedure.
1) Install the injector harness to the rocker arm
housing and fix the connector side with the
plate.
2) Fix the intermediate clamp with the clip.
3) Tighten the nut on the injector side.
3 Nut:
2 ± 0.2 Nm {0.2 ± 0.02 kgm}
8. Rotate the crankshaft by the starting motor and 4) Fasten the clamp and spacer with the bolt.
measure the compression pressure.
3 Rocker arm assembly mounting
a Read the compression pressure when the bolt:
gauge pointer stands still.
93 to 103 Nm {9.5 to 10.5 kgm}
a When measuring the compression pressure,
also check the engine speed and confirm a Adjust the valve clearance. For details of
that it is within a range of test condition. the procedure, see "Adjusting valve
clearance".
a The compression pressure is normal when it 5) Install cylinder head cover (1).
is within the standard value range. For
standard values, see "Standard value table", 3 Cylinder head cover (1) mounting
"Standard value for engine". bolt:
9. After finishing the test, remove the testing tools 29.4 to 34.3 Nm {3.0 to 3.5 kgm}
and restore the machine.
a Install the injector and fuel high-pressure
tube according to the following procedure.
a Before installing the injector, replace the
copper gasket and O-ring with new ones.
1) Push in injector (11) with the hand to
assemble holder (12) temporarily.
2) Tighten bolt (13) and washer (14) lightly.
2 Spherical surface of washer:
Engine oil
3) Tighten sleeve nut (15) of the fuel high-
pressure tube lightly.
4) Tighten bolt (13) to the specified torque.
3 Bolt:
59.0 to 74.0 Nm {6.0 to 7.5 kgm}
5) Tighten sleeve nut (15) to the specified
torque.

HM400-3M0 30-19
30 Testing and adjusting
Engine and cooling system

Testing blowby pressure (HM400_3R-A000-360-K-01-A)

a Testing tools a Read the blowby gas pressure when the

Sym- value on monitor stands still.
Part No. Part name
bol a The blowby pressure is normal when it is
F 799-201-1504 Blowby checker within the standard value range. For
standard values, see "Standard value table",
k Place the machine on a level ground, set the
"Standard value for engine".
parking brake switch to P (parking), and
chock the wheels. a After the checking is completed, set the
engine speed to low idle and return the shift
a Test the blowby pressure under the following lever to "N" position.
conditions.
• Coolant temperature: 60 to 100°C
• Hydraulic oil temperature: 45 to 55°C
• With torque converter stalled
Testing (HM400_3R-A000-36C-K-00-A)
Preparation
Install tool and adapter [1] of blowby checker F to
blowby hose (1), connect them to gauge [2], and
prepare for testing.

2. After finishing the test, remove the testing tools,

and restore the machine.

Testing
1. Select power mode "1" (Power) on "Engine
Mode Fixing" screen of special functions of the
machine monitor and check the blowby pressure
when the torque converter is stalled.
a For the operation method of the machine
monitor, see "Testing torque converter
speed".

30-20 HM400-3M0
 30 Testing and adjusting
Engine and cooling system

Testing engine oil pressure (HM400-AB00-001-K-00-A)

a Testing tools menu of special functions of the machine

Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
790-301-1190 • Adapter
1 is moved to the D position)
799-101-5160 • Nipple
G
799-101-5150 • Hose
2 790-261-1204 Digital hydraulic tester
3 799-401-2320 Gauge
k Place the machine on a level ground, set the
parking brake switch to P (parking), and
chock the wheels.
a Measure the engine oil pressure under the
following condition.
• Coolant temperature: Min. 80°C
Testing with machine monitor
AB00-362-K-00-A)
1. Start the engine and increase the coolant
temperature to 80°C or above.
2. Display monitoring code "37200 "Engine Oil
Pressure"" on "Monitoring/Pre-defined" or
"Monitoring" screen of the machine monitor.
a For the operating method, see "Special
functions of machine monitor".
a Monitoring code: 37200 "Engine Oil
Pressure"
monitor, set the parking brake switch to P
position, then set the shift lever to D position
while depressing the brake pedal. (The shift
indicator changes to F2 when the shift lever
k If the gear speed at start is set to any
position other than F2, machine may
start even if the brake pedal is
depressed. So you must confirm that
"F2" (gear speed at start) is selected in
"F1 Start at D Position Setting" menu
of special functions of the machine
monitor before moving the shift lever
to D position for testing.
2) Depress the accelerator pedal gradually,
then measure the engine oil pressure when
(HM400_3R-
the torque converter stalls with the engine at
high idle.
k Do not set the shift lever to any
position other than D. Otherwise
internal damage may be induced in the
transmission.
a After the checking is completed, set the
engine speed to low idle and return the
shift lever to "N" position.
4. After finishing the test, remove the testing tools,
and restore the machine.
Testing by use of testing
tools (HM400_3R-AB00-362-K-01-A)
1. Open the engine hood.
2. Remove oil pressure pickup plug (1) of the
cylinder block.

3. Measure the engine oil pressure while the

engine is running at low idle and while the torque
converter is stalled.
a The engine oil pressure is normal when it is
within the standard value range. For
standard values, see "Standard value table",
"Standard value for engine". 3. Install adapter [1], nipple [2] and hose [3] of
hydraulic tester G1, and connect them to gauge
a Perform the following procedure when
G3.
measuring the engine oil pressure by stalling
the torque converter. a Since plug hole size is R1/4, you many use
1) After confirming that F2 (gear speed at start) nipple (799-101-5201) instead of adapter [1]
is selected in "F1 Start at D Position Setting" and nipple [2].

HM400-3M0 30-21
30 Testing and adjusting
Engine and cooling system

4. Start the engine and increase the coolant 6. After finishing the test, remove the testing tools,
temperature to 80°C or above. and restore the machine.
5. Measure the engine oil pressure while the
engine is running at low idle and while the torque
converter is stalled.
a The engine oil pressure is normal when it is
within the standard value range. For
standard values, see "Standard value table",
"Standard value for engine".
a Perform the following procedure when
measuring the engine oil pressure by stalling
the torque converter.
1) After confirming that F2 (gear speed at start)
is selected in "F1 Start at D Position Setting"
menu of special functions of the machine
monitor, set the parking brake switch to P
(parking) position, then set the shift lever to
position D while depressing the brake pedal.
(The shift indicator changes to F2 when the
shift lever is moved to the D position)

k If the gear speed at start is set to any

position other than F2, machine may
start even if the brake pedal is
depressed. So you must confirm that
"F2" (gear speed at start) is selected in
"F1 Start at D Position Setting" menu
of special functions of the machine
monitor before moving the shift lever
to D position for testing.
2) Depress the accelerator pedal gradually,
then measure the engine oil pressure when
the torque converter stalls with the engine at
high idle.

k Do not set the shift lever to any

position other than D. Otherwise
internal damage may be induced in the
transmission.
a After the checking is completed, set the
engine speed to low idle and return the
shift lever to "N" position.

30-22 HM400-3M0
 30 Testing and adjusting
Engine and cooling system

Testing drive pressure of EGR valve and bypass valve (HM400_3M0-A9K1-360-K-00-A)

a Testing tools brush. Apply adhesive or liquid gasket, and

Sym- install it.
Part No. Part name
bol 2 Plug: LT-2 or LG-4
799-101-5002 Hydraulic tester
T 3 Plug: 9.8 to 19.6 Nm {1.0 to 2.0
790-261-1204 Digital hydraulic tester
kgm}
k Place the machine on a level ground, set the
parking brake switch to P (parking), and
chock the wheels.

a Test drive pressure of EGR valve and bypass

valve under the following condition.
• Coolant temperature: 60 to 100 °C
Testing (HM400_3M0-A9K1-362-K-00-A)

1. Remove oil pressure pickup plug (1) on the left

side of timign gear cover.

2. Install nipple [1] and hose [2] of hydraulic tester

T, and connect them to gauge G3.

3. Start the engine and measure the oil pressure at

low idle and high idle.
a When the EGR valve and bypass valve
driving oil pressure is in the standard range,
it is normal. For standard values, see
"Standard value table", "Standard value for
engine".
4. After finishing the test, remove the testing tools,
and restore the machine.
• Remove liquid gasket remained on the
thread portion of removed plug by using wire

HM400-3M0 30-23
30 Testing and adjusting
Engine and cooling system

Testing fuel pressure (HM400_3R-AE20-360-K-01-A)

a Testing tools
Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
H 795-790-5210 Screw
2
07005-01412 Gasket
3 799-401-2320 Gauge

k Place the machine on a level ground, set the

parking brake switch ON, and chock the
wheels.
4. Start the engine and measure the fuel pressure
k Before testing the fuel system or removing/ at engine high idle.
installing the tools, wait at least 30 seconds
after stopping the engine until the remaining a The fuel pressure is normal when it is within
pressure in the fuel circuit is released. (Do the following standard value range. For
not start the work immediately after stopping standard values, see "Standard value table",
the engine since there is remaining "Standard value for engine".
pressure.)

k Since the pressure in the high-pressure

circuit from the supply pump through the
common rail to the injector is very high and
dangerous, do not measure it.

a Measure the fuel pressure under the following

conditions.
• Coolant temperature: 60 to 100°C
Testing (HM400_3R-AE20-362-K-00-A)

1. Open the engine hood.

2. Remove fuel tube mounting joint (1) on the 5. After finishing the test, remove the testing tools,
upper side of fuel filter, and install screw H2. and restore the machine.

a Be sure to fit the gasket.

3. Install nipple and hose [1] of hydraulic tester J1

to screw and elbow J3, and then connect them
to gauge J4.

30-24 HM400-3M0
 30 Testing and adjusting
Engine and cooling system

Handling cylinder cutout mode operation (HM300-AD00-34F-K-01-A)

a The cylinder cutout mode operation means to

run the engine with the fuel injectors of 1 or more
cylinders disabled electrically to reduce the
number of active cylinders. The purposes and
affects of this operation are as follows.
1. This operation is used to find out a cylinder
which does not output power normally (or,
combustion in it is abnormal).
2. When a cylinder is selected for the cylinder
cutout mode operation, if the engine speed and
output do not change from the normal operation
(all-cylinder operation), that cylinder has a
failure.
The possible failures are as follows.
• Compression gas leakage from cylinder
head gasket area
• Defective injection
• Defective piston, piston ring or cylinder liner
• Defective valve mechanism (valve operating
system)
• Defective electrical system
3. The injector of each cylinder is separately
controlled electronically in the common rail fuel
injection system, so the cylinder cutout test can
be performed easily by the simple operations of
the switches compared with the mechanical fuel
injection system. So, the defective cylinder can
be found out easily.
a When performing the cylinder cutout mode
operation, see "Special functions of machine
monitor".

HM400-3M0 30-25
30 Testing and adjusting
Engine and cooling system

Handling no‐injection cranking operation (HM300-A000-25L-K-00-A)

a No-injection cranking operation means to crank

the engine by using the starting motor while
disabling injection in every cylinder electrically.
The purpose and effect of this operation are as
follows.
When the machine or engine is stored for a long
period, implementing the no-injection cranking
before starting the engine allows to lubricate the
engine parts, and thereby protecting the engine
from seizure.
a When performing the no-injection cranking
operation, see "Special functions of machine
monitor".

30-26 HM400-3M0
 30 Testing and adjusting
Engine and cooling system

Testing fuel return rate and leakage (HM400_3R-AE20-360-K-00-A)

a Testing tools 3 Joint bolt:

Sym- 14.8 to 19.6 Nm {1.5 to 2.0 kgm}
Part No. Part name
bol
1 6151-51-8490 Spacer
2 6206-71-1770 Joint
Commercially
3 Hose
available
J Commercially
4 Hose
available
Commercially Measuring cylinder
5
available
Commercially Stopwatch
6
available

k Place the machine on a level ground, set the

parking brake switch to P (parking), and
chock the wheels.
k Before testing the fuel system or removing/
installing the tools, wait at least 30 seconds
after stopping the engine until the remaining
pressure in the fuel circuit is released. (Do
not start the work immediately after stopping
the engine since there is remaining
pressure.)
a Since fuel flows out during the test, prepare a
container of approximately 20 l.
4) Insert joint J2 into the pressure limiter side
and tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends of
the joint.
3 Joint bolt:
17.7 to 22.6 Nm {1.8 to 2.3 kgm}
5) Connect test hose J3 to the end of joint J2.
a Tighten the connected part of the test
hose with a band, etc. to prevent it from
coming off.

a Measure the fuel return rate and leakage under a The above is the preparatory work for
the following condition. testing the leakage from the pressure
limiter.
• Coolant temperature: 60 to 100°C
Testing (HM400_3R-AE20-363-K-00-A)

1. Preparation
1) Open the engine hood.
2) Remove fuel tube (3) between pressure
limiter (1) and supply pump (2).

6) Disconnect the return hose of fuel return

block (4) and connect test hose J4.
a Plug the return hose side.
Plug: 07376-70315
a Tighten the connected part of the test
hose with a band, etc. to prevent it from
3) Insert spacer J1 into the supply pump side coming off.
and tighten the removed joint bolt again.
a The above is the preparatory work for
a Connect the return piping to the fuel tank measuring the return rate from the
again, as well. injector.
a Be sure to fit the gaskets to both ends of
the spacer.

HM400-3M0 30-27
30 Testing and adjusting
Engine and cooling system

a The fuel return rate from the injector is

normal when it is within the standard
value range. For standard values, see
"Standard value table", "Standard value
for engine".

2. Testing leakage from pressure limiter

1) Arrange the route of test hose J3 so that it
does not sag and put its end in a container.
2) Start the engine, and stall the torque
converter.
a For the torque converter stalling 5) Stop the engine after the measurement is
procedure, see "Testing engine speed". completed.
3) After the engine speed is stabilized, measure 4. Work after finishing test
the leakage for 1 minute by using measuring After finishing the test, remove the testing tools
cylinder J5. and restore the machine.
a You may measure the leakage for 20 3 Joint bolt of fuel tube (3)
seconds and multiply it by three to judge.
Pressure limiter side:
a Leakage from the pressure limiter is 17.7 to 22.6 Nm {1.8 to 2.3 kgm}
normal if it is within the standard value
Supply pump side:
range. For standard values, see
"Standard value table", "Standard value 14.8 to 19.6 Nm {1.5 to 2.0 kgm}
for engine".
4) Stop the engine after the measurement is
completed.
3. Testing fuel return rate from injector
a While you are measuring the fuel return rate
from the injector, keep hose J3 on the
pressure limiter side connected and its end in
the container.
1) Arrange the route of test hose J4 so that it
does not sag, and put its end in a container.
2) Set the machine monitor to check the engine
speed. For details, see "Testing engine
speed".
3) Start the engine, and stall the torque
converter.
a For the torque converter stalling
procedure, see "Testing engine speed".
4) After the engine speed is stabilized, measure
the return rate for 1 minute by using
measuring cylinder J5.
a You may measure the return rate for 20
seconds and multiply it by three to judge.
a If the error of no-pressure feed occurs on
the supply pump, the engine speed may
not rise. In this case, record the engine
speed during the test, as well.

30-28 HM400-3M0
 30 Testing and adjusting
Engine and cooling system

Bleeding air from fuel system (HM400_3R-AD00-360-K-00-A)

a In the following cases, bleed air according to this a Tighten the fuel prefilter 3/4 turns further after
procedure. its packing face touches the seal surface of
• When a fuel filter is replaced the filter head.
• When run out of fuel occurs
• When starting the engine for the first time
after replacing fuel piping or supply pump
Bleeding air (HM400_3R-AD00-231-K-00-A)

1. Open the engine hood.

2. Remove fuel prefilter (1) and fill it with fuel.
a Fill the fuel prefilter with clean fuel and take
care that dirt does not enter it.
a Check that the cap is fitted to part (a) (center
hole) of the fuel prefilter and pour fuel
through part (b) (surrounding holes).
4. Remove air bleeding plug (3) of fuel prefilter (2)
a After filling the fuel prefilter with fuel, remove
and operate priming pump (4).
the cap from portion (a).
a Operate the priming pump until fuel flows out
a If clean fuel is not available, fill the fuel
of the plug hole, and then install the plug.
prefilter with fuel by operating priming pump
(4) without removing the fuel prefilter. 3 Air bleeder plug:
a Do not pour fuel into fuel main filter (2) from 7.8 to 9.8 Nm {0.8 to 1.0 kgm}
outside. 5. Remove air bleeding plug (5) of the fuel main
filter and operate priming pump (4).
a Operate the priming pump until fuel flows out
of the plug hole, and then install the plug.
3 Air bleeder plug:
7.8 to 9.8 Nm {0.8 to 1.0 kgm}

6. Loosen air bleeder (6) of the supply pump and

operate priming pump (4) 90 to 100 times.
a Operate the priming pump until fuel flows out
of air bleeder (6), and then tighten air bleeder
(6) and operate priming pump (4) several
more times until its operating effort becomes
heavy.
3. Install fuel prefilter (1) to the filter head.
3 Air bleeder:
a Thinly apply the engine oil to the packing
surface on the fuel prefilter side. 4.9 to 6.9 Nm {0.5 to 0.7 kgm}

HM400-3M0 30-29
30 Testing and adjusting
Engine and cooling system

7. Start the engine by cranking it with the starting

motor.
a The air in the high-pressure circuit is bled
automatically by cranking the engine.
a If the engine does not start, there still may be
air in the low-pressure circuit. In this case,
repeat the above procedure from Step 4.

30-30 HM400-3M0
 30 Testing and adjusting
Engine and cooling system

Testing fuel circuit for leakage (HM300-AD00-001-K-01-A)

k Very high pressure is generated in the high- a Check the high-pressure circuit for fuel
pressure circuit of the fuel system. If fuel leakage focusing on the area where the color
leaks while the engine is running, it presents checker is sprayed.
a serious danger that could result in a fire.
a If any fuel leakage is detected, repair it and
After testing the fuel system and removing or perform the checks from step 1 again.
installing the tools for the test, test it for fuel
leakage according to the following procedure. a If no fuel leakage is detected, check is
completed.
k Place the machine on a level ground, set the
parking brake switch to P (parking), and
chock the wheels.

a Clean the engine and the parts around it, and

degrease them in advance so that you can
check it easily for fuel leakage.
Testing (HM300-AD00-364-K-00-A)

1. Spray color checker (developer) to the fuel

supply pump, common rail, fuel injectors, and
joints of the high-pressure piping.
2. Start the engine, keep its speed at 1,000 rpm or
below, and stop it when its speed is stabilized.
3. Check the fuel piping and devices for fuel
leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area where the color
checker is sprayed.
a If any fuel leakage is detected, repair it and
perform the checks from step 1 again.
4. Start the engine and keep it running at low idle.
5. Check the fuel piping and devices for fuel
leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area where the color
checker is sprayed.
a If any fuel leakage is detected, repair it and
perform the checks from step 1 again.
6. Start the engine and keep it running at high idle.
7. Check the fuel piping and devices for fuel
leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area where the color
checker is sprayed.
a If any fuel leakage is detected, repair it and
perform the checks from step 1 again.
8. Start the engine and keep it running at high idle,
then apply a load to the engine.
a When checking the engine for leakage as it is
installed on the machine, stall the torque
converter or relieve the hydraulic pump.
9. Check the fuel piping and devices for fuel
leakage.

HM400-3M0 30-31
30 Testing and adjusting
Engine and cooling system

Testing radiator fan and aftercooler fan speed (HM400_3R-B7P0-360-K-00-A)

a Test the speeds of the radiator fan and

aftercooler fan under the following conditions.
• Hydraulic oil temperature: 45 to 55°C
Testing (HM400_3R-B7P0-388-K-00-A)

1. Select "Fan Mode Fixing" on "Adjustment"

screen of "Service Menu". For details, see
"Special functions of machine monitor"

3. Select the following 4 monitoring codes on

"Monitoring Selection Menu" screen of "Service
Menu". For details, see "Special functions of
machine monitor".
• 01002: "Engine Speed"
• 46400: "Piston Pump Oil Temperature"
• 10014: "Radiator Fan Speed"
• 10015: "CAC Fan Speed"
2. Select the fan mode corresponding to the
desired condition on "Fan Mode Fixing" screen
and fix it.
a For fixing of the fan mode, see "Adjustment
(Fan Mode Fixing)".
• 1: "Brake" (sets the maximum mechanical
speed used when the brake is operated)
• 2: "Max" (sets the maximum regulatory
speed used in the normal operation)

4. Measure the radiator fan and aftercooler fan

speeds with the accelerator pedal depressed full
stroke and convert them into values at engine
speed of 2,000 rpm.
a The radiator fan and aftercooler fan speeds
are normal when they are in the standard
value range. For standard values, see
Standard value table, "Standard value table
for machine".

a When the setting is fixed, fan mode "2"

(Max.) is displayed in the fan mode as shown
in the following screen.
a The fan mode set in the above is held until
the starting switch is turned to OFF position.

30-32 HM400-3M0
 30 Testing and adjusting
Engine and cooling system

Testing and adjusting alternator belt tension (HM400_3R-AKM4-360-K-00-A)

a Since the auto-tensioner is provided, adjusting

the alternator belt is usually not necessary.
a The following describes the belt replacement
and the associated auto-tensioner adjustment.
k Place the machine on a level ground, set the
parking brake switch to P (parking), and
chock the wheels.

Testing (HM400_3R-AKM4-285-K-00-A)

1. Open the engine hood.

2. Press the intermediate point between alternator
pulley and drive pulley with a finger and
measure deflection (a).
a Pressing force: Approximately 98 N
{Approximately 10 kg}
a Deflection (a): 13 to 16 mm
Adjusting (HM400_3R-AKM4-27C-K-00-A)
4. While fixing adjustment nut (6), tighten lock nut
(5).
5. Tighten mounting bolts (4) and (3) of alternator
(2).
a After finishing the adjustment, check the belt
tension again.
6. Install belt cover (1).
a Check each pulley for damage and check
each V-groove for wear. In particular, be sure
to check that the V-belt does not touch the
bottom of the V-groove.
a If the V-belt is elongated exceeding the
adjustment allowance or it has a cut or a
crack, replace it with a new one.
a When the V-belt is replaced, check and
adjust its tension again after running the
engine for an hour.

a If the belt deflection is abnormal, adjust it

according to the following procedure.
1. Remove 4 mounting bolts to remove belt cover
(1).
a Remove the belt cover only when replacing
the belt.
2. Loosen mounting bolts (3) and (4) of alternator
(2).
3. Loosen locknut (5) of the adjustment rod and
adjust the belt tension by moving alternator (2)
with adjustment nut (6).

HM400-3M0 30-33
30 Testing and adjusting
Engine and cooling system

Testing and adjusting air conditioner compressor belt tension (HM400_3R-K5A0-

360-K-00-A)

k Place the machine on a level ground, set the

parking brake switch to P (parking), and
chock the wheels.

Testing (HM400_3R-K5A0-285-K-00-A)

1. Open the engine hood.

2. Press the intermediate point between
compressor pulley and drive pulley with a finger
and measure deflection (a).
a Pressing force: Approximately 58.8 N
{Approximately 6 kg}
a Deflection (a): Approximately 10 mm

Adjusting (HM400_3R-K5A0-27C-K-00-A)

a If the belt deflection is abnormal, adjust it

according to the following procedure.
1. Loosen mounting bolt (1).
2. Loosen locknut (2) and move compressor (4)
and bracket together by turning adjustment nut
(3) to adjust the belt tension.
3. While fixing adjustment nut (3), tighten lock nut
(2).
4. Tighten mounting bolts (1).
a Check each pulley for damage and check
each V-groove for wear. In particular, be sure
to check that the V-belt does not touch the
bottom of the V-groove.
a If the V-belt is elongated exceeding the
adjustment allowance or it has a cut or a
crack, replace it with a new one.
a When the V-belt is replaced, check and
adjust its tension again after operating for 2
to 3 days to eliminate the initial elongation.

30-34 HM400-3M0
 30 Testing and adjusting
Power train

Power train (ALL-C100-001-K-00-A)

Testing torque converter stall speed (HM300-CD00-001-K-00-A)

k Place the machine on a level ground, set the 3. Press numeral input switch (E) on "Engine Mode
parking brake switch to P (parking), and Fixing" screen. (Any switch of "0" to "9" is
chock the wheels. accepted.)

a Test the torque converter stall speed under the

following conditions.
• Coolant temperature: 60 to 100°C
• Transmission oil temperature: 70 to 90°C
• Hydraulic oil temperature: 45 to 55°C
• Torque converter oil temperature: 60 to 80°C
• Accelerator pedal: Full stroke
Testing (HM400_3R-CD00-388-K-00-A)

1. Start the engine to increase the hydraulic oil

temperature to 45 to 55°C.
2. Select "Engine Mode Fixing" on "Adjustment"
screen of "Service Menu" and press Enter 4. Enter a number (1 or 4) corresponding to the
switch (D). For details, see "Special functions of desired condition on "Numeric Pad Input" screen
machine monitor" and press Enter switch (D).
• Up switch (A): Moves the selection up by one • When the output mode is Power: select "1"
item (Power).
• Down switch (B): Moves the selection down • When the output mode is Economy: select
by one item "4" (Economy).
• Return switch (C): Returns the display to
Service Menu screen
• Enter switch (D): Validates the selection
• Numeral input switch (E): Used for entering
numbers.

5. Press Enter switch (D) again to enter the change

and the engine mode is fixed corresponding to
the selected condition.

HM400-3M0 30-35
30 Testing and adjusting
Power train

10.Run the engine at medium speed, and after the

torque converter oil temperature is lowered to
approximately 80°C, lower the engine speed to
low idle.
a Maintain the shift lever in the N position.
11.Repeat Steps 7 to 10 to equalize the oil
temperature of the torque converter and
transmission.
12.While repeating Steps 7 and 8, check the engine
speed when the torque converter oil temperature
is 60 to 80°C.
a Test the torque converter stall speed 2 to 3
a While engine mode is fixed, the following times.
gear speeds are selected corresponding to a Be sure to check the torque converter stall
the shift lever position. speed before delivery since it disperses
Shift lever position Gear speed under the following conditions.
R2 N 1) Variation unique to the engine serial numbers
R1 N 2) Variation due to differences in atmospheric
N N pressure and temperature
3) Variation due to differences in consumption
D F2
of torque by auxiliaries
5 F2
4) Variation due to differences in characteristics
4 F2 among torque converters
3 F2 5) Variation due to differences in the testing
2 F2 methods
1 F2
a The torque converter stall speed is normal
a While engine mode is fixed (when a number when it is within the standard value range.
other than 0 is selected), the maximum For standard values, see Standard value
speed control is applied to both the radiator table, "Standard value table for machine".
fan and after cooler fan.
a If the screen returns to "Adjustment" screen
by pressing Return switch (C) while engine
mode is fixed, both the maximum throttle limit
command and the fan control condition are
returned to the normal condition.
6. Start the engine and increase the torque
converter oil temperature to 60 to 80°C.
7. Set the parking brake switch to P (parking)
position, then set the shift lever to position D
while depressing the brake pedal.
8. Depress the accelerator pedal gradually and
stall the torque converter to increase the torque
converter oil temperature.
a It is prohibited to stall the torque converter
when the shift indicator at the top of the
monitor panel is indicating "F1", "R1" or "R2"
since the stalling can induce the internal
damage of the transmission.
9. As soon as the torque converter oil temperature
exceeds 90°C, lower the engine speed to low
idle and return the shift lever to N position.
a Do not operate the shift lever while
depressing the accelerator pedal. Such
practice not only generates a great shock but
reduces life expectancy of the machine.

30-36 HM400-3M0
 30 Testing and adjusting
Power train

Testing power train oil pressure (HM400-C100-001-K-00-A)

a Testing tools
Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
790-261-1204 Digital hydraulic tester
799-401-2320 Hydraulic gauge
799-101-5220 Nipple
07002-11023 O-ring
K
799-101-5260 Nipple
07002-11223 O-ring
799-101-5230 Nipple
07002-11423 O-ring
799-401-2320 Gauge

a List of oil pressure pick up places and gauges to be used

HM400-3M0 30-37
30 Testing and adjusting
Power train

Oil pressure to be Gauge a When tilt up or down the cab, see "Cab tilt up
No. procedure".
measured (MPa {kg/cm2})
Main relief pressure of a When checking ECMV-related oil pressures,
1 power train 6 {60}
installation and removal of the oil-pressure
Main flow rate selector testing nipples, hoses and gauges must be
2 valve inlet pressure 6 {60}
performed from the rear bottom of the cab.
Torque converter inlet
3 pressure 6 {60} • Torque converter oil temperature: 60 to 80°C
• Transmission oil temperature: 70 to 90°C
Torque converter outlet
4 pressure 1 {10}
Torque converter lockup
5 clutch actuating pressure 6 {60}
Transmission Lo clutch
6 actuating pressure 6 {60}
Transmission Hi clutch
7 actuating pressure 6 {60}
Transmission 1st clutch
8 actuating pressure 6 {60}
Transmission 2nd clutch
9 actuating pressure 6 {60}
Transmission 3rd clutch
10 actuating pressure 6 {60}
Transmission R clutch
11 actuating pressure 6 {60}
Inter-axle differential lock
12 clutch actuating pressure 6 {60}

a Measure the power train main relief pressure at

centralized remote pressure pickup port (1).

a Check of the transmission lubricating oil

pressure may be omitted since it can be
substituted with the torque converter outlet
pressure.
k Place the machine on a level ground, set the
parking brake switch to P (parking), and
chock the wheels.

k Install and remove the testing tools after the

oil temperature lowers.

k When checking the oil pressure while the

machine is traveling, you must secure a
sufficient traveling area and pay attention to
the safe of nearby people.

30-38 HM400-3M0

2. Testing main flow rate selector valve inlet
Testing (HM400-C100-362-K-00-A)
• Entire power train
1. Testing main relief pressure of power train
1) Install the nipple and hose [1] to oil pressure
pickup port (remote pickup point) (1).
2) Connect oil pressure gauge K to the hose.
3) Start the engine and increase the torque
converter oil temperature to 60 to 80°C.
4) Maintain the shift lever in N position and
measure the oil pressure at engine low idle
and at engine speed of 2,000 rpm.
a The main relief pressure of power train is
normal if it is within the standard value
range. For standard values, see Standard
value table, "Standard value table for
machine".
5) After finishing the test, remove the testing
tools, and restore the machine.
HM400-3M0
30 Testing and adjusting
Power train
pressure
1) Tilt up the cab.
2) Remove oil pressure pickup plug (2) and
install the nipple and hose [1].
a Pull out the hose to the rear side of the
transmission.
3) Tilt down the cab and return it to the original
position.
4) Connect oil pressure gauge K to the hose.
5) Start the engine and increase the torque
converter oil temperature to 60 to 80°C.
6) Maintain the shift lever in N position and
measure the oil pressure at engine low idle
and at engine speed of 2,000 rpm.
a When the main flow rate selector valve
inlet pressure is within the standard value
range, it is normal. For standard values,
see Standard value table, "Standard
value table for machine".
30-39
30 Testing and adjusting
Power train

6) Maintain the shift lever in N position and

measure the oil pressure at engine speed of
2,000 rpm with the foot brake not applied.
a The torque converter inlet pressure is
normal when it is within the standard
value range. For standard values, see
Standard value table, "Standard value
table for machine".

7) After finishing the test, remove the testing

tools, and restore the machine.
• Torque converter related oil pressure
1. Testing torque converter inlet pressure
1) Tilt up the cab.
2) Remove oil pressure pickup plug (3) and
install the nipple and hose [1].
3 Nipple:
44.1 to 53.9 Nm {4.5 to 5.5 kgm} 7) After finishing the test, remove the testing
tools, and restore the machine.
a Pull out the hose to the rear side of the
transmission. 3 Nipple:
44.1 to 53.9 Nm {4.5 to 5.5 kgm}
2. Testing torque converter outlet pressure
1) Tilt up the cab.
2) Remove oil pressure pickup plug (4) and
install the nipple and hose [1].
3 Nipple:
9.8 to 12.7 Nm {1 to 1.3 kgm}
a Pull out the hose to the rear side of the
transmission.

3) Tilt down the cab and return it to the original

position.
4) Connect oil pressure gauge K to the hose.
5) Start the engine and increase the torque
converter oil temperature to 60 to 80°C.

30-40 HM400-3M0
 30 Testing and adjusting
Power train

3) Tilt down the cab and return it to the original

position.
4) Connect oil pressure gauge K to the hose.
5) Start the engine and increase the torque
converter oil temperature to 60 to 80°C.
6) Maintain the shift lever in N position and
measure the oil pressure at engine speed of
2,000 rpm with the foot brake not applied or
applied.
a The torque converter outlet pressure is
normal when it is within the standard
value range. For standard values, see
Standard value table, "Standard value
table for machine". 3) Tilt down the cab and return it to the original
position.
4) Connect oil pressure gauge K to the hose.
5) Start the engine and increase the torque
converter oil temperature to 60 to 80°C.
6) Set the parking brake switch to OFF position,
then set the shift lever to 1 position while
depressing the brake pedal.
7) Release the brake, drive the machine with
engine at 2,000 rpm and measure the oil
pressure when the lockup pilot lamp lights
up.

k Since the maximum speed reaches

7) After finishing the test, remove the testing approximately 6.6 km/h in F1, you
tools, and restore the machine. must pay attention to the safety of
nearby people when driving the
3 Nipple:
machine.
9.8 to 12.7 Nm {1 to 1.3 kgm}
3. Testing lockup clutch pressure of torque a The torque converter lockup clutch
converter pressure is normal when it is within the
standard value range. For standard
1) Tilt up the cab.
values, see Standard value table,
2) Remove oil pressure pickup plug (5) and
"Standard value table for machine".
install the nipple and hose [1].
3 Nipple:
11.27 ± 1.47 Nm {1.15 ± 0.15 kgm}
a Pull out the hose to the rear side of the
transmission.

HM400-3M0 30-41
30 Testing and adjusting
Power train

• Transmission related oil pressure

a List of shift lever positions, travel speeds and
engaged clutches
Table of clutches
Shift lever Clutch
Speed
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
8) After finishing the test, remove the testing Q F6 w w
tools, and restore the machine. Q N
3 Nipple: Q R1 w q
Q R2 w w
11.27 ± 1.47 Nm {1.15 ± 0.15 kgm}
a Q mark indicates the travel gear speed that is
actuated at the respective shift lever position.
a "*" mark indicates the travel gear speed
activated when "F1" is selected in "F1 Start at D
Position Setting" menu. Check that "F2" is
selected before testing.
a w mark and q mark indicate the clutches that
are actuated at each gear speed.
a q mark indicates the travel gear speed when
measuring the oil pressure for each clutch.
1. Testing transmission Lo clutch pressure
1) Tilt up the cab.
2) Remove oil pressure pickup plug (6) and
install the nipple and hose [1].
3 Nipple:
11.27 ± 1.47 Nm {1.15 ± 0.15 kgm}
a Pull out the hose to the rear side of the
transmission.

30-42 HM400-3M0
 30 Testing and adjusting
Power train

3 Nipple:
11.27 ± 1.47 Nm {1.15 ± 0.15 kgm}
a Pull out the hose to the rear side of the
transmission.

3) Tilt down the cab and return it to the original

position.
4) Connect oil pressure gauge K to the hose.
5) Start the engine and increase the torque
converter oil temperature to 60 to 80°C.
6) Set the parking brake switch to OFF position,
then set the shift lever to 1 position while
depressing the brake pedal.
7) Release the brake, drive the machine with
engine at 2,000 rpm and measure the oil
pressure when the lockup pilot lamp lights
up.

k Since the maximum speed reaches

approximately 6.6 km/h in F1, you
must pay attention to the safety of
nearby people when driving the
machine.
a The transmission Lo clutch pressure is
normal when it is within the standard
value range. For standard values, see
Standard value table, "Standard value
table for machine".
3) Tilt down the cab and return it to the original
position.
4) Connect oil pressure gauge K to the hose.
5) Start the engine and increase the torque
converter oil temperature to 60 to 80°C.
6) Set the parking brake switch to OFF position,
then set the shift lever to 2 position while
depressing the brake pedal.
7) Release the brake, drive the machine with
engine at 2,000 rpm and measure the oil
pressure when the shift indicator displays
"2".

k Since the maximum speed reaches

8) After finishing the test, remove the testing
tools, and restore the machine.
3 Nipple:
11.27 ± 1.47 Nm {1.15 ± 0.15 kgm}
2. Testing transmission Hi clutch pressure
1) Tilt up the cab.
2) Remove oil pressure pickup plug (7) and
install the nipple and hose [1].
approximately 10.1 km/h in F2, you
must pay attention to the safety of
nearby people when driving the
machine.
a The transmission Hi clutch pressure is
normal when it is within the standard
value range. For standard values, see
Standard value table, "Standard value
table for machine".

HM400-3M0 30-43
30 Testing and adjusting
Power train

6) Set the parking brake switch to OFF position,

then set the shift lever to 1 position while
depressing the brake pedal.
7) Release the brake, drive the machine with
engine at 2,000 rpm and measure the oil
pressure when the lockup pilot lamp lights
up.

k Since the maximum speed reaches

approximately 6.6 km/h in F1, you
must pay attention to the safety of
nearby people when driving the
8) After finishing the test, remove the testing machine.
tools, and restore the machine. a The transmission 1st clutch pressure is
3 Nipple: normal when it is within the standard
value range. For standard values, see
11.27 ± 1.47 Nm {1.15 ± 0.15 kgm} Standard value table, "Standard value
3. Testing transmission 1st clutch pressure table for machine".
1) Tilt up the cab.
2) Remove oil pressure pickup plug (8) and
install the nipple and hose [1].
3 Nipple:
11.27 ± 1.47 Nm {1.15 ± 0.15 kgm}
a Pull out the hose to the rear side of the
transmission.

8) After finishing the test, remove the testing

tools, and restore the machine.
3 Nipple:
11.27 ± 1.47 Nm {1.15 ± 0.15 kgm}
4. Testing transmission 2nd clutch pressure
1) Tilt up the cab.
2) Remove oil pressure pickup plug (9) and
install the nipple and hose [1].
3 Nipple:
11.27 ± 1.47 Nm {1.15 ± 0.15 kgm}
a Pull out the hose to the rear side of the
transmission.

3) Tilt down the cab and return it to the original

position.
4) Connect oil pressure gauge K to the hose.
5) Start the engine and increase the torque
converter oil temperature to 60 to 80°C.

30-44 HM400-3M0
 30 Testing and adjusting
Power train

3 Nipple:
11.27 ± 1.47 Nm {1.15 ± 0.15 kgm}
a Pull out the hose to the rear side of the
transmission.

3) Tilt down the cab and return it to the original

position.
4) Connect oil pressure gauge K to the hose.
5) Start the engine and increase the torque
converter oil temperature to 60 to 80°C.
6) Set the parking brake switch to OFF position,
then set the shift lever to 3 position while
depressing the brake pedal.
7) Release the brake, drive the machine with
engine at 2,000 rpm and measure the oil
pressure when the shift indicator displays
"3".

k Since the maximum speed reaches

approximately 15.5 km/h in F3, you
must pay attention to the safety of
nearby people when driving the
machine.
a The transmission 2nd clutch pressure is
normal when it is within the standard
value range. For standard values, see
Standard value table, "Standard value
table for machine".
3) Tilt down the cab and return it to the original
position.
4) Connect oil pressure gauge K to the hose.
5) Start the engine and increase the torque
converter oil temperature to 60 to 80°C.
6) Set the parking brake switch to OFF position,
then set the shift lever to 5 position while
depressing the brake pedal.
7) Release the brake, drive the machine with
engine at 2,000 rpm and measure the oil
pressure when the shift indicator displays
"5".

k Since the maximum speed reaches

approximately 36.5 km/h in F5, you
must pay attention to the safety of
nearby people when driving the
machine.
8) After finishing the test, remove the testing
a The transmission 3rd clutch pressure is
tools, and restore the machine.
normal when it is within the standard
3 Nipple: value range. For standard values, see
11.27 ± 1.47 Nm {1.15 ± 0.15 kgm} Standard value table, "Standard value
5. Testing transmission 3rd clutch pressure table for machine".
1) Tilt up the cab.
2) Remove oil pressure pickup plug (10) and
install the nipple and hose [1].

HM400-3M0 30-45
30 Testing and adjusting
Power train

6) Set the parking brake switch to OFF position,

then set the shift lever to R1 position while
depressing the brake pedal.
7) Release the brake, drive the machine with
engine at 2,000 rpm and measure the oil
pressure.

k Since the maximum speed reaches

approximately 6.8 km/h in R1, you
must pay attention to the safety of
nearby people when driving the
machine.
8) After finishing the test, remove the testing a The transmission R clutch pressure is
tools, and restore the machine. normal when it is within the standard
3 Nipple: value range. For standard values, see
Standard value table, "Standard value
11.27 ± 1.47 Nm {1.15 ± 0.15 kgm} table for machine".
6. Testing transmission R clutch pressure
1) Tilt up the cab.
2) Remove oil pressure pickup plug (11) and
install the nipple and hose [1].
3 Nipple:
11.27 ± 1.47 Nm {1.15 ± 0.15 kgm}
a Pull out the hose to the rear side of the
transmission.

8) After finishing the test, remove the testing

tools, and restore the machine.
3 Nipple:
11.27 ± 1.47 Nm {1.15 ± 0.15 kgm}
7. Testing pressure of inter-axle differential lock
clutch
1) Tilt up the cab.
2) Remove oil pressure pickup plug (12) and
install the nipple and hose [1].
3 Nipple:
11.27 ± 1.47 Nm {1.15 ± 0.15 kgm}
a Pull out the hose to the rear side of the
transmission.

3) Tilt down the cab and return it to the original

position.
4) Connect oil pressure gauge K to the hose.
5) Start the engine and increase the torque
converter oil temperature to 60 to 80°C.

30-46 HM400-3M0
 30 Testing and adjusting
Power train

3) Tilt down the cab and return it to the original

position.
4) Connect oil pressure gauge K to the hose.
5) Start the engine and increase the torque
converter oil temperature to 60 to 80°C.
6) Activate the inter-axle differential lock. For
details, see "Setting and adjusting various
devices", "Checking KTCS system (2-5)".
7) Move the shift lever to N position, release the
brake, drive the machine with engine at
2,000 rpm and measure the oil pressure.
a The pressure of inter-axle differential lock
clutch is normal when it is within the
standard value range. For standard
values, see Standard value table,
"Standard value table for machine".

8) After finishing the test, remove the testing

tools, and restore the machine.
3 Nipple:
11.27 ± 1.47 Nm {1.15 ± 0.15 kgm}

HM400-3M0 30-47
30 Testing and adjusting
Power train

Adjusting transmission speed sensor (HM400-CNA1-001-K-00-A)

a 4 speed sensors are installed on the
transmission. Adjust each of them according to
the following procedure.
CN3: Input shaft speed sensor
CN4: Intermediate shaft speed sensor
CN5: Output shaft R speed sensor
T09: Output shaft F speed sensor
a Tilt up the cab before adjusting the input shaft
speed sensor.
a Remove the transmission and front differential
assembly before adjusting the intermediate shaft
speed sensor and output shaft F speed sensor.

30-48 HM400-3M0
 30 Testing and adjusting
Power train

Adjustment (HM400-CNA1-270-K-00-A)
Adjusting input shaft speed sensor (CN3)
1. Remove input shaft speed sensor (1) to check
its tip for the adherence of iron particles or the
presence of scratches. Then reinstall the sensor
temporarily to its original position after checking
that there is neither the adherence nor the
presence of the above.
2 Threaded part:
Liquid gasket (LG-5)
2. Screw in sensor (1) until its end lightly touches
the tooth tip of gear (2) of the input shaft.
3. Unscrew sensor (1) from that position by a 1/2 to
1 turn.
a A clearance (a) of 0.75 to 1.5 mm is made
between the sensor end and gear tooth tip.
4. With sensor (1) fixed, tighten lock nut (3).
3 Lock nut:
49.0 to 68.6 Nm {5 to 7 kgm}
Adjusting output shaft speed sensor (CN5)
1. Remove output shaft R speed sensor (7) to
check its tip for the adherence of iron particles or
the presence of scratches. Then reinstall the
sensor temporarily to its original position after
checking that there is neither the adherence nor
the presence of the above.
2 Threaded part:
Liquid gasket (LG-5)
2. Screw in sensor (7) until its end lightly touches
the tooth tip of gear (8) of the rear output shaft.
3. Unscrew sensor (7) from that position by 3/4 to 1
turn.
a A clearance (c) of 1.1 to 1.5 mm is made
between the sensor end and gear tooth tip.
4. With sensor (7) fixed, tighten lock nut (9).
3 Lock nut:
49.0 to 68.6 Nm {5 to 7 kgm}

Adjusting intermediate shaft speed sensor

(CN4)
1. Remove input shaft speed sensor (4) to check
its tip for the adherence of iron particles or the
presence of scratches. Then reinstall the sensor
temporarily to its original position after checking
that there is neither the adherence nor the
presence of the above.
2 Threaded part:
Liquid gasket (LG-5)
2. Screw in sensor (4) until its end lightly touches
tooth tip of gear (5) of the intermediate shaft. Adjusting differential input shaft speed sensor
3. Unscrew sensor (4) from that position by 1/2 to 1 (T09)
turn. 1. Remove output shaft F speed sensor (10) to
check its tip for the adherence of iron particles or
a A clearance (b) of 0.75 to 1.5 mm is made the presence of scratches. Then reinstall the
between the sensor end and gear tooth tip. sensor temporarily to its original position after
4. With sensor (4) fixed, tighten lock nut (6). checking that there is neither the adherence nor
3 Nut: the presence of the above.
49.0 to 68.6 Nm {5 to 7 kgm} 2 Threaded part:
Liquid gasket (LG-5)

HM400-3M0 30-49
30 Testing and adjusting
Power train

2. Screw in sensor (10) until its end lightly touches

the tooth tip of gear (11) of the rear output shaft.
3. Unscrew sensor (10) from that position by 1/2 to
1 turn.
a A clearance (d) of 0.75 to 1.5 mm is made
between the sensor end and gear tooth tip.
4. With sensor (10) fixed, tighten nut (12).
3 Nut:
49.0 to 68.6 Nm {5 to 7 kgm}

Checking sensor input signal

After the adjustment, check that the monitoring
function of the machine monitor displays the speed
of each transmission shaft correctly.
a For details of the monitoring function, see the
section of "Special functions of machine
monitor".

30-50 HM400-3M0
 30 Testing and adjusting
Power train

Adjusting transmission controller (HM300-CV10-001-K-00-A)

Adjusting (HM300-CV10-270-K-00-A)

a When the following operations are performed,

adjust the transmission to coordinate the feeling
between the transmission and the transmission
controller.
• When the transmission is overhauled or
replaced
• When the transmission control valve is
repaired or replaced
• When the transmission controller is replaced
• When the power train speed sensor is
repaired or replaced
• When the transmission oil temperature
sensor is repaired or replaced
• When the transmission oil filter is repaired to
remove its clogging
a Use the machine monitor service function for
adjustment of the transmission.
a For details of the operating procedure, see the
section of "Setting and adjustment of each
equipment".

HM400-3M0 30-51
30 Testing and adjusting
Power train

Retrieval of disabled machine that resulted from a trouble in electrical

system (HM300-C050-04E-K-00-A)
• A failure in the electrical system for the engine control system or transmission control system may disable
starting the engine, thereby blocking start of the machine.
In such case, first fix the failure in the electrical system of the engine or transmission temporarily to move
the machine. Then after moving the machine, perform the established troubleshooting.
1. When engine cannot be started due to a failure in the engine control system
a Select the retrieving method according to the following flowchart.
a For details of the failure code checking procedure, see the section of "Special functions of machine
monitor".

Note: When towing the machine because of the inoperable engine, the parking brake cannot be released
through the switch operations. In such case, release the parking brake temporarily according to "Parking
brake emergency releasing procedure".
2. When the machine cannot be started due to a failure in the transmission control system
a Check the failure code and select an appropriate retrieving procedure from the following table.

30-52 HM400-3M0
 30 Testing and adjusting
Power train

a For details of the failure code checking procedure, see the section of "Special functions of machine
monitor".
Starting gear speed that is
Failure Conditions when Retrieving determined by lever
position after retrieving Remarks
code failure occurs method
operation
Failure occurrence Retrieving -
1500L0 procedure 2
condition 2
Failure occurrence Retrieving D to 1: F2 speed
15G0MW procedure 1 Failure occurrence condition 1
condition 7
Failure occurrence Retrieving D to 1: F1 speed, R1 to R2: Gear speed is fixed and
15H0MW procedure 1 R1 speed unchangeable from that specified
condition 7
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2: at restart. Gear speed becomes
15J0MW procedure 1 R1 speed neutral when the lever is moved
condition 7
to N.
Failure occurrence Retrieving D to 1: F3 speed, R1 to R2:
15K0MW procedure 3 R2 speed Failure occurrence condition 2
condition 7
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2: The gear speed is suddenly set to
15L0MW procedure 3 R1 speed neutral while traveling and it
condition 7
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2: remains unchanged despite the
15M0MW procedure 3 R1 speed lever operation, disabling to start
condition 7
the machine.
Failure occurrence Retrieving R1 to R2: R1 speed
15SBL1 procedure 1 Failure occurrence condition 3
condition 7
Failure occurrence Retrieving Gear speed is suddenly set to
15SBMA D to 1: F2 speed neutral.
condition 7 procedure 1
Failure occurrence Retrieving Failure occurrence condition 4
15SCL1 D to 1: F2 speed
condition 7 procedure 1 After starting the engine, the gear
Failure occurrence Retrieving D to 1: F1 speed, R1 to R2: speed remains in neutral despite
15SCMA procedure 1 R1 speed the lever operation and the
condition 7
Failure occurrence Retrieving machine cannot be started.
15SDL1 D to 1: F1 speed
condition 7 procedure 1 Failure occurrence condition 5
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2: The lever response fails and the
15SDMA procedure 1 R1 speed
condition 7 lever operation does not work.
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2: Gear speed is set to neutral when
15SEL1 procedure 1 R1 speed
condition 7 the lever is operated.
Failure occurrence Retrieving D to 1: F3 speed, R1 to R2: Failure occurrence condition 6
15SEMA procedure 1 R2 speed
condition 7
Gear speed is fixed and
Failure occurrence Retrieving D to 1: F3 speed, R1 to R2: unchangeable from that specified
15SFL1 procedure 1 R2 speed
condition 7 at restart.
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2:
When the lever is moved to N, the
15SFMA procedure 1 R1 speed
condition 7 gear speed becomes neutral but
Failure occurrence Retrieving D to 1: F5 speed, R1 to R2: gear shift after that can not be
15SGL1 procedure 1 R3 speed or equivalent
condition 7 made.
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2: Failure occurrence condition 7
15SGMA procedure 1 R1 speed
condition 7
Use a clutch suited for the travel,
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2: then fix the gear speed. If a clutch
15SJMA procedure 1 R1 speed
condition 1 suitable for travel is not available,
If the normal display is the gear speed is set to neutral.
Failure occurrence Retrieving
DAQ0KK recovered, normal travel is Gear speed becomes neutral
condition 1 procedure 5
available (Note 1). when the lever is moved to N.
If the normal display is Note 1
Failure occurrence Retrieving recovered, normal travel is
DAQ2KK procedure 4
condition 1 available (Note 1). Even if a failure is eliminated,
neutral condition is maintained
Failure occurrence Retrieving - until the lever is once moved to N.
DAQ9KQ procedure 6
condition 4
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2:
DAQRMA procedure 1 R1 speed
condition 4
Failure occurrence Retrieving D to 1: F2 speed
DDTHKA procedure 1
condition 1

HM400-3M0 30-53
30 Testing and adjusting
Power train

Starting gear speed that is

Failure Conditions when Retrieving determined by lever
position after retrieving Remarks
code failure occurs method
operation
Failure occurrence Retrieving
DDTJKA D to 1: F1 speed
condition 1 procedure 1
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2:
DDTKKA procedure 1 R1 speed
condition 1
Failure occurrence Retrieving D to 1: F3 speed, R1 to R2:
DDTLKA procedure 1 R2 speed
condition 1
Failure occurrence Retrieving D to 1: F5 speed, R1 to R2:
DDTMKA procedure 1 R3 speed or equivalent
condition 1
Failure occurrence Retrieving
DDTNKA R1 to R2: R1 speed
condition 1 procedure 1
If the normal display is
Failure occurrence Retrieving recovered, normal travel is
DF10KA procedure 7
condition 5 available (Note 1).
If the normal display is
Failure occurrence Retrieving recovered, normal travel is
DF10KB procedure 7
condition 5 available (Note 1).
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2:
DLF1KA procedure 1 R1 speed
condition 1
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2:
DLF1LC procedure 1 R1 speed
condition 1
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2:
DLF2KA procedure 1 R1 speed
condition 1
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2:
DLF2LC procedure 1 R1 speed
condition 1
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2:
DLT3KA procedure 3 R1 speed
condition 6
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2:
DXH1KA procedure 1 R1 speed
condition 1
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2:
DXH1KB procedure 1 R1 speed
condition 1
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2:
DXH1KY procedure 1 R1 speed
condition 1
Failure occurrence Retrieving D to 1: F1 speed, R1 to R2:
DXH2KA procedure 1 R1 speed
condition 7
Failure occurrence Retrieving D to 1: F1 speed, R1 to R2:
DXH2KB procedure 1 R1 speed
condition 7
Failure occurrence Retrieving D to 1: F2 speed
DXH2KY procedure 1
condition 7
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2:
DXH3KA procedure 1 R1 speed
condition 7
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2:
DXH3KB procedure 1 R1 speed
condition 7
Failure occurrence Retrieving D to 1: F1 speed
DXH3KY procedure 1
condition 7
Failure occurrence Retrieving D to 1: F3 speed, R1 to R2:
DXH4KA procedure 1 R2 speed
condition 7
Failure occurrence Retrieving D to 1: F3 speed, R1 to R2:
DXH4KB procedure 1 R2 speed
condition 7
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2:
DXH4KY procedure 1 R1 speed
condition 7
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2:
DXH5KA procedure 1 R1 speed
condition 7
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2:
DXH5KB procedure 1 R1 speed
condition 7

30-54 HM400-3M0
 30 Testing and adjusting
Power train

Starting gear speed that is

Failure Conditions when Retrieving determined by lever
position after retrieving Remarks
code failure occurs method
operation
Failure occurrence Retrieving D to 1: F3 speed, R1 to R2:
DXH5KY procedure 1 R2 speed
condition 7
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2:
DXH6KA procedure 1 R2 speed
condition 7
Failure occurrence Retrieving D to 1: F2 speed, R1 to R2:
DXH6KB procedure 1 R2 speed
condition 7
Failure occurrence Retrieving D to 1: F5 speed, R1 to R2:
DXH6KY procedure 1 R3 speed or equivalent
condition 7
Failure occurrence Retrieving
DXH7KA D to 1: F2 speed
condition 7 procedure 1
Failure occurrence Retrieving
DXH7KB D to 1: F2 speed
condition 7 procedure 1
Failure occurrence Retrieving
DXH7KY R1 to R2: R1 speed
condition 7 procedure 1
Retrieving procedure 1:
1) Stop the machine travel and move the shift lever to N position.
2) Operate the shift lever again to start the machine.
a Release the accelerator pedal when operating the shift lever.
a N o D to 1 or N o R1 to R2
Retrieving procedure 2:
1) Tow the machine.
a When towing the machine because of the inoperable engine, the parking brake cannot be released
through switch operations. In such case, release the parking brake temporarily according to
"Parking brake emergency releasing procedure".
Retrieving procedure 3:
1) Stop the machine travel and move the shift lever to N position.
2) Pull out retrieval connectors A1 (female) and A2 (male) once, then connect them again to select the
retrieval mode.
3) Operate the shift lever to start the machine.
a Release the accelerator pedal when operating the shift lever.
a N o D to 1 or N o R1 to R2
a The retrieval mode remains turned on until the starting switch is turned to OFF position.
Retrieving procedure 4:
1) Check the circuit breaker, fuse, T/M solenoid relay, solenoid power supply circuit and GND. If they are
normal, replace the transmission controller.
• Circuit breaker: No. 84 (40A)
• Fuse: BT2-No.6 (15 A)
Retrieving procedure 5:
1) Check the fuse unit, fuse, power supply circuit and GND. If they work, replace the transmission
controller.
• Circuit breaker: No. 84 (40A)
• Fuse: BT2-No.6 (15 A)
Retrieving procedure 6:
1) Reset the model selection, then reset the option items.
Retrieving procedure 7:
1) Check the fuse. If it works, replace the shift lever.
a Fuse: BT1-No.10 (5 A)

HM400-3M0 30-55
30 Testing and adjusting
Power train

Retrieval of disabled machine due to traction control system (KTCS)

failure (HM300-C7K0-04E-K-00-A)
• A failure that occurs in the electrical system of KTCS while traveling on a soft ground stops operation of
KTCS, potentially disabling the machine from starting.
• In such case, tow the machine or move it activating KTCS temporarily by operating the secondary KTCS
operating connector. Then perform a full-scale troubleshooting.
• Failure in the electrical system of the traction control system (KTCS)
System action (q: Continued, X:
Canceled)
Action
Failure code Failure name Center Inter-axle
level Front KTCS
KTCS differential
control
control lock control
L03 DB13 KK Controller Power Source Low (RHC) x x x
L03 DB12 KK Solenoid Power Source Low (RHC) x x x
L01 DLF6 LC Failure of Wheel Speed Sensor (FR) q q q
L01 DLF7 LC Failure of Wheel Speed Sensor (FL) q q q
L01 DLFD LC Failure of Wheel Speed Sensor (CR) x q q
L01 DLFE LC Failure of Wheel Speed Sensor (CL) x q q
L01 DLT3 LC Failure of Output Speed Sensor (Main) x q x
Failure of Transmission Differential
L01 DLF4 LC x x x
Speed Sensor
L01 DLFF LC Failure of Wheel Speed Sensor (Front) x q q
Failure of Wheel Speed Sensor
L01 DLFG LC q x q
(Center)
AL01 DK30 KX Out of Range of Steering Angle Pot. x x x
L01 DK60 KX Out of Range of Acceleration Sensor q q q
Disconnection of Retarder EPC Sol.
L03 DX33 KA (FR) q q q
L03 DX33 KY Hot Short of Retarder EPC Sol. (FR) x q q
Ground Fault of Retarder EPC
L03 DX33 KB Solenoid (FR) q q q
Malfunction of Retarder EPC Valve
L03 DX33 MA (FR) q q q
Release Trouble of Retarder EPC
L03 DX33 K4 x q q
Valve (FR)
Disconnection of Retarder EPC Sol.
L03 DX30 KA (FL) q q q
L03 DX30 KY Hot Short of Retarder EPC Sol. (FL) x q q
Ground Fault of Retarder EPC Sol.
L03 DX30 KB (FL) q q q
Malfunction of Retarder EPC Valve
L03 DX30 MA (FL) q q q
Release Trouble of Retarder EPC
L03 DX30 K4 x q q
Valve (FL)
L03 DWNJ KZ Failure of TCS Shut off Sol. (Front) q q q
Disconnection of Retarder EPC Sol.
L03 DX31 KA (CR) q q q
L03 DX31 KY Hot Short of Retarder EPC Sol. (CR) q x q
Ground Fault of Retarder EPC Sol.
L03 DX31 KB (CR) q q q
L03 DX31 MA Malfunction of Retarder Valve (CR) q q q
Release Trouble of Retarder EPC
L03 DX31 K4 q x q
Valve (CR)
Disconnection of Retarder EPC Sol.
L03 DX32 KA (CL) q q q
L03 DX32 KY Hot Short of Retarder EPC Sol. (CL) q x q

30-56 HM400-3M0
 30 Testing and adjusting
Power train

System action (q: Continued, X:

Canceled)
Action
Failure code Failure name Center Inter-axle
level Front KTCS
KTCS differential
control
control lock control
Ground Fault of Retarder EPC Sol.
L03 DX32 KB (CL) q q q
Malfunction of Retarder EPC Valve
L03 DX32 MA (CL) q q q
Release Trouble of Retarder EPC
L03 DX32 K4 q x q
Valve (CL)
L03 DWNK KZ Failure of TCS Shut off Sol. (Center) q q q
AL03 DB1R KR CAN1 Discon (Retarder Hoist Con) x x x
L03 DAQR KR CAN1 Discon (Transmission Con) x x x
L03 DB2R KR CAN1 Discon (Engine Con) x x x
AL03 CA131 Throttle Sensor High Error x x x
AL03 CA132 Throttle Sensor Low Error x x x

a In the failure list, when KTCS is stopped due to a failure other than A-marked one, KTCS cannot be
operated even by using the secondary KTCS operating switch.

• Secondary KTCS operating connector operation

method
1. Stop the machine, then set the gear shift lever to
"N" and the parking brake switch to PARKING.
2. Start the engine and disconnect secondary
KTCS activating connector (1) at the bottom of
the fuse box once, then connect it again.
3. Operation of KTCS is enabled.

HM400-3M0 30-57
30 Testing and adjusting
Steering system

Steering system (ALL-F000-001-K-00-A)

Testing and adjusting steering circuit oil pressure (HM300-F210-001-K-00-A)

a Testing tools
Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
M
790-261-1204 Digital hydraulic tester

k Place the machine on a level ground, set the

parking brake switch to P (parking), and
chock the wheels.

a Test the steering circuit pressure under the

following condition.
• Hydraulic oil temperature: 45 to 55°C
Testing (HM400_3R-F210-362-K-00-A)

a Test the steering relief pressure by using remote

pressure pickup port (1) and "Steering Pump
Displacement Fixing" screen of "special
functions of machine monitor".

2. Select "1" (maximum) on "Steering Pump

Displacement Fixing" screen and press Enter
switch (D) to set the steering pump swash plate
angle to the maximum.

1. Select "Steering Pump Displacement Fixing" on

"Adjustment" screen of "Service Menu" and
press Enter switch (D). For details, see "Special
functions of machine monitor".
• Up switch (A): Moves the selection up by one
item
• Down switch (B): Moves the selection down
by one item
• Return switch (C): Returns the display to
Service Menu screen
• Enter switch (D): Validates the selection
• Numeral input switch (E): Used for entering 3. Install hose [1] and connect oil pressure gauge
numbers. M to it.
a Use an oil pressure gauge of 40 MPa {400
kg/cm2}.

30-58 HM400-3M0
 30 Testing and adjusting
Steering system

1. Remove lock nut (3).

2. Turn adjustment screw (4) to adjust the
pressure.
a When the adjustment screw is:
• turned clockwise, the pressure is
increased.
• turned counterclockwise, the pressure is
decreased.
3. Install lock nut (3).
a After the adjustment, check the oil pressure
again according to the preceding testing
4. Start the engine, and run it at high idle, then procedure.
continue turning the steering wheel to the right
or left. Measure the oil pressure (maximum
pressure at operating steering) when the
steering relief valve operates.
a The steering relief pressure is normal if it is
within the standard value range. For
standard values, see Standard value table,
"Standard value table for machine".

5. After finishing the test, remove the testing tools,

and restore the machine.
Adjusting (HM400-F210-27B-K-00-A)

a Tilt up the cab.

(See "Cab tilt-up procedure" in "Cab and its
attachments".)
a If the steering circuit relief pressure is not normal,
adjust relief valve (2) of the flow amplifier valve
according to the following procedure.

HM400-3M0 30-59
30 Testing and adjusting
Brake system

Brake system (ALL-G000-001-K-00-A)

Testing and adjusting brake oil pressure (HM400_3R-G210-360-K-00-A)

a Testing tools pressure is stopped after reaching the upper

Sym- limit.
Part No. Part name
bol a The cut-in pressure and cut-out pressure of
799-101-5002 Hydraulic tester the charge valve are normal when they are
1
709-261-1204 Digital hydraulic tester within the standard value range. For
L
2 793-520-1805 Brake test kit standard values, see Standard value table,
3 799-401-3200 Adapter assembly "Standard value table for machine".

k Place the machine on a level ground, set the Testing by use of testing tools
parking brake switch to P (parking), and a Besides the testing method by using the
chock the wheels. machine monitor as explained above, the
charge valve oil pressure can be measured at
a ACC (accumulator) charge oil pressure (cut-in
remote pressure pickup port (1).
pressure and cut-out pressure) can be checked
on "Monitoring/Pre-defined" or "Monitoring"
screen of the machine monitor.
Testing (HM400-G210-362-K-00-A)
Testing with machine monitor
1. Display the following 2 items on "Monitoring
Selection Menu" screen of the machine monitor.
a For the operating method, see "Special
functions of machine monitor".
• Monitoring code:
35500 "Accumulator Pressure (F)"
• Monitoring code:
35501 "Accumulator Pressure (R)" 1. Install hose [1] of hydraulic tester L1 to the port
and connect oil pressure gauge [2] to the hose.
a Use an oil pressure gauge of 40 MPa {400
kg/cm2}.

2. Start the engine.

3. Measure the cut-in pressure at high idle.
1) Repeat depressing and releasing of the
brake pedal to gradually decrease the oil
pressure in the accumulator.
2) Read the oil pressure at the point where the
lower pressure side of the displayed
"Accumulator Pressure" (front or rear) values
turns from descent to ascent.
4. Measure the cut-out pressure at high idle.
• Read the oil pressure at the point where the
ascent of the display value of "Accumulator
Pressure" (front or rear) from the cut-in
2. Start the engine.
3. Measure the cut-in pressure at high idle.
1) Repeat depressing and releasing of the
brake pedal to gradually decrease the oil
pressure in the accumulator.
2) Read the oil pressure at the point where the
pointer of oil pressure gauge [2] turns from
descent to ascent.
4. Measure the cut-out pressure at high idle.
Read the oil pressure at the point where the
move of the pointer of oil pressure gauge [2] is

30-60 HM400-3M0

stopped after a continuous ascent from the cut-
in.
4. Measure the actuating pressure of the foot brake
5. After finishing the test, remove the testing tools,
and restore the machine.
Testing wheel brake actuating pressure and
amount of pressure drop
a The same procedure applies to both the front
and center brake circuits.
1. Remove cover (1).
5. Measure the actuating pressure of the retarder
2. Remove air bleeder (2) of the slack adjuster.
a Air bleeder (2) is provided on the both sides.
Check the brake actuating pressures and
6. Measure the amount of pressure drop when the
amount of the pressure drops of the both
brake.
3. Install brake test kit L2 and bleed air from the
brake circuit.
a See "Bleeding air from brake circuit".
HM400-3M0
30 Testing and adjusting
Brake system
under the following conditions.
1) Run the engine at low idle for several
minutes and charge the accumulator, then
stop the engine.
2) Measure the oil pressure when the brake
pedal is depressed to the stroke end.
a When the foot brake operating pressure
is within the standard value range, it is
normal. For standard values, see
Standard value table, "Standard value
table for machine".
brake under the following conditions.
1) Run the engine at low idle for several
minutes and charge the accumulator, then
stop the engine.
2) Turn the starting switch to ON position.
3) Measure the oil pressure when the retarder
lever is pulled to the stroke end on your side.
a When the retarder brake operating
pressure is within the standard value
range, it is normal. For standard values,
see Standard value table, "Standard
value table for machine".
brake pedal is depressed under the following
conditions.
a Before starting this measurement, make sure
that the actuating pressures of the brake
pedal and retarder is normal.
1) Run the engine at low idle for several
minutes and charge the accumulator, then
stop the engine.
2) Measure the oil pressure when the brake
pedal is depressed to the stroke end.
a Keep on depressing the brake pedal.
3) Measure the oil pressure 5 minutes after to
calculate the amount of pressure drop.
30-61
30 Testing and adjusting
Brake system

a When the amount of drop of the wheel a When the parking brake operating (release)
brake operating pressure is within the pressure is within the standard value range,
standard value range, it is normal. For it is normal. For standard values, see
standard values, see Standard value Standard value table, "Standard value table
table, "Standard value table for machine". for machine".
7. After finishing the test, remove the testing tools,
and restore the machine.
a Bleed air from the brake circuit. For details,
see "Bleeding air from brake circuit".

Testing parking brake operating (release)

pressure
1. Set the parking brake switch to P (parking)
position.
2. Disconnect hose (3) of the parking brake
cylinder.

8. After finishing the test, remove the testing tools,

and restore the machine.
Adjusting (HM400-G210-27B-K-00-A)

a If the charge valve cut-in and cut-out pressures

are not normal, adjust R1 relief valve of charge
valve (5) according to the following procedure.
a Both the cut-in and cut-out pressures vary with
adjustment of R1 relief valve.
1. Open the inspection door at the rear right of the
cab.
3. Connect adapter assembly L3 and install the
hose again.
4. Install nipple [4] and hose [1] of hydraulic tester
L1 and connect oil pressure gauge [3] to the
hose.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.

2. Loosen lock nut (6) of R1 relief valve.

3. Turn adjustment screw (7) to adjust oil pressure.
a When the adjustment screw is:
• turned clockwise, the pressure is
increased.
• turned counterclockwise, the pressure is
decreased.
5. Start the engine and operate the parking brake
4. With adjustment screw (7) fixed, tighten lock nut
switch several times at high idle to bleed air in
(6).
the circuit.
6. Stop the engine and turn the starting switch to 3 Lock nut:
ON position. 19 to 21 Nm {1.9 to 2.1 kgm}
7. Measure the oil pressure when the parking
brake switch is turned to OFF (travel) position. a After the adjustment, recheck the oil
pressure according to the procedure
employed for the measurement.

30-62 HM400-3M0
 30 Testing and adjusting
Brake system

HM400-3M0 30-63
30 Testing and adjusting
Brake system

Testing accumulator nitrogen gas pressure and charging procedure for

accumulator nitrogen gas (HM300-G2G0-001-K-00-A)
a Testing tools • Nitrogen gas cylinder (c) must be connected
Sym- Applicable even when the gas pressure only is measured.
Part No. Part name 1. Stop the engine and eliminate the pressure in
bol standard
Gas charge the brake circuit completely by depressing the
P1 792-610-1702 — brake pedal until its reactive force disappears.
tool
Nipple (for
792-610-1310 Russia) GOST a Depressing the brake pedal roughly 30 times
eliminates its reactive force and no oil
Nipple (for pressure is left in the circuit.
792-610-1320 USA) CGA No. 351
2. Remove plug (2) and cap (3) from accumulator
Nipple (for ASA B-571- (1).
792-610-1330 USA)
1965
P2 DIN 477-1963
NEN 3268-
Nipple (for
792-610-1350 Germany) 1966
SIS-SMS
2235/2238
Nipple (for BS 341
792-610-1360 UK)
Part1-1962

k In order to prevent leaked nitrogen gas from

contacting your skin and clothing, be sure to
wear the appropriate protective items (such
as goggles, leather gloves and protective
clothing) and do the work from the windward
3. Connect gas charging tool P1 to valve (4) of
side as much as possible.
k When handling nitrogen in an ill-ventilated
location like in a room, you must improve
ventilation of the room and observe the local
regulation for labor safety and health to
prevent oxygen deficiency disease and other
hazards.
k The accumulator is charged with high-
pressure nitrogen gas. Its inappropriate
handling can cause an explosion accident,
leading to serious personal injury or death.
The following rules must be strictly observed
when handling the gas.
• Do not bring any open flame near the
accumulator or expose it to fire.
• Do not drill it, weld or fuse-cut it.
• Do not give impacts to it by hitting or rolling it.
• Bleed the gas in it before disposing it.
• Decrease the charged gas pressure to the level
of atmospheric pressure before disassembling
or removing it.
• The gas to be charged must be nitrogen gas.
• Do not use explosive gases including oxygen.
• The accumulator must be handled strictly
following this procedure described above.
Testing (HM300-G2G0-280-K-00-A)
accumulator (1) according to the following
procedure.
1) Turn handle (a) of gas charging tool P1 fully
counterclockwise until it stops.
2) Keep the valve and handle (b) of nitrogen
gas cylinder (c) closed.
3) Install the extension attached to gas
charging tool P1 to gas valve (4) of
accumulator (1), and then connect the gas
charging tool.
4) Connect gas charging tool assembly P1 and
nitrogen gas cylinder (c).
a Exercise care in the above operation
since the bending load applied to gas
valve (4) can damage it.
• 2 types of threads, W22-14 threads (male
thread A type) and w23-14 threads
(female thread B type), are available for
the nitrogen gas cylinder. When using a
cylinder with W23-14 threads (female
thread B type), connect the hose by using
the adapter. (The adapter is attached to
gas charging tool P1) [inside Japan]
• Connect the hose by using nipple P2,
depending on the specification of the
nitrogen gas cylinder. [Outside of Japan]

a The following testing procedure is applicable to

an independent accumulator as well.

30-64 HM400-3M0
 30 Testing and adjusting
Brake system

a Since the pressure indication varies

depending on the ambient temperature at the
time of measurement, you must refer to the
following table when measuring the gas
pressure.
Ambient
tempera- Gas pressure
ture Remarks
°C MPa kg/cm2
15 4.34 44.2
16 4.35 44.4
17 4.37 44.5
18 4.38 44.7
19 4.4 44.8
Base gas
20 4.41 45 pressure
21 4.43 45.2
22 4.44 45.3
23 4.46 45.5
24 4.47 45.6
25 4.49 45.8
26 4.5 45.9
27 4.52 46.1
28 4.53 46.2
29 4.55 46.4
4. Turn handle (a) of gas charging tool P1 30 4.56 46.5
clockwise slowly and read the value of the 31 4.58 46.7
gauge. 32 4.59 46.8
33 4.61 47
k In order to prevent damage of gas valve 34 4.62 47.2
(4), it is prohibited to rotate handle (a) 1.5 35 4.64 47.3
turns or more after the pressure of the 36 4.65 47.5
charged gas is displayed. 37 4.67 47.6
• Check that no gas leakage is recognized. 38 4.68 47.8
39 4.7 47.9
40 4.71 48.1
41 4.73 48.2
42 4.74 48.4
43 4.76 48.5
44 4.77 48.7
45 4.79 48.8
Displayed gas pressure = Base gas pressure
x ((273 + t) / (273 + 20))
(Every number in the formulas is represented
in °C.)
5. If the indicated gas pressure is below or above
the targeted level, adjust it referring to "Charging
procedure of accumulator nitrogen gas".
a A certain amount of nitrogen gas is
discharged every time measurement is done
and the pressure decreases. Be sure to
replenish it by the amount of the gas
discharged.
6. Turn handle (a) of gas charging tool
counterclockwise until it stops.

HM400-3M0 30-65
30 Testing and adjusting
Brake system

7. Remove gas charging tool P1 from accumulator

(1) and restore the machine. See "Procedure for
charging accumulator with nitrogen gas".
Charging procedure of accumulator
nitrogen gas (HM300-G2G0-219-K-00-A)
a The following charging procedure is applicable
to an independent accumulator as well.
1. Stop the engine and eliminate the pressure in
the brake circuit completely by depressing the
brake pedal until its reactive force disappears.
a Depressing the brake pedal roughly 30 times
eliminates its reactive force and no oil
pressure is left in the circuit.
2. Remove plug (2) and cap (3) from accumulator
(1).

4. Slightly open the valve of nitrogen gas cylinder

3. Connect gas charging tool P1 and nitrogen gas
cylinder (c) to valve (4) of accumulator (1)
according to the following procedure.
1) Turn handle (a) of gas charging tool P1
counterclockwise until it stops.
2) Turn handle (b) counterclockwise and leave
the valve open.
3) Install the extension attached to gas
charging tool P1 to gas valve (4) of
accumulator (1), and then connect the gas
charging tool.
4) Connect gas charging tool assembly P1 and
nitrogen gas cylinder (c).
• 2 types of threads, w22-14 threads (male
thread A type) and w23-14 threads
(female thread B type), are available for
the nitrogen gas cylinder. When using a
cylinder with w23-14 threads (female
thread B type), connect the hose by using
the adapter.
(The adapter is attached to gas charging
tool P1) [inside Japan]
• Connect the hose by using nipple P2,
depending on the specification of the
nitrogen gas cylinder. [Outside of Japan]
(c), and discharge the gas at pressure of 0.19 to
0.29 MPa {2 to 3 kg/cm2}.
5. Turn handle (b) clockwise to close the valve
when nitrogen gas starts to come out of handle
(b).
6. Turn handle (a) clockwise slowly to gradually
open valve (4) of accumulator (1).
a Exercise care in operating handle (a) since
excessive turning of handle (a) can damage
the accumulator valve core, inducing gas
leakage.
7. Open the valve of nitrogen gas cylinder (c)
further to charge the nitrogen gas to the
accumulator.
8. Close the valve of nitrogen gas cylinder (c) from
time to time during this operation to check the
nitrogen gas pressure in the accumulator.
a For the nitrogen gas pressure testing
procedure, see Item 4 of "Testing of
accumulator nitrogen gas pressure".
9. After the gas is charged up to the standard value,
close the valve of nitrogen gas cylinder (c).
• When the charged gas volume is excessive,
discharge excessive gas by turning handle
(b) slowly counterclockwise while keep the
valve of nitrogen gas cylinder (c) being
closed.
10.Remove gas charging tool P1 from valve (4) of
the accumulator (1) according to the following
procedure.

30-66 HM400-3M0
 30 Testing and adjusting
Brake system

1) Turn handle (a) counterclockwise to close

the accumulator valve.
2) Turn handle (b) counterclockwise to open the
valve, and discharge the nitrogen gas
remaining in gas charging tool assembly P1
and the hose.
3) Remove gas charging tool P1 from valve (4)
of the accumulator.
11.Apply soapsuds to valve (4) of the accumulator
to make sure there is not leakage of nitrogen
gas.
12.Install plug (2) and cap (3) to accumulator (1).
3 Plug
73.5 to 98.0 Nm {7.5 to 10.0 kgm}

13.Within a week from charging nitrogen gas,

check the performance of the brake according to
the following procedure to check that no
pressure drop of nitrogen gas is found.
a Check the brake function within 5 minutes
from stop of the engine. (If more than 5
minutes elapse from stop of the engine,
correct measurement becomes unavailable
because oil pressure in the brake circuit
drops.)
1) Place the machine on a flat ground and turn
the parking brake switch to "PARKING"
position.
2) Start the engine, and run it at medium speed
for 5 minutes, then stop the engine.
3) Turn the starting switch to ON position and
depress the brake pedal repeatedly to record
the depressing frequency required for the
brake oil pressure caution lamp to light up .
• Number of times of depressing is less than 5:
Accumulator gas pressure may be low
• Number of times of depressing is 5 or more:
Accumulator gas pressure is normal.

HM400-3M0 30-67
30 Testing and adjusting
Brake system

Testing braking performance (HM400_3R-G000-360-K-00-A)

k Place the machine on a level ground, set the

parking brake switch to P (parking), and
chock the wheels.

a Check that "F2" (gear speed at start) is selected

on "F1 Start at D Position Setting" screen of the
machine monitor.
Testing (HM300-G000-38E-K-00-A)
Testing foot brake performance
1. Start the engine and turn the parking brake
switch to OFF position.
2. Depress the brake pedal fully and turn the shift
lever to D position. 4. After the testing, run the engine at low idle and
a Any position other than D must not be used turn the shift lever to N position.
for testing the brake pedal performance. Testing parking brake performance
3. Depress the accelerator pedal gradually, and
check that stalling the torque converter at the k Movement of the machine can result in
specified speed does not cause movement of serious personal injuries. Therefore,
the machine. whenever the machine starts to move during
the test, decrease the engine speed
immediately, turn the gear shift lever to N
position and depress the brake pedal.

1. Turn the parking brake switch to ON position

and start the engine.
2. Turn the shift lever to D position.
a Any position other than D must not be used
for testing the performance of parking brake.
3. Depress the accelerator pedal gradually, and
check that stalling the torque converter at the
specified speed does not cause movement of
the machine.
4. After the testing, run the engine at low idle and 4. If the machine starts to move below the specified
turn the shift lever to N position. speed, check the pad and adjust the clearance.
For details, see "Checking wear of parking brake
Testing retarder brake performance
pad and adjusting clearance" described below.
1. Set the parking brake switch to P (parking)
position, and start the engine.
2. Pull the retarder lever fully to your side and turn
the shift lever to D position.
a Any position other than D must not be used
for testing the brake pedal performance.
3. Depress the accelerator pedal gradually, and
check that stalling the torque converter at the
specified speed does not cause movement of
the machine.

5. After the testing, run the engine at low idle and

turn the shift lever to N position.

30-68 HM400-3M0
 30 Testing and adjusting
Brake system

Bleeding air from brake circuit (HM300-G000-001-K-01-A)

k Place the machine on a level ground, set the 3) When oil without air starts to flow out, tighten
parking brake switch to P (parking), and air bleeder (1).
chock the wheels.
3 Air bleeder:
a When brake circuit equipment is removed or 10 to 20 Nm {1 to 2 kgm}
installed, bleed air from the brake circuit 5. Do the same with air bleeder (1) on the opposite
according to the following procedure. side to bleed air from the brake pedal circuit and
retarder brake circuit.
a When bleeding air from the foot brake circuit, be 6. Restore the machine after the adjustment
sure to bleed air in the order of the slack adjuster
and wheel brake. Bleeding air from wheel brake part of foot brake
Air bleeding procedure (HM400-G000-231-K-00-
circuit
A) a The same procedure applies to both the front
Bleeding air from slack adjuster of the foot and center brake circuits.
brake circuit
1. Connect air bleeding hose [1] to air bleeder (2).
a The same procedure applies to both the front
and center brake circuits.
Air bleeding cannot be performed when the oil
pressure is low (not charged). To obtain the cut-
in pressure, tighten the air bleeder once,
depress the foot brake 8 to 10 times, charge the
oil pressure to accumulator, and perform air
bleeding.
1. Connect air bleeding hose [1] to either right or
left air bleeder (1).

2. Start the engine and run it at low idle.

3. Keep depressing the brake pedal.
4. Loosen air bleeder (2) by approximately 1/2
turns to drain oil mixed with air.
5. When oil without air starts to flow out, tighten air
bleeder (2).

Bleeding air from parking brake circuit

1. Start the engine and run it at low idle.
2. Repeat activation and release several times by
using the parking brake switch.
2. Start the engine and run it at low idle.
3. Bleed air from the brake pedal circuit according a Air is bled automatically with above
to the following procedure. operation.
1) Keep depressing the brake pedal.
2) Loosen air bleeder (1) by approximately 3/4
turns to drain oil mixed with air.
3) When oil without air starts to flow out, tighten
air bleeder (1).
3 Air bleeder:
10 to 20 Nm {1 to 2 kgm}
4. Bleed air from the retarder brake circuit
according to the following procedure.
1) Pull the retarder lever fully to your side and
keep it in that position.
2) Loosen air bleeder (1) by approximately 1/2
turns to drain oil mixed with air.

HM400-3M0 30-69
30 Testing and adjusting
Brake system

Testing wear of wheel brake disc (HM300-G167-001-K-00-A)

k Place the machine on a level ground, set the
parking brake switch to P (parking), and
chock the wheels.
k The brake oil temperature must be 60°C or
below when measuring the wear.
k Increase the measuring frequency when the
disc nears the wear limit. At the same time,
braking performance of the retarder must
also be checked positively.
a Outside line (b) on rod (2) indicates the wear
limit of the disc.
If entire outside line (b) of rod (2) enters
inside guide (3) (if the line reaches the end
face), the wear is reached to its limit, and the
disc must be replaced.

a Measure the wheel brake disc wear amount

under the following conditions.
• Brake pedal: stroke end
• Measure with disc wear measuring gauge
Testing (HM400-G167-389-K-00-A)

1. Check that no other brake than the parking

brake is activated.
2. Turn the starting switch to ON position to check 6. Install cap nut (1) of the gauge.
that the brake oil pressure caution lamp is not lit. 3 Cap nut:
a If the lamp is lit, oil pressure in the brake 29.4 to 39.2 Nm {3 to 4 kgm}
circuit is low. In this case, Start the engine,
and run it approximately at 2,000 rpm and
stop the engine when the lamp goes out.
3. Remove cap nut (1) of the gauge.

4. Keep depressing the brake pedal.

a Be sure to stop the engine before starting the
measurement. If the engine runs, the brake
cooling oil interferes with the accurate
measurement.
5. Push in rod (2) of the gauge until it touches
piston (5), then measure the wear.
a A groove is machined in rod (2).
a On a new machine, inside line (a) of the
groove of rod (2) is adjusted to align with end
face (c) of guide (3).
In order to prevent displacement of the
above adjusted position, it is prohibited to
loosen fixing nut (4) of guide (3) except for
replacement of the disc.

30-70 HM400-3M0
 30 Testing and adjusting
Brake system

Parking brake emergency releasing procedure (HM400-GJ00-141-K-00-A)

a If the parking brake becomes not releasable due

to a failure in its electrical or hydraulic system,
perform the following procedure to release the
brake temporarily.
k If the failure occurs in the hydraulic system,
normal operation of the wheel brake is also
likely to be blocked. So, after releasing the
parking brake, tow and move the machine at
a low speed.

k The parking brake releasing operation must

be performed on a flat ground after checking
the safety in the surrounding area. If you are
forced to release the parking brake on a
slope due to an emergency, be sure to chock
the wheels.

1. Turn the parking brake adjustment screw (1)

counterclockwise to create a gap between the
pad and disc.

2. Tow the machine to a safe place.

a After moving the machine to the intended
place, chock the wheels.

HM400-3M0 30-71
30 Testing and adjusting
Brake system
Testing wear of parking brake pad and adjusting clearance
k Place the machine on a level ground, set the
parking brake switch to P (parking), and
chock the wheels.
a Before starting the measurement, start the
engine and raise the body to the stroke end of
the cylinder rod, set the body pivot pin and stop
the engine.
Testing (HM400-GJ34-389-K-00-A)
1. Turn the starting switch to ON position, turn the
parking brake switch to OFF position, and then
release the parking brake.
2. Remove the parking brake top cover.
3. Turn adjustment screw (1) clockwise to release
the parking brake.
4. Remove right and left brackets (2), then remove
2 each of springs (3) and (4).
5. Remove 2 pads (5).
6. Measure thickness (a) of pad (5).
a Limit thickness of pad: 1.5 mm
a If the thickness of either the front or rear pad
reaches the limit, replace the pads on both
sides at the same time.
30-72
(HM300-GJ34-001-K-00-A)
Adjusting (HM400-GJ34-27D-K-00-A)
a When performance of the parking brake is poor
or when the pad is replaced with a new one,
adjust the clearance according to the following
procedure.
k While the adjustment work is continued,
increase the oil pressure high enough to
prevent automatic application of the parking
brake. And attach a signboard to the parking
brake switch to prevent it from being
operated by unauthorized persons.
k Do not allow adhesion of oil and grease to
the brake pad and disc surfaces.
1. Turn the starting switch to ON position, turn the
parking brake switch to OFF position, and then
release the parking brake.
2. Install 2 pads (5).
3. Install springs (3) and (4) (2 each on right and
left brackets (2)), and install right and left
brackets (2).
a 2 types of springs are used. Check their
colors to avoid installing them in a wrong
position.
Spring (3): Black
Spring (4): Yellow
a Tighten the bracket mounting bolt temporarily
by screwing it 2 to 3 turns.
4. Turn adjustment screw (1) clockwise until pad
(5) closely contacts to disc (6).
5. While checking clearance (b and c) between pad
(5) and disc (6), push down the lock of
adjustment nut (1) and turn the nut clockwise
until the specified clearance is obtained.
a Standard clearance (total of b and c): 1.5 mm
HM400-3M0
 30 Testing and adjusting
Brake system

6. Start the engine.

7. Release the parking brake and recheck the
clearance of the pad.
a Clearance (total of b and c): 1.5 mm
a If the clearance is not normal, repeat the
adjustment work from step 3.
8. Tighten the mounting bolts for right and left
brackets (2).
a Exercise care not to allow displacement of
the mounting position.
9. Measure the clearance between pad (5) and
disc (6) again.
a Standard clearance (total of b and c): 0.05
mm
a If the clearance on one side is narrower,
adjust it by changing the mounting position of
the right and left brackets.

HM400-3M0 30-73
30 Testing and adjusting
Hydraulic system

Hydraulic system (ALL-C000-001-K-00-A)

Testing and adjusting suspension cylinder (HM300-E000-001-K-01-A)

a Testing tools k Place the machine on a level ground, set the

Sym- parking brake switch to P (parking), and
Part No. Part name chock the wheels.
bol
— 792-610-1000 Suspension tool
— 792-610-1100 Pump assembly
1 792-610-1130 • Pump
2 792-610-1110 • Hose
3 792-610-2200 • Joint
— 792-610-1200 Charging tool assembly
4 07020-21732 • Fitting
N 5 792-610-1140 • Joint
6 792-610-1250 Valve assembly
7 792-610-1260 • Nipple
8 792-610-1270 • Hose
9 792-610-1280 • Valve
10 792-610-1400 • Regulator
11 792-610-1430 Gauge
12 792-610-1440 Gauge
Note: [—] indicates the kit part number.

Testing (HM400_3M0-E000-360-K-00-A)

30-74 HM400-3M0
 30 Testing and adjusting
Hydraulic system

1. Measuring cylinder length k Exercise care in handling the

Measure the installed length of the suspension hydraulic jack to avoid damaging the
cylinder under the following condition. suspension cylinder by retract it
• On horizontal road excessively.
• Engine stopped
a Specified length when oil is put in (front)
• Dump body unloaded
(a): 76 ± 3 mm
a Front cylinder installed length (a):
a Specified length when oil is put in (rear)
176 ± 10 mm (b): 76 ± 3 mm
Rear cylinder installed length (b): 106 ± 5
mm
a If the cylinder length is not normal, adjust it
according to steps 2 to 5.
2. Extracting nitrogen gas
1) Set a hydraulic jack under the machine frame
and lift the wheels slightly.
a The jack to be used should be 490 kN {50
ton}.

k Be sure to securely set the jack under

the frame.
a When you work on the front, push up the
front frame until the front wheels are
slightly lifted off the ground.
a When you work on the rear, push up the
frame until either the front or rear wheels
are slightly lifted off the ground.
2) Move cover (1).
3) Loosen oil level valve (2) gradually and when
nitrogen gas starts to flow out, maintain the
valve as it is.
a If the nitrogen gas and oil blow out at the
same time, tighten the valve somewhat
closer until outflow of the oil stops. In
such a way, spend enough time to
release the nitrogen gas.

4) Lower the frame gradually by operating the

hydraulic jack and retract the suspension
cylinder to the specified length.

HM400-3M0 30-75
30 Testing and adjusting
Hydraulic system
Adjusting (HM400_3R-E000-270-K-00-A)
1. Adjusting oil level
a Oil level adjustment must be performed after
the release of the nitrogen gas is completed.
1) Check that the suspension cylinder conforms
to the specified oil-level length.
a Specified length when oil is put in (front)
(right and left) (a): 76 ± 3 mm
a Specified length when oil is put in (rear)
(b): 76 ± 3 mm
k Handle the hydraulic jack with care.
2) Remove oil level valve (2).
3) Remove the valve body of feed valve (3) and
install joint N5.
4) Install fitting N4 to joint N3 and connect hose
N2 and pump N1 to them.
5) Operate pump N1 to release the gas from the
mounting port of oil level valve (2).
a Spurt oil from the mounting port and add
oil until the oil not mixed with air bubbles
starts to flow out.
a Oil quantity to be added to front (right and
left) (reference): 7.8 l
a Oil quantity to be added to rear cylinder
(reference): 2.4 l
6) Install oil level valve (2).
30-76
3 Oil level valve:
39 to 49 Nm {4 to 5 kgm}
7) Remove suspension tools N1 to N4 and
install feed valve (3).
3 Feed valve:
39 to 49 Nm {4 to 5 kgm}
2. Charging nitrogen gas
a Charge the cylinder with the nitrogen gas
after the oil level adjustment is completed.
1) Remove the top cap of feed valve (3).
2) Connect suspension tools N6 to N12 as
shown in the figure.
a Connect valve N9 to the feed valve.
a Before installing the regulator, blow
foreign material off the adapter filter by
using nitrogen gas (min. 1 MPa {10 kg/
cm2 to prevent it from entering.
3) Open valve [C] of nitrogen gas cylinder [1]
and check the pressure (pressure inside the
cylinder) indicated by gauge N11.
a The indicated pressure must be higher
than the internal pressure of the cylinder
by at least 1 MPa {10 kg/cm2}.
HM400-3M0
 30 Testing and adjusting
Hydraulic system

a Internal pressure of cylinder (reference)

(Front right, left): 3.6 MPa {36.6 kg/cm2}
(Rear): 1.9 MPa {19.4 kg/cm2}
4) Turn the handle of regulator N10 gradually
counterclockwise to set the pressure
indicated by gauge N12.

k It is prohibited to fill the cylinder with

the nitrogen gas to extend the cylinder
to the stroke end.
5) Operate the handle of valve N6 and valve N9
to supply the nitrogen gas to the suspension
cylinder.
a Supply the nitrogen gas to the right and
left cylinders at the same time.
6) When the length of the right and left cylinders
reach the specified installed length, turn the
handle of regulator N10 counterclockwise to
stop the supply of nitrogen gas.
a Front cylinder installed length (a): 176 ±
10 mm
Rear cylinder installed length (b): 106 ± 5
mm
7) Rewind the handle of valve N9 fully and
loosen the air bleeding plug of valve N6 to 3. Adjusting cylinder length
discharge the gas in the hose.
8) Remove suspension tools N6 to N12. a Adjust the cylinder length after charging of
nitrogen gas.
a Take care not to lose the O-ring of the
feed valve. a Adjust the cylinder length with the dump
9) Install the top cap of feed valve (3). body empty and on a flat road.
10)Install the cover of the suspension cylinder. 1) Drive the machine forward approximately 15
m and stop it suddenly. Then drive the
machine in reverse to the original position
and stop it suddenly. After repeating these
operations 3 to 4 times, apply the retarder
brake gradually to stop the machine slowly.
a Stop the machine slowly as much as
possible by using the retarder brake to
eliminate skid resistance of the cylinder
(jamming of packing and bushing).
2) Measure the installed length of the cylinder:
a Front cylinder installed length (a): 176 ±
10 mm
Rear cylinder installed length (b): 106 ± 5
mm
3) If the installed length is excessive, adjust it
by discharging nitrogen gas from oil level
valve (2).
a In this case, loosen the oil level valve
slightly so that the cylinder may not be
moved when the gas is discharged.

HM400-3M0 30-77
30 Testing and adjusting
Hydraulic system

a If the volume of discharged gas is as

large as to move the cylinder, the
installed length can become shorter than
the specified length. Care must be taken
for that.
4) After the adjustment, measure the cylinder
length again according to the above Steps 1)
and 2).
5) Check oil level valve (2), feed valve (3) and
cylinder ground for gas leakage.

a Use soap water for checking the gas

leakage.
• Note 1: Testing after replacement of oil
and gas
If you operate the machine after replacing
oil or gas, the gas is dissolved into oil in
the cylinder until saturated condition is
reached. As a result, volume of the gas is
decreased and the cylinder length
becomes shorter than the allowable value.
Therefore, the cylinder installed length
must be measured 48 hours after the
replacement of the oil or gas. If the length
is below the specified length, adjustment
must be made with gas.
• Note 2: Measuring variations in cylinder
length due to temperature changes
The gas in the suspension cylinder
inflates or contracts depending on the
temperature during work, and this varies
the cylinder length.
Therefore, in the areas where the
temperature difference during a year is
large, the cylinder installed length must
be adjusted to the specified range
through the daily inspection.

30-78 HM400-3M0
 30 Testing and adjusting
Hydraulic system

Testing and adjusting dump circuit oil pressure (HM400-M510-001-K-00-A)

a Testing tools
Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
1
S 790-261-1204 Digital hydraulic tester
2 790-301-1720 Adapter

k Place the machine on a level ground, set the

parking brake switch to P (parking), and
chock the wheels.

k Relief pressure measurement must not be

performed when the cab is tilted.
2. Start the engine, raise the dump body to the
stroke end.
k Install and remove the testing tools after the
3. Run the engine at high idle, operate the dump
oil temperature lowers.
lever to RAISE, and measure the oil pressure
a Measure the dump circuit oil pressure under the during relieving.
following condition. a The main relief pressure is normal when it is
• Hydraulic oil temperature: 45 to 55°C within the standard value range. For
standard values, see Standard value table,
Testing (HM400-M510-360-K-00-A)
"Standard value table for machine".
Testing main relief pressure
a The dump main circuit shares the hydraulic
pump (source pressure) with the steering circuit.
Since precedence is given to the steering circuit
in this configuration, you must check that the
steering circuit pressure (steering relief
pressure) is normal before starting testing of this
circuit.
a Measure the main relief pressure at remote
pressure pickup port (1).

4. After finishing the test, remove the testing tools,

and restore the machine.
Testing pilot relief pressure
1. Tilt up the cab.
a When tilt up or down the cab, see "Cab tilt-up
procedure".
2. Remove oil pressure pickup plug (1).

1. Install hose [1] and connect oil pressure gauge

S1 to it.
a Use an oil pressure gauge of 40 MPa {400
kg/cm2}.

HM400-3M0 30-79
30 Testing and adjusting
Hydraulic system

3. Install adapter S2, nipple, and hose [1], and

connect oil pressure gauge S1 to the hose.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.

1. Loosen lock nut (2) and turn adjustment screw

(3) for the adjustment.
a Rotate the adjustment screw
• turned clockwise, the pressure increases.
4. Start the engine, and run it at high idle and • turned counterclockwise, the pressure
measure the oil pressure. (Dump lever in decreases.
neutral)
a The adjustment screw increases or
a The pilot relief pressure is normal when it is decreases the pressure by 12.5 MPa {128
within the standard value range. For kg/cm2} with its single turn.
standard values, see Standard value table,
"Standard value table for machine".

2. Support adjustment screw (3) with the

5. After finishing the test, remove the testing tools,
and restore the machine.
Adjusting (HM400_3R-M510-27B-K-00-A)
Adjusting main relief pressure on RAISE side
• Tilt up the cab.
(See "Cab tilt-up procedure" in "Cab and its
attachments".)
a If the main relief pressure on RAISE side is not
normal, adjust relief valve (1) of the hoist valve
according to the following procedure.
screwdriver and tighten lock nut (2).
3 Lock nut tightening torque:
29.4 to 39.2 Nm {3 to 4 kgm}
a After the adjustment, recheck the oil
pressure according to the procedure for the
measurement.
Adjusting pilot relief pressure
a If the pilot relief oil pressure is not normal, adjust
relief valve (1) according to the following
procedure.

30-80 HM400-3M0
 30 Testing and adjusting
Hydraulic system

1. Remove the cap, loosen lock nut (2) and turn

adjustment screw (3) for the adjustment.
a When the adjustment screw is:
• turned clockwise, the pressure increases.
• turned counterclockwise, the pressure
decreases.
a The adjustment screw increases or
decreases the pressure by 0.84 MPa {8.6 kg/
cm2} with its single turn.
2. Tighten lock nut (2) while holding adjustment
screw (3).
3 Lock nut tightening torque:
19 to 21 Nm {1.9 to 2.1 kgm}
a After the adjustment, recheck the oil
pressure according to the procedure
employed for the measurement.

HM400-3M0 30-81
30 Testing and adjusting
Work equipment

Work equipment (ALL-L000-001-K-00-A)

Adjusting dump body positioner sensor (HM300-M5D2-001-K-00-A)

a When the body positioner rod is disconnected or 6. Check that the normal input voltage is recovered
connected, or the positioner sensor is removed by using the above testing procedure.
or installed, test and adjust the positioner sensor
according to the following procedure.
Adjusting (HM400-M5D2-270-K-00-A)
Testing sensor input voltage
1. Select "Body Potentio. Volt" on "Monitoring
Selection Menu" screen of the machine monitor
to display the input voltage of the body
positioner sensor.
a For the operating method, see "Special
functions of machine monitor".
• Monitoring code: 34603 "Body Potentio. Volt"

System calibration work

2. Start the engine.
3. Operate the dump lever to measure the
monitoring voltage at the time when the body is
seated.
a When dump body is seated: 0.4 to 0.6 V
Adjusting link length
a If the monitoring voltage is not in the normal
range, adjust the link length according to the
following procedure.
1. Loosen lock nut (1).
2. Remove mounting bolts (2).
3. Turn rod end (3) to adjust link length (4).
a Standard installed length (a) of link: 220 mm
a Installed length (a) must not be shorter than
218 mm.
a Input voltage is
• decreased when the link is extended.
• increased when the link is retracted.
a Amount of voltage fluctuation per rotation of
rod end: Approximately 0.04 V
4. Install mounting bolt (2).
5. Tighten lock nut (1).
1. Start the engine to increase the hydraulic oil
temperature to 80 to 90°C.
2. Lower the dump body to the stroke end of the
cylinder with the engine at low idle, and in this
condition, move the dump lever to FLOAT
position and hold it there for 5 seconds or more.
a Check that the dump body float caution lamp
is turned OFF.
3. Raise the dump body to the stroke end of the
cylinder with the engine at low idle, and in this
condition, move the dump lever to RAISE
position and hold it there for 5 seconds or more.
4. Lower the dump body to the stroke end of the
cylinder with the engine at low idle.
5. After raising the dump body to the stroke end of
the cylinder with the engine at high idle, operate
the dump lever to LOWER position with the
engine at low idle. When the dump body starts
lowering, return the lever to FLOAT position to
lower the dump body to the stroke end of the
cylinder.
a Repeat the above operations 5 to 10 times.
6. After raising the dump body to the stroke end of
the cylinder with the engine at high idle, operate
the dump lever to LOWER position with the
engine at high idle. When the dump body starts
lowering, return the lever to FLOAT position to
lower the dump body to the stroke end of the
cylinder.
a Repeat the above operations 5 to 10 times.

30-82 HM400-3M0
 30 Testing and adjusting
Cab and its attachments

Cab and its attachments (ALL-K000-001-K-30-A)

Cab tilt up procedure (HM400_3R-K000-27G-K-00-A)

k In order to prevent serious or death
accidents due to falling of the cab, following
precautions must be observed when tilting
the cab.
• Precautions before starting cab-tilting operation
k Cab-tilting operation must be performed on a
flat ground.
k Set the machine to the straight-travel
condition to prevent the interference
between the cab and body, then fix the front
and rear frames by using the articulation
lock.
k Set the parking brake switch to PARKING
position to apply the parking brake.
k Lock the lever by using the dump lever lock
knob.
k Chock the wheels to prevent the machine
from moving.
k When dismounting the cab, always lock the
lock pin at the rear mounting part of cab
before starting the work.
k Do not perform the cab-tilting operation
when it is strongly windy.
k Do not give a large impact to the machine
when tilting up the cab.
k When lowering the cab by using the cab
power tilt (optional), do it gradually adjusting
the descending speed without decreasing
the oil pressure at a breath.
k The lock bar is equipped in the inner left side
corner of the engine hood. Be sure to return
the bar to the original place after using it.
a When you perform the inspection or
maintenance work around the hydraulic pump or
the upper part of the torque converter or
transmission, tilt up the cab toward rear side of
the machine according to the following
procedure.
a There are three ways of tilting up the cab as
described below. Choose the one that suits
better to the given jobsite situations.
• Lever block-based approach
• External crane-based approach
• Cab power tilt-based approach (see
Attachment in Operation and Maintenance
Manual)
1. Preparation
1) Open engine hood (1).

• Precautions for cab-tilting operation

k Do not perform the cab-tilting operation
when the dump body is loaded.

k Do not place yourself under the cab as long

as the cab-tilting operation is continued.

k Fix the cab securely by using the lock lever

before tilting up the cab.

k Installthe lock lever from the side of the cab

without entering into a space below the cab. 2) Remove lock bar (2) from the storage place
on the rear left side of the engine.
k Do not go in or out the cab when tilting up
the cab.

k Do not operate the gear shift lever and dump

lever when tilting up the cab.

k Do not start the engine when tilting up the

cab.

k When you are forced to start the engine for

inspection purpose, check that no person is
under the cab.

HM400-3M0 30-83
30 Testing and adjusting
Cab and its attachments

a The right side of the rear mounting part of

the cab is shown in the following
procedures. Perform the same work on
the left side.
5) Remove lock bolt (22), washer (23) and
collar (24) of the tilt pin (21).
6) Remove bolt (25) and washers (26).
7) Install bolt (22) into the tapped hole (c).
8) After the tip of bolt (22) faces the stopper
bracket (28), turn it further and pull tilt pin
(21) out.

3) Remove 4 mounting bolts (3) each on the

right and left mounts in front of the cab.

a In the case of using bar, pull tilt pin (21)

out by using bar A until the tilt pin lock
plate (21a) is off from the stepped boss
(27).

4) Change the fixing position of tilt pin of the a Pull tilt pin (21) out by using the stopper
mounting part at the rear of the cab from the bracket (28) as the fulcrum.
boss (a) to the boss (b) according to the
following procedure.
a: Plate position for travel
b: Plate position for tilting the cab
The figure shows the right side of the
mounting part at the rear of the cab.
a Before tilting up the cab, be sure to
change the pin (21) installation from the
cab mount to the frame mount.

9) Turn tilt pin (21) from the plate position (a) for
travel to the plate position (b) for tilting the
cab.

a Although the shape of the tilt pin which

mentioned in the following procedure has
been changed, the tilt pin (21) can be
replaced in the same way as the normal
tilt pin.

30-84 HM400-3M0

10)Insert the tilt pin (21) until the tilt pin lock
plate (21a) contacts with the stepped boss
(27).
11)Install the bolt (22), washer (23) and collar
(24), and fix tilt pin (21).
12)Install the bolt (25) and washers (26).
13)Remove fixing bolt (8) of guard (7) in the rear
of the cab, then secure guard (7) by using
rod (9).
HM400-3M0
30 Testing and adjusting
Cab and its attachments
2. Cab tilt up
1) Lever block-based approach
Set wire ropes (F) or chains, etc. to hooks
(10) and (11), then pull up the cab by
operating lever block (G).
F: Wire rope length - Min. 1.5 m
G: Lever block lifting height - Min. 1.5 m
Withstand load of the every sling to be used
must be 1.5 t or greater.
2) External crane-based approach
Put the slings to hook (12) (on both sides)
installed on the front side of the cab and sling
the cab to tilt it up.
3. Fixing cab
1) Lock securely lock bar (2) by using lock (13)
while paying attention to the mounting
direction of the lock bar.
30-85
30 Testing and adjusting
Cab and its attachments

2) After lowering the cab gradually, fix it.

k Check that lock (13) is closed and the

cab is securely fixed with lock bar (2).
a When you tilts up the cab by using the
cab power tilt (optional), lower the cab
slowly while releasing the oil pressure
gradually.
3) When using an external crane to tilt up the
cab, remove the external crane.
4. Cab tilt down
a Perform the tilt down in the reverse order of
the tilt up.
a After the tilt down, return lock bar (2) to its
original storage place and then tighten the
mounting bolts.
a For the fixing position of tilt pin (21) of the
mounting part at the rear of the cab, return
the plate position (b) for tilting the cab to the
plate position (a) for travel.

30-86 HM400-3M0

Electrical system (ALL-RA1D-001-K-30-A)
Setting and adjusting each equipment
Setting and adjustment items necessary for replacement, disassembly or assembly, or additional installation
of each equipment.
a When the replacement, disassembly or assembly, or additional installation work of the following equipment
is performed, setting and adjustment must be performed by using the machine monitor .
Contents of work
Replacement of monitor controller
Replacement of transmission controller
Replacement or disassembly/assembly of
transmission unit or transmission ECMV
solenoid valve
Replacement of retarder and hoist controller
Replacement or disassembly/assembly of
body positioner sensor or body positioner
rod
Replacement of retarder valve (when
optional ARAC is installed)
Replacement or disassembly/assembly of
KTCS-related parts (such as retarder
hydraulic pipes, wiring harnesses and
sensors)
Replacement of KOMTRAX terminal
Replacement of rearview monitor (if rearview • Initialization of rear view monitor (3-1)
camera is installed)
Replacement, disassembly, and assembly of
rearview camera (if rearview camera is
installed)
HM400-3M0
30 Testing and adjusting
Electrical system
(HM400_3M0-RA1E-110-K-00-A)
Necessary setting and adjustment items
• Language setting (1-1)
• Setting for Machine Model Selection (1-2)
• Setting for option selection (1-3)
• Setting for unit selection (1-4)
• Clearing of abnormality record information of electrical
system (1-5)
• Setting of service meter
• Setting of travel odometer
• Setting of reverse travel odometer
• Setting of KOMTRAX terminal
Perform the following settings when necessary
• Phone number entry (1-6)
• Setting of user password
• Setting usage limitation password (1-7)
• Setting for Machine Model Selection (1-2)
• Setting for option selection (1-3)
• Preparatory work for adjustment of transmission ECMV
current (2-1)
• Adjusting transmission ECMV current (2-2)
• Resetting initial learning of transmission and
implementation of learning (2-3)
• Clearing of abnormality record information of electrical
system (1-5)
• Preparatory work for adjustment of transmission ECMV
current (2-1)
• Adjusting transmission ECMV current (2-2)
• Resetting initial learning of transmission and
implementation of learning (2-3)
• Setting for Machine Model Selection (1-2)
• Setting for option selection (1-3)
• Clearing of abnormality record information of electrical
system (1-5)
• Adjusting dump body positioner sensor
• Setting characteristic values of ARAC (auto-retarder and
accelerator linked) (2-4)
• Implementation of KTCS system check (2-5)
• KOMTRAX terminal start-up procedure
• Adjustment of guide line position (3-2)
• Adjustment of guide line position (3-2)
30-87
30 Testing and adjusting
Electrical system
Contents of work
Parts related to payload meter (PLM) (When
machine is carried into jobsite after controller
or sensor is replaced or machine is
modified.)
(If equipped with payload meter (PLM))
Additional installation of optional equipment • Setting for option selection (1-3)
Language setting (1-1)
1. Press menu switch (E) on the standard screen.
2. Select "Language" on "Monitor Setting" menu
screen and press Enter switch (D).
• Up switch (A): Moves the selection up by one
item
• Down switch (B): Moves the selection down
by one item
• Return switch (C): Returns the display to the
standard screen
• Enter switch (D): Validates the selection
• Menu switch (E): Moves the selection to the
immediate right item
30-88
Necessary setting and adjustment items
• Execution of calibration (See Operation and Maintenance
Manual)
3. Select the language you want to display and
press Enter switch (D).
• The setting is maintained after the starting
switch is turned to OFF position.
Setting for Machine Model Selection (1-2)
• For the setting procedure of the machine model
selection, see "Initial setting (Machine Model
Section)" in "Special functions of machine
monitor".
Setting for option selection (1-3)
• For the setting procedure for the optional
equipment selection, see "Initial setting
(Optional equipment Selection)" in "Special
functions of machine monitor".
Setting for unit selection (1-4)
• For the setting procedure for the unit selection,
see "Initial setting (Unit)" in "Special functions of
machine monitor".
Clearing of abnormality record information of
electrical system (1-5)
• For the procedure for clearing of the abnormality
record information of electrical system, see
"Abnormality record (Display of abnormality
HM400-3M0

record information of electrical system" in
"Special functions of machine monitor".
Phone number entry (1-6)
• For the phone number entry procedure, see the
phone number entry in "Special functions of
machine monitor".
Setting usage limitation password (1-7)
• For the setting procedure of the usage limitation
password, see "Function of usage limitation
setting/changing password" in "Special functions
of machine monitor".
Preparatory work for adjustment of
transmission ECMV current (2-1)
k Place the machine on a level ground, set the
parking brake switch to P (parking), and
chock the wheels.
a The adjustment work must be performed at the
specified oil temperature. So adjust the
transmission oil temperature according to the
following procedure while checking that nothing
abnormal is displayed on the machine monitor.
Adjusting
1. Perform the following switch operation on the
standard screen.
• Switch operation: While pressing Down
switch (B), sequentially press (1), (2), and (3)
of numeral input switches (F).
2. Select "Monitoring/Custom" on "Service Menu"
screen.
HM400-3M0
30 Testing and adjusting
Electrical system
• Up switch (A): Moves the selection up by one
item
• Down switch (B): Moves the selection down
by one item
• Return switch (C): Returns the display to the
standard screen
• Enter switch (D): Validates the selection
3. Move to the tab of T/M by using menu switch (E)
and select "T/M Oil Temperature" (Monitoring
code [32500]), then press Enter switch (D) (for 2
seconds or more).
Or enter [32500] by using numeral input
switches (F) and press Enter switch (D).
a For the monitoring operating method, see
"Monitoring" of "Special functions of machine
monitor".
4. Before starting the engine, check that the
parking brake switch is turned to ON position.
30-89
30 Testing and adjusting
Electrical system

5. Set the gear shift lever to the D position while

depressing the brake pedal. (The shift indicator
changes to F2 when the shift lever is moved to D
position)

k If the gear speed at start is set to any

position other than F2, machine may start
even if the brake pedal is depressed. So
you must confirm that "F2" (gear speed at
start) is selected in "F1 Start at D Position
Setting" menu of special functions of the
machine monitor before moving the shift
lever to D position for adjusting.
3. After the "Adjustment" screen is displayed,
select "ECMV Automatic Compensation".

6. Stall the torque converter to increase the

transmission oil temperature to 60 to 70°C.
4. When "START" is displayed at (g), press Enter
a Use care to prevent overheating while the switch (D) to start the adjustment.
torque converter is stalled.
• Return switch (C): Cancels the adjustment
7. Return the gear shift lever to the N position and
and returns to the Adjustment screen
keep it in that position for 3 minutes to check that
• Enter switch (D): Starts adjustment
the transmission oil temperature is stable in the
• Menu switch (E): Switches between Hold
60 to 70°C range.
and Releasing hold (If the Hold is selected,
Adjusting transmission ECMV current (2-2)
the HOLD part is hatched.)
a The adjustment is performed 4 times on Hi, Lo,
R, 1st, 2nd, and 3rd valves automatically.
1. Check that the machine is in the following
conditions.
• Transmission oil temperature: 60 to 70°C
• Parking brake switch: ON.
• AISS LOW switch: LOW (low speed)
• Gear shift lever: N position
• Engine: Low idle
• Accelerator pedal: Released
2. Select "Adjustment" on "Service Menu" screen.

30-90 HM400-3M0
 30 Testing and adjusting
Electrical system

5. The adjustment is performed 4 times on each 2) The screen when it ends abnormally
valve automatically, and (a) displays according
a If (b) displays any item other than "0"
to the following.
(OK), it ends abnormally. (a) displays the
Monitor display valve which is abnormal.
Adjusting
sequence Valve 1st 2nd 3rd 4th
time time time time
1 Low L-1 L-2 L-3 L-4
2 High H-1 H-2 H-3 H-4
3 Reverse R-1 R-2 R-3 R-4
4 1st 1-1 1-2 1-3 1-4
5 2nd 2-1 2-2 2-3 2-4
6 3rd 3-1 3-2 3-3 3-4

a While adjusting, (b) displays "- - -".

a The condition displayed in (b) and

remedy are as follows.
• When "0: "OK (normal end)"" is
displayed:
Since the adjustment work ends normally,
proceed to the next Step 7.
• When "1: "NG (off the compensation
condition)"" is displayed:
Check the transmission oil temperature
and machine condition again, then repeat
6. The screen indicates for each adjustment work
the work from Step 1.
whether it ends normally or abnormally.
• When "2:"NG (no fill signal)"" is
1) The screen when it ends normally displayed:
(a): Adjusted valves Perform troubleshooting for failure codes
(b): Result of adjustment [15S*MA] and [DDT*KA] and when the
a When (a) displays "3-4" (last valve), and condition is checked to be normal, repeat
(b) displays "0" (OK), it ends normally. the work from Step 1 (symbols indicated
with * vary depending on the target clutch
of adjustment).
• When "3: "NG (excessive compensation
value)"" is displayed:
Perform troubleshooting for failure codes
[15S*L1] and when the condition is
checked to be normal, repeat the work
from Step 1 (symbols indicated with *
vary depending on the target clutch of
adjustment).

HM400-3M0 30-91
30 Testing and adjusting
Electrical system

7. When the adjustment work ends normally, turn 3. After "T/M Initial Learning Reset" screen is
the starting switch to OFF position and the displayed, check initialization condition (a).
compensation value will be stored on the When "0" (Initial learning completed) is
transmission controller in approximately 3 displayed, press Enter switch (D) to reset the
seconds. learned data.
a When you have to turn the starting to ON a When the gear shift lever is any position
position soon after the adjustment is finished, other than N, "2" (Out of Reset Cond.) is
hold the starting switch in OFF position for 10 displayed and the learned data cannot be
seconds minimum just to be safe, then turn it reset.
to ON position.
Resetting initial learning of transmission and
implementation of learning (2-3)
a Before starting the initial learning work, always
perform the "Adjusting transmission ECMV
current (2-2)", and check that the transmission
oil temperature is set to the specified level
referring to "Preparatory work (2-1) for
adjustment of transmission ECMV current".
(An adjustment performed at an unspecified
temperature may induce time lags and gearshift
shocks.)
k Be sure to perform the learning work in a
place where an ample traveling area is
available while paying attention to safety in
the surrounding area.

1. Select "Adjustment" on "Service Menu" screen.

4. After "Adjustment Value Check" screen is

displayed, press Enter switch (D) again to reset
the leaned data.

2. After "Adjustment" screen is displayed, select

"T/M Initial Learning Reset".

5. After resetting, check that initialization condition

(a) is"1" (Learning Not Done Yet).

30-92 HM400-3M0

6. Press Return switch (C) and select "T/M Initial
Learning" on "Adjustment" screen.
7. After "T/M Initial Learning" screen is displayed,
set the AISS LOW switch to LOW (low speed).
• Return switch (C): Returns the display to the
Adjustment screen
• Menu switch (E): Switches between Hold
and Releasing hold (If the Hold is selected,
the HOLD part is hatched.)
HM400-3M0
30 Testing and adjusting
Electrical system
8. Start the engine, run it at low idle, and operate
the gear shift lever as described below.
• Gear shift lever operation: N o R1 o N
9. On "T/M Initial Learning" screen, check the
learning state of "R Clutch".
a If "ON" is displayed, proceed to the next step.
a When "OFF" is displayed, repeat Step 8 until
"ON" appears on the screen.
a For the clutches other than R, the display can
be "ON" or "OFF" .
10.Move the gear shift lever to the D position, then
depress the accelerator pedal to move the
machine and shift up the transmission to F2 to
F4.
a Shift up: F2 o F3 o F4
a Take care not to shift up the transmission to
F5.
a When shift up to F5 is completed, repeat the
check from F2 start again.
11.After traveling at F4 for 10 seconds, release the
accelerator pedal to shift down the transmission
from F4 to F2 through coasting.
a Downshift: F4 o F3 o F2
a Do not operate the brake while the machine
is coasting.
12.On "T/M Initial Learning" screen, check the
learning state of "L Clutch", "R Clutch", and "1st
Clutch".
30-93
30 Testing and adjusting
Electrical system

a If "ON" is displayed, proceed to the next step.

a When "OFF" is displayed, repeat Steps 10
and 11 until "ON" appears on the screen.
a For the clutches other than "L Clutch", "R
Clutch", and "1st Clutch", the display can be
"ON" or "OFF" .

2. Select "ARAC Characteristic Value Setting" on

"Adjustment" screen.

13.Check the learning state of "L Clutch", "R

Clutch", and "1st Clutch" again, and when all 3
of them are"ON", the initial learning is ended
normally.
a For the clutches other than "L Clutch", "R
Clutch", and "1st Clutch", the display can be
"ON" or "OFF" .
3. After the "ARAC Characteristic Value Setting"
screen is displayed, select the valve of which
characteristic value you want to enter.
• Up switch (A), Down switch (B): Select
"ARAC Valve Characteristic (FR, FL, CR,
CL)".

14.If Initial Learning ends normally, turn starting

switch to OFF position.
Setting characteristic values of ARAC (auto-
retarder and accelerator linked) (2-4)
In order to reduce variations in the actuating force of
the ARAC (auto-retarder and accelerator linked)
caused by variations in the valve performance,
enter the characteristic value of each valve when
replacing the retarder valves to compensate the
actuating force of the accelerator-linked retarder.
Enter the valve characteristic value according to the
following procedure.
1. Select "Adjustment" on "Service Menu" screen.

30-94 HM400-3M0
 30 Testing and adjusting
Electrical system

a Stamping location of each valve is shown as

below.
• Front retarder valve
(a): Front side of machine

4. Press a numeral input switch (F) (the switch can

be any of 0 to 9).
5. After "Numeric Pad Input" screen is displayed,
enter the numbers (0 to 9) stamped on the
selected valve by using numeral input keys (F) • Rear retarder valve
and press Enter switch (D). (b): Front side of machine
• Up switch (A): Switches the mark (not used)
• Down switch (B): Inputs decimal point (not
used)
• Return switch (C): Cancels the input
• Enter switch (D): Validates the input
• Menu switch (E): Clears all the input values.
• Numeral input switch (F): Used for entering
numbers.

6. After the Correction Check screen is displayed,

press Enter switch (D) again to enter the
change.
(c): Selected valve
(d): Current characteristic value
(e): New characteristic value

HM400-3M0 30-95
30 Testing and adjusting
Electrical system

7. When the screen displays as shown the figure

below, the input of characteristic value is
reflected (fixed setting value is displayed at (d)
and at the corresponding monitoring value).
Repeat steps 3 to 7 as well, and input
characteristic value of other valves.

4. Set the machine to the following conditions.

• Accelerator pedal is released
• Parking brake, retarder brake and service
brake are all released
• Elapse 30 seconds minimum after engine is
started
KTCS (Komatsu traction control system) system
check (2-5) k Check that no person is found near the
Perform the KTCS system check after the tires.
replacement of the retarder hydraulic pipe and 5. After the conditions are satisfied, move the gear
wiring harness to check that they are free from shift lever to position "5" and set the gear speed
inappropriate assembling. to F1.
KTCS system check is performed according to the
following procedure.
1. Set all of 6 tires to be off the ground. (Jack up
the machine until all of 6 tires are lifted off the
ground and fix them with blocks or square logs)
2. Select "Adjustment" on "Service Menu" screen.

6. Select the wheel you want to check.

(a): Selected wheel
(b): Result of check
• Up switch (A), Down switch (B): Selects
wheel (FL, FR, CL, CR).
• Menu switch (E): Switches between the Hold
and the Releasing hold of a monitored value
3. After "Adjustment" screen is displayed, select
(If the Hold is selected, the HOLD part is
"TCS System Check".
hatched)

30-96 HM400-3M0
 30 Testing and adjusting
Electrical system

7. Press Enter switch (D) to start check.

a Check visually that the wheel selected on the
monitor coincides with the wheel to be
actually checked by KTCS (brake is applied).
8. After finishing the check, (b) displays "2" for
Good and "3" for No good.
a If the wheel selected on the monitor does not
coincide with the wheel of which brake is
applied, or "3" (No good) is displayed, check
the hydraulic piping and wiring harness for
wrong assembly.
9. Check that OK (Good) is indicated for every
wheel.
KOMTRAX terminal start-up procedure
• For the KOMTRAX terminal start-up procedure,
see "How to start operation of KOMTRAX
terminal" of "Special functions of machine
monitor".
Initialization of rearview monitor (3-1)
• For initialization of the rearview monitor, see
"Default value setting (Rearview Monitor
Setting)" in "Special functions of machine
monitor".
Adjustment of guide line position (3-2)
• For adjustment of the guide line position, see
"Default value setting (Rearview Monitor
Setting)" in "Special functions of machine
monitor".

HM400-3M0 30-97
30 Testing and adjusting
Electrical system
Special functions of machine monitor
Machine monitor
(a): LCD unit
(b): Meter unit
(c): LED unit
a When the engine is started or the self-check of
the emergency steering is taking place, the
battery voltage may drop suddenly depending
on the ambient temperature and the condition of
the battery.
In this case, the display of the machine monitor
may go out transiently or restart but this
phenomenon is not a failure.
a When the starting switch passes through OFF
position in the manual preheating, the meter unit
only may re-boot (the pointer of the tachometer
makes one round-swing and "88" are displayed
on the speedometer). This phenomenon is not a
failure.
30-98
(HM400_3R-Q170-042-K-00-A)
Switch panel
(d): Menu switch
(e): Enter switch
(f): Return switch
(g): Up switch
(h): Down switch
a In User/ Service Menu, the switches that are not
shown in the graphic display at the bottom of
LCD unit (a) does not function.
(i) Air conditioner switch/Numeral input switches
a Air conditioner switch/ numeral input switches
have two functions. One is graphically indicated
on the switch, and the other is numeral input
function.
a The machine monitor automatically judges which
function of each switch is currently enabled
according to the screen display of LCD unit (a).
HM400-3M0
 30 Testing and adjusting
Electrical system

Ordinary functions and special functions of machine monitor (HM400_3M0-Q170-042-K-00-A)

The machine monitor has the ordinary functions and special functions to display the various types of
information on LCD unit (a).
Some items are displayed automatically according to the internal setting of the machine monitor and the
others are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The information items in this mode are displayed ordinarily. The operator can display and set them by
operating the switches (display and setting of some items need special operations of the switches).
2. Special function: Service mode
The information items in this mode are not displayed ordinarily. Each technician can display them by
operating the switches specially. This function is used for special setting, testing, adjusting, or
troubleshooting.

Operator mode (outline) Service mode

A Display of KOMATSU logo(PAGE 30-101) Monitoring/ Pre-defined(PAGE 30-114)
Display of password input screen(PAGE 30-
A 101) Monitoring / Custom(PAGE 30-119)
Abnormality record (mechanical systems)(PAGE 30-
A Display of standard screen(PAGE 30-101) 129)
(Special operation)

Abnormality record (electrical systems)(PAGE 30-

A Display of end screen(PAGE 30-102) 130)
Display of operation screen for engine
A shutdown secondary switch(PAGE 30-102) Maintenance Record(PAGE 30-132)
B Operation of air conditioner(PAGE 30-102) Maintenance mode setting(PAGE 30-133)
Displaying and setting user menu(PAGE 30-
B 103) Phone number entry(PAGE 30-136)
o Default (Machine Model Select)(PAGE 30-137)
C Display of ECO guidance(PAGE 30-103)
Display of warning (caution and action level)
C (PAGE 30-106) Default (Option Select)(PAGE 30-138)
Display of maintenance time excess(PAGE
C 30-108) Default (Unit)(PAGE 30-140)

O (Special operation) Default (Rear View Monitor Setting)(PAGE 30-142)

LCD (Liquid Crystal Display) check function
D (PAGE 30-108) Testing (Cylinder Cut-out operation)(PAGE 30-148)
Function of checking service meter and Adjustment (ECMV automatic compensation)(PAGE
D odometer(PAGE 30-108) 30-149)
Function of usage limitation setting/changing Adjustment (Transmission initial learning)(PAGE 30-
D password(PAGE 30-109) 149)
Adjustment (Resetting transmission initial learning)
(PAGE 30-149)
Adjustment (Engine Mode Fixing)(PAGE 30-150)
Adjustment (Debug Mode Selection)(PAGE 30-150)
Adjustment (Fan Mode Fixing)(PAGE 30-150)
Adjustment (Steering Pump Displacement Fixing)
(PAGE 30-152)
Adjustment (Throttle Limit Check)(PAGE 30-152)
Adjustment (ARAC Characteristic Value Setting)
(PAGE 30-154)
Adjustment (ARAC Operating Force Compensation)
(PAGE 30-154)
Adjustment (KTCS System Check)(PAGE 30-154)
No Injection(PAGE 30-155)
Payload Meter Setting(PAGE 30-156)

HM400-3M0 30-99
30 Testing and adjusting
Electrical system

KOMTRAX Settings (terminal setting status)(PAGE

30-165)
KOMTRAX Settings (GPS and Communication
Status)(PAGE 30-166)
KOMTRAX Settings screen (Modem Status)(PAGE
30-166)
Service Message(PAGE 30-167)

a Classification of operator mode

A: Display or function that is indicated or enabled from the time when the starting switch is turned to ON
position to the time when display changes to the standard screen, and display after starting switch is
turned to OFF position
B: Display/Function when machine monitor switch is operated
C: Display/Function when certain condition is satisfied
D: Display/Function that require special operations of switches

30-100 HM400-3M0
 30 Testing and adjusting
Electrical system

Operator mode (outline) (HM400_3R-Q193-042-K-01-A) Display of password input screen (HM300-Q180-

a Only outline of the operator mode is described in
this section.
For details of each function and display, and
their operation, see "Structure and function ", or
the "Operation and Maintenance Manual".
a In this section, the following displays or functions
of the operator mode are explained (including
some items which need special operations).
Operator mode (outline)
044-K-04-A)
After Komatsu logo mark is displayed, input screen
of engine start lock password appears.
a This screen is displayed only when the engine
start lock function is enabled.
a When a correct password is input, the display
changes to the standard screen.
a The machine monitor equips with several protect
functions by passwords other than the engine
start lock. Those functions are independent from
each other.

Display of KOMATSU logo(PAGE 30-101)

Display of password input screen(PAGE 30-101)
Display of standard screen(PAGE 30-101)
Display of end screen(PAGE 30-102)
Display of operation screen for engine shutdown
secondary switch(PAGE 30-102)
Operation of air conditioner(PAGE 30-102)
Displaying and setting user menu(PAGE 30-103)
Display of ECO guidance(PAGE 30-103)
Display of warning (caution and action level)(PAGE
30-106)
Display of maintenance time excess(PAGE 30-
108) a The following screen may sometimes be
O (Special operation) displayed instead of the above Password Input
screen.
LCD (Liquid Crystal Display) check function(PAGE
30-108) a If this screen is displayed, call the person
Function of checking service meter and odometer responsible for the operation of KOMTRAX in
(PAGE 30-108) your Komatsu distributor and ask for remedy.
Function of usage limitation setting/changing
password(PAGE 30-109)

Display of KOMATSU logo (HM300-Q180-044-K-00-A)

When starting switch is turned to ON position,
KOMATSU logo is displayed for 2 seconds.
a After the 2-seconds display, the screen changes
to "Password Input (if password is set)" screen
or "standard screen".

Display of standard screen (HM400_3R-Q180-044-K-00-

A)
If the machine monitor starts normally, the standard
screen is displayed.
a For the displayed items, see "Structure and
function" or "Operation and Maintenance
Manual."

HM400-3M0 30-101
30 Testing and adjusting
Electrical system

a The engine shutdown secondary switch is

installed to the wall in the rear of the shift lever.
This switch is used to stop the engine when it
does not stop after the starting switch is turned
to OFF position.

Display of end screen (HM300-Q180-044-K-08-A)

Turning the starting switch to OFF position closes
the screen.
a If a KOMTRAX message or one point advice on
ECO guidance are prepared, they are displayed
If you turn the engine shutdown secondary switch to
on the end screen for 5 seconds.
OFF position, the KOMATSU logo appears once
and then the display is switched to the standard
screen.

Operation of air conditioner (HM400_3R-K500-100-K-

00-A)
When the air conditioner switch is operated on the
standard screen or User menu, the air conditioner
display is popped up, and you can adjust the air
conditioner.
a If other display is popped up by User menu, the
air conditioner adjustment screen does not
appear and operation of the air conditioner
becomes unavailable.
a On monitor screen described above displays
sentence having been inputted directly at the
distributor.

Display of operation screen for engine

shutdown secondary switch (HM300-AKHL-100-K-00-
A)
Turning on the engine shutdown secondary switch
displays "Engine Shutdown Secondary Switch
Activated" screen on every screen except the end
screen after 3 seconds.

30-102 HM400-3M0
 30 Testing and adjusting
Electrical system

a For the details of User Menu, see the "Operation

and Maintenance Manual".

Display of ECO guidance (HM400_3R-Q1L3-100-K-00-A)

When the machine remains in a certain operating
condition, the "ECO Guidance" screen is displayed
automatically to urge the operator to perform
energy-saving operation.
a "ECO Guidance" appears when its display
function is enabled in User Menu.
• Excessive Idling guidance
If the engine runs idle for 5 minutes or longer,
Excessive Idling guidance is displayed on the
Displaying and setting user menu (HM400_3R- monitor.
Q1C3-100-K-00-A)
Press the menu switch while the standard screen is a Excessive Idling guidance disappears if you
displayed and the "User Menu" screen will appear. depress the accelerator pedal or start
traveling the machine.
a While the machine is traveling, pressing the
menu switch does not display User Menu. a The guidance is not displayed during
warming-up operation.
If you start the machine travel while User Menu
is displayed, the display returns to the standard
screen.

• Hoist relief restriction guidance

The hoist relief restriction guidance is displayed
on the monitor when you continue the hoist relief
a There are following items in User Menu. restriction for 5 seconds or longer while stepping
• ECO Guidance on the accelerator pedal.
• Machine setting/information a The hoist relief restriction guidance
• Maintenance disappears automatically in 10 seconds.
• Monitor setting
• Check message a The hydraulic relief of the hoist occurs if the
hoist lever is moved to RAISE when the
[KOMTRAX message]
dump body is raised to the maximum or if the
• There are 2 types of KOMTRAX message; one hoist lever is moved to LOWER when the
is for the user and the other is for the technician. dump body is seated.
• For user:
This is a user-directed message received from
KOMTRAX base station. When this is received,
message pilot lamp is displayed on the standard
screen. Operate "Check Message" in "User
Menu" to read the message.
• For technician:
The standard screen does not display anything
when a message for the technician is received
from the KOMTRAX base station. Operate
"Service Message" in Service Menu to read the
message.

HM400-3M0 30-103
30 Testing and adjusting
Electrical system
• Guidance on deterrence of brake dragging
The brake dragging restriction guidance is
displayed on the monitor if you continue
depressing the accelerator pedal for 5 seconds
or longer while applying the brake during travel.
a The brake dragging restriction guidance
disappears automatically in 10 seconds.
• Shifting up recommendation guidance
The shifting up recommendation guidance is
displayed on the monitor if the shift up remains
unavailable for 5 seconds or longer by using the
shift lever or shift hold switch even when the
speed that requires shift up is reached during
travel.
a The shift up recommendation guidance
disappears automatically in 10 seconds.
a This guidance is displayed in the reverse
travel, as well.
a However, it does not appear in the downhill
travel with the retarder operated and when
the dump body is not seated.
30-104
• Acceleration restriction guidance while lowering
dump body
The acceleration restriction guidance is
displayed on the monitor while dump body is
lowering if you continue depressing the
accelerator pedal for 5 seconds or longer while
the dump body is lowering.
a The acceleration restriction guidance while
dump body is lowering disappears
automatically in 10 seconds.
• Steering relief restriction guidance
The steering relief restriction guidance is
displayed on the monitor if you continue the
hydraulic relief of the steering for 5 seconds or
longer.
a The acceleration restriction guidance
disappears automatically in 10 seconds.
a The hydraulic relief of the steering occurs if
you keep on turning the steering wheel fully
to the right or left.
HM400-3M0
 30 Testing and adjusting
Electrical system

HM400-3M0 30-105
30 Testing and adjusting
Electrical system

Display of warning (caution and action level) (HM400_3R-Q1FC-044-K-00-A)

If the controller detects a failure on the machine, a
warning is displayed on the standard screen.
(1): Caution lamp
(2): Action level (L01: Goes out in 2 seconds,
L02 to L04: Remains lit until the abnormality is
eliminated)
(3): Centralized warning lamp
(4): Guidance icon

a Remedies that displayed action levels requires

operator to do (The following table is an excerpt
from the Operation and Maintenance Manual)

If you press Enter switch while guidance icon (4) is

displayed, "Error List" appears.
(a): Caution lamp
(b): Action level (3 digits)
(c): Failure code (5 or 6 digits)
(d): Failure code name
(e): Message
(f): Telephone No. (if registered)
a This screen appears when trouble (failure code)
occurs only if its action level is set.
a The telephone number is displayed only when
the telephone number is registered in Service
Mode.
a If multiple troubles occur simultaneously, all the
codes are displayed repeatedly in order.
a As the information of the displayed failure code
is recorded in the "abnormality record" in the
service mode, check the details in the service
mode.
a "Error List" is replaced with the standard screen
if the machine travel is started or a switch is left
untouched for 30 seconds.

30-106 HM400-3M0
 30 Testing and adjusting
Electrical system

List of action levels and corresponding remedies

Degree Centralized
of Action warning Color of
Alarm buzzer Remedies
urgency level lamp caution
Stop the machine immediately, and perform
checking and maintenance.
Sounds
L04 Lights up Red Check the failure code and contact your
continuously
Komatsu distributor for inspection and
maintenance.
Cease the work and after moving the machine
to a safe place stopping it there, perform
Sounds checking and maintenance.
L03 Lights up Red
intermittently Check the failure code and contact your
Komatsu distributor for inspection and
High maintenance.
I When an overrun-related caution is displayed,
operate the machine reducing the engine speed
| and machine travel speed.
| When an overheat-related caution is displayed,
| stop the machine at a safe place and run the
| Sounds engine at medium speed with no load.
L02 Lights up Red
O intermittently When an emergency steering-related caution is
Low displayed, refrain from using the emergency
steering for a long time.
If the condition is not improved, check the failure
code and contact your Komatsu distributor for
inspection and maintenance.
Some functions may be restricted for use, but
the machine can operate. Whenever finished
working, perform the inspection and
L01 Goes out — Yellow maintenance.
As needed, ask your Komatsu distributor for
inspection and maintenance.

HM400-3M0 30-107
30 Testing and adjusting
Electrical system
Display of maintenance time excess (HM300-
Q180-044-K-09-A)
If a maintenance item that is near or exceeded the
set interval, the controller displays the maintenance
caution for 30 seconds after the starting switch is
turned to ON position to urge the operator to
perform maintenance.
a While the yellow caution is displayed if the
remaining time of any item before the
maintenance is 30 hours (default value) or less,
the red caution is displayed if the remaining time
of any item is 0 hour or less.
a You can check the maintenance information by
pressing the menu switch while guidance icon
(a) is displayed.
a To reset the remaining time left after finishing the
maintenance, further operations with user menu
are required.
a Perform setting and changing of the
maintenance function in the service menu.
LCD (Liquid Crystal Display) check
function (HM300-Q1LE-100-K-00-A)
If you perform the following operation when the
ordinary screen is displayed, entire LCD (Liquid
Crystal Display) lights up in white.
• Switch operation: Press Up switch (A) while
pressing Down switch (B) and release Up switch
(A) first.
30-108
a The entire LCD is not turned to white when the
engine is running.
a If there is a display error in the LCD, only that
part is indicated in black.
a If you press any of Up switch (A), Down switch
(B), Return switch (C), Enter switch (D) and
Menu switch (E), the display is returned to the
original screen.
Reference: On the LCD panel sometimes, there
may be black spots (spots not lit) and bright spots
(remaining constantly lit) as one of its
characteristics.
If the number of the bright spots and black spots
does not exceed 10, the LCD panel is not faulty or
defective.
Function of checking service meter and
odometer (HM300-Q1MB-100-K-00-A)
When the following operation is performed with the
stating switch being turned to OFF position, only the
service meter and odometer are displayed.
• Switch operation: Press Down switch (B) and Up
switch (A) at the same time.
a There is some time lag in start of the LCD, so
hold down the switches until the LCD displays
normally.
a If you release one of the switches, the monitor
goes out.
HM400-3M0
 30 Testing and adjusting
Electrical system

Reference: If you use the machine monitor for a

long time, bright spots (spots that remain being lit)
may appear on the screen. If the number of the
bright spots is 10 or less; the LCD panel is not faulty
or defective.

2. After the "Usage Limitation Password" screen is

displayed, input the current password by using
the numeral input switches and validate it with
the switch.
Return switch (C): Clears input numbers/Returns
the display to Standard screen
Function of usage limitation setting/changing Enter switch (D): Validates the input password
password (HM400_3R-Q19X-100-K-00-A)
Once you perform "Usage Limitation Setting", the a Default password: [000000]
password input screen is displayed when you a When the input password is correct, the
perform the maintenance resetting. Perform "Usage screen changes to the next screen.
Limitation Setting" according to the following
procedure. a When the input password is incorrect, the
screen displays message to request inputting
1. While the standard screen is displayed, perform the password again.
the following operations.
• Switch operation: Press "5" of numeral input
switch (F) 3 times while pressing Down
switch (B).
a This operation of the switches is not
accepted until 10 minutes elapse after the
starting switch is turned to ON position.

3. After the "Usage Limitation Setting" screen is

displayed, select a desired setting with the
switch.
• Up switch (A): Moves the selection up by one
item
• Down switch (B): Moves the selection down
by one item
• Return switch (C): Cancels the selection and
returns the display to the preceding screen
• Enter switch (D): Validates the selection

HM400-3M0 30-109
30 Testing and adjusting
Electrical system

a When the input password is incorrect, the

screen displays message to request inputting
the password again.
a Set a new password of 4 to 6 digits (If it has
only 3 or less digits or has 7 or more digits, it
is not accepted).

4. Selection of "Usage Limitation ON/OFF"

After the "Usage Limitation ON/OFF" screen is
displayed, select a desired setting with the
switch.
• Non-use: Password input screen is not
displayed
• Use: Displays the password input screen
when you perform maintenance resetting.
• Up switch (A): Moves the selection up by one
item
• Down switch (B): Moves the selection down
by one item
• Return switch (C): Cancels the selection and
returns the display to the preceding screen
• Enter switch (D): Validates the selection
For confirmation, after the "Usage Limitation
New Password Input" screen is displayed again,
input the new password again by using the
numeral input switches (F) and validate it by
using Enter switch (D).
• Return switch (C): Clears input numbers/
Returns the display to Standard screen
• Enter switch (D): Validates the input
password
a If the input password is different from the one
input before, the message to request
inputting again is displayed.

a The password for the Usage Limitation and

the engine start lock password are not
identical.
5. Changing a password
After the "Usage Limitation New Password If the usage limitation screen is displayed after
Input" screen is displayed, input the new the screen to notify completion of setting is
password by using the numeral input switches displayed, the password is changed successfully.
(F) and validate it by using Enter switch (D).
• Return switch (C): Clears input numbers/
Returns the display to Service Menu screen
• Enter switch (D): Validates the input
password
a Default password: [000000]
a When the input password is correct, the
screen changes to the next screen.

30-110 HM400-3M0
 30 Testing and adjusting
Electrical system

HM400-3M0 30-111
30 Testing and adjusting
Electrical system
Service mode (HM400_3M0-Q194-100-K-00-A)
To change the operator mode to the service mode,
perform the following operation.
This operation is always required when you use the
service mode.
1. Checking of display of screen, and switch
operation
While the standard screen is displayed, perform
the following switch operations.
Switch operation: While pressing Down switch
(B), press air conditioner/ numeral input
switches (F) "1" o "2" o "3" in order.
a This switch operation is accepted only while
the standard screen is displayed.
2. Selecting a service menu
When "Service Menu" screen is displayed, the
service mode is selected. Select a desired
service menu.
• Up switch (A): Moves the selection up by one
item
• Down switch (B): Moves the selection down
by one item
• Return switch (C): Returns the display to the
standard screen (operator mode)
• Enter switch (D): Validates the selection
a If you enter a 2 digit item number with the
numeral input switches (F), the entered item
is directly selected.
30-112
a The following shows the items selectable with
the service menu (including some items which
need special operations).
No. Menu items
01 Monitoring/ Pre-defined(PAGE 30-114)
02 Monitoring / Custom(PAGE 30-119)
Abnormality record (mechanical systems)
(PAGE 30-129)
03
Abnormality record (electrical systems)(PAGE
30-130)
04 Maintenance Record(PAGE 30-132)
05 Maintenance mode setting(PAGE 30-133)
06 Phone number entry(PAGE 30-136)
Default (Machine Model Select)(PAGE 30-
137)
Default (Option Select)(PAGE 30-138)
07
Default (Unit)(PAGE 30-140)
Default (Rear View Monitor Setting)(PAGE 30-
142)
Testing (Cylinder Cut-out operation)(PAGE 30-
08 148)
Adjustment (ECMV automatic compensation)
(PAGE 30-149)
Adjustment (Transmission initial learning)
(PAGE 30-149)
Adjustment (Resetting transmission initial
learning)(PAGE 30-149)
Adjustment (Engine Mode Fixing)(PAGE 30-
150)
Adjustment (Debug Mode Selection)(PAGE
30-150)
09 Adjustment (Fan Mode Fixing)(PAGE 30-150)
Adjustment (Steering Pump Displacement
Fixing)(PAGE 30-152)
Adjustment (Throttle Limit Check)(PAGE 30-
152)
Adjustment (ARAC Characteristic Value
Setting)(PAGE 30-154)
Adjustment (ARAC Operating Force
Compensation)(PAGE 30-154)
Adjustment (KTCS System Check)(PAGE 30-
154)
10 No Injection(PAGE 30-155)
11 Payload Meter Setting(PAGE 30-156)
HM400-3M0
 30 Testing and adjusting
Electrical system

No. Menu items

KOMTRAX Settings (terminal setting status)
(PAGE 30-165)
KOMTRAX Settings (GPS and
12 Communication Status)(PAGE 30-166)
KOMTRAX Settings screen (Modem Status)
(PAGE 30-166)
13 Service Message(PAGE 30-167)

HM400-3M0 30-113
30 Testing and adjusting
Electrical system

Monitoring/ Pre-defined (HM400_3R-Q1S1-100-K-00-A)

The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
various parts of the machine and the information
from the controllers which is controlling switches,
etc.
In "Monitoring/ Pre-defined", frequently used
monitoring items in daily work are selected
beforehand.
1. Selecting a menu
Select "Monitoring/Pre-defined" on "Service
Menu" screen.

a For the items not displayed in "Monitoring/

Pre-defined", you can freely select and check
from "Monitoring/Custom" items.

2. Checking Monitoring/Pre-defined information

"Monitoring/Pre-defined" screen displays the
following information and allows switching
among the monitoring items.
(a): Monitoring information
(b): Power mode pilot lamp
(c): Shift indicator
(d): Engine coolant temperature
(e): Torque converter oil temperature
(f): Retarder oil temperature
(g): Fuel level
(h): Current number of pages/total number of
pages
Up switch (A): Moves selection to the previous
page (screen)
Down switch (B): Moves selection to the next
page (screen)
Return switch (C): Returns the display to
"Service Menu"
Enter switch (D): Validates the selection
Menu switch (E): Switches between Hold and
Releasing hold
(If the Hold is selected, a diagonal line is drawn
on HOLD part.)

30-114 HM400-3M0
 30 Testing and adjusting
Electrical system

List of Monitoring/ Pre-defined items

(SI unit is the default value)
Monitoring/ Pre-defined screen (01/17) Machine basics 1
Monitoring Applicable
No. Monitoring item Unit (SI) Remarks
code component
1 01002 Engine Speed r/min ENG
2 04107 Coolant Temperature °C ENG
3 37200 Engine Oil Pressure kPa ENG
4 30100 T/C Oil Temperature °C T/M
5 30216 Retarder Oil Temp. (Gauge) °C MON
6 32701 Steering Oil Temperature °C RHC
Monitoring/ Pre-defined screen (02/17) Machine basics 2
Monitoring Applicable
No. Monitoring item Unit (SI) Remarks
code component
1 01002 Engine Speed r/min ENG
2 32500 T/M Oil Temperature °C T/M
3 55000 Aircon Outside Temp. °C MON
4 04307 Battery Charge Volt (T/M) V T/M
5 03208 Controller Battery Volt (T/M) V T/M
Monitoring/ Pre-defined screen (03/17) Engine fuel injection system
Monitoring Applicable
No. Monitoring item Unit (SI) Remarks
code component
1 01002 Engine Speed r/min ENG
2 36400 Rail Pressure MPa ENG
3 36200 Rail Pressure Command MPa ENG
4 17201 PCV Close Timing CA ENG
Monitoring / Pre-defined screen (04/17) Engine temperature system
Monitoring Applicable
No. Monitoring item Unit (SI) Remarks
code component
1 01002 Engine Speed r/min ENG
2 04107 Coolant Temperature °C ENG
3 18400 Intake Temperature °C ENG
4 18500 Charge Temperature °C ENG
Monitoring / Pre-defined screen (05/17) Engine intake and exhaust pressure system
Monitoring Applicable
No. Monitoring item Unit (SI) Remarks
code component
1 01002 Engine Speed r/min ENG
2 37400 Ambient Pressure kPa ENG
3 36500 Charge Pressure-A kPa ENG
4 18400 Intake Temperature °C ENG

HM400-3M0 30-115
30 Testing and adjusting
Electrical system

Monitoring /Pre-defined screen (06/17) Engine output command

Monitoring Applicable
No. Monitoring item Unit (SI) Remarks
code component
1 01002 Engine Speed r/min ENG
2 31701 Throttle Position % ENG
3 36000 Throttle Adjustment Command % T/M
4 44201 Throttle Lower Limit Command % T/M
5 44200 Throttle Higher Limit Command % T/M
Monitoring /Predefined screen (07/17) Transmission speed system
Monitoring Applicable
No. Monitoring item Unit (SI) Remarks
code component
1 01002 Engine Speed r/min ENG
2 31200 T/M Input Shaft Speed r/min T/M
3 31300 T/M Intermediate Shaft Speed r/min T/M
4 31400 T/M Output Shaft Speed r/min T/M
5 31402 T/M Differential Shaft Speed r/min T/M
6 31908 Inter-Axle Diff. Lock Command % RHC
Monitoring /Predefined screen (08/17) Transmission valve system
Monitoring Applicable
No. Monitoring item Unit (SI) Remarks
code component
1 01002 Engine Speed r/min ENG
2 30100 T/C Oil Temperature °C T/M
3 32600 T/C Oil Pressure MPa T/M
4 07701 Main Flow Selector V. Press MPa T/M
5 31644 Main Flow Selector Current mA T/M
6 95001 Lockup Status — T/M
Monitoring /Pre-defined screen (09/17) Radiator fan system
Monitoring Applicable
No. Monitoring item Unit (SI) Remarks
code component
1 01002 Engine Speed r/min ENG
2 04107 Coolant Temperature °C ENG
3 32701 Steering Oil Temperature °C RHC
4 10007 Radiator Fan Speed Command r/min T/M
5 10014 Radiator Fan Speed r/min RHC
6 41400 Rad. Fan Pump EPC Sol. Current mA T/M
Monitoring /Pre-defined screen (10/17) Aftercooler fan system
Monitoring Applicable
No. Monitoring item Unit (SI) Remarks
code component
1 01002 Engine Speed r/min ENG
2 18500 Charge Temperature °C ENG
3 55001 Aircon Outside Temp. °C MON
4 10008 CAC Fan Speed Command r/min T/M
5 10015 CAC Fan Speed r/min RHC
6 31645 CAC Fan Pump EPC Sol. Current mA T/M

30-116 HM400-3M0
 30 Testing and adjusting
Electrical system

Monitoring /Pre-defined screen (11/17) Retarder control system 1

Monitoring Applicable
No. Monitoring item Unit (SI) Remarks
code component
1 33903 Retarder Lever Potentio. Volt V RHC
2 91913 Retarder Pressure (FL) MPa RHC
3 33702 Retarder EPC Sol. Current (FL) mA RHC
4 91919 Retarder Pressure (FR) MPa RHC
5 33811 Retarder EPC Sol. Current (FR) mA RHC
Monitoring /Pre-defined screen (12/17) Retarder control system 2
Monitoring Applicable
No. Monitoring item Unit (SI) Remarks
code component
1 33903 Retarder Lever Potentio. Volt V RHC
2 91914 Retarder Pressure (CL) MPa RHC
3 33808 Retarder EPC Sol. Current (CL) mA RHC
4 91920 Retarder Pressure (CR) MPa RHC
5 33812 Retarder EPC Sol. Current (CR) mA RHC
Monitoring /Pre-defined screen (13/17) KTCS system
Monitoring Applicable
No. Monitoring item Unit (SI) Remarks
code component
1 31400 T/M Output Shaft Speed r/min T/M
2 39711 Wheel Speed (FL) r/min RHC
3 39710 Wheel Speed (FR) r/min RHC
4 39713 Wheel Speed (CL) r/min RHC
5 39712 Wheel Speed (CR) r/min RHC
6 31908 Inter-Axle Diff. Lock Command % RHC
Monitoring /Pre-defined screen (14/17) Hoist control system
Monitoring Applicable
No. Monitoring item Unit (SI) Remarks
code component
1 34506 Hoist Lever Potentio Volt Main V RHC
2 34507 Hoist Lever Potentio Volt Sub V RHC
3 34603 Body Potentio. Volt V RHC
4 45601 Hoist EPC Solenoid Current mA RHC
Hoist Selector Solenoid ON/OFF
5 40985 Hoist Output1 Kick out Solenoid ON/OFF
RHC
Steering Pump Sel. ON/OFF
Sol.
Monitoring /Pre-defined screen (15/17) Emergency steering control system
Monitoring Applicable
No. Monitoring item Unit (SI) Remarks
code component
1 31400 T/M Output Shaft Speed r/min T/M
2 91908 Parking Brake Pressure MPa RHC
3 95302 Steering Pressure MPa RHC
4 07703 Emerg. Steering Pressure MPa RHC
5 07704 Emerg. Steering Pressure 2 MPa RHC
Emerg. Steering Relay ON/OFF
Second. S/T
6 40986 Output 1 Emerg. Steering RHC
Relay2 ON/OFF

HM400-3M0 30-117
30 Testing and adjusting
Electrical system

Monitoring /Predefined screen (16/17) Parking brake system

Monitoring Applicable
No. Monitoring item Unit (SI) Remarks
code component
1 35500 Accumulator Pressure (F) MPa RHC
2 35501 Accumulator Pressure (R) MPa RHC
3 91908 Parking Brake Pressure MPa RHC
Parking Brake Parking Brake Sol
4 40987 Input1 ON/OFF RHC
Status
Parking Brake Parking Brake SW
5 40988 Output1 Lamp ON/OFF MON

Monitoring /Pre-defined screen (17/17) Payload meter control system

* Only when equipped with payload meter (PLM).
Monitoring Applicable
No. Monitoring item Unit (SI) Remarks
code component
1 42400 Truck Status — PLM
2 32901 Long. Inclination Angle deg. PLM
3 32805 Sus. Pressure (FL) MPa PLM
4 32804 Sus. Pressure (FR) MPa PLM
5 32807 Sus. Pressure (RL) MPa PLM
6 32806 Sus. Pressure (RR) MPa PLM

30-118 HM400-3M0

Monitoring / Custom (HM400_3R-Q19L-100-K-00-A)
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
various parts of the machine and the information
from the controllers which is controlling switches,
etc.
The monitoring function allows you to select a
desired monitoring item.
1. Selecting a menu
Select "Monitoring/Custom" on "Service Menu"
screen.
2. Selecting monitoring item
When "Monitoring Selection Menu" screen is
displayed, select the item to monitor.
• Up switch (A): Moves the selection up by one
item
• Down switch (B): Moves the selection down
by one item
• Return switch (C): Clears input numbers/
Returns the display to "Service Menu"
screen
• Enter switch (D): Validates the selection
• Menu switch (E): Moves the selection to the
immediate right item
a In setting of the monitoring, each time menu
switch (E) is pressed, the monitoring item
changes in the order of "ENG" o "T/M" o
"RHC" o "MON" o "ENG".
HM400-3M0
30 Testing and adjusting
Electrical system
a Selection with switch operation: Select the
component in charge with menu switch (E),
select the item with Up switch (A) or Down
switch (B) and validate your selection with
the Enter switch (D).
a Selection through entry of a monitoring code:
If you input a monitoring code (5-digit) by
using numeral input switches (F), the target
item is selected directly. So, enter it by using
Enter switch (D).
a If the color of the selected box changes from
yellow to red, the selection of the item of that
box is entered.
a Up to 6 monitoring items are selectable at a
time. However, all the 6 items may not be
selected depending on the condition of
display of the selected item.
3. Deciding monitoring items
After selecting monitoring items, execute the
monitoring according to the following operations.
• Switch operation: Double-click Enter switch
(D).
Or hold down Enter switch (D) (for
approximately 2 seconds).
Or enter [99999] by using numeral input
switches (F) and press Enter switch (D).
a If monitoring items are selected up to the limit
number, monitoring is executed
automatically.
30-119
30 Testing and adjusting
Electrical system

4. Executing monitoring Down switch (B): CLEAR (clears the selected

After "Monitoring" screen is displayed, perform item)
the necessary operation of the machine and
check the monitoring information.
"Monitoring" screen displays the following
information.
(a): Monitoring information
(b): Power mode pilot lamp
(c): Shift indicator
(d): Engine coolant temperature
(e): Torque converter oil temperature
(f): Retarder oil temperature
(g): Fuel level
a Monitoring information is indicated by value,
ON/OFF, or special display.
a The unit to be displayed can be set to "SI unit a When a monitoring item is saved, a
"or "Non-SI unit" with the "Default" function in confirmation screen appears asking whether
the service mode. the saved item should be displayed or not
when "Monitoring" is selected again.
a When an item is saved, it can be displayed
as many times as required unless it is
cleared.
a If another item is saved while having the
previous item saved, the previously saved
item is overwritten by the latest one.
a The saved monitoring item can be cleared by
Down switch (B), and in addition, the
following setting change clears a saved
monitoring item as well. Validating operation
also clears the selected item.
5. Holding monitoring information
• Default (Machine Model Select)
In the monitoring information, Hold and
• Default (Option Select)
Releasing hold can be made.
• Menu switch (E): Switches between the Hold
and the Releasing hold (If the Hold is
selected, the HOLD part is hatched)
• Return switch (C): Returns the display to
"Monitoring Selection Menu" screen

6. Saving of monitoring item

A selected monitoring item can be saved or
cleared.
Up switch (A): MEMORY (saves the selected
item)

30-120 HM400-3M0
 30 Testing and adjusting
Electrical system

Table of Monitoring items (HM400_3R-Q19L-208-K-00-A)

Unit (Default: SI)

Code Monitoring item (Display on screen) Applicable Remarks
No. SI Non-SI component
20216 ECM Build Version — — ENG
20217 Calibration Data Version — — ENG
18900 ECM Internal Temp °C °F ENG
20400 ECM S/N — — ENG
01002 Engine Speed r/min rpm ENG
36700 Engine Torque Ratio % % ENG
31701 Throttle Position % % ENG
03000 Throttle Position Sensor Volt V V ENG
17500 Engine Power Mode — — ENG
36400 Rail Pressure MPa psi ENG
36401 Rail Pressure Sensor Volt V V ENG
36200 Rail Pressure Command MPa psi ENG
36300 Inject Timing Command CA CA ENG
04107 Coolant Temperature °C °F ENG
04105 Coolant Temp Sensor Volt V V ENG
37200 Engine Oil Pressure kPa psi ENG
37201 Eng Oil Pressure Sensor Volt V V ENG
42700 Eng Oil Temperature °C °F ENG
42702 Eng Oil Temp Sens Volt V V ENG
14200 Fuel Temperature °C °F ENG
14201 Fuel Temp Sensor Volt V V ENG
37400 Ambient Pressure kPa psi ENG
37401 Ambient Pressure Sensor Volt V V ENG
36500 Charge Pressure-A kPa psi ENG
36501 Charge Pressure Sensor Volt V V ENG
03203 Battery Power Supply V V ENG
37300 Fuel Rate l/h gal/h ENG
31706 Final Throttle Position % % ENG
17900 EGR Dif Pressure Sensor kPa psi ENG
17901 EGR Dif Pressure Sensor Volt V V ENG
18000 EGR In Pressure-A kPa psi ENG
18001 EGR In Pressure Sensor Volt V V ENG
18400 Intake Temperature °C °F ENG
18401 Intake Temp Sensor Volt V V ENG
18500 Charge Temperature °C °F ENG
18501 Charge Temp Sensor Volt V V ENG
18100 EGR Valve Position mm in ENG
18101 EGR Valve Pos Sensor Volt V V ENG
18300 Idle Validation Sw 1 — — ENG
18301 Idle Validation Sw 2 — — ENG
18600 Inject Fueling Command mg/st mg/st ENG
17201 PCV Close Timing CA CA ENG
18700 Engine Output Torque Nm lbft ENG
31200 T/M Input Shaft Speed r/min rpm T/M
31300 T/M Intermediate Shaft Speed r/min rpm T/M
31400 T/M Output Shaft Speed r/min rpm T/M
31402 T/M Differential Shaft Speed r/min rpm T/M
10007 Radiator Fan Speed Command r/min rpm T/M
10008 CAC Fan Speed Command r/min rpm T/M
30100 T/C Oil Temperature °C °F T/M

HM400-3M0 30-121
30 Testing and adjusting
Electrical system

Unit (Default: SI)

Code Monitoring item (Display on screen) Applicable Remarks
No. SI Non-SI component
30101 T/C Oil Temp. Sensor Volt V V T/M
32500 T/M Oil Temperature °C °F T/M
32501 T/M Oil Temp. Sensor Volt V V T/M
32600 T/C Oil Pressure MPa psi T/M
32605 T/C Oil Press Sensor Volt V V T/M
07701 Main Flow Selector V. Press MPa psi T/M
07702 Main Flow Selector S.Volt V V T/M
31600 ECMV Current (H) mA mA T/M
31601 ECMV Current (L) mA mA T/M
31602 ECMV Current (1st) mA mA T/M
31603 ECMV Current (2nd) mA mA T/M
31604 ECMV Current (3rd) mA mA T/M
31606 ECMV Current (Reverse) mA mA T/M
31609 ECMV Current (Lockup) mA mA T/M
31607 ECMV Current (Inter—Axle Diff) mA mA T/M
31644 Main Flow Selector Current mA mA T/M
41400 Rad. Fan Pump EPC Sol. Current mA mA T/M
31645 CAC Fan Pump EPC Sol. Current mA mA T/M
33703 Brake Command (FR) % % T/M
33704 Brake Command (FL) % % T/M
33809 Brake Command (CR) % % T/M
33810 Brake Command (CL) % % T/M
36000 Throttle Adjustment Command % % T/M
38900 Trigger Compensation (L) — — T/M
38901 Trigger Compensation (H) — — T/M
38902 Trigger Compensation (1st) — — T/M
38903 Trigger Compensation (2nd) — — T/M
38904 Trigger Compensation (3rd) — — T/M
38906 Trigger Compensation (Reverse) — — T/M
41800 Fill Time (L) msec msec T/M
41801 Fill Time (H) msec msec T/M
41802 Fill Time (1st) msec msec T/M
41803 Fill Time (2nd) msec msec T/M
41804 Fill Time (3rd) msec msec T/M
41806 Fill Time (Reverse) msec msec T/M
44201 Throttle Lower Limit Command % % T/M
44200 Throttle Higher Limit Command % % T/M
38501 Elapsed Time after Gear Shift sec sec T/M
46400 Piston Pump Oil Temp. °C °F T/M
46401 Piston Pump Oil Temp.S.Volt V V T/M
When optional ARAC
49500 ARAC Valve Characteristic (FR) — — T/M
is used
When optional ARAC
49501 ARAC Valve Characteristic (FL) — — T/M
is used
When optional ARAC
49502 ARAC Valve Characteristic (CR) — — T/M
is used
When optional ARAC
49503 ARAC Valve Characteristic (CL) — — T/M
is used
03208 Controller Battery Volt (T/M) V V T/M
03216 Solenoid Battery Volt (T/M) V V T/M
04307 Battery Charge Volt (T/M) V V T/M
95001 Lockup Status ON/OFF ON/OFF T/M

30-122 HM400-3M0
 30 Testing and adjusting
Electrical system

Unit (Default: SI)

Code Monitoring item (Display on screen) Applicable Remarks
No. SI Non-SI component
Radiator Fan Rev. Sol. ON/OFF ON/OFF
T/M Con. CAC Fan Rev. Sol. ON/OFF ON/OFF
03900 Output T/M
Engine Start Relay ON/OFF ON/OFF
Sol. Self—Holding Relay ON/OFF ON/OFF
H Clutch ON/OFF ON/OFF
L Clutch ON/OFF ON/OFF
T/M Initial R Clutch ON/OFF ON/OFF
94100 Learning T/M
Status 1st Clutch ON/OFF ON/OFF
2nd Clutch ON/OFF ON/OFF
3rd Clutch ON/OFF ON/OFF
H Clutch ON/OFF ON/OFF
L Clutch ON/OFF ON/OFF
Clutch Fill R Clutch ON/OFF ON/OFF
31527 T/M
Status 1st Clutch ON/OFF ON/OFF
2nd Clutch ON/OFF ON/OFF
3rd Clutch ON/OFF ON/OFF
H Clutch ON/OFF ON/OFF
L Clutch ON/OFF ON/OFF
Clutch Fill R Clutch ON/OFF ON/OFF
02216 SW Input T/M
1st Clutch ON/OFF ON/OFF
2nd Clutch ON/OFF ON/OFF
3rd Clutch ON/OFF ON/OFF
Shift Lever R2 ON/OFF ON/OFF
Shift Lever R1 ON/OFF ON/OFF
T/M Con. SW Shift Lever N ON/OFF ON/OFF
02211 Input 1 T/M
Shift Lever D ON/OFF ON/OFF
Shift Lever 5 ON/OFF ON/OFF
Shift Lever 4 ON/OFF ON/OFF
Shift Lever 3 ON/OFF ON/OFF
T/M Con. SW Shift Lever 2 ON/OFF ON/OFF
02212 Input 2 T/M
Shift Lever 1 ON/OFF ON/OFF
Shift Lever Hold ON/OFF ON/OFF
Engine Mode Selector SW ON/OFF ON/OFF
AISS LOW SW ON/OFF ON/OFF
T/M Con. SW When optional ARAC
02213 Input 3 ARAC SW ON ON/OFF ON/OFF T/M
is used
When optional ARAC
ARAC SW OFF ON/OFF ON/OFF
is used
Starter Status ON/OFF ON/OFF
T/M Con. SW
02214 Secondary Travel SW ON/OFF ON/OFF T/M
Input 4
Emerg. Steering Status ON/OFF ON/OFF
Air Cleaner SW ON/OFF ON/OFF
T/M Con. SW T/M Oil Filter SW ON/OFF ON/OFF
02215 Input 5 T/M
Engine Oil Level SW ON/OFF ON/OFF
Coolant Level SW ON/OFF ON/OFF
20414 Assembly P/N (T/M Con.) — — T/M
20413 Serial No. (T/M Con.) — — T/M
20201 Software P/N (T/M Con.) — — T/M
20223 Application Version (T/M Con.) — — T/M
20224 Data Version (T/M Con.) — — T/M
35500 Accumulator Pressure (F) MPa psi RHC
35506 Accumulator Press. S. Volt (F) V V RHC

HM400-3M0 30-123
30 Testing and adjusting
Electrical system

Unit (Default: SI)

Code Monitoring item (Display on screen) Applicable Remarks
No. SI Non-SI component
35501 Accumulator Pressure (R) MPa psi RHC
35507 Accumulator Press. S. Volt (R) V V RHC
91913 Retarder Pressure (FL) MPa psi RHC
91915 Retarder Press. S. Volt (FL) V V RHC
91919 Retarder Pressure (FR) MPa psi RHC
91921 Retarder Press. S. Volt (FR) V V RHC
91914 Retarder Pressure (CL) MPa psi RHC
91916 Retarder Press. S. Volt (CL) V V RHC
91920 Retarder Pressure (CR) MPa psi RHC
91922 Retarder Press. S. Volt (CR) V V RHC
91908 Parking Brake Pressure MPa psi RHC
91909 Parking Brake Press. S. Volt V V RHC
95302 Steering Pressure MPa psi RHC
95303 Steering Press. Sensor Volt V V RHC
07703 Emerg. Steering Pressure MPa psi RHC
07705 Emerg. Steering Press S. Volt V V RHC
07704 Emerg. Steering Pressure 2 MPa psi RHC
07706 Emerg. Steering Press S. Volt2 V V RHC
33903 Retarder Lever Potentio. Volt V V RHC
43906 Steering Angle Potentio. Volt V V RHC
60201 Acceleration Sensor Voltage V V RHC
34506 Hoist Lever Potentio Volt Main V V RHC
34507 Hoist Lever Potentio Volt Sub V V RHC
34603 Body Potentio. Volt V V RHC
32904 Inclination Angle (Lateral) deg. deg. RHC
32905 Inclination S. Volt (Lateral) V V RHC
30211 Retarder Oil Temperature (F) °C °F RHC
30214 Retarder Oil Temp. S Volt (F) V V RHC
30215 Retarder Oil Temperature (C) °C °F RHC
30212 Retarder Oil Temp. S Volt (C) V V RHC
32701 Steering Oil Temperature °C °F RHC
32702 Steering Oil Temp. Sensor Volt V V RHC
10014 Radiator Fan Speed r/min rpm RHC
10015 CAC Fan Speed r/min rpm RHC
39710 Wheel Speed (FR) r/min rpm RHC
39711 Wheel Speed (FL) r/min rpm RHC
39712 Wheel Speed (CR) r/min rpm RHC
39713 Wheel Speed (CL) r/min rpm RHC
45100 Body Seating Command (High) mA mA RHC
45101 Body Seating Command (Low) mA mA RHC
45200 Body Seating Cal. Position V V RHC
45300 Cylinder Stopper Cal. Position V V RHC
45400 Body Seating Con. Time (High) sec sec RHC
45401 Body Seating Con. Time (Low) sec sec RHC
33811 Retarder EPC Sol. Current (FR) mA mA RHC
33702 Retarder EPC Sol. Current (FL) mA mA RHC
33812 Retarder EPC Sol. Current (CR) mA mA RHC
33808 Retarder EPC Sol. Current (CL) mA mA RHC
45601 Hoist EPC Solenoid Current mA mA RHC
46500 Remote Cooling EPC Sol Current mA mA RHC
31908 Inter—Axle Diff. Lock Command % % RHC

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 30 Testing and adjusting
Electrical system

Unit (Default: SI)

Code Monitoring item (Display on screen) Applicable Remarks
No. SI Non-SI component
36003 Throttle Adjustment Command % % RHC
03221 Controller Battery Volt (RHC) V V RHC
03222 Solenoid Battery Volt (RHC) V V RHC
04308 Battery Charge Volt (RHC) V V RHC
Hoist Selector Solenoid ON/OFF ON/OFF
Kick out Solenoid ON/OFF ON/OFF
RHC Output Steering Pump Sel. Sol. ON/OFF ON/OFF
03709 RHC
1 Emerg. Steering Relay ON/OFF ON/OFF
Emerg. Steering Relay 2 ON/OFF ON/OFF
Parking Interlock Relay ON/OFF ON/OFF
TCS Shut off Valve (F) ON/OFF ON/OFF
RHC Output TCS Shut off Valve (C)
03710 ON/OFF ON/OFF RHC
2
Stop Lamp (R&L) ON/OFF ON/OFF
Starter Status ON/OFF ON/OFF
02220 RHC Input 1 Emergency Steering SW ON/OFF ON/OFF RHC
Parking Brake Sol Status ON/OFF ON/OFF
Retarder Validation SW 1 ON/OFF ON/OFF
Retarder Validation SW 2 ON/OFF ON/OFF
02221 RHC Input 2 Service Brake Press. SW ON/OFF ON/OFF RHC
Secondary TCS SW ON/OFF ON/OFF
Inter-Axle Diff. Lock SW ON/OFF ON/OFF
20265 Assembly P/N (RHC) — — RHC
20420 Serial No. (RHC) — — RHC
20214 Software P/N (RHC) — — RHC
20231 Application Version (RHC) — — RHC
20232 Data Version (RHC) — — RHC
01001 Engine Speed (Tachometer) r/min rpm MON
40000 Travel Speed (Speedometer) km/h MPH MON
30216 Retarder Oil Temp. (Gauge) °C °F MON
04200 Fuel Level Sensor Volt V V MON
04201 Fuel Level Sensor Resistance z z MON
04202 Fuel Level % % MON
55001 Aircon Outside Temp. °C °F MON
03220 Controller Battery Volt (MON) V V MON
04306 Battery Charge Volt (MON) V V MON
Right Turn Signal ON/OFF ON/OFF
Left Turn Signal ON/OFF ON/OFF
Monitor Input High Beam Status ON/OFF ON/OFF
04507 MON
1 Dimmer SW ON/OFF ON/OFF
Lamp SW ON/OFF ON/OFF
Brightness Selector SW ON/OFF ON/OFF
Seat Belt SW ON/OFF ON/OFF
Monitor Input Secondary Engine Stop
04508 ON/OFF ON/OFF MON
2 SW
Door SW ON/OFF ON/OFF
Key SW ACC ON/OFF ON/OFF
Monitor Input Key SW C ON/OFF ON/OFF
04509 MON
3 Preheat Status ON/OFF ON/OFF
Unit Selector ON/OFF ON/OFF

HM400-3M0 30-125
30 Testing and adjusting
Electrical system

Unit (Default: SI)

Code Monitoring item (Display on screen) Applicable Remarks
No. SI Non-SI component
SW1 ON/OFF ON/OFF
SW2 ON/OFF ON/OFF
Monitor 1st & SW3 ON/OFF ON/OFF
04504 MON
2nd Row SW SW4 ON/OFF ON/OFF
SW5 ON/OFF ON/OFF
SW6 ON/OFF ON/OFF
SW7 ON/OFF ON/OFF
SW8 ON/OFF ON/OFF
Monitor 3rd & SW9 ON/OFF ON/OFF
04505 MON
4th Row SW SW10 ON/OFF ON/OFF
SW11 ON/OFF ON/OFF
SW12 ON/OFF ON/OFF
SW13 ON/OFF ON/OFF
Monitor 5th
04506 SW14 ON/OFF ON/OFF MON
Row SW
SW15 ON/OFF ON/OFF
Buzzer ON/OFF ON/OFF
Personal Code Relay ON/OFF ON/OFF
Monitor Night SW Lamp ON/OFF ON/OFF
04700 Output MON
Night Shift Lever Lamp ON/OFF ON/OFF
Parking Brake SW Lamp ON/OFF ON/OFF
Head Lamp (High) Relay ON/OFF ON/OFF
00205 Selected Model (MON) — — MON
20227 Assembly P/N (MON) — — MON
20402 Serial No. (MON) — — MON
20228 Software P/N (MON) — — MON
20221 Application Version (MON) — — MON
20222 Data Version (MON) — — MON
55300 Aircon Compressor Status ON/OFF ON/OFF MON
55000 Aircon Outside Temp. Code — — MON
55100 Aircon Inside Temp. Code — — MON
55200 Aircon Mode Data (MON) — — MON
55201 Aircon Mode Data (Aircon ECU) — — MON
20266 Assembly P/N (Rearview Mon.) — — MON
20421 Serial No. (Rearview Mon.) — — MON
20267 Software P/N (Rearview Mon.) — — MON
20268 Software Version(Rearview Mon.) — — MON
20260 Assembly P/N (KOMTRAX) — — MON
20418 Serial No. (KOMTRAX) — — MON
20261 Software P/N (KOMTRAX) — — MON
20273 Program Version (KOMTRAX) — — MON
When equipped with
32901 Long. Inclination Angle deg. deg. PLM payload meter
When equipped with
32902 Long. Inclination S. Volt V V PLM payload meter
When equipped with
42200 Payload t t PLM payload meter
When equipped with
42201 Rated Payload t t PLM payload meter
When equipped with
32804 Sus. Pressure (FR) MPa psi PLM payload meter
When equipped with
32810 Sus. Press. Sensor Volt (FR) V V PLM payload meter

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 30 Testing and adjusting
Electrical system

Unit (Default: SI)

Code Monitoring item (Display on screen) Applicable Remarks
No. SI Non-SI component
When equipped with
32805 Sus. Pressure (FL) MPa psi PLM payload meter
When equipped with
32811 Sus. Press. Sensor Volt (FL) V V PLM payload meter
When equipped with
32806 Sus. Pressure (RR) MPa psi PLM payload meter
When equipped with
32812 Sus. Press. Sensor Volt (RR) V V PLM payload meter
When equipped with
32807 Sus. Pressure (RL) MPa psi PLM payload meter
When equipped with
32813 Sus. Press. Sensor Volt (RL) V V PLM payload meter
0: Other, 1: Stopped
with no load, 2:
Traveling with no
load, 3: Being
loaded, 4: Traveling
42400 Truck Status — — PLM with load, 5: Stopped
with load, 6:
Dumping, 7: Other
When equipped with
payload meter
ON: Traveling, OFF:
Stopped
45000 Run Flag ON/OFF ON/OFF PLM
When equipped with
payload meter
When equipped with
03225 Controller Battery Volt (PLM) V V PLM payload meter
When equipped with
PLM Lamp Output (Red) ON/OFF ON/OFF PLM payload meter
PLM Lamp Output When equipped with
03712 PLM Output (Yellow) ON/OFF ON/OFF PLM payload meter
When equipped with
PLM Lamp Output (Green) ON/OFF ON/OFF PLM payload meter
When equipped with
Auto. Transmitting ON/OFF ON/OFF PLM payload meter
02224 PLM Input
When equipped with
MMS Communication ON/OFF ON/OFF PLM payload meter
When equipped with
20280 Assembly P/N (PLM) — — PLM payload meter
When equipped with
20425 Serial No. (PLM) — — PLM payload meter
When equipped with
20281 Software P/N (PLM) — — PLM payload meter
When equipped with
20282 Application Version (PLM) — — PLM payload meter
When equipped with
20283 Data Version (PLM) — — PLM payload meter

a Listing order in the table of monitoring items

The monitoring items are listed in the order of the display on the monitoring item selection menu screen.
a Unit
"SI" or "Non-SI" is selectable for the unit displayed on the screen.
(Switch of the displayed unit is made by using "Unit selection" of "Default " of the service menu.)
"mg/st" in the unit indicates the mass per stroke (milligram/stroke).

HM400-3M0 30-127
30 Testing and adjusting
Electrical system

a Applicable component
ENG: The engine controller is in charge of detecting the monitoring information.
T/M: The transmission controller is in charge of detecting the monitoring information.
RHC: The retarder hoist controller is in charge of detecting the monitoring information.
MON: The monitor controller is in charge of detecting the monitoring information.
Note 1: Instantaneous fuel consumption (Code No.: 37300) is the theoretical fuel consumption ratio. (Since it
is a theoretical value, it is slightly different from the actual fuel consumption ratio.)

30-128 HM400-3M0

Abnormality record (mechanical
systems) (HM300-Q1S2-100-K-00-A)
The machine monitor logs the past and currently
occurring failures classifying them into the
mechanical system abnormality and electrical
system abnormality.
To check the mechanical system abnormality record,
perform the following procedures.
a For the failure code list, see "(Chapter 40)
Failure code list for troubleshooting".
1. Selecting a menu
Select "Abnormality Record" on "Service Menu"
screen.
2. Selecting a sub menu
After "Abnormality Record" screen is displayed,
select "Mechanical Systems".
• Up switch (A): Moves the selection up by one
item
• Down switch (B): Moves the selection down
by one item
• Return switch (C): Returns the display to
"Service Menu" screen
• Enter switch (D): Validates the selection
a If you enter a 2 digit item number with the
numeral input switches (F), the entered item
is directly selected.
HM400-3M0
30 Testing and adjusting
Electrical system
3. Information displayed on "Abnormality Record"
screen
On "Mechanical Systems" screen, the following
information is displayed.
(a): Occurrence order from latest one/ Total
number of records
(b): Failure code
(c): Detail of failure
(d): Number of occurrences (displayable range:
0 to 65,535 times)
(e): Service meter reading at the first occurrence
(f): Service meter reading at the last occurrence
• Up switch (A): Moves display to the previous
page (screen) (when abnormality records are
described on multiple pages)
• Down switch (B): Moves dosplay to the next
page (screen) (when abnormality records are
described on multiple pages)
• Return switch (C): Returns display to
"Abnormality Record" screen
a If no abnormality is recorded, "No Error" is
displayed.
a In the mechanical systems abnormality
record screen, up to 50 cases currently
stored are displayed.
a If the number of occurrence is 1 (first
occurrence), the service meter readings at
the first and last occurrences are the same.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring or correction
of it is not confirmed.
a An abnormality record of the mechanical
system cannot be deleted.
a For all of the failure codes that the machine
monitor can record, see the failure code list.
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30 Testing and adjusting
Electrical system

Abnormality record (electrical

systems) (HM300-Q1S3-100-K-00-A)
The machine monitor logs the past and currently
occurring failures classifying them into the
mechanical system abnormality and electrical
system abnormality.
To check the electrical system abnormality record,
perform the following procedures.
a For the failure code list, see "40 Failure code list
for troubleshooting".
1. Selecting a menu
Select "Abnormality Record" on "Service Menu"
screen.
2. Selecting a sub menu
After "Abnormality Record" screen is displayed,
select "Electrical Systems"
• Up switch (A): Moves the selection up by one
item
• Down switch (B): Moves the selection down
by one item
• Return switch (C): Returns the display to
"Service Menu" screen
• Enter switch (D): Validates the selection
a If you enter a 2 digit item number with the
numeral input switches (F), the entered item
is directly selected.
3. Information displayed on "Abnormality Record"
screen
On "Electrical Systems" abnormality record
screen, the following information is displayed.
(a): Occurrence order from latest one/ Total
number of records
(b): Failure code
(c): Detail of failure
(d): Number of occurrences (displayable range:
0 to 65,535 times)
(e): Service meter reading at the first occurrence
(f): Service meter reading at the last occurrence
• Up switch (A): Moves your selection to the
item right above the current one (when 2 or
more abnormalities are recorded)
• Down switch (B): Moves your selection to the
item right below the current one (when 2 or
more abnormalities are recorded)
• Return switch (C): Returns to "Abnormality
Record" screen
a If no abnormality is recorded, "No Error" is
displayed.
a On the electrical systems abnormality record
screen, up to 20 cases currently stored are
displayed.
If the number of abnormality records
increases to 21 or beyond, the latest
occurrence code is displayed and the oldest
one is deleted.

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 30 Testing and adjusting
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a If the number of occurrence is 1 (first • Return switch (C): Returns to

occurrence), the time of the first occurrence
is identical with the time being read on the
service meter at the first occurrence.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring or correction
of it is not confirmed.
a For all of the failure codes that the machine
monitor can record, see the failure code list.
"Abnormality Record" screen
• Enter switch (D): Clears the information
one by one
• Menu switch (E): Clears all information at
once
a When clearing the information one by
one: Select the item to be cleared by
using Up switch (A) or Down switch (B)
and press the enter switch (D) to clear it.
a When clearing all the information at once:
Press menu switch (E) to clear all the
items regardless of the selection of the
individual item.
a If [E] is displayed on the left of a failure
code, the clearing operation is accepted
but the item is not cleared.

4. Clearing abnormality record

1) While "Electrical Systems" screen is
displayed, perform the following operation.
Switch operation: While pressing Down
switch (B), press numeral input switches (F)
in the sequence of "1"o"2"o"3".

3) After "Electrical Sys. Error Reset" screen is

displayed, operate the switches.
• Return switch (C): Returns the display to
"Electrical Systems" screen (clear mode).
• Enter switch (D): Clears the information.
a The screens for clearing all information
and clearing selected information slightly
differ.
(Clearing selected information)

2) Check that the display on the screen

becomes the clear mode, then clear the
individual information one by one or all
together.
a The screen is in the clear mode if graphic
mark "CLEAR" is indicated at the bottom
of the screen.
• Up switch (A): Moves your selection to
the item right above the current one
(when 2 or more abnormalities are
recorded)
• Down switch (B): Moves your selection to (Clearing all information)
the item right below the current one
(when 2 or more abnormalities are
recorded)

HM400-3M0 30-131
30 Testing and adjusting
Electrical system
4) If the screen to notify completion of clearing
is displayed and then "Electrical Sys. Error
Reset" screen is displayed, the clearing of
the abnormality record is completed.
a After a while, the screen returns to
"Electrical Systems" screen.
(Clearing selected information)
(Clearing all information)
Maintenance Record (HM400_3R-Q19Z-100-K-00-A)
The machine monitor records the maintenance
information of the filters, oils, etc., which are
displayed and checked by the following operations.
If you reset the data from User Menu after a
maintenance operation, the number of maintenance
performed is recorded in this section.
1. Selecting a menu
30-132
Select "Maintenance Record" on "Service Menu"
screen.
2. Selecting maintenance record item
After "Maintenance Record" screen is displayed,
select the item to confirm.
• Up switch (A): Moves the selection up by one
item
• Down switch (B): Moves the selection down
by one item
• Return switch (C): Returns the display to
"Service Menu" screen
• Enter switch (D): Validates the selection
a If you enter a 2 digit item number with the
numeral input switches (F), the entered item
is directly selected.
a The following items can be checked in the
maintenance record.
HM400-3M0
 30 Testing and adjusting
Electrical system

No. Maintenance record items

49 Air Cleaner Cleaning/Change
01 Engine Oil
02 Engine Oil Filter
41 Fuel Prefilter
24 Transmission Oil & Brake Oil
13 Transmission Oil Filter
14 Brake System Oil Filter
16 Brake Cooling Oil Filter
03 Fuel Main Filter
04 Hydraulic Oil Filter
05 Hydraulic Oil Tank Breather
11 Differential Oil 2. Selecting a sub menu
50 Final Drive Oil After "Maintenance Mode setting" screen is
Hydraulic oil displayed, select the item to change the setting.
10
• Up switch (A): Moves the selection up by one
3. Items displayed on Maintenance Record screen item
The following information is displayed. • Down switch (B): Moves the selection down
(a): Maintenance items by one item
(b): Number of replacements up to now • Return switch (C): Returns the display to
(c): Service meter reading (SMR) at the last "Service Menu" screen
replacement • Enter switch (D): Validates the selection

Maintenance mode setting (HM400_3R-Q1F1-100-K-00- a If you enter a 2 digit item number with the
A)
numeral input switches (F), the entered item
The actuating condition of the maintenance
is directly selected.
reminder function in Operator Mode can be set and
changed by using this menu.
• To enable or disable the function
• To change replacement interval setting (by item)
• To initialize all of replacement interval setting
1. Selecting a menu
Select "Maintenance Mode Setting" on "Service
Menu" screen.

a The following items can be set on the

Maintenance Mode Setting screen.

HM400-3M0 30-133
30 Testing and adjusting
Electrical system

No. Maintenance mode setting items

Maintenance Mode
Maintenance Mode On/Off
00 Change Maintenance
Notice Time Setting
Air Cleaner Cleaning/ OFF/ON Set
49 Change Interval
Set Value
Engine Oil Change OFF/ON Set
01
Interval Set Value
Engine Oil Filter Change OFF/ON Set
02
Interval Set Value
Fuel prefilter Change OFF/ON Set
41
Interval Set Value
4. Description of maintenance mode change
Transmission Oil & OFF/ON Set procedure (Maintenance Notice Time Setting)
24 Brake Oil Change
Interval Set Value Select "Maintenance Notice Time Setting" in
Transmission Oil Filter OFF/ON Set "Maintenance Mode Change" for setting.
13 Change Interval
Set Value
Brake System Oil Filter OFF/ON Set
14 Change Interval
Set Value
Brake Cooling Oil Filter OFF/ON Set
16 Change Interval
Set Value
Fuel Main Filter Change OFF/ON Set
03
Interval Set Value
Hydraulic Oil Filter OFF/ON Set
04 Change Interval
Set Value
Hydraulic Oil Tank OFF/ON Set
05 Breather Change Interval
Set Value
Differential Oil Change OFF/ON Set
11
Interval Set Value • Default value: Maintenance notice time set
Final Drive Oil Change OFF/ON Set on the machine monitor (Recommended by
50
Interval Set Value the manufacturer and not changeable).
Hydraulic Oil Change OFF/ON Set • Set value: Maintenance interval that can be
10
Interval Set Value freely set. Maintenance reminder function
99 All Default Value works according to this set time in operator
mode (the time increases or decreases in
3. Description of maintenance mode change
multiples of 10 hours).
procedure (Maintenance Mode On/Off)
• Up switch (A): Increases the set value
Select "Maintenance Mode On/Off" in
• Down switch (B): Decreases the set value
"Maintenance Mode Change" for setting.
• Return switch (C): Cancels the setting
• ON: All of functions of maintenance items
operation before entry and returns the
become effective in Operator Mode.
display to "Maintenance Mode Change"
• OFF: All of functions of maintenance items
screen.
becomes ineffective in Operator Mode.
• Enter switch (D): Validates the setting and
• Up switch (A): Moves the selection up by one
returns the display to "Maintenance Mode
item
Change" screen.
• Down switch (B): Moves the selection down
by one item
• Return switch (C): Cancels the selection and
returns the display to "Maintenance Mode
Change" screen.
• Enter switch (D): Validates the selection and
returns the display to "Maintenance Mode
Change" screen.
a Even if ON/OFF of each item has been set, if
the above setting is changed, it overrides the
individual setting.

30-134 HM400-3M0

5. Description of setting of individual maintenance
item (ON/OFF setting)
Select "ON/OFF Set" of individual maintenance
item, and proceed to its setting.
• ON: Function of the selected individual
maintenance item becomes effective in
operator mode.
• OFF: Function of the selected individual
maintenance item becomes ineffective in
operator mode.
• Up switch (A): Moves the selection up by one
item
• Down switch (B): Moves the selection down
by one item
• Return switch (C): Cancels the selection and
returns the display to the individual
maintenance item screen
• Enter switch (D): Validates the selection and
returns the display to the individual
maintenance screen
6. Description of setting of individual maintenance
item (set value)
Select "Set" of individual maintenance item, and
proceed to its setting.
7. Function to return all of the values to default
HM400-3M0
30 Testing and adjusting
Electrical system
• "Default": Maintenance interval set in
machine monitor (recommended by the
manufacturer and not changeable).
• "Set": Maintenance interval that can be freely
set. Maintenance interval function works
according to this set time in operator mode
(which is set in increments of 25 hours).
• Up switch (A): Increases "Set".
• Down switch (B): Decreases "Set".
• Return switch (C): Cancels the setting
operation before entering and returns the
display to the individual maintenance item
screen
• Enter switch (D): Validates the selection and
returns the display to the individual
maintenance screen
a When the selection is validated with Enter
switch (D) and the display returns to
"Maintenance Mode Setting" screen by
Return switch, the setting is entered.
a If currently selected "ON" for an item is
changed to "OFF" after operation of an hour
or longer, such change is recognized as a
reset operation.
values
After selecting "All Default Value" and the screen
is displayed, perform setting by using switches.
30-135
30 Testing and adjusting
Electrical system

• If you execute this item, the set values of all
the maintenance items are initialized
(returned to the default values).
• Return switch (C): Returns the display to
"Maintenance Mode Setting" screen.
• Enter switch (D): Executes the initialization
a When the Complete screen appears
sometime after pressing the Enter switch (D),
display "Maintenance Mode Setting" and the
initialization is completed.
2. Registering and changing phone number
After "Phone Number Entry" screen is displayed,
register or change the phone number
• Up switch (A): Moves the input position to the
immediate left place (if not blank).
• Down switch (B): Moves the input position to
the immediate right place (if not blank).
• Return switch (C): Cancels input numbers
and returns the display to Service Menu
screen
• Enter switch (D): Enter your input
• Menu switch (E): Clears all the input phone
numbers.

Phone number entry (HM300-Q19A-110-K-00-A)

The telephone number displayed together with
"Error List" in Operator mode can be input and
changed according to the following procedure.
If a telephone number is not input with this function,
no telephone number is displayed in Operator mode.
1. Selecting a menu
Select "Phone Number Entry" on "Service
Menu" screen.

a Up to 14 digits can be input from the left.

Leave the surplus places without inputting.

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 30 Testing and adjusting
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a When you entered a value that contains a

wrong number, move the input position (with
yellow background) to that digit and overwrite
it with the correct number.
a If you press Enter switch (D) without inputting
a digit, no phone number is displayed in
Operator mode since there is no phone
number information.

3. Selecting machine model

1) When "Machine Model Select" screen is
displayed, perform the following operation.
• Switch operation: While pressing Down
switch (B), press numeral input switches
(F) in the sequence of "1" o "2" o "3".

Default (Machine Model Select) (HM400_3R-Q1GB-

100-K-00-A)
Use the menu of "Default" to check or change
various settings of the machine monitor and
machine.
When a controller is replaced with a new one, the
machine model selection function informs the new
control of the machine model to which it is now
installed.
1. Selecting a menu
Select "Default" on "Service Menu" screen. 2) When the machine model selection is
enabled, select the model.
a Select "HM400GA" for machine model.
• Up switch (A): Moves the selection up by
one item
• Down switch (B): Moves the selection
down by one item
• Return switch (C): Cancels the selection
and returns the display to "Default"
screen
• Enter switch (D): Validates the selection

2. Selecting a sub menu

After the "Default" screen is displayed, select
"Machine Model Select".

HM400-3M0 30-137
30 Testing and adjusting
Electrical system

a If you press Enter switch (D) to validate Default (Option Select) (HM400-Q1GC-100-K-00-A)
"Machine Model Select", the followings Use the menu of "Default" to check or change
are performed. various settings of the machine monitor and
• "Monitoring/Custom": Currently stored machine.
items are cleared When all the settings relevant to the current optional
• "Maintenance Mode Setting": equipment are reset due to the machine model
"Maintenance Mode ON/OFF" and selection or when an option equipment is added
"Maintenance Notice Time Setting" later, the optional equipment selection function is
are returned to the default values of used to select the said optional equipment and
the model. enable its function.
• "Default(Option Select)": Returns to 1. Selecting a menu
the default settings of the machine Select "Default" on "Service Menu" screen.
model
• "ECO Guidance": All of the fuel
consumption data are reset
a The "Machine Model Select" screen
shown below is displayed when the
service menu is opened for the first time
after the monitor controller is replaced
with the one that has not been used for
the machine model selection before.
Therefore, select the model first (the
screen display may be somewhat
different from the actual one).

2. Selecting a sub menu

Select "Option Select" on "Default" screen.

3) When the screen that urges you to take the

key off appears, turn the starting switch to
OFF position once and turn it to ON position
again. Then, perform "Default(Option
Select)" below.
3. Selecting an optional equipment
1) After "Option Select" screen is displayed,
check the optional equipment installed to the
machine concerned and set each item.
a When the current settings are acceptable,
select either one of the items and press
Enter switch (D) without making any
modification, and the settings will be
reflected on the machine.

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a Setting for the following items is available

in optional equipment selection.
Item name Default Remarks
"Max Gear
F6 Select "F6" normally.
Speed"
Select "ADD" when
"ARAC" NO ADD
ARAC is installed.
Make the following
selection depending on
the tire size.
HM400
• Standard tire
(29.5R25): 0% 3) Setting ARAC (automatic control system for
a When there is a linked operation of retarder and accelerator)
"Tire Size contradiction Select and set "ARAC".
Compensa- 0% between the actual • "NO ADD": ARAC is not installed.
tion" and displayed travel • "ADD": ARAC is installed.
speed, adjust the • Up switch (A): Moves the selection up by
displayed speed by one item
using this function
• Down switch (B): Moves the selection
(increasing the
setting by 1% down by one item
increases the travel • Return switch (C): Cancels the selection
speed by 1% from and returns the display to "Option Select"
0% setting). screen
Select "ADD" when the • Enter switch (D): Validates the selection
"Payload and returns the display to "Option Select"
NO ADD payload meter is
Meter" screen
installed.
"Auto Idle Be sure to maintain
Stop Setting" NO ADD
"NO ADD".
2) Setting maximum gear speed
Select "Max Gear Speed" and select F6 or
F5 or F4.
• Up switch (A): Moves the selection up by
one item
• Down switch (B): Moves the selection
down by one item
• Return switch (C): Cancels the selection
and returns the display to "Option Select"
screen
• Enter switch (D): Enters the setting and
returns the display to "Option Select" 4) Setting tire size compensation
screen Select and set "Tire Size Compensation".
• Up switch (A): Increases the set value by
1%.

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• Down switch (B): Decreases the set value

by 1%.
• Return switch (C): Cancels the setting
operation before validation and returns
the display to "Option Select" screen
• Enter switch (D): Validates the setting
and returns the display to "Option Select"
screen

2. Selecting a sub menu

Select "Unit" on "Default" screen.

4. Reflecting setting
If you exit "Option Select" screen by using the
Return switch (C) after completing the setting of
the items, a screen appears to urge you to take
a key off. Turn the starting switch to OFF
position once and the optional equipment
selection is completed.
3. Selecting a unit
a When you do not press Enter switch (D) (no After "Unit" screen is displayed, select the unit to
change is made) even once for any item, be set.
even if you exit "Option Select" screen, this • Up switch (A): Moves the selection up by one
screen does not appear. item
• Down switch (B): Moves the selection down
by one item
• Return switch (C): Cancels the selection and
returns the display to "Default" screen
• Enter switch (D): Validates the setting and
returns the display to "Default" screen

Default (Unit) (HM300-Q1F3-100-K-00-A)

Use the menu "Default" to check or change various
settings of the machine monitor and machine.
The unit selecting function is used to select the unit
of the data to be displayed in monitoring, etc.
1. Selecting a menu
Select "Default" on "Service Menu" screen.

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Default (Rear View Monitor Setting) (HM300-Q1GD-100-K-00-A)

Use the menu "Default" to check or change various settings of the machine monitor and machine.
The rearview monitor setting function is used for the setting required for the removal or installation of the
rearview monitor of camera.
1. Selecting a menu
Select "Default" on "Service Menu" screen.

2. Selecting a sub menu

Select "Rear View Monitor Setting" on "Default" screen.

3. Setting rearview monitor (setting of camera 1)

ON/OFF setting of the rearview camera can be set.
1) Select "Camera 1 Setting" on "Rear View Monitor Setting" screen.

2) Setting of camera 1.
• "Unavailable": Camera is unavailable
• "Available": Camera is available
• Up switch (A): Moves the selection up by one item
• Down switch (B): Moves the selection down by one item
• Return switch (C): Cancels the selection and returns the display to "Rear View Monitor Setting"
screen

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• Enter switch (D): Validates the setting and returns the display to "Rear View Monitor Setting" screen
a Reverse images (mirror images) are displayed on the rearview monitor.
a Switching to the normal images (visual images) is not available.
a The factory default is "Available".

4. Setting rearview monitor (guide line position adjustment)

The position of the guide line displayed on the rearview monitor can be adjusted.
a Be sure to readjust the guide line position with this function whenever the rearview camera position is
changed due to its removal or installation.
a If the above adjustment is not done at all, you cannot select "Monitor Setting" o "Rear View Monitor
Setting" o "Reference Line" in User menu (guide line is not displayable).
1) After "Rear View Monitor Setting" screen is displayed, select "Guide Line Position Adjustment".
a Perform this adjustment with the rearview monitor displayed.
(In User menu, select and turn OFF "Monitor Setting" o "Rear View Monitor Setting" o "Reverse-
interlock enabled mode".)
a When "Unavailable" is selected for camera 1, this item is not selectable.

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30 Testing and adjusting
Electrical system

2) After "Guide Line Position Adjustment" screen is displayed, adjust the horizontal and vertical positions
at each point of the guide line displayed on the rearview monitor according to the following procedure.
1] Select point 1 from Guide Line Position Adjustment.
• Up switch (A): Moves the selection up by one item
• Down switch (B): Moves the selection down by one item
• Return switch (C): Cancels the selection and returns the display to "Rear View Monitor Setting"
screen
• Enter switch (D): Enters the selection and returns the display to the Point Position Adjustment
screen

2] This screen allows you to adjust the horizontal position of point 1. So, using the brightness
adjustment switch of the rearview monitor, align (a) part with the outside width of the tire.
• Brightness adjustment switch + (E): Moves the point rightward.
• Brightness adjustment switch - (F): Moves the point leftward.

3] Validate the setting with Enter switch (D).

4] Above operation allows you to adjust the vertical position of point 1. So, using the brightness
adjustment switch of the rearview monitor, align (b) part with the rear edge of the dump body.
• Brightness adjustment switch + (E): Moves the point upward.
• Brightness adjustment switch - (F): Moves the point downward.

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5] When the vertical position adjustment is over, validate the setting with Enter switch (D).
6] The display returns to the Point Selection screen. On this screen, adjust the guide line positions at
points 2 to 4 by using the same procedure.

3) Check that the positional relationship between the guide line and machine is as shown in the following
figure.
(c): Outer face of tire (green)
(d): Dump body rear edge (red)
(e): Outer face of tire (green)

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30 Testing and adjusting
Electrical system

4) When the setting of "Reverse-interlock enabled mode" of User Menu was changed at the first, return it
to the original condition and the guide line position adjustment is completed.

5. Initializing rearview monitor

This function allows initializing the rearview monitor setting.

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a Whenever you have replaced the rearview monitor, you must initialize the rearview monitor with this
function.
1) After "Rear View Monitor Setting" screen is displayed, select "Rear View Monitor Initialize".

2) The screen to confirm that want to perform the initialization appears. Answer affirmatively to it and start
the operation.
• Return switch (C): Returns the display to "Rear View Monitor Setting" screen
• Enter switch (D): Executes the initialization
a If you press Enter switch (D) to execute the initialization, the following "Rear View Monitor Setting"
is returned to the default values.
• Reference Line: OFF
• Reverse-interlock enabled mode ON
• Camera 1 Setting: Available
• Guide Line Position Adjustment: Not set

a When "Complete" screen appears sometime after pressing Enter switch (D), "Rear View Monitor
Setting" screen appears and the initialization is completed.

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Testing (Cylinder Cut-out operation) (HM400_3R-

AD00-34F-K-00-A)
On the machine monitor, you can perform the
cylinder cut-out mode operation.
Cylinder Cut-out mode operation means to run the
engine with one or more fuel injectors disabled
electrically to reduce the number of effective
cylinders. This operation is used to identify a
cylinder that does not output power normally
(combustion in it is abnormal).
1. Selecting a menu
Select "Diagnostic Tests" on "Service Menu"
screen.
a This operation may be performed while the
engine is running.
a If background (a) of the selected cylinder
number becomes white after you press Enter
switch (D), the cylinder is cut out.
a If the machine monitor cuts out a cylinder but
the engine controller cannot cut out that
cylinder, the background (a) of the cylinder
number becomes yellow.
a The number of cylinders cut out may be one
or more.
2. Selecting a sub menu
After "Diagnostic Tests" screen is displayed,
select "Cylinder Cut-out".

4. Releasing cut-out cylinder

3. Selecting cylinder to be cut-out
After "Cylinder Cut-out" screen is displayed,
select a cylinder to be cut out.
• Up switch (A): Moves selection to the left
• Down switch (B): Moves selection to the right
• Return switch (C): Returns the display to
Diagnostic Test screen
• Enter switch (D): Validates the selection
• Menu switch (E): Switches between the Hold
and the Releasing hold (If the Hold is
selected, the HOLD part is hatched)
When changing a cylinder to be cut out or when
the cylinder cut-out operation is finished, select
the cut-out cylinder(s) to be released.
a This operation may be performed while the
engine is running.
a If background (a) of the selected cylinder
number changes to gray when you press
Enter switch (D), the cylinder is released the
cut-out.
a If the machine monitor releases a cut-out
cylinder but the engine controller cannot
release the cut-out cylinder, the background
(a) of the cylinder number becomes red.

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a The cut-out cylinder mode operation is not

automatically released after the screen
returns to the operator mode. Accordingly, be
sure to perform the releasing operation after
the cylinder cut-out mode operation is
finished.
5. Holding displayed data
If you press menu switch (E) during the cylinder
cut-out operation, the displayed information is
held anew (b) (display of the real-time
information is maintained on the left side).
If you press menu switch (E) while the data is
held, the data holding function is canceled.
a The holding function is available for a Adjustment (Transmission initial
cylinder, regardless of whether it is cut out or learning) (HM300-CN16-270-K-01-A)
not. You can perform various adjustments related to the
machine with the machine monitor.
The transmission controller has the learning
capability to maintain a constant gear shift feeling
compensating the changes on the transmission
clutch due to wear.
The transmission initial learning function can display,
through the transmission controller, the items
necessary to perform this initial learning .
a For how to use this function, see "Resetting
initial learning of transmission and execution of
learning (2-3)" in "Setting and adjusting each
equipment".
[Reference]
• If a normally operating cylinder is cut out, the
following phenomena occur.
1) Decrease in engine speed
2) The quantity of final injection rate
command increases.
• If the engine is running at around high idle,
however, the engine speed may not
decrease because for the reason of engine
control.
• In this case, lower the engine speed by
adjusting the accelerator pedal depressing,
and make the judgment observing increase
of the final fuel injection volume command.
Adjustment (Resetting transmission initial
Adjustment (ECMV automatic learning) (HM300-CN16-271-K-00-A)
compensation) (HM300-CN16-270-K-00-A) You can perform various adjustments related to the
You can perform various adjustments related to the machine with the machine monitor.
machine with the machine monitor. The transmission initial learning resetting function is
The ECMV automatic compensation function allows capable of initializing the initial learning data
to correct the differences in operational feeling due through the transmission controller.
to the individual character of ECMV to a certain a For how to use this function, see "Resetting
level through the transmission controller. initial learning of transmission and execution of
a For how to use this function, see "Adjusting learning (2-3)" in "Setting and adjusting each
transmission ECMV current (2-2)" in "Setting equipment".
and adjusting each equipment".

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30 Testing and adjusting
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Adjustment (Debug Mode Selection) (HM300-

CN1P-270-K-00-A)

a This function is special for use in the plant only

and not used for the service.

Adjustment (Engine Mode Fixing) (HM300-CN1M-

270-K-00-A)
You can perform various adjustments related to the
machine with the machine monitor.
The engine mode fixing function allows, through the
transmission controller, to fix the engine output to Adjustment (Fan Mode Fixing) (HM400_3R-CN1Q-270-
K-00-A)
any torque curve when testing it. You can perform various adjustments related to the
a For use of this function, see "Testing torque machine with the machine monitor.
converter stall speed". The fan mode fixing function allows you to fix the
a The followings are "Engine Mode Fixing". ratio of the fan speed to the engine speed to any
level through the transmission controller.
• 0: "Normal": Normal state where the engine
When checking the radiator fan or after cooler fan
mode is not fixed (gear speed is not fixed)
speed, perform the following procedures.
• 1: "Power": Set state of the engine torque
curve when output mode is set to "Power" a The fan speed ratios for the radiator and after
• 2: "Low Noise": State where the output at cooler are fixed separately.
high idle is limited to reduce noise only when 1. Select "Adjustment" on "Service Menu" screen.
Shift Lever 1 is selected
• 3: "Economy": Set state of the engine torque
curve when output mode is set to "Economy"
• 5: "Out of Cond.": State where any condition
is out of the condition for setting the fixing
engine mode (example: the torque converter
oil temperature is out of the condition)

2. Select "Fan Mode Fixing" on "Adjustment"

screen.

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• Menu switch (E): Clears all the input values.

• Numeral input switches (F)
a The followings are "Fan mode fixing".
• 0: "Normal"
• 1: "Brake" (sets the maximum mechanical
speed used when the brake is operated)
• 2: "Max" (sets the maximum regulatory
speed used in the normal operation)
• 3: "Min" (sets the minimum regulatory
speed used in the normal operation)

3. Press numeral input switch (F) on "Fan Mode

Fixing" screen. (The switch can be any of 0 to 9.)
• Up switch (A): Switches the mark (not used)
• Down switch (B): Inputs decimal point (not
used)
• Return switch (C): Cancels the input
• Enter switch (D): Validates the input
• Menu switch (E): Clears all the input values.
• Numeral input switches (F)

5. The "Fan Mode Fixing" screen is displayed

again and you will be asked to enter the change.
Press Enter switch (D) to validate the change.
After validated, the value is displayed at (a).
• (a): Current setting
• (b) New setting

6. After the fan mode is fixed to the one you

desired through the above operation, check the
engine speed and fan speed by selecting a
monitoring code on "Monitoring" screen in
"Service Menu".
4. When "Numeric Pad Input" screen is displayed,
a The set content is held even after returning to
enter a number (0 to 3) of the fan mode you
"Adjustment" screen by pressing Return
want to fix by using numeral input switches (F)
switch (C), until the starting switch is turned
and press Enter switch (D).
to OFF position.
• Up switch (A): Switches the mark (not used)
• Down switch (B): Inputs decimal point (not
used)
• Return switch (C): Cancels the input
• Enter switch (D): Validates the input

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30 Testing and adjusting
Electrical system

• (a): Current setting

• (b): Behavior when Enter switch (D) is
pressed
• Return switch (C): Cancels the setting and
returns the display to the Adjustment screen
• Enter switch (D): Fixes the swash plate angle
to the maximum. Or returns it to the normal
angle.
• Menu switch (E): Switches between the Hold
and the Releasing hold of a monitored value
(If the Hold is selected, the HOLD part is
hatched)

Adjustment (Steering Pump Displacement

Fixing) (HM400_3R-CN1R-270-K-00-A)
You can perform various adjustments related to the
machine with the machine monitor.
The Steering Pump Displacement Fixing function
allows, through the retarder and hoist controller,
fixing the steering pump swash plate at the
maximum.
To check the steering relief pressure at the rated
speed, perform the following procedures.
a Before fixing, check that the dump body is
seated.
1. Select "Adjustment" on "Service Menu" screen.

a If the dump body is not seated or a failure is

detected on the machine, the value of (a) is
2. After "Adjustment" screen is displayed, select replaced with "2" (Out of Cond.) and
"Steering Pump Displacement Fixing". maximizing the pump swash plate angle
becomes unavailable.

Adjustment (Throttle Limit Check) (HM400_3R-

CN1S-270-K-00-A)
You can perform various adjustments related to the
machine with the machine monitor.
The Throttle Limit Check function allows, through
the transmission controller, setting the control state
of KTCS and fan as desired.
When checking the difference in the towing force
restricting function between when KTCS is activated
and not activated, perform the following procedures.

3. Set the steering pump swash plate angle to the

maximum by pressing Enter switch (D).

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a Make sure before starting the operation that the

parking brake is turned to ON position and "7:
Out of Cond" is not displayed on "Throttle Limit
Check" screen.
1. Select "Adjustment" on "Service Menu" screen.

4. When "Numeric Pad Input" screen is displayed,

enter a number (0 to 6) of the condition you want
to check by using numeral input switches (F)
and press Enter switch (D).
• Up switch (A): Switches the mark (not used)
• Down switch (B): Inputs decimal point (not
2. After "Adjustment" screen is displayed, select
used)
"Throttle Limit Check".
• Return switch (C): Cancels the input
• Enter switch (D): Validates the input
• Menu switch (E): Clears all the input values.
• Numeral input switches (F):
0: Normal
1: KTCS not operated & radiator fan normal
control
2: KTCS not operated & radiator fan max
speed
3: KTCS not operated & radiator fan
minimum speed
4: KTCS operated & radiator fan normal
control
5: KTCS operated & radiator fan max speed
6: KTCS operated & radiator fan minimum
speed
a The after cooler fan remains under the
normal control.

3. Press numeral input switch (F) on "Throttle Limit

Check" screen. (The switch can be any of 0 to
9.)

5. After the Confirmation screen is displayed, press

Enter switch (D) again to enter the change.
• (a): Current setting
• (b) New setting
• Return switch (C): Cancels the change and
returns the display to "Adjustment" screen

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30 Testing and adjusting
Electrical system
• Enter switch (D): Validates the change.
• Menu switch (E): Switches between Hold
and Releasing hold (If the Hold is selected,
the HOLD part is hatched.)
6. Check that the maximum throttle limit command
is changed according to the selected condition.
a While the throttle limit check (one of 1 to 6 is
set) is continued, the gear speed shown in
the below is selected depending on the shift
lever position.
Shift lever position Gear speed
R2 N
R1 N
N N
D F2
5 F2
4 F2
3 F2
2 F2
1 F2
a If the parking brake is turned OFF or a failure
is detected on the machine, the value of (b)
is replaced with "7: Out of Cond" and
checking of the throttle limit becomes
unavailable.
a The set content is returned to the normal
setting if you press Return switch (C) to
return the adjustment screen.
30-154
Adjustment (ARAC Characteristic Value
Setting) (HM300-CN1T-270-K-00-A)
You can perform various adjustments related to the
machine with the machine monitor.
The ARAC Characteristic Value Setting function can,
through the transmission controller, compensate the
variations in the actuating force of ARAC due to
variations in the valves, that can occur when the
retarder valve is replaced, by entering the
characteristic value of each valve.
a For how to use this function, see "ARAC (auto-
retarder, accelerator control system)
characteristic value setting" in "Setting and
adjusting each equipment".
Adjustment (ARAC Operating Force
Compensation) (HM300-CN1U-270-K-00-A)
a This function is special for use in the plant only
and not used for the service.
Adjustment (KTCS System Check) (HM300-CN1V-
270-K-00-A)
You can perform various adjustments related to the
machine with the machine monitor.
The KTCS System Check function can check the
KTCS-related parts (such as retarder hydraulic
pipes, wiring harnesses and sensors) for
inappropriate assembling after their replacement.
a For how to use this function, see "Checking
KTCS system" in "Setting and adjusting each
equipment".
HM400-3M0

No Injection (HM300-AD00-25L-K-00-A)
If the engine is operated after long storage of the
machine, it may be worn or damaged because of
insufficient lubrication with oil. To prevent this, the
machine monitor has a function to crank the engine
without injecting fuel to lubricate the engine before
starting it.
Set No Injection cranking while the engine is
stopped.
1. Selecting a menu
Select "No Injection" on "Service Menu" screen.
2. Displaying confirmation screen
When "No Injection" screen is displayed, you are
asked if you want to start No Injection cranking.
Answer as follows;
• Return switch (C): Does not execute (returns
the display to Service Menu screen)
• Enter switch (D): Executes
HM400-3M0
30 Testing and adjusting
Electrical system
3. Starting No-Injection cranking
If No-Injection cranking (no fuel injection to
every cylinder) is enabled, a message to notify
that is displayed on the screen. Under this
condition, turn the starting switch to START
position, and crank the engine.
a While the screen is changing to the following
screen, the screen of "Getting Ready." is
displayed.
a Do not crank the engine for 20 seconds or
longer to protect the starting motor.
4. Finishing No-Injection cranking
After the cranking is completed, turn the starting
switch to OFF position.
a You cannot change the screen described
above to another screen.
a When you want to turn the starting switch to
ON position again, set a sufficient time (1
minute minimum) before doing so.
5. Prohibiting No-Injection cranking
Even if the operator tries to perform No-Injection
cranking while the engine is running, the
message "The engine is operating" is displayed
and No-Injection cranking does not become
effective.
a This function can be selected even when the
engine is running. However, if you execute
No Injection cranking, a message "Please
turn the key off once." appears on the
screen.
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30 Testing and adjusting
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Also, if No-Injection cranking is operated while
"Check" screen appears, the function does not
become effective in the following case.
• The communication between the monitor and
engine controller is not normal.
• Perform an engine start operation before the
message "No injection is possible" appears.
Payload Meter Setting (HM400_3R-M710-110-K-00-A)
Use each item of "Payload Meter Setting" for
various settings of the payload meter (PLM).
"Payload Meter Setting" screen can be selected on
"Service Menu".
30-156
• Up switch (A): Moves the selection up by one
item
• Down switch (B): Moves the selection down by
one item
• Return switch (C): Returns the display to the
standard screen
• Enter switch (D): Validates the selection
Setting of payload to start loading
a Payload with which payload meter can
recognize "the start of loading" can be set.
(Default: 15%)
Recognition of it makes machine monitor and
external indicator lamp actuated (displayed and
lighted up).
a There are possibilities of the following
malfunction in this setting and the operation is
not guaranteed.
• When the value is less than the default value,
it may fail to recognize the start of loading
properly.
• When the value is more than the default
value, and if bucket capacity of the machine
loading is small (1 payload is small), it may
fail to display "Predicted load display"
properly.
a Range: 5.0 to 25.5 %
1. "Payload to start loading" screen can be
selected on "Payload Meter Setting" screen.
HM400-3M0
 30 Testing and adjusting
Electrical system

2. When "Payload to start loading" is displayed,

enter the value you want to input by using the
numeral input switches (F), and press enter
switch (D).

2. When "Travel distance to complete loading" is

displayed, enter the value you want to input by
using the numeral input switches (F), and press
enter switch (D).

• Down switch (B): Enters decimal point

• Return switch (C): Returns to "Payload Meter
Setting" screen
• Enter switch (D): Enter your input
• Menu switch (E): Clears all the input values.
• Numeral input switch (F): Used for entering
numbers.
a Enter switch (D) doesn't change the screen if
the inputted value is out of the range.
3. "Payload to start loading" is changed, and the
screen returns to "Payload Meter Setting".

Setting of travel distance to complete loading

a Travel distance with which payload meter can
recognize "the end of loading" can be set.
(Default: 160 m)
a When the value is less than the default value, it
may recognize it as the end of load during
loading by mistake.
a Range: 0 to 255 m
3. "Travel distance to complete loading" is changed,
1. "Travel distance to complete loading" screen
can be selected on "Payload Meter Setting"
screen.
• Return switch (C): Returns to "Payload Meter
Setting" screen
• Enter switch (D): Enter your input
• Menu switch (E): Clears all the input values.
• Numeral input switch (F): Used for entering
numbers.
a Enter switch (D) doesn't change the screen if
the inputted value is out of the range.
and the screen returns to "Payload Meter
Setting".

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30 Testing and adjusting
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Setting payload offset
a The amount of set load can be offset against
payload which is calculated by payload meter.
a Range: –5.0 to +5.0 tons
1. "Payload offset" screen can be selected on
"Payload Meter Setting" screen.
2. When "Payload offset" is displayed, enter the
value you want to input by using the numeral
input switches (F), and press enter switch (D).
• Up switch (A): Switches + and -
• Down switch (B): Enters decimal point
• Return switch (C): Returns to "Payload Meter
Setting" screen
• Enter switch (D): Enter your input
• Menu switch (E): Clears all the input values.
• Numeral input switch (F): Used for entering
numbers.
30-158
a Enter switch (D) doesn't change the screen if
the inputted value is out of the range.
3. "Payload offset" is changed, and the screen
returns to "Payload Meter Setting".
Setting method of entering saved payload
a Method that payload meter calculates "Payload
(load weight)" can be selected.
a There are 3 methods as follows.
• "A": It statistically calculates data collected
from the place of loading to the place of
dumping during traveling, decides hauled
payload when dumping, and memorizes it.
This is the most accurate method.
• "B": It memorizes the payload when dump
lever is shifted from "FLOAT" to the position
other than "FLOAT" at the place of dumping.
• "C": It memorizes the payload at the place of
loading.
1. "Method of entering saved payload" screen can
be selected on "Payload Meter Setting" screen.
2. After "Method of entering saved payload" screen
is displayed, select the condition by using the Up
switch (A) or the Down switch (B), and press the
enter switch (D).
• Up switch (A): Moves the selection up by one
item
• Down switch (B): Moves the selection down
by one item
HM400-3M0
 30 Testing and adjusting
Electrical system

• Return switch (C): Returns to "Payload Meter no load which is written down, and press enter
Setting" screen switch (D).
• Enter switch (D): Validates the selection
3. "Method of entering saved payload" is changed,
and the screen returns to "Payload Meter
Setting".

Correction of payload calculation

a This correction directly affects to accuracy of
payload meter. Make sure to perform this.
a Perform measurement of gross machinery
weight with no load and gross machinery weight
with maximum load in this order in according to
the following procedure.
a Secure travel path for measurement to be done • Up switch (A): Moves selection to the left
during traveling with no load and with maximum • Down switch (B): Moves selection to the right
load. This is performed after measurement of • Return switch (C): Returns to "Payload Meter
gross machinery weight with no load and gross Setting" screen
machinery weight with maximum load. • Enter switch (D): Validates the selection
Condition during traveling • Numeral input switch (F): Used for entering
• Shift Lever: F2 numbers.
• Accelerator pedal: Full stroke a Enter switch (D) doesn't enter it if the
• Travel for approximately 3 minutes inputted value is out of the range, and it
a Range for inputting gross machinery weight with returns to condition for inputting maximum
no load: ± 15 % of machine weight digits.
5. When machine is prepared for traveling and next
a Range for inputting gross machinery weight with screen is displayed, press enter switch (D).
maximum load: ± 25 % of machine weight +
maximum load
a Perform this correction after careful thought
since the relationship of suspension pressure
and payload cannot be returned to the condition
at shipment.
1. Measure the gross machine weight with no load
by using load meter, and write it down. (on paper,
etc.)
2. Move the machine to the place for the
measurement to be done during traveling.
3. "Correction of payload calculation" screen can
be selected on "Payload Meter Setting" screen.
6. After next screen is displayed, move shift lever
to "F2" position, and travel with accelerator
pedal at full stroke for approximately 3 minutes,
and measure the gross machine weight with no
load.
a Press return switch (C), and it returns the
display to the previous screen.

4. After "Input empty dump truck weight" screen is

displayed, enter the gross machine weight with

HM400-3M0 30-159
30 Testing and adjusting
Electrical system

9. Measure the gross machine weight with

a The measurement stops if oil pressure
maximum load by using load meter, and write it
sensor or inclination angle sensor on each
down. (on paper, etc.)
suspension detects an abnormality, and the
10.Move the machine to the place for the
screen displays "NG" as shown. If "NG"
measurement to be done during traveling.
screen is displayed, perform applicable
11.On "Input loaded dump truck weight" screen,
troubleshooting. Press return switch (C), and
enter the gross machine weight with maximum
it returns the display to "Payload Meter
load which is written down, and press enter
Setting" screen.
switch (D).
(Example of the screen which shows
abnormality occurred)

• Up switch (A): Moves selection to the left

• Down switch (B): Moves selection to the right
7. If the following screen is displayed, stop the
• Return switch (C): Returns to "Payload Meter
machine, and press enter switch (C).
Setting" screen
• Enter switch (D): Validates the selection
• Numeral input switch (F): Used for entering
numbers.
a Enter switch (D) doesn't enter it if the
inputted value is out of the range, and it
returns to condition for inputting the top
digits.
12.When machine is prepared for traveling and
next screen is displayed, press enter switch (D).

8. If "Input loaded dump truck weight" screen is

displayed, perform loading until it reaches to
maximum payload.
a For maximum payload, see "Specification
drawing" in Operation and Maintenance
Manual or Outline,

30-160 HM400-3M0
 30 Testing and adjusting
Electrical system

14.The following screen is displayed, and the

measurement of gross machine weight with
maximum load is completed. Dump the load at
the place of dumping.

13.After next screen is displayed, move shift lever

to "F2" position, and travel with accelerator
pedal at full stroke for approximately 3 minutes,
and measure the gross machine weight with
maximum load.
15.When dumping is completed normally,
a Press return switch (C), and it returns the correction of payload is completed. Then it
display to the previous screen. returns to "Payload Meter Setting" screen.

Correction of inclination angle sensor

a Set "standard level value" of inclination angle
sensor.
This setting directly affects accuracy of
correction and operation of inclination caution
lamp on a slope. Make sure to perform this.
1. Move the machine to the level ground.
2. Select "Correction of inclination sensor" screen
on "Payload Meter Setting" screen.

a The measurement stops if oil pressure

sensor or inclination angle sensor on each
suspension detects an abnormality, and the
screen displays"NG" as shown. If "NG"
screen is displayed, perform applicable
troubleshooting. Press return switch (C), and
it returns the display to "Payload Meter
Setting" screen.
(Example of the screen which shows
abnormality occurred)
3. When voltage of "1st" on "Correction of
inclination sensor" screen becomes stable,
press enter switch (D).

HM400-3M0 30-161
30 Testing and adjusting
Electrical system

a When an abnormality occurred on inclination

angle sensor, "NG" screen is displayed, and
the enter switch (D) does not proceed to the
next screen. If "NG" screen is displayed,
perform applicable troubleshooting.

7. When the correction is completed, it returns to

"Payload Meter Setting" screen.

Setting of indication range of lamp

(Example of the screen
abnormality occurred)
a Payload with which external indicator lamp
operates (lights up and goes out) can be set.
which shows
a Default value of payload with which each
external indicator lamp appears are as follows.
• "G" (green lamp): 50 % of maximum payload
• "A" (yellow lamp): 90 % of maximum payload
• "R" (red lamp): 105 % of maximum payload
a Range: 0 to 130 % of maximum payload
But, the value of "A" (yellow lamp) should be set
more than "G" (green lamp). The value of "R"
(red lamp) should be set more than "A" (yellow
lamp).
1. Select "Indication range of external lamps"
screen on "Payload Meter Setting" screen.

4. Turn the machine 180 deg. (to the opposite)

5. When voltage of "2nd" on "Correction of
inclination sensor" screen becomes stable,
press enter switch (D).

2. After "Indication range of external lamps" screen

is displayed, enter the indication range of each
lamp, and press enter switch (D).

6. When average value of "1st" and "2nd" is

displayed on "standard level value", press enter
switch (D).

30-162 HM400-3M0
 30 Testing and adjusting
Electrical system

• Up switch (A): Moves selection to the left

• Down switch (B): Moves selection to the right
• Return switch (C): Returns to "Payload Meter
Setting" screen
• Enter switch (D): Enter your input
• Menu switch (E): Returns all the inputted
value to previous values, and the top digit of
"G" can be set.
• Numeral input switch (F): Used for entering
numbers.
3. "Indication range of external lamps" is changed,
and the screen returns to "Payload Meter
Setting".
• Down switch (B): Enters decimal point
Setting stopper-hit threshold value
• Return switch (C): Returns to "Payload Meter
a If equalizer bar hits the stopper when a rear tire Setting" screen
run on a slope during loading, it affects the • Enter switch (D): Enter your input
accuracy of payload calculation during loading. • Menu switch (E): Clears all the input values.
The stopper-hit threshold value with which • Numeral input switch (F): Used for entering
equalizer bar is recognized if it is hit when the numbers.
machine with no load stops at loading place can
a Enter switch (D) doesn't change the screen if
be changed. But perform this setting after careful
the inputted value is out of the range.
thought since it may fail to recognize it when it is
3. "Stopper-hit threshold" is changed, and the
over the set stopper-hit threshold value. (Default
screen returns to "Payload Meter Setting".
value: 2.0 tons)
a Range: 2.0 to 5.0 tons Cycle data deletion
1. Select "Stopper-hit threshold" on "Payload Meter a Download the cycle data before deleting it.
Setting" screen. 1. Select "Cycle data deletion" on "Payload Meter
Setting" screen.

2. After "Stopper-hit threshold" is displayed, enter

the value you want to input by using the numeral 2. After "Cycle data deletion" screen is displayed,
input switches (F), and press enter switch (D). press enter switch (D).

HM400-3M0 30-163
30 Testing and adjusting
Electrical system

a Press return switch (C), and it returns the a Press return switch (C), and it returns the
display to "Payload Meter Setting" screen display to "Payload Meter Setting" screen
without deleting it. without initializing it.

3. After completion of deleting, it returns the display 3. After completion of initializing, it returns the
to "Payload Meter Setting" after displaying the display to "Payload Meter Setting" after
following screen. displaying the following screen.

Payload meter initialization Serial number confirmation

a If performing initialization, all items having been a Usually, it is not required.
set at operator mode and service mode return to 1. Select "S/N confirmation" on "Payload Meter
default value, and accumulated payload, Setting" screen.
accumulated number of cycles, and cycle data
are deleted.
1. Select "Payload meter initialization" on "Payload
Meter Setting" screen.

2. After "S/N confirmation" is displayed, enter the

serial number by using each switches, and press
enter switch (D).

2. After "Payload meter initialization" screen is

displayed, press enter switch (D).

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 30 Testing and adjusting
Electrical system

KOMTRAX Settings (terminal setting

status) (HM300-Q210-110-K-00-A)
The setting and operating conditions of KOMTRAX
can be checked on the display of "KOMTRAX
Settings".
Terminal setting status is used to check the setting
condition of the KOMTRAX terminal.
1. Selecting a menu
Select "KOMTRAX Settings" on "Service Menu"
screen.

• Up switch (A): Number of selected digit

increases
• Down switch (B): Number of selected digit
decreases
• Return switch (C): Returns to "Payload Meter
Setting" screen
• Enter switch (D): Validates the setting and
returns the display to validation screen
• Menu switch (E): Moves your selection to the
immediate right item
3. After the following screen is displayed, press
2. Selecting a sub menu
enter switch (D) again.
Select "Terminal Status" on "KOMTRAX
a Press return switch (C), and it returns the Settings" screen.
display to "Payload Meter Setting" screen
without changing the serial number.

3. Contents displayed on Terminal Status screen

4. After completion of setting of serial number, it
returns the display to "Payload Meter Setting"
after displaying the following screen.
On "Terminal Status" screen, the following items
of information are displayed.
• "Terminal Type": Model name of the
KOMTRAX communication modem
• "KOMTRAX Communication": Status of radio
station establishment underway
• "GMT Time": Greenwich Mean Time (add 9
hours to it for Japan time)
Return switch (C): Returns the display to
"KOMTRAX Settings" screen

HM400-3M0 30-165
30 Testing and adjusting
Electrical system

3. Contents of display of GPS & Communication

Status
On "GPS & Communication Status" screen, the
following items of information are displayed.
• "Positioning": GPS positioning status
• "Communication": Communication
environment and connecting condition of the
communication modem
• "Number of message not yet sent": Number
of message(s) not yet sent: Number of
unsent mails existing in the machine monitor
Return switch (C): Returns the display to
"KOMTRAX Settings" screen

KOMTRAX Settings (GPS and Communication

Status) (HM300-Q210-110-K-01-A)
The setting and operating conditions of KOMTRAX
can be checked on the display of "KOMTRAX
Settings".
GPS & Communication Status is used to check the
positioning and communication condition of the
KOMTRAX terminal.
1. Selecting a menu
Select "KOMTRAX Settings" on "Service Menu"
screen.

2. Selecting a sub menu

Select "Modem Status" on
Communication Status" screen.
"GPS &
KOMTRAX Settings screen (Modem
Status) (HM300-Q210-110-K-02-A)
The setting and operating conditions of KOMTRAX
can be checked on the display of "KOMTRAX
Settings".

30-166 HM400-3M0

Modem information is used to check the IP address
of the KOMTRAX communication modem.
1. Selecting a menu
Select "KOMTRAX Settings" on "Service Menu"
screen.
2. Selecting a sub menu
Select "Modem Status" on "KOMTRAX Settings"
screen.
3. Details displayed on Modem Status screen
IP addresses (2 systems) of the modem are
displayed.
Return switch (C): Returns the display to
"KOMTRAX Settings" screen
a An IP address is a unique number assigned
to each modem that is used when
communication between the modem and
server is established.
HM400-3M0
30 Testing and adjusting
Electrical system
Service Message (HM300-Q210-100-K-00-A)
Special messages for the technician sent from the
KOMTRAX base station (a distributor, etc.) can be
checked with this function.
If a received message includes a setting operation,
a return mail can be sent by using the numeral input
switches as well.
1. Selecting a menu
Select "Service Message"on "Service Menu"
screen.
2. Displaying message (read only)
If a message is received, the description in the
message is displayed. If there is no
message,"No message." is displayed.
Return switch (C): Returns to "Service Menu"
screen
a This message is different from that sent to
the operator with the machine monitor in the
operator mode.
a Since this message is special for the
technician, the message pilot lamp does not
light up when it is received unlike the
operator mode.
30-167
30 Testing and adjusting
Electrical system

3. Display of message (with return mail function)

If "Numeric Input" is displayed at the bottom of
the text, enter the number by using numeral
input switches (F) and validate it by using the
enter switch (D). Then, the information is
returned to the KOMTRAX base station.
• Return switch (C): Returns the display to
"KOMTRAX Settings" screen
• Enter switch (D): Validates the input value
and returns it
a This message is different from that sent to
the operator with the machine monitor in the
operator mode.
a Since this message is special for the
technician, the message pilot lamp does not
light up when it is received unlike the
operator mode.

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 30 Testing and adjusting
Electrical system

KOMTRAX terminal start-up procedure (HM400_3R-Q210-110-K-00-A)

Observe the following procedure when using

KOMTRAX.
1. Fill out the "Orbcomm Terminal Establishment
Application" form and send it to KOMTRAX
Service Hot Line by fax or mail.
2. Use KOMTRAX client PC for the distributor and
machine registration and for going through the
radio station establishment-related procedures.
a Operating the KOMTRAX client PC requires the
KOMTRAX operation administrator authority at
each distributor. Therefore you must consult the
KOMTRAX operation administrator before using
it. 2. Selecting a sub menu
When KOMTRAX terminal is replaced After the "KOMTRAX Settings" screen is
Observe the following procedure when using displayed, select "GPS & Communication
KOMTRAX. Status."
1. "Machine side inspection for radio station
establishment" must be done.
2. Fill out the "Orbcomm Terminal Establishment
Application" form and send it to KOMTRAX
Service Hot Line by fax or mail.
3. Use KOMTRAX client PC for the distributor and
machine registration and for going through the
radio station establishment-related procedures.
a Operating the KOMTRAX client PC requires the
KOMTRAX operation administrator authority at
each distributor. Therefore you must consult the
KOMTRAX operation administrator before using
it. 3. Implementation of radio station establishment
Machine side inspection for radio station inspection
establishment 1) After the "GPS & Communication Status"
When the KOMTRAX terminal is replaced, the radio screen is displayed, perform the following
station establishment inspection must be done to operation.
check whether normal communication is available Switch operation: While pressing DOWN
from the terminal. switch (B), press numeral input switches (E)
The above establishment inspection is done from "1" o "2" o "3" in order.
the machine monitor.
a Since communication with the Orbcomm satellite
is performed in the establishment inspection, the
machine should desirably placed outside under
a big sky
The establishment inspection may not be
completed successfully when the machine is
placed indoor where radiowave from the satellite
can be blocked.
1. Selecting a menu
Select "KOMTRAX Settings" on the "Service
Menu" screen.

HM400-3M0 30-169
30 Testing and adjusting
Electrical system
2) The screen confirms if you want to execute
the establishment inspection. Answer
affirmatively to it and start the operation.
Return switch: Returns the display to the
GPS & Communication Status screen
Enter switch: Executes the establishment
inspection.
a When the establishment inspection is
already completed, this screen does not
appear.
3) The screen displays the status of the
establishment inspection. Check on this
screen that every item is acceptable.
Modem: It is accepted when the system
enters the communication range.
GPS: It is accepted when it becomes
capable of acquiring GPS data.
Transmission: It is accepted when it
becomes capable of transmitting data
correctly.
Inspection status: The inspection completes
when the modem, GPS and transmission are
all accepted.
a It takes 90 seconds to 15 minutes until
approval is given to every item.
30-170
a While waiting for the approval, you may
do what you want to do like displaying
other screens, turning the starting switch
to OFF position or starting the engine.
If there is nothing abnormal, the
establishment inspection finishes
automatically. Select "KOMTRAX
Settings" o "Terminal Status" of the
service menu to make sure that "Already
Open." is indicated for the item
"KOMTRAX Settings (radio station
establishment)".
a The establishment inspection may not be
completed when the machine is placed
indoor where radiowave from the satellite
is blocked.
a If "Modem" is not accepted, check the
communication antenna and cable for
external failure. If any, repair it and repeat
the establishment inspection again.
a If "GPS" is not accepted, check the
communication antenna and cable for
external failure. If any, repair it and repeat
the establishment inspection again.
4) When every item is accepted, the
"KOMTRAX Communication Opened."
screen is automatically displayed.
Press Enter switch. If the "GPS &
Communication Status" appears, the
machine side establishment inspection is
completed.
HM400-3M0
 30 Testing and adjusting
Electrical system

HM400-3M0 30-171
30 Testing and adjusting
Electrical system

30-172 HM400-3M0
 30 Testing and adjusting
Electrical system

Handling voltage circuit of engine controller (HM300-AP40-2A4-K-00-A)

1. Disconnecting or connecting work of the

connector between the engine controller and the
engine must be performed only when the
starting switch and disconnect switch are in OFF
position and the system operating lamp goes
out.

k Before connecting the wiring harness

connector, be sure to completely remove
sand, dust, water, etc., inside the
connector on the controller side.
2. When you perform troubleshooting, do not start
the engine while a T-adapter is inserted into or
connected to the connector between the engine
controller and engine.
a You may turn the starting switch to OFF or
ON position but must not turn it to START
position.

HM400-3M0 30-173
30 Testing and adjusting
Electrical system

Handling battery disconnect switch (HM400-AW1P-100-K-00-A)

1. When you turned the battery disconnect switch

to OFF position, be sure to remove switch key
(1).

kA hazard can result if an irrelevant person

touches switch key (1) casually.
2. You can prevent an abnormal end of the
operation due to cutoff of the battery power
supply circuit while the controllers are in
operation by checking the operating status of
each controller with system operating lamp (2).
1) Before cutting off the battery power supply
circuit, turn the starting switch to OFF
position, and check that the system
operating lamp goes out, then turn the
battery disconnect switch to OFF position.
2) If you turn the battery disconnect switch to
OFF position (battery power supply circuit is
cut off) while the system operating lamp is lit,
Controller Data Lost Error can occur. Do not
operate the battery disconnect switch as long
as the system operating lamp is lit.
3) The system operating lamp goes out in 2
minutes longest after the starting switch is
turned to OFF position.
4) The system operating lamp may sometimes
light up while the starting switch is turned to
OFF position because KOMTRAX terminal
may maintain its communication under this
condition.
5) The system operating lamp may look slightly
luminous in the dark after it is turned off. It is
due to the minute leakage of current and not
an abnormal phenomenon.
• After the starting switch is turned to OFF
position, KOMTRAX terminal repeats the
start and stop to maintain the periodic
communication.
• The start and stop cycle (sleep cycle) of
KOMTRAX terminal varies depending on
the factors including the communication
status and machine stop time. So the
lamp can be lit as long as approximately
an hour.
6) When you want to cut off the battery circuit
for maintenance but the operating lamp
keeps on lighting up, turn the starting switch
to ON position once, then turn it to OFF
position. The lamp will go out in 2 minutes
maximum.
After the system operating lamp goes out,
turn the battery disconnect switch
immediately to OFF position.

30-174 HM400-3M0
 30 Testing and adjusting
Pm clinic

Pm clinic (ALL-2160-001-A-00-A)

Pm Clinic service (HM400-2160-209-A-00-A)

Pm clinic check sheet (HM400_3M0-2160-033-A-00-A)

Machine identification symbol

HM400-3M0
Engine serial No.

Work order No. Date of inspection Service meter reading Serviceman

Year Month Day Hours
Interview with operator and walk-around check
Is an abnormality detected before start of inspection? Ambient temperature
Max. °C
Min. °C
Altitude m
Is the maximum coolant Is the maximum torque converter Is the maximum retarder oil
temperature normal? (During oil temperature normal? (During temperature normal? (During
operation) operation) operation)

HM400-3M0 30-175
30 Testing and adjusting
Pm clinic

a After starting the engine

Unaccept-
Standard

Accept-
value for Repair Test

able

able
Measuring items Measurement condition Unit
new limit results
machine
Economy mode
700 to 750 700 to 750
At low idle
Power mode
700 to 750 700 to 750
At low idle
Power mode 2,200 to 2,200 to
At high idle 2,250 2,250
Economy mode 2,000 to 2,000 to
At high idle 2,050 2,050
Power mode 1,758 to
—
With torque converter stalled 1,958
• Coolant Economy mode 1,642 to
temperature: —
With torque converter stalled 1,842
60 to 100°C Torque converter lockup
• Transmission 1,150 to 1,150 to
actuated
oil 1,250 1,250
Engine speed

F1, F2, R1 or R2
temperature: Torque converter lockup
Engine

70 to 90°C 1,000 to 1,000 to

actuated rpm 1,100 1,100
• Hydraulic oil F3 to F6
temperature: Torque converter lockup
45 to 55°C released (Service brake 950 to 950 to
• Torque applied) 1,050 1,050
converter oil F1, F2, R1 or R2
temperature: Torque converter lockup
60 to 80°C released (Service brake 900 to 900 to
applied) 1,000 1,000
F3 to F6
Torque converter lockup
released (Service brake not 1,150 to 1,150 to
applied) 1,250 1,250
F1, F2, R1 or R2
Torque converter lockup
released (Service brake not
800 to 900 800 to 900
applied)
F3 to F6

30-176 HM400-3M0
 30 Testing and adjusting
Pm clinic

Unaccept-
Standard

Accept-
value for Repair Test

able

able
Measuring items Measurement condition Unit
new limit results
machine
• Coolant temperature: 60
to 100°C
• Hydraulic oil temperature: kPa Max. 2.94 Max. 3.92
Blowby pressure
45 to 55°C {mmH2O} {300} {400}
• With torque converter
stalled
• Engine oil With
temperature: torque Min. 0.34 Min. 0.21
Min. 80°C converter {3.5} {2.1}
• SAE0W30OS stalled MPa
Oil pressure • SAE5W40
{kg/cm2}
LEOS Min. 0.10 Min. 0.08
At low
• SAE10W30DH {1.0} {0.8}
idle
• SAE15W40DH
• SAE30DH
• Coolant
Engine

temperature:
60 to 100°C
• Hydraulic oil kPa Min. 163 Min. 139
Boost pressure Power
temperature:
mode {mmHg} {1,220} {1,040}
45 to 55°C
• With torque
converter
stalled
• Coolant
temperature:
60 to 100°C
• Hydraulic oil
Exhaust temperature: Power
temperature 45 to 55°C °C Max. 650 Max. 700
mode
• Whole speed
range (ambient
temperature:
20°C)

HM400-3M0 30-177
30 Testing and adjusting
Pm clinic

Unaccept-
Standard

Accept-
value for Test

able

able
Measuring items Measurement condition Unit Repair limit
new results
machine
Engine 2.36 to 2.76 2.36 to 2.76
speed: {24.1 to {24.1 to
Main relief 2,000 rpm 28.1} 28.1}
• Torque
pressure converter oil 2.25 to 2.65 2.25 to 2.65
Engine: At
temperature: 60 low idle {23.0 to {23.0 to
to 80°C 27.0} 27.0}
• Transmission Engine 0.86 to 1.06 0.86 to 1.06
oil temperature: speed:
Main flow rate 70 to 90°C 2,000 rpm {8.8 to 10.8} {8.8 to 10.8}
selector valve • Shift lever: N 2.25 to 2.65 2.25 to 2.65
inlet pressure Engine: At
low idle {23.0 to {23.0 to
27.0} 27.0}
Power train

Torque • Torque Service MPa 0.76 to 0.96 0.76 to 0.96

converter inlet converter oil brake not {kg/cm2} {7.8 to 9.8} {7.8 to 9.8}
pressure temperature: 60 applied
to 80°C Service
• Transmission brake not 0.39 to 0.59 0.39 to 0.59
Torque oil temperature: applied {4.0 to 6.0} {4.0 to 6.0}
converter 70 to 90°C
outlet • Shift lever: N Service 0.52 to 0.72 0.52 to 0.72
pressure • Engine speed: brake
applied {5.3 to 7.3} {5.3 to 7.3}
2,000 rpm
Torque • Torque converter oil
converter temperature: 60 to 80°C 1.81 to 2.21 1.81 to 2.21
lockup clutch • Transmission oil
temperature: 70 to 90°C {18.5 to {18.5 to
operating 22.5} 22.5}
pressure • Engine speed: 2,000 rpm
• Shift Lever: 1

30-178 HM400-3M0
 30 Testing and adjusting
Pm clinic

a In the every 1000-hour maintenance, change the oil and clean inside of the transmission case and
strainer.

Unaccept-
Standard

Accept-
value for Test

able

able
Measuring items Measurement condition Unit Repair limit
new results
machine
There must not be
excessive metallic
T/M

Visual check of transmission strainer —

powders and wrayflex
(black powders).
• Engine: At low idle
• Dump body: Unloaded
Steering
• Gear shift lever: N (stopped) sec.
operating Max. 7 Max. 7
position
time:
Steering

• Operating speed: 10 rpm

• LOCK o LOCK
• Hydraulic oil temperature: 45
to 55°C 19.61 to 19.61 to
Relief MPa
• Engine: At high idle 21.57 21.57
pressure {kg/cm 2}
• At maximum swash plate {200 to 220} {200 to 220}
angle
• Actuating pressure in the
Wheel brake 4.41 to 5.39 4.41 to 5.39
first operation after charging
operating
the accumulator and {45 to 55} {45 to 55}
pressure
stopping the engine.
Charge valve MPa 11.77 to 11.77 to
cut-in {kg/cm2} 12.95 12.95
pressure • Engine: At high idle {120 to 132} {120 to 132}
• Hydraulic oil temperature: 45
Charge valve 20.6 to 20.6 to
to 55°C
cut-out 22.07 22.07
pressure {210 to 225} {210 to 225}
Braking
Brake

performance Must not move at 1,100

The machine must not move
of service
when the engine speed is
brake
gradually increased at gear shift
Braking rpm
lever D (indicated as "F2" in shift
performance Must not move at 1,090
indicator) until the torque
of retarder
converter stalls while the brake
brake
is applied.
Parking brake
Must not move at 1,100
performance
• 9 (+1/0)% downhill slope
Braking • Dump body loaded with 40.0
distance of m Max. 59.0 Max. 59.0
ton cargo
service brake • Travel speed: 25 ± 2 km/h

• Hydraulic oil temperature: 45 27.91 to 27.91 to

Body RAISE to 55°C MPa
Hydraulic system

28.89 28.89
relief pressure • At high idle (Engine speed: {kg/cm2}
1,800 rpm) {285 to 295} {285 to 295}
Dump body • Hydraulic oil temperature: 70
10.5 to 13.5 10.5 to 13.5
raise time to 90°C
• At high idle sec.
Dump body • Measure lower time with 7.5 to 10.5 7.5 to 10.5
lower time operating FLOAT

HM400-3M0 30-179
30 Testing and adjusting
Pm clinic

a Set the body and stop the engine.

Unaccept-
Standard

Accept-
value for Test

able

able
Measuring items Measurement condition Unit Repair limit
new results
machine
• Hydraulic oil temperature: 70
to 90°C
Hydraulic drift

• Retraction amount of hoist

Hydraulic drift cylinder 5 minutes after mm/
of dump body setting dump body angle 50 Max. 85 Max. 170
5 min.
deg. (hoist cylinder stroke:
1,750 mm) and stopping the
engine.
Fan mode: 1,180 to 1,180 to
Hydraulic fan

Fan speed for • Hydraulic oil MAX 1,330 1,330

radiator temperature: 45 Fan mode: 1,453 to 1,453 to
to 55°C Brake rpm 1,603 1,603
Fan speed for • Engine speed:
2,000 rpm Fan mode: 1,858 to 1,858 to
aftercooler
MAX 2,358 2,358
(CAC)

a Replace the drain plug with a spare plug.

Unaccept-
Standard

Accept-
value for Test

able

able
Measuring items Measurement condition Unit Repair limit
new results
machine
Visual
inspection of There must not be
differential Engine: Stopped — excessive metallic
case drain powders.
Axle

plug
Visual check Left side There must not be
of final drive
Engine: Stopped — excessive metallic
case drain Right side powders.
plug

30-180 HM400-3M0
 30 Testing and adjusting
Pm clinic

a At every 1,000 hour maintenance

Unaccept-
Standard

Accept-
value for Test

able

able
Measuring items Measurement condition Unit Repair limit
new results
machine
Must be within the range
Left side indicated on the disc wear
• Disc wear
Brake

gauge
Wheel brake measuring —
gauge Must be within the range
Right side indicated on the disc wear
gauge
Front left Suspension cylinder length mm 166 to 186 166 to 186
suspension There must be no
cylinder Presence of oil and gas leakage —
leakage.
Front right Suspension cylinder length mm 166 to 186 166 to 186
suspension There must be no
cylinder Presence of oil and gas leakage —
leakage.
Suspension

Rear left Suspension cylinder length mm 101 to 111 101 to 111

suspension There must be no
cylinder Presence of oil and gas leakage —
leakage.
Rear right Suspension cylinder length mm 101 to 111 101 to 111
suspension There must be no
cylinder Presence of oil and gas leakage —
leakage.
Contact with Left side — Contact not allowed
rear
suspension Right side — Contact not allowed
stopper
Failure code record
Failure code Record Frequency Failure code Record Frequency
o h times o h times
Details: Details:

Failure code Record Frequency Failure code Record Frequency

o h times o h times
Details: Details:

Failure code Record Frequency Failure code Record Frequency

o h times o h times
Details: Details:

Note: Write down the phenomena and information which draw your attention during today's checkup.

HM400-3M0 30-181
30 Testing and adjusting
Pm clinic

30-182 HM400-3M0
SHOP MANUAL

ARTICULATED DUMP TRUCK

HM400-3M0
Model Serial Number

HM400-3M0 5001 and up

40 Troubleshooting
6 40 Troubleshooting

HM400-3M0 40-1
40 Troubleshooting
Table of contents

Table of contents (ALL-0310-002-A-00-A)

40 Troubleshooting............................................................................................................................ 40-1
Table of contents ........................................................................................................................ 40-2
Related information on troubleshooting....................................................................................... 40-10
Troubleshooting points ....................................................................................................... 40-10
Sequence of events in troubleshooting................................................................................. 40-12
Check before troubleshooting.............................................................................................. 40-14
Inspection procedure before troubleshooting ........................................................................ 40-16
Preparation for troubleshooting of electrical system............................................................... 40-25
Classification and procedures for troubleshooting ................................................................. 40-31
Symptom and troubleshooting numbers ............................................................................... 40-34
Information in troubleshooting table ..................................................................................... 40-36
Procedure for troubleshooting wiring harness of pressure sensor system for open
circuit................................................................................................................... 40-38
Connector list and layout .................................................................................................... 40-40
Connector contact identification........................................................................................... 40-56
T-branch box and T-branch adapter table ............................................................................. 40-92
Fuse location table ............................................................................................................. 40-97
Precautions on troubleshooting of machine monitor ............................................................ 40-101
Processing procedure of harness checker for troubleshooting of machine monitor LCD
unit .................................................................................................................... 40-103
Failure codes table........................................................................................................... 40-108
Troubleshooting by failure code (Display of code) ...................................................................... 40-121
Failure code [1500L0] Double Engagement of T/M Clutches ................................................ 40-121
Failure code [15B0NX] Transmission Oil Filter Clogging ...................................................... 40-122
Failure code [15F0KM] Abuse 1 of Gear Shifting from R to F................................................ 40-123
Failure code [15F0MB] Abuse 2 of Gear Shifting from R to F................................................ 40-124
Failure code [15F7KM] Abuse of TM Forward Clutch Disk ................................................... 40-125
Failure code [15G0MW] Failure of Clutch (Reverse)............................................................ 40-126
Failure code [15G7KM] Abuse of TM Reverse Clutch Disk................................................... 40-129
Failure code [15H0MW] Failure of Clutch (High) ................................................................. 40-130
Failure code [15J0MW] Failure of Clutch (Low) ................................................................... 40-133
Failure code [15K0MW] Failure of Clutch (1st) .................................................................... 40-136
Failure code [15L0MW] Failure of Clutch (2nd) ................................................................... 40-139
Failure code [15M0MW] Failure of Clutch (3rd) ................................................................... 40-142
Failure code [15SBL1] Release Trouble of ECMV (Reverse)................................................ 40-145
Failure code [15SBMA] Malfunction of ECMV (Reverse)...................................................... 40-148
Failure code [15SCL1] Release Trouble of ECMV (High) ..................................................... 40-149
Failure code [15SCMA] Malfunction of ECMV (High) ........................................................... 40-152
Failure code [15SDL1] Release Trouble of ECMV (Low)...................................................... 40-153
Failure code [15SDMA] Malfunction of ECMV (Low)............................................................ 40-156
Failure code [15SEL1] Release Trouble of ECMV (1st)........................................................ 40-157
Failure code [15SEMA] Malfunction of ECMV (1st).............................................................. 40-160
Failure code [15SFL1] Release Trouble of ECMV (2nd)....................................................... 40-161
Failure code [15SFMA] Malfunction of ECMV (2nd)............................................................. 40-164
Failure code [15SGL1] Release Trouble of ECMV (3rd) ....................................................... 40-165
Failure code [15SGMA] Malfunction of ECMV (3rd) ............................................................. 40-168
Failure code [15SJMA] Malfunction of ECMV (Lockup) ........................................................ 40-169
Failure code [15SKMA] Malfunction of ECMV (Inter-Axle Diff.) ............................................. 40-171
Failure code [2F00KM] Dragging of Parking Brake .............................................................. 40-173
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ............................................. 40-175
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) .............................................. 40-176
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-177
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-178
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-179
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-180
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-181
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-182

40-2 HM400-3M0
 40 Troubleshooting
Table of contents

Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-183

Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-184
Failure code [879GKX] Refrigerant Abnormality .................................................................. 40-185
Failure code [989D00] Tilt Caution ..................................................................................... 40-186
Failure code [989L00] Engine Controller Lock Caution1....................................................... 40-187
Failure code [989M00] Engine Controller Lock Caution2...................................................... 40-188
Failure code [989N00] Engine Controller Lock Caution3 ...................................................... 40-189
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-190
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-192
Failure code [AB00KY] Hot Short of Alternator R Terminal ................................................... 40-193
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-194
Failure code [B@BAZK] Engine Oil Level Low.................................................................... 40-195
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-196
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-197
Failure code [B@C6NS] Retarder Oil Overheat (Front)........................................................ 40-199
Failure code [B@C8NS] Retarder Oil Overheat (Center) ..................................................... 40-200
Failure code [B@CENS] T/C Oil Temp. Overheat................................................................ 40-201
Failure code [B@JANS] Steering Oil Overheat ................................................................... 40-202
Failure code [CA111] ECM Critical Internal Failure .............................................................. 40-203
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-204
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-205
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-207
Failure code [CA131] Throttle Sensor High Error................................................................. 40-209
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-211
Failure code [CA135] Eng Oil Press Sensor High Error........................................................ 40-213
Failure code [CA141] Eng Oil Press Sensor Low Error ........................................................ 40-215
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-217
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-219
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-221
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-223
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-225
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-227
Failure code [CA222] Ambient Press Sens Low Error .......................................................... 40-229
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-231
Failure code [CA234] Eng Overspeed ................................................................................ 40-232
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-233
Failure code [CA263] Fuel Temp Sensor High Error ............................................................ 40-234
Failure code [CA265] Fuel Temp Sensor Low Error ............................................................. 40-236
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-238
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-239
Failure code [CA273] PCV2 Short Error ............................................................................. 40-240
Failure code [CA274] PCV2 Open Error ............................................................................. 40-241
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-242
Failure code [CA323] Inj #5(L#5) Open/Short Error ............................................................. 40-244
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................. 40-246
Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................. 40-248
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................. 40-250
Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................. 40-252
Failure code [CA342] Calibration Code Incompatibility......................................................... 40-254
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-255
Failure code [CA352] Sensor 1 Supply Volt Low Error ......................................................... 40-256
Failure code [CA386] Sensor 1 Supply Volt High Error......................................................... 40-258
Failure code [CA431] Idle Validation Sw Error..................................................................... 40-259
Failure code [CA432] Idle Validation Process Error ............................................................. 40-262
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-265
Failure code [CA442] Battery Voltage High Error................................................................. 40-267
Failure code [CA449] Rail Press Very High Error................................................................. 40-268
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-269
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-271

HM400-3M0 40-3
40 Troubleshooting
Table of contents

Failure code [CA553] Rail Press High Error ........................................................................ 40-273

Failure code [CA554] Rail Press Sensor In Range Error ...................................................... 40-274
Failure code [CA559] Rail Press Low Error......................................................................... 40-275
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-279
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-281
Failure code [CA757] All Continuous Data Lost Error .......................................................... 40-282
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-283
Failure code [CA1228] EGR valve servo error 1 .................................................................. 40-285
Failure code [CA1625] EGR Valve Servo Error 2................................................................. 40-286
Failure code [CA1626] Bypass Valve Solenoid Current High Error........................................ 40-287
Failure code [CA1627] Bypass Valve Solenoid Current Low Error......................................... 40-289
Failure code [CA1628] Bypass Valve Servo Error 1 ............................................................. 40-291
Failure code [CA1629] Bypass Valve Servo Error 2 ............................................................. 40-292
Failure code [CA1631] BP valve Lift Position Sensor High Error ........................................... 40-293
Failure code [CA1632] BP valve Lift Position Sensor Low Error............................................ 40-295
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-297
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-299
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-301
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-302
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-304
Failure code [CA2351] EGR Valve Solenoid Short Error ...................................................... 40-306
Failure code [CA2352] EGR Valve Solenoid Open Error ...................................................... 40-308
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-310
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-312
Failure code [D150KB] Ground Fault of Emerg. Steering Relay ............................................ 40-314
Failure code [D150KZ] Failure of Emerg. Steering Relay ..................................................... 40-315
Failure code [D151KB] Ground Fault of Emerg. Steering Relay 2 ......................................... 40-316
Failure code [D151KZ] Failure of Emerg. Steering Relay 2................................................... 40-317
Failure code [D164KY] Hot Short of Head Light High Selector.............................................. 40-318
Failure code [D19HKZ] Failure of Stop Lamp (R&L) ............................................................ 40-319
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-321
Failure code [D1EHKA] Disconnection of Engine Start Relay ............................................... 40-322
Failure code [D1EHKB] Ground Fault of Engine Start Relay................................................. 40-323
Failure code [D1EHKY] Hot Short of Engine Start Relay ...................................................... 40-324
Failure code [D1EMKA] Disconnection of Parking Interlock Relay ........................................ 40-325
Failure code [D1EMKB] Ground Fault of Parking Interlock Relay .......................................... 40-326
Failure code [D1EMKY] Hot Short of Parking Interlock Relay ............................................... 40-327
Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay........................................... 40-328
Failure code [D5ZHL6] Disconnection of Key SW C ............................................................ 40-329
Failure code [D811MC] KOMTRAX Error............................................................................ 40-331
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-332
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...................................... 40-333
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-335
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 .......................................................... 40-337
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-338
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ..................................... 40-339
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-340
Failure code [DAF0MC] Monitor Error ................................................................................ 40-341
Failure code [DAF3KK] Controller Power Source Low (MON)............................................... 40-342
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-344
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit .......................................... 40-345
Failure code [DAFGMC] GPS Module Error........................................................................ 40-347
Failure code [DAFLKA] Operating Lamp Open Circuit (MON)............................................... 40-348
Failure code [DAFLKB] Operating Lamp Short Circuit (MON)............................................... 40-350
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-352
Failure code [DAQ0KK] Controller Power Source Low (T/M) ................................................ 40-353
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ....................................... 40-355
Failure code [DAQ0MC] T/M Con Error .............................................................................. 40-356
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) .............................................. 40-357

40-4 HM400-3M0
 40 Troubleshooting
Table of contents

Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ................................................. 40-359
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) .......................................... 40-361
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) ................................................ 40-362
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) ................................................ 40-364
Failure code [DAQQKR] CAN2 Discon (Transmission Con) ................................................. 40-366
Failure code [DAQRKR] CAN1 Discon (Transmission Con) ................................................. 40-367
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ......................................... 40-371
Failure code [DAQV00] Neutral Coast Caution ................................................................... 40-372
Failure code [DAQW00] Neutral Over Speed Caution.......................................................... 40-373
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-374
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-375
Failure code [DB10KT] Abnormality of Non-volatile Memory (RHC) ...................................... 40-376
Failure code [DB10MC] RHC Error .................................................................................... 40-377
Failure code [DB11KA] Disconnection of Key SW ACC (RHC) ............................................. 40-378
Failure code [DB12KK] Solenoid Power Source Low (RHC)................................................. 40-380
Failure code [DB13KK] Controller Power Source Low (RHC) ............................................... 40-382
Failure code [DB19KQ] Inconsistency of Model Selection (RHC).......................................... 40-384
Failure code [DB1LKA] Disconnection of System Ope. Lamp (RHC)..................................... 40-385
Failure code [DB1LKB] Short Circuit of System Ope. Lamp (RHC) ....................................... 40-387
Failure code [DB1QKR] CAN2 Discon (Retarder Hoist Con) ................................................ 40-389
Failure code [DB1QMA] Inconsistency of Option Selection (RHC) ........................................ 40-390
Failure code [DB1RKR] CAN1 Discon (Retarder Hoist Con)................................................. 40-391
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-392
Failure code [DBSQKR] CAN2 Discon (PLM) ..................................................................... 40-397
Failure code [DBSQKQ] Inconsistency of Model Selection (PLM) ......................................... 40-401
Failure code [DD1ML4] Failure of ARAC SW ...................................................................... 40-402
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ................................ 40-404
Failure code [DDTHKA] Disconnection of Fill Switch (High) ................................................. 40-406
Failure code [DDTJKA] Disconnection of Fill Switch (Low) ................................................... 40-408
Failure code [DDTKKA] Disconnection of Fill Switch (1st) .................................................... 40-410
Failure code [DDTLKA] Disconnection of Fill Switch (2nd) ................................................... 40-412
Failure code [DDTMKA] Disconnection of Fill Switch (3rd) ................................................... 40-414
Failure code [DDTNKA] Disconnection of Fill Switch (Reverse) ............................................ 40-416
Failure code [DF10KA] Disconnection of Shift Lever Input ................................................... 40-418
Failure code [DF10KB] Ground Fault of Shift Lever Input ..................................................... 40-421
Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor ............................................ 40-425
Failure code [DGR3KB] Ground Fault of Retarder Oil Temp. S.(C)........................................ 40-427
Failure code [DGR3L8] Failure of Retarder Oil Temp. Sensor (C) ......................................... 40-428
Failure code [DGR4KB] Ground Fault of Retarder Oil Temp. S.(F) ........................................ 40-429
Failure code [DGR4L8] Failure of Retarder Oil Temp. Sensor (F).......................................... 40-430
Failure code [DGR6KB] Ground Fault of Steering Oil Temp. S.............................................. 40-432
Failure code [DGR6L8] Failure of Steering Oil Temp. Sensor ............................................... 40-433
Failure code [DGR7KX] Out of Range of Piston Pump Oil Temp. S. ...................................... 40-435
Failure code [DGR8KX] Out of Range of CAC Output Temp. S............................................. 40-437
Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor ............................................ 40-439
Failure code [DHP4KY] Hot Short of Suspension Press. S. (FR) .......................................... 40-441
Failure code [DHP4KZ] Failure of Suspension Press. S. (FR) .............................................. 40-443
Failure code [DHP5KY] Hot Short of Suspension Press. S. (FL) ........................................... 40-445
Failure code [DHP5KZ] Failure of Suspension Press. S. (FL) ............................................... 40-447
Failure code [DHP6KY] Hot Short of Suspension Press. S. (RR) .......................................... 40-449
Failure code [DHP6KZ] Failure of Suspension Press. S. (RR) .............................................. 40-451
Failure code [DHP7KY] Hot Short of Suspension Press. S. (RL)........................................... 40-453
Failure code [DHP7KZ] Failure of Suspension Press. S. (RL)............................................... 40-455
Failure code [DHQ2KX] Out of Range of Main Flow Sel. Valve S. ......................................... 40-457
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor ..................................... 40-459
Failure code [DHT5L6] Failure of T/C Oil Press Sensor ....................................................... 40-461
Failure code [DHT8KX] Out of Range of Steering Oil Press. S.............................................. 40-463
Failure code [DHT8ZG] Steering Oil Pressure Low.............................................................. 40-465
Failure code [DHU2KX] Out of Range of Acc. Oil Press. S. (F) ............................................. 40-466

HM400-3M0 40-5
40 Troubleshooting
Table of contents

Failure code [DHU3KX] Out of Range of Acc. Oil Press. S. (R)............................................. 40-468
Failure code [DHUAKX] Out of Range of Retarder Press. S. (CR) ........................................ 40-470
Failure code [DHUBKX] Out of Range of Retarder Press. S. (FR)......................................... 40-472
Failure code [DHUCKX] Out of Range of Parking Brake Press. S. ........................................ 40-474
Failure code [DHUDKX] Out of Range of Emerg. Steering Press. S.1 ................................... 40-476
Failure code [DHUEKX] Out of Range of Emerg. Steering Press. S.2 ................................... 40-478
Failure code [DHUQKX] Out of Range of Retarder Press. S. (FL) ......................................... 40-480
Failure code [DHURKX] Out of Range of Retarder Press. S. (CL)......................................... 40-482
Failure code [DJF1KA] Disconnection of Fuel Level Sensor ................................................. 40-484
Failure code [DK30KX] Out of Range of Steering Angle Pot. ................................................ 40-486
Failure code [DK51L5] Failure of Retarder Lever Pot. and RVS............................................ 40-488
Failure code [DK52KX] Out of Range of Hoist Lever Potentio............................................... 40-491
Failure code [DK53L8] Failure of Hoist Lever Potentio. ........................................................ 40-493
Failure code [DK54KX] Out of Range of Body Potentio. ....................................................... 40-494
Failure code [DK60KX] Out of Range of Acceleration Sensor............................................... 40-496
Failure code [DKH0KX] Out of Range of Inclination Angle Sensor ........................................ 40-498
Failure code [DKH1KX] Out of Range of Long. Inclination Angle S. ...................................... 40-500
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor........................................ 40-502
Failure code [DLF1LC] Failure of T/M Input Speed Sensor................................................... 40-504
Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor........................................ 40-506
Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor........................................ 40-508
Failure code [DLF400] T/M Diff. Overrun Prevention Activated ............................................. 40-510
Failure code [DLF4KA] Disconnection of T/M Diff. Speed Sensor ......................................... 40-511
Failure code [DLF4LC] Failure of T/M Diff. Speed Sensor .................................................... 40-513
Failure code [DLF6LC] Failure of Wheel Speed Sensor (FR)................................................ 40-515
Failure code [DLF7LC] Failure of Wheel Speed Sensor (FL) ................................................ 40-517
Failure code [DLFDLC] Failure of Wheel Speed Sensor (CR)............................................... 40-519
Failure code [DLFELC] Failure of Wheel Speed Sensor (CL) ............................................... 40-521
Failure code [DLFFLC] Failure of Wheel Speed Sensor (Front) ............................................ 40-523
Failure code [DLFGLC] Failure of Wheel Speed Sensor (Center) ......................................... 40-524
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor.................................. 40-525
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor............................................. 40-527
Failure code [DLM3MB] Radiator Fan Control Mismatch...................................................... 40-529
Failure code [DLM4KA] Disconnection of CAC Fan Speed Sensor ....................................... 40-530
Failure code [DLM4LC] Failure of CAC Fan Speed Sensor .................................................. 40-532
Failure code [DLM4MB] CAC Fan Control Mismatch ........................................................... 40-534
Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main).................................... 40-535
Failure code [DLT3LC] Failure of Output Speed Sensor (Main)............................................. 40-537
Failure code [DPQ1KR] LIN Discon (Switch Panel) ............................................................. 40-539
Failure code [DPQ2KR] LIN Discon (LED Unit) ................................................................... 40-542
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ..................................................... 40-545
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) .............................................................. 40-548
Failure code [DV00KB] Ground Fault of Buzzer Output........................................................ 40-549
Failure code [DW2BKA] Disconnection of Main Flow Selector Sol. ....................................... 40-551
Failure code [DW2BKB] Ground Fault of Main Flow Selector Sol. ......................................... 40-552
Failure code [DW2BKY] Hot Short of Main Flow Selector Sol. .............................................. 40-553
Failure code [DW2BL1] Release Trouble of Main Flow Sel. Valve......................................... 40-554
Failure code [DW2BLH] Malfunction of Main Flow Selector Valve ......................................... 40-555
Failure code [DW4BK4] Release Trouble of Parking Brake Valve ......................................... 40-556
Failure code [DW4BMA] Malfunction of Parking Brake Valve ............................................... 40-558
Failure code [DW72KZ] Failure of Kick out Solenoid............................................................ 40-559
Failure code [DW73KA] Disconnection of Hoist Selector Sol. ............................................... 40-561
Failure code [DW73KB] Ground Fault of Hoist Selector Sol.................................................. 40-563
Failure code [DW73KY] Hot Short of Hoist Selector Sol. ...................................................... 40-565
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. .......................................... 40-567
Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol................................................. 40-569
Failure code [DW7BKZ] Failure of Radiator Fan Rev. Sol..................................................... 40-570
Failure code [DW7LKB] Ground Fault of CAC Fan Rev. Sol. ................................................ 40-572
Failure code [DW7LKY] Hot Short of CAC Fan Rev. Sol....................................................... 40-573

40-6 HM400-3M0
 40 Troubleshooting
Table of contents

Failure code [DW7LKZ] Failure of CAC Fan Rev. Sol........................................................... 40-574

Failure code [DW7NKZ] Failure of Steering Pump Selector Sol. ........................................... 40-575
Failure code [DWNJKZ] Failure of TCS Shut off Sol. (Front)................................................. 40-577
Failure code [DWNKKZ] Failure of TCS Shut off Sol. (Center) .............................................. 40-579
Failure code [DX13KA] Disconnection of Hoist EPC Solenoid .............................................. 40-581
Failure code [DX13KB] Ground Fault of Hoist EPC Solenoid................................................ 40-583
Failure code [DX13KY] Hot Short of Hoist EPC Solenoid ..................................................... 40-585
Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol....................................... 40-587
Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. ....................................... 40-588
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ....................................... 40-590
Failure code [DX29KA] Disconnection of CAC Fan Pump EPC Sol....................................... 40-591
Failure code [DX29KB] Ground Fault of CAC Fan Pump EPC Sol. ....................................... 40-592
Failure code [DX29KY] Hot Short of CAC Fan Pump EPC Sol.............................................. 40-593
Failure code [DX30K4] Release Trouble of Retarder EPC Valve(FL)..................................... 40-594
Failure code [DX30KA] Disconnection of Retarder EPC Sol. (FL) ......................................... 40-596
Failure code [DX30KB] Ground Fault of Retarder EPC Sol. (FL)........................................... 40-598
Failure code [DX30KY] Hot Short of Retarder EPC Sol. (FL) ................................................ 40-600
Failure code [DX30MA] Malfunction of Retarder EPC Valve (FL) .......................................... 40-602
Failure code [DX31K4] Release Trouble of Retarder EPC Valve(CR).................................... 40-604
Failure code [DX31KA] Disconnection of Retarder EPC Sol. (CR) ........................................ 40-606
Failure code [DX31KB] Ground Fault of Retarder EPC Sol. (CR).......................................... 40-608
Failure code [DX31KY] Hot Short of Retarder EPC Sol. (CR) ............................................... 40-610
Failure code [DX31MA] Malfunction of Retarder Valve (CR) ................................................. 40-612
Failure code [DX32K4] Release Trouble of Retarder EPC Valve(CL) .................................... 40-614
Failure code [DX32KA] Disconnection of Retarder EPC Sol. (CL)......................................... 40-616
Failure code [DX32KB] Ground Fault of Retarder EPC Sol. (CL) .......................................... 40-618
Failure code [DX32KY] Hot Short of Retarder EPC Sol. (CL)................................................ 40-620
Failure code [DX32MA] Malfunction of Retarder EPC Valve (CL).......................................... 40-622
Failure code [DX33K4] Release Trouble of Retarder EPC Valve (FR) ................................... 40-624
Failure code [DX33KA] Disconnection of Retarder EPC Sol. (FR)......................................... 40-626
Failure code [DX33KB] Ground Fault of Retarder EPC Sol. (FR) .......................................... 40-628
Failure code [DX33KY] Hot Short of Retarder EPC Sol. (FR) ............................................... 40-630
Failure code [DX33MA] Malfunction of Retarder EPC Valve (FR).......................................... 40-632
Failure code [DX34KA] Disconnection of Remote Cooling EPC Sol. ..................................... 40-634
Failure code [DX34KB] Ground Fault of Remote Cooling EPC Sol........................................ 40-635
Failure code [DX34KY] Hot Short of Remote Cooling EPC Sol. ............................................ 40-637
Failure code [DXH0KA] Disconnection of ECMV (Inter-Axle Diff.) ......................................... 40-638
Failure code [DXH0KB] Ground Fault of ECMV (Inter-Axle Diff.)........................................... 40-640
Failure code [DXH0KY] Hot Short of ECMV (Inter-Axle Diff.) ................................................ 40-642
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ..................................... 40-644
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) ....................................... 40-646
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) ............................................ 40-648
Failure code [DXH2KA] Disconnection of ECMV Solenoid (High) ......................................... 40-650
Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High) ........................................... 40-652
Failure code [DXH2KY] Hot Short of ECMV Solenoid (High) ................................................ 40-654
Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low) .......................................... 40-655
Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low)............................................ 40-657
Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low) ................................................. 40-659
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)............................................ 40-662
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) ............................................. 40-664
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st)................................................... 40-666
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)........................................... 40-669
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) ............................................ 40-671
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd).................................................. 40-673
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ........................................... 40-676
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) ............................................. 40-678
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) .................................................. 40-680
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse).................................... 40-683
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ..................................... 40-685

HM400-3M0 40-7
40 Troubleshooting
Table of contents

Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)........................................... 40-687

Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor........................................... 40-690
Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor .......................................... 40-693
Failure code [DY30ME] Emerg. Steering Long-Time Activated ............................................. 40-696
Failure code [DY32MC] Malfunction 2 of Emerg. Steering Motor 2........................................ 40-698
Troubleshooting of electrical system (E-mode) .......................................................................... 40-701
E-1 Engine does not start (Engine does not crank) .............................................................. 40-701
E-2 Manual preheating system does not work..................................................................... 40-706
E-3 Automatic preheating system does not work................................................................. 40-709
E-4 While preheating is working, preheating monitor does not light up .................................. 40-711
E-5 All of LCD unit, LED unit and meter unit on machine monitor display nothing ................... 40-713
E-6 LCD unit on machine monitor displays nothing.............................................................. 40-716
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or
flickers) .............................................................................................................. 40-718
E-8 LCD on machine monitor does not display properly ....................................................... 40-720
E-9 Meter unit display on machine monitor is abnormal ....................................................... 40-722
E-10 Night lighting lamp of meter unit on machine monitor is abnormal ................................. 40-725
E-11 LED unit lamp on machine monitor is abnormal ........................................................... 40-728
E-12 Night lighting lamp of switch panel on machine monitor is abnormal or switches does not
operate properly ................................................................................................. 40-730
E-13 2 switches operation of switch panel on machine monitor does not function................... 40-732
E-14 Switch panel buzzer of machine monitor is abnormal................................................... 40-734
E-15 Rear view monitor does not light up or backlight flickers............................................... 40-736
E-16 Rear view monitor images are not displayed clearly..................................................... 40-738
E-17 Rear view monitor brightness cannot be adjusted........................................................ 40-741
E-18 Night lighting lamp of rear view monitor is abnormal .................................................... 40-744
E-19 Rearview monitor does not display images while reverse linked display function is
enabled ............................................................................................................. 40-746
E-20 Guide line on rear view monitor is not displayed while guide line is set .......................... 40-749
E-21 Some items of gauges and caution lamps on machine monitor are not displayed
properly ............................................................................................................. 40-751
E-22 Fuel level gauge does not indicate correct level .......................................................... 40-752
E-23 Seat belt caution lamp indication is abnormal.............................................................. 40-754
E-24 Machine monitor cannot be operated when starting switch is in OFF position ................ 40-755
E-25 Alarm buzzer does not sound .................................................................................... 40-756
E-26 Alarm buzzer does not stop sounding......................................................................... 40-758
E-27 Engine mode selector function does not operate properly ............................................ 40-760
E-28 AISS function does not operate properly..................................................................... 40-761
E-29 Hoist lever does not operate properly ......................................................................... 40-762
E-30 Turn signal lamp and winker lamp (hazard lamp) do not operate properly ...................... 40-764
E-31 None of headlamp, clearance lamp, and tail lamp lights ............................................... 40-768
E-32 Clearance lamp does not light up............................................................................... 40-770
E-33 Tail lamp does not light up ......................................................................................... 40-772
E-34 Low beam of headlamp does not light up.................................................................... 40-774
E-35 High beam of headlamp does not light up ................................................................... 40-776
E-36 Neither Low beam nor High beam of headlamp lights up.............................................. 40-778
E-37 High beams do not light up while passing switch is operated ........................................ 40-780
E-38 KOMTRAX does not operate properly ........................................................................ 40-782
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-783
Information described in troubleshooting table (H-mode) ..................................................... 40-783
System chart of hydraulic and mechanical systems............................................................. 40-784
Failure mode and cause table ........................................................................................... 40-786
H-1 Machine does not start ............................................................................................... 40-790
H-2 Machine does not travel smoothly (engine hunts).......................................................... 40-792
H-3 Lockup clutch is not disengaged.................................................................................. 40-793
H-4 Abnormally large shocks result from starting of machine and gear shifting ...................... 40-794
H-5 Machine does not upshift ............................................................................................ 40-795
H-6 Machine lacks travel speed or power during travel in lockup drive mode through all gear
speeds............................................................................................................... 40-797

40-8 HM400-3M0
 40 Troubleshooting
Table of contents

H-7 Machine lacks travel speed or power during travel in torque converter drive
mode ................................................................................................................. 40-798
H-8 Machine lacks travel speed or power during travel in specific gear speed........................ 40-799
H-9 Machine starts or gear speed shifts with long time lag ................................................... 40-800
H-10 Torque converter oil temperature is high..................................................................... 40-802
H-11 Torque converter oil pressure is low ........................................................................... 40-803
H-12 Front brake does not work sufficiently ........................................................................ 40-804
H-13 Center brake does not work sufficiently ...................................................................... 40-805
H-14 Steering wheel is heavy to turn.................................................................................. 40-806
H-15 Steering wheel does not move .................................................................................. 40-807
H-16 Steering wheel swings.............................................................................................. 40-808
H-17 Dump body raise speed or power is slow.................................................................... 40-809
H-18 Dump body does not move ....................................................................................... 40-811
H-19 Hydraulic drift of dump body is large .......................................................................... 40-812
H-20 Radiator fan speed is abnormal (high, low, or stationary) ............................................. 40-813
H-21 Aftercooler fan speed is abnormal (high, low, or stationary) .......................................... 40-814
H-22 Unusual noise is heard from around radiator fan ......................................................... 40-815
H-23 Unusual noise is heard from around aftercooler fan..................................................... 40-816
Troubleshooting of engine (S-mode)......................................................................................... 40-817
Information mentioned in troubleshooting table (S mode)..................................................... 40-817
S-1 When starting switch is turned to START position, engine is not cranked......................... 40-818
S-2 The engine cranks but exhaust smoke does not come out ............................................. 40-819
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start
but does not) ...................................................................................................... 40-820
S-4 Engine startability is poor ............................................................................................ 40-821
S-5 Engine does not pick up smoothly ............................................................................... 40-823
S-6 Engine stops during operation ..................................................................................... 40-825
S-7 Engine runs rough or is unstable ................................................................................. 40-827
S-8 Engine lacks power .................................................................................................... 40-828
S-9 Exhaust smoke is black .............................................................................................. 40-830
S-10 Engine oil consumption is excessive .......................................................................... 40-832
S-11 Oil becomes contaminated quickly ............................................................................. 40-833
S-12 Fuel consumption is excessive .................................................................................. 40-834
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-835
S-14 Oil pressure drops .................................................................................................... 40-836
S-15 Fuel mixes into engine oil.......................................................................................... 40-837
S-16 Water mixes into engine oil (milky) ............................................................................. 40-838
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-839
S-18 Unusual noise is heard ............................................................................................. 40-840
S-19 Vibration is excessive ............................................................................................... 40-841
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-842

HM400-3M0 40-9
40 Troubleshooting
Related information on troubleshooting

Related information on troubleshooting (ALL-5100-001-A-00-A)

Troubleshooting points (ALL-5130-42A-A-00-A)

(Rev. 2012/11)

k Place the machine on a level ground, and make sure that the frame lock bar, chocks, and parking
brake are applied.

k When performing the operation with two or more service technicians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.

k Ifthe radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.

k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

k Before disconnecting wiring, remove the key and turn the battery disconnect switch to OFF
position.

k When removing the plug or cap from a component which is under pressure of oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to
connect it properly.

k Drain approximately 10l

l of coolant beforehand, because you may get scalded by hot water
spurting out from mounting location of coolant temperature sensor when removing radiator cap
during checking and replacing coolant temperature sensor.

k When performing checking and replacement of engine oil pressure sensor (switch), open oil filler
port, and check that engine oil temperature cools down enough not to get scalded.

k Loosen the oil filler cap of the hydraulic tank to release the pressure in the hydraulic tank. For
details, see Testing and adjusting "Releasing remaining pressure in hydraulic circuit" when
checking and replacing oil temperature sensor and oil pressure sensor. Check the code with
monitoring function and display the hydraulic oil temperature, then check that the temperature is
40°C or lower and cool enough not to burn.

Troubleshooting denotes to locate the primary cause, fix the trouble without delay and prevent its recurrence.
Despite the importance of understanding the structure and operation of the target system in troubleshooting,
you should be aware how interviewing with the operator concerned can facilitate in roughly identifying the
cause of the given undesirable symptom.
1. When performing troubleshooting, do not hurry to disassemble the components.
If components are disassembled immediately after any failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator.
For this reason, when performing troubleshooting, it is necessary to perform thorough prior investigation
and to perform troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before the failure?
4) Under what conditions did the failure occur?
5) Had any repairs been performed before the failure? When were these repairs performed?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Is there any sign of irregularities of the machine?
2) Make checks before starting day's work.

40-10 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

3) Make checks of other items.

4) Check other maintenance matters which can be checked externally and are considered to be
necessary.
4. Checking failure
Check the extent of the failure by yourself, and judge whether it is a real failure or a problem with the
method of operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not perform any inspection
or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 to 4 to narrow down the probable causes of
the failure, then use the troubleshooting flowchart to locate the failure exactly.
a The basic procedure for troubleshooting is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
6. Measures to remove root cause of failure
Fixing a trouble in hand does not necessarily prevents its recurrence unless the primary cause is
eliminated. To that end, you must locate and eliminate the primary cause behind the given failure.

HM400-3M0 40-11
40 Troubleshooting
Related information on troubleshooting

Sequence of events in troubleshooting (ALL-5140-42A-A-00-A)

(Rev. 2011. 7)

40-12 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

HM400-3M0 40-13
40 Troubleshooting
Related information on troubleshooting

Check before troubleshooting (HM400-5150-208-A-00-A)

No. Item Criteria Remedy

1 Check of unusual noise and smell ― Repair
2 Check of engine for dirt ― Remove
3 Check of engine for water leakage ― Repair
4 Check of engine for oil leakage ― Repair
5 Check of fuel line for leakage ― Repair
a Engine, lubricating oil and coolant

6 Check of radiator for clogging ― Remove

7 Check of fuel level and type ― Refilling with fuel
8 Check of foreign material in fuel ― Clean and drain
9 Check of fuel pre-filter ― Replace
10 Check of main fuel filter ― Replace
Check of engine oil level (in oil pan) and type Between Refilling with oil
11
H and L
Between Refilling with
12 Check of coolant level (in sub tank)
H and L coolant
Air
cleaner
clogging
monitor is
13 Check of air cleaner (dust indicator) for clogging not Clean or replace
shown in
the
machine
monitor.
1 Check of unusual noise and smell ― Repair
b Hydraulic and mechanical equipment

2 Check for oil leakage ― Repair

Check of hydraulic oil level Between Refilling with oil
3
H and L
4 Check of hydraulic oil strainer ― Clean or replace
5 Check of hydraulic oil filter ― Replace
Between Refilling with oil
6 Check of transmission case oil level
H and L
7 Check of transmission oil filter ― Clean or replace
8 Check of final drive case oil level ― Refilling with oil

9 Perform air bleeding. ― Air bleeding

40-14 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

No. Item Criteria Remedy

Retighten or
1 Check of battery terminal for looseness and corrosion ―
replace
Retighten or
2 Check of alternator terminal for looseness and corrosion ―
replace
Retighten or
3 Check of starting motor terminal for looseness and corrosion ―
replace
Check of battery voltage (with engine stopped) 20 to 30 Charge or replace
4
V
Check of battery electrolyte level Between Add or replace
5
H and L
Check of wiring harness for discoloration, burnt areas and cover
6 ― Repair or replace
peeling
c Electrical equipment

Check for coming off of wiring harness clamp and sagging of

7 ― Repair
wiring harness
8 Check of grounding ― Repair
9 Check for loose connector and damaged lock ― Repair or replace
10 Check of connector pin for corrosion, bends and deformation ― Repair or replace
Dry, clean or
11 Check of connector for water and foreign material ―
replace
12 Check of wiring harness for open or short circuit ― Repair or replace
13 Check of fuse for blowing out and corrosion ― Replace
14 Check of circuit breaker ― Reset
27.5 to
29.5 V
Check of alternator voltage (when engine speed is medium or
15 after few Replace
higher)
minutes
operation
Check of battery relay operation sound (when starting switch is
16 ― Replace
turned to ON or OFF position)
17 Check and cleaning of rear view camera ― Clean or repair
1 Check of undercarriage ― Repair
d Exterior parts

2 Check of handrails and steps ― Repair

3 Check of mirrors ― Clean or repair

1 Check of gauges and monitors ― Clean or replace

e Interior parts

2 Check of seat belt ― Repair

HM400-3M0 40-15
40 Troubleshooting
Related information on troubleshooting

Inspection procedure before troubleshooting (ALL-5150-001-A-00-A)

Walk-around check (HM400_3M0-5150-289-A-00-A)

Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages
of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, wiring harnesses for play, and accumulation of dust in places that reach
high temperatures.
k Any accumulation of flammable materials, or leakage of fuel or oil, around the battery, engine itself,
muffler, turbocharger, or other high temperature engine parts can cause the machine to catch fire.
Check carefully, and if any problem is found, repair it.

a a1, a2, ... b1, b2, ... , etc. correspond to the symbol in the table of the previous page.
a1. Check for unusual sounds and smells c17. Check, clean rear view camera
Check for unusual sounds or smells. Check the rearview camera for abnormality. If any,
If the machine is operated under the unusual repair it.
sounds or smells, the cause of it may damage the d1. Check of wheels (tires, rims) for abnormality,
machine, so stop the operation immediately once wear, loose bolts, and oil leakage
you recognize it. If any abnormality is found, repair it.
a2. Check around engine and dirt removal d2. Check of handrails and steps for
Check and remove any accumulated dirt around the abnormality and looseness of bolts
engine and any combustibles (dead leaves, twigs, If any abnormality is found, repair it and tighten any
etc.) on hot engine parts such as muffler, loose bolts.
turbocharger, etc.
d3. Check and clean rearview mirrors
a3. Check for water leakage around engine
Check rearview mirror for abnormality. If any, repair
a4. Check for oil leakage around engine it.
Check for oil leakage from engine and coolant Clean the mirror surface and adjust the mirror angle
leakage from cooling system. If any, repair it. so that the rear of the machine can be seen from
a5. Check for leakage from fuel line the operator's seat.
Check for fuel leakage, check hoses and pipes for e1. Check of gauges and monitors for abnormality
damage. If any, repair it. Check gauges and monitors in the operator's cab
a6. Check for radiator and dirt removal for abnormality. If any, replace it with new one.
Check and remove any accumulated dirt and any Clean up the surfaces.
combustibles (dead leaves, twigs, etc.) around the e2. Check of seat belt and mounting hardware
radiator.
Check hook, lock and hook mounting part for
For removal of dirt from the radiator, see the damage. If any, repair it.
Operation and Maintenance Manual, "Testing and
cleaning of radiator fins, oil cooler fins, aftercooler
fins, fuel cooler fins and air conditioner condenser
fins".
b1. Check for unusual sounds and smells
Check the work equipment, cylinders, linkage, and
hoses for breakage, wear, and clearance. If any,
repair it.
b2. Check of hydraulic equipment, hydraulic
tank, hoses and joints for oil leakage
Check and repair any oil leaks.
b9. Bleeding air
For the bleeding air from the fuel system, see
Testing and adjusting, "Bleeding air from fuel
circuit".)
For the bleeding air from the hydraulic system, see
Testing and adjusting, "Bleeding air from each
part".)

40-16 HM400-3M0

Testing in accordance with testing procedure
c. Electric equipment
c1. Check of battery terminal for looseness and
corrosion
• Check battery terminals for looseness and
corrosion.
• Check and remove any accumulated dirt and
combustibles (dead leaves, twigs, etc.) around
the batteries.
c2. Check of alternator terminal for looseness
and corrosion
• Open the engine hood.
• Check alternator terminals B (85), R (80) and E
(E1) for open circuit, looseness or corrosion.
c3. Check of starting motor terminal for
looseness and corrosion
• Check starting motor terminal B for open circuit,
looseness or corrosion.
c4. Check of battery voltage (with engine
stopped)
Check the battery voltage by using the battery tester
while the engine is stopped.
c5. Check of battery electrolyte level
Check before operating the machine.
HM400-3M0
40 Troubleshooting
Related information on troubleshooting
(HM400_3M0-5150-280-A-00-A)
k Do not use the battery if the battery
electrolyte level is below LOWER level line.
This will accelerate deterioration of the
inside of the battery and reduce the service
life of the battery. In addition, it may cause an
explosion.
k Since the battery produces combustible gas
that can explode, do not bring any open
flame near it.
k Battery electrolyte is dangerous. Be careful
that it does not come in contact with your
eyes or skin. If it does, wash it away with
water and contact your doctor.
a Do not add the battery fluid above the UPPER
LEVEL line. If done, the fluid may leak and the
coating surface may be damaged or the parts
may be corroded.
a To avoid freezing, add the purified water (such
as a commercial battery fluid) before starting the
work in the next day.
• When checking the electrolyte level through the
side face of the battery
1. Wipe and clean the battery surface, especially
around the battery level lines with a wet cloth,
and check to see that the battery fluid is
between the UPPER LEVEL and LOWER
LEVEL lines.
a Do not clean the battery with a dry cloth
since static electricity may cause an
explosion.
2. If the battery fluid drops below the center
position between the UPPER LEVEL and
LOWER LEVEL lines, remove the cap on top of
the battery and add fluid (such as a commercial
battery fluid) immediately until the fluid reaches
the UPPER LEVEL.
a After adding the refined water, tighten the
cap securely.
40-17
40 Troubleshooting
Related information on troubleshooting

a If the fluid exceeds the UPPER LEVEL, • Check wiring harness for sagging and looseness
remove the fluid using a dropping pipette or due to coming off of harness clamp
others until the fluid drops to the UPPER
a In particular, carefully check the wiring harness
LEVEL. When you have removed the fluid
around the hot and movable parts.
from the battery, neutralize it with the baking
soda (sodium bicarbonate) and wash it away • If removed from the clamp, secure it with the
with a large quantity of water. clamp.
• When electrolyte level cannot be checked
through the side face of the battery
1. Remove the cap from the top of battery. (As
described previously)
2. Observe fluid level port (3), and check the fluid
level. If the fluid level is below sleeve (4), always
add the fluid (such as a commercial battery fluid)
until it reaches the bottom of sleeve (the UPPER
LEVEL).
• (A) Correct level: Since the electrolyte level
reaches to the sleeve bottom, the shape of
the electrode plates will appear distorted due
to the surface tension.
• (B) Low: Since the electrolyte level does not c8. Check of grounding
reach the sleeve bottom, the shape of the a Take special care not to cause a loose cable
electrode plates will appear straight. connection and corrosion.
3. After adding the refined water, tighten the cap.
• Open the engine hood.
• Check the connection of ground terminals (ER4),
(ER5), (ER6), (ER15), (ER16), and (ER20).

a If the fluid exceeds the UPPER LEVEL,

remove the fluid using a dropping pipette or
others until the fluid drops to the UPPER • Check the connection of ground terminal [1]
LEVEL. When you have removed the fluid (between engine and frame).
from the battery, neutralize it with the baking
soda (sodium bicarbonate) and wash it away
with a large quantity of water.
c6. Check of wiring harness for discoloration,
burn and cover peeling
• Check the wiring harness and cables for
discoloration and burn.
a If discolored or burnt, the circuit may be shorted
or grounded.
• Check the wiring harnesses and cables for
damage and peeling of the covers.
• If any abnormality is found, repair or replace the
wiring harness or cables.
• Remove engine controller cover.
c7. Check for coming off of wiring harness • Check the connection of ground terminal
clamp and sagging of wiring harness (ER17).

40-18 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

• Check the connection of ground terminal

(CONT), [2] from part P and part Q.

• Check the connection of ground terminal

(ER12).
(Left lower of the cab)

• Tilt the cab up.

• Check the connection of transmission ground
• Raise the body.
[3].
• Remove cover and check the connection of
(Left lower of the cab)
ground terminal (ER7).
(Rear left of the cab)
(Front side ground of among front and rear
frame grounds)

• Check the connection of cab ground [4].

(Right lower of the cab)

• Check the connection of ground terminal (ER8).

(Left inner side of rear frame)
(Rear side ground of among front and rear frame
grounds)

HM400-3M0 40-19
40 Troubleshooting
Related information on troubleshooting

• Check the connection of ground terminal • Remove left fender cover.

(ER10). (Emergency steering motor ground)
(Left upper surface of rear frame) • Check the connection of ground terminals
(ER14) and (ER18).

• Check the connection of ground terminal

(ER11). c9. Check for loose connector and damaged
(Rear right of the cab) lock.
• Check the connection of male and female
connectors by pulling them by hand.
• If the connection is loose, secure it.

• Check the connection of cab ground terminals

(ER2) and (ER3).

• Check the connectors for unlocking, and check

the lock and connector housing for cracking.
• Check lock screws (2) to (3) of engine controller
(1) for looseness.
a Use a hexagonal wrench with 4 mm width
across flats.

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 40 Troubleshooting
Related information on troubleshooting

c10. Check the connector pins for corrosion, • Wipe and remove any foreign material with a
bending and deformation. cloth or others, and blow the air to clean the
• Disconnect the connectors, and check their pins connector.
for corrosion, bending, sinking than other pins,
and extension of female pins.
• If pins are defective, repair or replace them.
a If the pins are not shiny, apply contact restorer to
them and connect and disconnect the
connectors several times to shine them. (If the
pins do not become shiny, connect and
disconnect the connectors 10 times)
c11. Check of connector for water and foreign
material insertion.
• Disconnect connectors, and check them for
insertion of water or foreign materials.
c12. Check of wiring harness for open or short
circuit
• Check the connection (crimped part) between
connector pins and wiring harness.
• If the line is open as shown as (A), repair or
replace the wiring harness or cables.

a If any water or foreign materials are found, the

seals may be defective. Check the seals for
damage.
• If the seal is defective, repair or replace it.
• Dry the inside of the connector with a dryer.

• Visually check wiring harnesses for peeling of

harness covers and the pins for contact with
adjacent pins due to defective crimping.
c13. Check of fuse for blowing out and
corrosion
a When replacing a fuse, be sure to turn off the
power (turn the starting switch to OFF position)
and turn battery disconnect switch (8) to OFF
position.

HM400-3M0 40-21
40 Troubleshooting
Related information on troubleshooting

• A fuse unit is a large-capacity fuse.

• If a fuse is corroded and coated with white
powder, or there is any play between the fuse
and fuse holder, replace the fuse.
• Replace each fuse with the one of the same
capacity.
Opening battery cover provides access to fuse units
(5) to (7).

40-22 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

Removing the cover at the rear of the operator's cab provides access to fuse holders (BT1) to (BT4).

HM400-3M0 40-23
40 Troubleshooting
Related information on troubleshooting

c14. Check of alternator voltage (when engine

speed is medium or higher)
1. Open the engine hood.
2. Connect the positive (+) lead of the multimeter to
alternator terminal (B) and connect the negative
(-) lead to the chassis ground.
3. Start and warm up the engine and measure the
voltage while running the engine at a medium or
a higher speed.
• If the voltage is abnormal, repair or replace
the alternator.
c15. Check of battery relay operation sound
1. Open the battery cover.
2. Turn the starting switch to ON and OFF
positions, and check whether battery relay (1)
operation sound is heard or not.
• If the operation sound is not heard, check the
related circuits, referring to the description of
troubleshooting for E-1 described in the E
mode troubleshooting.
• If the relating circuit is normal, replace the
battery relay.

40-24 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

Preparation for troubleshooting of electrical system (HM400_3R-C050-42C-K-00-A)

a When performing troubleshooting of electrical

system of machine monitor, engine controller,
monitor controller, transmission controller, and
retarder and hoist controller related, expose
applicable connector part according to the
following procedure.
a For connectors whose lock method is special,
perform disconnection and connection in the
following procedure.
1. Transmission controller, retarder and hoist
controller, monitor controller
1) Fold operator's seat (1) forward.
3 Lock screw:
3 ± 1 Nm {0.3 ± 0.1 kgm}
a When restore them, tighten the lock
screws to the specified torque.
5) Disconnect monitor controller (11)
connectors MCM1 (12) and MCM2 (13), and
connect T-adapters for troubleshooting.
a Since the adapter for monitor controller is
not T-adapter, the voltage cannot be
measured by inserting adapter into
connector.

2) Remove cover (2). a Connector (14) is used to connect liquid

crystal unit of machine monitor. T-adapter
for troubleshooting is not provided. For
details of troubleshooting for connector
(14), see "Precautions when performing
troubleshooting of machine monitor" and
"Processing procedure of harness
checker for troubleshooting of machine
monitor LCD unit".

3) Disconnect transmission controller (3)

connectors ATC1 (4), ATC2 (5), and ATC3
(6), and insert or connect T-adapters for
troubleshooting.
a Use a hexagonal wrench with 4 mm width
across flats for lock screw.
4) Disconnect connectors BRC1 (8), BRC2 (9),
and BRC3 (10) of retarder and hoist
a Procedure for disconnecting connectors
controller (7), and insert or connect T-
MCM1 (12) and MCM2 (13) of monitor
adapters for troubleshooting.
controller (11)
a Use a hexagonal wrench with 4 mm width While pressing lock (L1), turn lock (L2)
across flats for lock screw. inward.
a Bar (B) comes out and the lock is
released.

HM400-3M0 40-25
40 Troubleshooting
Related information on troubleshooting
6) Reference (Connector cover of monitor
controller)
• Procedure for removing connector cover
(1)
1] Cut and remove cable tie (2).
2] Move lever (3) upward.
3] Lightly press part (A) on both sides of
connector cover (1) to release tabs
(B).
4] Remove connector cover (1) around
tab (C).
a Connector without connector cover
(1).
40-26
• Procedure for installing connector cover
1] Push in right and left sliders (4) as far
as they go.
a Right and left sliders (4) pushed in
as far as they go (left in the
following figure)
2] Move lever (3) on connector cover (1)
from the top position to the left
position (locked position) as shown in
the following figure.
a (B), (C): Tab
a If the sliders and lever are not set
as shown in the following figure,
the connector is not disconnected
or locked securely with the lever.
Accordingly, check their positions
again.
HM400-3M0

3] Set tab (C) to the connector and place
connector cover (1).
a Take care that wiring harness (5) is
not caught.
4] Put tabs (B) in to install connector
cover (1).
3. Machine monitor
5] Replace the cut cable ties with new
ones to bind connector cover (1) and
the wiring harness together.
2. Engine controller
1) Open engine cover.
a The engine controller is mounted on the
engine (left of the machine).
2) Remove cover (1).
3) Connect or insert T-adapters for
troubleshooting to connectors ECM (3), J2P
(4), and J3P (5) of engine controller (2).
HM400-3M0
40 Troubleshooting
Related information on troubleshooting
a Use a hexagonal wrench with 4 mm width
across flats for lock screw.
a When restore them, tighten the lock
screws to the specified torque.
3 Lock screw:
3 ± 1 Nm {0.3 ± 0.1 kgm}
1) Remove cover (1).
a See "Removal and installation of machine
monitor assembly" in Disassembly and
assembly.
2) Remove machine monitor.
3) From back of machine monitor, disconnect
connectors DPC2 and DPC3, and connect or
insert T-adapters for troubleshooting.
a Connector DPC1 is used to connect liquid
crystal unit of machine monitor to monitor
controller. T-adapter for troubleshooting is
not provided. For details of
troubleshooting for connector DPC1, see
"Precautions when performing
troubleshooting of machine monitor" and
"Processing procedure of harness
checker for troubleshooting of machine
monitor LCD unit".
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40 Troubleshooting
Related information on troubleshooting
4. KOMTRAX terminal
1) Remove cover (1).
2) Bkup (camshaft) speed sensor (G)
2) Disconnect KOMTRAX terminal (2)
connectors KOM1 and KOM2, and connect
or insert T-adapters for troubleshooting to
them.
5. Engine-related connectors
1) Engine Ne speed sensor (NE)
Engine oil pressure sensor (POIL)
3) Common rail pressure sensor (PFUEL)
40-28
a Disconnection and connection of
connectors
Since the connectors of ambient pressure
sensor and engine Ne speed sensor
have a special lock mechanism,
disconnect them in the order of (a) to (c),
and connect them in the order of (d) to (f)
as shown in the following figure.
Disconnection: (a) Slide the lever, (b)
unlock, and (c) disconnect the connectors.
Connection: (d) Connect the connectors,
(e) engage the lock, and (f) slide the lever.
Supply pump PCV1 (PCV1)
Supply pump PCV2 (PCV2)
a Disconnection and connection of
connectors
Since the connectors of Bkup speed
sensor and supply pump PCV have a
special lock mechanism, disconnect them
in the order of (a) to (b), and connect
them in the order of (c) to (d) as shown in
the following figure.
Disconnection: (a) Unlock and (b)
disconnect the connectors.
Connection: (c) Connect the connectors
and (d) engage the lock.
HM400-3M0

a Disconnection and connection of
connectors
Since the connectors of common rail
pressure sensor have a special lock
mechanism, disconnect them in the order
of (a) to (b), and connect them in the
order of (c) to (d) as shown in the
following figure.
Disconnection: (a) Unlock and (b)
disconnect the connectors.
Connection: (c) Connect the connectors
and (d) engage the lock.
4) Engine coolant temperature sensor (TWTR)
a Precautions for disconnection of
connectors
The direction of the lock for connector
may be changed toward the difficult
direction (facing to the bottom or to the
engine side) for unlocking depending on
the position where the sensor is screwed
in.
In such a case, turn the lock to the
direction (a) by using the needle nose
pliers with curved tip (commercially
available) [1], then the lock can be
canceled easily.
Since the lock is canceled with "click"
sound, listen to the sound and disconnect
the connectors.
HM400-3M0
40 Troubleshooting
Related information on troubleshooting
a Precautions for connecting connectors
When connecting connectors, pay
attention not to connect the connectors
reverse.
Engage lock portion (e) on the harness
side to triangle notch portion (f). (Pay
attention not to take square guide portion
(g) on the opposite side of triangle notch
portion (f) by mistake.)
Charge (Boost) temperature sensor (TIM)
Fuel temperature sensor: (TFUEL)
a Disconnection and connection of
connectors
Since the connectors of engine coolant
temperature sensor have a special lock
mechanism, disconnect them in the order
of (a) to (b), and connect them in the
order of (c) to (d) as shown in the
following figure.
Disconnection: (a) Unlock and (b)
disconnect the connectors.
Connection: (c) Connect the connectors
and (d) engage the lock.
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40 Troubleshooting
Related information on troubleshooting

a Removal and installation of sensor body

Since a deep socket is necessary when
removing and installing the engine
coolant temperature sensor, see "Tools
for testing, adjusting, and
troubleshooting".

40-30 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

Classification and procedures for troubleshooting (HM300-5160-40D-A-00-A)

Classification of troubleshooting codes
Mode Content
Display of code Troubleshooting by failure code
E mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical systems
S-mode Troubleshooting of engine

Procedure for troubleshooting

If a phenomenon which appears a source of a trouble occurs on the machine, go to the corresponding
troubleshooting section according to the following procedure.
1. Procedure for troubleshooting when user code and failure code are displayed on machine monitor:
If a user code and a failure code are displayed on the standard screen of the machine monitor, perform the
troubleshooting for the corresponding "Display of code" according to the displayed failure code.
a If multiple failures occur simultaneously, all failure codes are displayed repeatedly in order. Record all
failure codes on a paper.
2. Procedure for troubleshooting when user code and failure code are not displayed on machine monitor:
Check a mechanical system failure code and an electrical system failure code with the abnormality record
function of the machine monitor. (See [*1].)
1) If a failure code is displayed, perform troubleshooting for the corresponding "Display of code"
according to the failure code.
a If an electrical system failure code is displayed delete all the codes once and reproduce them, and
then see if the failure is still detected. (See [*2].)
a A failure code of the mechanical system cannot be deleted.
2) If no failure code is found in the abnormality record, a failure 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 which is assumed to show the failure again and select the same
phenomenon from the table of "Phenomenon to be assumed a failure and troubleshooting number",
and then perform troubleshooting corresponding to that phenomenon in the "E-mode", "H-mode", or
"S-mode".
3. Action to take after failure is eliminated
Clear all the failure codes in the electrical system abnormality record, referring to the next page.
[*1], [*2]
1. On the normal operation screen, hold down inverted triangle key [R] (6), and press numeric keys [1], [2]
and [3] in this order to enter to service menu screen.
• (4) is the Enter switch (check mark).
• (5) is the Return switch.
• (7) is the Menu switch (to clear all).

2. Press the inverted triangle key [R] twice on the Service Menu screen to select "03 Abnormality Record".
3. Press the Enter key (check mark) to validate it, and go to the "Abnormality Record" screen.

HM400-3M0 40-31
40 Troubleshooting
Related information on troubleshooting

4. Press the Enter key (check mark) on the "Abnormality Record" screen, and go to the "Mechanical
Systems" screen.

5. Press the inverted triangle key [R] and make sure that the following failure codes are not generated.
Record all failure codes on a paper.
a A failure code of the mechanical system cannot be deleted.
6. Return to the "Abnormality Record" screen by pressing the Return key (explained above).
7. Go to the "Electrical system abnormality record" similarly to steps 2 and 3.

8. Press the inverted triangle key [R] and make sure that the following failure codes are not generated.
Record all failure codes on a paper.

40-32 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

a If "E" is displayed at the left to the failure code, this code is "active" (that is, this failure still continues or
its recovery is not verified yet). If "E" is not displayed, the failure code is "inactive" and the code will be
cleared in the subsequent clearing step. Be sure to record this failure code on a paper.

9. Hold down the inverted triangle key [R], and press numeric keys [1], [2] and [3] in this order to go to the
"Clear mode". (Same as 1)
10.Press the Menu switch of the switch panel (as explained above).

11.Press the Enter key (check mark) to clear all failure codes.
12.Return to the "Electrical Systems" screen by pressing the Return key (explained above). Check if a failure
code is still displayed or not, and record it on a paper.
13.Return to the "Abnormality Record" screen by pressing the Return key (explained above).

HM400-3M0 40-33
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Related information on troubleshooting

Symptom and troubleshooting numbers (HM400_3M0-5540-441-A-00-A)

Troubleshooting
No. Symptom of failure
Index
User code, failure code
Action level is displayed on machine monitor. Press Enter switch (check mark)
1 to display "Occurred error list". Perform
2 Failure code is displayed on mechanical system abnormality record. troubleshooting for
The failure code is displayed on the electrical system abnormality record failure code.
3
screen
Symptom related to engine
4 Engine does not start E-1, S-1
5 Engine does not crank when starting switch is turned to "START" position. E-1, S-1
6 Engine cranks but no exhaust smoke comes out. S-2
7 Fuel is being injected but engine does not start S-3
8 Engine startability is poor. S-4
9 Engine does not pick up smoothly. S-5
10 Engine stops during operation. S-6
11 Engine runs rough or is unstable. S-7
12 Engine lacks power S-8
13 Exhaust smoke is black S-9
14 Engine oil consumption is excessive. S-10
15 Oil becomes contaminated quickly. S-11
16 Fuel consumption is excessive. S-12
17 Oil is in coolant (or coolant spurts back or coolant level goes down). S-13
18 Engine oil pressure drops. S-14
19 Fuel mixes into engine oil S-15
20 Water mixes into engine oil (milky). S-16
21 Coolant temperature rises too high (overheating). S-17
22 Unusual noise is heard. S-18
23 Vibration is excessive. S-19
24 Air cannot be bled from fuel circuit S-20
25 Manual preheater does not operate E-2
26 Automatic preheating does not work E-3
27 While preheating is working, preheating pilot lampdoes not light up E-4
28 Engine mode selector function does not operate properly E-27
29 AISS function does not operate properly E-28
Symptom related to travel
30 Machine does not start. H-1
31 Machine does not travel smoothly (engine hunts) H-2
32 Lockup is not releasable H-3
33 Abnormally large shocks result from starting of machine and gear shifting H-4
34 Shift up is unavailable H-5
Insufficient travel speed or travel power results from lockup drive mode through
35 all gear speeds H-6
36 Travel speed or power is low in torque converter drive mode H-7
37 Travel speed or power is low in specific gear speed H-8
38 Machine starts or gear speed shifts with long time lag. H-9
39 Torque converter oil temperature is high. H-10
40 Torque converter oil pressure is low H-11
41 Steering wheel is heavy H-14
42 Steering wheel does not move H-15
43 Steering wheel swings H-16
Symptom related to work equipment
44 Hoist lever does not operate properly E-29

40-34 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

Troubleshooting
No. Symptom of failure
Index
45 Dump body raise speed is low H-17
46 Dump body does not move H-18
47 Hydraulic drift of dump body is large H-19
Brake component
48 Front brake does not operate sufficiently H-12
49 Performance of center brake is poor H-13
Symptom related to fan
50 Radiator fan speed is abnormal (high, low, or does not rotate) H-20
51 After cooler fan speed is abnormal (high, low, or does not rotate) H-21
52 Abnormal sound is heard around radiator fan H-22
53 Abnormal sound is heard around after cooler fan H-23
Symptom related to machine monitor
54 All of LCD unit, LED unit, and meter unit on machine monitor displays nothing E-5
55 LCD unit on machine monitor displays nothing E-6
Backlight of LCD unit on machine monitor is abnormal. (Backlight goes out or
56 flickers.) E-7
57 LCD on machine monitor does not display properly E-8
58 LED unit lamp on machine monitor is abnormal E-9
59 Night lighting lamp of meter unit on machine monitor is abnormal E-10
60 Display of mete unit on machine monitor is abnormal E-11
LED of switch panel on machine monitor is abnormal or switches does not
61 operate properly E-12
62 2 switches operation of switch panel on machine monitor does not function E-13
63 Switch panel buzzer of machine monitor is abnormal E-14
64 Rearview monitor does not light up or backlight flickers E-15
65 Rear view monitor images are not displayed clearly E-16
66 Rear view monitor brightness cannot be adjusted E-17
67 Night lighting lamp of rear view monitor is abnormal E-18
Rearview monitor does not display images while reverse linked display
68 E-19
function is enabled
69 Guide line on rear view monitor is not displayed while guide line is set E-20
Some items of gauges and caution lamps on machine monitor are not
70 displayed properly E-21
71 Fuel gauge does not indicate correct level E-22
72 Seat belt caution lamp indication is abnormal E-23
73 Machine monitor cannot be operated when starting switch is in OFF position E-24
74 Alarm buzzer does not sound E-25
75 Alarm buzzer does not stop sounding E-26
"Procedure for testing
Air conditioner does not operate normally (including failure codes related to air
76 and troubleshooting" in
conditioner)
Chapter 80
Appendix
77 Turn signal lamp and winker lamp (hazard lamp) do not operate properly E-30
78 All of small lamp (clearance lamp and tail lamp) and head lamp do not light up E-31
79 Small lamp (clearance lamp) does not light up E-32
80 Tail lamp does not light up E-33
81 "Low beam" head lamp does not light up E-34
82 "High beam" head lamp does not light up E-35
83 Neither "Low beam" nor "High beam" head lamp lights up E-36
84 High beams do not light up while passing switch is operated E-37
85 KOMTRAX system does not work properly E-38

HM400-3M0 40-35
40 Troubleshooting
Related information on troubleshooting

Information in troubleshooting table (ALL-5170-421-A-01-A)

(Rev. 2011/12)

a The following information is summarized in the troubleshooting table. Before performing troubleshooting,
understand that information fully.
Action level Failure code
Display on Failure name displayed on the Abnormality Record screen
Display on Failure
machine of the machine monitor
machine monitor
monitor
Detail of Description of the failure detected by the machine monitor or controller
failure
Action of An action that is performed to protect the system and devices when a failure is detected by
controller the machine monitor or controller
Problem on A problem that appears as a failure on the machine as a result of an action (above) that is
machine performed by the machine monitor or controller.
Related Information on occurred failure or troubleshooting
information
No. Cause Procedure, measuring location, criteria and remarks
1 Defective — <Contents of description>
Open or short circuit in wiring • Procedure
2
harness • Measuring location
Open circuit in wiring harness
a "Between A and B" denotes measuring values such as voltage
3 (wire breakage or defective and resistance between A and B.
contact of connector)
Ground fault in wiring harness a "Between A and ground" means the measurement of voltage,
4 resistance or others between terminal A and the place which has
(contact with ground circuit) a continuity with chassis frame such as unpainted hexagonal
5 Hot short circuit head bolt or bolt hole which has no rust, etc.
• Criteria to judge probable causes (standard value), remarks
<How to use troubleshooting sheet>
• Perform troubleshooting procedures in numerical order.
• If the check result does not meet the criteria, the probable cause
described on the left column is the actual cause of the failure.
• If the check result meet the criteria and there is no specific
instruction, proceed to the next step (cause).
• If a defect is found and repaired, check that the defect has been
corrected.
<Failures in wiring harness>
Short circuit in wiring harness
6 • Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not to be connected to the ground (earth) circuit comes
into contact with the ground (earth) circuit or chassis accidentally.
• Hot short circuit
A harness not to be connected to the power circuit comes into
contact with the power circuit accidentally.
• Short circuit
An independent wire in the harness erroneously comes into contact
with another independent wire.
(poor insulation at connector and others)

40-36 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

No. Cause Procedure, measuring location, criteria and remarks

<Precautions for troubleshooting>
(1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapters as follows unless
otherwise specified.
• When "male" or "female" is not indicated with a connector number,
disconnect the connector, and insert T-adapter between the male
and female connectors.
• When "male" or "female" is indicated with a connector number,
disconnect the connector, and connect T-adapter to the male or
7 Defective controller female connector.
• "Male and female" means male and female of connector pins, not
connector housings.
• Male and female of connector pins and housing in DT series, etc, are
opposite to those described in this manual. Take care.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the positive (+) and negative (-) leads as
shown below unless otherwise specified.
• Connect the positive (+) lead to pin or wire indicated first.
• Connect the negative (-) lead to a pin or wire indicated second.

Related circuit diagram

This is the excerpted circuit diagram related to
troubleshooting
• The circuit diagram contains the connector Nos.,
pin Nos., and connector colors related to the
failure.
• The "/" in a connector number is either:
1) An abbreviation (of more than three letters)
Example: T/C (Torque Converter)
2) Different connector number at male and female
sides
Example: BREAK OUT/E24
• The circuit diagram contains the destination or
source of the branch line in a wiring harness.
• The arrow (io) indicates a rough installation
position on the given machine.
• NO: Normally Open
• NC: Normally Closed
• Signal names such as GND and 24 V are included
in addition to connector numbers at junctions, etc.
in circuit diagrams.
• Except for GND and 24 V, a signal name indicated
at a junction, etc. shows that the wire is connected
to another junction or controller at where the same
signal name is indicated.

HM400-3M0 40-37
40 Troubleshooting
Related information on troubleshooting

Procedure for troubleshooting wiring harness of pressure sensor

system for open circuit (HM400_3M0-E720-42A-P-00-A)
a Pressure sensors consist not only of resistors but also of "electronic circuit" components such as
amplifiers. Therefore, troubleshooting must be performed carefully taking into consideration of their
individual variability and polarities.
Failure codes applicable to this diagnosis
• CA451: Rail Pressure Sensor High Error
Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1), and connect socket (2) to the sensor side connector.
2) Measure resistance R1 and R2 between pins.
a If the polarities of multimeter probes are reversed, measured value may change. Therefore, when
measuring the resistance, apply the multimeter probes to the pins without changing their polarities
to the pressure sensor between measurements in steps 1 and 2.
a When a measured value is infinite, reverse the polarity and try measurement again. If you obtained
a non-infinity value in this manner, use it as the measurement value.
a Since the measured values may be dispersed, take several measurements.
Above is considered due to electric charge applied to inside of the sensor. Measurement must be
repeated several times similarly in steps 1 and 2. In step 3, you must determine whether the wiring
harness is open-circuited taking this dispersion into consideration.

2. Measure and record resistance of the pressure sensor to which the wiring harness between the engine
controller and pressure sensor is connected.
1) Since 5 V power supply to the pressure sensor is connected to other sensors, disconnect other sensor
connectors first. (*)
2) While the connector of the target pressure sensor of measurement is connected, disconnect connector
(3) of the engine controller, and connect T-adapter (4) to the wiring harness side.
3) Connect T-box (5) to T-adapter (4) and measure resistance R1' and R2' between respective pins.
3. Judging open circuit
If there is an "apparent difference" between resistance R1 and R2 measured in step 1 and resistance R1'
and R2' measured in step 2, you may judge that the wiring harness is open-circuited.
a "Apparent difference" means a difference of 10 or more times.

40-38 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

List of pressure sensor measuring locations and reference values

Inside of sensor
Measuring location at Measured internal
Sensor sensor pin Remarks
resistance of sensor
(reference)
R2: Between (3) and (1) Approximately 23 kz
Common rail
R1: Between (1) (+) and (2)
pressure sensor Approximately 10 Mz If the polarity is reversed, the
(–) resistance becomes infinite.
*: The following lists the connector to be disconnected when measuring R2'. (See related circuit diagram
listed in troubleshooting section of each failure code.)
• When measuring R2' of common rail pressure sensor (CA451):
Since 5 V power supply is used independently, there is no connector to be disconnected.
Measurement record (For measuring locations, see related circuit diagram listed in troubleshooting section of
each failure code.)
Sensor with wiring harness
Sensor unit connected
Measured Measured
Sensor (Measuring location at (Measuring location on
value value
sensor pin) harness connector of
engine controller)
R2': Between (37) and (47)
R2: Between (3) and (1)
Common rail (*)
pressure sensor R1: Between (1) (+) and (2) R1': Between (47) (+) and
(–) (25) (–)

HM400-3M0 40-39
40 Troubleshooting
Related information on troubleshooting

Connector list and layout (HM400_3M0-C050-055-K-00-A)

Number
Connector No. Connector type Equipment name Address
of pins
50 Terminal 1 Battery relay I-1
53 Terminal 1 Battery relay I-2
54 Terminal 1 Emergency steering relay 2 K-3
55 Terminal 1 Emergency steering relay 2 K-1
56 Terminal 1 Emergency steering relay 2 K-1
57 Terminal 1 Emergency steering relay 2 K-1
58 Terminal 1 Emergency steering relay 1 I-1
59 Terminal 1 Emergency steering relay 1 J-1
60 Terminal 1 Emergency steering relay 1 K-3
61 Terminal 1 Emergency steering relay 1 I-1
62 Terminal 1 Fuse 80A K-4
63 Terminal 1 Fuse 80A L-4
64 Terminal 1 Fuse 80A L-4
65 Terminal 1 Fuse 80A K-4
66 Terminal 1 Battery relay J-3
69 Terminal 1 Battery relay J-3
70 Terminal 1 Emergency steering relay 2 K-3
71 Terminal 1 Emergency steering relay 2 K-3
72 Terminal 1 Emergency steering relay 2 K-3
73 Terminal 1 Emergency steering relay 2 K-3
74 Terminal 1 Emergency steering relay 1 J-3
75 Terminal 1 Emergency steering relay 1 J-3
76 Terminal 1 Emergency steering relay 1 K-3
77 Terminal 1 Emergency steering relay 1 J-3
78 DT 2 Intermediate connector A-4
78 DT 2 Intermediate connector AL-8
80 Terminal 1 Alternator R terminal B-2
80 Terminal 1 Alternator R terminal AK-6
81 Terminal 1 Fuse 30A K-4
82 Terminal 1 Fuse 40A K-4
83 Terminal 1 Fuse 30A L-5
84 Terminal 1 Fuse 40A L-5
85 Terminal 1 Alternator B terminal A-2
86 Terminal 1 Junction block I-3
87 Terminal 1 Junction block H-3
88 Terminal 1 Junction block I-3
89 Terminal 1 Junction block I-3
A1 X 1 Emergency escape switch V-3
A2 X 1 Emergency escape switch W-3
AC1 090 10 Air conditioner unit M-7
AC2 SMD 4 Air conditioner unit M-7
ACC Terminal 1 Starting switch terminal ACC N-1
ACS YAZAKI 2 Accessory socket U-9
AISS SWP 6 AISS switch M-1
Automatic retarder, accelerator control
ARA SWP 6 O-3
switch
AS1 DT 6 Accelerator pedal sensor O-3
AS2 DT 2 Accelerator pedal sensor O-3
ASBF1 Terminal 1 Slow-blow fuse L-3
ASBF2 Terminal 1 Slow-blow fuse L-3
ASS DT 2 Air suspension seat T-2

40-40 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

Number
Connector No. Connector type Equipment name Address
of pins
ATC1 DRC26 24 Transmission controller Q-8
ATC2 DRC26 40 Transmission controller R-8
ATC3 DRC26 40 Transmission controller R-9
ATC6 X 4 For program rewriting S-9
B Terminal 1 Starting switch terminal B N-1
B01 DT 2 CAC fan speed sensor A-5
B02 DT 3 Emergency steering pressure sensor 1 F-2
B03 DT 3 Hoist selector valve C-6
B04 DT 2 Hoist EPC valve B-6
B05 DT 2 Center brake oil temperature sensor J-4
B06 DT 2 Front brake oil temperature sensor A-3
B07 DT 2 Remote cooling valve C-7
B08 DT 3 Steering oil pressure sensor F-5
B09 DT 2 PNC solenoid F-2
B10 DT 3 Body position sensor I-9
B11 DT 2 Steering oil temperature sensor G-8
B12 DT 3 Inclinometer I-9
B13 DT 2 RAD fan speed sensor A-4
B14 DT 2 P/B solenoid E-8
B15 DT 2 Service brake pressure switch I-8
B16 EJ2 3 Retarder pressure sensor (FR) E-8
B17 EJ2 3 P/B pressure sensor D-8
B18 DT 2 Retarder valve (FL) E-8
B19 DT 2 Retarder valve (FR) E-8
B20 DT 3 Emergency steering pressure sensor 2 F-2
B23 EJ2 3 Retarder pressure sensor (FL) D-8
B24 EJ2 3 ACC oil pressure sensor (R) D-8
B25 EJ2 3 ACC oil pressure sensor (F) D-8
B26 DT 2 Shut off valve F F-8
B27 DT 2 Shut off valve C F-8
B28 DT 2 Retarder valve (CR) J-8
B29 DT 2 Retarder valve (CL) K-4
B30 EJ2 3 Retarder pressure sensor (CR) I-8
B31 EJ2 3 Retarder pressure sensor (CL) J-4
B32 DT 3 Wheel speed sensor (FR) E-1
B34 DT 3 Wheel speed sensor (CR) J-4
B35 DT 3 Wheel speed sensor (CL) J-4
B36 DT 3 Articulate angle sensor F-8
B37 DT 2 Cooling motor speed sensor B-7
BA49 DT 2 Back-up alarm buzzer J-8
BL SWP 6 Revolving warning lamp switch Q-8
BL47 DT 2 Backup lamp (R) I-8
BLL DT 2 Backup lamp (L) J-8
BMN DT 4 Intermediate connector K-9
BP DT 2 Bypass valve AK-6
BR Terminal 1 Starting switch terminal BR N-1
BRC1 DRC26 24 Retarder & hoist controller S-9
BRC2 DRC26 40 Retarder & hoist controller S-9
BRC3 DRC26 40 Retarder & hoist controller S-9
BT1 Terminal 30 Fuse box W-7
BT-1A Terminal 1 Battery 1 J-1
BT-1B Terminal 1 Battery 1 K-1

HM400-3M0 40-41
40 Troubleshooting
Related information on troubleshooting

Number
Connector No. Connector type Equipment name Address
of pins
BT2 Terminal 30 Fuse box V-8
BT-2A Terminal 1 Battery 2 J-1
BT-2B Terminal 1 Battery 2 J-1
BT3 Terminal 30 Fuse box V-8
BT4 Terminal 30 Fuse box W-8
BZ2 MX4008 2 Buzzer P-2
C Terminal 1 Starting switch terminal C N-2
CAB1 SWP 12 Intermediate connector N-4
CANC DT 3 Resistance (120 z) AP-4
CC2 DT 2 Cab tilt switch E-1
CCR FURUKAWA 5 Compressor clutch relay R-8
CGG 08032 1 Cigarette lighter P-7
CGP 08022 1 Cigarette lighter P-7
CJA DT 6 Joint connector E-8
CJB DT 8 Joint connector A-8
CJE DT 8 Joint connector A-9
CJE4 DT 6 Joint connector AP-6
CJF DT 6 Joint connector D-1
CJG DT 6 Joint connector A-9
CJH DT 6 Joint connector K-5
CJK DT 6 Joint connector J-8
CJK2 DT 6 Joint connector J-8
CJL1 DT 6 Joint connector K-5
CJL2 DT 6 Joint connector K-4
CJM DT 6 Joint connector J-9
CJM DT 6 Joint connector K-8
CJP DT 6 Joint connector E-1
CJR DT 6 Joint connector B-9
CJS DT 8 Joint connector A-8
CJT DT 6 Joint connector E-1
CJU DT 8 Joint connector B-9
CJV DT 6 Joint connector A-9
CJW DT 8 Joint connector A-9
CJY DT 6 Joint connector D-1
CM X 2 Compressor clutch B-2
CM DTA 8 Switch assembly P-2
CN1 DT 2 Injector #1 AK-6
CN10 DT 2 H solenoid AJ-7
CN11 DT 2 H fill switch AJ-7
CN12 DT 2 1st solenoid AJ-8
CN13 DT 2 1st fill switch AJ-8
CN14 DT 2 2nd solenoid AG-9
CN15 DT 2 2nd fill switch AH-9
CN16 DT 2 3rd solenoid AH-9
CN17 DT 2 3rd fill switch AH-9
CN18 DT 2 T/C lockup solenoid AG-9
CN2 DT 2 Injector #2 AL-8
CN20 DT 2 T/M differential solenoid AJ-6
CN22 DT 3 T/C intermediate pressure sensor AJ-5
CN23 DT 2 Torque converter oil temperature sensor AE-8
CN24 DT 2 T/M lubricating oil temperature sensor AF-8
CN25 DT 2 T/M flow selector solenoid AJ-6

40-42 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

Number
Connector No. Connector type Equipment name Address
of pins
CN26 DT 3 Flow selecting pilot pressure sensor AF-9
CN3 DT 2 Input shaft speed sensor AJ-4
CN3 DT 2 Injector #3 AN-8
CN4 DT 2 Intermediate shaft speed sensor AJ-3
CN4 DT 2 Injector #4 AO-8
CN5 DT 2 Output shaft speed sensor AJ-4
CN5 DT 2 Injector #5 AO-7
CN6 DT 2 L solenoid AI-8
CN6 DT 2 Injector #6 AO-7
CN7 DT 2 L fill switch AI-8
CN8 DT 2 R solenoid AH-9
CN9 DT 2 R fill switch AI-8
CT1 Terminal 1 CAB tilt pump K-1
CTF1 Terminal 1 Fuse 200A H-2
CTF2 Terminal 1 Fuse 200A H-2
CTP2 DT 2 CAB tilt pump L-1
D01 DT 2 Diode O-7
D02 DT 2 Diode O-7
D03 DT 2 Diode O-7
D04 DT 2 Diode O-8
D05 DT 2 Diode O-8
D06 DT 2 Diode O-8
D07 DT 2 Diode N-3
D08 DT 2 Diode N-3
D09 DT 2 Diode O-7
D10 DT 2 Diode O-7
D11 DT 2 Diode O-8
D15 DT 2 Diode K-4
D15 DT 2 Diode O-7
DC1 Terminal 1 Disconnect switch K-3
DC2 Terminal 1 Disconnect switch K-3
DCC DT 6 DC/DC converter O-9
DL DTA 12 Service connector R-2
DPC1 MX4008 8 Monitor display O-2
DPC2 070 6 Monitor display N-3
DPC3 070 8 Monitor display M-1
DSL M 1 Door switch (L) (room lamp) AC-2
DSL X 2 Door solenoid X-4
DT10 DT 6 Intermediate connector A-5
DTL SWP 6 Daytime lighting ON switch R-2
E1 Terminal 1 Alternator E terminal A-3
E1 Terminal 1 Alternator E terminal AK-5
E11 Terminal 1 Heater relay J-3
E12 Terminal 1 Heater relay I-3
EGM SWP 6 Engine mode switch N-3
EGR DT 2 EGR valve AK-3
EMPR Terminal 2 Emergency steering fuse H-2
ENG DRC26 60 Engine controller AP-4
ER Terminal 1 Ground Q-2
ER1 Terminal 1 Ground Y-5
ER10 Terminal 1 Ground I-8
ER11 Terminal 1 Ground (floor frame) F-8

HM400-3M0 40-43
40 Troubleshooting
Related information on troubleshooting

Number
Connector No. Connector type Equipment name Address
of pins
ER14 Terminal 1 Emergency steering motor 2 H-2
ER15 Terminal 1 Ground (front frame) E-1
ER16 Terminal 1 Ground (front frame) D-1
ER17 Terminal 1 Ground (engine) AO-3
ER18 Terminal 1 Emergency steering motor 1 H-3
ER2 Terminal 1 Ground (cab) T-9
ER20 Terminal 1 Ground (front frame) L-2
ER3 Terminal 1 Ground (cab) T-2
ER4 Terminal 1 Ground (front frame) E-1
ER5 Terminal 1 Ground (front frame) D-1
ER6 Terminal 1 Ground (front frame) D-1
ER7 Terminal 1 Ground (front frame) G-8
ER8 Terminal 1 Ground (rear frame) I-4
ESS SWP 6 Secondary E/G stop switch P-7
EST DT 6 Intermediate connector M-2
FLS 08027 4 Flasher Q-2
FOG SWP 6 Fog lamp switch Q-8
FWL HD 2 Working lamp (front left) AB-2
FWL2 HD 2 Working lamp (front left) ―
FWM KES1 2 Washer motor (front) AA-2
FWR HD 2 Working lamp (front right) Z-7
FWR2 HD 2 Working lamp (front right) ―
G SUMITOMO 3 G sensor AM-2
RES DT 2 Fuel supply pump pullup resistance AN-8
HAZ SWP 6 Hazard switch N-3
HEAT SWP 6 Rear heater switch Q-8
HEAT1 YAZAKI 1 Rear glass heater AD-7
HEAT2 YAZAKI 1 Rear glass heater AB-8
HLS SMD 2 High and low pressure switches D-1
POTTER&BRUM-
HMR 4 Intermediate connector V-3
FIELD VF7-41H11
HMS SWP 6 Intermediate connector O-3
HN DT 2 Horn switch P-2
HR-BE Terminal 1 Heater relay J-3
HSL DT 4 Hoist lever potentiometer Q-8
IDA KNT 2 ID key M-1
IDJ DTB 8 Intermediate connector M-2
IDK AMP070 14 ID key M-1
ILK DT 2 Idle stop function W-7
J01 HD-55891 9 Intermediate connector M-7
J02 DTHD 1 Intermediate connector N-7
J03 DTHD 1 Intermediate connector O-7
J04 DTHD 1 Intermediate connector N-7
J05 DTHD 1 Intermediate connector N-7
J06 DRC12 70 Intermediate connector U-2
J07 DRC12 70 Intermediate connector U-3
J08 DRC12 70 Intermediate connector U-2
J09 DRC12 70 Intermediate connector T-2
J10 DTA 8 Intermediate connector N-7
J11 DTA 8 Intermediate connector L-1
J12 DTA 8 Intermediate connector G-2
J13 DTB 8 Intermediate connector A-8

40-44 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

Number
Connector No. Connector type Equipment name Address
of pins
J14 DTA 12 Intermediate connector G-8
J15 DTC 8 Intermediate connector G-2
J16 DTB 12 Intermediate connector A-7
J17 DT 8 Intermediate connector A-7
J18 DT 6 Intermediate connector G-2
J19 DTHD 1 Intermediate connector L-2
J1939 DT 3 CAN terminating resistor AO-7
J20 DTHD 1 Intermediate connector L-2
J21 DTHD 1 Intermediate connector AP-4
J22 DTB 12 Intermediate connector F-8
J23 DT 4 Intermediate connector F-8
J24 DTA 12 Intermediate connector B-2
J25 DTB 12 Intermediate connector B-2
J26 DTC 8 Intermediate connector A-8
J28 DT 4 Intermediate connector G-2
J29 DT 2 Intermediate connector F-8
J2P DRC26 50 Engine controller AP-5
J31 DTA 8 Intermediate connector C-6
J33 DT 2 System operating lamp L-4
J33 DT 4 Intermediate connector L-4
J34 DTB 12 Intermediate connector G-8
J35 DT 2 Intermediate connector C-6
J36 DT 2 Intermediate connector F-1
J38 Terminal 1 Junction block K-2
J39 Terminal 1 Junction block L-2
J3P DTP 4 Engine controller AP-3
J40 DT 12 Intermediate connector B-9
JCA SWP 16 Joint connector T-9
JCC SWP 16 Joint connector N-4
JCE SWP 16 Joint connector N-5
JCG DTB 8 Joint connector S-2
JCH DTB 8 Joint connector S-2
JM01 ― 8 Joint connector ―
JM02 ― 8 Joint connector ―
JM06 ― 3 Joint connector ―
JM07 ― 3 Joint connector ―
JM08 ― 3 Joint connector ―
JM09 ― 4 Joint connector ―
JM10 ― 3 Joint connector ―
JM11 ― 4 Joint connector ―
JM12 ― 3 Joint connector ―
JRE DTB 12 Intermediate connector T-2
KAI DT 2 Revolving warning lamp Z-7
KAI2 DT 2 Revolving warning lamp ―
KOM1 070 18 KOMTRAX Q-2
KOM2 070 12 KOMTRAX Q-2
LKO DT 2 Lever kickout solenoid Q-8
M06 DT 2 Fuel gauge sensor A-3
M-1 Terminal 1 Emergency steering motor 1 H-3
M-2 Terminal 1 Emergency steering motor 2 H-3
MCM1 AMP 80 Monitor controller N-9
MCM2 AMP 40 Monitor controller O-9

HM400-3M0 40-45
40 Troubleshooting
Related information on troubleshooting

Number
Connector No. Connector type Equipment name Address
of pins
MCM3 MX4008 8 Monitor controller O-8
NE FRAMATOME 3 Ne speed sensor AP-5
OPM 070 6 Monitor controls S-2
Air conditioner outside air temperature
OTS 090 2 A-3
sensor
P01 DT 2 Left head lamp Lo (70W) C-1
P01 DT 2 Right head lamp Lo (70W) A-4
P02 DT 3 Right combination lamp A-2
P02 DT 3 Left combination lamp C-1
P03 DT 2 Left head lamp Hi (70W) B-2
P03 DT 2 Right head lamp Hi (70W) A-4
P06 DT 2 Turn lamp D-8
P07 M 2 Left fog lamp C-1
P07 M 2 Right fog lamp A-3
P13 090 2 Left horn valve B-2
P13 090 2 Right horn valve A-2
P20 M 6 Intermediate connector K-8
P21 M 6 Intermediate connector I-8
P22 DT 2 Intermediate connector C-8
P23 DT 2 Intermediate connector F-8
PAMB FRAMATOME 3 Ambient pressure sensor AP-4
PBS SWP 6 P/B manual switch N-3
PCV1 SUMITOMO 2 Supply pump PCV1 AM-2
PCV2 SUMITOMO 2 Supply pump PCV2 AL-2
PFUEL FRAMATOME 3 Common rail pressure sensor AO-3
PHO Terminal 1 Heater relay I-3
PIM CANNON 4 Boost pressure sensor AP-6
PLS SWP 6 Power window switch P-7
POIL FRAMATOME 3 Engine oil pressure sensor AN-2
PPOT DT 2 Piston pump (Lo) oil temperature sensor H-8
PWL MX4008 2 Power window motor (left) X-3
R01 KES1 5 E/G starting relay U-2
R02 KES1 5 TM solenoid relay U-2
R03 KES1 5 Door solenoid relay U-2
R04 KES1 6 Brake lamp relay U-2
R05 KES1 6 Backup lamp/ buzzer relay U-1
R06 KES1 6 Fog lamp relay X-1
R07 KES1 5 Relay for auto preheat V-3
R08 KES1 5 Revolving warning lamp relay X-1
R09 KES1 6 Working lamp relay U-1
R1 Terminal 1 Starting switch terminal R1 N-1
R10 KES1 5 Horn relay V-1
R11 KES1 6 Side lamp relay X-2
R12 KES1 6 Hazard relay 1 W-3
R13 KES1 5 Hazard relay 2 W-3
R14 KES1 5 Head lamp (HI) relay W-3
R15 KES1 5 Passing relay V-1
R16 KES1 5 Head lamp (LO) relay V-1
R17 KES1 5 Auto emergency steering relay 1 V-1
R18 KES1 5 Rear heater relay W-1
R19 KES1 5 Starting motor cut-off relay X-1
R20 KES1 5 P/B safety relay X-2

40-46 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

Number
Connector No. Connector type Equipment name Address
of pins
R21 KES1 6 Auto emergency steering relay 2 X-3
R22 KES1 5 Manual emergency steering relay X-3
R23 KES1 5 P/B interlock relay X-2
R25 YAZAKI 11 Power window relay R-9
RAD YAZAKI-PA 12 Radio Q-2
RE1 08027 2 Terminating resistor R-2
Electrical intake air heater (ribbon
RH Terminal 1 heater) A-3
RL1 08027 2 Room lamp AA-8
RL2 08027 2 Room lamp 2 AA-8
RM1 SWP 6 Brightness adjustment switch M-3
RMN1 070 12 Rear view monitor O-6
RMN2 070 8 Rear view monitor N-6
RTL DT 6 Switch assembly P-2
RWM KES1 2 Washer motor (rear) Z-2
SAC DT 4 Acceleration sensor S-2
SBF1 Terminal 1 Slow-blow fuse K-3
SBF2 Terminal 1 Slow-blow fuse ―
SBP DT 4 Bypass valve lift sensor AL-8
SBS DT 2 Seat belt switch U-2
SDE SWP 6 Side lamp switch Q-8
SEGR DT 4 EGR valve lift sensor AM-8
SF1 DTC 12 Shift lever O-6
SF2 DT 2 Shift lever N-6
SLL M 2 Left side lamp H-8
SLR M 2 Right side lamp E-8
SPARE X 4 Intermediate connector T-9
SPL M 2 Speaker (L.H.) AC-7
SPR M 2 Speaker (R.H.) AB-8
ST1 Terminal 1 Emergency steering switch M-3
ST2 Terminal 1 Emergency steering switch M-3
ST3 Terminal 1 Emergency steering switch N-3
ST4 Terminal 1 Emergency steering switch M-2
ST5 Terminal 1 Emergency steering switch M-3
ST6 Terminal 1 Emergency steering switch M-2
STP DT 3 Stop/tail lamp right J-9
STP DT 3 Stop/tail lamp left J-9
STR Terminal 2 Starting motor A-4
T01 X 2 Coolant level switch reservoir tank B-5
T03 DT 2 T/M oil filter switch F-8
T05 DT 2 Air cleaner clogging sensor A-4
T06 DT 2 Engine oil level D-1
T09 DT 2 T/M differential speed sensor F-2
T11 DT 2 CAC fan pump EPC A-5
T12 DT 2 RAD fan reverse solenoid A-4
T14 DT 2 Radiator fan pump EPC B-5
T17 DT 2 CAC fan reverse solenoid B-5
TC1 X 1 TCS emergency escape switch V-3
TC2 X 1 TCS emergency escape switch V-3
TFUEL PACKARD 2 fuel temperature sensor AP-7
TIM PACKARD 2 Boost temperature sensor AP-6
TSL DT 2 Turn lamp H-8

HM400-3M0 40-47
40 Troubleshooting
Related information on troubleshooting

Number
Connector No. Connector type Equipment name Address
of pins
TWTR PACKARD 2 Coolant temperature sensor AO-8
VH1 DTA 12 Intermediate connector O-3
VH2 DTB 12 Intermediate connector O-3
WFM M 6 Front wiper motor P-2
WFR 08027 6 Front wiper relay R-2
WIN DT 2 Turn signal lamp right I-9
WIN DT 2 Turn signal lamp left K-9
WLF SWP 6 Work lamp switch R-2
WM M 4 Intermediate connector N-5
WPS DTB 12 Switch assembly Q-2
WRM YAZAKI 4 Rear wiper motor M-9

40-48 HM400-3M0
 40 Troubleshooting
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Layout of connectors (1/7)

HM400-3M0 40-49
40 Troubleshooting
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Layout of connectors (2/7)

40-50 HM400-3M0
 40 Troubleshooting
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Layout of connectors (3/7)

HM400-3M0 40-51
40 Troubleshooting
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Layout of connectors (4/7)

40-52 HM400-3M0
 40 Troubleshooting
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Layout of connectors (5/7)

HM400-3M0 40-53
40 Troubleshooting
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Layout of connectors (6/7)

40-54 HM400-3M0
 40 Troubleshooting
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Layout of connectors (7/7)

HM400-3M0 40-55
40 Troubleshooting
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Connector contact identification (HM400_3R-5310-030-A-00-A)

(Rev. 2012. 11.T3)

a The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.

40-56 HM400-3M0
 40 Troubleshooting
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HM400-3M0 40-57
40 Troubleshooting
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40-58 HM400-3M0
 40 Troubleshooting
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HM400-3M0 40-59
40 Troubleshooting
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40-60 HM400-3M0
 40 Troubleshooting
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HM400-3M0 40-61
40 Troubleshooting
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40-62 HM400-3M0
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HM400-3M0 40-63
40 Troubleshooting
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40-64 HM400-3M0
 40 Troubleshooting
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HM400-3M0 40-65
40 Troubleshooting
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40-66 HM400-3M0
 40 Troubleshooting
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HM400-3M0 40-67
40 Troubleshooting
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40-68 HM400-3M0
 40 Troubleshooting
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HM400-3M0 40-69
40 Troubleshooting
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40-70 HM400-3M0
 40 Troubleshooting
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HM400-3M0 40-71
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40-72 HM400-3M0
 40 Troubleshooting
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HM400-3M0 40-73
40 Troubleshooting
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40-74 HM400-3M0
 40 Troubleshooting
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HM400-3M0 40-75
40 Troubleshooting
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40-76 HM400-3M0
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HM400-3M0 40-77
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40-78 HM400-3M0
 40 Troubleshooting
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HM400-3M0 40-79
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40-80 HM400-3M0
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HM400-3M0 40-81
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40-82 HM400-3M0
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HM400-3M0 40-83
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40-84 HM400-3M0
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HM400-3M0 40-85
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40-86 HM400-3M0
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HM400-3M0 40-87
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40-88 HM400-3M0
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HM400-3M0 40-89
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40-90 HM400-3M0
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HM400-3M0 40-91
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T-branch box and T-branch adapter table (ALL-5330-305-A-00-A)

(Rev. 2014. 05)

a The part numbers of the T-boxes and T-adapters are listed in the vertical column, and the part numbers of
harness checker assemblies are listed in the horizontal line.
T-adapter kit

Not included in kit

Number of pins
Identifi-

799-601-2500

799-601-2700

799-601-2800

799-601-7000

799-601-7100

799-601-7400

799-601-7500

799-601-8000

799-601-9000

799-601-9100

799-601-9200

799-601-9300

799-601-4101

799-601-4201
Part No. Part name cation
Symbol

799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14 pins) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3420 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3430 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3440 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3450 Adapter for BENDIX (MS) 5 MS-5P q
799-601-3460 Adapter for BENDIX (MS) 10 MS-10P q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5P q
799-601-3520 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3530 Adapter for BENDIX (MS) 19 MS-19P q
799-601-2910 Adapter for BENDIX (MS) 14 MS-14P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
ECON-
799-601-2750 Adapter for ECONO 2 q q
O2P
ECON-
799-601-2760 Adapter for ECONO 3 q q
O3P
ECON-
799-601-2770 Adapter for ECONO 4 q q
O4P
ECON-
799-601-2780 Adapter for ECONO 8 q q
O8P
ECON-
799-601-2790 Adapter for ECONO 12 q q
O12P
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2820 Adapter for DLI 12 DLI-12P q q
799-601-2830 Adapter for DLI 16 DLI-16P q q
Extension cable (ECONO ECON-
799-601-2840 type) 12 q q q
O12P
799-601-2850 Case q
T-box (for DRC60,
799-601-4350 ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7030 Adapter for X 3 X3P q q q q

40-92 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

T-adapter kit

Not included in kit

Number of pins
Identifi-

799-601-2500

799-601-2700

799-601-2800

799-601-7000

799-601-7100

799-601-7400

799-601-7500

799-601-8000

799-601-9000

799-601-9100

799-601-9200

799-601-9300

799-601-4101

799-601-4201
Part No. Part name cation
Symbol

799-601-7040 Adapter for X 4 X4P q q q q

799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
799-601-7110 Adapter for M 3 M3P q q q q
799-601-7120 Adapter for M 4 M4P q q q q
799-601-7130 Adapter for M 6 M6P q q q q
799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (white) 10 S10P q q q q
799-601-7160 Adapter for S (blue) 12 S12P q q q
799-601-7170 Adapter for S (blue) 16 S16P q q q q
799-601-7330 Adapter for S (white) 16 S16PW q
799-601-7350 Adapter for S (white) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short socket adapter for X 2 q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (gray) 8 DT8GR q q
799-601-9070 Adapter for DT (black) 8 DT8B q q
799-601-9080 Adapter for DT (green) 8 DT8G q q
799-601-9090 Adapter for DT (brown) 8 DT8BR q q
799-601-9110 Adapter for DT (gray) 12 DT12GR q q
799-601-9120 Adapter for DT (black) 12 DT12B q q
799-601-9130 Adapter for DT (green) 12 DT12G q q

HM400-3M0 40-93
40 Troubleshooting
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T-adapter kit

Not included in kit

Number of pins
Identifi-

799-601-2500

799-601-2700

799-601-2800

799-601-7000

799-601-7100

799-601-7400

799-601-7500

799-601-8000

799-601-9000

799-601-9100

799-601-9200

799-601-9300

799-601-4101

799-601-4201
Part No. Part name cation
Symbol

799-601-9140 Adapter for DT (brown) 12 DT12BR q q

799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9220 Adapter for HD30-18 14 D18-14 q q
799-601-9230 Adapter for HD30-18 20 D18-20 q q
799-601-9240 Adapter for HD30-18 21 D18-21 q q
799-601-9250 Adapter for HD30-24 9 D24-9 q q
799-601-9260 Adapter for HD30-24 16 D24-16 q q
799-601-9270 Adapter for HD30-24 21 D24-21 q q
799-601-9280 Adapter for HD30-24 23 D24-23 q q
799-601-9290 Adapter for HD30-24 31 D24-31 q q
799-601-9310 Plate for HD30 (24 pins) q q q
799-601-9320 T-box (for ECONO) 24 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-
T2)
799-601-9420 Adapter PFUEL for engine 3 A3 q q
(CRI-T3)
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* Socket PCV for engine 2 P q q
(CRI-T3)
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* Socket TIM for engine 2 A q q
(CRI-T3)
795-799-5460 Cable for engine (HPI-T2) 3 q
795-799-5470 Cable for engine (HPI-T2) 3 q
795-799-5480 Cable for engine (HPI-T2) 3 q
Adapter PIM for engine
799-601-4110 (140-T3) 4 ITT3N q q
Adapter NE, CAM for
799-601-4130 engine (CRI-T3) 3 FCIN q q
Adapter for engine (CRI-
799-601-4140 T3) 3 FCIG q q
Ambient pressure
Adapter POIL for engine
799-601-4150 (CRI-T3) 3 FCIB q q
Adapter for engine (CRI-
799-601-4160 T3) 2 4160 q q

40-94 HM400-3M0
 40 Troubleshooting
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T-adapter kit

Not included in kit

Number of pins
Identifi-

799-601-2500

799-601-2700

799-601-2800

799-601-7000

799-601-7100

799-601-7400

799-601-7500

799-601-8000

799-601-9000

799-601-9100

799-601-9200

799-601-9300

799-601-4101

799-601-4201
Part No. Part name cation
Symbol

Oil pressure switch

Adapter PEVA for engine
799-601-4180 (CRI-T3) 3 4180 q q
Socket for engine (CRI-T3)
799-601-4190* 3 1, 2, 3 L q q
Common rail pressure
Socket for engine (CRI-T3)
1, 2, 3, 4
799-601-4230* Intake pressure/ 4 q q
C
temperature
Socket PAMB for engine
799-601-4240* 3 1, 2, 3A q q
(CRI-T3)
Socket PIM for engine
799-601-4250* 3 1, 2, 3B q q
(CRI-T3)
Socket G for engine (CRI- 1, 2, 3,
799-601-4330* T3) 3 q q
G
Socket for engine (CRI-T3)
799-601-4340* 2 2, PA q q
Pump actuator
Socket for engine (CRI-T3)
(95) 1, 2, 3,
799-601-4380* 4 q
Intake pressure/ 4T
temperature
Adapter for controller
799-601-4260 (ENG) 4 DTP4 q q
Adapter for controller
799-601-4211 (ENG) 50 DRC50 q
Adapter for controller
799-601-4220 (ENG) 60 DRC60 q
Socket for controller
799-601-4390* (95ENG) 60 q
12-
799-601-4280* Box for controller (PUMP) q
1
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for DT 2 to 4,
799-601-9890 DTM 2 pins 3, q
4
T-adapter for ICT control
799-902-9600 26 q
box
799-902-9700 T-box 26 q
*: These are not T-adapters but sockets.

HM400-3M0 40-95
40 Troubleshooting
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T-adapter kit

Not included in kit

Number of pins

799-A65-4600
Identification

799-902-9300
Part No. Part name
Symbol

799-601-4620 Adapter for controller (ENG-T4) 4 799-601-4620 q

799-601-4630 Adapter for controller (ENG-T4) 2 799-601-4630 q
799-601-4640 Adapter for controller (ENG-T4) 2 799-601-4640 q
799-601-4651 Adapter for controller (ENG-T4) 24 799-601-4651 q
799-601-4660 Adapter for controller (ENG-T4) 3 799-601-4660 q
799-902-9310 Adapter for control box 19 799-902-9310 q
799-902-9320 Adapter for IMU 10 799-902-9320 q
799-902-9330 Adapter for MS cylinder 6 799-902-9330 q
KDPF differential pressure sensor
799T-601-4611 short socket adapter 4 799T-601-4611 q
KDPF outlet pressure sensor short
799T-601-4670 socket adapter 4 799T-601-4670 q
799T-601-4680 KDPF dummy temperature sensor 4 799T-601-4680 q

40-96 HM400-3M0
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Fuse location table (HM400_3R-5530-04D-A-00-A)

Connection table of circuit breaker
• This connection table shows the devices to which each power supply of the circuit breakers supplies
power.
• When performing out troubleshooting related to the electrical system, check the circuit breakers first to see
if the power is supplied properly.
a If the circuit breaker works, the button pops out. If this happens, press in the button and check if the button
pops out again when the starting switch is turned to the "ON" position, engine started, and the machine
operated. If the button pops out again, there may be a ground fault.
a The switched power supply is the power which is supplied (battery relay output) while starting switch is in
ON position. By contrast, the unswitched power supplies power (battery direct output) regardless of the
starting switch position, ON or OFF.
Location and connection table for circuit breakers (30A, 40A, 80A) and slow blow fuses in battery box

Circuit
breaker No. Circuit
Type of power supply breaker Destination of power (pin No.)
(Connector capacity
No.)
1
Unswitched power 40 A Fuse box BT4 (23) *1
(81, 83)
supply
2 Fuse box BT2 all*1
(battery output) 30 A
(82, 84) Fuse box BT4 (27) to (29) *1
3 Fuse box BT1 (1) to (15) *1
80 A
Switched power supply (62, 63) Fuse box BT4 (1) to (7) *1
(battery relay output) 4 Fuse box BT3 all*1
80 A *
(64, 65) Fuse box BT4 (9) to (13) *1
*: 75 A when large capacity alternator is used
Fuse No.
Fuse
Type of power supply (Connector Destination of power
capacity
No.)
Switched power supply 5
120 A To ribbon heater (engine) through heater relay
(battery relay output) (SBF)
6
15 A
(EPF)
Unswitched power 7
supply 15 A Emergency steering
(EMPR)
(battery output)
8
200 A Main power supply for cab tilt
(CTF1)

*1: See the next and subsequent pages for fuse boxes (BT1) to (BT4).

HM400-3M0 40-97
40 Troubleshooting
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Locations of fuse boxes BT1 to BT4 and fuse No.

a Numbers in the circle indicate the corresponding terminal numbers shown in the circuit diagram of
respective failure codes.

40-98 HM400-3M0
 40 Troubleshooting
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• Connection table of fuse box (BT1)

Type of power Circuit Fuse No. Fuse
Destination of power
supply breaker No. Pin No. capacity
1 (1) 15 A Retarder controller
2 (3) 10 A Auto emergency steering
3 (5) -
Switched power 4 (7) 5A Switch panel SW
supply 5 (9) 5A Gearshift lever, personal lock
3 (80 A)
(battery relay 6 (11) 10 A Preheater relay
output) 7 (13) 20 A Air conditioner (blower motor)
8 (15) 10 A Air conditioner (compressor clutch)
9 (17) 10 A Heated mirror (right)
10 (19) 10 A Heated mirror (left)
• Connection table of fuse box (BT2)
Type of power Circuit Fuse No. Fuse
Destination of power
supply breaker No. Pin No. capacity
11 (1) 5A Air conditioner (continuous power supply)
12 (3) 15 A Terminal B
13 (5) 15 A Transmission controller
Retarder controller (continuous power
14 (7) 5A supply)
15 (9) 10 A Monitor controller (continuous power supply)
16 (11) 10 A
Unswitched power 17 (13) 10 A Payload meter
2 (40 A)
supply 18 (15) 10 A Download (continuous power supply)
19 (17) 5A Radio (continuous power supply)
20 (19) 10 A Hazard
21 (21) 5A Room lamp 1
22 (23) 15 A Horn
23 (25) 5A -
24 (27) 5A Rear view monitor (if equipped)
25 (29) 20 A Spare (continuous power supply)
• Connection table of fuse box (BT3)
Type of power Circuit Fuse No. Fuse
Destination of power
supply breaker No. Pin No. capacity
26 (1) 15 A Head lamp Hi
27 (3) 15 A Head lamp Lo
28 (5) 10 A Clearance lamp
29 (7) 10 A Stop lamp
30 (9) 15 A Fog lamp
31 (11) 10 A Radio
Switched power 32 (13) Turn signal
10 A
supply
4 (80 A) 33 (15) 20 A Air suspension seat
(battery relay
output) 34 (17) 15 A Backup lamp/buzzer
35 (19) 10 A Room lamp, door solenoid
36 (21) 15 A Working lamp
37 (23) 15 A Side lamp
38 (25) 20 A
39 (27) 30 A
40 (29) 20 A (Spare)

HM400-3M0 40-99
40 Troubleshooting
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• Connection table of fuse box (BT4)

Type of power Circuit Fuse No. Fuse
Destination of power
supply breaker No. Pin No. capacity
41 (1) 20 A Power window
42 (3) 20 A Front wiper
Switched power 3 (80 A)
43 (5) 10 A Rear wiper
supply
44 (7) 20 A 12 V power supply and cigar lighter
(battery relay
output) 45 (9) 10 A Revolving warning lamp
4 (80 A) 46 (11) 10 A Playload meter external indicator lamp
47 (13) 5A Heated mirror switch
48 (15) 5A Controller
ACC 2 (40 A) 49 (17) 5A Air conditioner (ACC signal)
50(19) 10 A Download (ACC signal)
51 (21) 10 A Parking brake
2 (40 A)
52 (23) 30 A Engine controller
Unswitched power
7 (EMPR) 53 (25) 10 A Manual emergency steering
supply
54 (27) 5A System operating lamp
2 (40 A)
55 (29) 10 A Cab power tilt switch (If equipped)

40-100 HM400-3M0
 40 Troubleshooting
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Precautions on troubleshooting of machine monitor (HM400-Q180-2A4-K-00-A)

• The machine monitor consists of various independent units that send and receive data to/from the monitor
controller through LIN communication (see the next page).
• As the result, troubleshooting of the machine monitor and related units involves complicated procedures
(see E-5 to E-20 of E-mode troubleshooting).
• Each unit related to the machine monitor has many new type of connectors (see Table 1).
• When performing the troubleshooting of the machine monitor LCD unit (see E-6 to E-8 of E-mode
troubleshooting), refer to "Processing procedure of harness checker for troubleshooting of machine
monitor LCD unit".
Table 1. Detail of connectors related to machine monitor
Con- Num- Manu- Connector
Name of unit nector ber of Type code factur- type, etc. Tool New Remarks
name pins er
MX40008U- ―
LCD unit DPC1 8 JAE q
Ma- Q1
chine 070 T-
LED unit DPC2 6 175954-1 AMP adapter q
moni- connector
tor 070 T-
Meter unit DPC3 8 175955-1 AMP adapter q
connector
― MCM1 81 Measuring
Same as
tool is not a T-
those used
adapter, so
TYCO- in pump Box-type
AMP operating
― MCM2 40 1241434 controller of socket
voltage
hydraulic
cannot be
excavators
measured.
See
Monitor controller "Processing
procedure of
harness
― MX40008N- Harness checker for
MCM3 8 JAE q
Q1 checker troubleshoot-
ing of
machine
monitor LCD
unit".
070 T-
― Switch panel OPM 6 175954-1 AMP q
connector adapter
070 T-
― RMN1 12 175957-1 AMP
connector adapter
Rear view monitor
070 T-
― RMN2 8 175955-1 AMP q
connector adapter

HM400-3M0 40-101
40 Troubleshooting
Related information on troubleshooting

Configuration drawing of machine monitor and related units

40-102 HM400-3M0
 40 Troubleshooting
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Processing procedure of harness checker for troubleshooting of

machine monitor LCD unit (HM300-Q000-330-K-00-A)
1. Purpose
This section describes the processing procedure of the monitor harness checker (jig) by using a mass-
produced harness between machine monitor LCD unit and monitor controller.
• The machine monitor receives data from the monitor controller and displays the information on its LCD
unit.
• The monitor harness checker allows you to measure the output voltage from the monitor controller and
determine whether cause of failure is in the monitor controller or not.
• Use the monitor harness checker for troubleshooting of the machine monitor LCD unit. (See E-6 to E-8
of E-mode troubleshooting.)

2. Outline
Mass-produced harness between machine monitor LCD unit and monitor controller: 7831-47-8710
Before being modified

O
After being modified
• Part to be modified is portion P.

HM400-3M0 40-103
40 Troubleshooting
Related information on troubleshooting

• Cut off the wiring harness at the connector (having no crimped portion), install a heat shrink tube to
each cable to prevent short circuit, and then install a check pin to each cable.
Finished harness checker

Fig. 1 Mass-produced harness between machine monitor LCD unit and monitor controller: 7831-47-8710
a Determine the pin number of each check pin by checking the cable color indicated at portion Q in the
figure or by checking the number of pin on the opposite side to which the cable is connected.

40-104 HM400-3M0
 40 Troubleshooting
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3. Preparation
• Materials to be prepared
No. Part name Type Manufacturer Quantity
Japan Aviation
1 Wiring harness 7831-47-8710 1
Electronics Industry
2 Check pin TJ-1-W *1 SATO PARTS 8
Heat shrink tube f5 (Min. 35 mm in Sumitomo Electric
3 SUMI-F2Z-5x0.25 *1 1
length) Industries
Heat shrink tube f5 (Min. 140 mm in Sumitomo Electric
4 SUMI-F2Z-3.5x0.25 *1 1
length) Industries
Labels (with numbers <1> to <8> 1 label each (8
5 printed on them) *2 – –
labels in total)
6 Vinyl tape – – 1
7 Nipper – – 1
8 Wire stripper (for AWG 20-34) – – 1
9 Cutter – – 1
10 Soldering iron – – 1
11 Solder – – 1
12 Dryer *3 – – 1
*1 Can be substituted with an equivalent
*2 They are attached for easy understanding of harness pin number. You may mark numbers on labels.
*3 Can be substituted with a heat gun.
4. Work procedure
• Modification of cables with pin Nos. 3 to 8
1) Use a nipper to cut off the wiring harness at the root of the connector that does not have crimped
portion ((07) in the Fig. 1).

2) Use a wire stripper to remove covers of cables with pin Nos. 3 to 8, 5 mm from the cut end.
a take care not to cut the wire inside the cover.
3) Make six 15-mm heat shrink tubes f3.5 (A).

4) Pass a heat shrink tube (A) over any one of the cut cables, and solder a check pin to the cable.

HM400-3M0 40-105
40 Troubleshooting
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5) Slide heat shrink tube (A) of the cable to which the check pin is soldered in step 4) to a position where
the check pin conductor is covered, and use a dryer to contract heat shrink tube (A).
6) Attach the label so that the pin number of the cable is easily read.
a Determine the pin number of each check pin by checking the cable color indicated at portion Q of
Fig. 1 or by checking the number of pin on the opposite side to which the pin is connected.

7) Repeat steps 4 to 6 for other cables with pin Nos. 3 to 8.

8) Remove tape (B) winding around the conduit to an appropriate position because it is an obstacle for
the work.

• Modification of cables with pin Nos. 1 and 2

1. Strip the cover of shield cable 35 mm in length with your nail.
a take care not to cut the wire inside the cover.
2. Tear off shield cable (C) with your fingers and wind it around the cover.
3. Strip aluminum leaf and yellow thin paper (D) with your nail, and wind it around the cover.

4. Strip the covers of cables with pin Nos. 1 and 2, 5 mm in length by using a wire stripper.
5. Make one 35-mm heat shrink tube f5 (E).
6. Pass the cut heat shrink tube (E) over the cables with pin Nos. 1 and 2.

40-106 HM400-3M0
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7. Make two 25-mm heat shrink tubes f3.5 (F).

8. Pass the cut heat shrink tube (F) over each of the cables with pin Nos. 1 and 2.
9. Solder the check pin to each of the cables with pin Nos. 1 and 2.
10.Slide heat shrink tube (F) to a position where the check pin conductor is covered, and use a dryer to
contract the heat shrink tube.
11.Attach the label so that the pin number of the cable is easily read.
a Determine the pin number of each check pin by checking the cable color indicated at portion Q of Fig. 1
or by checking the number of pin on the opposite side to which the cable is connected.

12.Slide heat shrink tube f5 (E) to a position where it overlaps heat shrink tube f3.5 (F) for cables with pin
Nos. 1 and 2, and then use a dryer to contract heat shrink tube (E).
13.Cut off tape (B) that was stripped from the conduit at an appropriate position, From that position, Wrap
vinyl tape around the cables with pin Nos. 3 to 8 to bind them. This completes the work.

HM400-3M0 40-107
40 Troubleshooting
Related information on troubleshooting

Failure codes table (HM400_3M0-5520-441-A-00-A)

Failure Applicable Action Category of

Failure (Displayed on screen) Remarks
code component level history
Failure code [1500L0] Double Engagement of Mechanical
1500L0 T/M Clutches(PAGE 40-121) T/M L04 system
Failure code [15B0NX] Transmission Oil Filter Mechanical
15B0NX Clogging(PAGE 40-122) T/M L01 system
Failure code [15F0KM] Abuse 1 of Gear Mechanical
15F0KM T/M —
Shifting from R to F(PAGE 40-123) system
Failure code [15F0MB] Abuse 2 of Gear Mechanical
15F0MB T/M —
Shifting from R to F(PAGE 40-124) system
Failure code [15F7KM] Abuse of TM Forward Mechanical
15F7KM T/M —
Clutch Disk(PAGE 40-125) system
Failure code [15G0MW] Failure of Clutch Electrical
15G0MW (Reverse)(PAGE 40-126) T/M L03 system
Failure code [15G7KM] Abuse of TM Reverse Mechanical
15G7KM T/M —
Clutch Disk(PAGE 40-129) system
Failure code [15H0MW] Failure of Clutch Electrical
15H0MW (High)(PAGE 40-130) T/M L03 system
Failure code [15J0MW] Failure of Clutch (Low) Electrical
15J0MW (PAGE 40-133) T/M L03 system
Failure code [15K0MW] Failure of Clutch (1st) Electrical
15K0MW (PAGE 40-136) T/M L03 system
Failure code [15L0MW] Failure of Clutch (2nd) Electrical
15L0MW (PAGE 40-139) T/M L03 system
Failure code [15M0MW] Failure of Clutch (3rd) Electrical
15M0MW (PAGE 40-142) T/M L03 system
Failure code [15SBL1] Release Trouble of Electrical
15SBL1 ECMV (Reverse)(PAGE 40-145) T/M L03 system
Failure code [15SBMA] Malfunction of ECMV Electrical
15SBMA (Reverse)(PAGE 40-148) T/M L03 system
Failure code [15SCL1] Release Trouble of Electrical
15SCL1 ECMV (High)(PAGE 40-149) T/M L03 system
Failure code [15SCMA] Malfunction of ECMV Electrical
15SCMA (High)(PAGE 40-152) T/M L03 system
Failure code [15SDL1] Release Trouble of Electrical
15SDL1 ECMV (Low)(PAGE 40-153) T/M L03 system
Failure code [15SDMA] Malfunction of ECMV Electrical
15SDMA (Low)(PAGE 40-156) T/M L03 system
Failure code [15SEL1] Release Trouble of Electrical
15SEL1 ECMV (1st)(PAGE 40-157) T/M L03 system
Failure code [15SEMA] Malfunction of ECMV Electrical
15SEMA (1st)(PAGE 40-160) T/M L03 system
Failure code [15SFL1] Release Trouble of Electrical
15SFL1 ECMV (2nd)(PAGE 40-161) T/M L03 system
Failure code [15SFMA] Malfunction of ECMV Electrical
15SFMA (2nd)(PAGE 40-164) T/M L03 system
Failure code [15SGL1] Release Trouble of Electrical
15SGL1 ECMV (3rd)(PAGE 40-165) T/M L03 system
Failure code [15SGMA] Malfunction of ECMV Electrical
15SGMA (3rd)(PAGE 40-168) T/M L03 system
Failure code [15SJMA] Malfunction of ECMV Electrical
15SJMA (Lockup)(PAGE 40-169) T/M L03 system
Failure code [15SKMA] Malfunction of ECMV Electrical
15SKMA (Inter-Axle Diff.)(PAGE 40-171) T/M L01 system
Failure code [2F00KM] Dragging of Parking Mechanical
2F00KM T/M —
Brake(PAGE 40-173) system

40-108 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

Failure Applicable Action Category of

Failure (Displayed on screen) Remarks
code component level history
Failure code [2G42ZG] Accumulator Oil Mechanical
2G42ZG Pressure Low (Front)(PAGE 40-175) RHC L03 system
Failure code [2G43ZG] Accumulator Oil Mechanical
2G43ZG Pressure Low (Rear)(PAGE 40-176) RHC L03 system
Failure code [879AKA] A/C Inner Sensor Open Electrical See Chapter
879AKA Circuit(PAGE 40-177) MON — 80, Other
system
items
Failure code [879AKB] A/C Inner Sensor Short Electrical See Chapter
879AKB Circuit(PAGE 40-178) MON — 80, Other
system
items
Failure code [879BKA] A/C Outer Sensor Electrical See Chapter
879BKA Open Circuit(PAGE 40-179) MON L01 system 80, Other
items
Failure code [879BKB] A/C Outer Sensor Electrical See Chapter
879BKB Short Circuit(PAGE 40-180) MON L01 system 80, Other
items
Failure code [879CKA] Ventilating Sensor Electrical See Chapter
879CKA Open Circuit(PAGE 40-181) MON — 80, Other
system
items
Failure code [879CKB] Ventilating Sensor Electrical See Chapter
879CKB Short Circuit(PAGE 40-182) MON — 80, Other
system
items
Failure code [879EMC] Ventilation Damper Electrical See Chapter
879EMC Abnormality(PAGE 40-183) MON L01 system 80, Other
items
Failure code [879FMC] Air Mix Damper Electrical See Chapter
879FMC Abnormality(PAGE 40-184) MON L01 system 80, Other
items
Failure code [879GKX] Refrigerant Electrical See Chapter
879GKX Abnormality(PAGE 40-185) MON L01 system 80, Other
items
Failure code [989D00] Tilt Caution(PAGE 40- Mechanical
989D00 186) RHC —
system
Failure code [989L00] Engine Controller Lock Electrical
989L00 Caution1(PAGE 40-187) MON —
system
Failure code [989M00] Engine Controller Lock Electrical
989M00 Caution2(PAGE 40-188) MON —
system
Failure code [989N00] Engine Controller Lock Electrical
989N00 Caution3(PAGE 40-189) MON —
system
Failure code [AA10NX] Air Cleaner Clogging Mechanical
AA10NX (PAGE 40-190) T/M L01 system
Failure code [AB00KE] Charge Voltage Low Electrical
AB00KE (PAGE 40-192) T/M L03 system
Failure code [AB00KY] Hot Short of Alternator Electrical
AB00KY R Terminal(PAGE 40-193) T/M L03 system
Failure code [B@BAZG] Eng Oil Press Low Mechanical
B@BAZG ENG L03
(PAGE 40-194) system
Failure code [B@BAZK] Engine Oil Level Low Mechanical
B@BAZK T/M L01
(PAGE 40-195) system
Failure code [B@BCNS] Eng Water Overheat Mechanical
B@BCNS ENG L02
(PAGE 40-196) system
Failure code [B@BCZK] Eng Water Level Low Mechanical
B@BCZK T/M L01
(PAGE 40-197) system
Failure code [B@C6NS] Retarder Oil Mechanical
B@C6NS MON L02
Overheat (Front)(PAGE 40-199) system
Failure code [B@C8NS] Retarder Oil Mechanical
B@C8NS MON L02
Overheat (Center)(PAGE 40-200) system

HM400-3M0 40-109
40 Troubleshooting
Related information on troubleshooting

Failure Applicable Action Category of

Failure (Displayed on screen) Remarks
code component level history
Failure code [B@CENS] T/C Oil Temp. Mechanical
B@CENS MON L02
Overheat(PAGE 40-201) system
Failure code [B@JANS] Steering Oil Overheat Mechanical
B@JANS RHC L02
(PAGE 40-202) system
Failure code [CA111] ECM Critical Internal Electrical
CA111 Failure(PAGE 40-203) ENG L04 system
Failure code [CA115] Eng Ne and Bkup Speed Electrical
CA115 Sens Error(PAGE 40-204) ENG L04 system
Failure code [CA122] Chg Air Press Sensor Electrical
CA122 High Error(PAGE 40-205) ENG L03 system
Failure code [CA123] Chg Air Press Sensor Electrical
CA123 Low Error(PAGE 40-207) ENG L03 system
Failure code [CA131] Throttle Sensor High Electrical
CA131 Error(PAGE 40-209) ENG L03 system
Failure code [CA132] Throttle Sensor Low Electrical
CA132 Error(PAGE 40-211) ENG L03 system
Failure code [CA135] Eng Oil Press Sensor Electrical
CA135 High Error(PAGE 40-213) ENG L01 system
Failure code [CA141] Eng Oil Press Sensor Electrical
CA141 Low Error(PAGE 40-215) ENG L01 system
Failure code [CA144] Coolant Temp Sens High Electrical
CA144 Error(PAGE 40-217) ENG L01 system
Failure code [CA145] Coolant Temp Sens Low Electrical
CA145 Error(PAGE 40-219) ENG L01 system
Failure code [CA153] Chg Air Temp Sensor Electrical
CA153 High Error(PAGE 40-221) ENG L01 system
Failure code [CA154] Chg Air Temp Sensor Electrical
CA154 Low Error(PAGE 40-223) ENG L01 system
Failure code [CA187] Sensor 2 Supply Volt Electrical
CA187 Low Error(PAGE 40-225) ENG L03 system
Failure code [CA221] Ambient Press Sensor Electrical
CA221 High Error(PAGE 40-227) ENG L01 system
Failure code [CA222] Ambient Press Sens Electrical
CA222 Low Error(PAGE 40-229) ENG L01 system
Failure code [CA227] Sensor 2 Supply Volt Electrical
CA227 High Error(PAGE 40-231) ENG L03 system
Failure code [CA234] Eng Overspeed(PAGE Mechanical
CA234 40-232) ENG L02 system
Failure code [CA238] Ne Speed Sensor Electrical
CA238 Supply Volt Error(PAGE 40-233) ENG L01 system
Failure code [CA263] Fuel Temp Sensor High Electrical
CA263 Error(PAGE 40-234) ENG L01 system
Failure code [CA265] Fuel Temp Sensor Low Electrical
CA265 Error(PAGE 40-236) ENG L01 system
Failure code [CA271] IMV/PCV1 Short Error Electrical
CA271 (PAGE 40-238) ENG L03 system
Failure code [CA272] IMV/PCV1 Open Error Electrical
CA272 (PAGE 40-239) ENG L03 system
Failure code [CA273] PCV2 Short Error(PAGE Electrical
CA273 40-240) ENG L03 system
Failure code [CA274] PCV2 Open Error(PAGE Electrical
CA274 40-241) ENG L03 system
Failure code [CA322] Inj #1(L#1) Open/Short Electrical
CA322 Error(PAGE 40-242) ENG L03 system
Failure code [CA323] Inj #5(L#5) Open/Short Electrical
CA323 Error(PAGE 40-244) ENG L03 system

40-110 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

Failure Applicable Action Category of

Failure (Displayed on screen) Remarks
code component level history
Failure code [CA324] Inj #3(L#3) Open/Short Electrical
CA324 Error(PAGE 40-246) ENG L03 system
Failure code [CA325] Inj #6(L#6) Open/Short Electrical
CA325 Error(PAGE 40-248) ENG L03 system
Failure code [CA331] Inj #2(L#2) Open/Short Electrical
CA331 Error(PAGE 40-250) ENG L03 system
Failure code [CA332] Inj #4(L#4) Open/Short Electrical
CA332 Error(PAGE 40-252) ENG L03 system
Failure code [CA342] Calibration Code Electrical
CA342 Incompatibility(PAGE 40-254) ENG L04 system
Failure code [CA351] Injectors Drive Circuit Electrical
CA351 Error(PAGE 40-255) ENG L03 system
Failure code [CA352] Sensor 1 Supply Volt Electrical
CA352 Low Error(PAGE 40-256) ENG L03 system
Failure code [CA386] Sensor 1 Supply Volt Electrical
CA386 High Error(PAGE 40-258) ENG L03 system
Failure code [CA431] Idle Validation Sw Error Electrical
CA431 (PAGE 40-259) ENG L01 system
Failure code [CA432] Idle Validation Process Electrical
CA432 Error(PAGE 40-262) ENG L03 system
Failure code [CA441] Battery Voltage Low Electrical
CA441 Error(PAGE 40-265) ENG L04 system
Failure code [CA442] Battery Voltage High Electrical
CA442 Error(PAGE 40-267) ENG L04 system
Failure code [CA449] Rail Press Very High Electrical
CA449 Error(PAGE 40-268) ENG L03 system
Failure code [CA451] Rail Press Sensor High Electrical
CA451 Error(PAGE 40-269) ENG L03 system
Failure code [CA452] Rail Press Sensor Low Electrical
CA452 Error(PAGE 40-271) ENG L03 system
Failure code [CA553] Rail Press High Error Electrical
CA553 (PAGE 40-273) ENG L01 system
Failure code [CA554] Rail Press Sensor In Electrical
CA554 Range Error(PAGE 40-274) ENG L03 system
Failure code [CA559] Rail Press Low Error Electrical
CA559 (PAGE 40-275) ENG L01 system
Failure code [CA689] Eng Ne Speed Sensor Electrical
CA689 Error(PAGE 40-279) ENG L01 system
Failure code [CA731] Eng Bkup Speed Sens Electrical
CA731 Phase Error(PAGE 40-281) ENG L01 system
Failure code [CA757] All Continuous Data Lost Electrical
CA757 Error(PAGE 40-282) ENG L04 system
Failure code [CA778] Eng Bkup Speed Sensor Electrical
CA778 Error(PAGE 40-283) ENG L01 system
Failure code [CA1228] EGR valve servo error Electrical
CA1228 1(PAGE 40-285) ENG L01 system
Failure code [CA1625] EGR Valve Servo Error Electrical
CA1625 2(PAGE 40-286) ENG L03 system
Failure code [CA1626] Bypass Valve Solenoid Electrical
CA1626 Current High Error(PAGE 40-287) ENG L03 system
Failure code [CA1627] Bypass Valve Solenoid Electrical
CA1627 Current Low Error(PAGE 40-289) ENG L03 system
Failure code [CA1628] Bypass Valve Servo Electrical
CA1628 Error 1(PAGE 40-291) ENG L03 system
Failure code [CA1629] Bypass Valve Servo Electrical
CA1629 Error 2(PAGE 40-292) ENG L03 system

HM400-3M0 40-111
40 Troubleshooting
Related information on troubleshooting

Failure Applicable Action Category of

Failure (Displayed on screen) Remarks
code component level history
Failure code [CA1631] BP valve Lift Position Electrical
CA1631 Sensor High Error(PAGE 40-293) ENG L03 system
Failure code [CA1632] BP valve Lift Position Electrical
CA1632 Sensor Low Error(PAGE 40-295) ENG L03 system
Failure code [CA2185] Throt Sensor Sup Volt Electrical
CA2185 High Error(PAGE 40-297) ENG L03 system
Failure code [CA2186] Throt Sensor Sup Volt Electrical
CA2186 Low Error(PAGE 40-299) ENG L03 system
Failure code [CA2249] Rail Press Very Low Electrical
CA2249 Error(PAGE 40-301) ENG L03 system
Failure code [CA2271] EGR Valve Pos Sens Electrical
CA2271 High Error(PAGE 40-302) ENG L03 system
Failure code [CA2272] EGR Valve Pos Sens Electrical
CA2272 Low Error(PAGE 40-304) ENG L03 system
Failure code [CA2351] EGR Valve Solenoid Electrical
CA2351 Short Error(PAGE 40-306) ENG L03 system
Failure code [CA2352] EGR Valve Solenoid Electrical
CA2352 Open Error(PAGE 40-308) ENG L03 system
Failure code [CA2555] Grid Htr Relay Volt Low Electrical
CA2555 Error(PAGE 40-310) ENG L01 system
Failure code [CA2556] Grid Htr Relay Volt Electrical
CA2556 High Error(PAGE 40-312) ENG L01 system
Failure code [D150KB] Ground Fault of Electrical
D150KB Emerg. Steering Relay(PAGE 40-314) RHC L03 system
Failure code [D150KZ] Failure of Emerg. Electrical
D150KZ Steering Relay(PAGE 40-315) RHC L03 system
Failure code [D151KB] Ground Fault of Electrical
D151KB Emerg. Steering Relay 2(PAGE 40-316) RHC L03 system
Failure code [D151KZ] Failure of Emerg. Electrical
D151KZ Steering Relay 2(PAGE 40-317) RHC L03 system
Failure code [D164KY] Hot Short of Head Electrical
D164KY Light High Selector(PAGE 40-318) MON L01 system
Failure code [D19HKZ] Failure of Stop Lamp Electrical
D19HKZ (R&L)(PAGE 40-319) RHC L01 system
Failure code [D19JKZ] Personal Code Relay Electrical
D19JKZ Abnormality(PAGE 40-321) MON L03 system
Failure code [D1EHKA] Disconnection of Electrical
D1EHKA Engine Start Relay(PAGE 40-322) T/M L03 system
Failure code [D1EHKB] Ground Fault of Electrical
D1EHKB Engine Start Relay(PAGE 40-323) T/M L03 system
Failure code [D1EHKY] Hot Short of Engine Electrical
D1EHKY Start Relay(PAGE 40-324) T/M L03 system
Failure code [D1EMKA] Disconnection of Electrical
D1EMKA Parking Interlock Relay(PAGE 40-325) RHC L03 system
Failure code [D1EMKB] Ground Fault of Electrical
D1EMKB Parking Interlock Relay(PAGE 40-326) RHC L03 system
Failure code [D1EMKY] Hot Short of Parking Electrical
D1EMKY Interlock Relay(PAGE 40-327) RHC L03 system
Failure code [D1FBKB] Ground Fault of Sol. Electrical
D1FBKB Self-Holding Relay(PAGE 40-328) T/M L03 system
Failure code [D5ZHL6] Disconnection of Key Electrical
D5ZHL6 SW C(PAGE 40-329) MON L01 system
Failure code [D811MC] KOMTRAX Error Mechanical
D811MC (PAGE 40-331) KOMTRAX —
system
Failure code [D862KA] GPS Antenna Open Mechanical
D862KA Circuit(PAGE 40-332) KOMTRAX —
system

40-112 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

Failure Applicable Action Category of

Failure (Displayed on screen) Remarks
code component level history
Failure code [D8ALKA] Operating Lamp Open Mechanical
D8ALKA Circuit (KOMTRAX)(PAGE 40-333) KOMTRAX —
system
Failure code [D8ALKB] Operating Lamp Short Mechanical
D8ALKB Circuit (KOMTRAX)(PAGE 40-335) KOMTRAX —
system
Failure code [D8AQK4] CAN2 Discon Electrical
D8AQK4 (KOMTRAX) 2(PAGE 40-337) MON L03 system
Failure code [D8AQKR] CAN2 Discon Electrical
D8AQKR (KOMTRAX)(PAGE 40-338) MON —
system
Failure code [DAF0KT] Abnormality of Non- Electrical
DAF0KT volatile Memory (MON)(PAGE 40-339) MON L03 system
Failure code [DAF0MB] Monitor ROM Electrical
DAF0MB Abnormality(PAGE 40-340) MON —
system
Failure code [DAF0MC] Monitor Error(PAGE Electrical
DAF0MC 40-341) MON —
system
Failure code [DAF3KK] Controller Power Electrical
DAF3KK Source Low (MON)(PAGE 40-342) MON —
system
Failure code [DAF8KB] Camera Power Supply Electrical
DAF8KB Short Circuit(PAGE 40-344) MON L03 system
Failure code [DAFDKB] Monitor 12V Power Electrical
DAFDKB Output Short Circuit(PAGE 40-345) MON L01 system
Failure code [DAFGMC] GPS Module Error Mechanical
DAFGMC (PAGE 40-347) KOMTRAX —
system
Failure code [DAFLKA] Operating Lamp Open Electrical
DAFLKA Circuit (MON)(PAGE 40-348) MON —
system
Failure code [DAFLKB] Operating Lamp Short Electrical
DAFLKB Circuit (MON)(PAGE 40-350) MON —
system
Failure code [DAFQKR] CAN2 Discon Mechanical
DAFQKR (Monitor)(PAGE 40-352) KOMTRAX —
system
Failure code [DAQ0KK] Controller Power Electrical
DAQ0KK Source Low (T/M)(PAGE 40-353) T/M L03 system
Failure code [DAQ0KT] Abnormality of Non- Electrical
DAQ0KT volatile Memory (T/M)(PAGE 40-355) T/M L01 system
Failure code [DAQ0MC] T/M Con Error(PAGE Mechanical
DAQ0MC 40-356) T/M —
system
Failure code [DAQ1KA] Disconnection of Key Electrical
DAQ1KA SW ACC (T/M)(PAGE 40-357) T/M L03 system
Failure code [DAQ2KK] Solenoid Power Electrical
DAQ2KK Source Low (T/M)(PAGE 40-359) T/M L03 system
Failure code [DAQ9KQ] Inconsistency of Electrical
DAQ9KQ Model Selection (T/M)(PAGE 40-361) T/M L03 system
Failure code [DAQLKA] Operating Lamp Open Electrical
DAQLKA Circuit (T/M)(PAGE 40-362) T/M —
system
Failure code [DAQLKB] Operating Lamp Short Electrical
DAQLKB Circuit (T/M)(PAGE 40-364) T/M —
system
Failure code [DAQQKR] CAN2 Discon Electrical
DAQQKR (Transmission Con)(PAGE 40-366) MON L03 system
Failure code [DAQRKR] CAN1 Discon Electrical
DAQRKR (Transmission Con)(PAGE 40-367) MON L03 system
Failure code [DAQRMA] Inconsistency of Electrical
DAQRMA Option Selection (T/M)(PAGE 40-371) T/M —
system
Failure code [DAQV00] Neutral Coast Caution
DAQV00 (PAGE 40-372) T/M T/M T/M

HM400-3M0 40-113
40 Troubleshooting
Related information on troubleshooting

Failure Applicable Action Category of

Failure (Displayed on screen) Remarks
code component level history

Failure code [DAQW00] Neutral Over Speed Mechanical

DAQW00 Caution(PAGE 40-373) T/M —
system

Failure code [DAZ9KQ] A/C Model Selection Electrical

DAZ9KQ Abnormality(PAGE 40-374) MON L01 system
Failure code [DAZQKR] CAN2 Discon (Aircon Electrical
DAZQKR ECU)(PAGE 40-375) MON L01 system
Failure code [DB10KT] Abnormality of Non- Electrical
DB10KT volatile Memory (RHC)(PAGE 40-376) RHC L01 system
Failure code [DB10MC] RHC Error(PAGE 40- Mechanical
DB10MC 377) RHC —
system
Failure code [DB11KA] Disconnection of Key Electrical
DB11KA SW ACC (RHC)(PAGE 40-378) RHC L03 system
Failure code [DB12KK] Solenoid Power Electrical
DB12KK Source Low (RHC)(PAGE 40-380) RHC L03 system
Failure code [DB13KK] Controller Power Electrical
DB13KK Source Low (RHC)(PAGE 40-382) RHC L03 system
Failure code [DB19KQ] Inconsistency of Electrical
DB19KQ Model Selection (RHC)(PAGE 40-384) RHC L03 system
Failure code [DB1LKA] Disconnection of Electrical
DB1LKA System Ope. Lamp (RHC)(PAGE 40-385) RHC —
system
Failure code [DB1LKB] Short Circuit of System Electrical
DB1LKB Ope. Lamp (RHC)(PAGE 40-387) RHC —
system
Failure code [DB1QKR] CAN2 Discon Electrical
DB1QKR (Retarder Hoist Con)(PAGE 40-389) MON L03 system
Failure code [DB1QMA] Inconsistency of Electrical
DB1QMA Option Selection (RHC)(PAGE 40-390) RHC L03 system
Failure code [DB1RKR] CAN1 Discon Electrical
DB1RKR (Retarder Hoist Con)(PAGE 40-391) MON L03 system
Failure code [DB2QKR] CAN2 Discon (Engine Electrical
DB2QKR Con)(PAGE 40-392) MON L03 system
Failure code [DBSQKQ] Inconsistency of Electrical
DBSQKQ Model Selection (PLM)(PAGE 40-401) PLM L01 system
Failure code [DBSQKR] CAN2 Discon (PLM) Electrical
DBSQKR (PAGE 40-397) MON L01 system
Failure code [DD1ML4] Failure of ARAC SW Electrical
DD1ML4 (PAGE 40-402) T/M L01 system
Failure code [DDAAL6] Discon of Engine Electrical
DDAAL6 Shutdown Secondary Switch(PAGE 40-404) MON L03 system
Failure code [DDTHKA] Disconnection of Fill Electrical
DDTHKA Switch (High)(PAGE 40-406) T/M L03 system
Failure code [DDTJKA] Disconnection of Fill Electrical
DDTJKA Switch (Low)(PAGE 40-408) T/M L03 system
Failure code [DDTKKA] Disconnection of Fill Electrical
DDTKKA Switch (1st)(PAGE 40-410) T/M L03 system
Failure code [DDTLKA] Disconnection of Fill Electrical
DDTLKA Switch (2nd)(PAGE 40-412) T/M L03 system
Failure code [DDTMKA] Disconnection of Fill Electrical
DDTMKA Switch (3rd)(PAGE 40-414) T/M L03 system
Failure code [DDTNKA] Disconnection of Fill Electrical
DDTNKA Switch (Reverse)(PAGE 40-416) T/M L03 system
Failure code [DF10KA] Disconnection of Shift Electrical
DF10KA Lever Input(PAGE 40-418) T/M L03 system
Failure code [DF10KB] Ground Fault of Shift Electrical
DF10KB Lever Input(PAGE 40-421) T/M L03 system

40-114 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

Failure Applicable Action Category of

Failure (Displayed on screen) Remarks
code component level history
Failure code [DGF1KX] Out of Range of T/M Electrical
DGF1KX Oil Temp. Sensor(PAGE 40-425) T/M L03 system
Failure code [DGR3KB] Ground Fault of Electrical
DGR3KB Retarder Oil Temp. S.(C)(PAGE 40-427) RHC L01 system
Failure code [DGR3L8] Failure of Retarder Oil Electrical
DGR3L8 Temp. Sensor (C)(PAGE 40-428) RHC L01 system
Failure code [DGR4KB] Ground Fault of Electrical
DGR4KB Retarder Oil Temp. S.(F)(PAGE 40-429) RHC L01 system
Failure code [DGR4L8] Failure of Retarder Oil Electrical
DGR4L8 Temp. Sensor (F)(PAGE 40-430) RHC L01 system
Failure code [DGR6KB] Ground Fault of Electrical
DGR6KB Steering Oil Temp. S.(PAGE 40-432) RHC L01 system
Failure code [DGR6L8] Failure of Steering Oil Electrical
DGR6L8 Temp. Sensor(PAGE 40-433) RHC L01 system
Failure code [DGR7KX] Out of Range of Electrical
DGR7KX Piston Pump Oil Temp. S.(PAGE 40-435) T/M L01 system
Failure code [DGR8KX] Out of Range of CAC Electrical
DGR8KX Output Temp. S.(PAGE 40-437) T/M L01 system
Failure code [DGT1KX] Out of Range of T/C Electrical
DGT1KX Oil Temp. Sensor(PAGE 40-439) T/M L01 system
Failure code [DHP4KY] Hot Short of Electrical
DHP4KY Suspension Press. S. (FR)(PAGE 40-441) PLM L01 system
Failure code [DHP4KZ] Failure of Suspension Electrical
DHP4KZ Press. S. (FR)(PAGE 40-443) PLM L01 system
Failure code [DHP5KY] Hot Short of Electrical
DHP5KY Suspension Press. S. (FL)(PAGE 40-445) PLM L01 system
Failure code [DHP5KZ] Failure of Suspension Electrical
DHP5KZ Press. S. (FL)(PAGE 40-447) PLM L01 system
Failure code [DHP6KY] Hot Short of Electrical
DHP6KY Suspension Press. S. (RR)(PAGE 40-449) PLM L01 system
Failure code [DHP6KZ] Failure of Suspension Electrical
DHP6KZ Press. S. (RR)(PAGE 40-451) PLM L01 system
Failure code [DHP7KY] Hot Short of Electrical
DHP7KY Suspension Press. S. (RL)(PAGE 40-453) PLM L01 system
Failure code [DHP7KZ] Failure of Suspension Electrical
DHP7KZ Press. S. (RL)(PAGE 40-455) PLM L01 system
Failure code [DHQ2KX] Out of Range of Main Electrical
DHQ2KX Flow Sel. Valve S.(PAGE 40-457) T/M L01 system
Failure code [DHT5KX] Out of Range of T/C Electrical
DHT5KX Input Pressure Sensor(PAGE 40-459) T/M L01 system
Failure code [DHT5L6] Failure of T/C Oil Press Electrical
DHT5L6 Sensor(PAGE 40-461) T/M L01 system
Failure code [DHT8KX] Out of Range of Electrical
DHT8KX Steering Oil Press. S.(PAGE 40-463) RHC L01 system
Failure code [DHT8ZG] Steering Oil Pressure Mechanical
DHT8ZG Low(PAGE 40-465) RHC L03 system
Failure code [DHU2KX] Out of Range of Acc. Electrical
DHU2KX Oil Press. S. (F)(PAGE 40-466) RHC L01 system
Failure code [DHU3KX] Out of Range of Acc. Electrical
DHU3KX Oil Press. S. (R)(PAGE 40-468) RHC L01 system
Failure code [DHUAKX] Out of Range of Electrical
DHUAKX Retarder Press. S. (CR)(PAGE 40-470) RHC L01 system
Failure code [DHUBKX] Out of Range of Electrical
DHUBKX Retarder Press. S. (FR)(PAGE 40-472) RHC L01 system
Failure code [DHUCKX] Out of Range of Electrical
DHUCKX Parking Brake Press. S.(PAGE 40-474) RHC L01 system

HM400-3M0 40-115
40 Troubleshooting
Related information on troubleshooting

Failure Applicable Action Category of

Failure (Displayed on screen) Remarks
code component level history
Failure code [DHUDKX] Out of Range of Electrical
DHUDKX Emerg. Steering Press. S.1(PAGE 40-476) RHC L01 system
Failure code [DHUEKX] Out of Range of Electrical
DHUEKX Emerg. Steering Press. S.2(PAGE 40-478) RHC L01 system
Failure code [DHUQKX] Out of Range of Electrical
DHUQKX Retarder Press. S. (FL)(PAGE 40-480) RHC L01 system
Failure code [DHURKX] Out of Range of Electrical
DHURKX Retarder Press. S. (CL)(PAGE 40-482) RHC L01 system
Failure code [DJF1KA] Disconnection of Fuel Electrical
DJF1KA Level Sensor(PAGE 40-484) MON L01 system
Failure code [DK30KX] Out of Range of Electrical
DK30KX Steering Angle Pot.(PAGE 40-486) RHC L01 system
Failure code [DK51L5] Failure of Retarder Electrical
DK51L5 Lever Pot. and RVS(PAGE 40-488) RHC L03 system
Failure code [DK52KX] Out of Range of Hoist Electrical
DK52KX Lever Potentio.(PAGE 40-491) RHC L03 system
Failure code [DK53L8] Failure of Hoist Lever Electrical
DK53L8 Potentio.(PAGE 40-493) RHC L03 system
Failure code [DK54KX] Out of Range of Body Electrical
DK54KX Potentio.(PAGE 40-494) RHC L03 system
Failure code [DK60KX] Out of Range of Electrical
DK60KX Acceleration Sensor(PAGE 40-496) RHC L01 system
Failure code [DKH0KX] Out of Range of Electrical
DKH0KX Inclination Angle Sensor(PAGE 40-498) RHC L01 system
Failure code [DKH1KX] Out of Range of Long. Electrical
DKH1KX Inclination Angle S.(PAGE 40-500) PLM L01 system
Failure code [DLF1KA] Disconnection of T/M Electrical
DLF1KA Input Speed Sensor(PAGE 40-502) T/M L03 system
Failure code [DLF1LC] Failure of T/M Input Electrical
DLF1LC Speed Sensor(PAGE 40-504) T/M L03 system
Failure code [DLF2KA] Disconnection of T/M Electrical
DLF2KA Inter. Speed Sensor(PAGE 40-506) T/M L03 system
Failure code [DLF2LC] Failure of T/M Electrical
DLF2LC Intermediate Speed Sensor(PAGE 40-508) T/M L03 system
Failure code [DLF400] T/M Diff. Overrun Electrical
DLF400 Prevention Activated(PAGE 40-510) T/M L01 system
Failure code [DLF4KA] Disconnection of T/M Electrical
DLF4KA Diff. Speed Sensor(PAGE 40-511) T/M L01 system
Failure code [DLF4LC] Failure of T/M Diff. Electrical
DLF4LC Speed Sensor(PAGE 40-513) RHC L01 system
Failure code [DLF6LC] Failure of Wheel Electrical
DLF6LC Speed Sensor (FR)(PAGE 40-515) RHC L01 system
Failure code [DLF7LC] Failure of Wheel Electrical
DLF7LC Speed Sensor (FL)(PAGE 40-517) RHC L01 system
Failure code [DLFDLC] Failure of Wheel Electrical
DLFDLC Speed Sensor (CR)(PAGE 40-519) RHC L01 system
Failure code [DLFELC] Failure of Wheel Electrical
DLFELC Speed Sensor (CL)(PAGE 40-521) RHC L01 system
Failure code [DLFFLC] Failure of Wheel Electrical
DLFFLC Speed Sensor (Front)(PAGE 40-523) RHC L01 system
Failure code [DLFGLC] Failure of Wheel Electrical
DLFGLC Speed Sensor (Center)(PAGE 40-524) RHC L01 system
Failure code [DLM3KA] Disconnection of Electrical
DLM3KA Radiator Fan Speed Sensor(PAGE 40-525) RHC L01 system
Failure code [DLM3LC] Failure of Radiator Electrical
DLM3LC Fan Speed Sensor(PAGE 40-527) T/M L01 system

40-116 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

Failure Applicable Action Category of

Failure (Displayed on screen) Remarks
code component level history
Failure code [DLM3MB] Radiator Fan Control Electrical
DLM3MB Mismatch(PAGE 40-529) T/M L01 system
Failure code [DLM4KA] Disconnection of CAC Electrical
DLM4KA Fan Speed Sensor(PAGE 40-530) RHC L01 system
Failure code [DLM4LC] Failure of CAC Fan Electrical
DLM4LC Speed Sensor(PAGE 40-532) T/M L01 system
Failure code [DLM4MB] CAC Fan Control Electrical
DLM4MB Mismatch(PAGE 40-534) T/M L01 system
Failure code [DLT3KA] Disconnection of Electrical
DLT3KA Output Speed Sens. (Main)(PAGE 40-535) T/M L03 system
Failure code [DLT3LC] Failure of Output Electrical
DLT3LC Speed Sensor (Main)(PAGE 40-537) RHC L01 system
Failure code [DPQ1KR] LIN Discon (Switch Electrical
DPQ1KR Panel)(PAGE 40-539) MON L01 system
Failure code [DPQ2KR] LIN Discon (LED Unit) Electrical
DPQ2KR (PAGE 40-542) MON L01 system
Failure code [DPQ3KR] LIN Discon (Rear Electrical
DPQ3KR View Monitor)(PAGE 40-545) MON L01 system
Failure code [DSJ0KR] CAN2 Discon (Meter Electrical
DSJ0KR Unit)(PAGE 40-548) MON L01 system
Failure code [DV00KB] Ground Fault of Electrical
DV00KB Buzzer Output(PAGE 40-549) MON L01 system
Failure code [DW2BKA] Disconnection of Main Electrical
DW2BKA Flow Selector Sol.(PAGE 40-551) T/M L01 system
Failure code [DW2BKB] Ground Fault of Main Electrical
DW2BKB Flow Selector Sol.(PAGE 40-552) T/M L01 system
Failure code [DW2BKY] Hot Short of Main Electrical
DW2BKY Flow Selector Sol.(PAGE 40-553) T/M L01 system
Failure code [DW2BL1] Release Trouble of Electrical
DW2BL1 Main Flow Sel. Valve(PAGE 40-554) T/M L01 system
Failure code [DW2BLH] Malfunction of Main Electrical
DW2BLH Flow Selector Valve(PAGE 40-555) T/M L01 system
Failure code [DW4BK4] Release Trouble of Electrical
DW4BK4 Parking Brake Valve(PAGE 40-556) RHC L03 system
Failure code [DW4BMA] Malfunction of Electrical
DW4BMA Parking Brake Valve(PAGE 40-558) RHC L03 system
Failure code [DW72KZ] Failure of Kick out Electrical
DW72KZ Solenoid(PAGE 40-559) RHC L01 system
Failure code [DW73KA] Disconnection of Hoist Electrical
DW73KA Selector Sol.(PAGE 40-561) RHC L03 system
Failure code [DW73KB] Ground Fault of Hoist Electrical
DW73KB Selector Sol.(PAGE 40-563) RHC L03 system
Failure code [DW73KY] Hot Short of Hoist Electrical
DW73KY Selector Sol.(PAGE 40-565) RHC L03 system
Failure code [DW7BKB] Ground Fault of Electrical
DW7BKB Radiator Fan Rev. Sol.(PAGE 40-567) T/M L01 system
Failure code [DW7BKY] Hot Short of Radiator Electrical
DW7BKY Fan Rev. Sol.(PAGE 40-569) T/M L01 system
Failure code [DW7BKZ] Failure of Radiator Electrical
DW7BKZ Fan Rev. Sol.(PAGE 40-570) T/M L01 system
Failure code [DW7LKB] Ground Fault of CAC Electrical
DW7LKB Fan Rev. Sol.(PAGE 40-572) T/M L01 system
Failure code [DW7LKY] Hot Short of CAC Fan Electrical
DW7LKY Rev. Sol.(PAGE 40-573) T/M L01 system
Failure code [DW7LKZ] Failure of CAC Fan Electrical
DW7LKZ Rev. Sol.(PAGE 40-574) T/M L01 system

HM400-3M0 40-117
40 Troubleshooting
Related information on troubleshooting

Failure Applicable Action Category of

Failure (Displayed on screen) Remarks
code component level history
Failure code [DW7NKZ] Failure of Steering Electrical
DW7NKZ Pump Selector Sol.(PAGE 40-575) RHC L01 system
Failure code [DWNJKZ] Failure of TCS Shut Electrical
DWNJKZ off Sol. (Front)(PAGE 40-577) RHC L03 system
Failure code [DWNKKZ] Failure of TCS Shut Electrical
DWNKKZ off Sol. (Center)(PAGE 40-579) RHC L03 system
Failure code [DX13KA] Disconnection of Hoist Electrical
DX13KA EPC Solenoid(PAGE 40-581) RHC L03 system
Failure code [DX13KB] Ground Fault of Hoist Electrical
DX13KB EPC Solenoid(PAGE 40-583) RHC L03 system
Failure code [DX13KY] Hot Short of Hoist EPC Electrical
DX13KY Solenoid(PAGE 40-585) RHC L03 system
Failure code [DX16KA] Disconnection of Rad. Electrical
DX16KA Fan Pump EPC Sol.(PAGE 40-587) T/M L03 system
Failure code [DX16KB] Ground Fault of Rad. Electrical
DX16KB Fan Pump EPC Sol.(PAGE 40-588) T/M L03 system
Failure code [DX16KY] Hot Short of Radiator Electrical
DX16KY Fan Pump EPC Sol.(PAGE 40-590) T/M L01 system
Failure code [DX29KA] Disconnection of CAC Electrical
DX29KA Fan Pump EPC Sol.(PAGE 40-591) T/M L01 system
Failure code [DX29KB] Ground Fault of CAC Electrical
DX29KB Fan Pump EPC Sol.(PAGE 40-592) T/M L01 system
Failure code [DX29KY] Hot Short of CAC Fan Electrical
DX29KY Pump EPC Sol.(PAGE 40-593) T/M L01 system
Failure code [DX30K4] Release Trouble of Electrical
DX30K4 Retarder EPC Valve(FL)(PAGE 40-594) RHC L03 system
Failure code [DX30KA] Disconnection of Electrical
DX30KA Retarder EPC Sol. (FL)(PAGE 40-596) RHC L03 system
Failure code [DX30KB] Ground Fault of Electrical
DX30KB Retarder EPC Sol. (FL)(PAGE 40-598) RHC L03 system
Failure code [DX30KY] Hot Short of Retarder Electrical
DX30KY EPC Sol. (FL)(PAGE 40-600) RHC L03 system
Failure code [DX30MA] Malfunction of Electrical
DX30MA Retarder EPC Valve (FL)(PAGE 40-602) RHC L03 system
Failure code [DX31K4] Release Trouble of Electrical
DX31K4 Retarder EPC Valve(CR)(PAGE 40-604) RHC L03 system
Failure code [DX31KA] Disconnection of Electrical
DX31KA Retarder EPC Sol. (CR)(PAGE 40-606) RHC L03 system
Failure code [DX31KB] Ground Fault of Electrical
DX31KB Retarder EPC Sol. (CR)(PAGE 40-608) RHC L03 system
Failure code [DX31KY] Hot Short of Retarder Electrical
DX31KY EPC Sol. (CR)(PAGE 40-610) RHC L03 system
Failure code [DX31MA] Malfunction of Electrical
DX31MA Retarder Valve (CR)(PAGE 40-612) RHC L03 system
Failure code [DX32K4] Release Trouble of Electrical
DX32K4 Retarder EPC Valve(CL)(PAGE 40-614) RHC L03 system
Failure code [DX32KA] Disconnection of Electrical
DX32KA Retarder EPC Sol. (CL)(PAGE 40-616) RHC L03 system
Failure code [DX32KB] Ground Fault of Electrical
DX32KB Retarder EPC Sol. (CL)(PAGE 40-618) RHC L03 system
Failure code [DX32KY] Hot Short of Retarder Electrical
DX32KY EPC Sol. (CL)(PAGE 40-620) RHC L03 system
Failure code [DX32MA] Malfunction of Electrical
DX32MA Retarder EPC Valve (CL)(PAGE 40-622) RHC L03 system
Failure code [DX33K4] Release Trouble of Electrical
DX33K4 Retarder EPC Valve (FR)(PAGE 40-624) RHC L03 system

40-118 HM400-3M0
 40 Troubleshooting
Related information on troubleshooting

Failure Applicable Action Category of

Failure (Displayed on screen) Remarks
code component level history
Failure code [DX33KA] Disconnection of Electrical
DX33KA Retarder EPC Sol. (FR)(PAGE 40-626) RHC L03 system
Failure code [DX33KB] Ground Fault of Electrical
DX33KB Retarder EPC Sol. (FR)(PAGE 40-628) RHC L03 system
Failure code [DX33KY] Hot Short of Retarder Electrical
DX33KY EPC Sol. (FR)(PAGE 40-630) RHC L03 system
Failure code [DX33MA] Malfunction of Electrical
DX33MA Retarder EPC Valve (FR)(PAGE 40-632) RHC L03 system
Failure code [DX34KA] Disconnection of Electrical
DX34KA Remote Cooling EPC Sol.(PAGE 40-634) RHC L03 system
Failure code [DX34KB] Ground Fault of Electrical
DX34KB Remote Cooling EPC Sol.(PAGE 40-635) RHC L03 system
Failure code [DX34KY] Hot Short of Remote Electrical
DX34KY Cooling EPC Sol.(PAGE 40-637) RHC L03 system
Failure code [DXH0KA] Disconnection of Electrical
DXH0KA ECMV (Inter-Axle Diff.)(PAGE 40-638) T/M L01 system
Failure code [DXH0KB] Ground Fault of ECMV Electrical
DXH0KB (Inter-Axle Diff.)(PAGE 40-640) T/M L01 system
Failure code [DXH0KY] Hot Short of ECMV Electrical
DXH0KY (Inter-Axle Diff.)(PAGE 40-642) T/M L03 system
Failure code [DXH1KA] Disconnection of Electrical
DXH1KA ECMV Solenoid (Lockup)(PAGE 40-644) T/M L03 system
Failure code [DXH1KB] Ground Fault of ECMV Electrical
DXH1KB Solenoid (Lockup)(PAGE 40-646) T/M L03 system
Failure code [DXH1KY] Hot Short of ECMV Electrical
DXH1KY Solenoid (Lockup)(PAGE 40-648) T/M L03 system
Failure code [DXH2KA] Disconnection of Electrical
DXH2KA ECMV Solenoid (High)(PAGE 40-650) T/M L03 system
Failure code [DXH2KB] Ground Fault of ECMV Electrical
DXH2KB Solenoid (High)(PAGE 40-652) T/M L03 system
Failure code [DXH2KY] Hot Short of ECMV Electrical
DXH2KY Solenoid (High)(PAGE 40-654) T/M L03 system
Failure code [DXH3KA] Disconnection of Electrical
DXH3KA ECMV Solenoid (Low)(PAGE 40-655) T/M L03 system
Failure code [DXH3KB] Ground Fault of ECMV Electrical
DXH3KB Solenoid (Low)(PAGE 40-657) T/M L03 system
Failure code [DXH3KY] Hot Short of ECMV Electrical
DXH3KY Solenoid (Low)(PAGE 40-659) T/M L03 system
Failure code [DXH4KA] Disconnection of Electrical
DXH4KA ECMV Solenoid (1st)(PAGE 40-662) T/M L03 system
Failure code [DXH4KB] Ground Fault of ECMV Electrical
DXH4KB Solenoid (1st)(PAGE 40-664) T/M L03 system
Failure code [DXH4KY] Hot Short of ECMV Electrical
DXH4KY Solenoid (1st)(PAGE 40-666) T/M L03 system
Failure code [DXH5KA] Disconnection of Electrical
DXH5KA ECMV Solenoid (2nd)(PAGE 40-669) T/M L03 system
Failure code [DXH5KB] Ground Fault of ECMV Electrical
DXH5KB Solenoid (2nd)(PAGE 40-671) T/M L03 system
Failure code [DXH5KY] Hot Short of ECMV Electrical
DXH5KY Solenoid (2nd)(PAGE 40-673) T/M L03 system
Failure code [DXH6KA] Disconnection of Electrical
DXH6KA ECMV Solenoid (3rd)(PAGE 40-676) T/M L03 system
Failure code [DXH6KB] Ground Fault of ECMV Electrical
DXH6KB Solenoid (3rd)(PAGE 40-678) T/M L03 system
Failure code [DXH6KY] Hot Short of ECMV Electrical
DXH6KY Solenoid (3rd)(PAGE 40-680) T/M L03 system

HM400-3M0 40-119
40 Troubleshooting
Related information on troubleshooting

Failure Applicable Action Category of

Failure (Displayed on screen) Remarks
code component level history
Failure code [DXH7KA] Disconnection of Electrical
DXH7KA ECMV Solenoid (Reverse)(PAGE 40-683) T/M L03 system
Failure code [DXH7KB] Ground Fault of ECMV Electrical
DXH7KB Solenoid (Reverse)(PAGE 40-685) T/M L03 system
Failure code [DXH7KY] Hot Short of ECMV Electrical
DXH7KY Solenoid (Reverse)(PAGE 40-687) T/M L03 system
Failure code [DY30MA] Malfunction 1 of Electrical
DY30MA Emerg. Steering Motor(PAGE 40-690) RHC L01 system
Failure code [DY30MC] Malfunction 2 of Electrical
DY30MC Emerg. Steering Motor(PAGE 40-693) RHC L03 system
Failure code [DY30ME] Emerg. Steering Long- Mechanical
DY30ME Time Activated(PAGE 40-696) RHC L02 system
Failure code [DY32MC] Malfunction 2 of Electrical
DY32MC Emerg. Steering Motor 2(PAGE 40-698) RHC L03 system

a In this table, failure codes are arranged in the order of characters from numeric to alphabelic character.
a A component in charge is a controller in charge of the system check.
MON: Monitor controller
ENG: Engine controller
Transmission: Transmission controller
RHC: Retarder hoist controller
PLM: Payload meter controller
KOMTRAX: KOMTRAX terminal
a The failure codes that do not have numbers in the action level columns are not displayed on the standard
screen even when a failure related to them occurs. They are simply recorded in the abnormality record
(electrical system or mechanical system) of the service menu.
a The history classification column shows in which system each failure is classified, the electrical system or
mechanical system, when it is recorded in the abnormality record.
For details, see "Troubleshooting by failure code (Display of code)".

40-120 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Troubleshooting by failure code (Display of code) (ALL-3840-001-A-00-A)

Failure code [1500L0] Double Engagement of T/M Clutches (HM300_3-1500L0-400-A-

Z0-A)

Action level Failure code Double Engagement of Transmission Clutches

Failure
L04 1500L0 (Transmission controller system)
Detail of • Fill switch ON signals from impossible combination of 2 or more clutches are input.
failure
• Shifts transmission suddenly to NEUTRAL while traveling, and does not allow gear to
Action of shift FORWARD or REVERSE.
controller • Even if failure is repaired, machine is not restored to normal until starting switch is turned
to OFF position.
Problem on • Shifts gear speed to NEUTRAL.
machine
• Other failure code (failure code related to clutch pressure control valve system: 15S*L1) is
Related generated together.
information • Method of reproducing failure code: Start engine and drive machine.
No. Cause Procedure, measuring location, criteria, and remarks
Generation of failure code
1 (15S*L1) related to clutch Perform troubleshooting for generated failure code.
pressure control valve
Defective hydraulic or Clutch ECMV may malfunction. Perform troubleshooting of hydraulic
2 mechanical system of clutch and mechanical systems.
ECMV
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed).

HM400-3M0 40-121
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15B0NX] Transmission Oil Filter Clogging (HM300_3-15B0NX-400-A-Z0-A)

Action level Failure code Transmission Oil Filter Clogging

Failure
L01 15B0NX (Transmission controller system)
Detail of • When torque converter oil temperature exceeds 50°C, signal circuit of transmission oil
failure filter clogging sensor becomes open (disconnected from ground).
Action of • None in particular
controller
Problem on • If machine is used as it is, transmission circuit may become contaminated.
machine
• This failure can be checked with monitoring function. (Code: 02215) (Bit [1]: Normal: 0,
Clogged: 1)
Related • After servicing filter and checking that failure code disappears, perform initial learning of
information transmission controller. For details, see Testing and adjusting, "Inspection of machine
monitor".
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria, and remarks
1 Clogged transmission oil filter • Clean or replace it.
1. Turn starting switch to OFF position.
Defective transmission oil 2. Disconnect connector T03 and connect T-adapter to male side.
2 filter clogging sensor Resis- Between T03 (male) When filter is normal Max. 1 z
tance (1) and (2) When filter is clogged Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC2, ATC3, and T03, and connect T-
Open circuit in wiring harness adapters to each female side.
3 (Wire breakage or defective Between ATC2 (female) (7) and T03 (female)
Max. 1 z
contact of connector) Resis- (1)
tance Between ATC3 (female) (21) and T03 (female)
(2) Max. 1 z

1. Turn starting switch to OFF position.

2. Insert T-adapters into connectors ATC2 and ATC3.
4 Defective transmission 3. Turn starting switch to ON position.
controller
Between ATC2 (7) and When filter is normal Max. 1 V
Voltage
ATC3 (21) When filter is clogged 6 to 12 V

Circuit diagram related to transmission oil filter clogging sensor

40-122 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15F0KM] Abuse 1 of Gear Shifting from R to F (HM300_3-15F0KM-400-A-

Z0-A)

Action level Failure code Abuse 1 of Gear Shifting from Reverse to Forward
Failure
- 15F0KM (Transmission controller system)
Detail of • A total of 10 reverse-to-forward shifts are detected at output shaft speed of 200 to 300
failure rpm (approximately 4 to 6 km/h).
Action of • None in particular
controller
Problem on • If machine is used as it is, it may be damaged.
machine • Only logged in abnormality record.
Related • Output shaft speed can be checked with monitoring function (Code: 31400 (rpm)).
information
No. Cause Procedure, measuring location, criteria, and remarks
Always stop the machine completely before performing directional
1 Abuse selection.
(Tell operator correct operation method.)
If no failure is found by above checks, transmission controller is
Defective transmission defective.
2
controller
(Since this is an internal defect, troubleshooting cannot be performed.)

HM400-3M0 40-123
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15F0MB] Abuse 2 of Gear Shifting from R to F (HM300_3-15F0MB-400-A-

Z0-A)

Action level Failure code Abuse 2 of Gear Shifting from Reverse to Forward.
Failure
- 15F0MB (Transmission controller system)
Detail of • A total of 5 reverse-to-forward shifts are detected at output shaft speed of 300 rpm
failure (approximately 7 km/h) or above.
Action of • None in particular
controller
Problem on • If machine is used as it is, it may be damaged.
machine • Only logged in abnormality record.
Related • Output shaft speed can be checked with monitoring function (Code: 31400 (rpm)).
information
No. Cause Procedure, measuring location, criteria, and remarks
Always stop the machine completely before performing directional
1 Abuse selection.
(Tell operator correct operation method.)
If no failure is found by above checks, transmission controller is
Defective transmission defective.
2
controller
(Since this is an internal defect, troubleshooting cannot be performed.)

40-124 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15F7KM] Abuse of TM Forward Clutch Disk (HM300_3-15F7KM-400-A-Z0-A)

Action level Failure code Abuse of Transmission Forward Clutch Disk

Failure
– 15F7KM (Transmission controller system)
Detail of • Total of 10 directional changes from NEUTRAL or REVERSE to FORWARD are made
failure while engine speed is 1800 rpm or higher.
Action of • None in particular.
controller
Problem on • Repeated improper operations can lead to machine damage.
machine • This failure code is only logged in abnormality record.
Related
information
No. Cause Procedure, measuring location, criteria and remarks
Always release accelerator pedal and stop machine completely before
1 Abuse making directional change. (Instruct operator on correct operation of
machine.)
If no failure is found by above checks, transmission controller is
Defective transmission defective.
2
controller
(Since this is an internal defect, troubleshooting cannot be performed.)

HM400-3M0 40-125
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15G0MW] Failure of Clutch (Reverse) (HM300_3-15G0MW-400-A-Z0-A)

Action level Failure code Failure of Clutch (Reverse)

Failure (R command, R clutch fill switch ON, slip detected)
L03 15G0MW
(Transmission controller system)
• When driving R clutch ECMV solenoid, transmission output shaft speed calculated from
Detail of signals from transmission input shaft speed sensor and transmission intermediate shaft
failure speed sensor differs from that sensed by transmission output shaft speed sensor.
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed.
controller • Disengages lockup clutch.
• Machine cannot drive in reverse.
• Machine cannot start again once gear shift lever is set to NEUTRAL position.
• Machine can be moved by using following retrieval procedure.
1) Stop traveling and return gear shift lever to NEUTRAL position.
2) Disconnect emergency retrieval connectors TCS (female) and TCS (male) once, and
Problem on connect them to put machine in emergency retrieval mode.
machine 3) Operate gear shift lever to restart machine.
a When operating gear shift lever, release accelerator pedal.
a From "N" to any of "D" to "L", or from "N" to "R"
a Machine remains in emergency retrieval mode until starting switch is turned to OFF
position.
• Output current to ECMV solenoid can be checked with monitoring function. (Code: 31606
(mA))
• First, check for mechanical failures such as problem in R clutch, clogged oil filter of
pressure control valve, etc.
Related • When performing emergency retrieval operation, see Testing and adjusting, "Emergency
information retrieval in case of failure in traction control system (TCS)".
k Tilt up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine and drive machine in R1.
No. Cause
Check whether clutch pressure is normal by referring to Testing and
1 Poor R clutch pressure
adjusting, "Testing power train oil pressure".
Ground fault in transmission
output shaft speed sensor
2 circuit
(Contact with ground circuit)
Hot short circuit in
transmission output shaft
3 speed sensor circuit
(Contact with 24 V circuit)
Defective R clutch ECMV
4
solenoid
Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector ATC2.
3. Tilt up cab (observe precautions mentioned above).
4. Disconnect connector N3. OUT (CN5) and connect T-adapter to
female side.
Resis- Between N3. OUT (CN5) (female) (1) and
ground Min. 1 Mz
tance
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector N3. OUT (CN5) and connect T-adapter to
female side.
4. Turn starting switch to ON position.
Voltage Between N3. OUT (CN5) (female) (1) and (2) 3 to 4 V
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector R.PS (CN8) and connect T-adapter to male
side.
Between R.PS (CN8) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and R.PS (CN8) (male) (1) or Min. 1 Mz
tance
(2)

40-126 HM400-3M0

No. Cause
Open and short circuit in
5 wiring harness
Open circuit in wiring harness 3.
6 (Wire breakage or defective
contact of connector)
Defective transmission
7
controller
Circuit diagram related to transmission output shaft speed sensor
Circuit diagram related to R clutch
HM400-3M0
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Procedure, measuring location, criteria, and remarks
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC3 and connect T-adapter to female side.
a If check result is unusual, disconnect connector J09 and perform
similar troubleshooting to locate defective wiring harness.
Resis- Between ATC3 (female) (5) and (23)
5 to 15 z
tance
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapter to female side.
Tilt up cab (observe precautions mentioned above).
4. Disconnect connector R.PS (CN8) and connect T-adapter to female
side.
Between ATC3 (female) (5) and R.PS (CN8)
Max. 1 z
Resis- (female) (1)
tance Between ATC3 (female) (23) and R.PS (CN8)
(female) (2) Max. 1 z
If no failure is found by above checks, transmission controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
40-127
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 1
Remedy taken when failure is detected
Gear speed when Action of controller
Failed clutch ON or OFF of lockup
failure is detected
(Selected clutch and gear speed) clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3rd and Hi F6 OFF
2nd 2nd 3rd and Lo F5 OFF
F4
Hi Hi 3rd and Lo F5 OFF
2nd 2nd 3rd and Lo F5 OFF
F3
Lo Lo 2nd and Hi F4 OFF
1st 1st 2nd and Lo F3 OFF
F2
Hi Hi 2nd and Lo F3 OFF
1st 1st 2nd and Lo F3 OFF
F1
Lo Lo 1st and Hi F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3rd and Reverse R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2nd and Reverse R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF

40-128 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15G7KM] Abuse of TM Reverse Clutch Disk (HM300_3-15G7KM-400-A-Z0-A)

Action level Failure code Abuse of Transmission Reverse Clutch Disk

Failure
- 15G7KM (Transmission controller system)
Detail of • A total of 10 shifts from neutral or forward to reverse are detected at engine speed of
failure 1,800 rpm or above.
Action of • None in particular
controller
Problem on • Repeated abnormal operations can lead to machine damage.
machine • Only logged in abnormality record.
Related
information
No. Cause Procedure, measuring location, criteria, and remarks
Stop the machine completely and release the throttle pedal before
1 Abuse performing directional selection. (Tell operator correct operation
method.)
If no failure is found by above checks, transmission controller is
Defective transmission defective.
2
controller
(Since this is an internal defect, troubleshooting cannot be performed.)

HM400-3M0 40-129
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15H0MW] Failure of Clutch (High) (HM300_3-15H0MW-400-A-Z0-A)

Action level Failure code Failure of Clutch (High)

Failure (H command, H clutch fill switch ON, slip detected)
L03 15H0MW
(Transmission controller system)
• When driving H clutch ECMV solenoid, transmission output shaft speed calculated from
Detail of signals from transmission input shaft speed sensor and transmission intermediate shaft
failure speed sensor differs from that sensed by transmission output shaft speed sensor.
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed.
controller • Disengages lockup clutch.
• Once gear shift lever is set to "N" during travel, even if gear shift lever is moved to position
Problem on other than "N", that gear does not engage until machine is stopped.
machine • Machine travels in gear speed that does not use H clutch.
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31600 (mA)).
• First, check for mechanical failures such as problem in H clutch, clogged oil filter of
pressure control valve, etc.
Related • When performing emergency retrieval operation, see Testing and adjusting, "Emergency
information retrieval in case of failure in traction control system (TCS)".
k Tilt up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine and drive machine in F2.
No. Cause
1 Defective H clutch pressure
Ground fault in transmission
output shaft speed sensor
2 circuit
(Contact with ground circuit)
Hot short circuit in
transmission output shaft
3 speed sensor circuit
(Contact with 24 V circuit)
Defective Hi clutch ECMV
4
solenoid
Open and short circuit in
5 wiring harness
Procedure, measuring location, criteria, and remarks
Check whether clutch pressure is normal by referring to Testing and
adjusting, "Testing power train oil pressure".
1. Turn starting switch to OFF position.
2. Disconnect connector ATC.
3. Tilt up cab (observe precautions mentioned above).
4. Disconnect connector N3. OUT (CN5) and connect T-adapter to
female side.
Resis- Between N3. OUT (CN5) (female) (1) and
ground Min. 1 Mz
tance
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector N3. OUT (CN5) and connect T-adapter to
female side.
4. Turn starting switch to ON position.
Voltage Between N3. OUT (CN5) (female) (1) and (2) 3 to 4 V
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector H.PS (CN10) and connect T-adapter to male
side.
Between H.PS (CN10) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and H.PS (CN10) (male) (1) or
tance Min. 1 Mz
(2)
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC3 and connect T-adapter to female side.
a If check result is unusual, disconnect connector J09 and perform
similar troubleshooting to locate defective wiring harness.
Resis- Between ATC3 (female) (6) and ATC3 (female) 5 to 15 z
tance (13)

40-130 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

Open circuit in wiring harness 3.
6 (Wire breakage or defective
contact of connector)
Defective transmission
7
controller
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapter to female side.
Tilt up cab (observe precautions mentioned above).
4. Disconnect connector H.PS (CN10) and connect T-adapter to
female side.
Between ATC3 (female) (6) and H.PS (CN10)
Max. 1 z
Resis- (female) (1)
tance Between ATC3 (female) (13) and H.PS (CN10)
(female) (2) Max. 1 z
If no failure is found by above checks, transmission controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)

Circuit diagram related to transmission output speed sensor

Circuit diagram related to H clutch

HM400-3M0 40-131
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 1
Remedy taken when failure is detected
Gear speed when Action of controller
Failed clutch ON or OFF of lockup
failure is detected
(Selected clutch and gear speed) clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3rd and Hi F6 OFF
2nd 2nd 3rd and Lo F5 OFF
F4
Hi Hi 3rd and Lo F5 OFF
2nd 2nd 3rd and Lo F5 OFF
F3
Lo Lo 2nd and Hi F4 OFF
1st 1st 2nd and Lo F3 OFF
F2
Hi Hi 2nd and Lo F3 OFF
1st 1st 2nd and Lo F3 OFF
F1
Lo Lo 1st and Hi F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3rd and Reverse R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2nd and Reverse R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF

40-132 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15J0MW] Failure of Clutch (Low) (HM300_3-15J0MW-400-A-Z0-A)

Action level Failure code Failure of Clutch (Low)

Failure (L command, L clutch fill switch ON, slip detected)
L03 15J0MW
(Transmission controller system)
• When driving L clutch ECMV solenoid, transmission output shaft speed calculated from
Detail of signals from transmission input shaft speed sensor and transmission intermediate shaft
failure speed sensor differs from that sensed by transmission output shaft speed sensor.
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed.
controller • Disengages lockup clutch.
• Once gear shift lever is set to "N" during travel, even if gear shift lever is moved to position
Problem on other than "N", that gear does not engage until machine is stopped.
machine • Machine travels in gear speed that does not use L clutch.
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31601 (mA)).
• First, check for mechanical failures such as problem in L clutch, clogged oil filter of
pressure control valve, etc.
Related • When performing emergency retrieval operation, see Testing and adjusting, "Emergency
information retrieval in case of failure in traction control system (TCS)".
k Tilt up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start the engine and drive machine in F1.
No. Cause
Defective L clutch oil
1 pressure
Ground fault in transmission
output shaft speed sensor
2 circuit
(Contact with ground circuit)
Hot short circuit in
transmission output shaft
3 speed sensor circuit
(Contact with 24 V circuit)
Defective Lo clutch ECMV
4 side.
solenoid
Open and short circuit in
5 wiring harness
Procedure, measuring location, criteria, and remarks
Check whether clutch pressure is normal by referring to Testing and
adjusting, "Testing power train oil pressure".
1. Turn starting switch to OFF position.
2. Disconnect connector ATC.
3. Tilt up cab (observe precautions mentioned above).
4. Disconnect connector N3. OUT (CN5) and connect T-adapter to
female side.
Resis- Between N3. OUT (CN5) (female) (1) and
ground Min. 1 Mz
tance
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector N3. OUT (CN5) and connect T-adapter to
female side.
4. Turn starting switch to ON position.
Voltage Between N3. OUT (CN5) (female) (1) and (2) 3 to 4 V
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector L.PS (CN6) and connect T-adapter to male
Resis- Between L.PS (CN6) (male) (1) and (2) 5 to 15 z
tance Between L.PS (CN6) (male) (1) and (2) Min. 1 Mz
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC3 and connect T-adapter to female side.
a If check result is unusual, disconnect connector J09 and perform
similar troubleshooting to locate defective wiring harness.
Resis- Between ATC3 (female) (37) and (3) 5 to 15 z
tance

HM400-3M0 40-133
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

Open circuit in wiring harness 3.
6 (wire breakage or defective
contact of connector)
Defective transmission
7
controller
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapter to female side.
Tilt up cab (observe precautions mentioned above).
4. Disconnect connector L.PS (CN6) and connect T-adapter to female
side.
Between ATC3 (female) (37) and L.PS (CN6)
Max. 1 z
Resis- (female) (1)
tance Between ATC3 (female) (3) and L.PS (CN6)
(female) (2) Max. 1 z
If no failure is found by above checks, transmission controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)

Circuit diagram related to transmission output shaft speed sensor

Circuit diagram related to lockup clutch

40-134 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 1
Remedy taken when failure is detected
Gear speed when Action of controller
Failed clutch ON or OFF of lockup
failure is detected
(Selected clutch and gear speed) clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3rd and Hi F6 OFF
2nd 2nd 3rd and Lo F5 OFF
F4
Hi Hi 3rd and Lo F5 OFF
2nd 2nd 3rd and Lo F5 OFF
F3
Lo Lo 2nd and Hi F4 OFF
1st 1st 2nd and Lo F3 OFF
F2
Hi Hi 2nd and Lo F3 OFF
1st 1st 2nd and Lo F3 OFF
F1
Lo Lo 1st and Hi F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3rd and Reverse R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2nd and Reverse R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF

HM400-3M0 40-135
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15K0MW] Failure of Clutch (1st) (HM300_3-15K0MW-400-A-Z0-A)

Action level Failure code Failure of Clutch (1st)

Failure
L03 15K0MW (Transmission controller system)
• When driving 1st clutch ECMV solenoid, transmission output shaft speed calculated from
Detail of signals from transmission input shaft speed sensor and transmission intermediate shaft
failure speed sensor differs from that sensed by transmission output shaft speed sensor.
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed.
controller • Disengages lockup clutch.
• Machine cannot start again once gear shift lever is set to NEUTRAL position.
• Machine can be moved by using following retrieval procedure.
1) Stop traveling and return gear shift lever to NEUTRAL position.
2) Disconnect emergency retrieval connectors TCS (female) and TCS (male) once, and
connect them to put machine in emergency retrieval mode.
Problem on 3) Operate gear shift lever to restart machine.
machine
a When operating gear shift lever, release accelerator pedal.
a From "N" to any of "D" to "L", or from "N" to "R"
a Machine remains in emergency retrieval mode until starting switch is turned to OFF
position.
• Output current to ECMV solenoid can be checked with monitoring function. (Code: 31602
(mA))
• First, check for mechanical failures such as problem in 1st clutch, clogged oil filter of
Related pressure control valve, etc.
information k Tilt up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start the engine and drive machine in F1.
No. Cause
Defective 1st clutch oil
1 pressure
Ground fault in transmission
output shaft speed sensor
2 circuit
(Contact with ground circuit)
Hot short circuit in
transmission output shaft
3 speed sensor circuit
(Contact with 24 V circuit)
Defective 1st clutch ECMV
4
solenoid
Procedure, measuring location, criteria, and remarks
Check whether clutch oil pressure is normal by referring to Testing and
adjusting, "Testing power train oil pressure".
1. Turn starting switch to OFF position.
2. Disconnect connector ATC.
3. Tilt up cab (observe precautions mentioned above).
4. Disconnect connector N3. OUT (CN5) and connect T-adapter to
female side.
Resis- Between N3. OUT (CN5) (female) (1) and
ground Min. 1 Mz
tance
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector N3. OUT (CN5) and connect T-adapter to
female side.
4. Turn starting switch to ON position.
Voltage Between N3. OUT (CN5) (female) (1) and (2) 3 to 4 V
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 1.PS (CN12) and connect T-adapter to male
side.
Between 1.PS (CN12) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and 1.PS (CN12) (male) (1) or Min. 1 Mz
tance
(2)

40-136 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

Open and short circuit in
5 wiring harness
Open circuit in wiring harness 3. Tilt up cab (observe precautions mentioned above).
6 (wire breakage or defective
contact of connector)
Defective transmission
7
controller
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC3 and connect T-adapter to female side.
a If check result is unusual, disconnect connector J09 and perform
similar troubleshooting to locate defective wiring harness.
Resis- Between ATC3 (female) (16) and (13)
5 to 15 z
tance
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapter to female side.
4. Disconnect connector 1.PS (CN12) and connect T-adapter to female
side.
Between ATC3 (female) (16) and 1.PS (CN12)
Max. 1 z
Resis- (female) (1)
tance Between ATC3 (female) (13) and 1.PS (CN12)
(female) (2) Max. 1 z
If no failure is found by above checks, transmission controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)

Circuit diagram related to transmission output shaft speed sensor

Circuit diagram related to 1st clutch

HM400-3M0 40-137
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 1
Remedy taken when failure is detected
Gear speed when Action of controller
Failed clutch ON or OFF of lockup
failure is detected
(Selected clutch and gear speed) clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3rd and Hi F6 OFF
2nd 2nd 3rd and Lo F5 OFF
F4
Hi Hi 3rd and Lo F5 OFF
2nd 2nd 3rd and Lo F5 OFF
F3
Lo Lo 2nd and Hi F4 OFF
1st 1st 2nd and Lo F3 OFF
F2
Hi Hi 2nd and Lo F3 OFF
1st 1st 2nd and Lo F3 OFF
F1
Lo Lo 1st and Hi F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3rd and Reverse R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2nd and Reverse R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF

40-138 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15L0MW] Failure of Clutch (2nd) (HM300_3-15L0MW-400-A-Z0-A)

Action level Failure code Failure of Clutch (2nd)

Failure
L03 15L0MW (Transmission controller system)
• When driving 2nd clutch ECMV solenoid, transmission output shaft speed calculated from
Detail of signals from transmission input shaft speed sensor and transmission intermediate shaft
failure speed sensor differs from that sensed by transmission output shaft speed sensor.
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed.
controller • Disengages lockup clutch.
• Machine cannot start again once gear shift lever is set to NEUTRAL position.
• Machine can be moved by using following retrieval procedure.
1) Stop traveling and return gear shift lever to NEUTRAL position.
2) Disconnect emergency retrieval connectors TCS (female) and TCS (male) once, and
connect them to put machine in emergency retrieval mode.
Problem on 3) Operate gear shift lever to restart machine.
machine
a When operating gear shift lever, release accelerator pedal.
a From "N" to any of "D" to "L", or from "N" to "R"
a Machine remains in emergency retrieval mode until starting switch is turned to OFF
position.
• Output current to ECMV solenoid can be checked with monitoring function. (Code: 31603
(mA))
• First, check for mechanical failures such as problem in 2nd clutch, clogged oil filter of
Related pressure control valve, etc.
information k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine and drive machine in F3.
No. Cause Procedure, measuring location, criteria, and remarks
Defective 2nd clutch oil Check whether clutch oil pressure is normal by referring to Testing and
1 pressure adjusting, "Testing power train oil pressure".
Ground fault in 1. Turn starting switch to OFF position.
transmission output 2. Disconnect connector ATC.
shaft speed sensor 3. Tilt up cab (observe precautions mentioned above).
2 circuit 4. Disconnect connector N3. OUT (CN5) and connect T-adapter to female
(Contact with ground side.
circuit) Resistance Between N3. OUT (CN5) (female) (1) and ground Min. 1 Mz
Hot short circuit in 1. Tilt up cab (observe precautions mentioned above).
transmission output 2. Turn starting switch to OFF position.
shaft speed sensor 3. Disconnect connector N3. OUT (CN5) and connect T-adapter to female
3 circuit side.
(Contact with 24 V 4. Turn starting switch to ON position.
circuit) Voltage Between N3. OUT (CN5) (female) (1) and (2) 3 to 4 V
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
Defective 2nd clutch 3. Disconnect connector 2.PS (CN14) and connect T-adapter to male side.
4
ECMV solenoid
Between 2.PS (CN14) (male) (1) and (2) 5 to 15 z
Resistance
Between ground and 2.PS (CN14) (male) (1) or (2) Min. 1 Mz
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC3 and connect T-adapter to female side.
Open and short circuit
5 in wiring harness a If check result is unusual, disconnect connector J09 and perform similar
troubleshooting to locate defective wiring harness.
5 to 15 z
Resistance Between ATC3 (female) (26) and (3)

HM400-3M0 40-139
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connector ATC3 and connect T-adapter to female side.
harness 3. Tilt up cab (observe precautions mentioned above).
6 (wire breakage or 4. Disconnect connector 2.PS (CN14) and connect T-adapter to female side.
defective contact of Between ATC3 (female) (26) and 2.PS (CN14)
connector) (female) (1) Max. 1 z
Resistance
Between ATC3 (female) (3) and 2.PS (CN14)
(female) (2) Max. 1 z
Defective transmission If no failure is found by above checks, transmission controller is defective.
7 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

Circuit diagram related to transmission output shaft speed sensor

Circuit diagram related to 2nd clutch

40-140 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 1
Remedy taken when failure is detected
Gear speed when Action of controller
Failed clutch ON or OFF of lockup
failure is detected
(Selected clutch and gear speed) clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3rd and Hi F6 OFF
2nd 2nd 3rd and Lo F5 OFF
F4
Hi Hi 3rd and Lo F5 OFF
2nd 2nd 3rd and Lo F5 OFF
F3
Lo Lo 2nd and Hi F4 OFF
1st 1st 2nd and Lo F3 OFF
F2
Hi Hi 2nd and Lo F3 OFF
1st 1st 2nd and Lo F3 OFF
F1
Lo Lo 1st and Hi F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3rd and Reverse R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2nd and Reverse R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF

HM400-3M0 40-141
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15M0MW] Failure of Clutch (3rd) (HM300_3-15M0MW-400-A-Z0-A)

Action level Failure code Failure of Clutch (3rd)

Failure
L03 15M0MW (Transmission controller system)
• When driving 3rd clutch ECMV solenoid, transmission output shaft speed calculated from
Detail of signals from transmission input shaft speed sensor and transmission intermediate shaft
failure speed sensor differs from that sensed by transmission output shaft speed sensor.
Action of • Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
controller gear speed.
• Machine cannot start again once gear shift lever is set to NEUTRAL position.
• Machine can be moved by using following retrieval procedure.
1) Stop traveling and return gear shift lever to NEUTRAL position.
2) Disconnect emergency retrieval connectors TCS (female) and TCS (male) once, and
connect them to put machine in emergency retrieval mode.
Problem on 3) Operate gear shift lever to restart machine.
machine
a When operating gear shift lever, release accelerator pedal.
a From "N" to any of "D" to "L", or from "N" to "R"
a Machine remains in emergency retrieval mode until starting switch is turned to OFF
position.
• Output current to ECMV solenoid can be checked with monitoring function. (Code: 31604
(mA))
• First, check for mechanical failures such as problem in 3rd clutch, clogged oil filter of
Related pressure control valve, etc.
information k Tilt up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine and drive machine in F5.
No. Cause
Defective 3rd clutch oil
1 pressure
Ground fault in transmission
output shaft speed sensor
2 circuit
(Contact with ground circuit)
Hot short circuit in
transmission output shaft
3 speed sensor circuit
(Contact with 24 V circuit)
Defective 3rd clutch ECMV
4
solenoid
Open and short circuit in
5 wiring harness
Procedure, measuring location, criteria, and remarks
Check whether clutch oil pressure is normal by referring to Testing and
adjusting, "Testing power train oil pressure".
1. Turn starting switch to OFF position.
2. Disconnect connector ATC.
3. Tilt up cab (observe precautions mentioned above).
4. Disconnect connector N3. OUT (CN5) and connect T-adapter to
female side.
Resis- Between N3. OUT (CN5) (female) (1) and
ground Min. 1 Mz
tance
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector N3. OUT (CN5) and connect T-adapter to
female side.
4. Turn starting switch to ON position.
Voltage Between N3. OUT (CN5) (female) (1) and (2) 3 to 4 V
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 3.PS (CN16) and connect T-adapter to male
side.
Between 3.PS (CN16) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and 3.PS (CN16) (male) (1) or
tance Min. 1 Mz
(2)
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC3 and connect T-adapter to female side.
a If check result is unusual, disconnect connector J09 and perform
similar troubleshooting to locate defective wiring harness.
Resis- Between ATC3 (female) (36) and (23)
5 to 15 z
tance

40-142 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

Open circuit in wiring harness 3. Tilt up cab (observe precautions mentioned above).
6 (wire breakage or defective
contact of connector)
Defective transmission
7
controller
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapter to female side.
4. Disconnect connector 3.PS (CN16) and connect T-adapter to female
side.
Between ATC3 (female) (36) and 3.PS (CN16)
Max. 1 z
Resis- (female) (1)
tance Between ATC3 (female) (23) and 3.PS (CN16)
(female) (2) Max. 1 z
If no failure is found by above checks, transmission controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)

Circuit diagram related to transmission output shaft speed sensor

Circuit diagram related to 3rd clutch

HM400-3M0 40-143
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 1
Remedy taken when failure is detected
Gear speed when Action of controller
Failed clutch ON or OFF of lockup
failure is detected
(Selected clutch and gear speed) clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3rd and Hi F6 OFF
2nd 2nd 3rd and Lo F5 OFF
F4
Hi Hi 3rd and Lo F5 OFF
2nd 2nd 3rd and Lo F5 OFF
F3
Lo Lo 2nd and Hi F4 OFF
1st 1st 2nd and Lo F3 OFF
F2
Hi Hi 2nd and Lo F3 OFF
1st 1st 2nd and Lo F3 OFF
F1
Lo Lo 1st and Hi F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3rd and Reverse R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2nd and Reverse R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF

40-144 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SBL1] Release Trouble of ECMV (Reverse) (HM300_3-15SBL1-400-A-Z0-

A)

Action level Failure code Release Trouble of ECMV (Reverse)

Failure
L03 15SBL1 (Transmission controller system)
Detail of • Signal from fill switch remains ON even after controller stops driving R clutch ECMV
failure solenoid.
• Shifts up gear according to gear speed before failure as shown in Table 2 and holds that
Action of gear speed.
controller • Disengages lockup clutch.
Problem on • Machine cannot restart unless it is stopped once.
machine
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31606 (mA)).
• Input signal from fill switch can be checked with code 02216. (0: OFF, 1: ON))
• First, check for mechanical trouble such as clogged oil filter of R clutch or pressure control
Related valve.
information
k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine.

No. Cause Procedure, measuring location, criteria, and remarks
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector R.SW (CN8).
4. Turn starting switch to ON position.
If failure code [15SBL1] is not displayed, R clutch fill switch is defective.
1 Defective R clutch fill switch
1. Turn starting switch to OFF position.
2. Disconnect connector R.SW (CN8) and connect T-adapter to male
side.
Resis- Between R.SW (CN8) (male) (1) and ground
Min. 1 Mz
tance (Fill switch: OFF)
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
Ground fault in wiring harness
3. Disconnect connector R.SW (CN8).
2 or defective transmission
4. Turn starting switch to ON position.
controller
If failure code [15SBL1] is still displayed, wiring harness has ground
fault or transmission controller is defective.
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector R.SW (CN8).
Ground fault in wiring harness 4. Lower tilted-up cab.
3
(Contact with ground circuit) 5. Disconnect connector ATC3.
6. Connect T-adapter to ATC3 (female).
Resis- Between ATC3 (female) (5) and ground
Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

HM400-3M0 40-145
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to R clutch

40-146 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 2
Remedy taken when failure is detected
Gear speed when Failed clutch
Action of controller ON or OFF of lockup
failure is detected (Fill switch: ON)
(Selected clutch and gear speed) 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 3rd and Hi F6 OFF
3rd 3rd and Lo F5 OFF
2nd 1st OFF NEUTRAL OFF
F4
Hi Reverse OFF NEUTRAL OFF
Lo 3rd and Lo F5 OFF
3rd 3rd and Lo F5 OFF
2nd 1st OFF NEUTRAL OFF
F3
Lo Reverse OFF NEUTRAL OFF
Hi 2nd and Hi F4 OFF
3rd 3rd and Lo F5 OFF
1st 2nd 2nd and Lo F3 OFF
F2
Hi Reverse OFF NEUTRAL OFF
Lo 2nd and Lo F3 OFF
3rd 3rd and Lo F5 OFF
1st 2nd 2nd and Lo F3 OFF
F1
Lo Reverse OFF NEUTRAL OFF
Hi 1st and Hi F2 OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
R3
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3rd and Reverse R3 OFF
2nd 1st OFF NEUTRAL OFF
R2
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3rd and Reverse R3 OFF
1st 2nd 2nd and Reverse R2 OFF
R1
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
No remedy is ―
N ANY NONE
taken

HM400-3M0 40-147
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SBMA] Malfunction of ECMV (Reverse) (HM300_3-15SBMA-400-A-Z0-A)

Action level Failure code Malfunction of ECMV (Reverse)

Failure
L03 15SBMA (Transmission controller system)
• When driving R clutch ECMV solenoid, signal from fill switch is OFF, and transmission
Detail of output shaft speed calculated from signals from transmission input shaft speed sensor
failure and transmission intermediate shaft speed sensor differs from that sensed by
transmission output shaft speed sensor.
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed. (See failure code [15G0MW].)
controller • Disengages lockup clutch.
Problem on • Machine cannot start unless it is stopped once.
machine
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31606 (mA)).
• First, check for mechanical trouble such as clogged oil filter of R clutch or pressure control
Related valve.
information k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine and drive machine in R1.
No. Cause Procedure, measuring location, criteria, and remarks
Defective R clutch solenoid
1 Perform troubleshooting for failure code [15G0MW].
system

40-148 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SCL1] Release Trouble of ECMV (High) (HM300_3-15SCL1-400-A-Z0-A)

Action level Failure code Release Trouble of ECMV (High)

Failure
L03 15SCL1 (Transmission controller system)
Detail of • Signal from fill switch remains ON even after controller stops driving H clutch ECMV
failure solenoid.
• Shifts up gear according to gear speed before failure as shown in Table 2 and holds that
Action of gear speed.
controller • Disengages lockup clutch.
Problem on • Machine travels in gear speed that use H clutch.
machine • Machine cannot travel in reverse.
• Output current to ECMV solenoid can be checked with monitoring function. (Code: 31600
(mA))
• Fill switch input signal can be checked with code 02216. (0: OFF, 1: ON)
• First, check for mechanical failures such as problem in H clutch, clogged oil filter of
Related pressure control valve, etc.
information
k Tilt up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine.

No. Cause Procedure, measuring location, criteria, and remarks
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector H.SW (CN11).
4. Turn starting switch to ON position.
If failure code [15SCL1] disappears, H clutch fill switch is defective.
1 Defective H clutch fill switch
1. Turn starting switch to OFF position.
2. Disconnect connector H.SW (CN11) and connect T-adapter to male
side.
Resis- Between H.SW (CN11) (male) (1) and ground
Min. 1 Mz
tance (Fill switch: OFF)
1. Tilt up cab (observe precautions mentioned above).
Ground fault in wiring harness 2. Turn starting switch to OFF position.
or 3. Disconnect connector H.SW (CN11).
2
Defective transmission 4. Turn starting switch to ON position.
controller If failure code [15SCL1] is still displayed, wiring harness has ground
fault or transmission controller is defective.
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector H.SW (CN11).
Ground fault in wiring harness 4. Lower tilted-up cab.
3
(Contact with ground circuit) 5. Disconnect connector ATC3.
6. Connect T-adapter to ATC3 (female).
Resis- Between ATC3 (female) (30) and ground
Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

HM400-3M0 40-149
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to H clutch

40-150 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 2
Remedy taken when failure is detected
Gear speed when Failed clutch
Action of controller ON or OFF of lockup
failure is detected (Fill switch: ON)
(Selected clutch and gear speed) 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 3rd and Hi F6 OFF
3rd 3rd and Lo F5 OFF
2nd 1st OFF NEUTRAL OFF
F4
Hi Reverse OFF NEUTRAL OFF
Lo 3rd and Lo F5 OFF
3rd 3rd and Lo F5 OFF
2nd 1st OFF NEUTRAL OFF
F3
Lo Reverse OFF NEUTRAL OFF
Hi 2nd and Hi F4 OFF
3rd 3rd and Lo F5 OFF
1st 2nd 2nd and Lo F3 OFF
F2
Hi Reverse OFF NEUTRAL OFF
Lo 2nd and Lo F3 OFF
3rd 3rd and Lo F5 OFF
1st 2nd 2nd and Lo F3 OFF
F1
Lo Reverse OFF NEUTRAL OFF
Hi 1st and Hi F2 OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
R3
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3rd and Reverse R3 OFF
2nd 1st OFF NEUTRAL OFF
R2
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3rd and Reverse R3 OFF
1st 2nd 2nd and Reverse R2 OFF
R1
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
No remedy is ―
N ANY NONE
taken

HM400-3M0 40-151
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SCMA] Malfunction of ECMV (High) (HM300_3-15SCMA-400-A-Z0-A)

Action level Failure code Malfunction of ECMV (High)

Failure
L03 15SCMA (Transmission controller system)
• When driving H clutch ECMV solenoid, signal from fill switch is OFF, and transmission
Detail of output shaft speed calculated from signals from transmission input shaft speed sensor
failure and transmission intermediate shaft speed sensor differs from that sensed by
transmission output shaft speed sensor.
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed. (See failure code [15H0MW].)
controller • Disengages lockup clutch.
Problem on • Machine travels in gear speed that does not use H clutch.
machine
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31600 (mA)).
• First, check for mechanical failures such as problem in H clutch, clogged oil filter of
Related pressure control valve, etc.
information k Tilt
up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine and drive machine in F2.
No. Cause Procedure, measuring location, criteria, and remarks
Defective H clutch ECMV
1 Perform troubleshooting for failure code [15H0MW].
system

40-152 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SDL1] Release Trouble of ECMV (Low) (HM300_3-15SDL1-400-A-Z0-A)

Action level Failure code Release Trouble of ECMV (Low)

Failure
L03 15SDL1 (Transmission controller system)
Detail of • Signal from fill switch remains ON even after controller stops driving L clutch ECMV
failure solenoid, and clutch is not disengaged.
• Shifts up gear according to gear speed before failure as shown in Table 2 and holds that
Action of gear speed.
controller • Disengages lockup clutch.
Problem on • Machine travels in gear speed that use L clutch.
machine
• Output current to ECMV solenoid can be checked with monitoring function. (Code: 31601
(mA))
• Input signal from fill switch can be checked with monitoring function. (Code 02216 (0:
OFF, 1: ON))
Related • First, check for mechanical failures such as problem in L clutch, clogged oil filter of
information pressure control valve, etc.
k Tilt up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine.

No. Cause Procedure, measuring location, criteria, and remarks
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector L.SW (CN7).
4. Turn starting switch to ON position.
If failure code [15SDL1] disappears, L clutch fill switch is defective
1 Defective L clutch fill switch
1. Turn starting switch to OFF position.
2. Disconnect connector L.SW (CN7) and connect T-adapter to male
side.
Resis- Between L.SW (CN7) (male) (1) and ground
Min. 1 Mz
tance (Fill switch: OFF)
1. Tilt up cab (observe precautions mentioned above).
Ground fault in wiring harness 2. Turn starting switch to OFF position.
or 3. Disconnect connector L.SW (CN7).
2
Defective transmission 4. Turn starting switch to ON position.
controller If failure code [15SDL1] is still displayed, wiring harness has ground
fault or transmission controller is defective.
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector L.SW (CN7).
Ground fault in wiring harness 4. Lower tilted-up cab.
3
(Contact with ground circuit) 5. Disconnect connector ATC3.
6. Connect T-adapter to ATC3 (female).
Resis- Between ATC3 (female) (20) and ground
Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

HM400-3M0 40-153
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to lockup clutch

40-154 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 2
Remedy taken when failure is detected
Gear speed when Failed clutch
Action of controller ON or OFF of lockup
failure is detected (Fill switch: ON)
(Selected clutch and gear speed) 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 3rd and Hi F6 OFF
3rd 3rd and Lo F5 OFF
2nd 1st OFF NEUTRAL OFF
F4
Hi Reverse OFF NEUTRAL OFF
Lo 3rd and Lo F5 OFF
3rd 3rd and Lo F5 OFF
2nd 1st OFF NEUTRAL OFF
F3
Lo Reverse OFF NEUTRAL OFF
Hi 2nd and Hi F4 OFF
3rd 3rd and Lo F5 OFF
1st 2nd 2nd and Lo F3 OFF
F2
Hi Reverse OFF NEUTRAL OFF
Lo 2nd and Lo F3 OFF
3rd 3rd and Lo F5 OFF
1st 2nd 2nd and Lo F3 OFF
F1
Lo Reverse OFF NEUTRAL OFF
Hi 1st and Hi F2 OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
R3
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3rd and Reverse R3 OFF
2nd 1st OFF NEUTRAL OFF
R2
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3rd and Reverse R3 OFF
1st 2nd 2nd and Reverse R2 OFF
R1
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
No remedy is ―
N ANY NONE
taken

HM400-3M0 40-155
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SDMA] Malfunction of ECMV (Low) (HM300_3-15SDMA-400-A-Z0-A)

Action level Failure code Malfunction of ECMV (Low)

Failure
L03 15SDMA (Transmission controller system)
• When driving L clutch ECMV solenoid, signal from fill switch is OFF, and transmission
Detail of output shaft speed calculated from signals from transmission input shaft speed sensor
failure and transmission intermediate shaft speed sensor differs from that sensed by
transmission output shaft speed sensor.
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed. (See failure code [15J0MW].)
controller • Disengages lockup clutch.
Problem on • Machine travels in gear speed that does not use L clutch.
machine
• Output current to ECMV solenoid can be checked with monitoring function. (Code: 31601
(mA))
• First, check for mechanical failures such as problem in L clutch, clogged oil filter of
Related pressure control valve, etc.
information k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position. (See Testing and adjusting, "Cab tilt-up procedure".)

• Method of reproducing failure code: Start the engine and drive machine in F1.
No. Cause Procedure, measuring location, criteria, and remarks
Defective L clutch solenoid
1 Perform troubleshooting for failure code [15J0MW].
system

40-156 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SEL1] Release Trouble of ECMV (1st) (HM300_3-15SEL1-400-A-Z0-A)

Action level Failure code Release Trouble of ECMV (1st)

Failure
L03 15SEL1 (Transmission controller system)
Detail of • Signal from fill switch remains ON even after controller stops driving 1st clutch ECMV
failure solenoid.
• Shifts up gear according to gear speed before failure as shown in Table 2 and holds that
Action of gear speed.
controller • Disengages lockup clutch.
Problem on • Machine travels in gear speed that use 1st clutch.
machine
• Output current to ECMV solenoid can be checked with monitoring function. (Code: 31602
(mA))
• Input signal from fill switch can be checked with monitoring function. (Code 02216 (0:
OFF, 1: ON))
Related • First, check for mechanical failures such as problem in 1st clutch, clogged oil filter of
information pressure control valve, etc.
k Tilt up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine.

No. Cause Procedure, measuring location, criteria, and remarks
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 1.SW (CN13).
4. Turn starting switch to ON position.
If failure code [15SEL1] disappears, 1st clutch fill switch is defective.
1 Defective 1st clutch fill switch
1. Turn starting switch to OFF position.
2. Disconnect connector 1.SW (CN13) and connect T-adapter to male
side.
Resis- Between L.SW (CN13) (male) (1) and ground
Min. 1 Mz
tance (Fill switch: OFF)
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
Ground fault in wiring harness
3. Disconnect connector 1.SW (CN13).
2 or defective transmission
4. Turn starting switch to ON position.
controller
If failure code [15SEL1] is still displayed, wiring harness has ground
fault or transmission controller is defective.
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 1.SW (CN13).
Ground fault in wiring harness 4. Lower tilted-up cab.
3
(Contact with ground circuit) 5. Disconnect connector ATC3.
6. Connect T-adapter to ATC3 (female).
Resis- Between ATC3 (female) (40) and ground
Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

HM400-3M0 40-157
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 1st clutch

40-158 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Remedy taken when failure is detected

Gear speed when Failed clutch
Action of controller ON or OFF of lockup
failure is detected (Fill switch: ON)
(Selected clutch and gear speed) 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 3rd and Hi F6 OFF
3rd 3rd and Lo F5 OFF
2nd 1st OFF NEUTRAL OFF
F4
Hi Reverse OFF NEUTRAL OFF
Lo 3rd and Lo F5 OFF
3rd 3rd and Lo F5 OFF
2nd 1st OFF NEUTRAL OFF
F3
Lo Reverse OFF NEUTRAL OFF
Hi 2nd and Hi F4 OFF
3rd 3rd and Lo F5 OFF
1st 2nd 2nd and Lo F3 OFF
F2
Hi Reverse OFF NEUTRAL OFF
Lo 2nd and Lo F3 OFF
3rd 3rd and Lo F5 OFF
1st 2nd 2nd and Lo F3 OFF
F1
Lo Reverse OFF NEUTRAL OFF
Hi 1st and Hi F2 OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
R3
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3rd and Reverse R3 OFF
2nd 1st OFF NEUTRAL OFF
R2
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3rd and Reverse R3 OFF
1st 2nd 2nd and Reverse R2 OFF
R1
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
No remedy is ―
N ANY NONE
taken

HM400-3M0 40-159
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SEMA] Malfunction of ECMV (1st) (HM300_3-15SEMA-400-A-Z0-A)

Action level Failure code Malfunction of ECMV (1st)

Failure (1st command, 1st clutch fill switch OFF, slip detected)
L03 15SEMA
(Transmission controller system)
• When driving 1st clutch ECMV solenoid, signal from fill switch is OFF, and transmission
Detail of output shaft speed calculated from signals from transmission input shaft speed sensor
failure and transmission intermediate shaft speed sensor differs from that sensed by
transmission output shaft speed sensor.
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed. (See failure code [15K0MW].)
controller • Disengages lockup clutch.
Problem on • Machine travels in gear speed that does not use 1st clutch.
machine
• Output current to ECMV solenoid can be checked with monitoring function. (Code: 31602
(mA))
• If the electrical system operates normally, check for mechanical failures such as problem
Related in 1st clutch, clogged oil filter of pressure control valve, etc.
information k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start the engine and drive machine in F1.
No. Cause Procedure, measuring location, criteria, and remarks
Defective 1st clutch solenoid
1 Perform troubleshooting for failure code [15K0MW].
system

40-160 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SFL1] Release Trouble of ECMV (2nd) (HM300_3-15SFL1-400-A-Z0-A)

Action level Failure code Release Trouble of ECMV (2nd)

Failure
L03 15SFL1 (Transmission controller system)
Detail of • Signal from fill switch remains ON even after controller stops driving 2nd clutch ECMV
failure solenoid.
• Shifts up gear according to gear speed before failure as shown in Table 2 and holds that
Action of gear speed.
controller • Disengages lockup clutch.
Problem on • Machine travels in gear speed that use 2nd clutch.
machine
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31603 (mA)).
• Input signal from fill switch can be checked with monitoring function. (Code 02216 (0:
OFF, 1: ON))
Related • First, check for mechanical failures such as problem in 2nd clutch, clogged oil filter of
information pressure control valve, etc.
k Tilt up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine.

No. Cause Procedure, measuring location, criteria, and remarks
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 2.SW (CN15).
4. Turn starting switch to ON position.
If failure code [15SFL1] disappears, 2nd clutch fill switch is defective.
1 Defective 2nd clutch fill switch
1. Turn starting switch to OFF position.
2. Disconnect connector 2.SW (CN15) and connect T-adapter to male
side.
Resis- Between 2.SW (CN15) (male) (1) and ground
Min. 1 Mz
tance (Fill switch: OFF)
1. Tilt up cab (observe precautions mentioned above).
Ground fault in wiring harness 2. Turn starting switch to OFF position.
or 3. Disconnect connector 2.SW (CN15).
2
Defective transmission 4. Turn starting switch to ON position.
controller If failure code [15SFL1] is still displayed, wiring harness has ground
fault or transmission controller is defective.
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 2.SW (CN15).
3 Ground fault in wiring harness 4. Lower tilted-up cab.
(Contact with ground circuit) 5. Disconnect connector ATC3.
6. Connect T-adapter to ATC3 (female).
Resis- Between ATC3 (female) (9) and ground
Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

HM400-3M0 40-161
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 2nd clutch

40-162 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 2
Remedy taken when failure is detected
Gear speed when Failed clutch
Action of controller ON or OFF of lockup
failure is detected (Fill switch: ON)
(Selected clutch and gear speed) 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 3rd and Hi F6 OFF
3rd 3rd and Lo F5 OFF
2nd 1st OFF NEUTRAL OFF
F4
Hi Reverse OFF NEUTRAL OFF
Lo 3rd and Lo F5 OFF
3rd 3rd and Lo F5 OFF
2nd 1st OFF NEUTRAL OFF
F3
Lo Reverse OFF NEUTRAL OFF
Hi 2nd and Hi F4 OFF
3rd 3rd and Lo F5 OFF
1st 2nd 2nd and Lo F3 OFF
F2
Hi Reverse OFF NEUTRAL OFF
Lo 2nd and Lo F3 OFF
3rd 3rd and Lo F5 OFF
1st 2nd 2nd and Lo F3 OFF
F1
Lo Reverse OFF NEUTRAL OFF
Hi 1st and Hi F2 OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
R3
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3rd and Reverse R3 OFF
2nd 1st OFF NEUTRAL OFF
R2
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3rd and Reverse R3 OFF
1st 2nd 2nd and Reverse R2 OFF
R1
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
No remedy is ―
N ANY NONE
taken

HM400-3M0 40-163
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SFMA] Malfunction of ECMV (2nd) (HM300_3-15SFMA-400-A-Z0-A)

Action level Failure code Malfunction of ECMV (2nd)

Failure (2nd command, 2nd clutch fill switch OFF, slip detected)
L03 15SFMA
(Transmission controller system)
• When driving 2nd clutch ECMV solenoid, signal from fill switch is OFF, and transmission
Detail of output shaft speed calculated from signals from transmission input shaft speed sensor
failure and transmission intermediate shaft speed sensor differs from that sensed by
transmission output shaft speed sensor.
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed. (See failure code [15L0MW].)
controller • Disengages lockup clutch.
Problem on • Machine travels in gear speed that does not use 2nd clutch.
machine
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31603 (mA)).
• First, check for mechanical failures such as problem in 2nd clutch, clogged oil filter of
Related pressure control valve, etc.
information k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine and drive machine in F3.

No. Cause Procedure, measuring location, criteria, and remarks

1 Defective 2nd clutch system Perform troubleshooting for failure code [15L0MW].

40-164 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SGL1] Release Trouble of ECMV (3rd) (HM300_3-15SGL1-400-A-Z0-A)

Action level Failure code Release Trouble of ECMV (3rd)

Failure
L03 15SFL1 (Transmission controller system)
Detail of • Signal from fill switch remains ON even after controller stops driving 3rd clutch ECMV
failure solenoid.
• Shifts up gear according to gear speed before failure as shown in Table 2 and holds that
Action of gear speed.
controller • Disengages lockup clutch.
Problem on • Machine travels in gear speed that use 3rd clutch.
machine
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31604 (mA)).
• Input signal from fill switch can be checked with monitoring function. (Code 02216 (0:
OFF, 1: ON))
Related • First, check for mechanical failures such as problem in 3rd clutch, clogged oil filter of
information pressure control valve, etc.
k Tilt up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine.

No. Cause Procedure, measuring location, criteria, and remarks
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 3.SW (CN17).
4. Turn starting switch to ON position.
If failure code [15SGL1] disappears, 3rd clutch fill switch is defective.
1 Defective 3rd clutch fill switch
1. Turn starting switch to OFF position.
2. Disconnect connector 3.SW (CN17) and connect T-adapter to male
side.
Resis- Between 3.SW (CN17) (male) (1) and ground
Min. 1 Mz
tance (Fill switch: OFF)
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
Ground fault in wiring harness
3. Disconnect connector 3.SW (CN17).
2 or defective transmission
4. Turn starting switch to ON position.
controller
If failure code [15SGL1] is still displayed, wiring harness has ground
fault or transmission controller is defective.
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 3.SW (CN17).
3 Ground fault in wiring harness 4. Lower tilted-up cab.
(Contact with ground circuit) 5. Disconnect connector ATC3.
6. Connect T-adapter to ATC3 (female).
Resis- Between ATC3 (female) (19) and ground
Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

HM400-3M0 40-165
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 3rd clutch

40-166 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 2
Remedy taken when failure is detected
Gear speed when Failed clutch
Action of controller ON or OFF of lockup
failure is detected (Fill switch: ON)
(Selected clutch and gear speed) 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 3rd and Hi F6 OFF
3rd 3rd and Lo F5 OFF
2nd 1st OFF NEUTRAL OFF
F4
Hi Reverse OFF NEUTRAL OFF
Lo 3rd and Lo F5 OFF
3rd 3rd and Lo F5 OFF
2nd 1st OFF NEUTRAL OFF
F3
Lo Reverse OFF NEUTRAL OFF
Hi 2nd and Hi F4 OFF
3rd 3rd and Lo F5 OFF
1st 2nd 2nd and Lo F3 OFF
F2
Hi Reverse OFF NEUTRAL OFF
Lo 2nd and Lo F3 OFF
3rd 3rd and Lo F5 OFF
1st 2nd 2nd and Lo F3 OFF
F1
Lo Reverse OFF NEUTRAL OFF
Hi 1st and Hi F2 OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
R3
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3rd and Reverse R3 OFF
2nd 1st OFF NEUTRAL OFF
R2
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3rd and Reverse R3 OFF
1st 2nd 2nd and Reverse R2 OFF
R1
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
No remedy is ―
N ANY NONE
taken

HM400-3M0 40-167
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SGMA] Malfunction of ECMV (3rd) (HM300_3-15SGMA-400-A-Z0-A)

Action level Failure code Malfunction of ECMV (3rd)

Failure (3rd command, 3rd clutch fill switch OFF, slip detected)
L03 15SGMA
(Transmission controller system)
• When driving 3rd clutch ECMV solenoid, signal from fill switch is OFF, and transmission
Detail of output shaft speed calculated from signals from transmission input shaft speed sensor
failure and transmission intermediate shaft speed sensor differs from that sensed by
transmission output shaft speed sensor.
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed. (See failure code [15M0MW].)
controller • Disengages lockup clutch.
Problem on • Machine travels in gear speed that does not use 3rd clutch.
machine
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31604 (mA)).
• First, check for mechanical failures such as problem in 3rd clutch, clogged oil filter of
Related pressure control valve, etc.
information k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine and drive machine in F5.
No. Cause Procedure, measuring location, criteria, and remarks
1 Defective 3rd clutch system Perform troubleshooting for failure code [15M0MW].

40-168 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SJMA] Malfunction of ECMV (Lockup) (HM300_3-15SJMA-400-A-Z0-A)

Action level Failure code Malfunction of ECMV (Lockup)

Failure (Lockup command, slip detected)
L03 15SJMW
(Transmission controller system)
• When driving lockup clutch solenoid, transmission output shaft speed calculated from
Detail of signals of engine speed sensor and transmission intermediate shaft speed sensor differs
failure from that sensed by transmission output shaft speed sensor.
Action of • Maintains current gear speed during travel and disables lockup clutch.
controller • Transmission will stay in neutral when gear shift lever is set to the N position.
• Lockup is disengaged and gear shifting becomes impossible
Problem on • Once gear shift lever is set to "N" during travel, even if gear shift lever is moved to position
machine other than "N", that gear does not engage until machine is stopped.
• Output current to solenoid can be checked with monitoring function (Code: 31609 (mA)).
• First, check for mechanical failures in lockup clutch or pressure control valve such as
clogged oil filter, etc.
Related
information k Tilt up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: start engine, travel in F1, turn lockup pilot lamp ON
No. Cause
1 Detective speed sensor
Defective lockup clutch
2
solenoid
Open and short circuit in
3 wiring harness
Open circuit in wiring harness 3.
4 (wire breakage or defective
contact of connector)
Defective transmission
5
controller
Procedure, measuring location, criteria, and remarks
• Troubleshoot by failure codes [DL**KA] and [DL**LC].
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector L/U.PS (CN18) and connect T-adapter to
male side.
Between L/U.PS (CN18) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and L/U.PS (CN18) (male) (1)
tance Min. 1 Mz
or (2)
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC3 and connect T-adapter to female side.
a If check result is unusual, disconnect connector J09 and perform
similar troubleshooting to locate defective wiring harness.
Resis- Between ATC3 (female) (27) and (23)
5 to 15 z
tance
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapter to female side.
Tilt up cab (observe precautions mentioned above).
4. Disconnect connector L/U.PS (CN18) and connect T-adapter to
female side.
Between ATC3 (female) (27) and L/U.PS
Max. 1 z
Resis- (CN18) (female) (1)
tance Between ATC3 (female) (23) and L/U.PS
(CN18) (female) (2) Max. 1 z
If no failure is found by above checks, transmission controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)

HM400-3M0 40-169
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to lockup clutch

40-170 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SKMA] Malfunction of ECMV (Inter-Axle Diff.) (HM300_3-15SKMA-

400-A-Z0-A)

Action level Failure code Malfunction of ECMV (Inter-Axle Differential)

Failure
L01 15SKMA (Transmission controller system)
Detail of • Clutch engagement is not made or clutch slips after driving differential lock clutch
failure solenoid.
• Stops driving inter-axle differential lock solenoid.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Inter-axle differential lock does not operate
machine
• Output current to inter-axle differential lock pressure control valve can be checked with
monitoring function. (Code: 31607)
• Slip can be confirmed by displaying transmission output shaft speed (Code: 31400) and
Related
transmission differential speed (Code: 31402) simultaneously.
information
k Tilt up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria, and remarks
Defective differential lock Check whether clutch pressure is normal by referring to Testing and
1 clutch oil pressure adjusting, "Testing power train oil pressure".
1. Turn starting switch to OFF position.
Ground fault in transmission 2. Disconnect connector ATC.
output shaft speed sensor 3. Tilt up cab (observe precautions mentioned above).
2 circuit 4. Disconnect connector N3.OUT (CN5) and connect T-adapter to
female side.
(Contact with ground circuit)
Resis- Between N3.OUT (CN5) (female) (1) and
ground Min. 1 Mz
tance
1. Tilt up cab (observe precautions mentioned above).
Hot short circuit in 2. Turn starting switch to OFF position.
transmission output shaft 3. Disconnect connector N3.OUT (CN5) and connect T-adapter to
3 speed sensor circuit female side.
(Contact with 24 V circuit) 4. Turn starting switch to ON position.
Voltage Between N3.OUT (CN5) (female) (1) and (2) 3 to 4 V
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector DIFF.PS (CN20) and connect T-adapter to
Defective differential lock male side.
4
clutch solenoid Between DIFF.PS (CN20) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and DIFF.PS (CN20) (male)
tance Min. 1 Mz
(1) or (2)
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC3 and connect T-adapter to female side.
Open and short circuit in
5 wiring harness a If abnormal, continue troubleshooting with J09 disconnected to
locate the faulty harness.
Resis- Between ATC3 (female) (15) and (23)
5 to 15 z
tance

HM400-3M0 40-171
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

Open circuit in wiring harness 3.
6 (wire breakage or defective
contact of connector)
Defective transmission
7
controller
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapter to female side.
Tilt up cab (observe precautions mentioned above).
4. Disconnect connectors ATC3 and DIFF.PS (CN20), and connect T-
adapters to each female side.
Between ATC3 (female) (15) and DIFF.PS
Max. 1 z
Resis- (CN20) (female) (1)
tance Between ATC3 (female) (23) and DIFF.PS
(CN20) (female) (2) Max. 1 z
If no failure is found by above checks, transmission controller is
defective.
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to transmission output shaft speed sensor

Circuit diagram related to inter-axle differential lock

40-172 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [2F00KM] Dragging of Parking Brake (HM400_3-2F00KM-400-A-Z0-A)

k Be sure to chock the wheels. When performing troubleshooting with parking brake released, be
sure to depress foot brake (2 persons required for this work).
Action level Failure code Dragging of Parking Brake
Failure
- 2F00KM (Transmission controller system)
• Machine is driven with parking brake switch in PARKING position (with relay R20
Detail of disengaged).
failure (Retarder controller does not recognize that parking brake switch is at OFF (release)
position.
Action of • None in particular
controller
Problem on • If machine is used as it is, parking brake may be damaged.
machine
• If accumulator pressure is low, parking brake is not released.
• If one or more of failure codes [DAQQKR], [DAQRKR], [DB1QKR] and [DB1RKR] which
indicate poor CAN communication between transmission controller and retarder controller
is generated, perform troubleshooting it (them) first.
Related • When 24 V is applied to parking brake solenoid, parking brake is released.
information • Accumulator pressure can be checked with monitoring function.
Code: 35500 Accumulator pressure (front), 35501 Accumulator pressure (rear)
• Failure code [DHUCKX] indicates problems with parking brake pressure sensor while
failure codes [DW4BK4] and [DW4BMA] indicate problems with parking brake valve.
• Method of reproducing failure code: Start the engine and drive machine in F1.
No. Cause Procedure, measuring location, criteria, and remarks
• Set parking brake switch to "RELEASE" position, and then drive
machine.
Inappropriate operation of
1 • Bring the machine to a complete stop, set emergency brake switch to
parking brake switch
"RELEASE" position, and then drive machine.
• Do not use parking brake while machine is travelling.
Working of emergency brake
2 (Emergency brake is applied • Do not apply emergency brake unless necessary.
during travel.)
1. Turn starting switch to OFF position.
2. Replace R20 with relay of known performance.
Check whether Machine becomes Relay (R20) is
problem is resolved normal. defective.
after parking brake
Defective parking brake Machine does not
3 safety relay (R20) is Relay (R20) is normal.
safety relay (R20) become normal.
replaced.
1. Turn starting switch to OFF position.
2. Disconnect connector R20 and connect T-adapter to male side.
Resis- Between R20 (male) (1) and (2) 200 to 400
tance z
1. Turn starting switch to OFF position.
2. Connect T-adapter to connector PBS (male).
3. Start engine.
Parking brake switch:
Between PBS (male) Min. 1 Mz
4 Defective parking brake Release
pressure switch (5) and (4) Parking brake switch:
Max. 1 z
Resis- PARKING
tance Parking brake switch:
Between PBS (male) Max. 1 z
Release
(5) and (6) Parking brake switch:
Min. 1 Mz
PARKING

HM400-3M0 40-173
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

1. Turn starting switch to OFF position.
2. Insert T-adapter into connector B17.
Defective parking brake
5 3. Turn starting switch to ON position.
pressure sensor
Between B17 (1) and Parking brake switch:
Voltage 3.5 to 4.5 V
(2) OFF (release)
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors BRC1 and BRC2.
Defective retarder controller 3. Turn starting switch to ON position.
6
Between BRC1 (4) Parking brake switch:
Voltage 3.5 to 4.5 V
and BRC2 (35) OFF (release)
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
7
controller performed).

Circuit diagram related to parking brake

40-174 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) (HM300_3-2G42ZG-

400-A-Z0-A)

Action level Failure code Accumulator Oil Pressure Low (Front)

Failure
L03 2G42ZG (Retarder hoist controller system)
Detail of • A drop in oil pressure (6.9 MPa {70 kg/cm2}) or less) is detected by signal (voltage 1.05 V
failure or less) from accumulator oil pressure sensor (front).
Action of • None in particular
controller
Problem on • If machine is used as it is, front brakes may not work.
machine
• Input signal from oil pressure sensor can be checked with monitoring function (Code:
Related 35500 (MPa), 35506 (V)).
information • Circuit diagram: See [DHU2KX].
No. Cause Procedure, measuring location, criteria, and remarks
Hydraulic system (pump, relief valve, piping) may be defective. If
1 Hydraulic system failure
pressure is too low, check and remove cause of failure.
Accumulator (front) • If no failure is found by check on Cause 1, the accumulator (front) oil
2 Defective oil pressure sensor pressure sensor system may be defective. Perform troubleshooting
system for failure code [DHU2KX].
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective.
3
controller
(Since this is an internal defect, troubleshooting cannot be performed.)

HM400-3M0 40-175
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) (HM300_3-2G43ZG-400-

A-Z0-A)

Action level Failure code Accumulator Oil Pressure Low (Rear)

Failure
L03 2G43ZG (Retarder hoist controller system)
Detail of • A drop in oil pressure (6.9 MPa {70 kg/cm2}) or less) is detected by signal (voltage 1.05 V
failure or less) from accumulator oil pressure sensor (rear).
Action of • None in particular
controller
Problem on • If machine is used as it is, rear brakes may not work.
machine
• Input signal from oil pressure sensor can be checked with monitoring function (Code:
Related 35501 (MPa), 35507 (V)).
information • Circuit diagram: See [DHU3KX].
No. Cause Procedure, measuring location, criteria, and remarks
Hydraulic system (pump, relief valve, piping) may be defective. If
1 Hydraulic system failure
pressure is too low, check and remove cause of failure.
• If no failure is found by check on Cause 1, the accumulator (rear) oil
Defective accumulator (rear)
2 pressure sensor system may be defective. Perform troubleshooting
oil pressure sensor system
for failure code [DHU3KX].
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective.
3
controller
(Since this is an internal defect, troubleshooting cannot be performed.)

40-176 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [879AKA] A/C Inner Sensor Open Circuit (PC400-879AKA-441-A-Z0-A)

See chapter 80 Appendix "Failure code [879AKA] Air Conditioner Inner Sensor Open Circuit"
a Since the inner air temperature sensor connector cannot be disconnected with the sensor installed on the
machine, the air conditioner controller or air conditioner unit must be replaced.

HM400-3M0 40-177
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [879AKB] A/C Inner Sensor Short Circuit (PC400-879AKB-441-A-Z0-A)

See chapter 80 Appendix "Failure code [879AKB] Air Conditioner Inner Sensor Short Circuit" .
a Since the inner air temperature sensor connector cannot be disconnected with the sensor installed on the
machine, the air conditioner controller or air conditioner unit must be replaced.

40-178 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [879BKA] A/C Outer Sensor Open Circuit (PC400-879BKA-441-A-Z0-A)

See chapter 80 Appendix "Failure code [879BKA] Air Conditioner Outer Sensor Open Circuit" .

HM400-3M0 40-179
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [879BKB] A/C Outer Sensor Short Circuit (PC400-879BKB-441-A-Z0-A)

See chapter 80 Appendix "Failure code [879BKB] Air Conditioner Outer Sensor Short Circuit" .

40-180 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [879CKA] Ventilating Sensor Open Circuit (PC400-879CKA-441-A-Z0-A)

See chapter 80 Appendix "Failure code [879CKA] Ventilating Sensor Open Circuit"
a Since the ventilating sensor (evaporator temperature sensor) cannot be disconnected with the sensor
installed on the machine, the air conditioner controller or air conditioner unit must be replaced.

HM400-3M0 40-181
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [879CKB] Ventilating Sensor Short Circuit (PC400-879CKB-441-A-Z0-A)

See chapter 80 Appendix "Failure code [879CKB] Ventilating Sensor Short Circuit"
a Since the ventilating sensor (evaporator temperature sensor) cannot be disconnected with the sensor
installed on the machine, the air conditioner controller or air conditioner unit must be replaced.

40-182 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [879EMC] Ventilation Damper Abnormality (PC400-879EMC-441-A-Z0-A)

See chapter 80 Appendix "Failure code [879EMC] Ventilation Damper Abnormality".

a Since the vent select servo motor cannot be disconnected on the machine, the air conditioner controller or
air conditioner unit must be replaced.

HM400-3M0 40-183
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [879FMC] Air Mix Damper Abnormality (PC400-879FMC-441-A-Z0-A)

See chapter 80 Appendix "Failure code [879FMC] Air Mix Damper Abnormality".
a Since the air mix servo motor connector cannot be disconnected on the machine, the air conditioner
controller or air conditioner unit must be replaced.

40-184 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [879GKX] Refrigerant Abnormality (PC400-879GKX-441-A-Z0-A)

See chapter 80 Appendix "Failure code [879GKX] Refrigerant Abnormality".

HM400-3M0 40-185
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [989D00] Tilt Caution (HM300_3-989D00-400-A-Z0-A)

Action level Failure code Tilt Caution

Failure
― 989D00 (Retarder hoist controller system)
Detail of • Dump body is raised with the machine tipped.
failure
Action of • Lights up tilt caution lamp.
controller
Problem on • If dump body is raised further, the machine may tip over.
machine
Related • Input signals from pitch angle sensor can be checked with monitoring function. (Code:
information 32904 (°), 32905 (V))
No. Cause Procedure, measuring location, criteria, and remarks
Do not raise dump body when machine is tilted 15 deg. or more.
1 Wrong operation
(Tell operator correct operation method.)
If no failure is found by check on Cause 1, pitch angle sensor system
2 Defective pitch angle sensor
may be defective. Perform troubleshooting for failure code [DKH0KX].
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective.
3
controller
(Since this is an internal defect, troubleshooting cannot be performed.)

40-186 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [989L00] Engine Controller Lock Caution1 (HM300_3-989L00-400-A-Z0-A)

Action level Failure code Engine Controller Lock Caution 1

Failure
― 989L00 (Machine monitor system)
Detail of • Machine monitor detects engine controller lock (cause 1).
failure
Action of • None in particular
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Engine does not start.
machine
• When this failure code occurs after replacement of monitor controller, user password must
Related be replaced with one before replacement of controller.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
Replacement of This trouble may result from replacement of monitor controller.
1
monitor controller

HM400-3M0 40-187
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [989M00] Engine Controller Lock Caution2 (HM300_3-989M00-400-A-Z0-A)

Action level Failure code Engine Controller Lock Caution 2

Failure
― 989M00 (Machine monitor system)
Detail of • Machine monitor detects engine controller lock (cause 2).
failure
Action of • None in particular
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Engine does not start.
machine
• When this failure code occurs after replacement of monitor controller, user password
Related must be replaced with one before replacement of controller.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
Replacement of This trouble may result from replacement of monitor controller.
1
monitor controller
If this failure code occurs when monitor controller is not replaced, monitor
Defective monitor controller may be defective. (Since this is an internal defect, troubleshooting
2
controller cannot be performed.)

40-188 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [989N00] Engine Controller Lock Caution3 (HM300_3-989N00-400-A-Z0-A)

Action level Failure code Engine Controller Lock Caution 3

Failure
― 989N00 (Machine monitor system)
Detail of • Machine monitor detects engine controller lock (cause 3).
failure
Action of • Tries automatic restoration.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on
machine
Related • Method of reproducing failure code: Failure code cannot be reproduced since machine
information recovers when cause of failure disappears.
No. Cause Procedure, measuring location, criteria, and remarks
Defective engine If this failure code appears repeatedly, engine controller may be defective.
1 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

HM400-3M0 40-189
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [AA10NX] Air Cleaner Clogging (HM400_3-AA10NX-400-A-Z0-A)

Action level Failure code Air Cleaner Clogging

Failure
L01 AA10NX (Transmission controller system)
Detail of • Air cleaner clogging signal circuit is open (disconnected from ground) while engine was
failure running.
Action of • None in particular
controller
Problem on • If machine is used as it is, air intake performance of engine may be deteriorated.
machine
• Voltage of ATC2 (17): GND level when air cleaner is normal, OPEN (6 to 12 V) when air
Related cleaner is clogged
information • Method of reproducing failure code : Start engine.
No. Cause Procedure, measuring location, criteria, and remarks
Dust indicator does not indicate
Air cleaner is normal.
1 Air cleaner is clogged. red zone.
Dust indicator indicates red zone. Air cleaner is clogged.
1. Turn starting switch to OFF position.
2. Disconnect connector T05 and connect T-adapter to male side.
Defective air cleaner clogging 3. Start engine
2
sensor
Resis- Between T05 (male) Air cleaner is normal. Max. 1 z
tance (1) and (2) Air cleaner is clogged. Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC2, ATC3, T05, and connect T-adapters to
Open circuit in wiring harness male side.
3 (wire breakage or defective Between ATC3 (female) (21) and T05 (female)
Max. 1 z
contact of connector) Resis- (2)
tance Between ATC2 (female) (17) and T05 (female)
(1) Max. 1 z

1. Turn starting switch to OFF position.

Ground fault in wiring 2. Disconnect connectors ATC2 and T05, and connect T-adapter to
4 harness either female side.
(Contact with ground circuit) Resis- Between ground ATC2 (female) (17) or T05
(female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors ATC3 and ATC2.
Defective transmission 3. Start engine
5
controller
Between ATC2 (17) Air cleaner is normal. Max. 1 V
Voltage
and ATC3 (21) Air cleaner is clogged. 6 to 12 V

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 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to air cleaner

HM400-3M0 40-191
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [AB00KE] Charge Voltage Low (HM400_3R-AB00KE-400-A-Z0-A)

Action level Failure code Charge Voltage Low

Failure
L03 AB00KE (Transmission controller system)
Detail of • Engine is running, but generation signal from alternator is not inputted.
failure
Action of • None in particular
controller
Problem on • If machine continues to be used, battery voltage may drop too low and machine may be
machine unable to travel.
Related • Battery charging voltage can be checked with monitoring function (Code: 04307)
information
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect wiring harness from alternator R terminal.
3. Start engine.
1 Defective alternator Voltage Between alternator R and E 20 to 30 V
a If battery is deteriorated or used at low temperatures, voltage may stay low
for a while after engine starts.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC1 and connect T-adapter to female side.
3. Start engine.
Open circuit in wiring Voltage Between ATC1 (female) (15) and ground 20 to 30 V
harness
2 (wire breakage or a If battery is deteriorated or used at low temperatures, voltage may stay low
defective contact of for a while after engine starts.
connector) 1. Turn starting switch to OFF position.
2. Disconnect connector ATC1 and connect T-adapter to female side.
Between ATC1 (female) (15) and alternator
Resistance Max. 1 z
terminal R
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector ATC1.
Defective transmission 3. Start engine.
3 Voltage Between ATC1 (15) and ground 20 to 30 V
controller
a If battery is deteriorated or used at low temperatures, voltage may stay low
for a while after engine starts.

Circuit diagram related to alternator

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 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [AB00KY] Hot Short of Alternator R Terminal (HM400_3R-AB00KY-400-A-Z0-

A)

Action level Failure code Hot Short of Alternator R Terminal

Failure
L03 AB00KY (Transmission controller system)
Detail of • When starting switch is turned to ON position, alternator terminal R signal is ON.
failure
Action of • None in particular
controller
Problem on • If machine continues to be used, battery voltage can drop and machine may not able to
machine travel.
Related • Battery charging voltage can be checked with monitoring function (Code: 04307).
information
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect wiring harness from alternator R terminal.
3. Start engine.
1 Defective alternator Voltage Between alternator R and E 20 to 30 V
a If battery is deteriorated or used at low temperatures, voltage may stay low
for a while after engine starts.
Hot short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect wiring harness from alternator R terminal.
2 3. Disconnect connector ATC1 and connect T-adapter to female side.
(contact with 24 V 4. Starting switch: ON
circuit)
Voltage Between ATC1 (female) (15) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector ATC1.
Defective transmission 3. Start engine.
3 Voltage Between ATC1 (15) and ground 20 to 30 V
controller
a If battery is deteriorated or used at low temperatures, voltage may stay low
for a while after engine starts.

Circuit diagram related to alternator

HM400-3M0 40-193
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [B@BAZG] Eng Oil Press Low (HM400_3R-BaBAZG-400-A-Z0-A)

Action level Failure code Engine Oil Pressure Low

Failure
L03 B@BAZG (Engine controller system)
Detail of • Engine controller determines that engine oil pressure drops abnormally because signal
failure voltage from engine oil pressure sensor drops while engine is running.
Action of • Lights up engine oil pressure low caution icon in red on machine monitor.
controller • Limits engine output and runs engine.
Problem on • If machine is used as it is, engine may be seized.
machine • Engine output lowers.
• Signal voltage of engine oil pressure sensor is input to engine controller that transmits
information to machine monitor through CAN communication system.
Related • Engine oil pressure can be checked with monitoring function.
information (Code: 37200)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria, and remarks
Lowered engine oil
pressure Engine oil pressure may drops. Check it and remove cause of failure if oil
1 pressure is low.
(When system works
properly)
If no failure is found by check on cause 1, engine oil pressure sensor system
Defective engine oil
2 may be defective. Perform troubleshooting for failure codes [CA135] and
pressure sensor system
[CA141].

40-194 HM400-3M0
 40 Troubleshooting
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Failure code [B@BAZK] Engine Oil Level Low (HM400_3-BaBAZK-400-A-Z0-A)

Action level Failure code Engine Oil Level Low

Failure
L01 B@BAZK (Transmission controller system)
Detail of • The engine oil level switch signal circuit is opened (disconnected from ground cable)
failure when the engine is stopped.
Action of • Controls engine usually and allows it to run.
controller
Problem on • If machine is used as it is, engine may be seized.
machine
Related • The operation of engine oil level switch can be checked with (Code: 02215)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
• Engine oil level is normal.
1 Engine Oil Level Low a If engine oil level is low, check for oil leakage from engine before
adding oil.
1. Turn starting switch to OFF position.
2. Disconnect connector T06 and connect T-adapter to male side.
Defective engine oil level Engine oil level
2 Max. 1 z
switch Resis- Between T06 (male) Normal
tance (1) and ground Engine oil level
Min. 1 Mz
Low
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ATC2 and T06, and connect T-adapters to
3 (wire breakage or defective female sides.
contact of connector) Resis- Between ATC2 (female) (2) and T06 (female)
(1) Max. 1 z
tance
1. Turn starting switch to OFF position.
2. Connect T-adapter to connector ATC2.
3. Turn starting switch to ON position.
Defective transmission
4 Engine oil level
controller Max. 1 V
Between ATC2 (2) and Normal
Voltage
ground Engine oil level
6 to 12 V
Low

Circuit diagram related to engine oil level

HM400-3M0 40-195
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [B@BCNS] Eng Water Overheat (HM400_3R-BaBCNS-400-A-Z0-A)

Action level Failure code Engine Water Overheat

Failure
L02 B@BCNS (Engine controller system)
Detail of • Engine controller determines that engine coolant overheats because signal voltage from
failure engine coolant temperature sensor drops while engine is running.
Action of • Lights up engine coolant overheat caution icon in red on machine monitor.
controller • Limits engine output and runs engine.
Problem on • If machine is used as it is, engine may be seized.
machine • Engine output lowers.
• Signal voltage of engine coolant temperature sensor is input to engine controller that
transmits information to machine monitor through CAN communication system.
Related • Engine coolant temperature can be checked with monitoring function.
information (Code: 04107 Engine coolant temperature)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria, and remarks
Overheating of engine
coolant Engine coolant may overheat. Check coolant temperature and remove
1
(When system works cause of failure if coolant overheats.
properly)
If no failure is found by check on cause 1, engine coolant temperature
Defective engine coolant
2 sensor system may be defective. Perform troubleshooting for failure
temperature sensor system
codes [CA144] and [CA145].

40-196 HM400-3M0
 40 Troubleshooting
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Failure code [B@BCZK] Eng Water Level Low (HM400_3-BaBCZK-400-A-Z0-A)

Action level Failure code Engine Water Level Low

Failure
L01 B@BCZK (Transmission controller system)
Detail of • Signal circuit of radiator coolant level switch is open (disconnected from ground) while
failure engine is stopped.
Action of • None in particular
controller
Problem on • If machine is used as it is with coolant at low level, engine may overheat.
machine
• Operating condition of radiator coolant level switch can be checked with monitoring
Related function. (Code: 02215)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
• Radiator coolant level is normal.
Lowered radiator coolant
1 a If radiator coolant level is low, check engine and radiator for coolant
level
leakage before adding coolant.
1. Turn starting switch to OFF position.
2. Disconnect connector T01 and connect T-adapter to male side.
Defective radiator coolant Radiator coolant level
2 Max. 1 z
level switch Resis- Between T01 (male) normal
tance (1) and ground Radiator coolant level
Min. 1 Mz
low
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC2, ATC3, and T01, and connect T-
Open circuit in wiring harness adapters to each female side.
3 (wire breakage or defective Between ATC2 (female) (12) and T01 (female)
Max. 1 z
contact of connector) Resis- (1)
tance Between ATC3 (female) (21) and T01 (female)
(2) Max. 1 z

1. Turn starting switch to OFF position.

2. Connect T-adapters to connectors ATC2 and ATC3.
3. Turn starting switch to ON position.
Defective transmission
4 Radiator coolant level
controller Max. 1 V
Between ATC2 (12) normal
Voltage
and ATC3 (21) Radiator coolant level
6 to 12 V
low

HM400-3M0 40-197
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to coolant level switch

40-198 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [B@C6NS] Retarder Oil Overheat (Front) (HM300_3-BaC6NS-400-A-Z0-A)

Action level Failure code Retarder Oil Overheat (Front)

Failure
L02 B@C6NS (Machine monitor system)
Detail of • Overheating (120°C) of front brake cooling oil is detected.
failure
Action of • Lights up retarder oil temperature overheat caution lamp.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
Problem on • If machine is used as it is, front brake may be damaged.
machine
• Information on the front retarder oil temperature is obtained from the retarder hoist
Related controller through CAN communication.
information • Front retarder oil temperature can be checked with monitoring function (Code: 30211 (°C),
30214 (V)).
No. Cause Procedure, measuring location, criteria, and remarks
Overheating of front brake
cooling oil (when system Front brake cooling oil may overheat. Check and remove cause of
1
works properly) failure.
Defective front retarder oil
2 Perform troubleshooting for failure codes [DGR4KB] and [DGR4L8].
temperature sensor
If no failure is found by check on cause 2 but there exists a substantial
Defective retarder hoist difference between the front retarder oil temperature sensed by the
3 monitoring function (code: 30211) and actual oil temperature, the
controller
retarder hoist controller may be defective.
4 Defective monitor controller If no failure is found by above checks, monitor controller is defective.

HM400-3M0 40-199
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [B@C8NS] Retarder Oil Overheat (Center) (HM300_3-BaC8NS-400-A-Z0-A)

Action level Failure code Retarder Oil Overheat (Center)

Failure
L02 B@C8NS (Machine monitor system)
Detail of • Overheating (120°C) of center brake cooling oil is detected.
failure
Action of • Lights up retarder oil temperature overheat caution lamp.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
Problem on • If machine is used as it is, center brake may be damaged.
machine
• Information on center retarder oil temperature is obtained from retarder hoist controller
Related through CAN communication.
information • Center retarder oil temperature can be checked with monitoring function (Code: 30215 (°
C), 30212 (V)).
No. Cause Procedure, measuring location, criteria, and remarks
Overheating of center brake Center brake cooling oil may overheat. Check and remove cause of
1 cooling oil failure.
Defective center retarder oil
2 Perform troubleshooting for failure codes [DGR3KB] and [DGR3L8].
temperature sensor
If no failure is found by check on cause 2 but substantial difference is
Defective retarder hoist observed between center retarder oil temperature sensed by using
3 monitoring function (code: 30215) and actual oil temperature, retarder
controller
hoist controller may be defective.
4 Defective monitor controller If no failure is found by above checks, monitor controller is defective.

40-200 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [B@CENS] T/C Oil Temp. Overheat (HM300_3-BaCENS-400-A-Z0-A)

Action level Failure code Torque Converter Oil Temperature Overheat

Failure
L02 B@CENS (Machine monitor system)
Detail of • Overheating of the torque converter oil temperature is detected (120°C or above).
failure
Action of • Lights up torque converter oil overheat caution lamp.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
Problem on • If machine is used as it is, torque converter may be damaged.
machine
• Information from torque converter oil temperature sensor is obtained from transmission
Related controller through CAN communication.
information • Torque converter oil temperature can be checked with monitoring function.
(Monitoring code: 30100 (°C), 30101 (V))
No. Cause Procedure, measuring location, criteria, and remarks
Overheating of torque
1 converter oil (when system is Torque converter oil may overheat. Check and remove cause of failure.
normal)
Defective torque converter oil
2 Perform troubleshooting for failure code [DGT1KX].
temperature sensor system
If no failure is found by check on cause 2 but substantial difference is
Defective transmission observe between torque converter oil temperature sensed by using
3 monitoring function (code: 30100) and actual oil temperature,
controller
transmission controller may be defective.
4 Defective monitor controller If no failure is found by above checks, monitor controller is defective.

HM400-3M0 40-201
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [B@JANS] Steering Oil Overheat (HM300_3-BaJANS-400-A-Z0-A)

Action level Failure code Steering Oil Overheat

Failure
L02 B@JANS (Retarder hoist controller system)
Detail of • Steering oil temperature sensor circuit voltage dropped to 2.2 V or below (oil temperature
failure 100°C or above).
Action of • None in particular
controller
Problem on • If machine is used as it is, oil leakage may occur.
machine
Related • Steering oil temperature can be checked with monitoring function (Code: 32701 (°C),
information 32702 (V)).
No. Cause Procedure, measuring location, criteria, and remarks
Overheating of steering oil
temperature Steering oil may overheat. Remove cause of failure if steering oil
1
(When system works overheats.
properly)
If no failure is found by check on Cause 1, steering oil temperature
Defective steering oil
2 sensor system may be defective. Carry out troubleshooting for failure
temperature sensor
codes [DGR6KB] and [DGR6LB].
Defective retarder hoist If no failure is found by above checks, retarder hoist controller is
3
controller defective.

40-202 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA111] ECM Critical Internal Failure (HM400_3R-CA111-400-A-Z0-A)

Action level Failure code Electronic Control Module Critical Internal Failure
Failure
L04 CA111 (Engine controller system)
Detail of • Engine controller has internal defect.
failure
Action of • None in particular
controller
Problem on • Engine continues to run normally, but it may stop during running or may not be able to
machine restart if it is stopped.
• Power supply voltage of engine controller can be checked with monitoring function.(Code:
Related 03203 (V))
information • Method of reproducing failure code: Turn starting switch to ON position
No. Cause Procedure, measuring location, criteria, and remarks
Defective power supply
1 Perform troubleshooting for failure code [CA441].
system

HM400-3M0 40-203
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA115] Eng Ne and Bkup Speed Sens Error (PC400-CA115-400-A-Z0-A)

Action level Failure code Engine Ne and Bkup Speed Sensor Error
Failure
L04 CA115 (Engine controller system)
Detail of • Abnormality is detected in signal circuits of Ne and Bkup speed sensors at the same time.
failure
Action of • Stops engine.
controller
Problem on • Engine does not start (if engine is stopped).
machine • Engine stops (if engine is running).
Related • Method of reproducing failure code: Start engine.
information
No. Cause Procedure, measuring location, criteria and remarks
Defective Ne speed sensor
1 Perform troubleshooting for failure code [CA689].
system
Defective Bkup speed sensor
2 Perform troubleshooting for failure code [CA778].
system
If no failure is found by above checks, engine controller is defective.
3 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

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 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA122] Chg Air Press Sensor High Error (HM400_3M0-CA122-400-A-Z0-A)

Action level Failure code Charge Air Pressure Sensor High Error
Failure
L03 CA122 (Engine controller system)
Detail of • High voltage occurs in charge (boost) pressure sensor signal circuit.
failure
Action of • Sets charge (boost) pressure to fixed value (400 kPa {4.1 kg/cm2}) and runs engine.
controller • Limits engine output and runs engine.
Problem on • Acceleration performance of engine drops.
machine • Engine output reduces.
• Signal voltage from charge pressure sensor (boost pressure sensor) can be checked with
monitoring function. (Code: 36501 (V))
• Boost pressure sensed by charge (boost) pressure sensor can be checked with
Related
monitoring function. (Code: 36500 (kPa))
information
• Method of reproducing failure code: Turn starting switch to ON position.
• If sensor connector is disconnected, failure code [CA123] for "Low Error" is displayed
even in normal condition.
No. Cause Procedure, measuring location, criteria, and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "Related information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
Defective sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2 supply system for it first.
1. Turn starting switch to OFF position.
Defective charge 2. Disconnect connector PIM.
3 (boost) pressure sensor 3. Turn starting switch to ON position.
If failure code changes from [CA122] to [CA123], charge (boost) pressure
sensor is defective.

Open circuit in wiring a To check open circuit in GND line

harness (wire breakage 1. Turn starting switch to OFF position.
4 or defective contact of 2. Disconnect connectors ENG and PIM, and connect T-adapters to each
connector) female side.
Resistance Between ENG (female) (47) and PIM (female) (2) Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and PIM, and connect T-adapter to either
Short circuit in wiring
5 female side.
harness
Between ENG (female) (37) and (44), or between
Resistance PIM (female) (1) and (3) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connector PIM.
Hot short circuit in
6 3. Insert T-adapter into connector ENG.
wiring harness
4. Turn starting switch to ON position (with connector PIM disconnected).
Voltage Between ENG (44) and (47) Max. 1 V
Defective engine If no failure is found by above checks, engine controller is defective. (Since
7 this is an internal defect, troubleshooting cannot be performed.)
controller

HM400-3M0 40-205
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to charge pressure sensor

40-206 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA123] Chg Air Press Sensor Low Error (HM400_3M0-CA123-400-A-Z0-A)

Action level Failure code Charge Air Pressure Sensor Low Error
Failure
L03 CA123 (Engine controller system)
Detail of • Low voltage occurs in charge (boost) pressure sensor signal circuit.
failure
Action of • Sets charge (boost) pressure to fixed value (400 kPa {4.1 kg/cm2}) and runs engine.
controller • Limits engine output and runs engine.
Problem on • Acceleration performance of engine drops.
machine • Engine output reduces.
• Signal voltage from charge pressure sensor (boost pressure sensor) can be checked with
monitoring function. (Code: 36501 (V))
Related • Boost pressure sensed by charge (boost) pressure sensor can be checked with
information monitoring function. (Code: 36500 (kPa))
• Method of reproducing failure code: Turn starting switch to ON position.
• This failure code appears if sensor connector is disconnected.
No. Cause Procedure, measuring location, criteria, and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "Related information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
Defective power supply
system of charge If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2 pressure sensor (boost for it first.
pressure sensor)
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connectors ENG and PIM, and connect T-adapters to each
harness (wire breakage female side.
3 or defective contact of Between ENG (female) (37) and PIM (female) (1) Max. 1 z
connector) Resistance Between ENG (female) (44) and PIM (female) (3) Max. 1 z
Between ENG (female) (47) and PIM (female) (2) Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and PIM, and connect T-adapter to either
Short circuit in wiring
4 female side.
harness
Between ENG (female) (44) and (47), or between
Resistance PIM (female) (2) and (3) Min. 1 Mz

Ground fault in wiring 1. Turn starting switch to OFF position, then perform troubleshooting.
harness 2. Disconnect connectors ENG and PIM, and connect T-adapter to either
5 female side.
(Contact with ground
Between ENG (female) (44) and ground, or
circuit) Resistance between PIM (female) (3) and ground Min. 1 Mz

a If no failure is found by checks on causes 1 to 5 and failure is found by

check on cause 6, sensor is defective.
Defective charge 1. Turn starting switch to OFF position.
6 (boost) pressure sensor 2. Insert T-adapter into connector ENG or PIM.
3. Turn starting switch to ON position.
Between ENG (44) and (47), or Sensor
Voltage 0.3 to 4.7 V
between PIM (female) (3) and (2) output
Defective engine If no failure is found by above checks, engine controller is defective. (Since
7 this is an internal defect, troubleshooting cannot be performed.)
controller

HM400-3M0 40-207
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to charge pressure sensor

40-208 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA131] Throttle Sensor High Error (HM400_3R-CA131-400-A-Z0-A)

Action level Failure code Throttle Sensor High Error

Failure
L03 CA131 (Engine controller system)
Detail of • High voltage occurs in throttle sensor signal circuit.
failure
Action of • Sets throttle position to 0% with accelerator pedal released and 38% with accelerator
controller pedal depressed, and runs engine.
Problem on • Engine does not run at full throttle.
machine
• Input voltage from throttle sensor can be checked with monitoring function. (Code: 03000)
Related • Accelerator pedal position sensed by throttle sensor can be checked with monitoring
information function. (Code: 31701)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
Defective throttle
2 sensor power supply If failure code [CA2185] is also displayed, perform troubleshooting for it first.
system
1. Turn starting switch to OFF position.
2. Disconnect connectors J2P and AS1, and connect T-adapter to either
Short circuit in wiring
3 female side.
harness
Between J2P (female) (9) and (22), or between
Resistance AS1 (female) (1) and (2) Min. 1 Mz

1. Turn starting switch to OFF position.

Hot short circuit in 2. Disconnect connector AS1 and connect T-adapter to female side.
4 wiring harness 3. Turn starting switch to ON position.
Voltage Between AS1 (female) (2) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector AS1.
3. Turn starting switch to ON position.
Defective accelerator
5 pedal (throttle sensor) When accelerator pedal
is depressed 3.7 to 4.0 V
Voltage Between AS1 (2) and (3)
When accelerator pedal
0.5 to 0.8 V
is released
If no failure is found by above checks, engine controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector J2P.
3. Turn starting switch to ON position.
Defective engine 4. Operate accelerator pedal to perform troubleshooting.
6
controller
Between J2P (22) and 4.75 to 5.25
Power supply
(23) V
Voltage When accelerator pedal
Between J2P (9) and is depressed 3.7 to 4.0 V
(23) When accelerator pedal
0.5 to 0.8 V
is released

HM400-3M0 40-209
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to throttle sensor

40-210 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA132] Throttle Sensor Low Error (HM400_3R-CA132-400-A-Z0-A)

Action level Failure code Throttle Sensor Low Error

Failure
L03 CA132 (Engine controller system)
Detail of • Low voltage occurs in throttle sensor signal circuit.
failure
Action of • Sets throttle position to 0% with accelerator pedal released and 38% with accelerator
controller pedal depressed, and runs engine.
Problem on • Engine does not run at full throttle.
machine
• Input voltage from throttle sensor can be checked with monitoring function. (Code: 03000)
Related • Accelerator pedal position sensed by throttle sensor can be checked with monitoring
information function. (Code: 31701)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
If failure code [CA2186] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position, and turn battery disconnect switch to
OFF position.
Defective throttle 2. Disconnect connectors AS1 and AS2 and connect T-adapters to each
2 sensor power supply female side.
system 3. Turn starting switch to ON position.
Between AS1 (female) (1) and (3) 4.75 to
Voltage 5.25V
Between AS2 (female) (1) and (2) 4.75 to
5.25V
1. Turn starting switch to OFF position, and turn battery disconnect switch to
OFF position.
2. Disconnect connectors J2P, AS1, AS2, ATC1, and ATC2 and connect T-
adapters to each female side.
a If no failure is found by check on cause 2, this
Open circuit in wiring check is not required. Max. 1 Mz
harness (wire breakage Between J2P (female) (22) and AS1 (female) (1)
3 or defective contact of
connector) a If no failure is found by check on cause 2, this
Resistance check is not required. Max. 1 z
Between J2P (female) (23) and AS1 (female) (3)
Between J2P (female) (9) and AS1 (female) (2) Max. 1 z
Between ATC1 (female) (4) and AS2 (1) Max. 1 z
Between ATC2 (female) (1) and AS2 (2) Max. 1 z
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors J2P and AS1, and connect T-adapter to either
4
harness female side.
Between J2P (female) (9) and (23), or between
Resistance AS1 (female) (2) and (3) Min. 1 Mz

Ground fault in wiring 1. Turn starting switch to OFF position.

harness 2. Disconnect connectors J2P and AS1, and connect T-adapter to either
5 female side.
(Contact with ground
Between ground and J2P (female) (9) or AS1 Min. 1 Mz
circuit) Resistance (female) (2)

HM400-3M0 40-211
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

1. Turn starting switch to OFF position.
2. Insert T-adapter into connector AS1.
3. Turn starting switch to ON position.
Defective accelerator
6 pedal (throttle sensor) When accelerator pedal
is depressed 3.7 to 4.0 V
Voltage Between AS1 (2) and (3)
When accelerator pedal
0.5 to 0.8 V
is released
If no failure is found by above checks, engine controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector J2P.
3. Turn starting switch to ON position.
Defective engine 4. Operate accelerator pedal to perform troubleshooting.
7
controller
Between J2P (22) and 4.75 to
Power supply
(23) 5.25V
Voltage When accelerator pedal
Between J2P (9) and is depressed 3.7 to 4.0 V
(23) When accelerator pedal
0.5 to 0.8 V
is released

Circuit diagram related to throttle sensor

40-212 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA135] Eng Oil Press Sensor High Error (HM400_3M0-CA135-400-A-Z0-A)

Action level Failure code Engine Oil Pressure Sensor High Error
Failure
L01 CA135 (Engine controller system)
Detail of • High voltage occurs in engine oil pressure sensor signal circuit.
failure
Action of • Sets engine oil pressure to default value (250 kPa {2.5 kg/cm2}), and runs engine.
controller
Problem on
machine
• Signal voltage from engine oil pressure sensor can be checked with monitoring function.
(Code: 37201 (V))
• Oil pressure sensed by engine oil pressure sensor sensor can be checked with
Related monitoring function. (Code: 37200 (kPa))
information • Method of reproducing failure code: Turn starting switch to ON position.
k When performing checking and replacement of engine oil pressure sensor, open oil
filler port, and check that engine oil temperature cools down enough not to get
scalded.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
Defective power supply
system of engine oil If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2
pressure sensor for it first.

1. Turn starting switch to OFF position.

Defective engine oil 2. Disconnect connector POIL.
3 pressure sensor 3. Turn starting switch to ON position.
If failure code changes from [CA135] to [CA141] , engine oil pressure sensor
is defective.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors ENG and POIL, and connect T-adapters to each
4 (Wire breakage or female side.
defective contact of a To check open circuit in GND line
connector) Resistance Between ENG (female) (47) and POIL (female) (2) Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and POIL, and connect T-adapter to either
Short circuit in wiring
5 female side.
harness
Between ENG (female) (13) and (37), or between
Resistance POIL (female) (1) and (3) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connector POIL.
3. Connect T-adapter to female side of connector POIL, or insert T-adapter
Hot short circuit in
6 into connector ENG.
wiring harness
4. Turn starting switch to ON position (with connector POIL disconnected).
Between ENG (13) and (47), or between POIL
Voltage Max. 1 V
(female) (3) and (2)
Defective engine If no failure is found by above checks, engine controller is defective. (Since
7 this is an internal defect, troubleshooting cannot be performed.)
controller

HM400-3M0 40-213
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to engine oil pressure sensor

40-214 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA141] Eng Oil Press Sensor Low Error (HM400_3M0-CA141-400-A-Z0-A)

Action level Failure code Engine Oil Pressure Sensor Low Error
Failure
L01 CA141 (Engine controller system)
Detail of • Low voltage occurs in engine oil pressure sensor signal circuit.
failure
Action of • Sets engine oil pressure to default value (250 kPa {2.5 kg/cm2}), and runs engine.
controller
Problem on
machine
• Signal voltage from engine oil pressure sensor can be checked with monitoring function.
(Code: 37201 (V))
• Oil pressure sensed by engine oil pressure sensor sensor can be checked with
Related monitoring function. (Code: 37200 (kPa))
information • Method of reproducing failure code: Turn starting switch to ON position.
k When performing checking and replacement of engine oil pressure sensor, open oil
filler port, and check that engine oil temperature cools down enough not to get
scalded.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
for it first.
Defective power supply 1. Turn starting switch to OFF position.
2 system of engine oil 2. Disconnect connector POIL, and connect T-adapter to female side.
pressure sensor 3. Turn starting switch to ON position.
Power 4.75 to
Voltage Between POIL (female) (1) and (2)
supply input 5.25V
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and POIL, and connect T-adapters to each
female side.
a If power supply input is normal in check on
cause 2, this check is not required.
Open circuit in wiring Max. 1 z
Between ENG (female) (37) and POIL (female)
harness (wire breakage (1)
3 or defective contact of
connector) Resistance a If power supply input is normal in check on
cause 2, this check is not required.
Max. 1 z
Between ENG (female) (47) and POIL (female)
(2)
Between ENG (female) (13) and POIL (female) (3)
(sensor output) Max. 1 z

1. Turn starting switch to OFF position.

Ground fault in wiring 2. Disconnect connectors ENG and POIL, and connect T-adapter to either
4 harness (contact with female side.
ground circuit) Between ground and ENG (female) (13) or POIL
Resistance (female) (3) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connectors ENG and POIL, and connect T-adapter to either
Short circuit in wiring female side.
5
harness Between ENG (female) (13) and (47), or between
Min. 1 Mz
Resistance POIL (female) (2) and (3)

HM400-3M0 40-215
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

a If no failure is found by checks on causes 1 to 5 and failure is found by
Defective engine oil check on cause 6, sensor is defective.
pressure sensor 1. Turn starting switch to OFF position.
6
(Improper input voltage 2. Insert T-adapter into connector ENG or POIL.
to engine controller) 3. Turn starting switch to ON position.
Between ENG (13) and (47), or Sensor
Voltage 0.3 to 4.7 V
between POIL (3) and (2) output
Defective engine If no failure is found by above checks, engine controller is defective. (Since
7 this is an internal defect, troubleshooting cannot be performed.)
controller

Circuit diagram related to engine oil pressure sensor

40-216 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA144] Coolant Temp Sens High Error (HM400_3M0-CA144-400-A-Z0-A)

Action level Failure code Coolant Temperature Sensor High Error

Failure
L01 CA144 (Engine controller system)
Detail of • High voltage occurs in engine coolant temperature sensor signal circuit.
failure
Action of • Sets coolant temperature to fixed value (90°C) and runs engine.
controller
Problem on • Engine startability is poor at low temperatures.
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring
function. (Code: 04105 (V))
• Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (°C))
• Method of reproducing failure code: Turn starting switch to ON position.
• This failure code appears if sensor connector is disconnected.
Related
• Since female connector alone is provided for "socket" used for troubleshooting of this
information
sensor, it is not connectable to female connector on sensor wiring harness side and thus
not usable for check of open circuit (not designed as T-adapter).
k Drain approximately 20 l of coolant beforehand, because you may get scalded by
hot water spurting out from mounting location of coolant temperature sensor when
removing radiator cap during checking and replacing coolant temperature sensor.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect connector TWTR, and connect to socket to male side.
a Regard coolant temperature sensor as normal if its resistance is 700 z to
37 kz when coolant temperature is min. 0°C.
0°C 30 to 37 kz
Defective coolant 9.3 to 10.7
2 temperature sensor 25°C
kz
Between TWTR (male) (A) and (B) 3.2 to 3.8
Resistance a Coolant temperature-Resistance 50°C
kz
characteristics 1.0 to 1.3
80°C
kz
700 to 800
95°C
z
1. Turn starting switch to OFF position.
2. Disconnect connector ENG, and connect T-adapter to female side.
Open or short circuit in Between ENG (female) (15) and (38) (Coolant
3 wiring harness temperature: Min. 0°C)
700 z to
Resistance a Use Coolant temperature-Resistance
37 kz
characteristics table for check on cause 2 as
resistance criteria.
Defective engine If no failure is found by above checks, engine controller is defective. (Since
4 this is an internal defect, troubleshooting cannot be performed.)
controller

HM400-3M0 40-217
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to coolant temperature sensor

40-218 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA145] Coolant Temp Sens Low Error (HM400_3M0-CA145-400-A-Z0-A)

Action level Failure code Coolant Temperature Sensor Low Error

Failure
L01 CA145 (Engine controller system)
Detail of • Low voltage occurs in engine coolant temperature sensor signal circuit.
failure
Action of • Sets coolant temperature to fixed value (90°C) and runs engine.
controller
Problem on • Engine startability is poor at low temperatures.
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring
function. (Code: 04105 (V))
• Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (°C))
• Method of reproducing failure code: Turn starting switch to ON position.
Related
• If temperature sensor connector is disconnected, failure code [CA144] for high error is
information
displayed in place of this failure code.
k Drain approximately 20 l of coolant beforehand, because you may get scalded by
hot water spurting out from mounting location of coolant temperature sensor when
removing radiator cap during checking and replacing coolant temperature sensor.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect connector TWTR, and connect to socket to male side.
a Regard coolant temperature sensor as normal if its resistance is 700 z to
37 kz when coolant temperature is min. 0°C.
0°C 30 to 37 kz
9.3 to 10.7
25°C
kz
Defective coolant Between TWTR (male) (A) and (B) 3.2 to 3.8
2 temperature sensor 50°C
a Coolant temperature-Resistance kz
characteristics 1.0 to 1.3
80°C
Resistance kz
700 to 800
95°C
z
Whole
coolant
Between (B) and ground
temperature Min. 1 Mz
range
1. Turn starting switch to OFF position.
2. Disconnect connector ENG, and connect T-adapter to female side.
Between ENG (female) (15) and (38) (Coolant
Short circuit in wiring
3 temperature: Min. 0°C)
harness 700 z to
Resistance a Use Coolant temperature-Resistance
37 kz
characteristics table for check on cause 2 as
resistance criteria.
Ground fault in wiring 1. Turn starting switch to OFF position.
harness (contact with 2. Disconnect connectors ENG and TWTR, and connect T-adapter to female
4
ground circuit) side of ENG.
Resistance Between ENG (female) (15) and ground Min. 1 Mz
Defective engine If no failure is found by above checks, engine controller is defective. (Since
5 this is an internal defect, troubleshooting cannot be performed.)
controller

HM400-3M0 40-219
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to coolant temperature sensor

40-220 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA153] Chg Air Temp Sensor High Error (HM400_3R-CA153-400-A-Z0-A)

Action level Failure code Charge Air Temperature Sensor High Error
Failure
L01 CA153 (Engine controller system)
Detail of • High voltage occurs in signal circuit of charge (boost) temperature sensor.
failure
Action of • Sets charge temperature (boost temperature) to fixed value (70°C) and runs engine.
controller
Problem on • Engine starting performance is deteriorated at low temperatures.
machine
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18501 (V))
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18500 (°C))
Related • Method of reproducing failure code: Turn starting switch to ON position.
information • Since female connector alone is provided for "socket" used for troubleshooting of this
sensor, it is not connectable to female connector on sensor wiring harness side and thus
not usable for check of open circuit (not designed as T-adapter).
• This failure code appears if sensor connector is disconnected.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect connector TIM and connect socket to male side.
a Regard charge temperature sensor as normal if its resistance is 280 z to
382 kz.
291 to 382
-40°C
kz
85 to 109
-20°C
Defective charge kz
2 temperature sensor 0°C 29 to 36 kz
Between TIM (male) (A) and (B) 7.3 to 8.8
Resistance a Charge temperature-Resistance 30°C
kz
characteristics 2.3 to 2.7
60°C
kz
860 to 970
90°C
z
280 to 320
130°C
z
1. Turn starting switch to OFF position.
2. Disconnect connector ENG, and connect T-adapter to female side.
Open or short circuit in Between ENG (female) (23) and (47)
3 wiring harness 280 z to
Resistance a Use Charge temperature-Resistance
characteristics table for check on cause 2 as 382 kz
resistance criteria.
Defective engine If no failure is found by above checks, engine controller is defective. (Since
4 this is an internal defect, troubleshooting cannot be performed.)
controller

HM400-3M0 40-221
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to charge (boost) temperature sensor

40-222 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA154] Chg Air Temp Sensor Low Error (HM400_3R-CA154-400-A-Z0-A)

Action level Failure code Charge Air Temperature Sensor Low Error
Failure
L01 CA154 (Engine controller system)
Detail of • Low voltage occurs in signal circuit of charge (boost) temperature sensor.
failure
Action of • Sets charge temperature (boost temperature) to fixed value (70°C) and runs engine.
controller
Problem on • Engine starting performance is deteriorated at low temperatures.
machine
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18501 (V))
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be
Related checked with monitoring function. (Code: 18500 (°C))
information • Method of reproducing failure code: Turn starting switch to ON position.
• If temperature sensor connector is disconnected, failure code [CA153] for "High error" is
displayed in place of this failure code.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect connector TIM and connect socket to male side.
a Regard charge temperature sensor as normal if its resistance is 280 z to
382 kz.
291 to 382
-40°C
kz
85 to 109
-20°C
Defective charge kz
2 temperature sensor 0°C 29 to 36 kz
Between TIM (male) (A) and (B) 7.3 to 8.8
Resistance a Charge temperature-Resistance 30°C
kz
characteristics 2.3 to 2.7
60°C
kz
860 to 970
90°C
z
280 to 320
130°C
z
1. Turn starting switch to OFF position.
2. Disconnect connector ENG, and connect T-adapter to female side.
Short circuit in wiring Between ENG (female) (23) and (47)
3
harness 280 z to
Resistance a Use Charge temperature-Resistance
characteristics table for check on cause 2 as 382 kz
resistance criteria.
Ground fault in wiring 1. Turn starting switch to OFF position.
harness (contact with 2. Disconnect connectors ENG and TIM, and connect T-adapter to female
4
ground circuit) side of ENG.
Resistance Between ENG (female) (23) and ground Min. 1 Mz
Defective engine If no failure is found by above checks, engine controller is defective. (Since
5 this is an internal defect, troubleshooting cannot be performed.)
controller

HM400-3M0 40-223
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to charge (boost) temperature sensor

40-224 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA187] Sensor 2 Supply Volt Low Error (HM400_3M0-CA187-400-A-Z0-A)

Action level Failure code Sensor 2 Supply Voltage Low Error

Failure
L03 CA187 (Engine controller system)
Detail of • Low voltage occurs in sensor power supply 2 (5 V) circuit.
failure
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
• Ignores signals from engine oil pressure sensor, sets engine oil pressure to default value
(250 kPa {2.5 kg/cm2}), and runs engine.
Action of • Ignores signals from ambient pressure sensor, sets ambient pressure to default value
controller (52.44 kPa {0.53 kg/cm2}), and runs engine.
• Ignores signals from charge (boost) pressure sensor, sets boost pressure to fixed value
(400 kPa {4.1 kg/cm2}), and runs engine.
• Ignores signals from EGR valve lift sensor and bypass valve lift sensor, limits engine
output and closes EGR valve and bypass valve.
Problem on • Engine output reduces.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. Each time troubleshooting is finished, return to step 1.
If this failure code is not displayed, disconnected sensor or engine wiring
harness is defective.
a Other failure codes (many codes) are also displayed. They are generated
Defective sensor or because of disconnection of connector. Ignore failure codes other than
2 wiring harness [CA187].
Bkup speed sensor G
Engine oil pressure sensor POIL
Charge (Boost) pressure sensor PIM
Connector Ambient pressure sensor PAMB
EGR valve lift sensor SEGR
Bypass valve lift sensor SBP
Engine harness ENG
Defective relevant
3 If other failure codes are also displayed, perform troubleshooting for them.
system
1. Turn starting switch to OFF position.
2. Disconnect connector ENG, and connect T-adapter to male side.
Defective engine
4 3. Turn starting switch to ON position with connector ENG disconnected.
controller
Voltage Between ENG (male) (37) and (47) 4.75 to
5.25V

HM400-3M0 40-225
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to sensor power supply 2 (5 V)

40-226 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA221] Ambient Press Sensor High Error (HM400_3M0-CA221-400-A-Z0-A)

Action level Failure code Ambient Pressure Sensor High Error

Failure
L01 CA221 (Engine controller system)
Detail of • High voltage occurs in signal circuit of ambient pressure sensor.
failure
Action of • Sets ambient pressure value to default value (52.44 kPa {0.53 kg/cm2}), and runs engine.
controller
Problem on • Engine output reduces.
machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
Related function. (Code: 37400 (kPa))
information • Method of reproducing failure code: Turn starting switch to ON position.
• Since female connector alone is provided for "socket" used for troubleshooting of this
sensor, it is not usable for check of open circuit in wiring harness and voltage at sensor
connector (not designed as T-adapter).
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
Defective ambient
2 pressure sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
supply system for it first.

1. Turn starting switch to OFF position.

Defective ambient 2. Disconnect connector PAMB.
3 pressure sensor 3. Turn starting switch to ON position.
If failure code changes from [CA221] to [CA222], sensor is defective.

Open circuit in wiring a To check open circuit in GND line

harness (wire breakage 1. Turn starting switch to OFF position.
4 or defective contact of 2. Disconnect connectors PAMB and ENG, and connect T-adapters to each
connector) female side.
Resistance Between ENG (female) (38) and PAMB (female) (2) Max. 1 z
1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors ENG and PAMB, and connect T-adapter to female
5
harness side of ENG.
Resistance Between ENG (female) (37) and (3) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector PAMB.
Hot short circuit in
6 3. Insert T-adapter into connector ENG.
wiring harness
4. Turn starting switch to ON position (with connector PAMB disconnected).
Voltage Between ENG (3) and (38) Max. 1 V
Defective engine If no failure is found by above checks, engine controller is defective. (Since
7 this is an internal defect, troubleshooting cannot be performed.)
controller

HM400-3M0 40-227
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to ambient pressure sensor

40-228 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA222] Ambient Press Sens Low Error (HM400_3M0-CA222-400-A-Z0-A)

Action level Failure code Ambient Pressure Sensor Low Error

Failure
L01 CA222 (Engine controller system)
Detail of • Low voltage occurs in signal circuit of ambient pressure sensor.
failure
Action of • Sets ambient pressure value to default value (52.44 kPa {0.53 kg/cm2}), and runs engine.
controller
Problem on • Engine output reduces.
machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
function. (Code: 37400 (kPa))
Related • Method of reproducing failure code: Turn starting switch to ON position.
information • Since female connector alone is provided for "socket" used for troubleshooting of this
sensor, it is not usable for check of open circuit in wiring harness and voltage at sensor
connector (not designed as T-adapter).
• This failure code appears if sensor connector is disconnected.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
for it first.
Defective ambient 1. Turn starting switch to OFF position.
2 pressure sensor power 2. Disconnect connector PAMB, and connect T-adapter to female side.
supply system 3. Turn starting switch to ON position.
Power 4.75 to
Voltage Between PAMB (female) (1) and (2)
supply input 5.25V
1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors PAMB and ENG.
3 3. Connect T-adapter to female side of ENG.
harness
Resistance Between ENG (female) (3) and (38) Min. 1 Mz
Ground fault in wiring 1. Turn starting switch to OFF position.
harness (contact with 2. Disconnect connectors PAMB and ENG, and connect T-adapter to female
4
ground circuit) side of ENG.
Resistance Between ENG (female) (3) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and PAMB, and connect T-adapters to each
female side.
a If power supply input is normal in check on
cause 2, this check is not required.
Max. 1 z
Open circuit in wiring Between ENG (female) (37) and PAMB (female)
harness (wire breakage (1)
5 or defective contact of
connector) Resistance a If power supply input is normal in check on
cause 2, this check is not required.
Max. 1 z
Between ENG (female) (38) and PAMB (female)
(2)
Between ENG (female) (3) and PAMB (female) (3)
Max. 1 z
(sensor output)

HM400-3M0 40-229
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

a If no failure is found by checks on causes 1 to 5 and failure is found by
check on cause 6, sensor is defective.
Defective ambient 1. Turn starting switch to OFF position.
6 pressure sensor 2. Insert T-adapter into connector ENG.
3. Turn starting switch to ON position.
Sensor
Voltage Between ENG (3) and (38) 0.3 to 4.7 V
output
Defective engine If no failure is found by above checks, engine controller is defective. (Since
7 this is an internal defect, troubleshooting cannot be performed.)
controller

Circuit diagram related to ambient pressure sensor

40-230 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA227] Sensor 2 Supply Volt High Error (HM400_3M0-CA227-400-A-Z0-A)

Action level Failure code Sensor 2 Supply Voltage High Error

Failure
L03 CA227 (Engine controller system)
Detail of • High voltage occurs in sensor power supply 2 (5V) circuit.
failure
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
• Ignores signals from engine oil pressure sensor, sets engine oil pressure to default value
(250 kPa {2.5 kg/cm2}), and runs engine.
Action of • Ignores signals from ambient pressure sensor, sets ambient pressure to default value
controller (52.44 kPa {0.53 kg/cm2}), and runs engine.
• Ignores signals from charge (boost) pressure sensor, sets boost pressure to fixed value
(400 kPa {4.1 kg/cm2}), and runs engine.
• Ignores signals from EGR valve lift sensor and bypass valve lift sensor, limits engine
output and closes EGR valve and bypass valve.
Problem on • Engine output reduces.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
Defective sensor power
1 Perform troubleshooting for failure code [CA187].
supply system

HM400-3M0 40-231
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA234] Eng Overspeed (PC400-CA234-400-A-Z0-A)

Action level Failure code Engine Overspeed

Failure
L02 CA234 (Engine controller system)
Detail of • Engine speed exceeds its operating range.
failure
Action of • Regulates fuel injection rate so that engine speed lowers within operating range.
controller
Problem on • Engine speed fluctuates.
machine
Related • Engine speed can be checked with monitoring function. (Code: 01002 (rpm))
information • Method of reproducing failure code: Start engine and run at high idle.
No. Cause Procedure, measuring location, criteria, and remarks
1 Improper fuel is used. Fuel used may be improper. Check it.
Defective relevant system If other failure codes are also displayed, perform troubleshooting for
2
them.
Method of using machine may be improper, so instruct operator on how
3 Improper machine usage
to use machine properly.
If no failure is found by above checks, engine controller is defective.
4 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

40-232 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA238] Ne Speed Sensor Supply Volt Error (HM400_3R-CA238-400-A-Z0-A)

Action level Failure code Ne Speed Sensor Supply Voltage Error

Failure
L01 CA238 (Engine controller system)
Detail of • High voltage occurs in Ne speed sensor power supply (5 V) circuit.
failure
Action of • Controls engine by using signals from engine Bkup speed sensor.
controller • Limits engine output and runs engine.
• Engine output reduces.
Problem on • Running engine stops (when Bkup speed sensor is also defective).
machine • Stopped engine cannot be restarted (when Bkup speed sensor is also defective).
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. Each time troubleshooting is finished, return to step 1.
If this failure code is not displayed, disconnected sensor or engine wiring
Defective sensor or harness is defective.
2 wiring harness
a Other failure codes (many codes) are also displayed. They are generated
because of disconnection of connector. Ignore failure codes other than
[CA238].
Ne speed sensor NE
Connector
Engine harness ENG
1. Turn starting switch to OFF position.
2. Disconnect connector ENG, and connect T-adapter to male side.
Defective engine 3. Turn starting switch to ON position with engine wiring harness
3
controller disconnected.
Voltage Between ENG (male) (16) and (48) 4.75 to 5.25
V

Circuit diagram related to Ne speed sensor

HM400-3M0 40-233
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA263] Fuel Temp Sensor High Error (HM400_3R-CA263-400-A-Z0-A)

Action level Failure code Fuel Temperature Sensor High Error

Failure
L01 CA263 (Engine controller system)
Detail of • High voltage occurs in fuel temperature sensor signal circuit.
failure
• Uses signals from coolant temperature sensor to perform fuel injection rate correction
Action of based on fuel temperature.
controller (Sets fuel temperature to fixed value (90°C) and runs engine.)
Problem on
machine
• Signal voltage from fuel temperature sensor can be checked with monitoring function.
(Code: 14201 (V))
• Temperature sensed by fuel temperature sensor can be checked with monitoring function.
(Code: 14200 (°C))
Related • Method of reproducing failure code: Turn starting switch to ON position.
information • This failure code appears if sensor connector is disconnected.
• Since female connector alone is provided for "socket" used for troubleshooting of this
sensor, it is not connectable to female connector on sensor wiring harness side and thus
not usable for check of open circuit (not designed as T-adapter).
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect connector TFUEL, and connect socket to male side.
a If fuel temperature sensor resistance is 700 z to 37 kz when fuel
temperature above 0°C, regard fuel temperature sensor as normal.
0°C 30 to 37 kz
Defective fuel 9.3 to 10.7
2 temperature sensor 25°C
kz
Between TFUEL (male) (A) and (B) 3.2 to 3.8
Resistance a Fuel temperature-resistance 50°C
kz
characteristics 1.0 to 1.3
80°C
kz
700 to 800
95°C
z
1. Turn starting switch to OFF position.
2. Disconnect connector ENG, and connect T-adapter to female side.
Open or short circuit in Between ENG (female) (30) and (47) (Fuel
3 wiring harness temperature: Min. 0°C)
700 z to 37
Resistance a Use fuel temperature-resistance characteristics
kz
table for check on cause 2 as resistance
criteria.
Defective engine If no failure is found by above checks, engine controller is defective. (Since
4 this is an internal defect, troubleshooting cannot be performed.)
controller

40-234 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to fuel temperature sensor

HM400-3M0 40-235
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA265] Fuel Temp Sensor Low Error (HM400_3R-CA265-400-A-Z0-A)

Action level Failure code Fuel Temperature Sensor Low Error

Failure
L01 CA265 (Engine controller system)
Detail of • Low voltage occurs in fuel temperature sensor signal circuit.
failure
• Uses signals from coolant temperature sensor to perform fuel injection rate correction
Action of based on fuel temperature.
controller (Sets fuel temperature to fixed value (90°C) and runs engine.)
Problem on
machine
• Signal voltage from fuel temperature sensor can be checked with monitoring function.
(Code: 14201 (V))
• Temperature sensed by fuel temperature sensor can be checked with monitoring function.
Related (Code: 14200 (°C))
information • Method of reproducing failure code: Turn starting switch to ON position.
• If temperature sensor connector is disconnected, failure code [CA263] for high error is
displayed in place of this failure code.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect connector TFUEL, and connect socket to male side.
a If fuel temperature sensor resistance is 700 z to 37 kz when fuel
temperature above 0°C, regard fuel temperature sensor as normal.
0°C 30 to 37 kz
9.3 to 10.7
25°C
Defective fuel kz
2 Between TFUEL (male) (A) and (B) 3.2 to 3.8
temperature sensor 50°C
a Fuel temperature-resistance kz
characteristics 1.0 to 1.3
Resistance 80°C
kz
700 to 800
95°C
z
All fuel
Between (B) and ground temperature Min. 1 Mz
range
1. Turn starting switch to OFF position.
2. Disconnect connector ENG, and connect T-adapter to female side.
Between ENG (female) (30) and (47) (Fuel
Short circuit in wiring
3 temperature: Min. 0°C)
harness 700 z to 37
Resistance a Use fuel temperature-resistance characteristics
kz
table for check on cause 2 as resistance
criteria.
Ground fault in wiring 1. Turn starting switch to OFF position.
harness (contact with 2. Disconnect connector TFUEL, and connect T-adapter to female side of
4
ground circuit) ENG.
Resistance Between ENG (female) (30) and ground Min. 1 Mz
Defective engine If no failure is found by above checks, engine controller is defective. (Since
5 this is an internal defect, troubleshooting cannot be performed.)
controller

40-236 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to fuel temperature sensor

HM400-3M0 40-237
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA271] IMV/PCV1 Short Error (HM400_3R-CA271-400-A-Z0-A)

Action level Failure code IMV/PCV1 Short Error

Failure
L03 CA271 (Engine controller system)
Detail of • Short circuit occurs in supply pump PCV1 circuit.
failure
Action of
controller
Problem on • Engine output reduces.
machine
• Under normal conditions, pulse voltage of approximately 24 V is applied to PCV1 (1) while
Related engine is running. However, it cannot be measured by using multimeter since it is pulse
information voltage.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
Defective supply pump 2. Disconnect connector PCV1.
2 PCV1 (internal short 3. Turn starting switch to ON position.
circuit) If failure code changes from [CA271] to [CA272], supply pump PCV1 is
defective.
1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connector ENG, and connect T-adapter to female side.
3
harness Between ENG (female) (4) and (5) (PCV1
Resistance resistance) 2.3 to 5.3 z

Ground fault in wiring 1. Turn starting switch to OFF position.

harness (contact with 2. Disconnect connectors ENG and PCV1, and connect T-adapter to female
4
ground circuit) side of ENG.
Resistance Between ENG (female) (4) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector PCV1.
Hot short circuit in
5 3. Insert T-adapter into connector ENG.
wiring harness
4. Turn starting switch ON (with connector PCV1 disconnected).
Voltage Between ENG (4) and (5) Max. 3 V
Defective engine If no failure is found by above checks, engine controller is defective. (Since
6 this is an internal defect, troubleshooting cannot be performed.)
controller

Circuit diagram related to PCV1

40-238 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA272] IMV/PCV1 Open Error (HM400_3R-CA272-400-A-Z0-A)

Action level Failure code IMV/PCV1 Open Error

Failure
L03 CA272 (Engine controller system)
Detail of • Open circuit occurs in supply pump PCV1 circuit.
failure
Action of
controller
Problem on • Engine output reduces.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
• Under normal conditions, pulse voltage of approximately 24 V is applied to PCV (1) while
engine is running. However, it cannot be measured by using multimeter since it is pulse
Related voltage.
information • Since female connector alone is provided for "socket" used for troubleshooting of this
sensor, it is not connectable to female connector on sensor wiring harness side and thus
not usable for check of open circuit (not designed as T-adapter).
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment" in
Defective wiring
1 "Checks before troubleshooting" of "Related information on troubleshooting", and
harness connector
check it.
Defective supply 1. Turn starting switch to OFF position.
2 pump PCV1 (internal 2. Disconnect connector PCV1, and connect to socket to male side.
open circuit) Resis- Between PCV1 (male) (1) and (2) 2.3 to 5.3
tance z
1. Turn starting switch to OFF position.
Open or short circuit 2. Disconnect connector ENG, and connect T-adapter to female side.
3 in wiring harness
Resis- Between ENG (female) (4) and (5) (PCV1 resistance) 2.3 to 5.3
tance z
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors ENG and PCV1.
4 harness (contact with 3. Connect T-adapter to female side of connector ENG.
ground circuit) Resis- Between ENG (4) and (5)
Min. 1 Mz
tance
Defective engine If no failure is found by above checks, engine controller is defective. (Since this is
5 an internal defect, troubleshooting cannot be performed.)
controller

Circuit diagram related to PCV1

HM400-3M0 40-239
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA273] PCV2 Short Error (HM400_3R-CA273-400-A-Z0-A)

Action level Failure code PCV2 Short Error

Failure
L03 CA273 (Engine controller system)
Detail of • Short circuit occurs in supply pump PCV2 circuit.
failure
Action of
controller
Problem on • Engine output reduces.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
Related • Under normal conditions, pulse voltage of approximately 24 V is applied to PCV2 (1) while
information engine is running. However, it cannot be measured by using multimeter since it is pulse
voltage.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
Defective supply pump 2. Disconnect connector PCV2.
2 PCV2 (internal short 3. Turn starting switch to ON position.
circuit) If failure code changes from [CA273] to [CA274], supply pump PCV2 is
defective.
1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connector ENG, and connect T-adapter to female side.
3
harness Between ENG (female) (9) and (10) (PCV2
Resistance resistance) 2.3 to 5.3 z

Ground fault in wiring 1. Turn starting switch to OFF position.

harness (contact with 2. Disconnect connectors ENG and PCV2, and connect T-adapter to female
4
ground circuit) side of ENG.
Resistance Between ENG (female) (9) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector PCV2.
Hot short circuit in
5 3. Insert T-adapter into connector ENG.
wiring harness
4. Turn starting switch ON (with connector PCV2 disconnected).
Voltage Between ENG (9) and (10) Max. 3 V
Defective engine If no failure is found by above checks, engine controller is defective. (Since
6 this is an internal defect, troubleshooting cannot be performed.)
controller

Circuit diagram related to PCV2

40-240 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA274] PCV2 Open Error (HM400_3R-CA274-400-A-Z0-A)

Action level Failure code PCV2 Open Error

Failure
L03 CA274 (Engine controller system)
Detail of • Open circuit occurs in supply pump PCV2 circuit.
failure
Action of
controller
Problem on • Engine output reduces.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
• Under normal conditions, pulse voltage of approximately 24 V is applied to PCV2 (1) while
engine is running. However, it cannot be measured by using multimeter since it is pulse
Related voltage.
information • Since female connector alone is provided for "socket" used for troubleshooting of this
sensor, it is not connectable to female connector on sensor wiring harness side and thus
not usable for check of open circuit (not designed as T-adapter).
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
Defective supply pump 1. Turn starting switch to OFF position.
2 PCV2 (internal open 2. Disconnect connector PCV2, and connect socket to male side.
circuit) Resistance Between PCV2 (male) (1) and (2) 2.3 to 5.3 z
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connector ENG, and connect T-adapter to female side.
3 wiring harness Between ENG (female) (9) and (10) (PCV2
Resistance resistance) 2.3 to 5.3 z

1. Turn starting switch to OFF position.

Ground fault in wiring
2. Disconnect connectors ENG and PCV2.
4 harness (contact with
3. Connect T-adapter to female side of connector ENG.
ground circuit)
Resistance Between ENG (9) and (10) Min. 1 Mz
Defective engine If no failure is found by above checks, engine controller is defective. (Since
5 this is an internal defect, troubleshooting cannot be performed.)
controller

Circuit diagram related to PCV2

HM400-3M0 40-241
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA322] Inj #1(L#1) Open/Short Error (HM400_3M0-CA322-400-A-Z0-A)

Action level Failure code Injector #1 (L#1) Open/Short Error

Failure
L03 CA322 (Engine controller system)
Detail of • Open circuit or short circuit is detected in injector #1 circuit.
failure
Action of
controller
Problem on • Engine output reduces.
machine • Engine speed does not stabilize.
• Method of reproducing failure code: Start engine.
Related • While engine is running normally, approximately 65 V of pulse voltage is applied to injector
information (positive) side. However, it cannot be measured by using multimeter since it is pulse
voltage.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect connector CN1, and connect T-adapter to male side.
2 Defective injector #1
Between CN1 (male) (1) and (2) 0.4 to 1.1 z
Resistance
Between CN1 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Open circuit or ground 2. Disconnect connector ENG, and connect T-adapter to female side.
3 fault in wiring harness Between ENG (female) (45) and (53) 0.4 to 1.1 z
Resistance
Between ENG (female) (45) and ground Min. 1 Mz
a If no failure is found by check on cause 3, this check is not required.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness (wire breakage 2. Disconnect connectors ENG and CN1, and connect T-adapters to each
4 or defective contact of female side.
connector) Between ENG (female) (45) and CN1 (female) (1) Max. 1 z
Resistance
Between ENG (female) (53) and CN1 (female) (2) Max. 1 z
a If no failure is found by check on cause 3, this check is not required.
Ground fault in wiring 1. Turn starting switch to OFF position.
5 harness (contact with 2. Disconnect connectors ENG and CN1, and connect T-adapter to either
ground circuit) female side.
Between ground and ENG (female) (45) or CN1
Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connectors ENG and CN1, and connect T-adapter to female
side of ENG.
Short circuit in wiring a Check by using multimeter in continuity mode.
6
harness Between ENG (female) (45) and each No continuity (no sound
pin other than pin (45) is heard)
Continuity
Between ENG (female) (53) and each No continuity (no sound
pin other than pin (53) is heard)
Defective other cylinder 1. Troubleshoot injectors of other cylinders.
7 injectors or injector 2. Confirm that injector wiring harnesses (H) of all cylinders are in good
wiring harness condition by referring to the following page.
Defective engine If no failure is found by above checks, engine controller is defective. (Since
8 this is an internal defect, troubleshooting cannot be performed.)
controller

40-242 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to injector #1

• Improper installation of injector wiring harness (H)

Q: Injector wiring harness (H) is in good condition being laid close to injector (N)
x: Injector wiring harness (H) is in bad condition without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with rocker arm.

HM400-3M0 40-243
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA323] Inj #5(L#5) Open/Short Error (HM400_3M0-CA323-400-A-Z0-A)

Action level Failure code Injector #5(L#5) Open/Short Error

Failure
L03 CA323 (Engine controller system)
Detail of • Open circuit or short circuit is detected in injector #5 circuit.
failure
Action of
controller
Problem on • Engine output reduces.
machine • Engine speed does not stabilize.
• Method of reproducing failure code: Start engine.
Related • While engine is running normally, approximately 65 V of pulse voltage is applied to injector
information (positive) side. However, it cannot be measured by using multimeter since it is pulse
voltage.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect connector CN5, and connect T-adapter to male side.
2 Defective injector #5
Between CN5 (male) (1) and (2) 0.4 to 1.1 z
Resistance
Between CN5 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Open circuit or ground 2. Disconnect connector ENG, and connect T-adapter to female side.
3 fault in wiring harness Between ENG (female) (46) and (60) 0.4 to 1.1 z
Resistance
Between ENG (female) (46) and ground Min. 1 Mz
a If no failure is found by check on cause 3, this check is not required.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness (wire breakage 2. Disconnect connectors ENG and CN5, and connect T-adapters to each
4 or defective contact of female side.
connector) Between ENG (female) (46) and CN5 (female) (1) Max. 1 z
Resistance
Between ENG (female) (60) and CN5 (female) (2) Max. 1 z
a If no failure is found by check on cause 3, this check is not required.
Ground fault in wiring 1. Turn starting switch to OFF position.
5 harness (contact with 2. Disconnect connectors ENG and CN5, and connect T-adapter to either
ground circuit) female side.
Between ground and ENG (female) (46) or CN5
Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connectors ENG and CN5, and connect T-adapter to female
side of ENG.
Short circuit in wiring a Check by using multimeter in continuity mode.
6
harness Between ENG (female) (46) and each No continuity (no sound
pin other than pin (46) is heard)
Continuity
Between ENG (female) (60) and each No continuity (no sound
pin other than pin (60) is heard)
Defective other cylinder 1. Troubleshoot injectors of other cylinders.
7 injectors or injector 2. Confirm that injector wiring harnesses (H) of all cylinders are in good
wiring harness condition by referring to the following page.
Defective engine If no failure is found by above checks, engine controller is defective. (Since
8 this is an internal defect, troubleshooting cannot be performed.)
controller

40-244 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to injector #5

• Improper installation of injector wiring harness (H)

Q: Injector wiring harness (H) is in good condition being laid close to injector (N)
x: Injector wiring harness (H) is in bad condition without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with rocker arm.

HM400-3M0 40-245
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA324] Inj #3(L#3) Open/Short Error (HM400_3M0-CA324-400-A-Z0-A)

Action level Failure code Injector #3 (L#3) Open/Short Error

Failure
L03 CA324 (Engine controller system)
Detail of • Open circuit or short circuit is detected in injector #3 circuit.
failure
Action of
controller
Problem on • Engine output reduces.
machine • Engine speed does not stabilize.
• Method of reproducing failure code: Start engine.
Related • While engine is running normally, approximately 65 V of pulse voltage is applied to injector
information (positive) side. However, it cannot be measured by using multimeter since it is pulse
voltage.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect connector CN3, and connect T-adapter to male side.
2 Defective injector #3
Between CN3 (male) (1) and (2) 0.4 to 1.1 z
Resistance
Between CN3 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Open circuit or ground 2. Disconnect connector ENG, and connect T-adapter to female side.
3 fault in wiring harness Between ENG (female) (55) and (52) 0.4 to 1.1 z
Resistance
Between ENG (female) (55) and ground Min. 1 Mz
a If no failure is found by check on cause 3, this check is not required.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness (wire breakage 2. Disconnect connectors ENG and CN3, and connect T-adapters to each
4 or defective contact of female side.
connector) Between ENG (female) (55) and CN3 (female) (1) Max. 1 z
Resistance
Between ENG (female) (52) and CN3 (female) (2) Max. 1 z
a If no failure is found by check on cause 3, this check is not required.
Ground fault in wiring 1. Turn starting switch to OFF position.
5 harness (contact with 2. Disconnect connectors ENG and CN3, and connect T-adapter to either
ground circuit) female side.
Between ground and ENG (female) (55) or CN3
Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connectors ENG and CN3, and connect T-adapter to female
side of ENG.
Short circuit in wiring a Check by using multimeter in continuity mode.
6
harness Between ENG (female) (55) and each No continuity (no sound
pin other than pin (55) is heard)
Continuity
Between ENG (female) (52) and each No continuity (no sound
pin other than pin (52) is heard)
Defective other cylinder 1. Troubleshoot injectors of other cylinders.
7 injectors or injector 2. Confirm that injector wiring harnesses (H) of all cylinders are in good
wiring harness condition by referring to the following page.
Defective engine If no failure is found by above checks, engine controller is defective. (Since
8 this is an internal defect, troubleshooting cannot be performed.)
controller

40-246 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to injector #3

• Improper installation of injector wiring harness (H)

Q: Injector wiring harness (H) is in good condition being laid close to injector (N)
x: Injector wiring harness (H) is in bad condition without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with rocker arm.

HM400-3M0 40-247
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA325] Inj #6(L#6) Open/Short Error (HM400_3M0-CA325-400-A-Z0-A)

Action level Failure code Injector #6(L#6) Open/Short Error

Failure
L03 CA325 (Engine controller system)
Detail of • Open circuit or short circuit is detected in injector #6 circuit.
failure
Action of
controller
Problem on • Engine output reduces.
machine • Engine speed does not stabilize.
• Method of reproducing failure code: Start engine.
Related • While engine is running normally, approximately 65 V of pulse voltage is applied to injector
information (positive) side. However, it cannot be measured by using multimeter since it is pulse
voltage.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect connector CN6, and connect T-adapter to male side.
2 Defective injector #6
Between CN6 (male) (1) and (2) 0.4 to 1.1 z
Resistance
Between CN6 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Open circuit or ground 2. Disconnect connector ENG, and connect T-adapter to female side.
3 fault in wiring harness Between ENG (female) (57) and (59) 0.4 to 1.1 z
Resistance
Between ENG (female) (57) and ground Min. 1 Mz
a If no failure is found by check on cause 3, this check is not required.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness (wire breakage 2. Disconnect connectors ENG and CN6, and connect T-adapters to each
4 or defective contact of female side.
connector) Between ENG (female) (57) and CN6 (female) (1) Max. 1 z
Resistance
Between ENG (female) (59) and CN6 (female) (2) Max. 1 z
a If no failure is found by check on cause 3, this check is not required.
Ground fault in wiring 1. Turn starting switch to OFF position.
5 harness (contact with 2. Disconnect connectors ENG and CN6, and connect T-adapter to either
ground circuit) female side.
Between ground and ENG (female) (57) or CN6
Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connectors ENG and CN6, and connect T-adapter to female
side of ENG.
Short circuit in wiring a Check by using multimeter in continuity mode.
6
harness Between ENG (female) (57) and each No continuity (no sound
pin other than pin (57) is heard)
Continuity
Between ENG (female) (59) and each No continuity (no sound
pin other than pin (59) is heard)
Defective other cylinder 1. Troubleshoot injectors of other cylinders.
7 injectors or injector 2. Confirm that injector wiring harnesses (H) of all cylinders are in good
wiring harness condition by referring to the following page.
Defective engine If no failure is found by above checks, engine controller is defective. (Since
8 this is an internal defect, troubleshooting cannot be performed.)
controller

40-248 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to injector #6

• Improper installation of injector wiring harness (H)

Q: Injector wiring harness (H) is in good condition being laid close to injector (N)
x: Injector wiring harness (H) is in bad condition without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with rocker arm.

HM400-3M0 40-249
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA331] Inj #2(L#2) Open/Short Error (HM400_3M0-CA331-400-A-Z0-A)

Action level Failure code Injector #2 Open/Short Error

Failure
L03 CA331 (Engine controller system)
Detail of • Open circuit or short circuit is detected in injector #2 circuit.
failure
Action of
controller
Problem on • Engine output reduces.
machine • Engine speed does not stabilize.
• Method of reproducing failure code: Start engine.
Related • While engine is running normally, approximately 65 V of pulse voltage is applied to injector
information (positive) side. However, it cannot be measured by using multimeter since it is pulse
voltage.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect connector CN2, and connect T-adapter to male side.
2 Defective injector #2
Between CN2 (male) (1) and (2) 0.4 to 1.1 z
Resistance
Between CN2 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Open circuit or ground 2. Disconnect connector ENG, and connect T-adapter to female side.
3 fault in wiring harness Between ENG (female) (54) and (51) 0.4 to 1.1 z
Resistance
Between ENG (female) (54) and ground Min. 1 Mz
a If no failure is found by check on cause 3, this check is not required.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness (wire breakage 2. Disconnect connectors ENG and CN2, and connect T-adapters to each
4 or defective contact of female side.
connector) Between ENG (female) (54) and CN2 (female) (1) Max. 1 z
Resistance
Between ENG (female) (51) and CN2 (female) (2) Max. 1 z
a If no failure is found by check on cause 3, this check is not required.
Ground fault in wiring 1. Turn starting switch to OFF position.
5 harness (contact with 2. Disconnect connectors ENG and CN2, and connect T-adapter to either
ground circuit) female side.
Between ground and ENG (female) (54) or CN2
Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connectors ENG and CN2, and connect T-adapter to female
side of ENG.
Short circuit in wiring a Check by using multimeter in continuity mode.
6
harness Between ENG (female) (54) and each No continuity (no sound
pin other than pin (54) is heard)
Continuity
Between ENG (female) (51) and each No continuity (no sound
pin other than pin (51) is heard)
Defective other cylinder 1. Troubleshoot injectors of other cylinders.
7 injectors or injector 2. Confirm that injector wiring harnesses (H) of all cylinders are in good
wiring harness condition by referring to the following page.
Defective engine If no failure is found by above checks, engine controller is defective. (Since
8 this is an internal defect, troubleshooting cannot be performed.)
controller

40-250 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to injector #2

• Improper installation of injector wiring harness (H)

Q: Injector wiring harness (H) is in good condition being laid close to injector (N)
x: Injector wiring harness (H) is in bad condition without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with rocker arm.

HM400-3M0 40-251
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA332] Inj #4(L#4) Open/Short Error (HM400_3M0-CA332-400-A-Z0-A)

Action level Failure code Injector #4 (L#4) Open/Short Error

Failure
L03 CA332 (Engine controller system)
Detail of • Open circuit or short circuit is detected in injector #4 circuit.
failure
Action of
controller
Problem on • Engine output reduces.
machine • Engine speed does not stabilize.
• Method of reproducing failure code: Start engine.
Related • While engine is running normally, approximately 65 V of pulse voltage is applied to injector
information (positive) side. However, it cannot be measured by using multimeter since it is pulse
voltage.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect connector CN4, and connect T-adapter to male side.
2 Defective injector #4
Between CN4 (male) (1) and (2) 0.4 to 1.1 z
Resistance
Between CN4 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Open circuit or ground 2. Disconnect connector ENG, and connect T-adapter to female side.
3 fault in wiring harness Between ENG (female) (56) and (58) 0.4 to 1.1 z
Resistance
Between ENG (female) (56) and ground Min. 1 Mz
a If no failure is found by check on cause 3, this check is not required.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness (wire breakage 2. Disconnect connectors ENG and CN4, and connect T-adapters to each
4 or defective contact of female side.
connector) Between ENG (female) (56) and CN4 (female) (1) Max. 1 z
Resistance
Between ENG (female) (58) and CN4 (female) (2) Max. 1 z
a If no failure is found by check on cause 3, this check is not required.
Ground fault in wiring 1. Turn starting switch to OFF position.
5 harness (contact with 2. Disconnect connectors ENG and CN4, and connect T-adapter to either
ground circuit) female side.
Between ground and ENG (female) (56) or CN4
Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connectors ENG and CN4, and connect T-adapter to female
side of ENG.
Short circuit in wiring a Check by using multimeter in continuity mode.
6
harness Between ENG (female) (56) and each No continuity (no sound
pin other than pin (56) is heard)
Continuity
Between ENG (female) (58) and each No continuity (no sound
pin other than pin (58) is heard)
Defective other cylinder 1. Troubleshoot injectors of other cylinders.
7 injectors or injector 2. Confirm that injector wiring harnesses (H) of all cylinders are in good
wiring harness condition by referring to the following page.
Defective engine If no failure is found by above checks, engine controller is defective. (Since
8 this is an internal defect, troubleshooting cannot be performed.)
controller

40-252 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to injector #4

• Improper installation of injector wiring harness (H)

Q: Injector wiring harness (H) is in good condition being laid close to injector (N)
x: Injector wiring harness (H) is in bad condition without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with rocker arm.

HM400-3M0 40-253
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA342] Calibration Code Incompatibility (HM400_3R-CA342-400-A-Z0-A)

Action level Failure code Calibration Code Incompatibility

Failure
L03 CA342 (Engine controller system)
Detail of • Matching error occurs in engine controller data.
failure
Action of • None in particular
controller
Problem on • Engine continues to run normally, but it may stop during running or may not be able to
machine restart if it is stopped.
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
Defective power supply
1 Perform troubleshooting for failure code [CA441].
system

40-254 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA351] Injectors Drive Circuit Error (PC400-CA351-400-A-Z0-A)

Action level Failure code Injectors Drive Circuit Error

Failure
L03 CA351 (Engine controller system)
Detail of • Injector drive circuit is defective.
failure
Action of • Limits engine output (limits common rail pressure) and allows engine to run.
controller
Problem on • Engine output lowers.
machine
Related • Method of reproducing failure code: Start engine.
information
No. Cause Procedure, measuring location, criteria and remarks
Check failure code (injector system failure code) that is displayed at the
1 Defect in related system
same time. If another code is displayed, perform troubleshooting for it.
Defective engine controller
2 Perform troubleshooting for failure code [CA441].
system

HM400-3M0 40-255
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA352] Sensor 1 Supply Volt Low Error (HM400_3M0-CA352-400-A-Z0-A)

Action level Failure code Sensor 1 Supply Voltage Low Error

Failure
L03 CA352 (Engine controller system)
Detail of • Low voltage occurs in sensor power supply 1 (5 V) circuit.
failure
Action of • Limits engine output and runs engine (limits common rail pressure).
controller
Problem on • Engine output reduces.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. Each time troubleshooting is finished, return to step 1.
If this failure code is not displayed, disconnected sensor or engine wiring
Defective sensor or harness is defective.
2 wiring harness
a Other failure codes (many codes) are also displayed. They are generated
because of disconnection of connector. Ignore failure codes other than
[CA352].
Common rail pressure PFUEL
Connector
Engine harness ENG
Defective relevant
3 If other failure codes are also displayed, perform troubleshooting for them.
system
1. Turn starting switch to OFF position.
2. Disconnect connector ENG, and connect T-adapter to male side.
Defective engine
4 3. Turn starting switch to ON position with connector ENG disconnected.
controller
Voltage Between ENG (male) (33) and (47) 4.75 to 5.25
V

40-256 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to sensor power supply 1 (5 V)

HM400-3M0 40-257
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA386] Sensor 1 Supply Volt High Error (HM400_3R-CA386-400-A-Z0-A)

Action level Failure code Sensor 1 Supply Voltage High Error

Failure
L03 CA386 (Engine controller system)
Detail of • High voltage occurs in sensor power supply 1 (5 V) circuit.
failure
Action of • Limits engine output and runs engine (limits common rail pressure).
controller
Problem on • Engine output reduces.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
Defective sensor power
1 Perform troubleshooting for failure code [CA352].
supply system

40-258 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA431] Idle Validation Sw Error (HM400_3R-CA431-400-A-Z0-A)

Action level Failure code Idle Validation Switch Error

Failure
L01 CA431 (Engine controller system)
Detail of • Idle validation switch signals 1 and 2 (IVS1 and IVS2) are abnormal.
failure
Action of • Uses throttle position from throttle sensor to run engine.
controller
Problem on
machine
• Input (ON/OFF) of idle validation signal 1 can be checked with monitoring function. (Code:
18300)
Related • Input (ON/OFF) of idle validation signal 2 can be checked with monitoring function. (Code:
information 18301)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector AS2.
Defective power supply 3. Turn starting switch to ON position.
2 system a If check result is unusual, go to check on cause 4.
Voltage Between AS2(1) to (2) 4.75 to
5.25V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector AS1.
3. Turn starting switch to ON position.
Defective accelerator
3 pedal a If check result is unusual, perform checks on causes 4 and 5 to check
(Internal defect) wiring harness. If wiring harness is normal, regard accelerator pedal as
defective.
Between AS1 (5) and (4) See IVS1 in Fig.1.
Between AS1 (6) and (4) See IVS2 in Fig.1.
1. Turn starting switch to OFF position, and turn battery disconnect switch to
OFF position.
Open circuit in wiring 2. Disconnect connectors AS1, AS2, ATC1, and ATC2, and connect T-
harness adapters to each female side.
4 (Wire breakage or Between J2P (female) (32) and AS1 (female) (4) Max. 1 z
defective contact of Between J2P (female) (11) and AS1 (female) (5) Max. 1 z
connector) Resistance Between J2P (female) (1) and AS1 (female) (6) Max. 1 z
Between ATC1 (female) (4) and AS2 (female) (1) Max. 1 z
Between ATC2 (female) (1) and AS2 (female) (2) Max. 1 z
1. Turn starting switch to OFF position, and turn battery disconnect switch to
OFF position.
2. Disconnect connectors AS1 and J2P, and connect T-adapter to female
Short circuit in wiring side of J2P.
5
harness Between J2P (female) (11) and each pin other than
pin (11) Min. 1 Mz
Resistance
Between J2P (female) (1) and each pin other than
pin (1) Min. 1 Mz

1. Turn starting switch to OFF position, and turn battery disconnect switch to
OFF position.
Defective transmission 2. Insert T-adapters into connectors ATC1 and ATC2.
6 controller (internal 3. Turn battery disconnect switch to ON position.
defect) 4. Turn starting switch to ON position.
Voltage Between ATC2 (1) and ATC1 (4) 4.75 to
5.25V

HM400-3M0 40-259
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

If no failure is found by above checks, engine controller is defective.
• Reference
Defective engine 1. Turn starting switch to OFF position.
7 controller 2. Insert T-adapter into connector J2P.
(Internal defect) 3. Turn starting switch to ON position.
Between J2P (11) and (32) See IVS1 in Fig.1.
Between J2P (1) and (32) See IVS2 in Fig.1.

Circuit diagram related to idle validation switch

40-260 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Fig. 1
Pedal stroke: Stroke of accelerator pedal
Output voltage: Output voltage (pin 2 of connector AS1 and pin 9 of connector J2P)
IVS1: Signal voltage of idle validation switch 1
IVS2: Signal voltage of idle validation switch 2
Switch gap: Zone where both signals of IVS1 and IVS2 are OFF

HM400-3M0 40-261
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA432] Idle Validation Process Error (HM400_3R-CA432-400-A-Z0-A)

Action level Failure code Idle Validation Process Error

Failure
L03 CA432 (Engine controller system)
Detail of • Idle validation switch signal does not match with (but contradicts) signal of throttle sensor.
failure
1. When idle validation switch signal indicates that accelerator pedal is OFF but throttle
sensor signal indicates that accelerator pedal is ON: Controls throttle position to 0% while
idle validation signal is indicating that accelerator pedal is OFF, and to 38% while idle
Action of
validation signal is indicating that accelerator pedal is ON.
controller
2. When idle validation switch signal indicates that accelerator pedal is ON but throttle
sensor signal indicates that accelerator pedal is OFF: Controls throttle position to 0%. (Fix
engine speed to low idle.)
• Engine speed does not increase from low idle speed.
Problem on • Centralized warning lamp lights up and alarm buzzer sounds (according to command from
machine machine monitor).
• Input (ON/OFF) of idle validation signal 1 can be checked with monitoring function. (Code:
18300)
• Input (ON/OFF) of idle validation signal 2 can be checked with monitoring function. (Code:
Related 18301)
information • Input voltage from throttle sensor can be checked with monitoring function. (Code: 03000)
• Accelerator pedal position sensed by throttle sensor can be checked with monitoring
function. (Code: 31701)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
For idle validation switch signal error, perform troubleshooting for failure code [CA431].
1
(For throttle sensor error, perform checks on causes 2 and after)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector AS1.
Defective power supply 3. Turn starting switch to ON position.
2 system a If check result is unusual, go to check on cause 4.
Between AS1 (1) and (3) Voltage 4.75 to
5.25V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector AS1.
3. Turn starting switch to ON position.
Defective accelerator
3 pedal a If check result is unusual, perform checks on causes 4 and 5 to check
(Internal defect) wiring harness. If wiring harness is normal, regard accelerator pedal as
defective.
See output voltage in
Between AS1 (2) and (3)
Fig. 1

Open circuit in wiring 1. Turn starting switch to OFF position.

harness 2. Disconnect connectors AS1 and J2P, and connect T-adapters to each
female side.
4 (Wire breakage or Between J2P (female) (22) and AS1 (female) (1) Resistance Max. 1 z
defective contact of
Between J2P (female) (9) and AS1 (female) (2) Resistance Max. 1 z
connector)
Between J2P (female) (23) and AS1 (female) (3) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors AS1 and J2P, and connect T-adapter to female
Short circuit in wiring
5 side of J2P.
harness
Between J2P (female) (9) and each pin other than Min. 1 Mz
pin (9) Resistance

40-262 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

If no failure is found by above checks, engine controller is defective.
• Reference
Defective engine 1. Turn starting switch to OFF position.
6 controller 2. Insert T-adapter into connector J2P.
(Internal defect) 3. Turn starting switch to ON position.
See output voltage in
Between J2P (9) and (23)
Fig. 1

Circuit diagram related to idle validation switch

HM400-3M0 40-263
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Fig. 1
Pedal stroke: Stroke of accelerator pedal
Output voltage: Output voltage (pin 2 of connector AS1 and pin 9 of connector J2P)
IVS1: Signal voltage of idle validation switch 1
IVS2: Signal voltage of idle validation switch 2
Switch gap: Zone where both signals of IVS1 and IVS2 are OFF

40-264 HM400-3M0
 40 Troubleshooting
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Failure code [CA441] Battery Voltage Low Error (HM400_3R-CA441-400-A-Z0-A)

Action level Failure code Battery Voltage Low Error

Failure
L04 CA441 (Engine controller system)
Detail of • Low voltage occurs in engine controller power supply circuit.
failure
Action of • Sets power supply voltage to fixed value (24 V) and runs engine.
controller
Problem on • Engine continues to run normally, but it may stop during running or may not be able to
machine restart if it is stopped.
• Power supply voltage of engine controller can be checked with monitoring function.(Code:
Related 03203 (V))
information • Method of reproducing failure code: Turn starting switch to ON position
No. Cause Procedure, measuring location, criteria, and remarks
Loose or corroded
1 Battery cable terminal may be loose or corroded. Check it.
battery terminal
Loose terminal or partial 1. Turn starting switch to OFF position.
2 open circuit at terminal Check terminals of alternator, battery relay, ground, etc. for loose connection.
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "Related information on
Defective wiring troubleshooting", and check it.
3 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
1. Turn starting switch to OFF position, then perform troubleshooting.
Improper battery
4 2. Measure voltage while cranking engine.
voltage
Voltage Between battery terminals (+) and (-). 20 to 30 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector J3P.
5 Defective alternator 3. Start engine. (Engine speed: Middle or faster)
Voltage Between J3P (6) and ground 26 to 30.5 V
If no failure is found by above checks, engine controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
Defective engine 2. Insert T-adapter into connector J3P.
6
controller 3. Set battery disconnect switch to ON position.
4. Measure voltage with starting switch at OFF position and when starting
engine.
Between J3P (3) and (1) 20 to 30 V
Voltage
Between J3P (4) and (2) 20 to 30 V

HM400-3M0 40-265
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to engine controller power supply

40-266 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA442] Battery Voltage High Error (PC400-CA442-400-A-Z0-A)

Action level Failure code Battery Voltage High Error

Failure
L04 CA442 (Engine controller system)
Detail of • High voltage (approximately 36 V or higher) appears in controller power supply circuit.
failure
Action of • Sets power supply voltage to fixed value (24 V) and allows engine to run.
controller
Problem on • Engine continues to run normally, but it may stop during running or may not be able to
machine restart if it is stopped.
• Method of reproducing failure code: Turn starting switch to ON position.
Related • Power supply voltage of engine controller can be checked with monitoring function.
information (Code: 03203)
No. Cause Procedure, measuring location, criteria and remarks
Defective power supply
1 Perform troubleshooting for failure code [CA441].
system of engine controller

HM400-3M0 40-267
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA449] Rail Press Very High Error (PC400-CA449-400-A-Z0-A)

Action level Failure code Rail Pressure Very High Error

Failure
L03 CA449 (Engine controller system)
Detail of • High voltage (exceeding the preset limit) occurs in common rail pressure sensor circuit.
failure
Action of • Limits engine output and allows engine to run (limits common rail pressure).
controller
Problem on • Engine output reduces.
machine
• Signal voltage from common rail pressure sensor can be checked with monitoring
function. (Code: 36401 (V))
Related • Common rail pressure sensed by common rail pressure sensor can be checked with
information monitoring function. (Code: 36400 (MPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective common rail
1 Perform troubleshooting for failure code [CA553].
pressure sensor system

40-268 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA451] Rail Press Sensor High Error (HM400_3M0-CA451-400-A-Z0-A)

Action level Failure code Rail Pressure Sensor High Error

Failure
L03 CA451 (Engine controller system)
Detail of • High voltage occurs in signal circuit of common rail pressure sensor.
failure
Action of • Limits engine output and runs engine (limits common rail pressure).
controller
Problem on • Engine output reduces.
machine
• Signal voltage from common rail pressure sensor can be checked with monitoring
function. (Code: 36401 (V))
Related • Common rail pressure sensed by common rail pressure sensor can be checked with
information monitoring function. (Code: 36400 (MPa))
• This failure code appears if common rail pressure sensor connector is disconnected.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
a If failure code [CA352] or [CA386] is also displayed, perform
troubleshooting for it first.
Defective common rail 1. Turn starting switch to OFF position.
2 pressure sensor power 2. Disconnect connector PFUEL, and connect T-adapter to female side.
supply system 3. Turn starting switch to ON position.
Power 4.75 to
Voltage Between PFUEL (female) (1) and (3)
supply input 5.25V
1. Turn starting switch to OFF position.
2. Disconnect connectors PFUEL and ENG, and connect T-adapters to each
female side.
a If power supply input is normal in check on
cause 2, this check is not required. Max. 1 z
Open circuit in wiring Between ENG (female) (33) and PFUEL (female)
harness (wire breakage (1)
3 or defective contact of
connector) Resistance a If power supply input is normal in check on
cause 2, this check is not required. Max. 1 z
Between ENG (female) (47) and PFUEL (female)
(3)
Between ENG (female) (25) and PFUEL (female)
(2) (sensor output) Max. 1 z

1. Turn starting switch to OFF position.

Short circuit in wiring 2. Disconnect connectors PFUEL and ENG.
4 3. Connect T-adapter to female side of ENG.
harness
Resistance Between ENG (female) (25) and (33) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector PFUEL, and insert T-adapter into connector ENG.
3. Turn starting switch to ON position (with connector PFUEL disconnected).
Hot short circuit in
5 a Pin (25) of ENG is connected to 5 V line via resistor inside engine
wiring harness
controller.
Approxi-
Voltage Between ENG (25) and (47) mately 5 V

HM400-3M0 40-269
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

a If no failure is found by checks on causes 1 to 5 and if failure is found by
check on cause 6, sensor is defective.
Defective common rail
pressure sensor 1. Turn starting switch to OFF position.
6 (Improper input voltage 2. Insert T-adapter into connector ENG.
to engine controller) 3. Turn starting switch to ON position.
Sensor
Voltage Between ENG (25) and (47) 0.2 to 4.6 V
output
Defective engine If no failure is found by above checks, engine controller is defective. (Since
7 this is an internal defect, troubleshooting cannot be performed.)
controller

Circuit diagram related to common rail pressure sensor

40-270 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA452] Rail Press Sensor Low Error (HM400_3M0-CA452-400-A-Z0-A)

Action level Failure code Rail Pressure Sensor Low Error

Failure
L03 CA452 (Engine controller system)
Detail of • Low voltage occurs in signal circuit of common rail pressure sensor.
failure
Action of • Limits engine output and runs engine (limits common rail pressure).
controller
Problem on • Engine output reduces.
machine
• Signal voltage from common rail pressure sensor can be checked with monitoring
function. (Code: 36401 (V))
• Common rail pressure sensed by common rail pressure sensor can be checked with
Related monitoring function. (Code: 36400 (MPa))
information • Method of reproducing failure code: Turn starting switch to ON position.
• Even in normal condition, if sensor connector is disconnected, failure code [CA451] for
"High Error" is generated instead of this code.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
a If failure code [CA352] or [CA386] is also displayed, perform
troubleshooting for it first.
Defective common rail 1. Turn starting switch to OFF position.
2 pressure sensor power 2. Disconnect connector PFUEL, and connect T-adapter to female side.
supply system 3. Turn starting switch to ON position.
Power 4.75 to 5.25
Voltage Between PFUEL (female) (1) and (3)
supply input V
1. Turn starting switch to OFF position.
Defective common rail 2. Disconnect connector PFUEL.
3 pressure sensor 3. Turn starting switch to ON position.
If failure code [CA452] changes to [CA451], sensor is defective.

Ground fault in wiring 1. Turn starting switch to OFF position.

harness (contact with 2. Disconnect connectors ENG and PFUEL, and connect T-adapter to
4
ground circuit) female side of ENG.
Resistance Between ENG (female) (25) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors ENG and PFUEL, and connect T-adapter to
5
harness female side of ENG.
Resistance Between ENG (25) and (47) Min. 1 Mz
Defective engine If no failure is found by above checks, engine controller is defective. (Since
6 this is an internal defect, troubleshooting cannot be performed.)
controller

HM400-3M0 40-271
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to common rail pressure sensor

40-272 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA553] Rail Press High Error (PC400-CA553-400-A-Z0-A)

Action level Failure code Rail Pressure High Error

Failure
L01 CA553 (Engine controller system)
Detail of • High voltage (above the limit) appears and continued 15 or more seconds in signal circuit
failure of common rail pressure sensor.
Action of • None in particular
controller
Problem on • Engine output lowers.
machine
• Signal voltage from common rail pressure sensor can be checked with monitoring
function. (Code: 36401 (V))
Related • Common rail pressure sensed by common rail pressure sensor can be checked with
information monitoring function. (Code: 36400 (MPa))
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Defective relevant system If other failure codes are also displayed, perform troubleshooting for
1
them.
2 Improper fuel Fuel used may be improper. Check it (the viscosity is high).
Defective electric system of Electrical system of common rail pressure sensor may be defective.
3 common rail pressure sensor Perform troubleshooting for failure codes [CA451] and [CA452].
Defective mechanical system
4 of common rail pressure Common rail pressure sensor may have mechanical failure. Check it.
sensor
The overflow valve may has a damaged spring, worn seat, or ball
5 Defective overflow valve clogging trouble. Check it.
6 Clogging of overflow piping Check overflow piping for clogging.
7 Defective pressure limiter The pressure limiter may have a mechanical failure. Check it.

HM400-3M0 40-273
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA554] Rail Press Sensor In Range Error (HM400_3R-CA554-400-A-Z0-A)

Action level Failure code Rail Pressure Sensor In Range Error

Failure
L03 CA554 (Engine controller system)
Detail of • Signal voltage of common rail pressure sensor is out of input range.
failure
Action of • Limits engine output and runs engine (limits common rail pressure).
controller
Problem on • Engine output reduces.
machine
• Signal voltage from common rail pressure sensor can be checked with monitoring
function. (Code: 36401 (V))
Related • Common rail pressure sensed by common rail pressure sensor can be checked with
information monitoring function. (Code: 36400 (MPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
Defective common rail
1 Perform troubleshooting for failure codes [CA451] and [CA452].
pressure sensor system

40-274 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA559] Rail Press Low Error (HM400_3R-CA559-400-A-Z0-A)

Action level Failure code Rail Pressure Low Error.

Failure
L01 CA559 (Engine controller system)
Detail of • Supply pump pressure is very low (level 1).
failure
Action of
controller
Problem on • Engine output reduces.
machine
• Common rail pressure sensed by common rail pressure sensor can be checked with
Related monitoring function. (Code: 36400 (MPa))
information • Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria, and remarks
Defective relevant
1 If another failure code is displayed, perform troubleshooting for it first.
system
2 Improper fuel is used. Improper fuel may be used, so check fuel.
a For details of troubleshooting, see Note 1.
a For check of fuel pressure in low-pressure circuit, see Testing and
Defective low-pressure adjusting, "Testing fuel pressure".
3
circuit devices Fuel pressure in low-pressure circuit
0.15 to 0.3 MPa
(with engine running at high idle or
{1.5 to 3.0 kg/cm2}
under load equivalent to rated load)
Clogged fuel filter or
4 a For details of troubleshooting, see Note 3.
strainer
Defective electrical Electrical system of supply pump PCV may be defective. Perform
5 system of supply pump troubleshooting for failure codes [CA271], [CA272], [CA273], and [CA274].
PCV
Defective common rail Common rail pressure sensor may be defective. Check wiring harness for
6 pressure sensor damage.
a For check of leakage from pressure limiter, see Testing and adjusting,
"Testing fuel return rate and leakage".
Defective pressure Leakage from pressure limiter
7
limiter (Engine operation equivalent to rated
Max. 10 cc/min
operation (with load by torque
converter stall))
a For check of limit return rate (spill) from injector, see Testing and adjusting,
"Testing fuel return rate and leakage".
Speed at rated operation Injector
(at stall) Limit return (spill) rate
8 Defective injector 1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
Defective supply pump If no failure is found by checks on causes 1 to 8, supply pump may be
9
defective.
<How to use check sheet>
Perform above troubleshooting and fill in check results on attached "Check sheet for fuel pressure low error".
Note:
1. Check low-pressure fuel circuit parts for following items.
1) Remaining quantity of fuel
2) Clogging of fuel tank breather
3) Looking and wear of fuel feed pump and clogging of filter
4) Leakage from or clogging of low-pressure fuel piping

HM400-3M0 40-275
40 Troubleshooting
Troubleshooting by failure code (Display of code)

5) Malfunction of bypass valve and installation of wrong part (See Fig. 1)

6) Clogging of fuel filter
7) Fuel in oil pan (fuel leakage inside cylinder head cover)
2. Figure 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
• Overflow valve (1): Spring is seen through both holes.
• Bypass valve (2): Spring is seen through the nut hole.
• Fuel inlet joint (3): Gauze filter is seen through both holes.

3. Check, clean, and replace filters and strainers according to following procedure.
1) Gauze filter: Disassemble and check gauze filter. If clogged, clean it.
2) Upstream filter of gauze filter: If gauze filter is clogged, clean upstream filter, as well.
3) Fuel filter: If trouble is not solved by performing above steps 1) and 2), replace fuel filter.
Check sheet for fuel pressure low error
Model Work No.
Machine serial No. # Date of check / /
Engine SAA6D140E-5 Service meter h
Engine serial No. # Worker's name
No good
Good

A. Visual check

1 Fuel leakage to outside

2 Clogging of fuel tank breather

40-276 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No good
Good
B. Inspection with machine monitor (02 = Abnormality record; 01 = Monitoring; 09 = Cylinder cutout
mode operation)

3 Check of failure code / / / /

Check of monitoring information

No good
Standard value

Good
Item displayed Testing conditions (Reference Measured
Code ISO unit
value) value

Low idle r/min 725 ± 25

01002 Engine speed High idle r/min 2200 (+50/ – 0)
Torque converter stall r/min 1,950 ± 100
Low idle % 0
31701 Throttle opening
High idle % 100
Last fuel injection
18600 quantity command Torque converter stall mg/st - - -
4
(in weight)
Last common rail
36200 pressure command Torque converter stall MPa -
Common rail
36400 pressure Torque converter stall MPa -
Low idle CA - - -
Last injection
36300 timing command High idle CA - - -
Torque converter stall CA - - -
36500 Charge pressure Torque converter stall kPa - - -
Coolant
04107 temperature Low idle °C - - -
14200 Fuel temperature Low idle °C - - -
Check result of cylinder cutout mode operation (engine speed)

No good
Standard value

Good
Cutout Measured
Function Testing conditions ISO unit (Reference
cylinder value
value)
No. 1
Low idle r/min - - -
cylinder
No. 2
Low idle r/min - - -
5 cylinder
No. 3
Set cylinder Low idle r/min - - -
cylinder
to be cut out
by cylinder. No. 4
Low idle r/min - - -
cylinder
No. 5
Low idle r/min - - -
cylinder
No. 6
Low idle r/min - - -
cylinder
No good

Standard value
Good

C. Check of fuel circuit pressure Testing conditions (Reference Measured

Unit
value) value

High idle or under load

Fuel pressure in low- equivalent to rated MPa 0.15 to 0.3
6 pressure circuit operation (load by torque {kg/cm2} {1.5 to 3.0}
converter stall)

HM400-3M0 40-277
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No good
Good
D. Check of strainers and filters

7 Visual check of strainer

8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve

No good
Standard value

Good
E. Check of leakage and return Testing conditions (Reference Measured
Unit
rate value) value

Engine operation
Leakage from pressure equivalent to rated
11 operation (with load by cc/min Max. 10
limiter
torque converter stall)
Torque converter stall at
1,600 rpm cc/min 960
Torque converter stall at
cc/min 1,020
1,700 rpm
Torque converter stall at Speed:
12 Return rate from injector 1,800 rpm cc/min 1,080
Return rate:
Torque converter stall at
cc/min 1,140
1,900 rpm
Torque converter stall at
cc/min 1,200
2,000 rpm

40-278 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA689] Eng Ne Speed Sensor Error (HM400_3R-CA689-400-A-Z0-A)

Action level Failure code Engine Ne Speed Sensor Error

Failure
L01 CA689 (Engine controller system)
Detail of • Engine Ne speed sensor signal is abnormal.
failure
Action of • Controls engine by using signals from engine Bkup speed sensor.
controller
Problem on • Running engine stops (when Bkup speed sensor is also defective).
machine • Stopped engine cannot be restarted (when Bkup speed sensor is also defective).
• Method of reproducing failure code: Start engine.
• Since interior portion of speed sensor is configured with hall sensor and electronic circuit
rather than coil, measurements of speed sensor resistance by using mulitimeter cannot
Related be used to determine whether sensor is normal or not.
information • Since speed sensor output is pulse voltage of 5 V in normal state, multimeter is not usable
for measurement.
• The speed sensor detects holes drilled through the flywheel and calculates the engine
speed.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
Defective Ne speed
2 sensor power supply If failure code [CA238] is also displayed, perform troubleshooting for it first.
system
Breakage or improper
installation (loosened) Engine Ne speed sensor may be broken or installed improperly (loosened).
3
of engine Ne speed Check it.
sensor
1. Turn starting switch to OFF position.
Defective Ne speed 2. Disconnect connector NE, and connect T-adapter to female side.
4 sensor power supply 3. Turn starting switch to ON position.
input Power 4.75 to
Voltage Between NE (female) (1) and (2)
supply input 5.25V
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and NE.
If no failure is found by checks on cause 4, this
Open circuit in wiring check is not required. Max. 1 z
harness (wire breakage Between ENG (female) (16) and NE (female) (1)
5 or defective contact of
connector) Resistance If no failure is found by checks on cause 4, this
check is not required. Max. 1 z
Between ENG (female) (48) and NE (female) (2)
Between ENG (female) (27) and NE (female) (3) Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and NE.
Ground fault in wiring Between ENG (female) (16) and (27), or between
6 Min. 1 Mz
harness NE (female) (1) and (3)
Resistance
Between ENG (female) (27) and (48), or between
NE (female) (2) and (3) Min. 1 Mz

Ground fault in wiring 1. Turn starting switch to OFF position.

harness (contact with 2. Disconnect connectors ENG and NE.
7
ground circuit) Between ground and ENG (female) (27) or NE
Resistance (female) (3) Min. 1 Mz

1. Turn starting switch to OFF position.

Hot short circuit in
2. Disconnect connector NE.
8 wiring harness (Contact
3. Turn starting switch to ON position.
with 24 V circuit)
Voltage Between NE (female) (3) and ground Max. 1 V

HM400-3M0 40-279
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

If no failure is found by above checks, engine Ne speed sensor may be
Defective engine Ne
9 defective. (Since this is an internal defect, troubleshooting cannot be
speed sensor
performed.)
Defective engine If no problem is found by above checks, engine controller may be defective.
10 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

Circuit diagram related to engine Ne speed sensor

• The Ne speed sensor detects area (A) where holes (H) are not drilled through flywheel (1), and the engine
controller calculates the engine speed and signal phase.

40-280 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA731] Eng Bkup Speed Sens Phase Error (PC400-CA731-400-A-Z0-A)

Action level Failure code Engine Bkup Speed Sensor Phase Error
Failure
L01 CA731 (Engine controller system)
• Engine controller receives signals from engine Bkup sensor, and detects a signal phase
Detail of error.
failure (The signal is out of phase when compared with signals sent from Ne speed sensor.)
Action of • Controls engine by using signals from engine Ne speed sensor.
controller
Problem on • Running engine stops (when Ne speed sensor is also defective).
machine • Stopped engine cannot be restarted (when Ne speed sensor is also defective).
• Method of reproducing failure code: Start engine.
Related
information a The fuel supply pump must also be replaced during replacement of Bkup speed sensor.
(See Disassembly and assembly, "Removal and installation of fuel supply pump".)
No. Cause Procedure, measuring location, criteria and remarks
Defective engine Ne speed Engine Ne speed sensor may be defective. Perform troubleshooting for
1 failure code [CA689].
sensor circuit
Defective engine Bkup speed Engine Bkup speed sensor may be defective. Perform troubleshooting
2 for failure code [CA778].
sensor circuit

HM400-3M0 40-281
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA757] All Continuous Data Lost Error (HM400_3R-CA757-400-A-Z0-A)

Action level Failure code All Continuous Data Lost Error

Failure
L04 CA757 (Engine controller system)
Detail of • All data in engine controller were lost.
failure
Action of • None in particular
controller
Problem on • Engine continues to run normally, but it may stop during running or may not be able to
machine restart if it is stopped.
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
Defective power supply
1 Perform troubleshooting for failure code [CA441].
system

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 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA778] Eng Bkup Speed Sensor Error (HM400_3M0-CA778-400-A-Z0-A)

Action level Failure code Engine Bkup Speed Sensor Error

Failure
L01 CA778 (Engine controller system)
Detail of • Abnormality occurs in engine Bkup speed sensor circuit.
failure
Action of • Controls engine by using signals of Ne speed sensor.
controller

Problem on • Running engine stops (when Ne speed sensor is also defective).

machine • Stopped engine cannot be restarted (when Ne speed sensor is also defective).

• Method of reproducing failure code: Start engine.

a If engine Bkup speed sensor needs to be replaced, fuel supply pump must be
replaced as a unit.
Related (See Disassembly and assembly, "Removal and installation of fuel supply pump".)
information • Since inside of speed sensor is not composed of coil but electronic circuit, speed sensor
cannot be determined to be normal by measuring its resistance by using multimeter.
• Since speed sensor output is pulse voltage of 5 V in normal state, multimeter is not usable
for measurement.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
Defective sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2 supply system for it first.
Damage or improper
(loose) installation of Engine Bkup speed (G) sensor may be damaged or incorrectly (loosely)
3
engine Bkup speed (G) installed. Check it.
sensor
1. Turn starting switch to OFF position.
4 Defective resistor (RES) 2. Disconnect connector RES, and connect T-adapter to male side.
Resistance Between RES (male) (1) and (2) 620 z
1. Turn starting switch to OFF position.
Improper power supply 2. Disconnect connector G, and connect T-adapter to female side.
5 input to engine Bkup 3. Turn starting switch to ON position.
speed sensor Power 4.75 to
Voltage Between G (female) (1) and (2)
supply 5.25V
Open or short circuit in 1. Turn starting switch to OFF position.
wiring harness (resistor 2. Disconnect connectors ENG and G, and connect T-adapter to female side
6
RES system) of ENG.
Resistance Between ENG (female) (37) and (26) 620 z
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG, G, and RES, and connect T-adapters to
each female side.
a If power supply voltage in check on cause 5 is
Open circuit in wiring Max. 1 z
normal, this check is not required.
harness (wire breakage
7 Between ENG (female) (37) and G (female) (1)
or defective contact of
connector) Resistance a If power supply voltage in check on cause 5 is
normal, this check is not required. Max. 1 z
Between ENG (female) (47) and G (female) (2)
Between ENG (female) (26) and G (female) (3) Max. 1 z

HM400-3M0 40-283
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors ENG, G, and RES, and connect T-adapter to
female side of ENG or G.
Short circuit in wiring
8 Between ENG (female) (26) and (37), or between G
harness Min. 1 Mz
(female) (1) and (3)
Resistance
Between ENG (female) (26) and (47), or between G
(female) (2) and (3) Min. 1 Mz

1. Turn starting switch to OFF position.

Ground fault in wiring 2. Disconnect connectors ENG and G, and connect T-adapter to either
9 harness (contact with female side.
ground circuit) Between ground and ENG (female) (26) or G
Resistance (female) (3) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connectors G and RES, and connect T-adapters to each
Hot short circuit in
10 wiring harness female side.
3. Turn starting switch to ON position.
Voltage Between G (female) (3) and ground Max. 1 V
If no failure is found by above checks, engine Bkup speed sensor may be
Defective engine Bkup
11 speed sensor defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
Defective engine If no problem is found by above checks, engine controller may be defective.
12 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

Circuit diagram related to engine Bkup speed sensor

40-284 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1228] EGR valve servo error 1 (HM400_3M0-CA1228-400-A-Z0-A)

Action level Failure code EGR Valve Servo Error 1

Failure
L01 CA1228 (Engine controller system)
Detail of • EGR valve servo error (level 1) occurs.
failure (EGR lift sensor sends back EGR valve position value that differs from command value.)
Action of • Limits engine output and runs engine.
controller • Does not supply current to EGR valve (closes EGR valve).
Problem on • Engine output reduces.
machine
• Position of EGR valve can be checked with monitoring function. (Code: 18100 EGR Valve
Related Position (mm))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
Defective relevant
1 If other failure codes are also displayed, perform troubleshooting for them.
system
a For testing of EGR valve drive pressure, see .Testing and adjusting,
"Testing EGR valve and bypass valve drive oil pressure".
Insufficient EGR valve EGR valve 1.18 MPa {12 kg/cm2}
2 Engine Low idle
drive pressure drive oil Min
speed 1.43 MPa {14.6 kg/cm2}
pressure High idle
Min
If EGR valve drive pressure is abnormal, perform checks on causes 3 and 4.
a For check of engine oil pressure, see Testing and adjusting, "Testing
engine oil pressure".
Defective engine oil 0.08 MPa {0.8 kg/cm2}
Engine oil Engine Low idle
3 pressure system (main Min
circuit) pressure speed 0.21 MPa {2.1 kg/cm2}
High idle
Min
If engine oil pressure is abnormal, perform troubleshooting (S mode) for
mechanical system. (S-14 Oil pressure drops.)
Defective oil pump for Oil pump or relief valve for EGR valve circuit may be defective. Check them.
4
EGR valve
Defective hydraulic
5 Hydraulic piping of EGR valve circuit may be defective. Check it.
piping for EGR valve
Defective return
6 hydraulic piping for Return hydraulic piping for EGR valve circuit may be defective. Check it.
EGR valve
7 Defective EGR valve EGR valve may have mechanical trouble. Check it.
Defective EGR valve lift Perform troubleshooting for failure code [CA2271].
8
sensor
If no failure is found by checks on Causes 1 and 8, engine controller may be
Defective engine defective. (Since this is an internal defect, troubleshooting cannot be
9
controller performed.)

HM400-3M0 40-285
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1625] EGR Valve Servo Error 2 (HM400_3M0-CA1625-400-A-Z0-A)

Action level Failure code EGR Valve Servo Error 2

Failure
L03 CA1625 (Engine controller system)
Detail of • EGR valve servo error (level 2) occurs.
failure (EGR lift sensor sends back EGR valve position value that differs from command value.)
Action of • Limits engine output and runs engine.
controller • Does not supply current to EGR valve (closes EGR valve).
Problem on • Engine output reduces.
machine
• Position of EGR valve can be checked with monitoring function. (Code: 18100 EGR Valve
Related Position (mm))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
EGR valve servo
1 Perform troubleshooting for failure code [CA1228].
system error

40-286 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1626] Bypass Valve Solenoid Current High Error (HM400_3M0-
CA1626-400-A-Z0-A)

Action level Failure code Bypass Valve Solenoid Current High Error
Failure
L03 CA1626 (Engine controller system)
Detail of • Short circuit occurs in bypass valve solenoid drive circuit.
failure
Action of • Limits engine output and runs engine.
controller • Does not supply current to EGR valve and bypass valve (closes both valves).
Problem on • Engine output reduces.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wirings harness and connectors in "c: Electrical
Defective wiring equipment" in "Checks before troubleshooting" of "General information on
1
harness connector troubleshooting", and check them.
1. Turn starting switch to OFF position.
Defective bypass valve 2. Disconnect connector BP and connect T-adapter to male side.
2 solenoid (internal open
circuit) Between BP (male) (1) and (2) 10 to 21 z
Resistance
Between BP (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector ENG, and connect T-adapter to male side.
Open or short circuit in
3 wiring harness a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Resistance Between ENG (female) (31) and (11) 10 to 21 z
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and BP, and connect T-adapter to either
Short circuit in wiring
4 female side.
harness
Between ENG (female) (31) and (11), or between
Resistance BP (female) (1) and (2) Min. 1 Mz

1. Turn starting switch to OFF position.

Hot short circuit in 2. Disconnect connector BP and connect T-adapter to male side.
5 wiring harness 3. Turn starting switch ON (with connector BP disconnected).
Voltage Between BP (female) (1) and (2) Max. 1 V
Defective engine If no failure is found by above checks, engine controller may be defective.
6 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

HM400-3M0 40-287
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to bypass valve

40-288 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1627] Bypass Valve Solenoid Current Low Error (HM400_3M0-
CA1627-400-A-Z0-A)

Action level Failure code Bypass Valve Solenoid Current Low Error
Failure
L03 CA1627 (Engine controller system)
Detail of • Open circuit occurs in bypass valve solenoid drive circuit.
failure
Action of • Limits engine output and runs engine.
controller • Does not supply current to EGR valve and bypass valve (closes both valves).
Problem on • Engine output reduces.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
Defective bypass valve 1. Turn starting switch to OFF position.
2 solenoid (internal open 2. Disconnect connector BP and connect T-adapter to male side.
circuit) Resistance Between BP (male) (1) and (2) 10 to 21 z
1. Turn starting switch to OFF position.
2. Disconnect connector ENG, and connect T-adapter to female side.
Open or short circuit in
3 wiring harness a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Resistance Between ENG (female) (31) and (11) 10 to 21 z
a If no failure is found by check on cause 3, this check is not required.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness (wire breakage 2. Disconnect connectors ENG and BP, and connect T-adapters to each
4 or defective contact of female side.
connector) Between ENG (female) (31) and BP (female) (1) Max. 1 z
Resistance
Between ENG (female) (11) and BP (female) (2) Max. 1 z
Defective engine If no failure is found by above checks, engine controller may be defective.
5 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

HM400-3M0 40-289
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to bypass valve

40-290 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1628] Bypass Valve Servo Error 1 (HM400_3M0-CA1628-400-A-Z0-A)

Action level Failure code Bypass Valve Servo Error 1

Failure
E15 CA1628 (Engine controller system)
• Bypass valve servo error (level 1) occurs.
Detail of (Bypass lift sensor sends back bypass valve position value that differs from command
failure value.)
Action of • Limits engine output and runs engine.
controller • Does not supply current to EGR valve and bypass valve (closes both valves).
Problem on • Engine output reduces.
machine
• Position of bypass valve can be checked with monitoring function. (Code: 18200 BPS
Related Valve Position (mm))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
Defective relevant
1 If other failure codes are also displayed, perform troubleshooting for them.
system
a For testing of bypass valve drive pressure, see .Testing and adjusting,
"Testing EGR valve and bypass valve drive oil pressure".
Bypass 1.18 MPa {12 kg/cm2}
Insufficient bypass Engine Low idle
2 valve drive Min
valve drive pressure speed
pressure High idle 1.43 MPa {14.6 kg/cm2}
Min
If bypass valve drive pressure is abnormal, perform checks on causes 3 and
4.
a For check of engine oil pressure, see Testing and adjusting, "Testing
engine oil pressure".
Defective engine oil 0.08 MPa {0.8 kg/cm2}
Engine oil Engine Low idle
3 pressure system (main Min
circuit) pressure speed 0.21 MPa {2.1 kg/cm2}
High idle
Min
If engine oil pressure is abnormal, perform troubleshooting (S mode) for
mechanical system. (S-14 Oil pressure drops.)
Defective oil pump for Oil pump or relief valve for bypass valve circuit may be defective. Check
4 bypass valve them.
Defective hydraulic
5 Hydraulic piping of bypass valve circuit may be defective. Check it.
piping for bypass valve
Defective return
6 hydraulic piping for Return hydraulic piping of bypass valve circuit may be defective. Check it.
bypass valve
7 Defective bypass valve Bypass valve may have mechanical trouble. Check it.
Defective bypass valve Perform troubleshooting for failure code [CA1631].
8
lift sensor
If no failure is found by checks on Causes 1 and 8, engine controller may be
Defective engine defective. (Since this is an internal defect, troubleshooting cannot be
9
controller performed.)

HM400-3M0 40-291
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1629] Bypass Valve Servo Error 2 (HM400_3M0-CA1629-400-A-Z0-A)

Action level Failure code Bypass Valve Servo Error 2

Failure
L03 CA1629 (Engine controller system)
• Bypass valve servo error (level 2) occurs.
Detail of (Bypass lift sensor sends back bypass valve position value that differs from command
failure value.)
Action of • Limits engine output and runs engine.
controller • Does not supply current to EGR valve and bypass valve (closes both valves).
Problem on • Engine output reduces.
machine
• Position of bypass valve can be checked with monitoring function. (Code: 18200 BPS
Related Valve Position (mm))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
Defective bypass valve
1 Perform troubleshooting for failure code [CA1628].
servo motor system

40-292 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1631] BP valve Lift Position Sensor High Error (HM400_3M0-
CA1631-400-A-Z0-A)

Action level Failure code BP valve Lift Position Sensor High Error
Failure
L03 CA1631 (Engine controller system)
Detail of • High voltage occurs in signal circuit of bypass valve lift sensor.
failure
Action of • Limits engine output and runs engine.
controller • Does not supply current to EGR valve and bypass valve (closes both valves).
Problem on • Engine output reduces.
machine
• Signal voltage from bypass valve lift sensor can be checked with monitoring function.
(Code: 18201 (V))
Related • Bypass valve position (mm) sensed by bypass valve lift sensor can be checked with
information monitoring function. (Code: 18200 (mm))
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
Defective sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2 supply system for it first.
1. Turn starting switch to OFF position.
Defective bypass valve
2. Disconnect connector SBP.
3 lift sensor (internal
3. Turn starting switch to ON position (with connector SBP disconnected).
defect)
If failure code [CA1631] changes to [CA1632], sensor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and SBP, and connect T-adapter to either
Short circuit in wiring female side.
4
harness Between ENG (female) (37) and (29) or between
Resistance SBP (female) (1) and (3) or between SBP (female) Min. 1 Mz
(1) and (4)
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector SBP, and connect T-adapter to female side.
5 wiring harness 3. Turn starting switch to ON position (with connector SBP disconnected).
Voltage Between SBP (female) (3) or (4) and (2) Max. 1 V
If no failure is found by above checks, engine controller may be defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
Defective engine 1. Turn starting switch to OFF position.
6
controller 2. Insert T-adapter into connector ENG.
3. Turn starting switch to ON position.
Voltage Between ENG (29) and (38) 1.0 to 4.0 V

HM400-3M0 40-293
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to bypass valve lift sensor

40-294 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1632] BP valve Lift Position Sensor Low Error (HM400_3M0-
CA1632-400-A-Z0-A)

Action level Failure code BP valve Lift Position Sensor Low Error
Failure
L03 CA1632 (Engine controller system)
Detail of • Low voltage occurs in signal circuit of bypass valve lift sensor.
failure
Action of • Limits engine output and runs engine.
controller • Does not supply current to EGR valve and bypass valve (closes both valves).
Problem on • Engine output reduces.
machine
• Signal voltage from bypass valve lift sensor can be checked with monitoring function.
(Code: 18201 (V))
Related • Bypass valve position (mm) sensed by bypass valve lift sensor can be checked with
information monitoring function. (Code: 18200 (mm))
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wirings harness and connectors in "c: Electrical
Defective wiring equipment" in "Checks before troubleshooting" of "General information on
1
harness connector troubleshooting", and check them.
If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
for it first.
Defective sensor power 1. Turn starting switch to OFF position.
2 supply system 2. Disconnect connector SBP, and connect T-adapter to female side.
3. Turn starting switch to ON position.
Power 4.75 to 5.25
Voltage Between SBP (female) (1) and (2)
supply V
1. Turn starting switch to OFF position.
2. Disconnect connectors SBP and ENG, and connect T-adapters to each
female side.
a If power supply voltage in check on cause 2 is
normal, this check is not required.
Open circuit in wiring Max. 1 z
Between ENG (female) (37) and SBP (female)
harness (wire breakage (1)
3 or defective contact of
connector) Resistance a If power supply voltage in check on cause 2 is
normal, this check is not required.
Max. 1 z
Between ENG (female) (38) and SBP (female)
(2)
Between ENG (female) (29) and each of SBP
(female) (3) and (4) (sensor output) Max. 1 z

1. Turn starting switch to OFF position.

Ground fault in wiring 2. Disconnect connectors ENG and SBP, and connect T-adapter to either
4 harness (contact with female side.
ground circuit) Between ground and ENG (female) (29) or SBP
Resistance (female) (3) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connectors ENG and SBP, and connect T-adapter to either
Short circuit in wiring
5 female side.
harness
Between ENG (female) (29) and (38), or between
Resistance SBP (female) (2) and (3) Min. 1 Mz

HM400-3M0 40-295
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

a If no failure is found by checks on causes 1 to 5 and failure is found by
check on cause 6, sensor is defective.
Defective bypass valve 1. Turn starting switch to OFF position.
6 2. Insert T-adapter into connector ENG or SBP.
lift sensor
3. Turn starting switch to ON position.
Between ENG (29) and (38), or between SBP (3)
Voltage 1.0 to 4.0 V
and (2)
Defective engine If no failure is found by above checks, engine controller is defective. (Since
7 this is an internal defect, troubleshooting cannot be performed.)
controller

Circuit diagram related to bypass valve lift sensor

40-296 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2185] Throt Sensor Sup Volt High Error (HM400_3R-CA2185-400-A-Z0-A)

Action level Failure code Throttle Sensor Supply Voltage High Error
Failure
L03 CA2185 (Engine controller system)
Detail of • High voltage (5.25 V or higher) appears in throttle sensor power supply circuit.
failure
Action of • Sets throttle position by using signal other than throttle sensor signal and runs engine.
controller
Problem on • Engine speed cannot be controlled by fuel dial.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect connector AS1 and turn starting switch to ON position.
Defective throttle
2 If this failure code disappears, throttle sensor is defective.
sensor (throttle pedal)
a Other failure codes are also displayed. They are generated because of
disconnection of connector. Ignore failure codes other than [CA2185].
1. Turn starting switch to OFF position.
2. Disconnect connectors J2P, J3P, and AS1 and connect T-adapters to
Short circuit in wiring female side of J2P and J3P.
3
harness Between J2P (female) (22) and each pin other than
Min. 1 Mz
Resistance J2P (female) (22) pin.
Between J2P (female) (22) and J3P (female) (3) Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector AS1 and connect T-adapter to female side.
4 wiring harness 3. Turn starting switch to ON position.
Voltage Between AS1 (female) (1) and ground 4.75 to
5.25V
1. Turn starting switch to OFF position.
2. Disconnect connector J2P and connect T-adapter to male side.
Defective engine
5 3. Turn starting switch to ON position with connector J2P disconnected.
controller
Voltage Between J2P (male) (22) and (23) 4.75 to
5.25V

HM400-3M0 40-297
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to throttle sensor

40-298 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2186] Throt Sensor Sup Volt Low Error (HM400_3R-CA2186-400-A-Z0-A)

Action level Failure code Throttle Sensor Supply Voltage Low Error
Failure
L03 CA2186 (Engine controller system)
Detail of • Low voltage occurs in throttle sensor power supply circuit.
failure
Action of • Sets throttle position by using signal other than throttle sensor signal and runs engine.
controller
Problem on • Engine speed cannot be controlled by fuel dial.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect connector AS1 and turn starting switch to ON position.
Defective throttle
2 If this failure code disappears, throttle sensor is defective.
sensor (throttle pedal)
a Other failure codes are also displayed. They are generated because of
disconnection of connector. Ignore failure codes other than [CA2186].
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors J2P and AS1, and connect T-adapter to either
3 harness (contact with female side.
ground circuit) Between ground and J2P (female) (22) or AS1
Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connectors J2P and AS1, and connect T-adapter to female
Short circuit in wiring side of J2P.
4 3. Turn starting switch to ON position.
harness
Between J2P (female) (22) and each pin other than
Resistance J2P (female) (22) pin. Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connector J2P and connect T-adapter to male side.
Defective engine
5 3. Turn starting switch to ON position with connector J2P disconnected.
controller
Voltage Between J2P (male) (22) and (23) 4.75 to 5.25
V

HM400-3M0 40-299
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to throttle sensor

40-300 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2249] Rail Press Very Low Error (PC400-CA2249-400-A-Z0-A)

Action level Failure code Rail Pressure Very Low Error

Failure
L03 CA2249 (Engine controller system)
Detail of • Supply pump does not feed fuel (level 2).
failure
Action of • Limits engine output (limits common rail pressure) and allows engine to run.
controller
Problem on • Engine output lowers.
machine
• Signal voltage from common rail pressure sensor can be checked by using monitoring
function. (Code: 36401 (V))
Related • Common rail pressure sensed by common rail pressure sensor can be checked with
information monitoring function. (Code: 36400 (MPa))
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Supply pump pressure low Perform troubleshooting for failure code [CA559].
1
error

HM400-3M0 40-301
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2271] EGR Valve Pos Sens High Error (HM400_3M0-CA2271-400-A-Z0-A)

Action level Failure code EGR Valve Position Sensor High Error
Failure
L03 CA2271 (Engine controller system)
Detail of • High voltage occurs in signal circuit of EGR valve lift sensor.
failure
Action of • Limits engine output and runs engine.
controller • Does not supply current to EGR valve (closes EGR valve).
Problem on • Engine output reduces.
machine
• Signal voltage from EGR valve lift sensor can be checked with monitoring function. (Code:
18101 (V))
Related • EGR valve position (mm) sensed by EGR valve lift sensor can be checked with
information monitoring function. (Code: 18100 (mm))
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "Related information on
1
harness connector troubleshooting", and check it.
Defective sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2 supply system for it first.
1. Turn starting switch to OFF position.
Defective EGR valve lift 2. Disconnect connector SEGR.
3 sensor(internal defect) 3. Turn starting switch to ON position (with connector SEGR disconnected).
If failure code changes from [CA2271] to [CA2272], sensor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and EGR, and connect T-adapter to either
Short circuit in wiring female side.
4
harness Between ENG (female) (37) and (19) or between
Resistance SEGR (female) (1) and (3) or between SEGR Min. 1 Mz
(female) (1) and (4)
1. Turn starting switch to OFF position.
Hot short circuit in
2. Disconnect connector SEGR and connect T-adapter to female side.
5 wiring harness (Contact
3. Turn starting switch to ON position (with connector SEGR disconnected).
with 24 V circuit)
Voltage Between SEGR (female) (3) or (4) and (2) Max. 1 V
If no failure is found by above checks, engine controller may be defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
Defective engine 1. Turn starting switch to OFF position.
6
controller 2. Insert T-adapter into connector ENG.
3. Turn starting switch to ON position.
Voltage Between ENG (19) and (47) 1.0 to 4.0 V

40-302 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to EGR valve lift sensor

HM400-3M0 40-303
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2272] EGR Valve Pos Sens Low Error (HM400_3M0-CA2272-400-A-Z0-A)

Action level Failure code EGR Valve Position Sensor Low Error
Failure
L03 CA2272 (Engine controller system)
Detail of • Low voltage occurs in signal circuit of EGR valve lift sensor.
failure
Action of • Limits engine output and runs engine.
controller • Does not supply current to EGR valve (closes EGR valve).
Problem on • Engine output reduces.
machine
• Signal voltage from EGR valve lift sensor can be checked with monitoring function. (Code:
18101 (V))
Related • EGR valve position (mm) sensed by EGR valve lift sensor can be checked with
information monitoring function. (Code: 18100 (mm))
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wirings harness and connectors in "c: Electrical
Defective wiring equipment" in "Checks before troubleshooting" of "General information on
1
harness connector troubleshooting", and check them.
If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
for it first.
Defective sensor power 1. Turn starting switch to OFF position.
2 supply system 2. Disconnect connector SEGR and connect T-adapter to female side.
3. Turn starting switch to ON position.
Power 4.75 to 5.25
Voltage Between SEGR (female) (1) and (2)
supply V
1. Turn starting switch to OFF position.
2. Disconnect connectors SEGR and ENG, and connect T-adapters to each
female side.
a If power supply voltage in check on cause 2 is
normal, this check is not required.
Open circuit in wiring Max. 1 z
Between ENG (female) (37) and SEGR (female)
harness (wire breakage (1)
3 or defective contact of
connector) Resistance a If power supply voltage in check on cause 2 is
normal, this check is not required.
Max. 1 z
Between ENG (female) (47) and SEGR (female)
(2)
Between ENG (female) (19) and each of SEGR
(female) (3) and (4) (sensor output) Max. 1 z

1. Turn starting switch to OFF position.

Ground fault in wiring 2. Disconnect connectors ENG and SEGR, and connect T-adapter to either
4 harness (contact with female side.
ground circuit) Between ground and ENG (female) (19) or SEGR
Resistance (female) (3) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connectors ENG and SEGR, and connect T-adapter to either
Short circuit in wiring
5 female side.
harness
Between ENG (female) (19) and (47), or between
Resistance SEGR (female) (2) and (3) Min. 1 Mz

40-304 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

a If no failure is found by checks on causes 1 to 5 and failure is found by
check on cause 6, sensor is defective.
Defective EGR valve lift 1. Turn starting switch to OFF position.
6 2. Insert T-adapter into connector ENG or SEGR.
sensor
3. Turn starting switch to ON position.
Between ENG (19) and (47), or between SEGR (3)
Voltage 1.0 to 4.0 V
and (2)
Defective engine If no failure is found by above checks, engine controller is defective. (Since
7 this is an internal defect, troubleshooting cannot be performed.)
controller

Circuit diagram related to EGR valve lift sensor

HM400-3M0 40-305
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2351] EGR Valve Solenoid Short Error (HM400_3M0-CA2351-400-A-Z0-A)

Action level Failure code EGR Valve Solenoid Short Error

Failure
L03 CA2351 (Engine controller system)
Detail of
• Short circuit occurs in EGR valve solenoid drive circuit.
failure
Action of • Limits engine output and runs engine.
controller • Does not supply current to EGR valve and bypass valve (closes both valves).
Problem on • Engine output reduces.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wirings harness and connectors in "c: Electrical
Defective wiring equipment" in "Checks before troubleshooting" of "General information on
1
harness connector troubleshooting", and check them.
1. Turn starting switch to OFF position.
Defective EGR valve 2. Disconnect connector EGR and connect T-adapter to male side.
2 solenoid　(internal
open circuit) Between EGR (male) (1) and (2) 10 to 21 z
Resistance
Between EGR (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector ENG, and connect T-adapter to male side.
Open or short circuit in
3 wiring harness a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Resistance Between ENG (male) (22) and (11) 10 to 21 z
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and EGR, and connect T-adapter to either
Short circuit in wiring
4 female side.
harness
Between ENG (female) (22) and (11), or between
Resistance EGR (female) (1) and (2) Min. 1 Mz

1. Turn starting switch to OFF position.

Hot short circuit in 2. Disconnect connector EGR and connect T-adapter to male side.
5 wiring harness 3. Turn starting switch ON (with connector EGR disconnected).
Voltage Between EGR (female) (1) and (2) Max. 1 V
Defective engine If no failure is found by above checks, engine controller may be defective.
6 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-306 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to EGR valve solenoid

HM400-3M0 40-307
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2352] EGR Valve Solenoid Open Error (HM400_3M0-CA2352-400-A-Z0-A)

Action level Failure code EGR Valve Solenoid Open Error

Failure
L03 CA2352 (Engine controller system)
Detail of • Open circuit occurs in EGR valve solenoid drive circuit.
failure
Action of • Limits engine output and runs engine.
controller • Does not supply current to EGR valve and bypass valve (closes both valves).
Problem on • Engine output reduces.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
See descriptions of wirings harness and connectors in "c: Electrical
Defective wiring equipment" in "Checks before troubleshooting" of "General information on
1
harness connector troubleshooting", and check them.
Defective EGR valve 1. Turn starting switch to OFF position.
2 solenoid　(internal 2. Disconnect connector EGR and connect T-adapter to male side.
open circuit) Resistance Between EGR (male) (1) and (2) 10 to 21 z
1. Turn starting switch to OFF position.
2. Disconnect connector ENG, and connect T-adapter to female side.
Open or short circuit in
3 wiring harness a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Resistance Between ENG (female) (22) and (11) 10 to 21 z
a If no failure is found by check on cause 3, this check is not required.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness (wire breakage 2. Disconnect connectors ENG and EGR, and connect T-adapters to each
4 or defective contact of female side.
connector) Between ENG (female) (22) and EGR (female) (1) Max. 1 z
Resistance
Between ENG (female) (11) and EGR (female) (2) Max. 1 z
Defective engine If no failure is found by above checks, engine controller may be defective.
5 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-308 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to EGR valve solenoid

HM400-3M0 40-309
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2555] Grid Htr Relay Volt Low Error (HM400_3R-CA2555-400-A-Z0-A)

Action level Failure code Grid Heater Relay Voltage Low Error
Failure
L01 CA2555 (Engine controller system)
Detail of • Open circuit is in preheat relay drive circuit (primary circuit).
failure
Action of • None in particular
controller
Problem on • Intake air heater does not work in auto preheating mode (resulting in degraded startability
machine and emission of white smoke at low temperatures).
• Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (°C))
• Method of reproducing failure code: Turn starting switch to ON position (Coolant
Related temperature: Max. -5°C)
information • Troubleshooting of this failure code covers circuit from engine controller to primary (coil)
circuit of preheater relay R07.
• For troubleshooting of circuit from heater relay to secondary side of preheater relay R07,
see E-3 in E-mode troubleshooting.
No. Cause Procedure, measuring location, criteria, and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "Related information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
1. Turn starting switch to OFF position.
Defective preheater 2. Disconnect relay R07, and connect T-adapter to male side.
2 relay R07 200 to 400
Resistance Between R07 (male) (1) and (2)
z
1. Turn starting switch to OFF position.
2. Disconnect connector J2P, and connect T-adapter to female side.
Open or short circuit in
3 wiring harness Between J2P (female) (40) and (42)
200 to 400
Resistance a To measure coil resistance of preheater relay
z
R07
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connector J2P and relay R07, and connect T-adapters to each
4
harness female side.
Between J2P (female) (40) and R07 (female) (1) Max. 1 z
Resistance
Between J2P (female) (42) and R07 (female) (2) Max. 1 z
Defective engine If no failure is found by above checks, engine controller is defective. (Since
5 this is an internal defect, troubleshooting cannot be performed.)
controller

40-310 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to preheater relay

HM400-3M0 40-311
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2556] Grid Htr Relay Volt High Error (HM400_3R-CA2556-400-A-Z0-A)

Action level Failure code Grid Heater Relay Voltage High Error
Failure
L01 CA2556 (Engine controller system)
Detail of • Short circuit is in preheat relay drive circuit (primary circuit).
failure
Action of • None in particular
controller
Problem on • Intake air heater does not work in auto preheating mode (resulting in degraded startability
machine and emission of white smoke at low temperatures).
• Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (°C))
• Method of reproducing failure code: Turn starting switch to ON position (Coolant
Related temperature: Max. -5°C)
information • Troubleshooting of this failure code covers circuit from engine controller to primary (coil)
circuit of preheater relay R07.
• For troubleshooting of circuit from heater relay to secondary side of preheater relay R07,
see E-3 in E-mode troubleshooting.
No. Cause Procedure, measuring location, criteria, and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "Related information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
1. Turn starting switch to OFF position.
Defective preheater 2. Disconnect relay R07, and connect T-adapter to male side.
2 relay R07 200 to 400
Resistance Between R07 (male) (1) and (2)
z
1. Turn starting switch to OFF position.
2. Disconnect connector J2P and relay R07, and connect T-adapter to either
Ground fault in wiring
3 female side.
harness
Between ground and J2P (female) (40) or R07
Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connector J2P and relay R07, and connect T-adapter to
Short circuit in wiring female side of J2P.
4
harness a Check by using multimeter in continuity mode.
Between J2P (female) (40) and each No continuity (no sound
Continuity
pin other than pin (40) is heard)
Defective engine If no failure is found by above checks, engine controller is defective. (Since
5 this is an internal defect, troubleshooting cannot be performed.)
controller

40-312 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to intake air heater relay

HM400-3M0 40-313
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D150KB] Ground Fault of Emerg. Steering Relay (HM300_3-D150KB-

400-A-Z0-A)

Action level Failure code Ground Fault of Emergency Steering Relay

Failure
L03 D150KB (Retarder hoist controller system)
Detail of • When controller drives primary circuit (coil) of auto emergency steering relay 1, large
failure current flows.
Action of • Stops driving auto emergency steering relay 1.
controller
Problem on • Automatic emergency steering does not work.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Defective R17 (auto 2. Disconnect connector R17 and connect T-adapter to male side.
1 emergency steering relay 1) Resis- Between connectors R17 (male) (1) and (2)
290 ± 60 z
tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors BRC2 and R17, and connect T-adapter to
2 either female side.
(Contact with ground circuit)
Resis- Between ground and BRC2 (female) (19) or
R17 (female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC2, BRC3 and R17, and connect T-
adapter to any female side.
3 Short circuit in wiring harness
Between BRC2 (female) (19) and BRC3
Resis- (female) (23), or between R17 (female) (1) and
Min. 1 Mz
tance (2)
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

Circuit diagram related to emergency steering relay 1

40-314 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D150KZ] Failure of Emerg. Steering Relay (HM300_3-D150KZ-400-A-Z0-A)

Action level Failure code Failure of Emergency Steering Relay

Failure
L03 D150KZ (Retarder hoist controller system)
Detail of • No current flows when controller drives primary circuit (coil) of auto emergency steering
failure relay 1, or current flows when controller does not drive relay.
Action of • None in particular
controller
Problem on • Auto emergency steering does not work or cannot be canceled.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
Related • When starting switch is turned to ON position, controller drives emergency steering relay
information to diagnose emergency steering motor.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Defective R17 (auto 2. Disconnect connector R17 and connect T-adapter to male side.
1 emergency steering relay) Resis- Between connectors R17 (male) (1) and (2)
290 ± 60 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC2, BRC3 and R17, and connect T-
Open circuit in wiring harness adapters to each female side.
2 (Wire breakage or defective Between BRC2 (female) (19) and R17 (female)
Max. 1 z
contact of connector) Resis- (1)
tance Between BRC3 (female) (23) and R17 (female)
(2) Max. 1 z

Hot short circuit in wiring 1. Turn starting switch to OFF position.

harness 2. Disconnect connector R17 and connect T-adapter to female side.
3 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Voltage Between R17 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

Circuit diagram related to emergency steering relay 1

HM400-3M0 40-315
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D151KB] Ground Fault of Emerg. Steering Relay 2 (HM400_3-

D151KB-400-A-Z0-A)

Action level Failure code Ground Fault of Emergency Steering Relay 2

Failure
L03 D151KB (Retarder hoist controller system)
Detail of • When controller drives primary circuit (coil) of auto emergency steering relay 2, large
failure current flows.
Action of • Stops driving auto emergency steering relay 2.
controller
Problem on • Automatic emergency steering does not work.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Defective R21 (auto 2. Disconnect connector R21 and connect T-adapter to male side.
1 emergency steering relay 2) Resis- Between connector R21 (male) (1) and (2)
290 ± 60 z
tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors BRC2 and R21, and connect T-adapter to
2 either female side.
(Contact with ground circuit)
Resis- Between ground and BRC2 (female) (9) or R21
(female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC2, BRC3 and R21, and connect T-
3 Short circuit in wiring harness adapter to any female side.
Resis- Between BRC2 (female) (9) and BRC3 (female)
(23), or between R21 (female) (1) and (2) Min. 1 Mz
tance
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

Circuit diagram related to emergency steering relay 2

40-316 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D151KZ] Failure of Emerg. Steering Relay 2 (HM400_3-D151KZ-400-A-Z0-A)

Action level Failure code Failure of Emergency Steering Relay 2

Failure
L03 D151KZ (Retarder hoist controller system)
Detail of • No current flows when controller drives primary circuit (coil) of auto emergency steering
failure relay 2, or current flows when controller does not drive relay.
Action of • None in particular
controller
Problem on • Auto emergency steering does not work or cannot be canceled.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
Related • When starting switch is turned to ON position, controller drives emergency steering relay
information to diagnose emergency steering motor.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Defective R21 (auto 2. Disconnect connector R21 and connect T-adapter to male side.
1 emergency steering relay 2) Resis- Between connector R21 (male) (1) and (2)
290 ± 60 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC2, BRC3 and R21, and connect T-
Open circuit in wiring harness adapters to each female side.
2 (Wire breakage or defective Between BRC2 (female) (9) and R21 (female)
Max. 1 z
contact of connector) Resis- (1)
tance Between BRC3 (female) (23) and R21 (female)
(2) Max. 1 z

Hot short circuit in wiring 1. Turn starting switch to OFF position.

harness 2. Disconnect connector R21 and connect T-adapter to female side.
3 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Voltage Between R21 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

Circuit diagram related to emergency steering relay 2

HM400-3M0 40-317
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D164KY] Hot Short of Head Light High Selector (HM300_3-D164KY-400-
A-Z0-A)

Action level Failure code Hot Short of Head Light High Selector
Failure
L01 D164KY (Machine monitor system)
Detail of • When driving head lamp (high beam) relay, output terminal voltage of controller is higher
failure than specified value.
• Stops driving head lamp (high beam) relay.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Head lamp (high beam) does not light up (However, lamp works as passing lamp
machine normally).
• Command (ON/OFF) from controller to head lamp (high beam) relay can be checked with
Related monitoring function. (Code: 04700)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Defective head lamp (high 2. Disconnect connector R14 and connect T-adapter to male side.
1 beam) relay
Resis- Between R14 (male) (1) and (2)
290 ± 60 z
tance
Hot short circuit in wiring 1. Turn starting switch to OFF position.
2. Disconnect connector R14, and connect T-adapter to female side.
2 harness 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Voltage Between R14 (female) (1) and ground Max. 1 V
If no failure is found by above checks, monitor controller is defective.
3 Defective monitor controller
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to head lamp relay

40-318 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D19HKZ] Failure of Stop Lamp (R&L) (HM300_3-D19HKZ-400-A-Z0-A)

Action level Failure code Failure of Stop Lamp (Right and Left).
Failure
L01 D19HKZ (Retarder hoist controller system)
• When driving primary circuit (coil) of stop lamp relay, no current flows or excessive current
Detail of flows through circuit.
failure • When controller does not drive primary circuit (coil) of stop lamp relay, current flows
through circuit.
Action of • Stops driving stop lamp output circuit for short circuit.
controller
Problem on • Stop lamp does not light up or stays lit.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position and depress brake
information pedal.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Defective R04 (stop
1 2. Disconnect connector R04 and connect T-adapter to male side.
lamp relay)
Resistance Between connectors R04 (male) (5) and (6) 290 ± 60 z
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors BRC3 and R04, and connect T-adapters to female
2 (Wire breakage or side of each connector.
defective contact of Between BRC3 (female) (25) and R04 (female) (5) Max. 1 z
connector) Resistance
Between BRC3 (female) (3) and R04 (female) (6) Max. 1 z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors BRC3 and R04, and connect T-adapter to female
3 side of either connector.
(Contact with ground
Between ground and BRC3 (female) (25) or R04
circuit) Resistance (female) (5) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC3 and R04, and connect T-adapter to female
Short circuit in wiring
4 side of either connector.
harness
Between BRC3 (female) (25) and (3), or between
Resistance R04 (female) (5) and (6) Min. 1 Mz
Hot short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connector R04, and connect T-adapter to female side.
5 (Contact with 24 V 3. Turn starting switch to ON position.
circuit) Voltage Between R04 (female) (5) and (6) or ground Max. 4.5 V
If no failure is found by above checks, retarder hoist controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
6 Defective retarder hoist 2. Insert T-adapter into connector BRC3.
controller 3. Turn starting switch to ON position.
Between BRC3 (25) and Retarder and service
Voltage Max. 1 V
(3) brake: OFF
Between BRC3 (25) and Retarder and service
Voltage 20 to 30 V
(3) brake: ON

HM400-3M0 40-319
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to stop lamp relay

40-320 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D19JKZ] Personal Code Relay Abnormality (HM300_3-D19JKZ-400-A-Z0-A)

Action level Failure code Personal Code Relay Abnormality

Failure
L03 D19JKZ (Machine monitor system)
• When controller does not drive primary circuit (coil) of personal code relay, monitor
Detail of controller detects open circuit or ground fault because output terminal voltage is lower
failure than approximately 5.7 V.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on
machine
• Output (ON/OFF) for personal code relay can be checked with monitoring function. (Code:
Related 04700)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
Defective fuse -10 in If fuse is blown, circuit may have ground fault, etc. (See check on cause 4.)
1
fuse box BT1
1. Turn starting switch to OFF position.
Defective personal
2 2. Disconnect connector R19 and connect T-adapter to male side.
code relay R19
Resistance Between connectors R19 (male) (1) and (2) 290 ± 60 z
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors MCM1 and R19, and connect T-adapters to each
female side.
3 (Wire breakage or 3. Remove fuse BT1-10.
defective contact of Between MCM1 (female) (19) and R19 (female) (2) Max. 1 z
connector) Resistance
Between BT1-10 and R19 (female) (1) Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors MCM1. R19 and SF1, and connect T-adapter to
harness either female side.
4 3. Remove fuse BT1-10.
(Contact with ground Between ground and MCM1 (female) (19) or R19
circuit) Min. 1 Mz
Resistance (female) (2)
Between ground and BT1-10 or R19 (female) (1) Min. 1 Mz
Defective monitor If no failure is found by above checks, monitor controller is defective. (Since
5 this is an internal defect, troubleshooting cannot be performed).
controller

Circuit diagram related to personal code relay

HM400-3M0 40-321
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D1EHKA] Disconnection of Engine Start Relay (HM300_3-D1EHKA-400-

A-Z0-A)

Action level Failure code Disconnection of Engine Start Relay

Failure
L03 D1EHKA (Transmission controller system)
Detail of • When controller drives primary circuit (coil) of engine start relay, no current flows through
failure circuit.
Action of • None in particular
controller
Problem on • Engine does not start.
machine
Related • Engine start relay output signal can be checked with monitoring (Code: 03900).
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector R01 and connect T-adapter to male side.
1 Defective engine start relay
Resis- Between connectors R01 (male) (1) and (2)
290 ± 30 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC3 and R01, and connect T-adapters to
each female side.
Open circuit in wiring harness
2 (Wire breakage or defective a Check ground terminal ER2 for looseness and rust.
contact of connector) Between R01 (female) (1) and ATC3 (female)
Max. 1 z
Resis- (25)
tance Between connector R01 (female) (2) and
ground Max. 1 z
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed).

Circuit diagram related to engine start relay

40-322 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D1EHKB] Ground Fault of Engine Start Relay (HM300_3-D1EHKB-400-A-

Z0-A)

Action level Failure code Ground Fault of Engine Start Relay

Failure
L03 D1EHKB (Transmission controller system)
Detail of • When controller drives primary circuit (coil) of engine start relay, large current flows.
failure
Action of • Stops driving engine start relay.
controller
Problem on • Engine does not start.
machine
Related • Engine start relay output signal can be checked with monitoring (Code: 03900).
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector R01 and connect T-adapter to male side.
1 Defective engine start relay
Resis- Between connectors R01 (male) (1) and (2) 290 ± 30 z
tance Between connector R01 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ATC3 and R01, and connect T-adapter to
2 either female side.
(Contact with ground circuit)
Resis- Between ground and ATC3 (female) (25) or
R01 (female) (1) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed).

Circuit diagram related to engine start relay

HM400-3M0 40-323
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D1EHKY] Hot Short of Engine Start Relay (HM300_3-D1EHKY-400-A-Z0-A)

Action level Failure code Hot Short of Engine Start Relay

Failure
L03 D1EHKY (Transmission controller system)
Detail of • When controller does not drive primary circuit (coil) of engine start relay, current flows
failure through circuit.
Action of • None in particular
controller
Problem on • Engine does not start.
machine
Related • Engine start relay output signal can be checked with monitoring (Code: 03900).
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Defective engine start
1 2. Disconnect connector R01 and connect T-adapter to male side.
relay
Resistance Between connectors R01 (male) (1) and (2) 290 ± 30 z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connectors ATC3 and R01, and connect T-adapter to either
wiring harness female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V
circuit) Between ground and ATC3 (female) (25) or R01
Voltage Max. 1 V
(female) (1)
Defective transmission If no failure is found by above checks, transmission controller is defective.
3 (Since this is an internal defect, troubleshooting cannot be performed).
controller

Circuit diagram related to engine start relay

40-324 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D1EMKA] Disconnection of Parking Interlock Relay (HM300_3-

D1EMKA-400-A-Z0-A)

Action level Failure code Disconnection of Parking Interlock Relay

Failure
L03 D1EMKA (Retarder hoist controller system)
Detail of • When controller drives primary circuit (coil) of parking interlock relay, no current flows
failure through circuit.
Action of • None in particular
controller
Problem on • When auto idle stop function is actuated, parking brake is not applied automatically.
machine
Related • Method of reproducing failure code: Actuate auto idle stop function.
information
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Defective connector R23 2. Disconnect connector R23 and connect T-adapter to male side.
1 (parking interlock relay)
Resis- Between connectors R23 (male) (1) and (2)
290 ± 60 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector BRC3 and connect T-adapter to female side.
Open or short circuit in wiring
2 a Solenoid coil resistance
harness
Resis- Between BRC3 (female) (35) and (23)
290 ± 60 z
tance
a If no failure is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors BRC3 and R23, and connect T-adapters to
3 (wire breakage or defective each female side.
contact of connector) Between BRC3 (female) (35) and R23 (female)
Max. 1 z
Resis- (1)
tance Between BRC3 (female) (23) and R23 (female)
(2) Max. 1 z
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

Circuit diagram related to parking interlock relay

HM400-3M0 40-325
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D1EMKB] Ground Fault of Parking Interlock Relay (HM300_3-

D1EMKB-400-A-Z0-A)

Action level Failure code Ground Fault of Parking Interlock Relay

Failure
L03 D1EMKB (Retarder hoist controller system)
Detail of • When controller drives primary circuit (coil) of parking interlock relay, abnormal current
failure flows through circuit.
Action of • Stops driving parking interlock relay.
controller
Problem on • When auto idle stop function is actuated, parking brake is not applied automatically.
machine
Related • Method of reproducing failure code: Actuate auto idle stop function.
information
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Defective connector R23 2. Disconnect connector R23 and connect T-adapter to male side.
1 (parking interlock relay)
Resis- Between connectors R23 (male) (1) and (2) 290 ± 60 z
tance Between connector R23 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors BRC3 and R23, and connect T-adapter to
2 either female side.
(Contact with ground circuit)
Resis- Between ground and BRC3 (female) (35) or
R23 (female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC3 and R23, and connect T-adapter to
3 Short circuit in wiring harness either female side.
Resis- Between BRC3 (female) (35) and (23), or
between R23 (female) (1) and (2) Min. 1 Mz
tance
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

Circuit diagram related to parking interlock relay

40-326 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D1EMKY] Hot Short of Parking Interlock Relay (HM300_3-D1EMKY-400-

A-Z0-A)

Action level Failure code Hot Short of Parking Interlock Relay

Failure
L03 D1EMKY (Retarder hoist controller system)
Detail of • When controller does not drive primary circuit (coil) of auto idle stop parking brake relay,
failure current flows through circuit.
Action of • None in particular
controller
Problem on • Parking brake is applied.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Defective connector R23 2. Disconnect connector R23 and connect T-adapter to male side.
1 (parking interlock relay)
Resis- Between connectors R23 (male) (1) and (2)
290 ± 60 z
tance
Hot short circuit in wiring 1. Turn starting switch to OFF position.
2. Disconnect connector R23, and connect T-adapter to female side.
2 harness 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Voltage Between R23 (female) (1) and ground Max. 4.5 V
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)

Circuit diagram related to parking interlock relay

HM400-3M0 40-327
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay (HM300_3-

D1FBKB-400-A-Z0-A)

Action level Failure code Ground Fault of Solenoid Self-Holding Relay

Failure
L03 D1FBKB (Transmission controller system)
Detail of • Excessive current flows when the output to primary circuit (coil) of solenoid self-holding
failure relay is turned ON.
Action of • Stops driving solenoid self-holding relay circuit.
controller
• Gear speed is held in Neutral and machine cannot travel.
Problem on • Radiator fan runs at its maximum speed and may be damaged.
machine • Fan rotating in reverse changes its direction to normal.
• Output signal from solenoid self-holding relay can be checked with monitoring function
Related (Code: 03900).
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Defective transmission 2. Disconnect connector R02 and connect T-adapter to male side.
1 solenoid (self-holding) relay
Resis- Between connector R02 (male) (1) and (2)
290 ± 30 z
tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ATC3 and R02, and connect T-adapter to
2 either female side.
(Contact with ground circuit)
Resis- Between ground and ATC3 (female) (4) or R02
(female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC3 and R02, and connect T-adapter to
3 Short circuit in wiring harness either female side.
Resis- Between ATC3 (female) (4) and (21), or
between R02 (female) (1) and (2) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed).

Circuit diagram related to transmission solenoid (self-holding) relay

40-328 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D5ZHL6] Disconnection of Key SW C (HM400_3-D5ZHL6-400-A-Z0-A)

Action level Failure code Disconnection of Key Switch C

Failure
L01 D5ZHL6 (Machine monitor system)
Detail of • While engine speed is 500 (rpm) or above and signal voltage of alternator terminal R is 8
failure V or above, signal of key switch terminal C remains OFF on monitor controller.
• None in particular
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • None in particular
machine
• Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Related • Input signal (ON/OFF) to machine monitor from starting switch terminal C can be checked
information with monitoring function. (Code: 04509)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors MCM1 and BRC3, and insert T-adapters into
1 (wire breakage or defective each female side.
contact of connector) Resis- Between BRC3 (female) (10) and MCM1
(female) (11) Max. 1 z
tance
If no failure is found by above checks, monitor controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed).
• Reference
2 Defective monitor controller 1. Turn starting switch to OFF position.
2. Disconnect connector MCM1, and connect T-adapter to female side.
3. Starting switch to START position.
Voltage Between MCM1 (female) (11) and (2) or (3) 20 to 30 V

HM400-3M0 40-329
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to key switch terminal C

40-330 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D811MC] KOMTRAX Error (HM300_3-D811MC-400-A-Z0-A)

Action level Failure code KOMTRAX Error

Failure
- D811MC (KOMTRAX system)
Detail of
• Malfunction of KOMTRAX terminal
failure
Action of • None in particular
controller
Problem on • KOMTRAX system does not operate normally.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
Malfunction of KOMTRAX KOMTRAX terminal is defective.
1
terminal (Since this is an internal defect, troubleshooting cannot be performed.)

HM400-3M0 40-331
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D862KA] GPS Antenna Open Circuit (HM300_3-D862KA-400-A-Z0-A)

Action level Failure code GPS Antenna Open Circuit

Failure
- D862KA (KOMTRAX system)
Detail of • Open circuit occurs in GPS antenna circuit.
failure
Action of • None in particular
machine • If cause of failure disappears, machine becomes normal by itself.
monitor
Problem on • GPS positioning system does not work.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
Defective GPS antenna or GPS antenna may be defective, or antenna cable may have open or
1 short circuit, or poor contact at terminal area (GPS).
antenna cable

Figure of structure

40-332 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) (HM400_3R-

D8ALKA-400-A-Z0-A)

Action level Failure code Operating Lamp Open Circuit (KOMTRAX)

Failure
- D8ALKA (KOMTRAX system)
• KOMTRAX terminal determines that output circuit to system operating lamp is open
Detail of because voltage of output circuit remains at 3.8 to 5.7 V for approximately 3 seconds after
failure starting switch is turned to ON position, during which KOMTRAX terminal does not drive
system operating lamp.
• Even if cause of failure disappears, machine does not become normal until starting switch
Action of is turned to OFF position.
controller • It does not output for system operating lamp.
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine KOMTRAX terminal memory.
• Method of reproducing failure code: Turn starting switch to ON position.
• Although KOMTRAX terminal is not able to light up system operating lamp, no trouble will
Related result unless battery disconnect switch is turned to OFF position.
information • When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after
starting switch is turned to ON position, open circuit can be detected.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Turn the battery disconnect switch to OFF position.
harness 3. Disconnect connectors KOM1 and J33, and connect T-adapters to each
1 (Wire breakage or female side.
defective contact of Between KOM1 (female) (15) and J33 (female) (2) Max. 1 z
connector) Resistance Between J33 (female) (1) and battery relay terminal
(66) Max. 1 z

Defective KOMTRAX If no failure is found by above checks, KOMTRAX terminal is defective.

2
terminal (Since this is an internal defect, troubleshooting cannot be performed.)

HM400-3M0 40-333
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to system operating lamp

40-334 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) (HM400_3R-

D8ALKB-400-A-Z0-A)

Action level Failure code Operating Lamp Short Circuit (KOMTRAX)

Failure
— D8ALKB (KOMTRAX system)
• KOMTRAX terminal determines that output circuit to system operating lamp shorts
Detail of because voltage of output circuit does not become Low level while KOMTRAX terminal
failure drives system operating lamp.
• Stops driving system operating lamp.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine KOMTRAX terminal memory.
• Method of reproducing failure code: Turn starting switch to ON position.
• Although KOMTRAX terminal is not able to light up system operating lamp, no trouble will
result unless battery disconnect switch is turned to OFF position.
Related • When controller lights up system operating lamp, output circuit voltage is at low level.
information
a Since the voltage between pin (2) of female side and ground becomes 20 V or above after
turning starting switch to ON position when connector J33 is open, the check of hot short
circuit cannot be performed.
No. Cause Procedure, measuring location, criteria, and remarks
1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
3.Remove fuse 28 in fuse box BT4.
4.Disconnect connectors MCM1, ATC3, KOM1, J3, J33 and BRC3, and
connect T-adapter to female side of J33.
Resistance Between J33 (female) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector J33.
Short circuit in wiring
1 4. Disconnect connectors MCM1, ATC3, BRC3, and KOM1, and connect T-
harness
adapters to each female side.
Between ATC3 (female) (34) and each pin other No
than pin (34) continuity
Between BRC3 (female) (34) and each pin other No
than pin (34) continuity
Continuity
Between KOM1 (female) (15) and each pin other No
than pin (15) continuity
Between MCM1 (female) (57) and each pin other No
than pin (57) continuity
Defective KOMTRAX If no failure is found by above checks, KOMTRAX terminal is defective. (Since
2 this is an internal defect, troubleshooting cannot be performed.)
terminal

HM400-3M0 40-335
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to system operating lamp

40-336 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 (HM300_3-D8AQK4-400-A-Z0-A)

Action level Failure code CAN2 Disconnection (KOMTRAX) 2

Failure
L03 D8AQK4 (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller does not recognize KOMTRAX terminal over CAN communication-2
failure line (KOMNET/c).
Action of • Does not update communication information.
controller
Problem on • Engine does not start.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• Monitor controller uses six failure codes, [D8AQK*], [DAQQKR], [DAZQKR], [DB1QKR],
[DB2QKR], and [DSJ0KR] to indicate failure in CAN communication through CAN 2 line.
When all of these six failure codes are displayed simultaneously on screen, ground fault,
short circuit, or hot short circuit may occur in wiring harness (CAN communication line). In
this case, check whether air conditioner is operated (ON/OFF and air flow adjustment)
Related from air conditioner operation screen since air conditioner is also controlled over CAN
information communication line.
a Air conditioner can be controlled even when failure code is displayed on screen. If air
conditioner is controlled, wiring harness (CAN communication line) does not have ground
fault, short circuit, or hot short circuit.
• Since each controller and machine monitor (meter unit) are connected directly to battery,
they are supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria, and remarks
Defective CAN2
1 Perform troubleshooting for [D8AQKR].
communication system

HM400-3M0 40-337
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D8AQKR] CAN2 Discon (KOMTRAX) (HM300_3-D8AQKR-400-A-Z0-A)

Action level Failure code CAN2 Disconnection (KOMTRAX)

Failure
- D8AQKR (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller does not recognize KOMTRAX terminal over CAN communication-2
failure line (KOMNET/c).
Action of • Does not update communication information.
controller
Problem on • None in particular
machine
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• Monitor controller uses six failure codes, [D8AQK*], [DAQQKR], [DAZQKR], [DB1QKR],
[DB2QKR], and [DSJ0KR] to indicate failure in CAN communication through CAN 2 line.
When all of these six failure codes are displayed simultaneously on screen, ground fault,
short circuit, or hot short circuit may occur in wiring harness (CAN communication line). In
this case, check whether air conditioner is operated (ON/OFF and air flow adjustment)
Related from air conditioner operation screen since air conditioner is also controlled over CAN
information communication line.
a Air conditioner can be controlled even when failure code is displayed on screen. If air
conditioner is controlled, wiring harness (CAN communication line) does not have ground
fault, short circuit, or hot short circuit.
• Since each controller and machine monitor (meter unit) are connected directly to battery,
they are supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Defective fuse 12 in fuse box
1 2. Remove fuse 12 in fuse box BT2.
BT2
If fuse is blown, circuit probably has ground fault.
Defective power supply to Perform troubleshooting for "E-38" of E-mode.
2
KOMTRAX terminal
Defective CAN2 Perform checks on causes 4 to 10 in troubleshooting for failure code
3 communication system [DB2QKR].
If no failure is found by above checks, KOMTRAX terminal is defective.
4 Defective KOMTRAX terminal
(Since this is an internal defect, troubleshooting cannot be performed.)
If no failure is found by above checks, monitor controller is defective.
5 Defective monitor controller
(Since this is an internal defect, troubleshooting cannot be performed.)

40-338 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) (HM300_3-

DAF0KT-400-A-Z0-A)

Action level Failure code Abnormality of Non-volatile Memory (Monitor)

Failure
L03 DAF0KT (Machine monitor system)
Detail of • Data is not written to or read from non-volatile memory of monitor controller.
failure
Action of
controller
Problem on • Reading of service meter and odometer and other set values are changed.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
Monitor controller is defective.
1 Defective monitor controller
(Since this is an internal defect, troubleshooting cannot be performed.)

HM400-3M0 40-339
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAF0MB] Monitor ROM Abnormality (HM300_3-DAF0MB-400-A-Z0-A)

Action level Failure code Monitor ROM Abnormality

Failure
― DAF0MB (Machine monitor system)
Detail of • Program of monitor controller is rewritten (program error).
failure
Action of
controller
Problem on • Data displayed on machine monitor are unreliable.
machine • Machine monitor cannot exchange data with controllers normally.
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
Monitor controller is defective.
1 Defective monitor controller
(Since this is an internal defect, troubleshooting cannot be performed.)

40-340 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAF0MC] Monitor Error (HM300_3-DAF0MC-400-A-Z0-A)

Action level Failure code Monitor Error

Failure
― DAF0MC (Machine monitor system)
Detail of
• Monitor controller malfunctions.
failure
Action of
controller
Problem on • Data displayed on machine monitor are unreliable.
machine • Machine monitor cannot exchange data with controllers normally.
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
Monitor controller is defective.
1 Defective monitor controller
(Since this is an internal defect, troubleshooting cannot be performed.)

HM400-3M0 40-341
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAF3KK] Controller Power Source Low (MON) (HM400_3-DAF3KK-400-

A-Z0-A)

Action level Failure code Controller Power Source Low (Monitor)

Failure
― DAF3KK (Machine monitor system)
Detail of • Continuous power supply voltage of monitor controller is below 10 V.
failure
Action of • Inhibits writing to memory.
controller • If cause of failure disappears, machine becomes normal by itself.
• In some cases, monitor screen displays nothing.
Problem on
• Since writing to non-volatile memory is inhibited, reliability of data displayed on screen
machine
lowers.
Related • Machine monitor does not display any failure code.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
If circuit breaker is tripped, circuit may have ground fault etc. (See
1 Defective circuit breaker check on cause 4.)
Defective fuses in fuse box If fuse is blown, circuit may have ground fault, etc. (See check on cause
2 4.)
BT2-9.
1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
3.Disconnect connector MCM1, and connect T-adapter to female side.
4.Turn battery disconnect switch to ON position.
5.Turn starting switch to ON position.
Between MCM1 (female) (1) and (2) 20 to 30 V
Voltage
Between MCM1 (female) (4) and (3) 20 to 30 V
Open circuit in wiring harness
1. Turn starting switch to OFF position.
3 (wire breakage or defective
contact of connector) a Replace fuse 10 in fuse box BT2 if it is blown.
2. Disconnect connector MCM1, and connect T-adapter to female side.
Between battery relay terminal B and each of
MCM1 (female) (1) and (4) Max. 1 z

Resis- a Check ground terminal ER5 for looseness

tance and rust. Max. 1 z
Between ground and each of MCM1 (female)
(2) and (3)
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect fuse 10 in fuse box BT2 and connector MCM1, and
4 connect T-adapter to female side.
(Contact with ground circuit)
Resis- Between ground and fuse 10 in fuse box BT2
or each of MCM1 (female) (1) and (4) Min. 1 Mz
tance
If no failure is found by above checks, monitor controller is defective.
5 Defective monitor controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-342 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to monitor controller power supply

HM400-3M0 40-343
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAF8KB] Camera Power Supply Short Circuit (HM400_3-DAF8KB-400-A-

Z0-A)

Action level Failure code Camera Power Supply Short Circuit

Failure
L03 DAF8KB (Machine monitor system)
Detail of • Output power supply voltage (rating: 8 V) from rearview monitor to rearview camera is 10
failure V and above when controller does not drive camera.
• Stops driving rearview camera.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Rearview camera image is not displayed on rearview monitor screen.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect rearview camera connector BMN, and turn starting
Defective rearview camera switch to ON position.
1
(Internal short circuit) After rearview camera connector is disconnected and failure code
reproducing procedure is performed, if failure code disappears,
rearview camera has internal defect.
1. Turn starting switch to OFF position.
2. Disconnect connector RMN2 and connect T-adapter to male side.
2 Defective rearview monitor 3. Turn starting switch to ON position.
Voltage Between RMN2 (male) (1) and ground 6 to 10 V
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector BMN and connect T-adapter to female side.
harness 3. Turn starting switch to ON position.
3 (Disconnect rearview camera and check that rearview camera is not
(Contact with 24 V circuit) defective in advance.)
Voltage Between BMN (female) (1) and ground Max. 10 V

Circuit diagram related to rearview camera

40-344 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAFDKB] Monitor 12V Power Output Short Circuit (HM300_3-
DAFDKB-400-A-Z0-A)

Action level Failure code Monitor 12V Power Output Short Circuit
Failure
L01 DAFDKB (Machine monitor system)
Detail of • When starting switch is turned to ON position, 12 V power supply voltage is 8 V or below,
failure or 14 V or above.
Action of • Stops supplying 12 V power (stops until starting switch is turned to OFF position).
controller
• Switch panel cannot be operated.
Problem on • LED unit does not light up or lights up incorrectly.
machine • If engine start lock is enabled, you cannot start engine since you cannot enter password.
• If failure code [DAF3KK] (Controller Power Source Low (MON)) is generated, perform
Related troubleshooting for it first.
information • Method of reproducing failure code: Turn starting switch to OFF position, and then to ON
position.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors MCM2, DPC2 and OPM, and connect T-
1 adapter to either female side.
(Contact with ground circuit)
Resis- Between ground and MCM2 (female) (107) or
DPC2 (female) (1) or OPM (female) (1). Min. 1 Mz
tance
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector MCM2, and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Voltage Between MCM2 (female) (107) and (99) Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connector MCM2 and connect T-adapter to male side.
3 Defective monitor controller 3. Turn starting switch to ON position.
Voltage Between MCM2 (male) (107) and (99) Approx. 12
V

HM400-3M0 40-345
40 Troubleshooting
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Circuit diagram related to monitor controller 12 V power supply

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 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAFGMC] GPS Module Error (HM300_3-DAFGMC-400-A-Z0-A)

Action level Failure code GPS Module Error

Failure
― DAFGMC (KOMTRAX system)
Detail of • Location data are not sent from GPS module in KOMTRAX terminal although 50 seconds
failure or more has elapsed since start of KOMTRAX terminal.
Action of • None in particular
machine • If cause of failure disappears, machine becomes normal by itself.
monitor
Problem on
machine
Related • Method of reproducing failure code: Turn starting switch to ON position (at least 50
information seconds after starting switch is turned to ON position).
No. Cause Procedure, measuring location, criteria, and remarks
GPS module in KOMTRAX terminal may be defective.
1 Defective KOMTRAX terminal
(Since this is an internal defect, troubleshooting cannot be performed.)

HM400-3M0 40-347
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAFLKA] Operating Lamp Open Circuit (MON) (HM400_3R-DAFLKA-

400-A-Z0-A)

Action level Failure code Operating Lamp Open Circuit (Monitor)

Failure
- DAFLKA (Machine monitor system)
• Monitor controller determines that output circuit to system operating lamp is open
Detail of because voltage of output circuit remains at 3.8 to 5.7 V for approximately 3 seconds after
failure starting switch is turned to ON position, during which monitor controller does not drive
system operating lamp.
• Even if cause of failure disappears, machine does not become normal until starting switch
Action of is turned to OFF position.
controller • It does not output for system operating lamp.
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine monitor controller memory.
• Method of reproducing failure code: Turn starting switch to ON position.
• Although monitor controller is not able to light up system operating lamp, no trouble will
Related result unless battery disconnect switch is turned to OFF position.
information • When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after
starting switch is turned to ON position, open circuit can be detected.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Turn the battery disconnect switch to OFF position.
harness 3. Disconnect connectors MCM1 and J33, and connect T-adapters to each
1 (Wire breakage or female side.
defective contact of Between MCM1 (female) (57) and J33 (female) (2) Max. 1 z
connector) Resistance Between J33 (female) (1) and battery relay terminal
(66) Max. 1 z

Defective monitor If no failure is found by above checks, monitor controller is defective.

2
controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-348 HM400-3M0
 40 Troubleshooting
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Circuit diagram related to system operating lamp

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40 Troubleshooting
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Failure code [DAFLKB] Operating Lamp Short Circuit (MON) (HM400_3R-DAFLKB-

400-A-Z0-A)

Action level Failure code Operating Lamp Short Circuit (Monitor)

Failure
— DAFLKB (Machine monitor system)
• Monitor controller determines that output circuit to system operating lamp shorts because
Detail of voltage of output circuit does not become Low level while monitor controller drives system
failure operating lamp.
• Stops driving system operating lamp.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine monitor controller memory.
• Method of reproducing failure code: Turn starting switch to ON position.
• Although monitor controller is not able to light up system operating lamp, no trouble will
result unless battery disconnect switch is turned to OFF position.
Related • When controller lights up system operating lamp, output circuit voltage is at low level.
information
a Since the voltage between pin (2) of female side and ground becomes 20 V or above after
turning starting switch to ON position when connector J33 is open, the check of hot short
circuit cannot be performed.
No. Cause Procedure, measuring location, criteria, and remarks
1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
3.Remove fuse 28 in fuse box BT4.
4.Disconnect connectors MCM1, ATC3, KOM1, J3, J33 and BRC3, and
connect T-adapter to female side of J33.
Resistance Between J33 (female) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector J33.
Short circuit in wiring
1 4. Disconnect connectors MCM1, ATC3, BRC3, and KOM1, and connect T-
harness
adapters to each female side.
Between ATC3 (female) (34) and each pin other No
than pin (34) continuity
Between BRC3 (female) (34) and each pin other No
than pin (34) continuity
Continuity
Between KOM1 (female) (15) and each pin other No
than pin (15) continuity
Between MCM1 (female) (57) and each pin other No
than pin (57) continuity
Defective monitor If no failure is found by above checks, monitor controller is defective. (Since
2 this is an internal defect, troubleshooting cannot be performed).
controller

40-350 HM400-3M0
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Circuit diagram related to system operating lamp

HM400-3M0 40-351
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAFQKR] CAN2 Discon (Monitor) (HM300_3-DAFQKR-400-A-Z0-A)

Action level Failure code CAN2 Disconnection (Monitor)

Failure
- DAFQKR (KOMTRAX system)
Detail of • KOMTRAX terminal does not recognize monitor controller over CAN communication-2
failure line (KOMNET/c).
Action of
• None
controller
Problem on • System may not function normally.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• Failure code is transmitted to and displayed on machine monitor over CAN
communication line. Accordingly, if CAN communication with machine monitor fails,
Related failure code [DAFQKR] is not displayed on machine monitor and it can be observed only
information through KOMTRAX system.
• Since each controller and monitor controller are connected directly to battery, they are
supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria, and remarks
Defective power supply to Perform troubleshooting for "E-5" in E mode troubleshooting.
1
monitor controller
2 Defective CAN communication Perform checks on Causes 4 to 10 for failure code [DB2QKR]

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 40 Troubleshooting
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Failure code [DAQ0KK] Controller Power Source Low (T/M) (HM300_3-DAQ0KK-400-A-

Z0-A)

Action level Failure code Controller Power Source Low (Transmission)

Failure
L03 DAQ0KK (Transmission controller system)
Detail of • Continuous power supply voltage drops 18 V or lower with starting switch at ON position
failure except when engine is cranked or emergency steering is operated.
Action of • Keeps current gear speed.
controller • Set transmission to neutral by moving gear shift lever to N.
• When supply voltage is lost (open circuit), transmission reverts to neutral suddenly while
driving, and the machine cannot be restarted until supply voltage is restored.
Problem on • Radiator fan runs at its maximum speed and may be damaged.
machine • Fan rotating in reverse changes its direction to normal.
• The machine can be moved when voltage is low, however, the transmission may slip due
to overload.
• If failure code [AB00KE] (low charge voltage) is present, carry out troubleshooting for it
Related first.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
a Check battery voltage and specific gravity of battery electrolyte.
1 Defective battery Voltage Battery voltage Min. 24 V
Specific
Specific gravity of battery electrolyte Min. 1.26
gravity
Defective circuit breaker or If circuit breaker between contacts (82) and (84) is tripped, or fuse BT2-
2 6 (No. 13) is blown out, circuit may have ground fault.
fuse
1. Turn starting switch to OFF position.
2. Check that system operating lamp is turned OFF, and then turn
battery disconnect switch to OFF position.
3. Disconnect connector ATC3 and connect T-adapter to female side.
4. Turn battery disconnect switch to ON position.
a If voltage appears between battery relay terminal (66) and ground
but not between ground and each of ATC3 (1) and (11), wiring
harness or fuse has open circuit.
Between battery relay terminal (66) and ground 20 to 30 V
Open circuit in wiring harness Voltage Between ground and each of ATC3 (female) (1)
3 (wire breakage or defective and (11) 20 to 30 V
contact of connector)
a If no failure is found by above checks, this check is not required.
5. Turn starting switch to OFF position.
6. Check that system operating lamp is turned OFF, and then turn
battery disconnect switch to OFF position.
7. Disconnect connector ATC3 and connect T-adapter to female side.
Between ground and ATC3 (female) (21), (31),
Max. 1 z
Resis- (32) and (33)
tance Between ATC3 (1), (11) and battery relay (66)
Max. 1 z
terminal
1. Turn starting switch to OFF position.
2. Check that system operating lamp is turned OFF, and then turn
battery disconnect switch to OFF position.
Defective transmission 3. Insert T-adapter into connector ATC3.
4 4. Turn battery disconnect switch to ON position.
controller
5. Turn starting switch to ON position.
Between ATC3 (1), (11) and each of (21), (31),
Voltage 20 to 30 V
(32), and (33).

HM400-3M0 40-353
40 Troubleshooting
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Circuit diagram related to power supply of transmission controller

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 40 Troubleshooting
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Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) (HM300_3-

DAQ0KT-400-A-Z0-A)

Action level Failure code Abnormality of Non-volatile Memory (Transmission)

Failure
L01 DAQ0KT (Transmission controller system)
• Non-volatile memory in transmission controller is abnormal.
Detail of • When starting switch is turned to OFF position, end processing is not completed
failure successfully.
Action of • Controls machine by applying default values to machine model selection and option
controller settings.
Problem on • Machine control parameters change and transmission shifting shock increases in some
machine cases.
• Perform initial setting and initial adjustment similar to those required when transmission is
Related replaced.
information (See Testing and adjusting, "Setting and adjustment of devices".)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
Since this is an internal defect, troubleshooting cannot be performed.
Defective transmission
1 (If noticeable failure symptom does not appear, you may use that
controller
transmission controller.)

HM400-3M0 40-355
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQ0MC] T/M Con Error (HM300_3-DAQ0MC-400-A-Z0-A)

Action level Failure code Transmission Controller Error

Failure
- DAQ0MC (Transmission controller system)
Detail of • Controller exhibits unusual behavior (unexpected behavior).
failure
Action of
• Resets controller CPU and restarts it.
controller
Problem on • Machine returns to same initial condition as that when starting switch is turned to ON
machine position.
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
Defective transmission Since this is an internal defect, troubleshooting cannot be performed.
1
controller

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Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) (HM300_3-DAQ1KA-400-

A-Z0-A)

Action level Failure code Disconnection of Key Switch ACC (Transmission)

Failure
L03 DAQ1KA (Transmission controller system)
Detail of • Key switch signal recognized by transmission controller is "OFF" while that recognized by
failure engine controller is "ON".
Controller detects that key is turned to OFF position and commands the following actions.
Action of
• Keeps current gear speed.
controller
• Leaves transmission in NEUTRAL once gear shift lever is returned to NEUTRAL position.
• Gear cannot shift.
Problem on • When gear shift lever is put in "N", machine will be unable to restart unless it is brought to
machine a stop.
Related • Method of reproducing failure code: Turn starting switch to ON position.
information

No. Cause Procedure, measuring location, criteria, and remarks

1. Turn starting switch to OFF position.

Open circuit in wiring harness 2. Disconnect connectors ATC3 and ESS, and insert T-adapters into
1 (wire breakage or defective each female side.
contact of connector) Resis- Between ATC3 (female) (14) and ESS (female)
(4) Max. 1 z
tance
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector ATC3.
Defective transmission 3. Turn starting switch to ON position.
2
controller
Between ATC3 (female) (14), (24) and (21),
Voltage 20 to 30 V
(31), (32), (33)

HM400-3M0 40-357
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to power supply of transmission controller

40-358 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQ2KK] Solenoid Power Source Low (T/M) (HM300_3-DAQ2KK-400-A-Z0-

A)

Action level Failure code Solenoid Power Source Low (Transmission)

Failure
L03 DAQ2KK (Transmission controller system)
• Solenoid power supply voltage (appears at transmission controller pins 2, 12, and 22) is
Detail of
18 V or lower while controller power supply circuit (continuous power supply from battery)
failure
is normal.
Action of • Keeps current gear speed.
controller • Leaves transmission in NEUTRAL once gear shift lever is returned to NEUTRAL position.
• When voltage drops to zero while driving, transmission shifts to NEUTRAL suddenly while
Problem on driving, and machine cannot be restarted
machine • If voltage drops to low, transmission may slip depending on load.
• If failure code [D1FBKB] (Ground Fault of Sol. Self-Holding Relay) is also displayed,
perform troubleshooting for it first.
Related • If circuit breaker (82) - (84) is tripped or fuse BT2-No. 13 is blown, failure code [DAQ0KK]
information appears.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector R02.
3. Solid part check.
Resis- Between R02 (male) (1) and (2)
290 ± 30 z
tance
Defective transmission 1. Turn starting switch to OFF position.
1 solenoid (power supply 2. Replace R02 with relay of known performance.
holding) relay
Check if machine Machine becomes Original relay (R02) is
becomes normal when normal. defective.
transmission solenoid Original relay (R02) is
(power supply holding) Machine does not normal.
relay (R02) is become normal.
replaced.
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connectors R02 and ATC3, and insert T-adapters into
each female side.
Between ATC3 (female) (1) and R02 (female)
Open circuit in wiring harness Max. 1 z
(5)
2 (wire breakage or defective Between ATC3 (female) (2) and R02 (female)
contact of connector) Max. 1 z
Resis- (3)
tance Between ATC3 (female) (4) and R02 (female)
(1) Max. 1 z
Between ATC3 (female) (21), (31) and R02
(female) (2) Max. 1 z

1. Turn starting switch to OFF position.

2. Turn the battery disconnect switch to OFF position.
3. Insert T-adapter into connector ATC3.
Defective transmission 4. Turn battery disconnect switch to ON position.
3
controller 5. Turn starting switch to ON position.
Between ATC3 (4) and each of (21), (31), (32),
Voltage 20 to 30 V
and (33).

HM400-3M0 40-359
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to power supply of transmission controller

40-360 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) (HM300_3-

DAQ9KQ-400-A-Z0-A)

Action level Failure code Inconsistency of Model Selection (Transmission)

Failure
L03 DAQ9KQ (Transmission controller system)
Detail of • Model selection information sent from machine monitor differs from that stored in
failure transmission controller.
Action of • Shifts gear speed to NEUTRAL.
controller
Problem on
• Machine cannot travel.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
The machine model setting of machine monitor is probably incorrect.
Incorrect model setting on After replacing the machine monitor or transmission controller, set the
1
machine monitor options correctly. For details, see Testing and Adjusting.
Incorrect transmission Incorrect transmission controller may be installed. Check part number
2 and, if required, install correct transmission controller.
controller installed
If no failure is found by above checks, machine monitor or transmission
Defective machine monitor or controller is defective. (Since this is an internal defect, troubleshooting
3
transmission controller cannot be performed).

HM400-3M0 40-361
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) (HM400_3R-DAQLKA-400-

A-Z0-A)

Action level Failure code Operating Lamp Open Circuit (Monitor)

Failure
- DAFLKA (Machine monitor system)
• Monitor controller determines that output circuit to system operating lamp is open
Detail of because voltage of output circuit remains at 3.8 to 5.7 V for approximately 3 seconds after
failure starting switch is turned to ON position, during which monitor controller does not drive
system operating lamp.
• Even if cause of failure disappears, machine does not become normal until starting switch
Action of is turned to OFF position.
controller • It does not output for system operating lamp.
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine monitor controller memory.
• Method of reproducing failure code: Turn starting switch to ON position.
• Although monitor controller is not able to light up system operating lamp, no trouble will
Related result unless battery disconnect switch is turned to OFF position.
information • When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after
starting switch is turned to ON position, open circuit can be detected.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Turn the battery disconnect switch to OFF position.
harness 3. Disconnect connectors MCM1 and J33, and connect T-adapters to each
1 (Wire breakage or female side.
defective contact of Between MCM1 (female) (57) and J33 (female) (2) Max. 1 z
connector) Resistance Between J33 (female) (1) and battery relay terminal
(66) Max. 1 z

Defective monitor If no failure is found by above checks, monitor controller is defective.

2
controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-362 HM400-3M0
 40 Troubleshooting
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Circuit diagram related to system operating lamp

HM400-3M0 40-363
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) (HM400_3R-DAQLKB-400-

A-Z0-A)

Action level Failure code Operating Lamp Short Circuit (Transmission)

Failure
- DAQLKB (Transmission controller system)
• Transmission controller determines that output circuit to system operating lamp shorts
Detail of because voltage of output circuit does not become Low level while transmission controller
failure drives system operating lamp.
• Stops driving system operating lamp.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• When controller drives system operating lamp, large current may flow through circuit
causing burnout of controller.
Problem on • System operating lamp may not light up while controller is performing end processing
machine a While controller is performing end processing, if battery disconnect switch is set to OFF
position, fan stops suddenly and may be damaged. In addition, initial learning data are not
saved resulting in increased shifting shocks.
• Although transmission controller is not able to light up system operating lamp, no trouble
will result unless battery disconnect switch is turned to OFF position.
Related • When controller lights up system operating lamp, output circuit voltage is at low level.
information a Since the voltage between pin (2) of female side and ground becomes 20 V or above after
turning starting switch to ON position when connector J33 is open, the check of hot short
circuit cannot be performed.
No. Cause Procedure, measuring location, criteria, and remarks
1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
3.Remove fuse 28 in fuse box BT4.
4.Disconnect connectors MCM1, ATC3, KOM1, J3, J33 and BRC3, and
connect T-adapter to female side of J33.
Resistance Between J33 (female) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector J33.
Short circuit in wiring
1 4. Disconnect connectors MCM1, ATC3, BRC3, and KOM1, and connect T-
harness
adapters to each female side.
Between ATC3 (female) (34) and each pin other No
than pin (34) continuity
Between BRC3 (female) (34) and each pin other No
than pin (34) continuity
Continuity
Between KOM1 (female) (15) and each pin other No
than pin (15) continuity
Between MCM1 (female) (57) and each pin other No
than pin (57) continuity
Defective transmission If no failure is found by above checks, transmission controller is defective.
3 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-364 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to system operating lamp

HM400-3M0 40-365
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQQKR] CAN2 Discon (Transmission Con) (HM300_3-DAQQKR-400-A-

Z0-A)

Action level Failure code CAN2 Disconnection (Transmission Controller)

Failure
L03 DAQQKR (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller does not recognize transmission controller over CAN communication-2
failure line (KOMNET/c).
Action of • Does not update communication information.
controller
• Failure codes to be generated by transmission controller are not displayed.
Problem on • Monitoring data for which transmission controller is responsible are not updated.
machine • Fan rotation direction cannot be reverse.
• Adjustment function is unavailable.
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• Monitor controller uses six failure codes, [D8AQK*], [DAQQKR], [DB1QKR], [DB2QKR],
[DAZQKR], and [DSJ0KR] to indicate failure in CAN communication through CAN 2 line.
When all of these 7 failure codes are displayed simultaneously on screen, ground fault,
short circuit, or hot short circuit may occur in wiring harness (CAN communication line). In
this case, check whether air conditioner is operated (ON/OFF and air flow adjustment)
from air conditioner operation screen since air conditioner is also controlled over CAN
Related
communication line. (For the machines equipped with payload meter, failure code
information
[DBSQKR] also indicates failure in CAN communication through CAN 2 line.)
a Air conditioner can be controlled even when failure code is displayed on screen. If air
conditioner is controlled, wiring harness (CAN communication line) does not have ground
fault, short circuit, or hot short circuit.
• Since each controller and machine monitor (meter unit) are connected directly to battery,
they are supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria, and remarks
Defective power supply
1 to transmission Perform troubleshooting for failure code [DAQ0KK].
controller
Defective CAN2 Perform checks on causes 4 to 10 in troubleshooting for failure code
2 communication system [DB2QKR].
Defective transmission If no failure is found by above checks, transmission controller is defective.
3 (Since this is an internal defect, troubleshooting cannot be performed.)
controller
Defective monitor If no failure is found by above checks, monitor controller is defective. (Since
4 this is an internal defect, troubleshooting cannot be performed).
controller

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Failure code [DAQRKR] CAN1 Discon (Transmission Con) (HM400_3R-DAQRKR-400-A-

Z0-A)

Action level Failure code CAN1 Disconnection (Transmission Controller)

Failure
L03 DAQRKR (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller does not recognize transmission controller over CAN communication-1
failure line (KOMNET/r).
Action of • Hides pointer of torque converter oil temperature gauge from screen.
controller • Changes display of speedometer to "00".
• Information to be obtained from transmission controller is not displayed and special
Problem on functions that need information do not work. Or update of received data is stopped.
machine • Pointer of torque converter oil temperature gauge disappears from screen.
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• Monitor controller also uses failure code [DB1RKR] to indicate failure in CAN
communication through CAN 1 line. When failure code [DB1RKR] is displayed
simultaneously on screen, there may be a ground fault, short circuit, or hot short circuit in
Related wiring harness (CAN communication line).
information • A CAN1 terminating resistor is located in monitor controller on operator's cab side and
another one is located in connector "CAN R" on engine side. (Engine controller has no
relationship with CAN1 communication line.)
• Since each controller and machine monitor are connected directly to battery, they are
supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria, and remarks
Defective power supply
1 to transmission Perform troubleshooting for [DAQ0KK].
controller
Defective CAN 1. Turn starting switch to OFF position.
terminating resistor 2. Disconnect connectors MCM2 and CAN-R, and connect T-adapters to
2 male side of them.
(Internal open or short Between CAN1 (male) (A) and (B) 120 ± 12 z
circuit) Resistance
Between MCM2 (male) (105) and (112) 120 ± 12 z
• CAN communication line
a CAN terminating resistor of 120 z is also located in monitor controller.
That is, two CAN terminating resistors of 120 z are connected in parallel.
When circuit resistance is measured at connector of controller other than
monitor controller, if combined resistance is 60 z, wiring harness does not
have open circuit.
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect connectors MCM2, ATC2, BRC2, and CAN R one by one, and
connect T-adapter to female side of each connector.
Open or short circuit in
3 wiring harness a If open circuit is found (resistance between 2 terminals is 1 z or below),
disconnect all CAN communication connectors of every controller and
check whether open circuit occurs in wiring harness or inside controller.
Between MCM2 (female) (113) and (105) Approx. 120
z
Between BRC2 (female) (33) and (23) Approx. 60
z
Resistance Between ATC2 (female) (33) and (23) Approx. 60
z
Approx. 120
Between CAN R (female) (A) and (B) z

HM400-3M0 40-367
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

• ACC signal of starting switch (start of CAN communication is not
recognized)
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect connectors MCM1, ATC3, and BRC3, and insert T-adapters
into them.
3. Turn battery disconnect switch to ON position, and turn starting switch to
ON position.
Between MCM1 (24), (43) and (3) 20 to 30 V
Voltage Between BRC3 (14), (24) and (21) 20 to 30 V
Between ATC3 (14), (24) to (21) 20 to 30 V

Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position, and set battery disconnect switch to
4 (Wire breakage or OFF position.
defective contact of 2. Disconnect connectors MCM2, ATC2, BRC2, and CAN R, and connect T-
connector) adapters to each female side.
Between MCM2 (female) (113) and ATC2 (female)
(33) Max. 1 z
Between MCM2 (female) (105) and ATC2 (female)
(23) Max. 1 z
Between MCM2 (female) (113) and BRC2 (female)
(33) Max. 1 z
Resistance
Between MCM2 (female) (105) and BRC2 (female)
(23) Max. 1 z
Between MCM2 (female) (113) and CAN R (female)
(A) Max. 1 z
Between MCM2 (female) (105) and CAN R
(female) (B) Max. 1 z

1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect connectors MCM2, BRC2, ATC2, J1, J2, and CAN R, and
Ground fault in wiring connect T-adapter to any of female side.
harness Between ground and any of BRC2 (female) (33),
5
(Contact with ground ATC2 (female) (33), MCM2 (female) (113), (112) Min. 1 Mz
circuit) and J1 (female) (8)
Resistance
Between ground and any of BRC2 (female) (23),
ATC2 (female) (23), MCM2 (female) (105), and Min. 1 Mz
CAN R (female) (B)
a If no failure (open circuit) is found by check on cause 3, measure voltage
at any one place in each case.
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect any of connectors MCM2, BRC2, ATC2, and CAN R, and
connect T-adapter to female side.
Short circuit or hot short 3. Set battery disconnect switch to ON position.
circuit in wiring harness 4. Turn starting switch to ON position.
6
(Contact with 24 V
circuit) a Do not take measurements at MCM2.
a Voltage of CAN H and CAN L is 2.5 ± 1 V including during communication,
so regard wiring harness as normal if measured voltage is 1 to 4 V.
Between ground and any of BRC2 (female) (33),
ATC2 (female) (33) and CAN R (female) (A) 1 to 4 V
Voltage
Between ground and any of BRC2 (female) (22), 1 to 4 V
ATC2 (female) (22) and CAN R (female) (B)

40-368 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

• If failure code on [DB1RKR] is also displayed:
a Disconnect transmission controller and retarder controller one by one from
CAN communication line to determine which controller is defective.
1. Turn starting switch to OFF position, and set battery disconnect switch to
Defective transmission OFF position.
7 2. Disconnect transmission controller (connector ATC2).
controller
3. Turn battery disconnect switch to ON position, and turn starting switch to
ON position.
Does either of failure codes [DAQRKR] and
[DB1RKR] for CAN1 communication error If YES, transmission
disappear? controller is defective.
• If failure code on [DB1RKR] is also displayed:
a Locate failure in retarder hoist controller or in transmission controller by
disconnecting them one by one from CAN communication circuit.
1. Turn starting switch to OFF position, and set battery disconnect switch to
Defective retarder hoist OFF position.
8 2. Disconnect retarder hoist controller (connector BRC2).
controller
3. Turn battery disconnect switch to ON position, and turn starting switch to
ON position.
Does either of failure codes [DAQRKR] and
[DB1RKR] for CAN1 communication error If YES, retarder hoist
disappear? controller is defective.
Defective monitor If no failure is found by above checks, monitor controller is defective. (Since
9 this is an internal defect, troubleshooting cannot be performed).
controller

HM400-3M0 40-369
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to CAN communication-1 line

40-370 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQRMA] Inconsistency of Option Selection (T/M) (HM300_3-

DAQRMA-400-A-Z0-A)

Action level Failure code Inconsistency of Option Selection (Transmission)

Failure
L03 DAQRMA (Transmission controller system)
Detail of • When starting switch is turned to ON position, option setting information sent from
failure machine monitor differs from that stored in transmission controller.
• Gear speed is held in Neutral.
Action of • Controls with the option settings stored in the controller.
controller • Not recovered until starting switch is turned to OFF position.
Problem on • Gear speed is set to Neutral and becomes unable to restart.
machine
• Perform initial setting and initial adjustment similar to those required when transmission is
Related replaced.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
Improper option setting of Option setting of machine monitor is probably incorrect. Perform correct
1 setting referring to Testing and adjustment.
machine monitor
If no failures is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
2
controller performed.)

HM400-3M0 40-371
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQV00] Neutral Coast Caution (HM400_3M0-DAQV00-400-A-Z0-A)

Action level Failure code Neutral Coast Caution

Failure
- DAQV00 (Transmission controller system)
Detail of • Set the shift lever to N position while traveling at 4 km/h or faster.
failure • In downhill traveling with shift lever at N position, travel speed exceeds 20 km/h.
Action of • Sounds the alarm buzzer.
controller • Performs same control for gear shifting as selecting shift lever D position.
Problem on Transmission does not shift to NEUTRAL until the travel speed becomes 4 km/h or below.
machine
Related
information
No. Cause Procedure, measuring location, criteria, and remarks
Instruct operator on correct operating method.
Operation error of the shift • Do not set the shift lever to N position while traveling at 4 km/h or
1
lever faster.
• Set shift lever to N position, and do not drive downhill.

40-372 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQW00] Neutral Over Speed Caution (HM400_3M0-DAQW00-400-A-Z0-A)

Action level Failure code Neutral Over Speed Caution

Failure
- DAQW00 (Transmission controller system)
Detail of In downhill traveling with shift lever at N position, travel speed exceeds 4 km/h.
failure
Action of
Sounds the alarm buzzer.
controller
Problem on None in particular
machine
Related
information
No. Cause Procedure, measuring location, criteria, and remarks
Operation error of the shift Instruct operator on correct operating method.
1
lever Set shift lever to N position, and do not drive downhill.

HM400-3M0 40-373
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAZ9KQ] A/C Model Selection Abnormality (HM300_3-DAZ9KQ-400-A-Z0-A)

Action level Failure code Air Conditioner Model Selection Abnormality

Failure
― DAZ9KQ (Machine monitor system)
• Different machine models are set by monitor controller program from that by air
Detail of conditioner controller program.
failure (Replaced machine monitor or air conditioner controller has wrong part number.)
Action of
controller
Problem on • Air conditioner does not work normally.
machine
• Model codes registered in monitor controller can be checked with monitoring function.
(Code: 00205)
Related • Air conditioner controller data (machine model and series) can be checked with
information monitoring function. (Code: 55201) (Control data must be 03 (indicating HM (articulated
dump truck )).)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
Defective monitor controller
1 Defective monitor controller
(Wrong machine model is programmed.)
Defective air conditioner Defective air conditioner controller
2
controller (Wrong machine model is programmed.)

40-374 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAZQKR] CAN2 Discon (Aircon ECU) (HM300_3-DAZQKR-400-A-Z0-A)

Action level Failure code CAN2 Disconnection (Air Conditioner ECU)

Failure
L01 DAZQKR (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller does not recognize air conditioner controller over CAN communication-
failure 2 line (KOMNET/c).
Action of
• Retains information at time of occurrence of failure.
controller
• Failure codes to be generate by air conditioner controller are not displayed.
Problem on • Monitoring data for which air conditioner controller is responsible are not updated.
machine • Operation of air conditioner is disabled.
• Display of air conditioner operation screen of machine monitor is not correct.
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• Monitor controller uses six failure codes, [D8AQK*], [DAQQKR], [DB1QKR], [DB2QKR],
[DAZQKR], and [DSJ0KR] to indicate failure in CAN communication through CAN 2 line.
Related When all of these six failure codes are displayed simultaneously on screen, ground fault,
information short circuit, or hot short circuit may occur in wiring harness (CAN communication line).
• Since each controller and machine monitor (meter unit) are connected directly to battery,
they are supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria, and remarks
Defective fuse 18 in fuse box If fuse is blown, circuit may have ground fault.
1
BT4
Defective power supply to air a Perform troubleshooting shown in Chapter 80 "Troubleshooting of
2
conditioner controller power supply system".
Defective CAN2 Perform checks on Causes 4 to 10 in troubleshooting for failure code
3 communication system [DB2QKR].
If no failure is found by above checks, air conditioner controller is
Defective air conditioner defective.
4
controller
(Since this is an internal defect, troubleshooting cannot be performed.)
If no failure is found by above checks, monitor controller is defective.
5 Defective monitor controller
(Since this is an internal defect, troubleshooting cannot be performed.)

HM400-3M0 40-375
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB10KT] Abnormality of Non-volatile Memory (RHC) (HM300_3-

DB10KT-400-A-Z0-A)

Action level Failure code Abnormality of Non-volatile Memory (RHC)

Failure
L01 DB10KT (Retarder hoist controller system)
Detail of • The non-volatile memory in the controller has failed.
failure
• Controls machine by applying default values to machine model selection and option
Action of settings.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • Change in control parameter values for the machine can lead to increased or decreased
machine force.
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
Defective retarder hoist Since this is an internal defect, troubleshooting cannot be performed.
1
controller Replace controller.

40-376 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB10MC] RHC Error (HM300_3-DB10MC-400-A-Z0-A)

Action level Failure code RHC Error

Failure
― DB10MC (Retarder hoist controller system)
Detail of
• Retarder hoist controller malfunction
failure
Action of
controller
Problem on • The system does not operate normally.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
Defective retarder hoist Defective retarder hoist controller
1
controller (Since this is an internal defect, troubleshooting cannot be performed.)

HM400-3M0 40-377
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB11KA] Disconnection of Key SW ACC (RHC) (HM400_3-DB11KA-400-

A-Z0-A)

Action level Failure code Disconnection of Key Switch ACC (RHC)

Failure
L03 DB11KA (Retarder hoist controller system)
Detail of • Key switch signal recognized by retarder hoist controller is "OFF" while that recognized by
failure engine controller is "ON".
Action of • Stops TCS control and inter axle differential lock control.
controller
Problem on
• TCS and inter axle differential lock do not work.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
3.Disconnect connector BRC3 and connect T-adapter to female side.
4.Turn battery disconnect switch to ON position.
5.Turn starting switch to ON position.
Between BRC3 (female) (14) and (21) 20 to 30 V
Voltage
Between BRC3 (female) (24) and (31) 20 to 30 V
Open circuit in wiring harness
1 (wire breakage or defective a If no failure is found by above checks, this check is not required.
contact of connector) 1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector BRC3 and ESS, and connect T-adapters to
each female side.
Between BRC3 (female) (14) and ESS (female)
Max. 1 z
Resis- (4)
tance Between BRC3 (female) (24) and ESS (female)
(1) Max. 1 z

1.Turn starting switch to OFF position.

2.Turn the battery disconnect switch to OFF position.
3.Insert T-adapter into connector BRC3.
Defective retarder hoist 4.Turn battery disconnect switch to ON position.
2
controller 5.Turn starting switch to ON position.
Between BRC3 (14) and (21) 20 to 30 V
Voltage
Between BRC3 (24) and (31) 20 to 30 V

40-378 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to key switch ACC signal circuit of retarder hoist controller

HM400-3M0 40-379
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB12KK] Solenoid Power Source Low (RHC) (HM400_3-DB12KK-400-A-

Z0-A)

Action level Failure code Solenoid Power Source Low (RHC)

Failure
L03 DB12KK (Retarder hoist controller system)
Detail of • Solenoid power supply voltage is 18 V or lower while controller continuous power supply
failure voltage is normal.
Action of • Stops driving hoist selector valve solenoid and hoist EPC valve solenoid.
controller
• Retarder does not work properly.
Problem on • Dump body does not move.
machine • Failure codes [DHU2KX] and [DHU3KX] are displayed at same time.
• If fuse is blown, check for ground fault in circuits between fuse and each of BRC3
(female) (2), (12) and (22).
Related • If failure codes [DAQ0KK] or [DAQ2KK] (failure in transmission controller power supply) is
information also displayed, perform troubleshooting for that failure code first.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
Defective circuit breaker
between contacts (62) and If circuit breaker between contacts (62) and (63) is tripped, or fuse BT1
1 (63), or defective fuse BT1 between contacts (1) and (2) is blown, circuit may have ground fault.
between contacts (1) and (2)
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector BRC3 and connect T-adapter to female side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
a When voltage measured at terminal M of battery relay is normal and
voltages measured at BRC3 (2), (12), and (22) are unusual, open
circuit is in wiring harness between battery relay terminal M and
BRC3 (female) (2), (12), and (22).
Open circuit in wiring harness Between battery relay terminal M and ground 20 to 30 V
2 (wire breakage or defective
contact of connector) a Check ground terminal ER5 for looseness
Voltage and rust. 20 to 30 V
Between ground and each of BRC3 (female)
(2), (12), and (22)
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector BRC3 and connect T-adapter to female side.
Between ground and each of BRC3 (female)
Resis- (21), (31), (32), and (33)
Max. 1 z
tance
a Check terminal ER5 for looseness or rust.
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
Ground fault in wiring harness 3. Disconnect fuse BT1 between contacts(1) and (15).
3 4. Disconnect connector BRC3 and connect T-adapter to female side.
(Contact with ground circuit)
Between ground and each of BRC3 (female)
Resis- (2), (12), and (22) Min. 1 Mz
tance
Between BT1-1 and ground Min. 1 Mz
1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
3.Insert T-adapter into BRC3.
4 Defective retarder controller 4.Turn battery disconnect switch to ON position.
5.Turn starting switch to ON position.
Between ground and each of BRC3 (female)
Voltage 20 to 30 V
(2), (12), and (22)

40-380 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder controller power supply

HM400-3M0 40-381
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB13KK] Controller Power Source Low (RHC) (HM400_3-DB13KK-400-A-

Z0-A)

Action level Failure code Controller Power Source Low (RHC)

Failure
L03 DB13KK (Retarder hoist controller system)
Detail of • Continuous power supply voltage drops 18 V or lower with starting switch at ON position
failure except when engine is cranked or emergency steering is operated.
Action of • Stops driving hoist selector valve solenoid and hoist EPC valve solenoid.
controller • Stops TCS control and inter axle differential lock control.
• Retarder does not work properly.
Problem on
• Dump body does not move.
machine
• TCS and inter axle differential lock do not work.
• If fuse is blown, check for ground fault in circuits between fuse and each of BRC3
Related (female) (1), (11), (2), (12) and (22) lines.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
Defective transmission If failure codes [DAQ0KK] or [DAQ2KK] is also displayed, perform
1 controller power supply troubleshooting for it first.
a Check battery voltage and specific gravity of battery electrolyte.
2 Defective battery Voltage Battery voltage Min. 24 V
Specific
Specific gravity of battery electrolyte Min. 1.26
gravity
Defective circuit breaker
between contacts (82) and If circuit breaker between contacts (82) and (84) is tripped, or fuse BT2
3 (84), or fuse BT2 between between contacts (7) and (8) is blown, circuit may have ground fault.
contacts (7) and (8)
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector BRC3 and connect T-adapter to female side.
Between ground and each of BRC3 (female)
Resis- (21), (31), (32), and (33)
Max. 1 z
tance
a Check terminal ER5 for looseness or rust.
Open circuit in wiring harness 1. Turn starting switch to OFF position.
4 (wire breakage or defective 2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector BRC3, and insert T-adapter into BRC3.
contact of connector)
4. Turn battery disconnect switch to ON position.
a If voltage appears between battery relay terminal B and ground but
does not appear between ground and each of BRC3 (1) and (11),
wiring harness or fuse has open circuit.
Between battery relay terminal B and ground 20 to 30 V
Voltage Between ground and each of BRC3 (female)
(1) and (11) 20 to 30 V

1. Turn starting switch to OFF position.

2. Turn the battery disconnect switch to OFF position.
3. Disconnect connectors BRC3 and J20, all of fuse BT2 and lower two
Ground fault in wiring harness fuses of BT4.
5 4. Connect T-adapter to female side of connector BRC3.
(Contact with ground circuit)
Resis- Between ground and each of BRC3 (female)
(1) and (11) Min. 1 Mz
tance
Resis- Between BT2-7 and ground
Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
Defective retarder hoist 3. Insert T-adapter into BRC3.
6 4. Turn battery disconnect switch to ON position.
controller
Between ground and each of BRC3 (female)
Voltage 20 to 30 V
(1) and (11)

40-382 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder controller power supply

HM400-3M0 40-383
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB19KQ] Inconsistency of Model Selection (RHC) (HM300_3-

DB19KQ-400-A-Z0-A)

Action level Failure code Inconsistency of Model Selection (RHC)

Failure
E03 DB19KQ (Retarder hoist controller system)
Detail of • Model selection signals sent from machine monitor when starting switch is turned to ON
failure position differ from model settings stored in retarder hoist controller.
Action of • Stops TCS control and inter axle differential lock control.
controller
Problem on
• TCS and inter axle differential lock do not work.
machine
• Perform initial setting and initial adjustment similar to those required when the retarder
hoist controller is replaced.
Related • Method of reproducing failure code: Turn starting switch to ON position.
information • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
No. Cause Procedure, measuring location, criteria, and remarks

Incorrect model setting on a The machine model setting of machine monitor is probably incorrect.
1 After replacing the machine monitor or retarder hoist controller, set
machine monitor
the options correctly. For details, see Testing and Adjusting.
Installation of incorrect Incorrect retarder hoist controller may be installed. Check part number
2 and, if required, install correct retarder hoist controller.
retarder hoist controller
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)

40-384 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB1LKA] Disconnection of System Ope. Lamp

(RHC) (HM400_3R-DB1LKA-400-A-Z0-A)
Action level Failure code Disconnection of System Operating Lamp (RHC)
Failure
- DB1LKA (Retarder hoist controller system)
• Monitor controller determines that output circuit to system operating lamp is open
Detail of because voltage of output circuit remains at 3.8 to 5.7 V for approximately 3 seconds after
failure starting switch is turned to ON position, during which monitor controller does not drive
system operating lamp.
• Even if cause of failure disappears, machine does not become normal until starting switch
Action of is turned to OFF position.
controller • It does not output for system operating lamp.
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
Problem on position. Turning battery disconnect switch to OFF position may destroy data stored in
machine retarder hoist controller memory.
• Method of reproducing failure code: Turn starting switch to ON position.
• Although retarder hoist controller is not able to light system operating lamp, no trouble will
Related result unless battery disconnect switch is turned to OFF position.
information • When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after
starting switch is turned to ON position, open circuit can be detected.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Turn the battery disconnect switch to OFF position.
harness 3. Disconnect connectors BRC3 and J33, and connect T-adapters to each
1 (Wire breakage or female side.
defective contact of Between BRC3 (female) (34) and J33 (female) (2) Max. 1 z
connector) Resistance Between J33 (female) (1) and battery relay terminal
(66) Max. 1 z

Defective retarder hoist If no failure is found in above checks, retarder hoist controller is defective.
2
controller (Since this is an internal defect, troubleshooting cannot be performed.)

HM400-3M0 40-385
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to system operating lamp

40-386 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB1LKB] Short Circuit of System Ope. Lamp (RHC) (HM400_3R-
DB1LKB-400-A-Z0-A)

Action level Failure code Short Circuit of System Operating Lamp (RHC)
Failure
- DB1LKB (Retarder hoist controller system)
Detail of • Retarder hoist controller detects short circuit because output from retarder hoist controller
failure to system operating lamp does not make output voltage low.
• Stops driving system operating lamp.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
Problem on position. Turning battery disconnect switch to OFF position may destroy data stored in
machine retarder hoist controller memory.
• Method of reproducing failure code: Turn starting switch to ON position.
• Although retarder hoist controller is not able to light system operating lamp, no trouble will
result unless battery disconnect switch is turned to OFF position.
Related • When controller lights up system operating lamp, output circuit voltage is at low level.
information
a Since the voltage between pin (2) of female side and ground becomes 20 V or above after
turning starting switch to ON position when connector J33 is open, the check of hot short
circuit cannot be performed.
No. Cause Procedure, measuring location, criteria, and remarks
1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
3.Remove fuse 28 in fuse box BT4.
4.Disconnect connectors MCM1, ATC3, KOM1, J3, J33 and BRC3, and
connect T-adapter to female side of J33.
Resistance Between J33 (female) (1) and (2) Min. 1 Mz
1.
Turn starting switch to OFF position.
2.
Turn the battery disconnect switch to OFF position.
3.
Disconnect connector J33.
Short circuit in wiring
1 4.
Disconnect connectors MCM1, ATC3, BRC3, and KOM1, and connect T-
harness
adapters to each female side.
Between ATC3 (female) (34) and each pin other No
than pin (34) continuity
Between BRC3 (female) (34) and each pin other No
than pin (34) continuity
Continuity
Between KOM1 (female) (15) and each pin other No
than pin (15) continuity
Between MCM1 (female) (57) and each pin other No
than pin (57) continuity
Defective retarder hoist If no failure is found by above checks, retarder hoist controller is defective.
2 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

HM400-3M0 40-387
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to system operating lamp

40-388 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB1QKR] CAN2 Discon (Retarder Hoist Con) (HM300_3-DB1QKR-400-A-

Z0-A)

Action level Failure code CAN2 Disconnection (Retarder Hoist Controller)

Failure
L03 DB1QKR (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller does not recognize retarder hoist controller over CAN communication-2
failure circuit (KOMNET/c).
Action of • Does not update communication information.
controller
• No failure code related to retarder hoist controller is displayed.
Problem on • No monitoring data related to retarder hoist controller is updated.
machine • Adjustment function (TCS system check) cannot be used.
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• Monitor controller uses six failure codes, [D8AQK*], [DAQQKR], [DB1QKR], [DB2QKR],
[DAZQKR], and [DSJ0KR] to indicate failure in CAN communication through CAN 2 line.
When all of these six failure codes are displayed simultaneously on screen, ground fault,
short circuit, or hot short circuit may occur in wiring harness (CAN communication line). In
this case, check whether air conditioner is operated (ON/OFF and air flow adjustment)
Related from air conditioner operation screen since air conditioner is also controlled over CAN
information communication line.
a Air conditioner can be controlled even when failure code is displayed on screen. If air
conditioner is controlled, wiring harness (CAN communication line) does not have ground
fault, short circuit, or hot short circuit.
• Since each controller and machine monitor (meter unit) are connected directly to battery,
they are supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria, and remarks
Improper power supply to Perform troubleshooting for failure code [DB13KK].
1
retarder hoist controller
Defective CAN2 Perform checks on causes 4 to 10 in troubleshooting for failure code
2 communication system [DB2QKR].
If no failure is found in above checks, retarder hoist controller is
Defective retarder hoist defective.
3
controller
(Since this is an internal defect, troubleshooting cannot be performed.)
If no failure is found by above checks, monitor controller is defective.
4 Defective monitor controller
(Since this is an internal defect, troubleshooting cannot be performed.)

HM400-3M0 40-389
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB1QMA] Inconsistency of Option Selection (RHC) (HM300_3-

DB1QMA-400-A-Z0-A)

Action level Failure code Inconsistency of Option Selection (RHC)

Failure
L03 DB1QMA (Retarder hoist controller system)
Detail of • When starting switch is turned to ON position, the option setting information sent from
failure machine monitor differs from that stored in the retarder hoist controller.
• Controls with the option settings stored in the controller.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • None in particular
machine
• Perform initial setting and initial adjustment similar to those required when the retarder
Related hoist controller is replaced.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
The option setting of machine monitor is probably incorrect. After
Improper option setting of replacing the machine monitor and retarder hoist controller, set the
1
machine monitor options correctly. For details, see Testing and Adjusting.
If no failure is found by above checks, retarder hoist controller may be
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
2
controller performed.)

40-390 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB1RKR] CAN1 Discon (Retarder Hoist Con) (HM400_3R-DB1RKR-400-A-

Z0-A)

Action level Failure code CAN1 Disconnection (Retarder Hoist Controller)

Failure
L03 DB1RKR (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller does not recognize retarder hoist controller over CAN communication-1
failure circuit (KOMNET/r).
Action of • Makes retarder oil temperature gauge pointer get out of machine monitor screen.
controller
• Information to be obtained from retarder hoist controller is not displayed and special
Problem on functions that need information do not work. Or update of received data is stopped.
machine • Retarder oil temperature gauge pointer goes off on machine monitor screen.
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• Monitor controller uses another failure code [DAQRKR] to indicate failure in CAN
communication through CAN 1 line. When failure code [DAQRKR] is displayed
simultaneously on screen, ground fault, short circuit, or hot short circuit may occur in
Related wiring harness (CAN communication line).
information • A CAN1 terminating resistor is located in monitor controller on operator's cab side and
another one is located in connector "CAN R" on engine side. (Engine controller has no
relationship with CAN1 communication line.)
• Since each controller and machine monitor are connected directly to battery, they are
supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria, and remarks
Improper power supply
1 system to retarder hoist Perform troubleshooting for failure codes [DB13KK].
controller
Defective CAN-1 Perform checks on causes 2 to 9 in troubleshooting for failure code
2 [DAQRKR].
communication line

HM400-3M0 40-391
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB2QKR] CAN2 Discon (Engine Con) (HM400_3R-DB2QKR-400-A-Z0-A)

Action level Failure code CAN2 Disconnection (Engine Controller)

Failure
L03 DB2QKR (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller does not recognize engine controller over CAN communication-2 line
failure (KOMNET/c).
Action of • Does not update communication information.
controller
• Failure codes to be generated by engine controller are not displayed.
Problem on • Monitoring data for which engine controller is responsible are not updated.
machine • Manual regeneration of KDPF cannot be performed.
• Cylinder cutout mode operation and No Injection cranking cannot be performed.
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• If failure code [DB2RKR] is also displayed, engine controller may be defective (cause 2).
• Monitor controller uses six failure codes, [D8AQK*], [DAQQKR], [DB1QKR], [DB2QKR],
[DAZQKR], and [DSJ0KR] to indicate failure in CAN communication through CAN 2 line.
When all of these 7 failure codes are displayed simultaneously on screen, ground fault,
short circuit, or hot short circuit may occur in wiring harness (CAN communication line). In
this case, check whether air conditioner is operated (ON/OFF and air flow adjustment)
Related from air conditioner operation screen since air conditioner is also controlled over CAN
information communication line. (For the machines equipped with payload meter, failure code
[DBSQKR] also indicates failure in CAN communication through CAN 2 line.)
a Air conditioner can be controlled even when failure code is displayed on screen. If air
conditioner is controlled, wiring harness (CAN communication line) does not have ground
fault, short circuit, or hot short circuit.
• Since each controller and machine monitor (meter unit) are connected directly to battery,
they are supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Defective fuses 23 and 2. Remove fuse 23 in fuse box BT4.
1
15 in fuse box BT4 • When fuse is blown, engine controller may have internal short circuit.
• If fuse 15 is blown, the wiring harness may be grounded.
a If fuse is not blown, this check is not required.
Defective engine 1. Turn starting switch to OFF position.
2 2. Disconnect connector J3P and connect T-adapter to male side.
controller
Between J3P (male) (1) and (3) Min. 10 z
Resistance
Between J3P (male) (2) and (4) Min. 10 z
a Check ground terminal ER17 for looseness and corrosion.
1. Turn starting switch to OFF position.
2. Disconnect connector J3P, and connect T-adapter to female side.
Defective power supply 3. Turn starting switch to ON position.
3 to engine controller
a If any trouble is found, perform troubleshooting for failure code [CA441].
Between J3P (female) (1) and (3) 20 to 30 V
Voltage
Between J3P (female) (2) and (4) 20 to 30 V
1. Turn starting switch to OFF position.
Defective CAN 2. Disconnect connectors DPC3 and CANC, and connect T-adapters to male
terminating resistor side of them.
4
(Internal open or short Between CANC (male) (A) and (B) 120 ± 12 z
circuit) Resistance 120 ± 12 z
Between DPC3 (male) (7) and (8)

40-392 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

• CAN communication line
a CAN terminating resistor of 120 z is also located in machine monitor. That
is, 2 CAN terminating resistors of 120 z are connected in parallel. When
circuit resistance is measured at connector of controller other than
machine monitor, if combined resistance is 60 z, wiring harness does not
have open circuit.
1. Turn starting switch to OFF position, and turn battery disconnect switch to
OFF position.
2. Disconnect related connectors and connect T-adapters to connectors to
be measured.
a If open circuit is found (resistance between 2 terminals is 1 z or below),
disconnect all CAN communication connectors of every controller and
check whether open circuit occurs in wiring harness or inside controller.
Open or short circuit in Approx. 120
5 wiring harness Between DPC3 (female) (3) and (8)
z
Between J2P (female) (46) and (47) Approx. 60
z
Between MCM2 (female) (97) and (89) Approx. 60
z
Between BRC2 (female) (32) and (22) Approx. 60
z
Resistance
Between ATC2 (female) (32) and (22) Approx. 60
z
Between AC01 (female) (9) and (10) Approx. 60
z
Between KOM1 (female) (10) and (11) Approx. 60
z
Between CANC (male) (A) and (B) Approx. 120
z
• ACC signal of starting switch (start of CAN communication is not
recognized)
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect connectors to be measured and insert T-adapters into them.
Open circuit of wiring 3. Turn battery disconnect switch to ON position, and turn starting switch to
harness (ACC signal) ON position.
6 (Wire breakage or Between J2P (39) and (21) 20 to 30 V
defective contact of Between MCM1 (24) and (2) 20 to 30 V
connector) Between BRC3 (14), (24) and (21) 20 to 30 V
Voltage Between ATC3 (14), (24) to (21) 20 to 30 V
Between AC02 (4) and (1) 20 to 30 V
Between KOM2 (3) and (1) 20 to 30 V

HM400-3M0 40-393
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

a If no failure is found by check on cause 5, this check is not required.
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect related connectors and connect T-adapters to female side of
connectors to be measured.
Between DPC3 (female) (3) and MCM2 (female)
(97) Max. 1 z
Between DPC3 (female) (8) and MCM2 (female)
(89) Max. 1 z
Between MCM2 (female) (97) and ATC2 (female)
(32) Max. 1 z
Between MCM2 (female) (89) and ATC2 (female)
(22) Max. 1 z
Open circuit in wiring
Between MCM2 (female) (97) and J2P (female)
harness Max. 1 z
(46)
7 (Wire breakage or
Between MCM2 (female) (89) and J2P (female)
defective contact of Max. 1 z
(47)
connector)
Resistance Between MCM2 (female) (97) and BRC2 (female) Max. 1 z
(32)
Between MCM2 (female) (89) and BRC2 (female)
(22) Max. 1 z
Between MCM2 (female) (97) and AC1 (female) (9) Max. 1 z
Between MCM2 (female) (89) and AC1 (female)
(10) Max. 1 z
Between MCM2 (female) (97) and KOM1 (female)
(10) Max. 1 z
Between MCM2 (female) (89) and KOM1 (female)
(11) Max. 1 z
Between J2P (female) (46) and CANC (female) (A) Max. 1 z
Between J2P (female) (47) and CANC (female) (B) Max. 1 z
a If no failure (open circuit) is found by check on cause 5, measure
resistance at any one place in each case.
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect related connectors and connect T-adapters to female side of
Ground fault in wiring connectors to be measured.
harness Between ground and any of DPC3 (female) (3),
8
(Contact with ground ATC2 (female) (32), KOM1 (female) (10), AC1
circuit) (female) (9), J2P (female) (46), BRC2 (female) (32), Min. 1 Mz
MCM2 (female) (97)
Resistance
Between ground and any of DPC3 (female) (8),
ATC2 (female) (22), KOM1 (female) (11), AC1 Min. 1 Mz
(female) (10), J2P (female) (47), BRC2 (female)
(22), MCM2 (female) (89)

40-394 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

a If no failure (open circuit) is found by check on cause 5, measure voltage
at any one place in each case.
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect connectors to be measured and insert T-adapters into them.
3. Set battery disconnect switch to ON position.
Short circuit or hot short 4. Turn starting switch to ON position.
circuit in wiring harness a Voltage of CAN H and CAN L is 2.5 ± 1 V including during communication,
9 so regard wiring harness as normal if measured voltage is 1 to 4 V.
(Contact with 24 V
circuit) Between ground and any of DPC3 (female) (3),
ATC2 (female) (32), KOM1 (female) (10), AC1
(female) (9), J2P (female) (46), and BRC2 (female) 1 to 4 V
(32)
Voltage
Between ground and any of DPC3 (female) (8),
ATC2 (female) (22), KOM1 (female) (11), AC1
(female) (10), J2P (female) (47), and BRC2 1 to 4 V
(female) (22)
• If all six failure codes [D8AQK*], [DB1QKR], [DB2QKR], [DAQQKR],
[DAZQKR], and [DSJ0KR] are displayed.
a For the machines equipped with payload meter, [DBSQKR] is also
displayed.
Defective engine a To identify defective controller, repeat following steps 1. to 3. to disconnect
controller, retarder hoist controllers one by one from CAN communication line.
controller, transmission 1. Turn starting switch to OFF position, and set battery disconnect switch to
controller, air OFF position.
10 conditioner controller, 2. Disconnect CAN communication connector of engine controller (connector
machine monitor (meter J2P), retarder hoist controller (connector BRC2), transmission controller
unit), KOMTRAX (connector ATC2), air conditioner controller (connector AC1), machine
terminal, or PLM monitor (connector DPC3), KOMTRAX terminal (connector KOM1), and
controller (if equipped) payload meter controller (connector HM4A) one by one in order.
3. Turn battery disconnect switch to ON position, turn starting switch to ON
position, then perform troubleshooting.
4. Return to step 1. to check next connector.
Has the number of displayed failure codes If YES, disconnected
decreased from 6? controller is defective.
Defective engine If no failure is found by above checks, engine controller is defective. (Since
11 this is an internal defect, troubleshooting cannot be performed.)
controller
Defective monitor If no failure is found by above checks, monitor controller is defective. (Since
12 this is an internal defect, troubleshooting cannot be performed).
controller

HM400-3M0 40-395
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to CAN2 communication

40-396 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DBSQKR] CAN2 Discon (PLM) (HM400_3R-DBSQKR-400-A-Z0-A)

Action level Failure code CAN2 Disconnection (PLM)

Failure
L01 DBSQKR (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller does not recognize payload meter controller over CAN communication-
failure 2 line (KOMNET/c).
Action of • Does not update communication information.
controller
• Failure codes to be generated by payload meter controller are not displayed.
Problem on • Monitoring data for which payload meter controller is responsible are not updated.
machine • Payload is not displayed.
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• Monitor controller uses 7 failure codes, [D8AQK*], [DAQQKR], [DB1QKR], [DB2QKR],
[DAZQKR], [DSJ0KR], and [DBSQKR] to indicate failure in CAN communication through
CAN 2 line. When all of these 7 failure codes are displayed simultaneously on screen,
ground fault, short circuit, or hot short circuit may occur in wiring harness (CAN
communication line). In this case, check whether air conditioner is operated (ON/OFF and
Related air flow adjustment) from air conditioner operation screen since air conditioner is also
information controlled over CAN communication line.
a Air conditioner can be controlled even when failure code is displayed on screen. If air
conditioner is controlled, wiring harness (CAN communication line) does not have ground
fault, short circuit, or hot short circuit.
• Since each controller and machine monitor (meter unit) are connected directly to battery,
they are supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria, and remarks
a Check battery voltage and specific gravity of battery electrolyte.
1 Defective battery Voltage Battery voltage Min. 24 V
Gravity Gravity of battery Min. 1.26
Defective circuit breaker
(82) to (84), and If circuit breaker (between terminals 82 and 84) is tripped, or between -13 and
2
between -13 and 14 of 14 of fuse BT2 is burnt out, circuit probably has ground fault.
fuse BT2
1. Turn the starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector HM1, and connect T-adapter to female side.
Between ground and each of HM1 (female) (11),
Resistance (12), (19), and (20) Max. 1 z
a Check ER5 terminal for looseness and rust
Open circuit in wiring 1. Turn the starting switch to OFF position.
3 harness (wire breakage 2. Turn the battery disconnect switch to OFF position.
or defective contact) 3. Disconnect connector HM1, and connect T-adapter to female side.
4. Turn the battery disconnect switch to ON position.
a If voltage appears between battery relay terminal B and ground but not
between ground and each of HM1 (female) (6) and (7), wiring harness or
fuse has open circuit.
Between battery relay terminal B and ground 20 to 30 V
Voltage Between ground and each of HM1 (female) (6) and
(7) 20 to 30 V

1. Turn the starting switch to OFF position.

Ground fault in wiring 2. Turn the battery disconnect switch to OFF position.
4 harness (contact with 3. Disconnect connectors HM1 and J20, all of fuse BT2 and lower 2 fuses of
GND circuit) BT4.
4. Connect T-adapter to female side of connector HM1.

HM400-3M0 40-397
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

Between ground and each of HM1 (female) (6) and
Min. 1 Mz
Resistance (7)
Between BT2-7 and ground Min. 1 Mz
Defective CAN2 If failure code [DB2QKR] is displayed, perform checks on causes 4 to 9 in
5 communication system troubleshooting for failure code [DB2QKR].
• CAN communication line
a CAN terminating register of 120 z is also located in machine monitor. That
is, 2 CAN terminating resistors of 120 z are connected in parallel. When
circuit resistance is measured at connector of controller other than
machine monitor, if combined resistance is 60 z, wiring harness does not
have open circuit.
1. Turn the starting switch to OFF position, and turn the battery disconnect
Open circuit or short switch to OFF position.
6 circuit in wiring harness 2. Disconnect the related connectors, and connect T-adapter to the
connector to be measured.
a If short circuit is found (resistance between 2 terminals is 1 z and below),
disconnect all CAN communication connectors of every controller, and
check whether short circuit occurs between wiring harnesses or inside
controller.
Approx. 60
Resistance Between HM4A (female) (4) and (14)
z
• ACC signal of starting switch (start of CAN communication is not
recognized)
1. Turn the starting switch to OFF position, and turn the battery disconnect
Open circuit in wiring switch to OFF position.
harness (ACC signal) 2. Disconnect the connector to be measured and insert T-adapter.
7 (wire breakage or 3. Turn the battery disconnect switch to ON position, and turn the starting
defective contact of switch to ON position.
connector) Between HM1 (8) and (11) 20 to 30 V
Voltage Between HM1 (9) and (12) 20 to 30 V
Between HM1 (17) and (19) 20 to 30 V
a If no failure is found by check on cause 6, this check is not required.
1. Turn the starting switch to OFF position, and turn the battery disconnect
Open circuit in wiring switch to OFF position.
harness (wire breakage 2. Disconnect the related connectors, and connect T-adapter to each female
8 or defective contact of side connector to be measured.
connector) Between HM4A (female) (4) and MCM2 (female)
(97) Max. 1 z
Resistance
Between HM4A (female) (14) and MCM2 (female)
(89) Max. 1 z
• If all 7 failure codes [D8AQK*], [DB1QKR], [DB2QKR], [DAQQKR],
[DAZQKR], [DSJ0KR], and [DBSQKR] are displayed.
a To identify defective controller, repeat following steps 1 through 3 to
disconnect controllers one by one from CAN communication line.
Defective engine
controller, retarder hoist 1. Turn the starting switch to OFF position, and turn the battery disconnect
controller, transmission switch to OFF position.
controller, air 2. Disconnect CAN communication connector of engine controller (connector
9 conditioner controller, J2P), retarder hoist controller (connector BRC2), transmission controller
machine monitor (meter (connector ATC2), air conditioner controller (connector AC1), machine
unit), KOMTRAX monitor (DPC3), KOMTRAX terminal (connector KOM1), and payload
terminal, or payload meter controller (connector HM4A) one by one.
meter controller 3. Turn the battery disconnect switch to ON position, and turn the starting
switch to ON position, and then perform troubleshooting
4. Return to step 1 to check next controller.
Has the number of displayed failure codes If YES, the disconnected
decreased from 7? controller is defective.

40-398 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

Defective payload If no failure is found by above checks, payload meter controller is defective.
10 (Since this is an internal defect, troubleshooting cannot be performed).
meter controller
Defective monitor If no failure is found by above checks, monitor controller is defective. (Since
11 this is an internal defect, troubleshooting cannot be performed).
controller

Circuit diagram related to payload meter power supply

HM400-3M0 40-399
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to CAN communication line

40-400 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DBSQKQ] Inconsistency of Model Selection (PLM) (HM400_3R-

DBSQKQ-400-A-Z0-A)

Action level Failure code Inconsistency of Model Selection (PLM)

Failure
L01 DBSQKQ (Payload meter controller system)
Detail of • Model selection signals sent from machine monitor when starting switch is turned to ON
failure position differ from model settings stored in payload meter controller.
Action of • None in particular
controller
Problem on • The calculation accuracy of the payload becomes worse.
machine
• Perform initial setting and initial adjustment similar to those required when the payload
meter controller is replaced.
Related • Method of reproducing failure code: Turn starting switch to ON position.
information • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
No. Cause Procedure, measuring location, criteria, and remarks

Incorrect model setting a The machine model setting of machine monitor is probably incorrect. After
1 replacing the machine monitor or payload meter controller, set the options
on machine monitor
correctly. For details, see Testing and Adjusting.
Installation of incorrect Incorrect payload meter controller may be installed. Check part No. and install
2 payload meter controller correct payload meter controller.
Defective payload If no failure is found by above checks, payload meter controller is defective.
3 (Since this is an internal defect, troubleshooting cannot be performed).
meter controller

HM400-3M0 40-401
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DD1ML4] Failure of ARAC SW (HM300_3-DD1ML4-400-A-Z0-A)

Action level Failure code Failure of ARAC Switch

Failure
L01 DD1ML4 (Transmission controller system)
Detail of • Accelerator connected retarder switch signals 1 and 2 are both ON at the same time.
failure • Accelerator connected retarder switch signals 1 and 2 are both OFF at the same time.
Action of • Stops accelerator connected retarder.
controller
Problem on
• Accelerator connected retarder does not work.
machine
• Accelerator connected retarder switch input signal can be checked with monitoring
Related function (Code: 02213).
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
If circuit breaker is tripped, circuit may have ground fault etc. (See
1 Trip of circuit breaker (80 A) check on cause 5.)
2 Defective fuse (BT1-No. 4 (8)) If fuse is blown, circuit may have ground fault. (See check on cause 5.)
1. Turn starting switch to OFF position.
2. Disconnect connector ARA and connect T-adapter to male side.
Between ARA (male) Accelerator connected
(4) and (5) retarder switch: Up Min. 1 Mz
Defective accelerator
Between ARA (male) Accelerator connected
3 connected retarder switch Max. 1 z
(internal defect) Resis- (4) and (5) retarder switch: Down
tance Between ARA (male) Accelerator connected
(5) and (6) retarder switch: Up Max. 1 z
Between ARA (male) Accelerator connected
(5) and (6) Min. 1 Mz
retarder switch: Down
1. Turn starting switch to OFF position.
2. Disconnect connectors ARA and ATC1, and connect T-adapters to
Open circuit in wiring harness each female side.
4 (Wire breakage or defective Between ARA (female) (4) and ATC1 (female)
Max. 1 z
contact of connector) Resis- (5)
tance Between ARA (female) (6) and ATC1 (female)
(24) Max. 1 z

1. Turn starting switch to OFF position.

Ground fault in wiring harness
5 Between ground and ARA (female) (4) or ATC1
(contact with ground circuit)
Hot short circuit in wiring
6 harness
(contact with 24V circuit)
7 Short circuit in wiring harness
Defective transmission
8
controller
2. Remove fuse BT2-8.
3. Disconnect connectors ARA and ATC1, and connect T-adapter to
either female side.
(female) (5) Min. 1 Mz
Resis- Between ground and ARA (female) (6) or ATC1
tance (female) (24) Min. 1 Mz
Between ARA (female) (5) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector ARA and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between ARA (female) (4) and ground Max. 1 V
Voltage
Between ARA (female) (6) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors ARA and ATC3, and connect T-adapter to
female side of ARA.
Between ARA (female) (4) and (5) Min. 1 Mz
Resis- Between ARA (female) (4) and (6)
Min. 1 Mz
tance
Between ARA (female) (5) and (6) Min. 1 Mz
If no failure is found by above checks, transmission controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)

40-402 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to accelerator connected retarder switch

HM400-3M0 40-403
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDAAL6] Discon of Engine Shutdown Secondary

Switch (HM400_3-DDAAL6-400-A-Z0-A)
Action level Failure code Disconnection of Engine Shutdown Secondary Switch
Failure
L03 DDAAL6 (Machine monitor system)
Detail of • Monitor controller detects disconnection in the signals from engine shutdown secondary
failure switch.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • None in particular
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria, and remarks
Incorrect operation of engine
1 shutdown secondary switch Check that engine shutdown secondary switch is in OFF position.

1. Turn starting switch to OFF position.

Defective engine shutdown
2 secondary switch
Open circuit in wiring harness
3 (wire breakage or defective
contact of connector)
4 Defective monitor controller
2. Disconnect connector ESS and connect T-adapter to male side.
a Engine shutdown secondary switch: OFF
Resis- Between ESS (male) (1) and (2) Max. 1 z
tance Between ESS (male) (4) and (5) Max. 1 z
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector MCM1, and connect T-adapter to female side.
a Engine shutdown secondary switch: OFF
Resis- Between MCM1 (female) (24) and (31)
Max. 1 z
tance
a If no failure is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connectors MCM1 and ESS, and connect T-adapters to
each female side.
Between MCM1 (female) (24) and each of ESS
Max. 1 z
Resis- (female) (2) and (5)
tance Between MCM1 (female) (31) and each of ESS
(female) (1) and (4) Max. 1 z
If no failure is found by above checks, monitor controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed).

40-404 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to monitor controller power supply

HM400-3M0 40-405
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDTHKA] Disconnection of Fill Switch (High) (HM300_3-DDTHKA-400-A-

Z0-A)

Action level Failure code Disconnection of Fill Switch (High)

Failure
L03 DDTHKA (Transmission controller system)
Detail of • When H clutch ECMV solenoid is energized, clutch engages but signal from fill switch is
failure not ON.
Action of • Maintains current gear speed during travel.
controller • Transmission will stay in neutral when gear shift lever is set to the N position.
• Machine cannot travel.
• Once gear shift lever is set to "N" during travel, even if gear shift lever is moved to position
Problem on
other than "N", that gear does not engage until machine is stopped.
machine
• Machine travels in gear speed that use H clutch.
• Machine cannot drive in reverse.
• Fill switch input signal can be checked with monitoring function (Code: 02216).

Related k Before removing or installing connectors for clutch, tilt up cab and fix it securely
information by using lock bar (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine and drive machine in F2.
No. Cause Procedure, measuring location, criteria, and remarks
1. Start engine.
2. While depressing brake pedal, move gear shift lever to 1, gear
speed F1 (Lo: 1st) and check that failure code [DDTJKA] does no
appear.
3. Turn starting switch to OFF position.
4. Tilt up cab and fix it by using lock bar.
5. Interchange connections of connectors of H clutch and L clutch.
• Exchange L.PS(CN6) with H.PS(CN10)
• Exchange L.SW(CN7) with H.SW(CN11)
1 Defective Hi clutch fill switch 6. Lower tilted-up cab.
7. Start engine.
8. While depressing brake pedal, move gear shift lever to D, gear
speed F2 (Hi: 1st).
a If failure code [DDTJKA] appears, check clutch pressure. If clutch
pressure is normal, H clutch fill switch is defective.
a If failure code [DDTJKA] does not appear, wiring harness has open
circuit or transmission controller is defective.
a After check, tilt the cab again and restore connectors.
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
3. Disconnect connectors ATC3 and H.SW (CN11), and connect T-
2 Open circuit in wiring harness adapters to each female side.
Resis- Between ATC3 (female) (30) and H.SW (CN11)
(female) (1) Max. 1 z
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)

40-406 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to H clutch

HM400-3M0 40-407
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDTJKA] Disconnection of Fill Switch (Low) (HM300_3-DDTJKA-400-A-Z0-

A)

Action level Failure code Disconnection of Fill Switch (Low)

Failure
L03 DDTJKA (Transmission controller system)
Detail of • When L clutch ECMV solenoid is energized, clutch engages but signal from fill switch is
failure not ON.
Action of • Maintains current gear speed during travel.
controller • Transmission will stay in neutral when gear shift lever is set to the N position.
• Machine cannot travel.
• Once gear shift lever is set to "N" during travel, even if gear shift lever is moved to position
Problem on
other than "N", that gear does not engage until machine is stopped.
machine
• Machine travels in gear speed that use H clutch.
• Machine cannot drive in reverse.
• Fill switch input signal can be checked with monitoring function (Code: 02216).

Related k Before removing or installing connectors for clutch, tilt up cab and fix it securely
information by using lock bar (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start the engine and drive machine in F1.
No. Cause Procedure, measuring location, criteria, and remarks
1. Start engine.
2. While depressing brake pedal, move gear shift lever to D, gear
speed F2 (Hi: 1st) and check that failure code [DDTHKA] does no
appear.
3. Turn starting switch to OFF position.
4. Tilt up cab and fix it by using lock bar.
5. Interchange connections of connectors of L clutch and H clutch.
• Exchange H.PS(CN10) with L.PS(CN6)
• Exchange H.SW(CN11) with L.SW(CN7)
1 Defective L clutch fill switch 6. Lower tilted-up cab.
7. Start engine.
8. While depressing brake pedal, move gear shift lever to 1, gear
speed F1 (Lo: 1st).
a If failure code [DDTHKA] appears, check clutch pressure. If clutch
pressure is normal, L clutch fill switch is defective.
a If failure code [DDTHKA] does not appear, wiring harness has open
circuit or transmission controller is defective.
a After check, tilt the cab again and restore connectors.
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
3. Disconnect connectors ATC3 and L.SW (CN7), and connect T-
2 Open circuit in wiring harness adapters to each female side.
Resis- Between ATC3 (female) (20) and L.SW (CN7)
(female) (1) Max. 1 z
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)

40-408 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to lockup clutch

HM400-3M0 40-409
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDTKKA] Disconnection of Fill Switch (1st) (HM300_3-DDTKKA-400-A-Z0-A)

Action level Failure code Disconnection of Fill Switch (1st)

Failure
L03 DDTKKA (Transmission controller system)
Detail of • When 1st clutch ECMV solenoid is energized, clutch engages but signal from fill switch is
failure not ON.
Action of • Maintains current gear speed during travel.
controller • Transmission will stay in neutral when gear shift lever is set to the N position.
• Machine cannot travel.
• Once gear shift lever is set to "N" during travel, even if gear shift lever is moved to position
Problem on
other than "N", that gear does not engage until machine is stopped.
machine
• Machine travels in gear speed that use Hi clutch.
• Machine cannot drive in reverse.
• Fill switch input signal can be checked with monitoring function (Code: 02216).

Related k Before removing or installing connectors for clutch, tilt up cab and fix it securely
information by using lock bar (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine and drive machine in F2.
No. Cause Procedure, measuring location, criteria, and remarks
1. Start engine.
2. While depressing brake pedal, move gear shift lever to R2, gear
speed R2 (R: 2nd) and check that failure code [DDTNKA] does not
appear.
3. Turn starting switch to OFF position.
4. Tilt up cab and fix it by using lock bar.
5. Interchange connections of connectors of 1st clutch and R clutch.
• Exchange R.PS(CN8) with 1.PS(CN12)
• Exchange R.SW(CN9) with 1.SW(CN13)
1 Defective 1st clutch fill switch 6. Lower tilted-up cab.
7. Start engine.
8. While depressing brake pedal, move shift lever to position R1 to set
gear speed R1 (to engage R and 1st clutches).
a If failure code [DDTNKA] appears, check clutch pressure. If clutch
pressure is normal, 1st clutch fill switch is defective.
a If failure code [DDTNKA] does not appear, wiring harness has open
circuit or transmission controller is defective.
a After check, tilt the cab again and restore connectors.
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
3. Disconnect connectors ATC3 and 1.SW (CN13), and connect T-
2 Open circuit in wiring harness adapters to each female side.
Resis- Between ATC3 (female) (40) and 1.SW (CN13)
(female) (1) Max. 1 z
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)

40-410 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 1st clutch

HM400-3M0 40-411
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDTLKA] Disconnection of Fill Switch (2nd) (HM300_3-DDTLKA-400-A-Z0-

A)

Action level Failure code Disconnection of Fill Switch (2nd)

Failure
L03 DDTLKA (Transmission controller system)
Detail of • When 2nd clutch ECMV solenoid is energized, clutch engages but signal from fill switch is
failure not ON.
Action of • Maintains current gear speed during travel.
controller • Transmission will stay in neutral when gear shift lever is set to the N position.
• Machine cannot travel.
• Once gear shift lever is set to "N" during travel, even if gear shift lever is moved to position
Problem on
other than "N", that gear does not engage until machine is stopped.
machine
• Machine travels in gear speed that use 2nd clutch.
• Machine cannot drive in reverse.
• Fill switch input signal can be checked with monitoring function (Code: 02216).

Related k Before removing or installing connectors for clutch, tilt up cab and fix it securely
information by using lock bar (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine and drive machine in F3.
No. Cause Procedure, measuring location, criteria, and remarks
1. Start engine.
2. While depressing brake pedal, move gear shift lever to R3, gear
speed R3 (R: 3rd) and check that failure code [DDTMKA] does not
appear.
3. Turn starting switch to OFF position.
4. Tilt up cab and fix it by using lock bar.
5. Interchange connections of connectors of 2nd clutch and 3rd clutch.
• Exchange 2.PS(CN14) with 3.PS(CN16)
• Exchange 2.SW(CN15) with 3.SW(CN17)
1 Defective 2nd clutch fill switch 6. Lower tilted-up cab.
7. Start engine.
8. While depressing brake pedal, move gear shift lever to R2, gear
speed R2 (R: 2nd).
a If failure code [DDTMKA] appears, check clutch pressure. If clutch
pressure is normal, 2nd clutch fill switch is defective.
a If failure code [DDTMKA] does not appear, wiring harness has open
circuit or transmission controller is defective.
a After check, tilt the cab again and restore connectors.
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
3. Disconnect connectors ATC3 and 2.SW (CN15), and connect T-
2 Open circuit in wiring harness adapters to each female side.
Resis- Between ATC3 (female) (9) and 2.SW (CN15)
(female) (1) Max. 1 z
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)

40-412 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 2nd clutch

HM400-3M0 40-413
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDTMKA] Disconnection of Fill Switch (3rd) (HM300_3-DDTMKA-400-A-Z0-

A)

Action level Failure code Disconnection of Fill Switch (3rd)

Failure
L03 DDTMKA (Transmission controller system)
Detail of • When 3rd clutch ECMV solenoid is energized, clutch engages but signal from fill switch is
failure not ON.
Action of • Maintains current gear speed during travel.
controller • Transmission will stay in neutral when gear shift lever is set to the N position.
• Machine cannot travel.
• Once gear shift lever is set to "N" during travel, even if gear shift lever is moved to position
Problem on
other than "N", that gear does not engage until machine is stopped.
machine
• Machine travels in gear speed that use 3rd clutch.
• Machine cannot drive in reverse.
• Fill switch input signal can be checked with monitoring function (Code: 02216).

Related k Before removing or installing connectors for clutch, tilt up cab and fix it securely
information by using lock bar (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine and drive machine in F5.
No. Cause Procedure, measuring location, criteria, and remarks
1. Start engine.
2. While depressing brake pedal, move gear shift lever to R2, gear
speed R2 (R: 2nd) and check that failure code [DDTLKA] does not
appear.
3. Turn starting switch to OFF position.
4. Tilt up cab and fix it by using lock bar.
5. Interchange connections of connectors of 3rd clutch and 2nd clutch.
• Exchange 2.PS(CN14) with 3.PS(CN16)
• Exchange 2.SW(CN15) with 3.SW(CN17)
1 Defective 3rd clutch fill switch 6. Lower tilted-up cab.
7. Start engine.
8. While depressing brake pedal, move gear shift lever to R3, gear
speed R3 (R: 3rd).
a If failure code [DDTLKA] appears, check clutch pressure. If clutch
pressure is normal, 3rd clutch fill switch is defective.
a If failure code [DDTLKA] does not appear, wiring harness has open
circuit or transmission controller is defective.
a After check, tilt the cab again and restore connectors.
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
3. Disconnect connectors ATC3 and 3.SW (CN17), and connect T-
2 Open circuit in wiring harness adapters to each female side.
Resis- Between ATC3 (female) (19) and 3 SW (CN17)
(female) (1) Max. 1 z
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)

40-414 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 3rd clutch

HM400-3M0 40-415
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDTNKA] Disconnection of Fill Switch (Reverse) (HM300_3-DDTNKA-

400-A-Z0-A)

Action level Failure code Disconnection of Fill Switch (Reverse)

Failure
L03 DDTNKA (Transmission controller system)
Detail of • When R clutch ECMV solenoid is energized, clutch engages but signal from fill switch is
failure not ON.
Action of • Maintains current gear speed during travel.
controller • Transmission will stay in neutral when gear shift lever is set to the N position.
• Machine cannot travel.
• Once gear shift lever is set to "N" during travel, even if gear shift lever is moved to position
Problem on
other than "N", that gear does not engage until machine is stopped.
machine
• Machine travels in gear speed that use R clutch.
• Machine cannot drive in reverse.
• Fill switch input signal can be checked with monitoring function (Code: 02216).

Related k Before removing or installing connectors for clutch, tilt up cab and fix it securely
information by using lock bar (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine and drive machine in R1.
No. Cause Procedure, measuring location, criteria, and remarks
1. Start engine.
2. While depressing brake pedal, move gear shift lever to 1, gear
speed F1 (Lo: 1st) and check that failure code [DDTLKA] does no
appear.
3. Turn starting switch to OFF position.
4. Tilt up cab and fix it by using lock bar.
5. Interchange connections of connectors of R clutch and 1st clutch.
• Exchange R.PS(CN8) with 1.PS(CN12)
• Exchange R.SW(CN9) with 1.SW(CN13)
1 Defective R clutch fill switch 6. Lower tilted-up cab.
7. Start engine.
8. While depressing brake pedal, move shift lever to position R1 to set
gear speed R1 (to engage R and 1st clutches).
a If failure code [DDTKKA] appears, check clutch pressure. If clutch
pressure is normal, R clutch fill switch is defective.
a If failure code [DDTKKA] does not appear, wiring harness has open
circuit or transmission controller is defective.
a After check, tilt the cab again and restore connectors.
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
3. Disconnect connectors ATC3 and R.SW (CN9), and connect T-
2 Open circuit in wiring harness adapters to each female side.
Resis- Between ATC3 (female) (29) and R.SW (CN9)
(female) (1) Max. 1 z
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)

40-416 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to R clutch

HM400-3M0 40-417
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DF10KA] Disconnection of Shift Lever Input (HM300_3-DF10KA-400-A-Z0-

A)

Action level Failure code Disconnection of Shift Lever Input

Failure
L03 DF10KA (Transmission controller system)
Detail of • No input of gear shift lever signal
failure
Action of • Controls machine using the lever information before the failure occurrence.
controller
• Transmission may shift into higher gear speeds than the one selected by gear shift lever.
Problem on • Machine will stay neutral and will not start off.
machine • Directional selections cannot be performed.
• All gear shift lever position lamps go out.
Related • Gear shift lever in N can be checked with monitoring function (02211).
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
Defective operation of • Force may be applied to depress lever while shift lever is not operated.
1
shift lever • Shift lever is stopped intermediate point between two positions.
1. Turn starting switch to OFF position.
2. Remove No. 5 of fuse BT1.
3. Disconnect connectors SF1, ATC1, ATC2, ATC3, and connect T-adapters
to each female side.
Between BT1 (10) and SF1 (female) (1) Max. 1 z
Between ATC2 (female) (35) and SF1 (female) (3) Max. 1 z
Open circuit in wiring Between ATC2 (female) (25) and SF1 (female) (4) Max. 1 z
harness Between ATC1 (female) (6) and SF1 (female) (5) Max. 1 z
2 (Wire breakage or Between ATC2 (female) (15) and SF1 (female) (6) Max. 1 z
defective contact of
Between ATC2 (female) (5) and SF1 (female) (7) Max. 1 z
connector) Resistance
Between ATC2 (female) (36) and SF1 (female) (8) Max. 1 z
Between ATC2 (female) (26) and SF1 (female) (9) Max. 1 z
Between ATC2 (female) (16) and SF1 (female) (10) Max. 1 z
Between ATC2 (female) (6) and SF1 (female) (11) Max. 1 z
Between ATC3 (female) (21), (31), (32), (33) and
SF1 (female) (2) Max. 1 z

1. Turn starting switch to OFF position.

2. Disconnect connectors ATC1, ATC2, SF1, and connect T-adapters to each
female side.
Between ground and ATC2 (female) (35) or SF1
(female) (3) Min. 1 Mz
Between ground and ATC2 (female) (25) or SF1
(female) (4) Min. 1 Mz
Between ground and ATC1 (female) (6) or SF1
(female) (5) Min. 1 Mz
Short circuit in wiring
harness Between ground and ATC2 (female) (15) or SF1
(female) (6) Min. 1 Mz
3
(Contact with ground
Between ground and ATC2 (female) (5) or SF1
circuit) Resistance (female) (7) Min. 1 Mz
Between ground and ATC2 (female) (36) or SF1
(female) (8) Min. 1 Mz
Between ground and ATC2 (female) (26) or SF1
(female) (9) Min. 1 Mz
Between ground and ATC2 (female) (16) or SF1
(female) (10) Min. 1 Mz
Between ground and ATC2 (female) (6) or SF1
(female) (11) Min. 1 Mz

40-418 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

1. Turn starting switch to OFF position.
2. Insert T-adapter into connector SF1.
3. Turn starting switch to ON position.
4. Operate gear shift lever to perform troubleshooting.
In shift range R2 20 to 30 V
Between SF1 (3) and
ground In any shift range other
Max. 1 V
than R2
In shift range R1 20 to 30 V
Between SF1 (4) and
ground In any shift range other
Max. 1 V
than R1
In shift range N 20 to 30 V
Between SF1 (5) and
ground In any shift range other
Max. 1 V
than N
In shift range D 20 to 30 V
Between SF1 (6) and
ground In any shift range other
Max. 1 V
than D
4 Defective gear shift lever In shift range 5 20 to 30 V
Between SF1 (7) and
Voltage In any shift range other
ground Max. 1 V
than 5
In shift range 4 20 to 30 V
Between SF1 (8) and
ground In any shift range other
Max. 1 V
than 4
In shift range 3 20 to 30 V
Between SF1 (9) and
ground In any shift range other
Max. 1 V
than 3
In shift range 2 20 to 30 V
Between SF1 (10) and
ground In any shift range other
Max. 1 V
than 2
In shift range 1 20 to 30 V
Between SF1 (11) and
ground In any shift range other
Max. 1 V
than 1
If wiring harness is normal and voltage in each selected range is below
standard value, power supply for gear shift lever or ground circuit is
defective.
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5 performed.)
controller
a For voltage between any pins of controller, see following codes.

HM400-3M0 40-419
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to gear shift lever

40-420 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DF10KB] Ground Fault of Shift Lever Input (HM300_3-DF10KB-400-A-Z0-A)

Action level Failure code Ground Fault of Shift Lever Input

Failure
L03 DF10KB (Transmission controller system)
Detail of • Gear shift lever signals have been input from more than 2 channels simultaneously
failure
• Controls the machine with the signal of highest priority.
(1): N > D > 5 > 4 > 3 > 2 > 1
Action of (2): N > R2 > R1
controller • Place the transmission in neutral when there are simultaneous signal inputs from
channels (1) and (2).
• Transmission may shift into higher gear speeds than the one selected by gear shift lever.
Problem on • Machine will stay neutral and will not start off.
machine • The illuminated gear shift lever position lamp does not match the position of the lever.
Related • Gear shift lever in N can be checked with monitoring function (02211).
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector SF1 and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between SF1 (female) (3) and ground Max. 1 V
Between SF1 (female) (4) and ground Max. 1 V
Hot short circuit in wiring Between SF1 (female) (5) and ground Max. 1 V
1 harness (Contact with 24 V Between SF1 (female) (6) and ground
circuit) Max. 1 V
Voltage Between SF1 (female) (7) and ground Max. 1 V
Between SF1 (female) (8) and ground Max. 1 V
Between SF1 (female) (9) and ground Max. 1 V
Between SF1 (female) (10) and ground Max. 1 V
Between SF1 (female) (11) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC1, ATC2, SF1, and connect T-adapters
to each female side.
a Check by using multimeter in continuity range.
Between ATC1 (female) (6) and each pin other No continuity
than pin (6) (No sound is heard.)
Between ATC2 (female) (5) and each pin other No continuity
than pin (5) (No sound is heard.)
Between ATC2 (female) (6) and each pin other No continuity
Short circuit in wiring harness than pin (6) (No sound is heard.)
2 (Short circuit between wiring
Between ATC2 (female) (15) and each pin No continuity
harnesses)
other than pin (15) (No sound is heard.)
Between ATC2 (female) (16) and each pin No continuity
other than pin (16) (No sound is heard.)
Between ATC2 (female) (25) and each pin No continuity
other than pin (25) (No sound is heard.)
Between ATC2 (female) (26) and each pin No continuity
other than pin (26) (No sound is heard.)
Between ATC2 (female) (35) and each pin No continuity
other than pin (35) (No sound is heard.)

HM400-3M0 40-421
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

Between ATC2 (female) (36) and each pin No continuity
other than pin (36) (No sound is heard.)
Between SF1 (female) (3) and each pin other No continuity
than pin (3) (No sound is heard.)
Between SF1 (female) (4) and each pin other No continuity
than pin (4) (No sound is heard.)
Between SF1 (female) (5) and each pin other No continuity
than pin (5) (No sound is heard.)
Between SF1 (female) (6) and each pin other No continuity
Short circuit in wiring harness than pin (6) (No sound is heard.)
2 (Short circuit between wiring
Between SF1 (female) (7) and each pin other No continuity
harnesses)
than pin (7) (No sound is heard.)
Between SF1 (female) (8) and each pin other No continuity
than pin (8) (No sound is heard.)
Between SF1 (female) (9) and each pin other No continuity
than pin (9) (No sound is heard.)
Between SF1 (female) (10) and each pin other No continuity
than pin (10) (No sound is heard.)
Between SF1 (female) (11) and each pin other No continuity
than pin (11) (No sound is heard.)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector SF1.
3. Turn starting switch to ON position.
4. Operate gear shift lever to perform troubleshooting.
In shift range R2 20 to 30 V
Between SF1 (3) and
ground In any shift range other
Max. 1 V
than R2
In shift range R1 20 to 30 V
Between SF1 (4) and
ground In any shift range other
Max. 1 V
than R1
In shift range N 20 to 30 V
Between SF1 (5) and
ground In any shift range other
Max. 1 V
than N
In shift range D 20 to 30 V
Between SF1 (6) and
ground In any shift range other
3 Defective gear shift lever Max. 1 V
than D
In shift range 5 20 to 30 V
Between SF1 (7) and
Voltage In any shift range other
ground Max. 1 V
than 5
In shift range 4 20 to 30 V
Between SF1 (8) and
ground In any shift range other
Max. 1 V
than 4
In shift range 3 20 to 30 V
Between SF1 (9) and
ground In any shift range other
Max. 1 V
than 3
In shift range 2 20 to 30 V
Between SF1 (10) and
ground In any shift range other
Max. 1 V
than 2
In shift range 1 20 to 30 V
Between SF1 (11) and
ground In any shift range other
Max. 1 V
than 1

40-422 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

If no failure is found in above checks, transmission controller is
defective.
a Reference
1.Turn starting switch to OFF position.
2.Insert T-adapters into connectors ATC1 and ATC2.
3.Turn starting switch to ON position.
4.Operate gear shift lever to perform troubleshooting.
In shift range R2 20 to 30 V
Between ATC2 (35)
and ground In any shift range other
Max. 1 V
than R2
In shift range R1 20 to 30 V
Between ATC2 (25)
and ground In any shift range other
Max. 1 V
than R1
In shift range N 20 to 30 V
Between ATC1 (6) and
ground In any shift range other
Max. 1 V
than N
Defective transmission In shift range D 20 to 30 V
4 Between ATC2 (15)
controller In any shift range other
and ground Max. 1 V
than D
In shift range 5 20 to 30 V
Between ATC2 (5) and
Voltage In any shift range other
ground Max. 1 V
than 5
In shift range 4 20 to 30 V
Between ATC2 (36)
and ground In any shift range other
Max. 1 V
than 4
In shift range 3 20 to 30 V
Between ATC2 (26)
and ground In any shift range other
Max. 1 V
than 3
In shift range 2 20 to 30 V
Between ATC2 (16)
and ground In any shift range other
Max. 1 V
than 2
In shift range 1 20 to 30 V
Between ATC2 (6) and
ground In any shift range other
Max. 1 V
than 1

HM400-3M0 40-423
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to gear shift lever

40-424 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor (HM300_3-DGF1KX-
400-A-Z0-A)

Action level Failure code Out of Range of Transmission Oil Temperature Sensor
Failure
L03 DGF1KX (Transmission controller system)
• The voltage of the signal circuit of the transmission oil temperature sensor is below 0.97 V
Detail of (above 150°C) or only transmission oil temperature is low (transmission oil temperature
failure sensor signal circuit voltage is above 4.56 V (below 15°C) and torque converter and brake
oil temperature sensor voltage is below 3.7 V (above 55°C).
Action of • Controls clutch oil pressure while recognizing oil temperature as fixed high temperature
controller
Problem on • Gear shift shocks will be larger
machine
• Can be checked with monitoring function (Code: 32500 (°C), 32501 (V)).
• After confirming that normal condition is recovered after repair work, perform the initial
learning of the transmission controller, referring to Testing and adjusting, "Setting and
Related adjusting of each equipment".
information k Tilt up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria, and remarks
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector T/M.T (CN24) and connect T-adapter to male
Defective transmission oil side.
1 temperature sensor Between Oil temperature: 25°C 37 to 50 kz *
T/M.T
Resis- (CN24)
tance (male) (1) Oil temperature: 100°C 3.5 to 4.0 kz *
and (2)
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC1 and connect T-adapter to female side.
Open or short circuit in wiring Between Oil temperature: 25°C 37 to 50 kz
2
harness ATC1
Resis- (female)
tance (3) and Oil temperature: 100°C 3.5 to 4.0 kz
(21)
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC1 and connect T-adapter to female side.
Open circuit in wiring harness 3. Tilt up cab (observe precautions mentioned above).
3 (wire breakage or defective 4. Disconnect connector T/M.T (CN24) and connect T-adapter to
contact of connector) female side.
Between ATC1 (female) (21) and T/M.T (CN24)
Max. 1 z
Resis- (female) (2)
tance Between ATC1 (female) (3) and T/M.T (CN24)
(female) (1) Max. 1 z

1. Turn starting switch to OFF position.

2. Lower tilted-up cab.
3. Disconnect connector ATC1 and connect T-adapter to female side.
Ground fault in wiring harness 4. Tilt up cab (observe precautions mentioned above).
4
(Contact with ground circuit) 5. Disconnect connector T/M.T (CN23) and connect T-adapter to
female side.
Resis- Between ground and ATC1 (female) (3) or T/M.
T (CN24) (female) (1) Min. 1 Mz
tance

HM400-3M0 40-425
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
Short circuit or hot short circuit
3. Tilt the cab when inserting T-adapter into T/M.T (CN24).
5 (Contact with 24 V circuit) in 4. Turn starting switch to ON position.
wiring harness
Between ground and ATC1 (3) or T/M.T (CN24)
Voltage Max. 4.5 V
(1)
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
6
controller performed).
*: See [DGR2KZ] for average sensor resistance at various temperatures (same as for retarder oil temperature
sensor).

Circuit diagram related to transmission oil temperature sensor

40-426 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DGR3KB] Ground Fault of Retarder Oil Temp. S.(C) (HM300_3-
DGR3KB-400-A-Z0-A)

Action level Failure code Ground Fault of Retarder Oil Temperature Sensor (Center).
Failure
L01 DGR3KB (Retarder hoist controller system)
Detail of • Voltage of retarder oil temperature sensor signal circuit drops below 0.97 V.
failure
Action of • None in particular
controller
Problem on • Oil temperature gauge is disabled depending on failure mode of sensor.
machine
• Input signal from retarder oil temperature sensor can be checked with monitoring function
Related (Code: 30215 (°C), 30212 (V)).
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector B05 and connect T-adapter to male side.
Center brake oil
temperature: 25°C 42.7 kz
Center brake oil
Defective retarder oil temperature: 30°C 35.13 kz
1 temperature sensor (center)
Resis- Between B05 (male) Center brake oil
(1) and (2) temperature: 80°C 6.556 kz
tance
Center brake oil
temperature: 90°C 4.925 kz
Center brake oil
temperature: 100°C 3.75 kz

1. Turn starting switch to OFF position.

Ground fault in wiring harness 2. Disconnect connector BRC1 and connect T-adapter to female side.
2
(Contact with ground circuit) Resis- Between BRC1 (female) (20) and ground
Min. 1 Mz
tance
Defective retarder hoist If no failure is found by above checks, retarder hoist controller is
3 controller (when system works defective. (Since this is an internal defect, troubleshooting cannot be
normally) performed.)
*: Sensor resistances at various temperatures are average figures and they may vary depending on sensor.

Electrical circuit diagram related to retarder oil temperature sensor (center)

HM400-3M0 40-427
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DGR3L8] Failure of Retarder Oil Temp. Sensor (C) (HM300_3-
DGR3L8-400-A-Z0-A)

Action level Failure code Failure of Retarder Oil Temperature Sensor (Center).
Failure
L01 DGR3L8 (Retarder hoist controller system)
Detail of • Signal circuit voltage of retarder oil temperature sensor (center) is above 4.721 V while
failure signal circuit voltage of retarder oil temperature sensor (front) is below 3.606 V.
Action of • None in particular.
controller
Problem on
• None
machine
• Signal from oil temperature sensor can be checked with monitoring function.
Related 1. Retarder oil temperature sensor (front) (Code: 30211 ( °C), 30214 (V))
information 2. Retarder oil temperature sensor (center) (Code: 30215 ( °C), 30212 (V))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1 and B05, and connect T-adapters to
each female side.
1 Open circuit in wiring harness Between BRC1 (female) (20) and B05 (female)
(1) Max. 1 z
Resis-
tance Between BRC1 (female) (21) and B05 (female)
(2) Max. 1 z

1. Turn starting switch to OFF position.

Hot short circuit in wiring 2. Insert T-adapters into connector BRC1 or B05.
2 harness 3. Turn starting switch to ON position.
(contact with 24 V circuit) Between BRC1 (20) and (21), or between B05
Voltage Max. 4.7 V
(female) (1) and (2)
1. Turn starting switch to OFF position.
2. Disconnect connector B05 and connect T-adapters to male side.
Center brake oil
B05 (male) temperature Resistance (kz)
Defective retarder oil ( °C )
3 temperature sensor (center) 25 42.7
30 35.13
Between (1) and (2) 80 6.556
90 4.925
100 3.75
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

Defective retarder oil temperature sensor (center)

40-428 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DGR4KB] Ground Fault of Retarder Oil Temp. S.(F) (HM300_3-
DGR4KB-400-A-Z0-A)

Action level Failure code Ground Fault of Retarder Oil Temperature Sensor (Front).
Failure
L01 DGR4KB (Retarder hoist controller system)
Detail of • Voltage of retarder oil temperature sensor signal circuit drops below 0.97 V.
failure
Action of • None in particular
controller
Problem on • Oil temperature gauge is disabled depending on failure mode of sensor.
machine
• Input signal from oil temperature sensor can be checked with monitoring function (Code:
Related 30211 (°C), 30214 (V)).
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector B06 and connect T-adapter to male side.
Front retarder oil
temperature: 25°C 42.7 kz
Front retarder oil
Defective retarder oil temperature: 30°C 35.13 kz
1 temperature sensor (front)
Resis- Between B06 Front retarder oil
6.556 kz
tance (male) (1) and (2) temperature: 80°C
Front retarder oil
temperature: 90°C 4.925 kz
Front retarder oil
temperature: 100°C 3.75 kz

1. Turn starting switch to OFF position.

Ground fault in wiring harness 2. Disconnect connector BRC1 and connect T-adapter to female side.
2
(Contact with ground circuit) Resis- Between BRC1 (female) (3) and ground
Min. 1 Mz
tance
Defective retarder hoist If no failure is found by above checks, retarder hoist controller is
3 controller (when system works defective. (Since this is an internal defect, troubleshooting cannot be
normally) performed.)
*: Sensor resistances at various temperatures are average figures and they may vary depending on sensor.

Circuit diagram related to retarder oil temperature sensor (front)

HM400-3M0 40-429
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DGR4L8] Failure of Retarder Oil Temp. Sensor (F) (HM300_3-
DGR4L8-400-A-Z0-A)

Action level Failure code Failure of Retarder Oil Temperature Sensor (Front).
Failure
L01 DGR4L8 (Retarder hoist controller system)
Detail of • Signal circuit voltage of retarder oil temperature sensor (front) is 4.721 V or above while
failure signal circuit voltage of retarder oil temperature sensor (center) is 3.606 V or lower.
Action of • None in particular
controller
Problem on • None in particular
machine
• Signal from oil temperature sensor can be checked with monitoring function.
Related 1. Retarder oil temperature sensor (front) (Code: 30211 (°C), 30214 (V))
information 2. Retarder oil temperature sensor (center) (Code: 30215 (°C), 30212 (V))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1 and B06, and connect T-adapters to
each female side.
1 Open circuit in wiring harness Between BRC1 (female) (3) and B06 (female)
Max. 1 z
Resis- (1)
tance Between BRC1 (female) (21) and B06 (female)
(2) Max. 1 z

1. Turn starting switch to OFF position.

Hot short circuit in wiring 2. Insert T-adapter into connector BRC1 or B06.
2 harness 3. Turn starting switch to ON position.
(Contact with 24 V circuit) Between BRC1 (3) and (21), or between B06
Voltage Max. 4.7 V
(female) (1) and (2)
1. Turn starting switch to OFF position.
2. Disconnect connector B06 and connect T-adapter to male side.
Front brake oil
temperature: 25°C 42.7 kz
Front brake oil
Defective retarder oil temperature: 30°C 35.13 kz
3 temperature sensor (front)
Resis- Between B06 (male) Front brake oil
(1) and (2) temperature: 80°C 6.556 kz
tance
Front brake oil
temperature: 90°C 4.925 kz
Front brake oil
temperature: 100°C 3.75 kz
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

40-430 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder oil temperature sensor (front)

HM400-3M0 40-431
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DGR6KB] Ground Fault of Steering Oil Temp. S. (HM300_3-DGR6KB-

400-A-Z0-A)

Action level Failure code Ground Fault of Steering Oil Temperature Sensor
Failure
L01 DGR6KB (Retarder hoist controller system)
Detail of • Voltage of steering oil temperature sensor signal circuit drops below 0.97 V.
failure
Action of • None in particular
controller
Problem on • Oil temperature gauge is disabled depending on failure mode of sensor.
machine
• Input signal from steering temperature sensor can be checked with monitoring function
Related (Code: 32701 (°C), 32702 (V)).
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector B11 and connect T-adapter to male side.
Steering oil
temperature: 25°C 42.7 kz
Steering oil
Defective steering oil temperature: 30°C 35.13 kz
1 temperature sensor Resis- Between B11 (male) Steering oil
(1) and (2) temperature: 80°C 6.556 kz
tance
Steering oil
temperature: 90°C 4.925 kz
Steering oil
temperature: 100°C 3.75 kz

1. Turn starting switch to OFF position.

Ground fault in wiring harness 2. Disconnect connector BRC1 and connect T-adapter to female side.
2
(Contact with ground circuit) Resis- Between BRC1 (female) (9) and ground
Min. 1 Mz
tance
Defective retarder hoist If no failure is found by above checks, retarder hoist controller is
3 controller (when system works defective. (Since this is an internal defect, troubleshooting cannot be
normally) performed.)
*: Sensor resistances at various temperatures are average figures and they may vary depending on sensor.

Circuit diagram related to steering oil temperature sensor

40-432 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DGR6L8] Failure of Steering Oil Temp. Sensor (HM300_3-DGR6L8-400-A-

Z0-A)

Action level Failure code Failure of Steering Oil Temperature Sensor

Failure
L01 DGR6L8 (Retarder hoist controller system)
• Steering oil temperature sensor signal voltage above 4.56 V, torque converter oil
Detail of temperature above 55°C, retarder oil temperature sensor (front) signal voltage below 3.7
failure V, and retarder oil temperature sensor (center) signal voltage below 3.7 V
Action of • None in particular
controller
Problem on • None in particular
machine
• Signal from oil temperature sensor can be checked with monitoring function.
1. Steering oil temperature sensor (Codes: 32701 (°C) and 32702 (V))
Related 2. Torque converter oil temperature sensor (Codes: 30100 (°C) and 32101 (V))
information 3. Retarder oil temperature sensor (front) (Code: 30211 (°C), 30214 (V))
4. Retarder oil temperature sensor (center) (Code: 30215 (°C), 30212 (V))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1 and B11, and connect T-adapters to
each female side.
1 Open circuit in wiring harness Between BRC1 (female) (9) and B11 (female)
Max. 1 z
Resis- (1)
tance Between BRC1 (female) (4) and B11 (female)
(2) Max. 1 z

1. Turn starting switch to OFF position.

Hot short circuit in wiring 2. Insert T-adapter into connector BRC1 or B11.
2 harness 3. Turn starting switch to ON position.
(Contact with 24 V circuit) Between BRC1 (9) and (4), or between B11
Voltage Max. 4.7 V
(female) (1) and (2)
1. Turn starting switch to OFF position.
2. Disconnect connector B11 and connect T-adapter to male side.
Steering oil
temperature: 25°C 42.7 kz
Steering oil
Defective steering oil temperature: 30°C 35.13 kz
3 temperature sensor
Resis- Between B11 (male) Steering oil
(1) and (2) temperature: 80°C 6.556 kz
tance
Steering oil
temperature: 90°C 4.925 kz
Steering oil
temperature: 100°C 3.75 kz
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

HM400-3M0 40-433
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to steering oil temperature sensor

40-434 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DGR7KX] Out of Range of Piston Pump Oil Temp. S. (HM400_3-
DGR7KX-400-A-Z0-A)

Action level Failure code Out of Range of Piston Pump Oil Temperature Sensor.
Failure
L01 DGR7KX (Transmission controller system)
• When steering oil temperature sensor is normal and indicates a temperature of 20°C or
below, piston pump oil temperature sensor signal circuit voltage is 0.352 V (temperature
Detail of 100°C or above).
failure • When steering oil temperature sensor is normal and indicates a temperature of 20°C or
above, piston pump oil temperature sensor signal circuit voltage is 4.449 V (temperature
–30°C or below).
Action of • Steering oil temperature and piston pump oil temperature are used as operating threshold
controller value of pump protection function at low temperatures.
Problem on • Pump protection function at low temperatures may not operate normally, resulting in
machine pump damage.
Related • Can be checked with monitoring function (Code: 46400 (°C), 46401 (V)).
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector PPOT and connect T-adapter to male side.
PPOT (male) Oil temperature Resistance (kz)
Defective piston pump oil
1 temperature sensor 25°C 4.18
30°C 3.461
Between (1) and (2)
40°C 2.41
50°C 1.712
1. Turn starting switch to OFF position.
2. Disconnect connector ATC1 and connect T-adapter to female side.
Open circuit or short circuit in Between Oil temperature: 25°C 3.7 to 4.6 kz
2 wiring harness ATC1
Resis- (female)
tance (20) and Oil temperature: 50°C 1.5 to 1.9 kz
(21)
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connector ATC1 and connect T-adapter to female side.
3 (wire breakage or defective 3. Disconnect connector PPOT and connect T-adapter to female side.
contact of connector) Between ATC1 (female) (21) and PPOT
Max. 1 z
Resis- (female) (2)
tance Between ATC1 (female) (20) and PPOT
(female) (1) Max. 1 z

1. Turn starting switch to OFF position.

Short circuit in wiring harness 2. Disconnect connector ATC1 and connect T-adapter to female side.
4 3. Disconnect connector PPOT and connect T-adapter to female side.
(Contact with ground circuit)
Resis- Between ground and ATC1 (female) (20) or
PPOT (female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
Open circuit or hot short 2. Insert T-adapter into connector ATC1.
5 circuit in wiring harness 3. Insert T-adapter into connector PPOT.
(Contact with 24 V circuit) 4. Turn starting switch to ON position.
Voltage Between ground and ATC1 (20) or PPOT (1) Max. 4.5 V
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
6
controller performed).
*: Sensor resistance at various temperatures are only the average figures and they may vary.

HM400-3M0 40-435
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to piston pump oil pressure sensor

40-436 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DGR8KX] Out of Range of CAC Output Temp. S. (HM400_3R-DGR8KX-

400-A-Z0-A)

Action level Failure code Out of Range of Charge Air Cooler Output Temperature Sensor
Failure
L01 DGR8KX (Transmission controller system)
• The signal voltage of aftercooler (CAC) outlet temperature sensor circuit is 0.97 V or
Detail of lower, or the aftercooler (CAC) outlet temperature is low (signal voltage of aftercooler
failure (CAC) outlet temperature sensor circuit is 4.56 V or more.)
Action of • Fixes outlet temperature of aftercooler (CAC) to set pressure in controller and continues
controller control.
Problem on • Machine is not affected in particular
machine
• Temperature sensed by CAC outlet temperature sensor can be checked with monitoring
function. (Code: 46600 (°C), 46601 (V))
• After confirming that normal condition is recovered after repair work, perform the initial
learning of the transmission controller, referring to Testing and adjusting, "Setting and
Related adjusting of each equipment".
information k When making an access to intermediate connector, tilt up cab, fix it securely by
using lock bar, and check that lock lever is set to CLOSE position (see Testing and
adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector T18, and connect T-adapter to male side.
–30°C 45 to 57 kz
–10°C 16 to 21 kz
0°C 10 to 13 kz
4.6 to 5.5
20°C
Defective CAC outlet kz
1 temperature sensor Between T18 (male) (A) and (B) 2.2 to 2.6
Resistance 40°C
kz
1.1 to 1.4
60°C
kz
600 to 750
80°C
z
Whole
Between T18 (male) (A) and ground Min. 1 Mz
range
1. Turn starting switch to OFF position.
2. Disconnect connector ATC1 and connect T-adapter to female side.
Open or short circuit in
2 wiring harness a Resistance accords with the value measured in cause 1.
600 z to
Resistance Between ATC1 (female) (14) and (21)
70 kz

Open circuit in wiring a If no failure is found by check on cause 2, this check is not required.
harness 1. Turn starting switch to OFF position.
3 (Wire breakage or 2. Disconnect connectors ATC1 and T18, and connect T-adapters to each
defective contact of female side.
connector) Between ATC1 (female) (21) and T18 (female) (2) Max. 1 z
Resistance
Between ATC1 (female) (14) and T18 (female) (1) Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors ATC1 and T18, and connect T-adapters to each
harness female side.
4
(Contact with ground Between ground and ATC1 (female) (14) or T18
circuit) Min. 1 Mz
Resistance (female) (1)

HM400-3M0 40-437
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

1. Turn starting switch to OFF position.
Short circuit or hot short 2. Insert T-adapter into connector T18 or ATC1.
5 circuit in wiring harness 3. Turn starting switch to ON position.
Voltage Between ground and ATC1 (14) or T18 (1) Max. 4.5 V
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
6
controller performed.)

Circuit diagram related to CAC outlet temperature sensor

40-438 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor (HM300_3-DGT1KX-
400-A-Z0-A)

Action level Failure code Out of Range of Torque Converter Oil Temperature Sensor
Failure
E01 DGT1KX (Transmission controller system)
• Signal circuit voltage of torque converter oil temperature sensor is below 0.97 V (rose
Detail of above 150 °C ). Or when signal circuit voltage of transmission oil temperature sensor is
failure normal (below 3.7 V (above 55 °C )), signal circuit voltage of torque converter oil
temperature sensor is above 4.56 V (below 15 °C ).
Action of • None in particular
controller
Problem on • Torque converter oil temperature gauge does not read correctly.
machine

k Tilt the cab up and secure it in place with lock bar. Ensure that lock lever is in the
CLOSED position. (See Testing and adjusting, "Method of tilting cab up".
Related
information • Signal from torque converter oil temperature sensor can be checked with monitoring
function (Code: 30100 ( °C ), 30101 (V)).
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt the cab up (as explained above).
2. Turn starting switch to OFF position.
3. Disconnect connector T/C.T (CN23) and connect T-adapter to male
Defective torque converter oil side.
1 temperature sensor Between Oil temperature: 25 °C 37 to 50 kz *
T/C.T
Resis- (CN23)
tance Oil temperature: 100 °
(male) (1) C 3.5 to 4.0 kz *
and (2)
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC1 and connect T-adapter to female side.
Open or short circuit in wiring
2 Between Oil temperature: 25 °C 37 to 50 kz
harness
Resis- ATC1
tance (female) Oil temperature: 100 °
3.5 to 4.0 kz
(9) to (21) C
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC1 and connect T-adapter to female side.
Open circuit in wiring harness 3. Tilt the cab up (as explained above).
3 (wire breakage or defective 4. Disconnect connector T/M.T (CN23) and connect T-adapter to
contact of connector) female side.
Between ATC1 (female) (21) and T/C.T (CN23)
(female) (2) Max. 1 z
Resis-
tance Between ATC1 (female) (9) and T/C.T (CN23)
(female) (1) Max. 1 z

1. Lower tilted-up cab.

2. Turn starting switch to OFF position.
3. Disconnect connector ATC1 and connect T-adapter to female side.
Ground fault in wiring 4. Tilt the cab up (as explained above).
4
harness 5. Disconnect connector T/M.T (CN23) and connect T-adapter to
female side.
Resis- Between ground and ATC1 (female) (9) or T/C. Min. 1 Mz
tance T (CN23) (female) (1)

HM400-3M0 40-439
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Insert T-adapter into connector ATC1.
Short circuit or hot short
5 4. Tilt cab up when inserting T-adapter into connector T/M.T (CN23).
circuit in wiring harness
5. Turn starting switch to ON position.
Between ATC1 (9) and (21) or between T/C.T
Voltage Max. 1V
(CN23) (1) and (2)
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
6
controller performed.)
*: See troubleshooting of [DGR2KZ] for average sensor resistance by temperature (same as for retarder oil
temperature sensor).

Circuit diagram related to torque converter oil temperature sensor

40-440 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHP4KY] Hot Short of Suspension Press. S. (FR) (HM400_3R-

DHP4KY-400-A-Z0-A)

Action level Failure code Hot Short of Suspension Pressure Sensor (FR)
Failure
L01 DHP4KY (Payload meter controller system) (Display: PLM)
Detail of • Abnormal current flows through signal circuit from suspension pressure sensor (front
failure right).
Action of • None in particular
controller
Problem on • PLM cannot be displayed correctly.
machine
Related • Suspension pressure can be checked with monitoring function. (Code: 32804 (MPa),
information 32810 (V))
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector SUFR.
3. Insert T-adapter into connector HM2B, or connect T-adapter to female side
Hot short circuit in of SUFR.
1 wiring harness 4. Turn starting switch to ON position.
a Ignore displayed failure codes.
Between ground and HM2B (1) or SUFR (female)
Voltage Max. 1 V
(C)
1. Turn starting switch to OFF position.
2. Disconnect connector SUFR and connect T-adapter to female side.
3. Turn starting switch to ON position.
Defective sensor power
2 supply system a Ignore displayed failure codes.
Power
supply Between SUFR (female) (B) and (A) Approx. 24
voltage V

1. Turn starting switch to OFF position.

2. Disconnect connector SUFR.
Defective suspension
3 3. Turn starting switch to ON position.
pressure sensor (FR)
If failure code changes from [DHP4KY] to [DHP4KZ], suspension pressure
sensor (FR) is defective.
If no failure is found by above checks, payload meter controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
a Reference
Defective payload 1. Turn starting switch to OFF position.
4
meter controller 2. Insert T-adapters into connectors HM1 and HM2B.
3. Turn starting switch to ON position.
Between HM1 (2) and HM2B (9) Approx. 24
Voltage V
Between HM2B (1) and (9) 1.0 to 5 V

HM400-3M0 40-441
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to suspension pressure sensor

40-442 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHP4KZ] Failure of Suspension Press. S. (FR) (HM400_3R-DHP4KZ-400-

A-Z0-A)

Action level Failure code Failure of Suspension Pressure Sensor (FR)

Failure
L01 DHP4KZ (Payload meter controller system) (Display: PLM)
Detail of • Signal is not sent from suspension pressure sensor (front right) or is grounded
failure (abnormal).
Action of • None in particular
controller
Problem on • PLM cannot be displayed correctly.
machine
Related • Suspension pressure can be checked with monitoring function. (Code: 32804 (MPa),
information 32810 (V))
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors SUFR, HM1, and HM2B, and connect T-adapter to
any of female side.
Ground fault in wiring
1 Between ground and HM2B (female) (1) or SUFR
harness Min. 1 Mz
(female) (C)
Resistance
Between ground and HM1 (female) (2) or SUFR
(female) (B) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connector SUFR and connect T-adapter to female side.
3. Turn starting switch to ON position.
Defective sensor power
2 supply system a If power supply voltage is abnormal, go to check on cause 4.
Power
supply Between SUFR (female) (B) and (A) Approx. 24
voltage V

1. Turn starting switch to OFF position.

Defective suspension 2. Insert T-adapter into connector SUFR.
3 pressure sensor (FR) 3. Turn starting switch to ON position.
Voltage Between SUFR (C) and (A) 1.0 to 5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors SUFR, HM1, and HM2B, and connect T-adapters
to female side of each connector.
Between HM2B (female) (1) and SUFR (female)
(C) Max. 1 z
Open circuit in wiring
harness (wire breakage
4 or defective contact of a If power supply voltage in check on cause 2 is
normal, this check is not required. Max. 1 z
connector) Resistance Between HM2B (female) (9) and SUFR (female) (A)

a If power supply voltage in check on cause 2 is

normal, this check is not required. Max. 1 z
Between HM (female) (2) and SUFR (female) (B)
If no failure is found by above checks, payload meter controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
a Reference
Defective payload 1. Turn starting switch to OFF position.
5
meter controller 2. Insert T-adapters into connectors HM1 and HM2B.
3. Turn starting switch to ON position.
Between HM1 (2) and HM2B (9) Approx. 24
Voltage V
Between HM2B (1) and (9) 1.0 to 5 V

HM400-3M0 40-443
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to suspension pressure sensor

40-444 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHP5KY] Hot Short of Suspension Press. S. (FL) (HM400_3R-

DHP5KY-400-A-Z0-A)

Action level Failure code Hot Short of Suspension Pressure Sensor (FL)
Failure
L01 DHP5KY (Payload meter controller system) (Display: PLM)
Detail of • Abnormal current flows through signal circuit from suspension pressure sensor (front left).
failure
Action of • None in particular
controller
Problem on • PLM cannot be displayed correctly.
machine
Related • Suspension pressure can be checked with monitoring function. (Code: 32805 (MPa),
information 32811 (V))
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector SUFL.
3. Insert T-adapter into connector HM2B, or connect T-adapter to female side
Hot short circuit in of SUFL.
1 wiring harness 4. Turn starting switch to ON position.
a Ignore displayed failure codes.
Between ground and HM2B (2) or SUFL (female)
Voltage Max. 1 V
(C)
1. Turn starting switch to OFF position.
2. Disconnect connector SUFL and connect T-adapter to female side.
3. Turn starting switch to ON position.
Defective sensor power
2 supply system a Ignore displayed failure codes.
Power
supply Between SUFL (female) (B) and (A) Approx. 24
voltage V

1. Turn starting switch to OFF position.

Defective suspension
3 3. Turn starting switch to ON position.
pressure sensor (FL)
Defective payload
4
meter controller
2. Disconnect connector SUFL.
If failure code changes from [DHP5KY] to [DHP5KZ], suspension pressure
sensor (FL) is defective.
If no failure is found by above checks, payload meter controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
a Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors HM1 and HM2B.
3. Turn starting switch to ON position.
Between HM1 (2) and HM2B (9) Approx. 24
Voltage V
Between HM2B (2) and (9) 1.0 to 5 V

HM400-3M0 40-445
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to suspension pressure sensor

40-446 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHP5KZ] Failure of Suspension Press. S. (FL) (HM400_3R-DHP5KZ-400-

A-Z0-A)

Action level Failure code Failure of Suspension Pressure Sensor (FL)

Failure
L01 DHP5KZ (Payload meter controller system) (Display: PLM)
Detail of • Signal is not sent from suspension pressure sensor (front right) or is grounded
failure (abnormal).
Action of • None in particular
controller
Problem on • PLM cannot be displayed correctly.
machine
Related • Suspension pressure can be checked with monitoring function. (Code: 32805 (MPa),
information 32811 (V))
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors SUFL, HM1, and HM2B, and connect T-adapter to
any of female side.
Ground fault in wiring
1 Between ground and HM2B (female) (2) or SUFL
harness Min. 1 Mz
(female) (C)
Resistance
Between ground and HM1 (female) (2) or SUFL
(female) (B) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connector SUFL and connect T-adapter to female side.
3. Turn starting switch to ON position.
Defective sensor power
2 supply system a If power supply voltage is abnormal, go to check on cause 4.
Power
supply Between SUFL (female) (B) and (A) Approx. 24
voltage V

1. Turn starting switch to OFF position.

2. Insert T-adapter into connector SUFL.
Defective suspension 3. Turn starting switch to ON position.
3 pressure sensor (FL) Sensor
output Between SUFL (C) and (A) 1.0 to 5 V
voltage
1. Turn starting switch to OFF position.
2. Disconnect connectors SUFL, HM1, and HM2B, and connect T-adapters
to female side of each connector.
Between HM2B (female) (2) and SUFL (female) (C) Max. 1 z
Open circuit in wiring
harness (wire breakage a If power supply voltage in check on cause 2 is
4 or defective contact of Max. 1 z
normal, this check is not required.
connector) Resistance Between HM2B (female) (9) and SUFL (female) (A)
a If power supply voltage in check on cause 2 is
normal, this check is not required. Max. 1 z
Between HM1 (female) (2) and SUFL (female) (B)
If no failure is found by above checks, payload meter controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
a Reference
Defective payload 1. Turn starting switch to OFF position.
5
meter controller 2. Insert T-adapters into connectors HM1 and HM2B.
3. Turn starting switch to ON position.
Between HM1 (2) and HM2B (9) Approx. 24
Voltage V
Between HM2B (2) and (9) 1.0 to 5 V

HM400-3M0 40-447
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to suspension pressure sensor

40-448 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHP6KY] Hot Short of Suspension Press. S. (RR) (HM400_3R-

DHP6KY-400-A-Z0-A)

Action level Failure code Hot Short of Suspension Pressure Sensor (RR)
Failure
L01 DHP6KY (Payload meter controller system) (Display: PLM)
Detail of • Abnormal current flows through signal circuit from suspension pressure sensor (rear
failure right).
Action of • None in particular
controller
Problem on • PLM cannot be displayed correctly.
machine
Related • Suspension pressure can be checked with monitoring function. (Code: 32806 (MPa),
information 32812 (V))
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector SURR.
3. Insert T-adapter into connector HM2B, or connect T-adapter to female side
Hot short circuit in of SURR.
1 wiring harness 4. Turn starting switch to ON position.
a Ignore displayed failure codes.
Between ground and HM2B (7) or SURR (female)
Voltage Max. 1 V
(C)
1. Turn starting switch to OFF position.
2. Disconnect connector SURR and connect T-adapter to female side.
3. Turn starting switch to ON position.
Defective sensor power
2 supply system a Ignore displayed failure codes.
Power
supply Between SURR (female) (B) and (A) Approx. 24
voltage V

1. Turn starting switch to OFF position.

2. Disconnect connector SURR.
Defective suspension
3 3. Turn starting switch to ON position.
pressure sensor (RR)
If failure code changes from [DHP6KY] to [DHP6KZ], suspension pressure
sensor (RR) is defective.
If no failure is found by above checks, payload meter controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
Defective payload a Reference
4
meter controller 1. Turn starting switch to OFF position.
2. Insert T-adapter into connector HM2B.
3. Turn starting switch to ON position.
Voltage Between HM2B (7) and (9) 1.0 to 5 V

HM400-3M0 40-449
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to suspension pressure sensor

40-450 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHP6KZ] Failure of Suspension Press. S. (RR) (HM400_3R-DHP6KZ-

400-A-Z0-A)

Action level Failure code Failure of Suspension Pressure Sensor (RR)

Failure
L01 DHP6KZ (Payload meter controller system) (Display: PLM)
Detail of • Signal is not sent from suspension pressure sensor (rear right) or is grounded (abnormal).
failure
Action of • None in particular
controller
Problem on • PLM cannot be displayed correctly.
machine
Related • Suspension pressure can be checked with monitoring function. (Code: 32806 (MPa),
information 32812 (V))
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors SURR, HM1, and HM2B, and connect T-adapter to
any of female side.
Ground fault in wiring
1 Between ground and HM2B (female) (7) or SURR
harness Min. 1 Mz
(female) (C)
Resistance
Between ground and HM1 (female) (2) or SURR
(female) (B) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connector SURR and connect T-adapter to female side.
Defective sensor power 3. Turn starting switch to ON position.
2 supply system Power
supply Between SURR (female) (B) and (A) Approx. 24
voltage V

1. Turn starting switch to OFF position.

2. Insert T-adapter into connector SURR.
Defective suspension 3. Turn starting switch to ON position.
3 pressure sensor (RR)
a If power supply voltage is abnormal, go to check on cause 4.
Voltage Between SURR (C) and (A) 1.0 to 5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors SURR, HM1, and HM2B, and connect T-adapters
to female side of each connector.
Between HM2B (female) (7) and SURR (female)
(C) Max. 1 z
Open circuit in wiring
harness (wire breakage a If power supply voltage in check on cause 2 is
4 or defective contact of normal, this check is not required. Max. 1 z
connector) Resistance Between HM2B (female) (9) and SURR (female)
(A)
a If power supply voltage in check on cause 2 is
normal, this check is not required. Max. 1 z
Between HM1 (female) (2) and SURR (female) (B)
If no failure is found by above checks, payload meter controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
Defective payload a Reference
5
meter controller 1. Turn starting switch to OFF position.
2. Insert T-adapter into connector HM2B.
3. Turn starting switch to ON position.
Voltage Between HM2B (7) and (9) 1.0 to 5 V

HM400-3M0 40-451
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to suspension pressure sensor

40-452 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHP7KY] Hot Short of Suspension Press. S. (RL) (HM400_3R-

DHP7KY-400-A-Z0-A)

Action level Failure code Hot Short of Suspension Pressure Sensor (RL)
Failure
L01 DHP7KY (Payload meter controller system) (Display: PLM)
Detail of • Abnormal current flows through signal circuit from suspension pressure sensor (rear left).
failure
Action of • None in particular
controller
Problem on • PLM cannot be displayed correctly.
machine
Related • Suspension pressure can be checked with monitoring function. (Code: 32807 (MPa),
information 32813 (V))
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector SURL.
3. Insert T-adapter into connector HM2B, or connect T-adapter to female side
Hot short circuit in of SURL.
1 wiring harness 4. Turn starting switch to ON position.
a Ignore displayed failure codes.
Between ground and HM2B (8) or SURL (female)
Voltage Max. 1 V
(C)
1. Turn starting switch to OFF position.
2. Disconnect connector SURL and connect T-adapter to female side.
3. Turn starting switch to ON position.
Defective sensor power
2 supply system a Ignore displayed failure codes.
Power
supply Between SURL (female) (B) and (A) Approx. 24
voltage V

1. Turn starting switch to OFF position.

Defective suspension
3 3. Turn starting switch to ON position.
pressure sensor (RL)
Defective payload
4
meter controller
2. Disconnect connector SURL.
If failure code changes from [DHP7KY] to [DHP7KZ], suspension pressure
sensor (RL) is defective.
If no failure is found by above checks, payload meter controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
a Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector HM2B.
3. Turn starting switch to ON position.
Voltage Between HM2B (8) and (9) 1.0 to 5 V

HM400-3M0 40-453
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to suspension pressure sensor

40-454 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHP7KZ] Failure of Suspension Press. S. (RL) (HM400_3R-DHP7KZ-400-

A-Z0-A)

Action level Failure code Failure of Suspension Pressure Sensor (RL)

Failure
L01 DHP7KZ (Payload meter controller system) (Display: PLM)
Detail of • Signal is not sent from suspension pressure sensor (rear left) or is grounded (abnormal).
failure
Action of • None in particular
controller
Problem on • PLM cannot be displayed correctly.
machine
Related • Suspension pressure can be checked with monitoring function. (Code: 32807 (MPa),
information 32813 (V))
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors SURL, HM1, and HM2B, and connect T-adapter to
any of female side.
Ground fault in wiring
1 Between ground and HM2B (female) (8) or SURL
harness Min. 1 Mz
(female) (C)
Resistance
Between ground and HM1 (female) (2) or SURL
(female) (B) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connector SURL and connect T-adapter to female side.
3. Turn starting switch to ON position.
Defective sensor power
2 supply system a If power supply voltage is abnormal, go to check on cause 4.
Power
supply Between SURL (female) (B) and (A) Approx. 24
voltage V

1. Turn starting switch to OFF position.

2. Insert T-adapter into connector SURL.
Defective suspension 3. Turn starting switch to ON position.
3 pressure sensor (RL) Sensor
output Between SURL (C) and (A) 1.0 to 5 V
voltage
1. Turn starting switch to OFF position.
2. Disconnect connectors SURL, HM1, and HM2B, and connect T-adapters
to female side of each connector.
Between HM2B (female) (8) and SURL (female) (C) Max. 1 z
Open circuit in wiring
harness (wire breakage a If power supply voltage in check on cause 2 is
4 or defective contact of Max. 1 z
normal, this check is not required.
connector) Resistance Between HM2B (female) (9) and SURL (female) (A)
a If power supply voltage in check on cause 2 is
normal, this check is not required. Max. 1 z
Between HM1 (female) (2) and SURL (female) (B)
If no failure is found by above checks, payload meter controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
Defective payload a Reference
5
meter controller 1. Turn starting switch to OFF position.
2. Insert T-adapter into connector HM2B.
3. Turn starting switch to ON position.
Voltage Between HM2B (8) and (9) 1.0 to 5 V

HM400-3M0 40-455
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to suspension pressure sensor

40-456 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHQ2KX] Out of Range of Main Flow Sel. Valve S. (HM300_3-
DHQ2KX-400-A-Z0-A)

Action level Failure code Out of Range of Main Flow Selector Valve Sensor
Failure
L01 DHQ2KX (Transmission controller system)
Detail of • Voltage of signal circuit of main flow selector solenoid operating pressure sensor drops
failure below 0.3 V or increases above 4.7 V.
Action of • Stops driving main flow selector valve.
controller
Problem on • Main flow selector solenoid does not function and fuel consumption may lower.
machine

k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
Related CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
information
• Can be checked with monitoring function (Code: 77000 (MPa), 77001 (V)).
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector ATC1.
Ground fault in wiring harness 3. Tilt up cab and fix it by using lock bar.
1 4. Disconnect connector V.P (CN26) and connect T-adapter to female
(Contact with ground circuit) side.
Resis- Between V.P (CN26) (female) (B) and ground Min. 1 Mz
tance Between V.P (CN26) (female) (C) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Tilt up cab and fix it by using lock bar.
3. Disconnect connector V.P (CN26) and connect T-adapter to female
2 harness side.
(Contact with 24 V circuit) 4. Turn starting switch to ON position.
Voltage Between V.P (CN26) (female) (B) and (A) Max. 1 V
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
3. Disconnect connector V.P (CN26) and connect T-adapter to female
side.
Defective sensor power supply 4. Turn starting switch to ON position.
3 system
a If power supply voltage is abnormal, go to check on cause 5.
Power
supply Between V.P (CN26) (female) (C) and (A) Approx. 5
voltage V

1. Turn starting switch to OFF position.

2. Tilt up cab and fix it by using lock bar.
Defective pilot pressure sensor 3. Insert T-adapter into connector V.P (CN26).
4
of main flow selector solenoid 4. Turn starting switch to ON position.
Voltage Between V.P (CN26) (B) and (A) 0.4 to 3.0
V

HM400-3M0 40-457
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
3. Disconnect connector ATC1 and connect T-adapter to female side.
4. Tilt up cab and fix it by using lock bar.
5. Turn starting switch to ON position.
a If power supply voltage is normal, this check
Open circuit in wiring harness is not required. Max. 1 z
5 (wire breakage or defective Between ATC1 (female) (22) and V.P (CN26)
contact of connector) (female) (C)
Resis-
a If power supply voltage is normal, this check
tance
is not required. Max. 1 z
Between ATC1 (female) (21) and V.P (CN26)
(female) (A)
Between ATC1 (female) (13) and V.P (CN26)
(female) (B) Max. 1 z
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
6
controller performed).

Circuit diagram related to pilot pressure sensor of main flow selector valve

40-458 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor (HM300_3-
DHT5KX-400-A-Z0-A)

Action level Failure code Out of Range of Torque Converter Input Pressure Sensor
Failure
L01 DHT5KX (Transmission controller system)
• Voltage of signal circuit of torque converter oil pressure sensor drops below 0.5 V or
Detail of failure
increases above 4.5 V.
Action of • Fixes torque converter oil pressure to set pressure in controller and continues control.
controller
Problem on • Large shocks are made when torque converter lockup clutch is engaged.
machine

k Tilt
up cab, fix it securely by using lock bar, and check that lock lever is set to
Related CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
information
• Can be checked with monitoring function (Code: 32600 (MPa), 32605 (V)).
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector ATC1 and connect T-adapter to female side.
3. Tilt up cab (observe precautions mentioned above).
4. Disconnect connector T/C.P (CN22) and connect T-adapter to
1 Ground fault in wiring harness female side.
Between ground and ATC1 (female) (16) or T/
Min. 1 Mz
Resis- C.P (CN22) (female) (B)
tance Between ground and ATC1 (female) (1) or T/C.
P (CN22) (female) (C) Min. 1 Mz

1. Tilt up cab (observe precautions mentioned above).

2. Turn starting switch to OFF position.
3. Disconnect connector T/C.P (CN22) and connect T-adapter to
Hot short circuit in wiring female side.
2
harness 4. Turn starting switch to ON position.
Between T/C.P (CN22) (female) (C) and
Voltage Max. 1 V
ground
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector T/C.P (CN22) and connect T-adapter to
female side.
Defective sensor power supply 4. Turn starting switch to ON position.
3 system
a If power supply voltage is abnormal, go to check on cause 5.
Power
supply Between T/C.P (CN22) (female) (B) and (A) 20 to 30 V
voltage
1. Tilt up cab (observe precautions mentioned above).
2. Turn starting switch to OFF position.
3. Insert T-adapter into connector T/C.P (CN22).
Defective torque converter oil
4 pressure sensor 4. Turn starting switch to ON position.
Sensor
output Between T/C.P (CN22) (C) and (A) 0.8 to 2.0
voltage V

HM400-3M0 40-459
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC1 and connect T-adapter to female side.
4. Tilt up cab (observe precautions mentioned above).
5. Disconnect connector T/C.P (CN22) and connect T-adapter to
female side.

Open circuit in wiring harness a If power supply voltage is normal, this check
is not required. Max. 1 z
5 (wire breakage or defective Between ATC1 (female) (16) and T/C.P (CN22)
contact of connector) (female) (B)
Resis-
a If power supply voltage is normal, this check
tance
is not required. Max. 1 z
Between ATC1 (female) (21) and T/C.P (CN22)
(female) (A)
Between ATC1 (female) (1) and T/C.P (CN22)
(female) (C) Max. 1 z
If no failure is found by above checks, transmission controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
a Reference
Defective transmission 1. Lower tilted-up cab.
6 2. Turn starting switch to OFF position.
controller
3. Insert T-adapter into connector ATC1.
4. Turn starting switch to ON position.
Between ATC1 (16) and (21) 20 to 30 V
Voltage 0.8 to 2.0
Between ATC1 (1) and (21)
V

Circuit diagram related to torque converter oil temperature sensor

40-460 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHT5L6] Failure of T/C Oil Press Sensor (HM300_3-DHT5L6-400-A-Z0-A)

Action level Failure code Failure of Torque Converter Oil Pressure Sensor
Failure
L01 DHT5KX (Transmission controller system)
• After engine is stopped, transmission controller receives signal voltage from torque
Detail of converter oil pressure sensor and determines that torque converter oil is at some
failure pressure. (Even after engine is stopped, signal voltage from torque converter oil pressure
sensor does not drop.)
Action of • Controls machine taking it that torque converter oil pressure is at set pressure stored in
controller controller.
Problem on • Excessive shock is made when lockup clutch engages.
machine

k Tilt the cab up and secure it in place with lock bar. Ensure that lock lever is in the
CLOSED position. (See Testing and adjusting, "Method of tilting cab up".
Related
information • Signal voltage from torque converter oil pressure sensor can be checked with monitoring
function (Code: 32601 (MPa), 32600 (V)).
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt the cab up (as explained above).
3. Insert T-adapter into connector ATC1.
4. Disconnect connector T/C.P (CN22) and connect T-adapter to
Hot short circuit in wiring female side.
1 5. Turn starting switch to ON position.
harness
a Ignore failure code that is displayed due to disconnection of
connector.
Between ground and ATC1 (1) or T/C.P (CN22)
Voltage Max. 1 V
(female) (C)
1. Turn starting switch to OFF position.
2. Tilt the cab up (as explained above).
3. Disconnect connector T/C.P (CN22).
4. Turn starting switch to ON position.
Defective torque converter oil a Ignore failure code [DHT5KX] that is displayed due to disconnection
2 pressure sensor of connector.
If failure code [DHT5L6] is no longer displayed, torque converter oil
pressure sensor is defective.
a If failure code [DHT5L6] is still displayed, wiring harness or
transmission controller is defective.
If no failure is found by above checks, transmission controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
a Reference
Defective transmission 1. Lower tilted-up cab.
3 2. Turn starting switch to OFF position.
controller
3. Disconnect connector ATC1.
4. Turn starting switch to ON position.
Between ATC1 (16) and (21) 20 to 30 V
Voltage 0.8 to 2.0
Between ATC1 (1) and (21)
V

HM400-3M0 40-461
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to torque converter oil pressure sensor

40-462 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHT8KX] Out of Range of Steering Oil Press. S. (HM400_3-DHT8KX-

400-A-Z0-A)

Action level Failure code Out of Range of Steering Oil Pressure Sensor
Failure
L01 DHT8KX (Retarder hoist controller system)
Detail of • Voltage of signal circuit of steering oil pressure sensor drops below 0.3 V or increases
failure above 4.42 V.
Action of • Stops auto emergency steering control.
controller
• Auto emergency steering system does not work.
Problem on • Emergency steering self check function that starts automatically when starting switch is
machine turned to ON position does not work.
• Signal from pressure sensor can be checked with monitoring function. (Code: 95302
Related (MPa) or 95303 (V))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector B08 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Defective sensor power a If power supply voltage is unusual, perform checks on causes 2 to 4.
1 supply circuit
If no failure is found, sensor power supply system is defective.
Power
supply Between B08 (female) (B) and (A) 4.6 to 5.4 V
voltage
1. Turn starting switch to OFF position.
2. Disconnect connector BRC2 and B08, and connect T-adapters to
each female side.
Between BRC2 (female) (25) and B08 (female)
(C) Max. 1 z

Open circuit in wiring harness a If power supply voltage in check on cause 1

2 (wire breakage or defective is normal, this check is not required. Max. 1 z
contact of connector) Resis- Between BRC1 (female) (4) and B08 (female)
tance (A)
a If power supply voltage in check on cause 1
is normal, this check is not required. Max. 1 z
Between BRC2 (female) (1) and B08 (female)
(B)
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC2 and B08, and connect T-adapters to
either female side.
3 Ground fault in wiring harness Between ground and BRC2 (female) (25) or
Min. 1 Mz
Resis- B08 (female) (C)
tance Between ground and BRC2 (female) (1) or B08
(female) (B) Min. 1 Mz

1. Turn starting switch to OFF position.

Hot short circuit in wiring
4 harness
(contact with 24 V circuit)
2. Disconnect connector B08.
3. Insert T-adapters to connector BRC2, or connect T-adapters to
female side of connector B08.
4. Turn starting switch to ON position.
Between ground and BRC2 (25) or B08 Max. 1 V
Voltage
(female) (C)

HM400-3M0 40-463
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Insert T-adapters to connector B08.
Defective steering oil pressure 3. Turn starting switch to ON position, then perform troubleshooting.
5
sensor Sensor
output Between B08 (C) and (A) 0.56 to 4.42
voltage V
If no failure is found by above checks, retarder hoist controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
a Reference
Defective retarder hoist 1. Turn starting switch to OFF position.
6
controller 2. Connect T-adapter to connector BRC2.
3. Turn starting switch to ON position.
Between BRC2 (1) and BRC1 (4) 4.6 to 5.4 V
Voltage 0.56 to 4.42
Between BRC2 (25) and BRC1 (4)
V

Circuit diagram related to steering oil pressure sensor

40-464 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHT8ZG] Steering Oil Pressure Low (HM400_3-DHT8ZG-400-A-Z0-A)

Action level Failure code Steering Oil Pressure Low

Failure
L03 DHT8ZG (Retarder hoist controller system)
Detail of • While engine is run, signal from steering oil pressure sensor went to below 0.56 V (oil
failure pressure is below 0.7 MPa).
Action of • Activates auto-emergency steering function if machine is traveling.
controller
Problem on • Auto-emergency steering function is activated if machine is traveling.
machine
• Signal voltage from steering oil pressure sensor can be checked with monitoring function.
Related (Code: 95302 (MPa) and 95303 (V))
information • Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Steering oil pressure is normal (0.7 MPa minimum)
1 Steering Oil Pressure Low a If oil pressure is not normal, troubleshoot hydraulic and mechanical
systems.
1. Turn starting switch to OFF position.
2. Disconnect connector B08 and connect T-adapter to female side.
Defective steering oil pressure
2 3. Turn starting switch to ON position.
sensor
Voltage Between B08 (C) and (A) 0.56 to 4.42
V
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)

Circuit diagram related to steering oil pressure sensor

HM400-3M0 40-465
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHU2KX] Out of Range of Acc. Oil Press. S. (F) (HM400_3-DHU2KX-
400-A-Z0-A)

Action level Failure code Out of Range of Accumulator Oil Pressure Sensor (F)
Failure
L01 DHU2KX (Retarder hoist controller system)
Detail of • Voltage of signal circuit of front accumulator pressure sensor drops below 0.3 V or
failure increases above 4.7 V.
Action of • None in particular.
controller
Problem on
• None
machine
• Signal from pressure sensor can be checked with monitoring function. (Code: 35500
Related (MPa) or 35506 (V))
information • T-adapter is not prepared for connector B25.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Insert T-adapters to connector J22.
3. Turn starting switch to ON position.
Defective sensor power supply a If power supply voltage is unusual, perform checks on causes 2 to 4.
1
circuit If no failure is found, sensor power supply system is defective.
Power
supply Between J22 (female) (1) and (4) 4.6 to 5.4
voltage V

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC1 and B25, and connect T-adapters to
female sides of BRC1 and BRC2.
Between BRC2 (female) (36) and B25 (female)
(2) Max. 1 z

Open circuit in wiring harness a If power supply voltage in check on cause 1

2 (wire breakage or defective is normal, this check is not required. Max. 1 z
contact of connector) Resis- Between BRC1 (female) (4) and B25 (female)
tance (1)
a If power supply voltage in check on cause 1
is normal, this check is not required. Max. 1 z
Between BRC2 (female) (1) and B25 (female)
(3)
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors BRC2 and B25, and connect T-adapters to
3 female side of BRC2.
(contact with ground circuit)
Resis- Between BRC2 (female) (1) and ground Min. 1 Mz
tance Between BRC2 (female) (36) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector B25.
4 harness 3. Insert T-adapters into connector BRC2.
(contact with 24 V circuit) 4. Turn starting switch to ON position.
Voltage Between BRC2 (36) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapters to connector J22.
Defective front accumulator oil 3. Turn starting switch to ON position.
5 pressure sensor
Sensor
output Between J22 (2) and (4) 0.3 to 4.7
voltage V

40-466 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, retarder hoist controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
a Reference
Defective retarder hoist 1. Turn starting switch to OFF position.
6 2. Insert T-adapters to connectors BRC1 and BRC2.
controller
3. Turn starting switch to ON position.
Between BRC2 (1) and BRC1 (4) 4.6 to 5.4
Voltage V
Between BRC2 (36) and BRC1 (4) 0.3 to 4.7
V

Circuit diagram related to accumulator oil pressure sensor

HM400-3M0 40-467
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHU3KX] Out of Range of Acc. Oil Press. S. (R) (HM400_3-DHU3KX-
400-A-Z0-A)

Action level Failure code Out of Range of Accumulator Oil Pressure Sensor (R)
Failure
L01 DHU3KX (Retarder hoist controller system)
Detail of • Voltage of signal circuit of rear accumulator pressure sensor drops below 0.3 V or
failure increases above 4.7 V.
Action of • None in particular.
controller
Problem on
• None
machine

• Signal from pressure sensor can be checked with monitoring function. (Code: 35501
Related (MPa) or 35507 (V))
information • T-adapter is not prepared for connector B24.
• Method of reproducing failure code: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Insert T-adapters to connector J22.
3. Turn starting switch to ON position.
Defective sensor power supply a If power supply voltage is unusual, perform checks on causes 2 to 4.
1
circuit If no failure is found, sensor power supply system is defective.
Power
supply Between J22 (female) (1) and (11) 4.6 to 5.4
voltage V

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC1 and B24, and connect T-adapters to
female sides of BRC1 and BRC2.
Between BRC2 (female) (26) and B24 (female)
(2) Max. 1 z

Open circuit in wiring harness a If power supply voltage in check on cause 1

2 (wire breakage or defective
contact of connector)
Ground fault in wiring harness
3 female side of BRC2.
(contact with ground circuit)
Hot short circuit in wiring
4 harness
(contact with 24 V circuit)
Defective rear accumulator oil
5 pressure sensor
is normal, this check is not required. Max. 1 z
Resis- Between BRC1 (female) (4) and B24 (female)
tance (1)
a If power supply voltage in check on cause 1
is normal, this check is not required. Max. 1 z
Between BRC2 (female) (1) and B24 (female)
(3)
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC2 and B24, and connect T-adapters to
Resis- Between BRC2 (female) (1) and ground Min. 1 Mz
tance Between BRC2 (female) (26) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector B24.
3. Insert T-adapters into connector BRC2.
4. Turn starting switch to ON position.
Voltage Between BRC2 (26) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapters to connector J22.
3. Turn starting switch to ON position.
Sensor
output Between J22 (3) and (11) 0.3 to 4.7
voltage V

40-468 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, retarder hoist controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
a Reference
Defective retarder hoist 1. Turn starting switch to OFF position.
6 2. Insert T-adapters to connectors BRC1 and BRC2.
controller
3. Turn starting switch to ON position.
Between BRC2 (1) and BRC1 (4) 4.6 to 5.4
Voltage V
Between BRC2 (26) and BRC1 (4) 0.3 to 4.7
V

Circuit diagram related to accumulator oil pressure sensor

HM400-3M0 40-469
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHUAKX] Out of Range of Retarder Press. S. (CR) (HM400_3-

DHUAKX-400-A-Z0-A)

Action level Failure code Out of Range of Retarder Pressure Sensor (CR)
Failure
L01 DHUAKX (Retarder hoist controller system)
Detail of • Voltage of signal circuit of retarder pressure sensor (CR) drops below 0.3 V or increases
failure above 4.7 V.
Action of • None in particular.
controller
Problem on
• None
machine
• Signal from pressure sensor can be checked with monitoring function. (Code: 91920
Related (MPa) or 91922 (V))
information • T-adapter is not prepared for connector B30.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC1.
3. Turn starting switch to ON position.
Defective sensor power supply a If power supply voltage is unusual, perform checks on causes 2 to 4.
1
circuit If no failure is found, sensor power supply is defective.
Power
supply Between BRC1 (22) and (21) 4.6 to 5.4
voltage V

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC1 and B30, and connect T-adapters to
female side of BRC1.
Between BRC1 (female) (13) and B30 (female)
(2) Max. 1 z

Open circuit in wiring harness a If power supply voltage in check on cause 1

2 (wire breakage or defective
contact of connector)
Ground fault in wiring harness
3 female side of BRC1.
(contact with ground circuit)
Hot short circuit in wiring
4 harness
(contact with 24 V circuit)
Defective retarder pressure
5 sensor (CR)
is normal, this check is not required. Max. 1 z
Resis- Between BRC1 (female) (21) and B30 (female)
tance (1)
a If power supply voltage in check on cause 1
is normal, this check is not required. Max. 1 z
Between BRC1 (female) (22) and B30 (female)
(3)
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1 and B30, and connect T-adapters to
Resis- Between BRC1 (female) (22) and ground Min. 1 Mz
tance Between BRC1 (female) (13) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector B30.
3. Insert T-adapters into connector BRC1.
4. Turn starting switch to ON position.
Voltage Between BRC1 (13) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC1.
3. Turn starting switch to ON position.
Sensor 0.3 to 4.7
output Between BRC1 (13) and (21) V
voltage

40-470 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, retarder hoist controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
a Reference
Defective retarder hoist 1. Turn starting switch to OFF position.
6 2. Insert T-adapters into connector BRC1.
controller
3. Turn starting switch to ON position.
Between BRC1 (22) and (21) 4.6 to 5.4
Voltage V
Between BRC1 (13) and (21) 0.3 to 4.7
V

Circuit diagram related to retarder pressure sensor

HM400-3M0 40-471
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHUBKX] Out of Range of Retarder Press. S. (FR) (HM400_3-

DHUBKX-400-A-Z0-A)

Action level Failure code Out of Range of Retarder Pressure Sensor (FR)
Failure
L01 DHUBKX (Retarder hoist controller system)
Detail of • Voltage of signal circuit of retarder pressure sensor (FR) drops below 0.3 V or increases
failure above 4.7 V.
Action of • None in particular.
controller
Problem on
• None
machine
• Signal from pressure sensor can be checked with monitoring function. (Code: 91919
Related (MPa) or 91921 (V))
information • T-adapter is not prepared for connector B16.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC1.
3. Turn starting switch to ON position.
Defective sensor power supply a If power supply voltage is unusual, perform checks on causes 2 to 4.
1
circuit If no failure is found, sensor power supply is defective.
Power
supply Between BRC1 (22) and (21) 4.6 to 5.4
voltage V

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC1 and B16, and connect T-adapters to
female side of BRC1.
Between BRC1 (female) (2) and B16 (female)
(2) Max. 1 z

Open circuit in wiring harness a If power supply voltage in check on cause 1

2 (wire breakage or defective
contact of connector)
Ground fault in wiring harness
3 female side of BRC1.
(contact with ground circuit)
Hot short circuit in wiring
4 harness
(contact with 24 V circuit)
Defective retarder pressure
5 sensor (FR)
is normal, this check is not required. Max. 1 z
Resis- Between BRC1 (female) (21) and B16 (female)
tance (1)
a If power supply voltage in check on cause 1
is normal, this check is not required. Max. 1 z
Between BRC1 (female) (22) and B16 (female)
(3)
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1 and B16, and connect T-adapters to
Resis- Between BRC1 (female) (22) and ground Min. 1 Mz
tance Between BRC1 (female) (2) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector B16.
3. Insert T-adapters into connector BRC1.
4. Turn starting switch to ON position.
Voltage Between BRC1 (2) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC1.
3. Turn starting switch to ON position.
Sensor 0.3 to 4.7
output Between BRC1 (2) and (21) V
voltage

40-472 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, retarder hoist controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
a Reference
Defective retarder hoist 1. Turn starting switch to OFF position.
6 2. Insert T-adapters into connector BRC1.
controller
3. Turn starting switch to ON position.
Between BRC1 (22) and (21) 4.6 to 5.4
Voltage V
Between BRC1 (2) and (21) 0.3 to 4.7
V

Circuit diagram related to retarder pressure sensor

HM400-3M0 40-473
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHUCKX] Out of Range of Parking Brake Press. S. (HM400_3-

DHUCKX-400-A-Z0-A)

Action level Failure code Out of Range of Parking Brake Pressure Sensor
Failure
L01 DHUCKX (Retarder hoist controller system)
Detail of • Voltage of signal circuit of parking brake pressure sensor drops below 0.3 V or increases
failure above 4.7 V.
Action of • None in particular.
controller
Problem on
• None
machine
• Signal from ambient pressure sensor can be checked with monitoring function. (Code:
Related 91908 (MPa) or 91909 (V))
information • T-adapter is not prepared for connector B17.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Insert T-adapters to connectors J22 and CJA.
3. Turn starting switch to ON position.
Defective sensor power supply a If power supply voltage is unusual, perform checks on causes 2 to 4.
1
circuit If no failure is found, sensor power supply is defective.
Power
supply Between CJA (female) (4) and J22 (female) (6) 4.6 to 5.4
voltage V

1. Turn starting switch to OFF position.

Open circuit in wiring harness
2 (wire breakage or defective
contact of connector)
Ground fault in wiring harness
3 female side of BRC2.
(contact with ground circuit)
Hot short circuit in wiring
4 harness
(contact with 24 V circuit)
Defective parking brake
5 pressure sensor
2. Disconnect connectors BRC1, BRC2, and B17, and connect T-
adapters to female sides of BRC1 and BRC2.
Between BRC2 (female) (35) and B17 (female)
(2) Max. 1 z
a If power supply voltage in check on cause 1
is normal, this check is not required. Max. 1 z
Resis- Between BRC1 (female) (4) and B17 (female)
tance (1)
a If power supply voltage in check on cause 1
is normal, this check is not required. Max. 1 z
Between BRC2 (female) (1) and B17 (female)
(3)
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC2 and B17, and connect T-adapters to
Resis- Between BRC2 (female) (1) and ground Min. 1 Mz
tance Between BRC2 (female) (35) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector B17.
3. Insert T-adapters into connector BRC2.
4. Turn starting switch to ON position.
Voltage Between BRC2 (35) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapters to connector J22.
3. Turn starting switch to ON position.
Sensor
output Between J22 (5) and (6) 0.3 to 4.7
voltage V

40-474 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, retarder hoist controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
a Reference
Defective retarder hoist 1. Turn starting switch to OFF position.
6 2. Insert T-adapters to connectors BRC1 and BRC2.
controller
3. Turn starting switch to ON position.
Between BRC2 (1) and BRC1 (4) 4.6 to 5.4
Voltage V
Between BRC2 (35) and BRC1 (4) 0.3 to 4.7
V

Circuit diagram related to parking brake pressure sensor

HM400-3M0 40-475
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHUDKX] Out of Range of Emerg. Steering Press.

S.1 (HM400_3-DHUDKX-400-A-Z0-A)
Action level Failure code Out of Range of Emergency Steering Pressure Sensor 1
Failure
L01 DHUDKX (Retarder hoist controller system)
Detail of • Voltage of signal circuit of emergency steering oil pressure sensor drops below 0.3 V or
failure increases above 4.4 V.
Action of • Continues auto emergency steering control.
controller
Problem on • Emergency steering self check function that starts automatically when starting switch is
machine turned to ON position does not work.
• Signal from pressure sensor can be checked with monitoring function. (Code: 07703
Related (MPa) or 07705 (V))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector B02.
3. Turn starting switch to ON position.
Defective sensor power supply a If power supply voltage is unusual, perform checks on causes 2 to 4.
1
circuit If no failure is found, sensor power supply is defective.
Power
supply Between B02 (female) (B) and (A) 4.6 to 5.4
voltage V

1. Turn starting switch to OFF position.

Open circuit in wiring harness
2 (wire breakage or defective
contact of connector)
Ground fault in wiring harness
3 female side of BRC2.
(contact with ground circuit)
Hot short circuit in wiring
4 harness
(contact with 24 V circuit)
Defective emergency steering
5 pressure sensor
2. Disconnect connectors BRC1, BRC2, and B02, and connect T-
adapters to female sides of BRC1 and BRC2.
Between BRC2 (female) (15) and B02 (female)
(C) Max. 1 z
a If power supply voltage in check on cause 1
is normal, this check is not required. Max. 1 z
Resis- Between BRC1 (female) (4) and B02 (female)
tance (A)
a If power supply voltage in check on cause 1
is normal, this check is not required. Max. 1 z
Between BRC2 (female) (1) and B02 (female)
(B)
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC2 and B02, and connect T-adapters to
Resis- Between BRC2 (female) (1) and ground Min. 1 Mz
tance Between BRC2 (female) (15) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector B02.
3. Insert T-adapters into connector BRC2.
4. Turn starting switch to ON position.
Voltage Between BRC2 (15) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapters to connector B02.
3. Turn starting switch to ON position.
Sensor 0.3 to 4.4
output Between B02 (C) and (A) V
voltage

40-476 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, retarder hoist controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
a Reference
Defective retarder hoist 1. Turn starting switch to OFF position.
6 2. Insert T-adapters to connectors BRC1 and BRC2.
controller
3. Turn starting switch to ON position.
Between BRC2 (1) and BRC1 (4) 4.6 to 5.4
Voltage V
Between BRC2 (15) and BRC1 (4) 0.3 to 4.7
V

Circuit diagram related to emergency steering pressure sensor

HM400-3M0 40-477
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHUEKX] Out of Range of Emerg. Steering Press.

S.2 (HM400_3-DHUEKX-400-A-Z0-A)
Action level Failure code Out of Range of Emergency Steering Pressure Sensor 2
Failure
L01 DHUEKX (Retarder hoist controller system)
Detail of • Voltage of signal circuit of emergency steering oil pressure sensor drops below 0.3 V or
failure increases above 4.4 V.
Action of • Continues auto emergency steering control.
controller
Problem on • Emergency steering self check function that starts automatically when starting switch is
machine turned to ON position does not work.
• Signals from pressure sensor can be checked with monitoring function. (Code: 07704
Related (MPa), 07706 (V))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector B20.
3. Turn starting switch to ON position.
Defective sensor power
1 supply system a If power supply voltage is unusual, perform checks on causes 2 to 4.
If no failure is found, sensor power supply is defective.
Battery 4.6 to 5.4
Between B20 (female) (B) and (A)
Voltage V
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1, BRC2, B20, and connect T-adapters
to female side of BRC1 and BRC2.
Between BRC2 (female) (5) and B20 (female)
(C) Max. 1 z

Open circuit in wiring harness a If power supply voltage in check on cause 1

2 (wire breakage or defective is normal, this check is not required. Max. 1 z
contact of connector) Resis- Between BRC1 (female) (4) and B20 (female)
tance (A)
a If power supply voltage in check on cause 1
is normal, this check is not required. Max. 1 z
Between BRC2 (female) (1) and B20 (female)
(3)
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors BRC2 and B20, and connect T-adapter to
3 female side of BRC2.
(contact with ground circuit)
Resis- Between BRC2 (female) (1) and ground Min. 1 Mz
tance Between BRC2 (female) (5) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector B20.
4 harness 3. Insert T-adapter into connector BRC2.
(contact with 24 V circuit) 4. Turn starting switch to ON position.
Voltage Between BRC2 (5) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector B20.
Defective emergency steering 3. Turn starting switch to ON position.
5 oil pressure sensor Sensor
output Between B20 (C) and (A) 0.3 to 4.4
voltage V

40-478 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, retarder hoist controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
a Reference
Defective retarder hoist 1. Turn starting switch to OFF position.
6 2. Insert T-adapters into connectors BRC1 and BRC2.
controller
3. Turn starting switch to ON position.
Between BRC2 (1) and BRC1 (4) 4.6 to 5.4
Voltage V
Between BRC2 (5) and BRC1 (4) 0.3 to 4.7
V

Circuit diagram related to emergency steering pressure sensor 2

HM400-3M0 40-479
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHUQKX] Out of Range of Retarder Press. S. (FL) (HM400_3-

DHUQKX-400-A-Z0-A)

Action level Failure code Out of Range of Retarder Pressure Sensor (FL)
Failure
L01 DHUQKX (Retarder hoist controller system)
Detail of • Voltage of signal circuit of retarder pressure sensor (FL) drops below 0.3 V or increases
failure above 4.7 V.
Action of • None in particular.
controller
Problem on
• None
machine
• Signal from pressure sensor can be checked with monitoring function. (Code: 91913
Related (MPa) or 91915 (V))
information • T-adapter is not prepared for connector B23.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC1.
3. Turn starting switch to ON position.
Defective sensor power supply a If power supply voltage is unusual, perform checks on causes 2 to 4.
1
circuit If no failure is found, sensor power supply is defective.
Power
supply Between BRC1 (22) and (21) 4.6 to 5.4
voltage V

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC1 and B23, and connect T-adapters to
female side of BRC1.
Between BRC1 (female) (19) and B23 (female)
(2) Max. 1 z

Open circuit in wiring harness a If power supply voltage in check on cause 1

2 (wire breakage or defective
contact of connector)
Ground fault in wiring harness
3 female side of BRC1.
(contact with ground circuit)
Hot short circuit in wiring
4 harness
(contact with 24 V circuit)
Defective retarder pressure
5 sensor (FL)
is normal, this check is not required. Max. 1 z
Resis- Between BRC1 (female) (21) and B23 (female)
tance (1)
a If power supply voltage in check on cause 1
is normal, this check is not required. Max. 1 z
Between BRC1 (female) (22) and B23 (female)
(3)
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1 and B23, and connect T-adapters to
Resis- Between BRC1 (female) (22) and ground Min. 1 Mz
tance Between BRC1 (female) (19) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector B23.
3. Insert T-adapters into connector BRC1.
4. Turn starting switch to ON position.
Voltage Between BRC1 (19) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC1.
3. Turn starting switch to ON position.
Sensor 0.3 to 4.7
output Between BRC1 (19) and (21) V
voltage

40-480 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, retarder hoist controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
a Reference
Defective retarder hoist 1. Turn starting switch to OFF position.
6 2. Insert T-adapters into connector BRC1.
controller
3. Turn starting switch to ON position.
Between BRC1 (22) and (21) 4.6 to 5.4
Voltage V
Between BRC1 (19) and (21) 0.3 to 4.7
V

Circuit diagram related to retarder pressure sensor

HM400-3M0 40-481
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHURKX] Out of Range of Retarder Press. S. (CL) (HM400_3-

DHURKX-400-A-Z0-A)

Action level Failure code Out of Range of Retarder Pressure Sensor (CL)
Failure
L01 DHURKX (Retarder hoist controller system)
Detail of • Voltage of signal circuit of retarder pressure sensor (CL) drops below 0.3 V or increases
failure above 4.7 V.
Action of • None in particular.
controller
Problem on
• None
machine
• Input voltage from pressure sensor can be checked with monitoring function. (Code:
Related 91913 (MPa) or 91915 (V))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector B31.
3. Turn starting switch to ON position.
Defective sensor power supply a If power supply voltage is unusual, perform checks on causes 2 to 4.
1
circuit If no failure is found, sensor power supply is defective.
Power
supply Between B31 (female) (3) and (1) 4.6 to 5.4
voltage V

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC1 and B31, and connect T-adapters to
female side of BRC1.
Between BRC1 (female) (7) and B31 (female)
(2) Max. 1 z

Open circuit in wiring harness a If power supply voltage in check on cause 1

2 (wire breakage or defective
contact of connector)
Ground fault in wiring harness
3 female side of BRC1.
(contact with ground circuit)
Hot short circuit in wiring
4 harness
(contact with 24 V circuit)
Defective retarder pressure
5 sensor (CL)
is normal, this check is not required. Max. 1 z
Resis- Between BRC1 (female) (21) and B31 (female)
tance (1)
a If power supply voltage in check on cause 1
is normal, this check is not required. Max. 1 z
Between BRC1 (female) (22) and B31 (female)
(3)
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1 and B31, and connect T-adapters to
Resis- Between BRC1 (female) (22) and ground Min. 1 Mz
tance Between BRC1 (female) (7) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector B31.
3. Insert T-adapters into connector BRC1.
4. Turn starting switch to ON position.
Voltage Between BRC1 (7) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector J34.
3. Turn starting switch to ON position.
Sensor 0.3 to 4.7
output Between J34 (3) and (4) V
voltage

40-482 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, retarder hoist controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
a Reference
Defective retarder hoist 1. Turn starting switch to OFF position.
6 2. Insert T-adapters into connector BRC1.
controller
3. Turn starting switch to ON position.
Between BRC1 (22) and (21) 4.6 to 5.4
Voltage V
Between BRC1 (7) and (21) 0.3 to 4.7
V

Circuit diagram related to retarder pressure sensor

HM400-3M0 40-483
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DJF1KA] Disconnection of Fuel Level Sensor (HM400_3-DJF1KA-400-A-

Z0-A)

Action level Failure code Disconnection of Fuel Level Sensor

Failure
L01 DJF1KA (Machine monitor system)
Detail of • Voltage of signal circuit of fuel level sensor increases 2 V or above.
failure
Action of • None in particular.
controller
Problem on • Fuel level gauge pointer disappears.
machine
• Signal from fuel level sensor can be checked with monitoring function. (code: 04200 (V),
Related 04201 (z))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector M06 and connect T-adapters to male side.
1 Defective fuel level sensor Between Fuel level: Full Max. 20 z
Resis- M06
tance (male) (1) Fuel level: Empty 70 to 100
and (2) z
1. Turn starting switch to OFF position.
Open circuit or hot short circuit 2. Disconnect connector M06, and connect T-adapters to female side.
2 in wiring harness 3. Turn starting switch to ON position.
Voltage Between M06 (female) (1) and (2) Approx.
3.3 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector MCM1, and connect T-adapters to female
Open or short circuit in wiring side.
3
harness Between Fuel level: Full Max. 20 z
Resis- MCM1
tance (female) Fuel level: Empty 70 to 100
(8) and (9) z

a If no failure is found by check on cause 2, this check is not required.

1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors MCM1 and M06, and connect T-adapters to
4 (wire breakage or defective each female side.
contact of connector) Between MCM1 (female) (8) and M06 (female)
Max. 1 z
Resis- (1)
tance Between MCM1 (female) (9) and M06 (female)
(2) Max. 1 z
If no failure is found by above checks, monitor controller may be
5 Defective monitor controller defective. (Since this is an internal defect, troubleshooting cannot be
performed).

40-484 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to fuel level sensor

HM400-3M0 40-485
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK30KX] Out of Range of Steering Angle Pot. (HM400_3-DK30KX-400-A-

Z0-A)

Action level Failure code Out of Range of Steering Angle Potentiometer

Failure
L01 DK30KX (Retarder hoist controller system)
Detail of • Voltage of signal of steering angle potentiometer (articulate angle sensor) drops below 0.3
failure V or increases above 4.7 V.
Action of • Stops TCS control and inter axle differential lock control.
controller
Problem on
• TCS and inter axle differential lock do not work.
machine
• Signal from articulate angle sensor can be checked with monitoring function. (Code:
Related 43906)
information • Method of reproducing failure code: Start engine and turn steering wheel from leftmost to
rightmost position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector B36 and connect T-adapters to male side.
Defective steering angle Between B36 (male) (A) and (C) 5 kz ± 20%
1 Resis- Between B36 (male) (A) and (B)
sensor 0 to 5 kz *1
tance
Between B36 (male) (B) and (C) 0 to 5 kz *1
*1 Between (A) and (B) + (B) and (C) = 5 kz ± 20%
1. Turn starting switch to OFF position.
2. Disconnect connector BRC1 and connect T-adapters to female side.
Open or short circuit in wiring Between BRC1 (female) (22) and (21) 4 to 6 kz
2
harness Resis- Between BRC1 (female) (1) and (21)
tance 1.5 to 3.5 kz
a Machine is set straight
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1 and B36, and connect T-adapters to
Open circuit in wiring harness each female side.
3 (wire breakage or defective Between BRC1 (female) (22) and B36
(female) (C) Max. 1 z
contact of connector)
Resis- Between BRC1 (female) (1) and B36 (female)
(B) Max. 1 z
tance
Between BRC1 (female) (21) and B36
(female) (A) Max. 1 z

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC1 and B36, and connect T-adapters to
Ground fault in wiring harness either female side.
4 Between ground and BRC1 (female) (22) or
(contact with ground circuit) Min. 1 Mz
Resis- B36 (female) (C)
tance Between ground and BRC1 (female) (1) or
B36 (female) (B) Min. 1 Mz

a If no failure is found by check on cause 2, this check is not required.

1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1 and B36, and connect T-adapters to
5 Short circuit in wiring harness either female side.
Between BRC1 (female) (1) and (21), or
Min. 1 Mz
Resis- between B36 (female) (A) and (B)
tance Between BRC1 (female) (21) and (22), or
between B36 (female) (B) and (C) Min. 1 Mz

40-486 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector B36 and connect T-adapters to female side.
Hot short circuit in wiring 3. Turn starting switch to ON position.
6 harness
Between B36 (female) (B) and (A) Max. 1 V
(contact with 24 V circuit)
Voltage Between B36 (female) (C) and (A)
Approx. 5 V
a Power supply
If no failure is found by above checks, retarder hoist controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
Reference
1. Turn starting switch to OFF position.
Defective retarder hoist 2. Insert T-adapters into connector BRC1 or B36.
7
controller 3. Start engine and turn steering wheel from leftmost to rightmost
position.
Between BRC1 (1) and (21), or between B36
Voltage (female) (B) and (A) 1.15 to 3.85
V
a Machine is set straight: Approx. 2.5 V

Circuit diagram related to steering angle sensor

HM400-3M0 40-487
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK51L5] Failure of Retarder Lever Pot. and RVS (HM300_3-DK51L5-
400-A-Z0-A)

Action level Failure code Failure of Retarder Lever Potentiometer and RVS
Failure
L03 DK51L5 (Retarder hoist controller system)
Detail of • Signal voltage of retarder lever potentiometer is below 0.3 V or above 4.7 V, or disagrees
failure with switch signal.
Takes following action depending on occurrence condition of failure
Action of • Controls retarder using signals from retarder lever potentiometer.
controller • Drives solenoid with 70% of its output.
• Stops driving solenoid.
Problem depends on action taken by controller.
Problem on • No major problem appears on machine.
machine • Fine control of retarder cannot be made.
• Retarder does not work (foot brake works).
• Signal voltage of retarder lever potentiometer can be checked with monitoring function.
Related (Code: 33903 (V))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1, BRC3, RE1, and RTL, and connect T-
adapters to each female side.
Between BRC1 (female) (22) and RE1 (female)
(2) Max. 1 z
Between RE1 (female) (1) and RTL (female)
(1) Max. 1 z
Open circuit in wiring harness Between BRC1 (female) (21) and RTL (female)
(3) Max. 1 z
1 (wire breakage or defective
contact of connector) Resis- Between BRC1 (female) (8) and RTL (female)
(2) Max. 1 z
tance
Between BRC2 (female) (13) and RTL (female)
(4) Max. 1 z
Between BRC2 (female) (3) and RTL (female)
(5) Max. 1 z
Between RTL (female) (6) and each of BRC3
(female) (21), (31), (32), and (33) Max. 1 z

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC1, RE1, and RTL, and connect T-
adapters to each female side.
Ground fault in wiring Between ground and BRC1 (female) (22) or
harness RE1 (female) (2) Min. 1 Mz
2
(contact with ground circuit) Resis- Between ground and RE1 (female) (1) or RTL
(female) (1) Min. 1 Mz
tance
Between ground and BRC1 (female) (8) or RTL
(female) (2) Min. 1 Mz

1.Turn starting switch to OFF position.

2.Disconnect connector RTL.
Hot short circuit in wiring 3.Insert T-adapter to female side of BRC1 or RTL.
harness 4.Turn starting switch to ON position.
3
(contact with power supply Between ground and BRC1 (22) or RTL
Approx. 5 V
circuit) (female) (1)
Voltage
Between ground and BRC1 (8) or RTL (female)
(2) Max. 1 V

40-488 HM400-3M0

No. Cause
4 Defective resistor (RE1)
5 Defective retarder lever
6 Defective retarder controller
HM400-3M0
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector RE1.
3. Connect T-adapter.
Resis- Between RE1 (male) (1) and (2)
250 ± 5 z
tance
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector RTL
3. Turn starting switch to ON position.
4. Check potentiometer.
Between RTL (1) and (3) 4.1 to 4.8 V
Voltage
Between RTL (2) and (3) 0.3 to 4.7 V
1. Turn starting switch to OFF position.
2. Disconnect connector RTL.
3. Connect T-adapter.
4. Check retarder switch.
Between RTL (male) Lever in OFF position Max. 1 z
Resis- (4) and (6) Lever in ON position Min. 1 Mz
tance Between RTL (male) Lever in OFF position Min. 1 Mz
(5) and (6) Lever in ON position Max. 1 z
If no failure is found by above checks, retarder controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
a Reference
1.Turn starting switch to OFF position.
2.Insert T-adapters into connectors BRC1 and BRC3.
3.Turn starting switch to ON position.
Between BRC1 (22) and each of BRC3 (21),
Approx. 5 V
(31), (32), and (33)
Voltage
Between BRC1 (8) and each of BRC3 (21),
(31), (32), and (33) 0.3 to 4.7 V
1. Turn starting switch to OFF position.
2. Disconnect connector BRC1.
3. Connect T-adapter.
4. Check retarder switch.
Between BRC2 Lever in OFF position Max. 1 z
(female) (13) and
Lever in ON position Min. 1 Mz
Resis- ground
tance Between BRC2 Lever in OFF position Min. 1 Mz
(female) (3) and
ground Lever in ON position Max. 1 z
40-489
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder lever potentiometer

40-490 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK52KX] Out of Range of Hoist Lever Potentio. (HM300_3-DK52KX-400-

A-Z0-A)

Action level Failure code Out of Range of Hoist Lever Potentiometer

(Input signal from lever potentiometer signal circuit 1 or 2 is
Failure out of range)
L03 DK52KX
(Retarder hoist controller system)
Detail of • Signal voltage of hoist lever potentiometer signal circuit 1 or signal circuit 2 is below 0.3 V
failure or above 4.7 V.
• Controls hoist system using signal from potentiometer signal circuit 1 or 2 whichever is
Action of normal.
controller • Determines that hoist lever is in HOLD position if both signals from hoist lever
potentiometer signal circuit 1 and 2 are out of range.
Problem on • If both signals from hoist lever potentiometer signal circuit 1 and 2 are out of range, dump
machine body does not move.
• Signal voltage of hoist lever potentiometer signal circuit 1 or 2 can be checked with
Related monitoring function. (Code: 34506, 34507 (V))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1, BRC3, and HSL, and connect T-
adapters to each female side.
Between BRC1 (female) (21) and HSL (female)
Open circuit in wiring harness (1) Max. 1 z
1 (open circuit or defective Between BRC1 (female) (12) and HSL (female)
Max. 1 z
contact) Resis- (2)
tance Between BRC1 (female) (24) and HSL (female)
(3) Max. 1 z
Between BRC2 (female) (1) and HSL (female)
(4) Max. 1 z

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC1, BRC3, and HSL, and connect T-
adapters to any one of female sides.
Ground fault in wiring Between ground and BRC2 (female) (1) or
harness HSL (female) (4) Min. 1 Mz
2
(contact with ground circuit) Resis- Between ground and BRC1 (female) (12) or
HSL (female) (2) Min. 1 Mz
tance
Between ground and BRC1 (female) (24) or
HSL (female) (3) Min. 1 Mz

1. Turn starting switch to OFF position.

Hot short circuit in wiring
harness
3 Between HSL (female) (4) and ground
(contact with power supply
circuit)
4 Defective hoist lever
2. Disconnect connector HSL and connect T-adapter to female side.
3. Turn starting switch to ON position.
Approx. 5 V
Voltage Between HSL (female) (2) and ground Max. 1 V
Between HSL (female) (3) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector HSL.
3. Turn starting switch to ON position.
Between HSL (4) and (1) 4.6 to 5.4 V
Between HSL (3) and
Dump lever in HOLD 2.3 to 2.7 V
Voltage (1)
Between HSL (3) and 1.47 to 2.01
Dump lever in FLOAT
(1) V

HM400-3M0 40-491
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, retarder controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
a Reference
Defective retarder hoist 1. Turn starting switch to OFF position.
5
controller 2. Insert T-adapters into connectors BRC1 and BRC2.
3. Turn starting switch to ON position.
Between BRC2 (1) and BRC1 (21) 4.6 to 5.4 V
Voltage Between BRC1 (12) and (21) 0.3 to 4.7 V
Between BRC1 (24) and (21) 0.3 to 4.7 V

Circuit diagram related to hoist lever

40-492 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK53L8] Failure of Hoist Lever Potentio. (HM300_3-DK53L8-400-A-Z0-A)

Action level Failure code Failure of Hoist Lever Potentiometer

Failure
L03 DK53L8 (Retarder hoist controller system)
Detail of • Total of signal voltages from hoist lever potentiometer signal circuits 1 and 2 is below 4.4
failure V or above 5.6 V.
Action of • Determines that hoist lever is in HOLD position.
controller
Problem on • Dump body does not move.
machine
• Signal voltage of hoist lever potentiometer signal circuit 1 or 2 can be checked with
Related monitoring function. (Code: 34506, 34507 (V))
information • If failure code [DK52KX] is displayed, perform troubleshooting for it
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1, BRC2, and HSL.
1 Short circuit in wiring harness 3. Connect T-adapter to female side of HSL.
Resis- Between HSL (female) (2) and (3)
Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connector HSL and connect T-adapter to male side.
Resis- Between HSL (male) (2) and (3)
Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2 Defective hoist lever 2. Insert T-adapter into connector HSL.
3. Turn starting switch to ON position.
Voltage Between HSL (4) and (1) 4.6 to 5.4 V
Voltage 2 Between HSL (2) and (1) 0.3 to 4.7 V
Voltage 3 Between HSL (3) and (1) 0.3 to 4.7 V
Voltage Total of voltage 2 and voltage 3 4.5 to 5.5 V
3 Defective retarder controller If no failure is found by above checks, retarder controller is defective

Circuit diagram related to hoist lever potentiometer

HM400-3M0 40-493
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK54KX] Out of Range of Body Potentio. (HM400_3-DK54KX-400-A-Z0-A)

Action level Failure code Out of Range of Body Potentiometer.

Failure
L03 DK54KX (Retarder hoist controller system)
Detail of • Signal circuit voltage of dump body position sensor drops below 0.3 V or increases above
failure 4.7 V.
Action of • Carries out dump control according to signal from dump lever.
controller • Carries out control on the assumption that body is not seated.
• Shocks that result when body is seated are increased.
Problem on • Functions of dump lever positioner are disabled.
machine • Maximum gear speed is limited.
• Reverse travel becomes unavailable unless dump lever is turned to "Float" position.
• Signal from body position sensor can be checked with monitoring function. (Code: 34603
Related (V))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective dump body 2. Disconnect connector B10 and connect T-adapters to male side.
1 positioner sensor
Resis- Between B10 (male) (C) and (A) 5 kz ± 20%
tance Between B10 (male) (B) and (A) 0 to 6 kz
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1, BRC2 and B10, and connect T-
adapters to each female side.
Open circuit in wiring harness Between BRC1 (female) (14) and B10
(female) (B) Max. 1 z
2 (wire breakage or defective
contact of connector) Resis- Between BRC2 (female) (1) and B10 (female)
(C) Max. 1 z
tance
Between BRC1 (female) (4) and B10 (female)
(A) Max. 1 z

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC1, BRC2 and B10, and connect T-
Ground fault in wiring harness adapters to any female side.
3 Between ground and BRC1 (female) (14) or
(contact with ground circuit) Min. 1 Mz
Resis- B10 (female) (B)
tance Between ground and BRC2 (female) (1) or
B10 (female) (C) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connector B10.
Hot short circuit in wiring 3. Insert T-adapters into connectors BRC1 and BRC2, or connect T-
harness adapters to female side of B10.
4 4. Turn starting switch to ON position.
(contact with power supply
Between ground and BRC1 (14) or B10
circuit) Max. 1 V
(female) (B)
Voltage
Between ground and BRC2 (1) or B10 Max. 1 V
(female) (C)

40-494 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

5 Defective retarder controller
If no failure is not found in above checks, retarder controller may be
defective. (Since this is internal defect, troubleshooting cannot be
performed.)
a Reference
1.Turn starting switch to OFF position.
2.Insert T-adapters into connector BRC1.
3.Turn starting switch to ON position.
Between BRC1 (14)
Dump body seating 0.3 to 0.62 V
and (4)
Voltage
Between BRC1 (14) When body cylinder is
and (4) 4.0 to 4.7 V
in full stroke

Circuit diagram related to dump body positioner sensor

HM400-3M0 40-495
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK60KX] Out of Range of Acceleration Sensor (HM300_3-DK60KX-400-

A-Z0-A)

Action level Failure code Out of Range of Acceleration Sensor

Failure
L01 DK60KX (Retarder hoist controller system)
Detail of • Signal voltage from acceleration sensor is below 0.5 V or above 4.5 V.
failure
Action of
• Continues TCS control.
controller
Problem on • TCS control does not work normally.
machine
Related • Input signal from acceleration sensor can be checked with monitoring function. (Code:
information 60201 (V))
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Connect T-adapter to female side of connector SAC.
Defective sensor power
1 3. Turn starting switch to ON position.
supply system
Battery Approx. 5
Between SAC (female) (1) and (3)
Voltage V
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1 and SRC, and connect T-adapters to
each female side.
Between BRC1 (female) (18) and SAC (female)
(2) Max. 1 z

Open circuit in wiring harness a If power supply voltage is normal, this check
2 (wire breakage or defective is not required Max. 1 z
contact of connector) Resis- Between BRC1 (female) (22) and SAC (female)
tance (1)
a If power supply voltage is normal, this check
is not required Max. 1 z
Between BRC1 (female) (21) and SAC (female)
(3)
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1 and SAC, and connect T-adapter to
either female side.
Between ground and BRC1 (female) (18) or
Ground fault in wiring harness SAC (female) (2) Min. 1 Mz
3
(contact with ground circuit)
Resis- a If power supply voltage is normal, this check
tance is not required Min. 1 Mz
Between ground and BRC1 (female) (22) or
SAC (female) (1)
1. Turn starting switch to OFF position.
2. Disconnect connector SAC.
Hot short circuit in wiring 3. Insert T-adapter to BRC1, or connect T-adapter to female side of
4 harness SAC.
(contact with 24 V circuit) 4. Turn starting switch to ON position.
Between ground and BRC1 (18) or SAC
Voltage Max. 1 V
(female) (2)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector SAC.
5 Defective acceleration sensor 3. Turn starting switch to ON position.
Between SAC (2) and (3) 2.2 to 2.8
Voltage
a With machine on level ground and stopped V

40-496 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, retarder hoist controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
a Reference
Defective retarder hoist 1. Turn starting switch to OFF position.
6 2. Insert T-adapter into connector BRC1.
controller
3. Turn starting switch to ON position.
Between BRC1 (22) and (21) 20 to 30 V
Voltage Between BRC1 (18) and (21) 2.2 to 2.8
a With machine on level ground and stopped V

Circuit diagram related to acceleration sensor

HM400-3M0 40-497
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DKH0KX] Out of Range of Inclination Angle Sensor (HM300_3-

DKH0KX-400-A-Z0-A)

Action level Failure code Out of Range of Inclination Angle Sensor

Failure
L01 DKH0KX (Retarder hoist controller system)
Detail of • Signal circuit voltage of pitch angle sensor is below 0.3 V or above 4.7 V.
failure
Action of • None in particular
controller
Problem on • Failure code of backward tipping alarm [989D00] cannot be generated.
machine
• Signal from pitch angle sensor can be checked with monitoring function. (Code: 32904
Related (deg.), 32905(V))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Connect T-adapter to female side of connector B12.
Defective sensor power
1 3. Turn starting switch to ON position.
supply system
Battery
Between B12 (female) (C) and (A) 20 to 30 V
Voltage
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1, BRC2, and B12, and connect T-
adapters to each female side.
Between BRC2 (female) (6) and B12 (female)
(B) Max. 1 z
Open circuit in wiring harness a If power supply voltage is normal, this check
2 (wire breakage or defective is not required Max. 1 z
contact of connector) Resis- Between BRC1 (female) (16) and B12 (female)
tance (C)
a If power supply voltage is normal, this check
is not required Max. 1 z
Between BRC1 (female) (21) and B12 (female)
(A)
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1 and B12, and connect T-adapter to
either female side.
Between ground and BRC2 (female) (6) or B12
Ground fault in wiring harness (female) (B) Min. 1 Mz
3
(contact with ground circuit)
Resis- a If power supply voltage is normal, this check
tance is not required Min. 1 Mz
Between ground and BRC1 (female) (16) or
B12 (female) (C)
1. Turn starting switch to OFF position.
2. Disconnect connector B12.
Hot short circuit in wiring 3. Insert T-adapter to BRC2, or connect T-adapter to female side of
4 harness B12.
(contact with 24 V circuit) 4. Turn starting switch to ON position.
Between ground and BRC2 (6) or B12 (female)
Voltage Max. 1 V
(B)

40-498 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

5 Defective pitch angle sensor
Defective retarder hoist
6 2.Insert T-adapters into connectors BRC1 and BRC2.
controller
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector B12.
3. Turn starting switch to ON position.
Between B12 (B) and (A) 2.2 to 2.8
Voltage
a With machine on level ground and stopped V
If no failure is found by above checks, retarder hoist controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
a Reference
1.Turn starting switch to OFF position.
3.Turn starting switch to ON position.
Between BRC1 (16) and (21) 20 to 30 V
Voltage Between BRC2 (6) and BRC1 (21) 2.2 to 2.8
a With machine on level ground and stopped V

Circuit diagram related to pitch angle sensor

HM400-3M0 40-499
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DKH1KX] Out of Range of Long. Inclination Angle S. (HM400_3R-

DKH1KX-400-A-Z0-A)

Action level Failure code Out of Range of Longitudinal Inclination Angle Sensor
Failure
L01 DKH1KX (Payload meter controller system) (Display: PLM)
Detail of • An abnormality is detected in the inclination angle sensor signal circuit (open circuit, wire
failure breakage).
Action of • None in particular
controller
Problem on • The load weight cannot be correctly displayed or recorded.
machine
Related • Input signal from inclination angle sensor can be checked with monitoring function. (Code:
information 32901 (deg.), 32902 (V))
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Connect T-adapter to female side of connector PCL.
Defective sensor power 3. Turn starting switch to ON position.
1 supply system Power
supply Between PCL (female) (C) and (A) 20 to 30 V
voltage
1. Turn starting switch to OFF position.
2. Connect T-adapters to each female side of connectors HM1, HM2B, and
PCL.
Between HM2B (female) (3) and PCL (female) (B) Max. 1 z
Open circuit in wiring
harness (wire breakage a If power supply voltage is normal, this check is
2 or defective contact of Max. 1 z
not required.
connector) Resistance Between HM1 (female) (2) and PCL (female) (C)
a If power supply voltage is normal, this check is
not required. Max. 1 z
Between HM2B (female) (9) and PCL (female) (A)
1. Turn starting switch to OFF position.
2. Disconnect connectors HM1, HM2B, and PCL, and connect T-adapter to
any female side.
Ground fault in wiring Between ground and HM2B (female) (3) or PLC
(female) (B) Min. 1 Mz
3 harness (contact with
ground circuit)
Resistance a If power supply voltage is normal, this check is
not required. Min. 1 Mz
Between ground and HM1 (female) (2) or PCL
(female) (C)
1. Turn starting switch to OFF position.
2. Disconnect connector PCL.
Hot short circuit in
4 3. Insert T-adapter into HM2B, or connect T-adapter to female side of PCL.
wiring harness
4. Turn starting switch to ON position.
Voltage Between ground and HM2B (3) or PCL (female) (B) Max. 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PCL.
Defective inclination 3. Turn starting switch to ON position.
5 angle sensor
Between PCL (B) and (A) 0.5 to 4.5 V
Voltage
a Approx. 2.6 V when machine is level

40-500 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria, and remarks

If no failure is found by above checks, payload meter controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
a Reference
Defective payload 1. Turn starting switch to OFF position.
6 2. Insert T-adapters into connectors HM1 and HM2B.
meter controller
3. Turn starting switch to ON position.
Between HM1 (2) and HM2B (9) 20 to 30 V
Voltage Between HM2B (3) and HM2B (9)
0.5 to 4.5 V
a Approx. 2.6 V when machine is level

Circuit diagram related to longitudinal inclination angle sensor

HM400-3M0 40-501
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor (HM300_3-

DLF1KA-400-A-Z0-A)

Action level Failure code Disconnection of Transmission Input Speed Sensor

Failure
L03 DLF1KA (Transmission controller system)
Detail of • No signal is input from transmission input shaft speed sensor due to open circuit in its
failure signal circuit.
Action of • Keeps current gear speed and disengages lockup clutch.
controller • Leaves transmission in NEUTRAL, once gear shift lever is set to "N" position.
• Lockup clutch is disengaged and gear shifting becomes impossible.
Problem on • If gear shift lever is put in "N" position during traveling, machine cannot drive unless it is
machine stopped once.

k Tilt the cab up and secure it in place with lock bar. Ensure that lock lever is in the
CLOSED position. (See Testing and adjusting, "Method of tilting cab up".
Related
information • Transmission input shaft speed can be checked with monitoring function. (Code: 31200
(rpm))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt the cab up (as explained above).
Defective adjustment of Screw in sensor until it touches speed pickup gear lightly, then return it
1 transmission input shaft by 1/2 to 1 turn.
speed sensor
a For details, see Testing and adjusting, "Adjusting transmission speed
sensors".
1. Turn starting switch to OFF position.
2. Disconnect connector N1 (CN3) and connect T-adapter to male side.
Defective transmission input 500 to 1,000
2 shaft speed sensor Between N1 (CN3) (male) (1) and (2)
Resis- z
tance Between ground and each of N1 (CN3) (male)
(1) and (2) Min. 1 Mz

1. Lower tilted-up cab.

2. Turn starting switch to OFF position.
Open or short circuit in wiring
3 3. Disconnect connector ATC2 and connect T-adapter to female side.
harness
Resis- Between ATC2 (female) (40) and (39) 500 to 1,000
tance z
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC2 and connect T-adapter to female side.
Open circuit in wiring 3. Tilt the cab up (as explained above).
harness 4. Disconnect connector N1 (CN3) and connect T-adapter to female
4
(wire breakage or defective side.
contact of connector) Between ATC2 (female) (40) and N1 (CN3)
Max. 1 z
Resis- (female) (1)
tance Between ATC2 (female) (39) and N1 (CN3)
(female) (2) Max. 1 z
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-502 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to transmission input shaft speed sensor

HM400-3M0 40-503
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLF1LC] Failure of T/M Input Speed Sensor (HM300_3-DLF1LC-400-A-Z0-A)

Action level Failure code Failure of Transmission Input Speed Sensor

Failure
L03 DLF1LC (Transmission controller system)
• Transmission input shaft speed calculated from signals of engine speed sensor,
Detail of transmission intermediate shaft speed sensor and transmission output shaft speed
failure sensor differs from that sensed by transmission input shaft speed sensor.
Action of • Keeps current gear speed and disengages lockup clutch.
controller • Leaves transmission in NEUTRAL, once gear shift lever is set to "N" position.
• Lockup clutch is disengaged and gear shifting becomes impossible.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.

k Tilt the cab up and secure it in place with lock bar. Ensure that lock lever is in the
CLOSED position. (See Testing and adjusting, "Method of tilting cab up".
Related
information • Transmission input shaft speed can be checked with monitoring function. (Code: 31200
(rpm))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt the cab up (as explained above).
2. Turn starting switch to OFF position.
3. Disconnect connector N1 (CN3) and connect T-adapter to male side.
Defective transmission input
1 shaft speed sensor Resis- 500 to
Between N1 (CN3) (male) (1) and (2)
tance 1,000 z
Between ground and each of N1 (CN3) (male) Resis-
(1) and (2) Min. 1 Mz
tance
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC2 and connect T-adapter to female side.
2 Ground fault in wiring harness 4. Tilt the cab up (as explained above).
5. Disconnect connector N1 (CN3) and connect T-adapter to female
side.
Between ground and ATC2 (female) (40) or N1 Resis-
(CN3) (female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Connect T-adapter to connector N1 (CN3).
3 3. Turn starting switch to ON position.
harness
Between N1 (CN3) (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connector N1 (CN3).
3. Lower tilted-up cab.
4 Short circuit in wiring harness
4. Disconnect connector ATC2 and connect T-adapter to female side.
Between ATC2 (female) (40) and each pin Resis-
other than (40) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-504 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to transmission input shaft speed sensor

HM400-3M0 40-505
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor (HM300_3-

DLF2KA-400-A-Z0-A)

Action level Failure code Disconnection of Transmission Intermediate Speed Sensor

Failure
L03 DLF2KA (Transmission controller system)
Detail of • No signal is input from transmission intermediate shaft speed sensor due to open circuit
failure in its signal circuit.
Action of • Keeps current gear speed.
controller • Leaves transmission in NEUTRAL, once gear shift lever is set to "N" position.
• Gear shifting becomes impossible.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.

k Tilt the cab up and secure it in place with lock bar. Ensure that lock lever is in the
CLOSED position. (See Testing and adjusting, "Method of tilting cab up".
Related
information • Transmission intermediate shaft speed can be checked with monitoring function. (Code:
31300 (rpm))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
Defective adjustment of • Screw in sensor until it touches speed pickup gear lightly, then return
1 transmission intermediate it by 1/2 to 1 turn.
shaft speed sensor a For details, see Testing and adjusting, "Adjusting transmission
speed sensors".
1. Turn starting switch to OFF position.
2. Disconnect connector N2 (CN4) and connect T-adapter to male side.
Defective transmission
2 intermediate shaft speed 500 to
Between N2 (CN4) (male) (1) and (2)
sensor Resis- 1,000 z
tance Between ground and each of N2 (CN4) (male)
(1) and (2) Min. 1 Mz

1. Lower tilted-up cab.

2. Turn starting switch to OFF position.
Open or short circuit in wiring
3 3. Disconnect connector ATC2 and connect T-adapter to female side.
harness
Resis- Between ATC2 (female) (20) and (39) 500 to
tance 1,000 z
a If check result on cause 3 is normal, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC2 and connect T-adapter to female side.
Open circuit in wiring harness 3. Tilt the cab up (as explained above).
4 (wire breakage or defective 4. Disconnect connector N2 (CN4) and connect T-adapter to female
contact of connector) side.
Between ATC2 (female) (20) and N2 (CN4)
Max. 1 z
Resis- (female) (1)
tance Between ATC2 (female) (39) and N2 (CN4)
(female) (2) Max. 1 z
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-506 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to transmission intermediate shaft speed sensor

HM400-3M0 40-507
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor (HM300_3-

DLF2LC-400-A-Z0-A)

Action level Failure code Failure of Transmission Intermediate Speed Sensor

Failure
L03 DLF2LC (Transmission controller system)
• Transmission intermediate shaft speed calculated from signals of engine speed sensor,
Detail of transmission input shaft speed sensor and transmission output shaft speed sensor differs
failure from that sensed by transmission intermediate shaft speed sensor.
Action of • Keeps current gear speed.
controller • Leaves transmission in NEUTRAL, once gear shift lever is set to "N" position.
• Gear shifting becomes impossible.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.

k Tilt the cab up and secure it in place with lock bar. Ensure that lock lever is in the
CLOSED position. (See Testing and adjusting, "Method of tilting cab up".
Related
information • Transmission intermediate shaft speed can be checked with monitoring function. (Code:
31300 (V))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt the cab up (as explained above).
2. Turn starting switch to OFF position.
Defective transmission 3. Disconnect connector N2 (CN4) and connect T-adapter to male side.
1 intermediate shaft speed 500 to
Between N2 (CN4) (male) (1) and (2)
sensor Resis- 1,000 z
tance Between ground and each of N2 (CN4) (male)
(1) and (2) Min. 1 Mz

1. Lower tilted-up cab.

2. Turn starting switch to OFF position.
3. Disconnect connector ATC2 and connect T-adapter to female side.
2 Ground fault in wiring harness 4. Tilt the cab up (as explained above).
5. Disconnect connector N2 (CN4) and connect T-adapter to female
side.
Resis- Between ground and ATC2 (female) (20) or N2 500 to
tance (CN4) (female) (1) 1,000 z
1. Turn starting switch to OFF position.
2. Disconnect connector N2.(CN4) and connect T-adapters to female
Hot short circuit in wiring side.
3
harness 3. Turn starting switch to ON position.
Voltage Between N2 (CN4) (female) (1) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connector N2 (CN4).
3. Lower tilted-up cab.
4 Short circuit in wiring harness
4. Disconnect connector ATC2 and connect T-adapter to female side.
Resis- Between ATC2 (female) (20) and each pin
other than (20) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-508 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to transmission intermediate shaft speed sensor

HM400-3M0 40-509
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLF400] T/M Diff. Overrun Prevention Activated (HM300_3-DLF400-

400-A-Z0-A)

Action level Failure code Transmission Differential Overrun Prevention Activated

Failure
L01 DLF400 (Transmission controller system)
Detail of • Transmission front shaft speed exceeds 4200 rpm.
failure
Action of • Keeps transmission in NEUTRAL.
controller
Problem on • Transmission shifts to Neutral at high speeds.
machine
• Signal from transmission differential speed sensor can be checked with monitoring
Related function. (Code: 31402 (rpm))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective transmission
1 differential speed sensor Perform troubleshooting for failure code [DLF4LC].
system

40-510 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLF4KA] Disconnection of T/M Diff. Speed Sensor (HM300_3-

DLF4KA-400-A-Z0-A)

Action level Failure code Disconnection of Transmission Differential Speed Sensor

Failure
L01 DLF4KA (Transmission controller system)
Detail of • No signal is input from transmission differential speed sensor due to open circuit in its
failure signal circuit.
Action of • Disengages inter-axle differential lock and holds it disengaged.
controller
Problem on • Inter-axle differential lock does not operate.
machine

k Tiltthe cab up and secure it in place with lock bar. Ensure that lock lever is in the
CLOSED position. (See Testing and adjusting, "Method of tilting cab up".
Related
information • Signal from transmission differential speed sensor can be checked with monitoring
function. (Code: 31402 (rpm))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
Defective adjustment of Screw in sensor until it touches speed pickup gear lightly, then return it
1 transmission differential by 1/2 to 1 turn.
speed sensor a For details, see Testing and adjusting, "Adjusting transmission
speed sensors".
1. Turn starting switch to OFF position.
2. Disconnect connector T09 and connect T-adapter to male side.
Defective transmission 500 to
2 differential speed sensor Between T09 (male) (1) and (2)
Resis- 1,000 z
tance Between ground and each of T09 (male) (1)
and (2) Min. 1 Mz

1. Lower tilted-up cab.

2. Turn starting switch to OFF position.
Open or short circuit in wiring
3 3. Disconnect connector ATC2 and connect T-adapter to female side.
harness
Resis- 500 to
Between ATC2 (female) (10) and (29)
tance 1,000 z
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC2 and connect T-adapter to female side.
Open circuit in wiring harness 3. Tilt the cab up (as explained above).
4 (wire breakage or defective 4. Disconnect connector T09 and connect T-adapter to female side.
contact of connector) Between ATC2 (female) (10) and T09 (female)
(1) Max. 1 z
Resis-
tance Between ATC2 (female) (29) and T09 (female)
(2) Max. 1 z
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

HM400-3M0 40-511
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to transmission differential speed sensor

40-512 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLF4LC] Failure of T/M Diff. Speed Sensor (HM300_3-DLF4LC-400-A-Z0-A)

Action level Failure code Failure of Transmission Differential Speed Sensor

Failure
L01 DLF4LC (Retarder hoist controller system)
Detail of • Transmission differential speed sensor signal received from transmission controller is not
failure normal.
Action of • Stops inter axle differential lock control and TCS control.
controller
Problem on • TCS does not work.
machine • Inter-axle differential lock does not operate.

k Tilt the cab up and secure it in place with lock bar. Ensure that lock lever is in the
CLOSED position. (See Testing and adjusting, "Method of tilting cab up".
Related
information • Transmission differential speed sensor readings can be checked with monitoring function.
(Code: 31402 (rpm))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector T09 and connect T-adapter to male side.
Defective transmission
1 differential speed sensor 500 to
Between T09 (male) (1) and (2)
Resis- 1,000 z
tance Between ground and each of T09 (male) (1)
and (2) Min. 1 Mz

1. Lower tilted-up cab.

2. Turn starting switch to OFF position.
3. Disconnect connector ATC2 and connect T-adapter to female side.
2 Ground fault in wiring harness 4. Tilt the cab up (as explained above).
5. Disconnect connector T09 and connect T-adapter to female side.
Resis- Between ground and ATC2 (female) (40) or T09 500 to
tance (female) (1) 1,000 z
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector T09 and connect T-adapter to female side.
3 3. Turn starting switch to ON position.
harness
Voltage Between T09 (female) (1) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connector T09.
3. Lower tilted-up cab.
4 Short circuit in wiring harness
4. Disconnect connector ATC2 and connect T-adapter to female side.
Resis- Between ATC2 (female) (10) and each pin
other than (10) Min. 1 Mz
tance
If no failure is found by above checks, retarder hoist controller may be
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

HM400-3M0 40-513
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to transmission differential speed sensor

40-514 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLF6LC] Failure of Wheel Speed Sensor (FR) (HM400_3-DLF6LC-400-A-

Z0-A)

Action level Failure code Failure of Wheel Speed Sensor (FR)

Failure
L01 DLF6LC (Retarder hoist controller system)
Detail of • Signal from wheel speed sensor (right-hand side in front) is abnormal.
failure
Action of • Continues control of TCS (front).
controller • Stops TCS (center) control and inter axle differential lock control.
Problem on • TCS (center) and inter axle differential lock do not work.
machine
• Speed sensed by wheel speed sensor (FR) can be checked with monitoring function.
(Code: 39710)
• Since wheel speed sensor is configured with Hall elements rather than coils,
Related troubleshooting of a failure due to internal resistance is not available.
information • Since wheel speed sensor outputs its signals in pulse voltage, multimeter is not usable for
their measurement.
• Method of reproducing failure code: Start engine and drive machine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1, BRC2 and B32, and connect T-
adapters to each female side.
Open circuit in wiring harness Between BRC1 (female) (22) and B32 (female)
(A) Max. 1 z
1 (wire breakage or defective
contact of connector) Resis- Between BRC2 (female) (37) and B32 (female)
(C) Max. 1 z
tance
Between BRC2 (female) (39) and B32 (female)
(B) Max. 1 z

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC1, BRC2 and B32, and connect T-
Ground fault in wiring harness adapters to any female side.
2 Between ground and BRC1 (female) (22) or
(contact with ground circuit) Min. 1 Mz
Resis- B32 (female) (A)
tance Between ground and BRC2 (female) (37) or
B32 (female) (C) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC1 and B32, and connect T-adapters to
either female side.
Between BRC2 (female) (37) and (39), or
3 Short circuit in wiring harness Min. 1 Mz
between B32 (female) (C) and (B)
Resis-
Between BRC1 (female) (22) and BRC2
tance
(female) (37), or between B32 (female) (A) and Min. 1 Mz
(B)
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector B32 and connect T-adapters to female side.
4 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between B32 (female) (C) and (B) Max. 1 V
a Be ready with starting switch at OFF, and then turn starting switch to
ON position to perform troubleshooting.
When
Defective wheel speed Speed sensed by wheel speed sensor (FR) machine is 0 rpm
5
sensor while machine is traveling on a dry road without stopped
load can be checked with monitoring function. While
(Code: 39710) 20 to 50
traveling at rpm
10 km/h
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
6
controller performed.)

HM400-3M0 40-515
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to wheel speed sensor (FR)

40-516 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLF7LC] Failure of Wheel Speed Sensor (FL) (HM400_3-DLF7LC-400-A-

Z0-A)

Action level Failure code Failure of Wheel Speed Sensor (FL)

Failure
L01 DLF7LC (Retarder hoist controller system)
Detail of • Signal from wheel speed sensor (left-hand side in front) is abnormal.
failure
Action of • Continues control of TCS (front).
controller • Stops TCS (center) control and inter axle differential lock control.
Problem on • TCS (center) and inter axle differential lock do not work.
machine
• Speed sensed by wheel speed sensor (FL) can be checked with monitoring function.
(Code: 39711)
• Since wheel speed sensor is configured with Hall elements rather than coils,
Related troubleshooting of a failure due to internal resistance is not available.
information • Since wheel speed sensor outputs its signals in pulse voltage, multimeter is not usable for
their measurement.
• Method of reproducing failure code: Start engine and drive machine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1, BRC2 and B33, and connect T-
adapters to each female side.
Open circuit in wiring harness Between BRC1 (female) (22) and B33 (female)
(A) Max. 1 z
1 (wire breakage or defective
contact of connector) Resis- Between BRC2 (female) (27) and B33 (female)
(C) Max. 1 z
tance
Between BRC2 (female) (39) and B33 (female)
(B) Max. 1 z

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC1, BRC2 and B33, and connect T-
Ground fault in wiring harness adapters to any female side.
2 Between ground and BRC1 (female) (22) or
(contact with ground circuit) Min. 1 Mz
Resis- B33 (female) (A)
tance Between ground and BRC2 (female) (27) or
B33 (female) (C) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC1 and B33, and connect T-adapters to
either female side.
Between BRC2 (female) (27) and (39), or
3 Short circuit in wiring harness Min. 1 Mz
between B33 (female) (C) and (B)
Resis-
Between BRC1 (female) (22) and BRC2
tance
(female) (27), or between B33 (female) (A) and Min. 1 Mz
(B)
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector B33 and connect T-adapters to female side.
4 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between B33 (female) (C) and (B) Max. 1 V
a Be ready with starting switch at OFF, and then turn starting switch to
ON position to perform troubleshooting.
When
Defective wheel speed Speed sensed by wheel speed sensor (FL) machine is 0 rpm
5
sensor while machine is traveling on a dry road without stopped
load can be checked with monitoring function. While
(Code: 39711) 20 to 50
traveling at rpm
10 km/h
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
6
controller performed.)

HM400-3M0 40-517
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to wheel speed sensor (FL)

40-518 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLFDLC] Failure of Wheel Speed Sensor (CR) (HM400_3-DLFDLC-400-A-

Z0-A)

Action level Failure code Failure of Wheel Speed Sensor (CR)

Failure
L01 DLFDLC (Retarder hoist controller system)
Detail of • Signal from wheel speed sensor (right-hand side in center) is abnormal.
failure
Action of • Continues control of TCS (center).
controller • Stops TCS (front) control and inter axle differential lock control.
Problem on • TCS (front) and inter axle differential lock do not work.
machine
• Speed sensed by wheel speed sensor (CR) can be checked with monitoring function.
(Code: 39712)
• Since wheel speed sensor is configured with Hall elements rather than coils,
Related troubleshooting of a failure due to internal resistance is not available.
information • Since wheel speed sensor outputs its signals in pulse voltage, multimeter is not usable for
their measurement.
• Method of reproducing failure code: Start engine and drive machine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1, BRC2 and B34, and connect T-
adapters to each female side.
Open circuit in wiring harness Between BRC1 (female) (22) and B34 (female)
(A) Max. 1 z
1 (wire breakage or defective
contact of connector) Resis- Between BRC2 (female) (17) and B34 (female)
(C) Max. 1 z
tance
Between BRC2 (female) (39) and B34 (female)
(B) Max. 1 z

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC1, BRC2 and B34, and connect T-
Ground fault in wiring harness adapters to any female side.
2 Between ground and BRC1 (female) (22) or
(contact with ground circuit) Min. 1 Mz
Resis- B34 (female) (A)
tance Between ground and BRC2 (female) (17) or
B34 (female) (C) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC1 and B34, and connect T-adapters to
either female side.
Between BRC2 (female) (17) and (39), or
3 Short circuit in wiring harness Min. 1 Mz
between B34 (female) (C) and (B)
Resis-
Between BRC1 (female) (22) and BRC2
tance
(female) (17), or between B34 (female) (A) and Min. 1 Mz
(B)
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector B34 and connect T-adapters to female side.
4 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between B34 (female) (C) and (B) Max. 1 V
a Be ready with starting switch at OFF, and then turn starting switch to
ON position to perform troubleshooting.
When
Defective wheel speed Speed sensed by wheel speed sensor (CR) machine is 0 rpm
5
sensor while machine is traveling on a dry road without stopped
load can be checked with monitoring function. While
(Code: 39712) 20 to 50
traveling at rpm
10 km/h
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
6
controller performed.)

HM400-3M0 40-519
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to wheel speed sensor (CR)

40-520 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLFELC] Failure of Wheel Speed Sensor (CL) (HM400_3-DLFELC-400-A-

Z0-A)

Action level Failure code Failure of Wheel Speed Sensor (CL)

Failure
L01 DLFELC (Retarder hoist controller system)
Detail of • Signal from wheel speed sensor (left-hand side in center) is abnormal.
failure
Action of • Continues control of TCS (center).
controller • Stops TCS (front) control and inter axle differential lock control.
Problem on • TCS (front) and inter axle differential lock do not work.
machine
• Speed sensed by wheel speed sensor (CL) can be checked with monitoring function.
(Code: 39713)
• Since wheel speed sensor is configured with Hall elements rather than coils,
Related troubleshooting of a failure due to internal resistance is not available.
information • Since wheel speed sensor outputs its signals in pulse voltage, multimeter is not usable for
their measurement.
• Method of reproducing failure code: Start engine and drive machine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC1, BRC2 and B35, and connect T-
adapters to each female side.
Open circuit in wiring harness Between BRC1 (female) (22) and B35 (female)
(A) Max. 1 z
1 (wire breakage or defective
contact of connector) Resis- Between BRC2 (female) (7) and B35 (female)
(C) Max. 1 z
tance
Between BRC2 (female) (39) and B35 (female)
(B) Max. 1 z

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC1, BRC2 and B35, and connect T-
Ground fault in wiring harness adapters to any female side.
2 Between ground and BRC1 (female) (22) or
(contact with ground circuit) Min. 1 Mz
Resis- B35 (female) (A)
tance Between ground and BRC2 (female) (7) or B35
(female) (C) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC1 and B35, and connect T-adapters to
either female side.
Between BRC2 (female) (7) and (39), or
3 Short circuit in wiring harness Min. 1 Mz
between B35 (female) (C) and (B)
Resis-
Between BRC1 (female) (22) and BRC2
tance
(female) (7), or between B35 (female) (A) and Min. 1 Mz
(B)
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector B35 and connect T-adapters to female side.
4 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between B35 (female) (C) and (B) Max. 1 V
a Be ready with starting switch at OFF, and then turn starting switch to
ON position to perform troubleshooting.
When
Defective wheel speed Speed sensed by wheel speed sensor (CL) machine is 0 rpm
5
sensor while machine is traveling on a dry road without stopped
load can be checked with monitoring function. While
(Code: 39713) 20 to 50
traveling at rpm
10 km/h
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
6
controller performed.)

HM400-3M0 40-521
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to wheel speed sensor (CL)

40-522 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLFFLC] Failure of Wheel Speed Sensor (Front) (HM300_3-DLFFLC-

400-A-Z0-A)

Action level Failure code Failure of Wheel Speed Sensor (Front)

Failure
L01 DLFFLC (Retarder hoist controller system)
Detail of • Signals from wheel speed sensors (front right and front left) are abnormal.
failure
Action of • Cancels TCS control (front).
controller
Problem on • TCS control (front) does not work.
machine
• Speed measured by wheel speed sensors (FR) and (FL) can be checked with monitoring
Related function. (Code: 39710, 39711)
information • Method of reproducing failure code: Start engine and drive machine.
No. Cause Procedure, measuring location, criteria and remarks
Defective wheel speed
1 Perform troubleshooting for failure code [DLF6LC].
sensor (FR)
Defective wheel speed
2 Perform troubleshooting for failure code [DLF7LC].
sensor (FL)
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)

HM400-3M0 40-523
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLFGLC] Failure of Wheel Speed Sensor (Center) (HM300_3-

DLFGLC-400-A-Z0-A)

Action level Failure code Failure of Wheel Speed Sensor (Center)

Failure
L01 DLFGLC (Retarder hoist controller system)
Detail of • Signals from wheel speed sensors (center right and center left) are abnormal.
failure
Action of • Cancels TCS control (center).
controller
Problem on • TCS control (center) does not work.
machine
• Speed measured by wheel speed sensors (CR) and (CL) can be checked with monitoring
Related function. (Code: 39712, 39713)
information • Method of reproducing failure code: Start engine and drive machine.
No. Cause Procedure, measuring location, criteria and remarks
Defective wheel speed
1 Perform troubleshooting for failure code [DLFDLC].
sensor (CR)
Defective wheel speed
2 Perform troubleshooting for failure code [DLFELC].
sensor (CL)
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)

40-524 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLM3KA] Disconnection of Radiator Fan Speed

Sensor (HM400_3-DLM3KA-400-A-Z0-A)
Action level Failure code Disconnection of Radiator Fan Speed Sensor
Failure
L01 DLM3KA (Retarder hoist controller system)
Detail of • Radiator fan speed went to zero while engine is run and fan is rotating in normal direction.
failure
Action of • None in particular.
controller
Problem on • Degraded fuel economy or overheating may result because of unachievable target speed.
machine
• Radiator fan speed and target radiator fan speed can be checked with monitoring
Related function.
information (Code: Radiator fan speed is 10007 (rpm) and target radiator fan speed is 10014 (rpm).
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector B13 and connect T-adapters to male side.
Defective radiator fan
1 speed sensor 1,500 to
Between B13 (male) (1) and (2)
Resistance 3,500 z
Between ground and each of B13 (male) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector BRC2 and connect T-adapters to female side.
Open or short circuit in
2 wiring harness a Coil resistance of radiator fan speed sensor
1,500 to
Resistance Between BRC2 (female) (40) and (29) 3,500 z
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector BRC1 and connect T-adapters to female side.
3 (wire breakage or Between BRC2 (female) (40) and B13 (female) (1) Max. 1 z
defective contact of Resistance
connector) Between BRC2 (female) (29) and B13 (female) (2) Max. 1 z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector B13.
wiring harness 3. Insert T-adapters into connector BRC2, or connect T-adapters to
4 connector B13.
(contact with 24 V
circuit) 4. Turn starting switch to ON position.
Voltage Between ground and BRC2 (40) or B13 (female) (1) Max. 4.5 V
1. Start engine.
2. Monitoring code: Check radiator fan speed using 10007 and 10014 as
Defective retarder hoist reference values.
5
controller If no failure is found by above checks and monitored radiator speed remains
at "0", retarder hoist controller may be defective. (Since this is an internal
defect, troubleshooting cannot be performed).

HM400-3M0 40-525
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to radiator fan speed sensor

40-526 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor (HM400_3-DLM3LC-

400-A-Z0-A)

Action level Failure code Failure of Radiator Fan Speed Sensor

Failure
L01 DLM3LC (Transmission controller system)
Detail of • Radiator fan speed went to zero while engine is run and fan is rotating in normal direction.
failure
Action of • Stops feedback control of radiator fan.
controller
Problem on • Degraded fuel economy or overheating may result because of unachievable target speed.
machine
• Radiator fan speed and target radiator fan speed can be checked with monitoring
function.
Related (Code: Radiator fan speed is 10007 (rpm) and target radiator fan speed is 10014 (rpm).
information • Data from radiator fan speed sensor is sent by hoist controller to transmission controller
through CAN communication.
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector B13 and connect T-adapters to male side.
Defective radiator fan
1 speed sensor 1,500 to
Between B13 (male) (1) and (2)
Resistance 3,500 z
Between ground and each of B13 (male) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector BRC2 and connect T-adapters to female side.
Open or short circuit in
2 wiring harness a Coil resistance of radiator fan speed sensor
1,500 to
Resistance Between BRC2 (female) (40) and (29) 3,500 z
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector BRC1 and connect T-adapters to female side.
3 (wire breakage or Between BRC2 (female) (40) and B13 (female) (1) Max. 1 z
defective contact of Resistance
connector) Between BRC2 (female) (29) and B13 (female) (2) Max. 1 z

Ground fault in wiring 1. Turn starting switch to OFF position.

harness 2. Disconnect connectors BRC2 and B13, and connect T-adapters to either
4 female side.
(contact with ground
Between ground and BRC2 (female) (40) or B13
circuit) Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connectors BRC2 and B13.
Short circuit in wiring 3. Connect T-adapters to female side of BRC2.
5
harness
Between BRC2 (female) (40) and each pin other
Resistance than pin (40) Min. 1 Mz

1. Turn starting switch to OFF position.

Hot short circuit in 2. Disconnect connector B13.
wiring harness 3. Insert T-adapters into connector BRC2, or connect T-adapters to
6 connector B13.
(contact with 24 V 4. Turn starting switch to ON position.
circuit)
Between ground and BRC2 (female) (40) or B13
Voltage Max. 4.5 V
(female) (1)

HM400-3M0 40-527
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

1. Start engine.
2. Monitoring code: Check radiator fan speed using 10007 and 10014 as
Defective retarder hoist reference values.
7
controller If no failure is found by above checks and monitored radiator speed remains
at "0", retarder hoist controller may be defective. (Since this is an internal
defect, troubleshooting cannot be performed).
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
8
controller performed).

Circuit diagram related to radiator fan speed sensor

40-528 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLM3MB] Radiator Fan Control Mismatch (HM400_3-DLM3MB-400-A-Z0-A)

Action level Failure code Radiator Fan Control Mismatch

Failure
L01 DLM3MB (Transmission controller system)
Detail of • Difference between actual radiator fan speed and target speed reached 400 rpm or
failure greater while engine is run and fan is rotating in normal direction.
Action of • Stops feedback control of radiator fan.
controller
Problem on • Overheating or degraded fuel economy may result because of unachievable target speed.
machine
• Radiator fan speed and target radiator fan speed can be checked with monitoring
function.
Related (Code: Radiator fan speed is 10007 (rpm) and target radiator fan speed is 10014 (rpm).
information • Data from radiator fan speed sensor is sent by hoist controller to transmission controller
through CAN communication.
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Increase hydraulic oil temperature to 50°C minimum and turn starting
Variations in performance switch to OFF position once. Then start engine again and check whether
1 due to hydraulic oil failure will be indicated again.
temperature
If indicated again, check the followings.
1. Turn starting switch to OFF position.
2. Disconnect connector B13 and connect T-adapters to male side.
Defective radiator fan speed 1,500 to 3,500
2 Between B13 (male) (1) and (2)
sensor Resis- Mz
tance Between ground and each of B13 (male)
(1) and (2) Min. 1 Mz
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed).

Circuit diagram related to radiator fan speed sensor

HM400-3M0 40-529
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLM4KA] Disconnection of CAC Fan Speed Sensor (HM300_3-

DLM4KA-400-A-Z0-A)

Action level Failure code Disconnection of CAC Fan Speed Sensor

Failure
L01 DLM4KA (Retarder hoist controller system)
Detail of • CAC fan speed falls to zero while engine is running and fan is running in normal direction.
failure
Action of • None in particular.
controller
Problem on • Target speed is not reached, so engine power may be degraded or fuel consumption may
machine increase.
• CAC fan speed and CAC fan target speed can be checked with monitoring function.
Related (Code: CAC fan speed 10008 (rpm), CAC fan target speed 10015 (rpm))
information • Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector B01 and connect T-adapter to male side.
Defective CAC fan speed 1,500 to 3,500
1 Between B01 (male) (1) and (2)
sensor Resis- z
tance Between ground and each of B01 (male)
(1), (2) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connector BRC2 and connect T-adapter to female side.
Open or short circuit in wiring
2 a Coil resistance of CAC fan speed sensor
harness
Resis- Between BRC2 (female) (30) and (29) 1,500 to 3,500
tance z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connector BRC1 and connect T-adapter to female side.
Between BRC2 (female) (30) and B01
3 (wire breakage or defective Max. 1 z
Resis- (female) (1)
contact of connector)
tance Between BRC2 (female) (29) and B01
(female) (2) Max. 1 z

1.Turn starting switch to OFF position.

Hot short circuit in wiring
harness
4 4.Turn starting switch to ON position.
(contact with 24 V circuit)
5 Defective retarder controller
2.Disconnect connector B01.
3.Insert T-adapter to BRC2, or connect T-adapter to B01.
Between ground and BRC2 (female) (30)
Voltage Max. 1 V
or B01 (female) (1)
1. Start engine.
2. Use monitoring code 10015 to check CAC speed.
If no failure is found by above checks and CAC fan speed indicated on
monitor is zero, retarder controller may be defective. (Since this is an
internal defect, troubleshooting cannot be performed.)

40-530 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to CAC fan speed sensor

HM400-3M0 40-531
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLM4LC] Failure of CAC Fan Speed Sensor (HM300_3-DLM4LC-400-A-Z0-

A)

Action level Failure code Failure of CAC Fan Speed Sensor

Failure
L01 DLM4LC (Transmission controller system)
Detail of • CAC fan speed falls to zero while engine is running and fan is running in normal direction.
failure
Action of
• Cancels CAC fan feedback control.
controller
Problem on • Target speed is not reached, so engine power may be degraded or fuel consumption may
machine increase.
• CAC fan speed and CAC fan target speed can be checked with monitoring function.
(Code: CAC fan speed 10008 (rpm), CAC fan target speed 10015 (rpm))
Related • CAC fan speed sensor data is sent from retarder hoist controller to transmission controller
information through CAN.
• Method of reproducing failure code: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.

2. Disconnect connector B01 and connect T-adapter to male side.
Defective CAC fan speed 1,500 to 3,500
1 Between B01 (male) (1) and (2)
sensor Resis- z
tance Between ground and each of B01 (male)
(1), (2) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connector BRC2 and connect T-adapter to female side.
Open or short circuit in wiring
2 a Coil resistance of CAC fan speed sensor
harness
Resis- Between BRC2 (female) (30) and (29) 1,500 to 3,500
tance z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connector BRC1 and connect T-adapter to female side.
Between BRC2 (female) (30) and B01
3 (wire breakage or defective Max. 1 z
Resis- (female) (1)
contact of connector)
tance Between BRC2 (female) (29) and B01
(female) (2) Max. 1 z

1. Turn starting switch to OFF position.

Ground fault in wiring harness 2. Disconnect connectors BRC2, B01, and connect T-adapter to either
4 female side.
(contact with ground circuit)
Resis- Between ground and BRC2 (female) (30)
or B01 (female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC2 and B01.
5 Short circuit in wiring harness 3. Connect T-adapter to female side of BRC2.
Resis- Between BRC2 (female) (30) and each pin Min. 1 Mz
tance other than (30)

40-532 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.

Hot short circuit in wiring
harness
6 4. Turn starting switch to ON position.
(contact with 24 V circuit)
7 Defective retarder controller
Defective transmission
8
controller
2. Disconnect connector B01.
3. Insert T-adapter to BRC2, or connect T-adapter to B01.
Between ground and BRC2 (female) (30)
Voltage Max. 1 V
or B01 (female) (1)
1. Start engine.
2. Use monitoring code 10015 to check CAC speed.
If no failure is found by above checks and CAC fan speed indicated on
monitor is zero, retarder controller may be defective. (Since this is an
internal defect, troubleshooting cannot be performed.)
If no failure is found by above checks, transmission controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)

Circuit diagram related to CAC fan speed sensor

HM400-3M0 40-533
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLM4MB] CAC Fan Control Mismatch (HM300_3-DLM4MB-400-A-Z0-A)

Action level Failure code CAC Fan Control Mismatch

Failure
L01 DLM4MB (Transmission controller system)
Detail of • Difference between actual CAC fan speed and target speed exceeded 300 rpm while
failure engine is running and fan is running in normal direction.
Action of
• Cancels CAC fan feedback control.
controller
Problem on • Target speed is not reached, so engine power may be degraded or fuel consumption may
machine increase.
• CAC fan speed and CAC fan target speed can be checked with monitoring function.
(Code: CAC fan speed 10008 (rpm), CAC fan target speed 10015 (rpm))
Related • CAC fan speed sensor data is sent from retarder hoist controller to transmission controller
information through CAN.
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Run engine and raise hydraulic oil temperature above 50 °C . Shut down
Variation in performance due engine, and then restart engine to check if this failure code appears.
1 to hydraulic oil temperature
If this failure code appears again, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector B01 and connect T-adapter to male side.
Defective CAC fan speed 1,500 to 3,500
2 Between B01 (male) (1) and (2)
sensor Resis- Mz
tance Between ground and each of B01 (male)
(1) and (2) Min. 1 Mz
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)

Circuit diagram related to CAC fan speed sensor

40-534 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLT3KA] Disconnection of Output Speed Sens.

(Main) (HM300_3-DLT3KA-400-A-Z0-A)
Action level Failure code Disconnection of Output Speed Sensor (Main)
Failure
L03 DLT3KA (Transmission controller system)
Detail of • No speed signal is input due to open circuit in transmission output shaft speed sensor
failure circuit.
Action of • Keeps current gear speed and disables lockup.
controller • Leaves transmission in NEUTRAL once gear shift lever is returned to NEUTRAL position.
• Lockup clutch is disengaged and gear shifting is disabled.
Problem on
• When gear shift lever is put in NEUTRAL, machine is unable to drive unless it is stopped
machine
once.

k Tilt the cab up and secure it in place with lock bar. Ensure that lock lever is in the
CLOSED position. (See Testing and adjusting, "Method of tilting cab up".
Related
information • Transmission output shaft speed can be checked with monitoring function. (Code: 31400
(rpm))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks

k Tilt the cab up (as explained above).

Defective adjustment of
transmission output shaft • Screw in sensor until it touches speed pickup gear lightly, then return
1
speed sensor it by 1/2 to one turn.
a For details, see Testing and adjusting, "Adjusting transmission
speed sensors".
1. Turn starting switch to OFF position.
2. Disconnect connector N3 (CN5) and connect T-adapter to male side.
Defective transmission output
2 shaft speed sensor Between N3 (CN5) (male) (1) and (2) 500 to 1,000 z
Resis-
Between ground and each of N3 (CN5)
tance Min. 1 Mz
(male) (1) and (2)
a Lower tilted-up cab.
Open or short circuit in wiring 1. Turn starting switch to OFF position.
3 2. Disconnect connector ATC2 and connect T-adapter to female side.
harness
Resis- Between ATC2 (female) (30) and (29)
500 to 1,000 z
tance
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC2 and connect T-adapter to female side.

Open circuit in wiring harness
4 (wire breakage or defective
contact of connector)
Defective transmission
5
controller
k Tilt the cab up (as explained above).
3. Disconnect connector N3 (CN5) and connect T-adapter to female
side.
Between ATC2 (female) (30) and N3 (CN5)
Max. 1 z
Resis- (female) (1)
tance Between ATC2 (female) (29) and N3 (CN5)
(female) (2) Max. 1 z
If no failure is found by above checks, transmission controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)

HM400-3M0 40-535
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to transmission output shaft speed sensor

40-536 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLT3LC] Failure of Output Speed Sensor (Main) (HM300_3-DLT3LC-

400-A-Z0-A)

Action level Failure code Failure of Output Speed Sensor (Main)

Failure
L01 DLT3LC (Transmission controller system)
• Unusual calculated speed is obtained from signals of engine speed sensor, transmission
Detail of input shaft speed sensor, and transmission output shaft speed sensor, and speed
failure obtained from transmission intermediate shaft speed sensor signals is also unusual.
Action of • Keeps current gear speed and disables lockup.
controller • Leaves transmission in NEUTRAL once gear shift lever is returned to NEUTRAL position.
• Lockup clutch is disengaged and gear shifting is disabled.
Problem on
• When gear shift lever is put in NEUTRAL, machine is unable to drive unless it is stopped
machine
once.

k Tilt the cab up and secure it in place with lock bar. Ensure that lock lever is in the
CLOSED position. (See Testing and adjusting, "Method of tilting cab up".
Related
information • Transmission output shaft speed can be checked with monitoring function. (Code: 31400
(rpm))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt the cab up (as explained above).
2. Turn starting switch to OFF position.
Defective transmission output 3. Disconnect connector N3 (CN5) and connect T-adapter to male side.
1 shaft speed sensor Between N3 (CN5) (male) (1) and (2) 500 to 1,000 z
Resis-
Between ground and each of N3 (CN5)
tance Min. 1 Mz
(male) (1) and (2)
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC2 and connect T-adapter to female side.
2 Ground fault in wiring harness 4. Tilt the cab up (as explained above).
5. Disconnect connector N2 (CN4) and connect T-adapter to female
side.
Resis- Between ground and ATC2 (female) (30) or
N3 (CN5) (female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connector N3 (CN5) and connect T-adapter to female
Hot short circuit in wiring side.
3
harness 3. Turn starting switch to ON position.
Voltage Between N3 (CN5) (female) (1) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connector N3 (CN5).
3. Tilt the cab up (as explained above).
4 Short circuit in wiring harness
4. Disconnect connector ATC2 and connect T-adapter to female side.
Resis- Between ATC2 (female) (30) and each pin
other than (30) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

HM400-3M0 40-537
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to transmission output shaft speed sensor

40-538 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DPQ1KR] LIN Discon (Switch Panel) (HM300_3-DPQ1KR-400-A-Z0-A)

Action level Failure code LIN Disconnection (Switch Panel)

Failure
L01 DPQ1KR (Machine monitor system)
Detail of • Updating of data received from switch panel (control switch of machine monitor) via LIN
failure communication is interrupted.
Action of • None in particular.
controller
• You cannot enter user menu and service menu screens, so settings using these menus
cannot be performed.
Problem on • Air conditioner cannot be controlled.
machine • SMR cannot be displayed on screen while starting switch is in OFF position.
• If engine start lock is enabled, you cannot start engine since you cannot enter password.
• Since signal of active LIN communication line is pulse voltage, it cannot be measured by
using multimeter.
Related • When failure code [DPQ2KR] or [DPQ3KR] is displayed simultaneously on screen,
information ground fault or hot short circuit may occur in LIN communication line.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Ground fault or hot short
If failure code [DAFDKB] is also displayed, perform troubleshooting for
1 circuit in 12 V power supply
[DAFDKB] first.
line of switch panel
1. Turn starting switch to OFF position.
Open circuit in 12 V power 2. Disconnect connector OPM and connect T-adapters to female side.
2 supply line of switch panel 3. Turn starting switch to ON position.
Voltage Between OPM (female) (1) and (2) 9 to 14 V
1. Turn starting switch to OFF position.
Open circuit in 5 V power 2. Disconnect connector OPM and connect T-adapters to female side.
3 supply line of switch panel 3. Turn starting switch to ON position.
Voltage Between OPM (female) (4) and (2) 4 to 6 V
a If failure code [DPQ2KR] or [DPQ3KR] is not displayed, this check is
Hot short circuit in wiring not required.
harness (LIN communication 1. Turn starting switch to OFF position.
4 line) 2. Disconnect connector OPM and connect T-adapters to female side.
(contact with 24 V circuit) 3. Turn starting switch to ON position.
Voltage Between OPM (female) (3) and (2) Approx. 9 V
a If failure code [DPQ2KR] or [DPQ3KR] is not displayed, this check is
not required.
a If no failure is found by check on cause 4, this check is not required.
Ground fault in wiring harness 1. Turn starting switch to OFF position.
5
(contact with ground circuit) 2. Disconnect connectors MCM2, DPC2, OPM and RMN1, and
connect T-adapters to either female side.
Between ground and any of MCM2
Resis- (female) (108) or DPC2 (female) (3) or
Min. 1 Mz
tance OPM (female) (3) or RMN1 (female) (9)
• If failure code [DPQ2KR] or [DPQ3KR] is also displayed, perform
following check.
Defective switch panel 1. Turn starting switch to OFF position.
6 (control switch on machine 2. Disconnect connector OPM.
monitor) 3. Turn starting switch to ON position.
If failure code [DPQ2KR] or [DPQ3KR] is no longer displayed, switch
panel is defective.

HM400-3M0 40-539
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

Defective LED unit (machine
7 2. Disconnect connector DPC2.
monitor display)
8 Defective rear view monitor
9 Defective monitor controller
• If failure code [DPQ2KR] or [DPQ3KR] is also displayed, perform
following check.
1. Turn starting switch to OFF position.
3. Turn starting switch to ON position.
If failure code [DPQ1KR] or [DPQ3KR] is no longer displayed, LED unit
is defective.
• If failure code [DPQ2KR] or [DPQ3KR] is also displayed, perform
following check.
1. Turn starting switch to OFF position.
2. Disconnect connector RMN1.
3. Turn starting switch to ON position.
If failure code [DPQ1KR] or [DPQ2KR] is no longer displayed, rear view
monitor is defective.
If no failure is found by above checks, monitor controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).

40-540 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to LIN communication

HM400-3M0 40-541
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DPQ2KR] LIN Discon (LED Unit) (HM300_3-DPQ2KR-400-A-Z0-A)

Action level Failure code LIN Disconnection (LED Unit)

Failure
L01 DPQ2KR (Machine monitor system)
Detail of • Updating of data received from LIN unit (machine monitor display) via LIN communication
failure is interrupted.
Action of • None in particular.
controller
Following displays do not indicate actual conditions.
• Turn signal lamp (hazard lamp)
• High beam
Problem on
• Parking brake
machine
• Pressure drop of accumulator
• Clearance pilot lamp
• Centralized warning lamp
• Since signal of active LIN communication line is pulse voltage, it cannot be measured by
using multimeter.
Related • When failure code [DPQ1KR] or [DPQ3KR] is displayed simultaneously on screen,
information ground fault or hot short circuit may occur in LIN communication line.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Ground fault or hot short If failure code [DAFDKB] is also displayed, perform troubleshooting for
1 circuit in 12 V power supply [DAFDKB] first.
line of LED unit.
1. Turn starting switch to OFF position.
Open circuit in 12 V power 2. Disconnect connector DPC2 and connect T-adapters to female side.
2 supply line of LED unit 3. Turn starting switch to ON position.
Voltage Between DPC2 (female) (1) and (2) 9 to 14 V
1. Turn starting switch to OFF position.
Defective 5 V power supply 2. Disconnect connector DPC2 and connect T-adapters to female side.
3 3. Turn starting switch to ON position.
line of LED unit
Voltage Between DPC2 (female) (4) and (2) 4 to 6 V
a If failure code [DPQ1KR] or [DPQ3KR] is not displayed, this check is
Hot short circuit in wiring not required.
harness (LIN communication 1. Turn starting switch to OFF position.
4 line) 2. Disconnect connector DPC2 and connect T-adapters to female side.
(contact with 24 V circuit) 3. Turn starting switch to ON position.
Voltage Between DPC2 (female) (3) and (2) Approx. 9 V
a If failure code [DPQ1KR] or [DPQ3KR] is not displayed, this check is
not required.
a If no failure is found by check on cause 4, this check is not required.
Ground fault in wiring harness 1. Turn starting switch to OFF position.
5
(contact with ground circuit) 2. Disconnect connectors MCM2, DPC2, OPM and RMN1, and
connect T-adapters to either female side.
Between ground and any of MCM2
Resis- (female) (108) or DPC2 (female) (3) or
Min. 1 Mz
tance OPM (female) (3) or RMN1 (female) (9)

40-542 HM400-3M0

No. Cause
Defective switch panel
6 (control switch on machine
monitor)
Defective LED unit (machine
7 2. Disconnect connector DPC2.
monitor display)
8 Defective rear view monitor
9 Defective monitor controller
HM400-3M0
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Procedure, measuring location, criteria and remarks
• If failure code [DPQ1KR] or [DPQ3KR] is also displayed, perform
following check.
1. Turn starting switch to OFF position.
2. Disconnect connector OPM.
3. Turn starting switch to ON position.
If failure code [DPQ2KR] or [DPQ3KR] is no longer displayed, switch
panel is defective.
• If failure code [DPQ1KR] or [DPQ3KR] is also displayed, perform
following check.
1. Turn starting switch to OFF position.
3. Turn starting switch to ON position.
If failure code [DPQ1KR] or [DPQ3KR] is no longer displayed, LED unit
is defective.
• If failure code [DPQ1KR] or [DPQ3KR] is also displayed, perform
following check.
1. Turn starting switch to OFF position.
2. Disconnect connector RMN1.
3. Turn starting switch to ON position.
If failure code [DPQ1KR] or [DPQ2KR] is no longer displayed, rear view
monitor is defective.
If no failure is found by above checks, monitor controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
40-543
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to LIN communication

40-544 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DPQ3KR] LIN Discon (Rear View Monitor) (HM300_3-DPQ3KR-400-A-Z0-A)

Action level Failure code LIN Disconnection (Rear View Monitor)

Failure
L01 DPQ3KR (Machine monitor system)
Detail of • Updating of data received from rear view monitor via LIN communication is interrupted. .
failure
Action of • None in particular.
controller
Problem on • Rear view camera related settings are disabled (reference line display selection, reverse-
machine interlock mode selection, guide line position adjustment, rear view monitor initialization).
• Since signal of active LIN communication line is pulse voltage, it cannot be measured by
using multimeter.
Related • When failure code [DPQ1KR] or [DPQ2KR] is displayed simultaneously on screen,
information ground fault or hot short circuit may occur in LIN communication line.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse No. 28 in fuse If fuse is blown, circuit may have ground fault. (See check on cause 5.)
1
box BT2
Defective engine shutdown If failure code [DDAAL6] is also displayed, perform troubleshooting for
2 secondary switch system [DDAAL6] first.
1. Turn starting switch to OFF position.
2. Disconnect connector RMN1, and connect T-adapters to female side.
3 Defective power supply line 3. Turn starting switch to ON position.
Between RMN1 (female) (1) and (2) 20 to 30 V
Voltage
Between RMN1 (female) (1) and (2) 20 to 30 V
a If failure code [DPQ1KR] or [DPQ2KR] is not displayed, this check is
Hot short circuit in wiring not required.
harness (LIN communication 1. Turn starting switch to OFF position.
4 line) 2. Disconnect connector RMN1, and connect T-adapters to female side.
(contact with 24 V circuit) 3. Turn starting switch to ON position.
Voltage Between RMN1 (female) (9) and (2) Approx. 9 V
a If failure code [DPQ1KR] or [DPQ2KR] is not displayed, this check is
not required.
a If no failure is found by check on cause 4, this check is not required.
Ground fault in wiring
harness 1. Turn starting switch to OFF position.
5
2. Disconnect connectors MCM2, DPC2, OPM and RMN1, and connect
(contact with ground circuit) T-adapters to either female side.
Between ground and any of MCM2 (female)
Resis- (108) or DPC2 (female) (3) or OPM (female) Min. 1 Mz
tance (3) or RMN1 (female) (9)
• If failure code [DPQ1KR] or [DPQ2KR] is also displayed, perform
following check.
Defective switch panel 1. Turn starting switch to OFF position.
6 (control switch on machine 2. Disconnect connector RMN1.
monitor) 3. Turn starting switch to ON position.
If failure code [DPQ2KR] or [DPQ3KR] is no longer displayed, switch
panel is defective.
• If failure code [DPQ1KR] or [DPQ2KR] is also displayed, perform
following check.
1. Turn starting switch to OFF position.
Defective LED unit (machine
7 2. Disconnect connector DPC2.
monitor display)
3. Turn starting switch to ON position.
If failure code [DPQ1KR] or [DPQ3KR] is no longer displayed, LED unit
is defective.

HM400-3M0 40-545
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

8 Defective rear view monitor
9 Defective monitor controller
• If failure code [DPQ1KR] or [DPQ2KR] is also displayed, perform
following check.
1. Turn starting switch to OFF position.
2. Disconnect connector RMN1.
3. Turn starting switch to ON position.
If failure code [DPQ1KR] or [DPQ2KR] is no longer displayed, rear view
monitor is defective.
If no failure is found by above checks, monitor controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).

40-546 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to LIN communication

HM400-3M0 40-547
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DSJ0KR] CAN2 Discon (Meter Unit) (HM300_3-DSJ0KR-400-A-Z0-A)

Action level Failure code CAN2 Disconnection (Meter Unit)

Failure
L03 DSJ0KR (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller cannot recognize meter unit (display unit: connector DPC3) of machine
failure monitor over CAN 2 communication line (KOMNET/c).
Action of • None in particular.
controller
Problem on • Engine tachometer pointer indicates zero.
machine • Speedometer displays "00".
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• Monitor controller uses six failure codes, [D8AQK*], [DAQQKR], [DAZQKR], [DB1QKR],
[DB2QKR], and [DSJ0KR] to indicate failure in CAN communication through CAN 2 line.
When all of these six failure codes are displayed simultaneously on screen, ground fault,
short circuit, or hot short circuit may occur in wiring harness (CAN communication line).
Since air conditioner is also controlled through CAN communication, check whether air
Related
conditioner is operated (ON/OFF and air flow adjustment) on air conditioner screen.
information
a Air conditioner can be operated even when failure code is displayed on machine monitor
screen. If air conditioner is operated, there is no possibility of ground fault, short circuit, or
hot short circuit in wiring harness (CAN communication circuit).
• Since each controller and machine monitor (meter unit) are connected directly to battery,
they are supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria and remarks
Defective power supply to Perform troubleshooting for E-9 "Meter unit display on machine monitor
1
meter unit of machine monitor is abnormal" of E-mode.
Defective CAN2 Perform checks on causes 4 to 10 in troubleshooting for failure code
2 communication system [DB2QKR].
If no failure is found by above checks, meter unit of machine monitor is
Defective meter unit of defective.
3
machine monitor
(Since this is an internal defect, troubleshooting cannot be performed.)
If no failure is found in above checks, monitor controller is defective.
4 Defective monitor controller
(Since this is an internal defect, troubleshooting cannot be performed.)

40-548 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DV00KB] Ground Fault of Buzzer Output (HM300_3-DV00KB-400-A-Z0-A)

Action level Failure code Ground Fault of Buzzer Output

Failure
L01 DV00KB (Machine monitor system)
Detail of • Unusual current flows when power is output to alarm buzzer circuit.
failure
• Stops outputting signal voltage to alarm buzzer circuit.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on
• Alarm buzzer does not sound.
machine
• Operating condition of alarm buzzer (ON or OFF) can be checked with monitoring
function.
Related
(Code: 04700 buzzer)
information
• Method of reproducing failure code: Turn starting switch to ON position and take action to
sound alarm buzzer.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector BZ2 and connect T-adapters to female side.
3. Turn starting switch to ON position.
a If the following voltages are normal and alarm buzzer does not
Defective alarm buzzer operate, alarm buzzer may be defective.
1
(internal defect) When not driving
Max. 1 V
alarm buzzer
Between BZ2 (female) (1)
Voltage When driving
and (2)
alarm buzzer (at 20 to 30 V
start)
1. Turn starting switch to OFF position.
2. Disconnect connectors MCM1 and BZ2, and connect T-adapters to
2 Open circuit in wiring harness each female side.
Resis- Between MCM1 (female) (20) and BZ2 (female)
(1) Max. 1 z
tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors MCM1 and BZ2, and connect T-adapters to
3 either female side.
(contact with ground circuit)
Resis- Between ground and MCM1 (female) (20) or
BZ2 (female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BZ2.
3. Turn starting switch to ON position.
4 Defective monitor controller When not driving
Max. 1 V
alarm buzzer
Voltage Between BZ2 (1) and (2) When driving
alarm buzzer (at 20 to 30 V
start)

HM400-3M0 40-549
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to buzzer

40-550 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW2BKA] Disconnection of Main Flow Selector Sol. (HM300_3-

DW2BKA-400-A-Z0-A)

Action level Failure code Disconnection of Main Flow Selector Solenoid

Failure
L01 DW2BKA (Transmission controller system)
Detail of • When driving main flow selector solenoid, no current flows through circuit.
failure
Action of • Stops driving main flow selector solenoid.
controller
Problem on • Fuel consumption may increase since two pumps are constantly used.
machine
• Output signal to main flow selector solenoid can be checked with monitoring function.
Related (Code: 31644 (mA)
information • Method of reproducing failure code: Start engine and increase transmission oil
temperature above 60 °C .
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective main flow selector 2. Disconnect connector CN25 and connect T-adapters to male side.
1
solenoid Resis- Between CN25 (male) (1) and (2) 5 to 15 z
tance Between ground and CN25 (1) or (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC3 and CN25, and connect T-adapters to
each female side.
2 Open circuit in wiring harness Between ATC3 (female) (7) and CN25 (female)
Max. 1 z
Resis- (1)
tance Between ATC3 (female) (13) and CN25
(female) (2) Max. 1 z
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)

Circuit diagram related to main flow selector solenoid

HM400-3M0 40-551
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW2BKB] Ground Fault of Main Flow Selector Sol. (HM300_3-
DW2BKB-400-A-Z0-A)

Action level Failure code Ground Fault of Main Flow Selector Solenoid
Failure
L01 DW2BKB (Transmission controller system)
Detail of • When driving main flow selector solenoid, excessive current flows through circuit.
failure
Action of • Stops driving main flow selector solenoid.
controller
Problem on • If machine continues traveling, more fuel is consumed.
machine
• Output signal to main flow selector solenoid can be checked with monitoring function.
Related (Code: 31644 (mA)
information • Method of reproducing failure code: Start engine and increase transmission oil
temperature above 60 °C .
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective main flow selector 2. Disconnect connector CN25 and connect T-adapters to male side.
1
solenoid Resis- Between CN25 (male) (1) and (2) 5 to 15 z
tance Between ground and each of CN25 (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
Short circuit in wiring harness 2. Disconnect connectors ATC3 and CN25, and connect T-adapters to
2 female side of ATC3.
(contact with ground circuit)
Resis- Between ATC3 (female) (7) and ground
Min. 1 Mz
tance
1. Turn starting switch to OFF position.
Short circuit in wiring harness 2. Disconnect connectors ATC3 and CN25, and connect T-adapters to
3 female side of ATC3.
(Contact between harnesses)
Resis- Between ATC3 (female) (7) and ATC3 (female)
(13) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed).

Circuit diagram related to main flow selector solenoid

40-552 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW2BKY] Hot Short of Main Flow Selector Sol. (HM300_3-DW2BKY-400-
A-Z0-A)

Action level Failure code Hot Short of Main Flow Selector Solenoid
Failure
L01 DW2BKY (Transmission controller system)
Detail of • When controller does not drive main flow selector solenoid, current flows through circuit.
failure
Action of • Stops driving main flow selector solenoid.
controller
Problem on • Failure code "15*0MW" may be generated due to insufficient oil pressure.
machine
• Output signal to main flow selector solenoid can be checked with monitoring function.
Related (Code: 31644 (mA)
information • Method of reproducing failure code: Start engine and raise transmission oil temperature
60°C or above.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective main flow selector 2. Disconnect connector CN25 and connect T-adapters to male side.
1
solenoid Resis- Between CN25 (male) (1) and (2) 5 to 15 z
tance Between CN25 (1), (2) and ground Min. 1 Mz
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector CN25 and connect T-adapters to male side.
2 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between CN (25) (female) (1) and ground Max. 4.5 V
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed).

Circuit diagram related to main flow selector solenoid

HM400-3M0 40-553
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW2BL1] Release Trouble of Main Flow Sel. Valve (HM300_3-
DW2BL1-400-A-Z0-A)

Action level Failure code Release Trouble of Main Flow Selector Valve
Failure
L01 DW2BL1 (Transmission controller system)
Detail of • When controller is not driving main flow selector solenoid circuit, signal from pressure
failure sensor of main flow selector solenoid valve does not respond correctly.
Action of • Stops driving main flow selector solenoid.
controller
Problem on • Failure code "15*0MW" may be generated due to insufficient oil pressure.
machine

k Tilt the cab up and hold it securely with lock bar before connecting and
disconnecting the solenoid connector (See Testing and adjusting, "Method of tilting
cab up")

k Do not start the engine while the cab is tilted up.

Related
information • Output to main flow selector solenoid can be checked with monitoring function.
(Code: Solenoid output condition 31644 (mA), pressure sensor signal 77000 (MPa),
77001 (V))
• Transmission oil temperature can be checked with monitoring function.
(Code: Transmission oil temperature 32500 ( °C ))
• Method of reproducing failure code: Start engine and raise transmission oil temperature
60 °C or above.
No. Cause Procedure, measuring location, criteria and remarks
1 Defective hydraulic system If failure code [15*0MW] is displayed, perform troubleshooting for it first.
2 Defective hydraulic piping Hydraulic piping may be defective. Check it.
a Start engine and raise transmission oil temperature above 60 °C
Defective operating pressure 1. Turn starting switch to OFF position.
3 sensor of main flow selector 2. Tilt cab up and hold it with lock bar.
solenoid valve 3. Insert T-adapter into connector CN26.
4. Turn starting switch to ON position.
Voltage Between CN26 (2) and (1) 0.8 to 2.0 V
Defective main flow selector
4 Perform troubleshooting for failure codes [DW2BKB] and [DW2BKY].
solenoid system
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

Circuit diagram related to operating pressure sensor of main flow selector solenoid valve

40-554 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW2BLH] Malfunction of Main Flow Selector Valve (HM300_3-

DW2BLH-400-A-Z0-A)

Action level Failure code Malfunction of Main Flow Selector Valve

Failure
L01 DW2BLH (Transmission controller system)
Detail of • When controller is driving main flow selector solenoid circuit, signal from pressure sensor
failure of main flow selector solenoid valve does not respond correctly.
Action of • Stops driving main flow selector solenoid.
controller
Problem on • If machine continues to travel in this condition, fuel consumption may increase.
machine

k Tilt the cab up and hold it securely with lock bar before connecting and
disconnecting the solenoid connector (See Testing and adjusting, "Method of tilting
cab up")

k Do not start the engine while the cab is tilted up.

Related
information • Output to main flow selector solenoid can be checked with monitoring function.
(Code: Solenoid output condition 31644 (mA), pressure sensor signal 77000 (MPa),
77001 (V))
• Transmission oil temperature can be checked with monitoring function.
(Code: Transmission oil temperature 32500 ( °C ))
• Method of reproducing failure code: Start engine and raise transmission oil temperature
60 °C or above.
No. Cause Procedure, measuring location, criteria and remarks
Defective main flow selector
1 Perform troubleshooting for failure code [DW2BL1]
solenoid system

HM400-3M0 40-555
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW4BK4] Release Trouble of Parking Brake Valve (HM400_3-

DW4BK4-400-A-Z0-A)

Action level Failure code Release Trouble of Parking Brake Valve

Failure
L03 DW4BK4 (Retarder hoist controller system)
Detail of • Parking brake oil pressure appears when parking brake switch is set to PARKING
failure position.
Action of • None in particular.
controller
Problem on • Parking break is not applied.
machine
• Signal from parking brake pressure sensor can be checked with monitoring function.
(Code: 91908 (MPa) and 91909 (V))
• Parking brake safety relay works as self-holding relay.
1. When parking brake switch is operated, pin 5 and pin 6 of parking brake switch are
connected with each other.
Related 2. Parking brake safety relay R20 is engaged and R20 works as self-holding relay.
information 3. Releasing parking brake switch connects pins 4 and 5 of parking brake switch, while
R20 remains activated. As a result, parking brake solenoid is activated.
• Method of reproducing failure code: Turn the parking brake switch to the PARKING
position and start the engine.
• Since T-adapter is not prepared for connector of parking brake pressure sensor, measure
voltage at controller.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Interchange parking brake safety relay R20 and horn relay R10.
Defective connector R20 3. Turn the parking brake switch to the PARKING position and start the
1 (parking brake safety relay) engine.
If this failure code does not appear, original parking brake safety relay is
defective.
1. Turn starting switch to OFF position.
2. Disconnect connector BRC3 and connect T-adapters to female side.
Open circuit in parking brake 3. Turn starting switch to ON position.
2 switch signal input circuit. Parking brake switch:
Between BRC3 (female) (29) and Max. 1 V
PARKING
(23) Parking brake switch:
Min. 18 V
TRAVEL
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC2.
Defective parking brake 3. Turn starting switch to ON position.
3 pressure sensor Parking brake switch:
Between BRC2 (35) and BRC3 0.3 to 0.81 V
(23) PARKING
Parking brake switch: 2.42 to 3.22
(Between B17 (2) and (1))
TRAVEL V
Defective parking brake Perform testing and troubleshooting of parking brake hydraulic piping or
4 hydraulic circuit or parking parking brake valve.
brake valve

40-556 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to parking brake

HM400-3M0 40-557
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW4BMA] Malfunction of Parking Brake Valve (HM400_3-DW4BMA-400-

A-Z0-A)

Action level Failure code Malfunction of Parking Brake Valve

Failure
L03 DW4BMA (Retarder hoist controller system)
Detail of • Parking brake oil pressure does not appear when parking brake switch is set to TRAVEL
failure position.
Action of • None in particular.
controller
Problem on • Parking brake is not released.
machine
• Signal from parking brake pressure sensor can be checked with monitoring function.
Related (Code: 91908 (MPa) and 91909 (V))
information • Method of reproducing failure code: Start engine and set parking brake switch to TRAVEL
position.
No. Cause Procedure, measuring location, criteria and remarks
Defective parking brake
1 Perform troubleshooting for failure code [DW4BK4]
system

40-558 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW72KZ] Failure of Kick out Solenoid (HM300_3-DW72KZ-400-A-Z0-A)

Action level Failure code Failure of Kick out Solenoid

Failure
L01 DW72KZ (Retarder hoist controller system)
• No current flows or too much current flows when controller drives dump lever kick out
Detail of
solenoid circuit, or current flows when controller does not drive dump lever kick out
failure
solenoid circuit.
Action of • Stops driving kick out solenoid if cause of failure is short circuit.
controller
Problem on • Dump lever detent (between HOLD and RAISE) does not work, or remains working.
machine
Related • Method of reproducing failure code: Start engine and set dump lever to RAISE position.
information
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector LKO and connect T-adapter to male side.
Defective dump lever kick out
1 Between LKO (male) (1) and (2) 39 z ± 5%
solenoid Resis-
Between ground and each of LKO (male) (1)
tance Min. 1 Mz
and (2)
1. Turn starting switch to OFF position.
2. Disconnect connector BRC3 and connect T-adapter to female side.
Open or short circuit in wiring
2 a Coil resistance of solenoid
harness
Resis- Between BRC3 (female) (18) and (23) Approx. 40
tance z
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors BRC3 and LKO, and connect T-adapters to
3 (wire breakage or defective each female side.
contact of connector) Between BRC3 (female) (18) and LKO (female)
Max. 1 z
Resis- (1)
tance Between BRC3 (female) (23) and LKO (female)
(2) Max. 1 z

1. Turn starting switch to OFF position.

Ground fault in wiring 2. Disconnect connectors BRC3 and LKO, and connect T-adapters to
4 harness either female side.
(contact with ground circuit) Resis- Between ground and BRC3 (female) (18) or
LKO (female) (1) Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
5 Short circuit in wiring harness 2. Disconnect connectors BRC3 and LKO, andconnect T-adapters to
either female side.
Resis- Between BRC3 (female) (18) and (23) or
between LKO (female) (1) and (2) Min. 1 Mz
tance
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector LKO and connect T-adapter to female side.
6 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between LKO (female) (1) and (2) Max. 4.5V
If no failure is found by above checks, retarder hoist controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
Reference
Defective retarder hoist 1. Turn starting switch to OFF position.
7
controller 2. Insert T-adapter into connector BRC3.
3. Start engine.
Dump lever in Hold Max. 4.5 V
Between BRC3 (18)
Voltage Dump lever between
and (23) 20 to 30 V
RAISE and detent

HM400-3M0 40-559
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to kick out solenoid

40-560 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW73KA] Disconnection of Hoist Selector Sol. (HM400_3-DW73KA-400-

A-Z0-A)

Action level Failure code Disconnection of Hoist Selector Solenoid

Failure
L03 DW73KA (Retarder hoist controller system)
Detail of • When driving hoist selector solenoid, no current flows through circuit.
failure
Action of • Stops driving hoist EPC solenoid.
controller
Problem on • Dump body does not move.
machine

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Start engine and, after turning dump lever to "Hold" or
"Float" position once, turn it to "Lower" position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
Defective hoist selector 3. Disconnect connector B03 and connect T-adapters to male side.
1
solenoid
Resis- Between B03 (male) (A) and (B) 30 to 70 z
tance Between ground and each of B03 (A) and (B) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
Open or short circuit in wiring 3. Disconnect connector BRC3 and connect T-adapters to female side.
2
harness a Coil resistance of solenoid
Resis- Between BRC3 (female) (8) and (23) 30 to 70 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector BRC3 and connect T-adapters to female side.
Open circuit in wiring harness 3. Tilt up cab and fix it by using lock bar.
3 (wire breakage or defective 4. Disconnect connector B03 and connect T-adapters to female side.
contact of connector) Between BRC3 (female) (8) and B03 (female)
Max. 1 z
Resis- (B)
tance Between BRC3 (female) (23) and B03 (female)
(A) Max. 1 z
If no failure is found by above checks, retarder hoist controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
Reference
1. Turn starting switch to OFF position.
Defective retarder hoist
4 2. Lower tilted-up cab.
controller
3. Insert T-adapters into connector BRC3.
4. Start engine.
Dump lever: HOLD Max. 3 V
Between BRC3 (8)
Voltage Duration from raising of
and (23) 20 to 30 V
dump lever to detent

HM400-3M0 40-561
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to hoist selector solenoid

40-562 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW73KB] Ground Fault of Hoist Selector Sol. (HM400_3-DW73KB-400-A-

Z0-A)

Action level Failure code Ground Fault of Hoist Selector Solenoid

Failure
L03 DW73KB (Retarder hoist controller system)
Detail of • When driving hoist selector solenoid, excessive current flows through circuit.
failure
Action of • Stops driving hoist selector solenoid.
controller • Stops driving hoist EPC valve solenoid.
Problem on • Dump body does not move.
machine

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Start engine and, after turning dump lever to "Hold" or
"Float" position once, turn it to "Lower" position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
Defective hoist selector 3. Disconnect connector B03 and connect T-adapters to male side.
1
solenoid
Resis- Between B03 (male) (A) and (B) 30 to 70 z
tance Between ground and each of B03 (A) and (B) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
Open or short circuit in wiring 3. Disconnect connector BRC3 and connect T-adapters to female side.
2
harness a Coil resistance of solenoid
Resis- Between BRC3 (female) (8) and (23)
30 to 70 z
tance
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connector BRC3.
harness 3. Tilt up cab and fix it by using lock bar.
3
4. Disconnect connector B03 and connect T-adapters to female side.
(contact with ground circuit)
Resis- Between B03 (female) (B) and ground
Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
4 Short circuit in wiring harness 3. Disconnect connector BRC3.
4. Tilt up cab and fix it by using lock bar.
5. Disconnect connector B03 and connect T-adapters to female side.
Resis- Between B03 (female) (A) and (B)
Min. 1 Mz
tance
If no failure is found by above checks, transmission controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
Reference
1. Turn starting switch to OFF position.
Defective retarder hoist
5 2. Lower tilted-up cab.
controller
3. Insert T-adapters into connector BRC3.
4. Start engine.
Dump lever: HOLD Max. 3 V
Between BRC3 (8)
Voltage Duration from raising of
and (23)
dump lever to detent 20 to 30 V

HM400-3M0 40-563
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to hoist selector solenoid

40-564 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW73KY] Hot Short of Hoist Selector Sol. (HM400_3-DW73KY-400-A-Z0-A)

Action level Failure code Hot Short of Hoist Selector Solenoid

Failure
L03 DW73KY (Retarder hoist controller system)
Detail of • When controller does not drive hoist selector solenoid, current flows through circuit.
failure
Action of • Stops driving hoist EPC solenoid.
controller
Problem on • Dump body does not move.
machine

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Start engine and, after turning dump lever to "Hold" or
"Float" position once, turn it to "Lower" position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
Defective hoist selector 3. Disconnect connector B03 and connect T-adapters to male side.
1
solenoid
Resis- Between B03 (male) (A) and (B) 30 to 70 z
tance Between ground and each of B03 (A) and (B) Min. 1 Mz
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector B03 and connect T-adapters to female side.
2 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between B03 (female) (B) and (A) Max. 4.5 V
If no failure is found by above checks, retarder hoist controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
Reference
1. Turn starting switch to OFF position.
Defective retarder hoist
3 2. Lower tilted-up cab.
controller
3. Insert T-adapters into connector BRC3.
4. Start engine.
Dump lever: HOLD Max. 4.5 V
Between BRC3 (8)
Voltage Duration from raising of
and (23) 20 to 30 V
dump lever to detent

HM400-3M0 40-565
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to hoist selector solenoid

40-566 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. (HM300_3-
DW7BKB-400-A-Z0-A)

Action level Failure code Ground Fault of Radiator Fan Reverse Solenoid
Failure
L01 DW7BKB (Transmission controller system)
Detail of
• Too much current flows when controller drives radiator fan reverse solenoid circuit.
failure
Action of • Stops driving radiator fan reverse solenoid.
controller
Problem on
• Radiator fan does not rotate in reverse direction.
machine
• Output to radiator fan reverse solenoid can be checked with monitoring function.
Related (Code: 03900)
information • Method of reproducing failure code: Turn starting switch to ON and set radiator fan in
reverse mode.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective radiator fan reverse 2. Disconnect T12 and connect T-adapter to male side.
1
solenoid Resis- Between T12 (male) (1) and (2) 35 to 45 z
tance Between ground and each of T12 (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC2 and ATC3, and connect T-adapters to
Open or short circuit in wiring each female side.
2
harness a Coil resistance of solenoid
Resis- Between ATC2 (female) (19) and ATC3
(female) (23) 35 to 45 z
tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ATC2 and T12, and connect T-adapter to
3 either female side.
(contact with ground circuit)
Resis- Between ground and ATC2 (female) (19) or T12
(female) (1) Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC2, ATC3, and T12, and connect T-
4 Short circuit in wiring harness adapter to any of female sides.
Between ATC2 (female) (19) and ATC3
Resis- (female) (23) or between T12 (female) (1) and
Min. 1 Mz
tance (2)
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

HM400-3M0 40-567
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to radiator fan reverse solenoid

40-568 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol. (HM400_3-DW7BKY-400-A-
Z0-A)

Action level Failure code Hot Short of Radiator Fan Reverse Solenoid
Failure
L01 DW7BKY (Transmission controller system)
Detail of • When controller does not drive radiator fan reverse solenoid, current flows through circuit.
failure
Action of • Stops driving radiator fan reverse solenoid.
controller
• Radiator fan constantly rotates in reverse direction. If this failure occurs while fan is
Problem on
rotating in normal direction, fan may be damaged due to sudden switching to reverse
machine
rotation.
• Output signal to radiator fan reverse solenoid can be checked with monitoring function.
Related (Code: 03900)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective radiator fan reverse 2. Disconnect T12 and connect T-adapters to male side.
1
solenoid Resis- Between T12 (male) (1) and (2) 35 to 45 z
tance Between ground and each of T12 (1) and (2) Min. 1 Mz
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector T12 and connect T-adapters to female side.
2 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between T12 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed).

Circuit diagram related to radiator fan reverse solenoid

HM400-3M0 40-569
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW7BKZ] Failure of Radiator Fan Rev. Sol. (HM400_3-DW7BKZ-400-A-Z0-A)

Action level Failure code Failure of Radiator Fan Reverse Solenoid

Failure
L01 DW7BKZ (Transmission controller system)
Detail of • When controller does not drive radiator fan reverse solenoid, circuit voltage remains
failure between 2.5 V and 7.0 V.
Action of • Stops driving radiator fan reverse solenoid.
controller
Problem on • Fuel consumption may increase since two pumps are constantly used.
machine
• Output signal to radiator fan reverse solenoid can be checked with monitoring function.
Related (Code: 03900)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective radiator fan reverse 2. Disconnect T12 and connect T-adapters to male side.
1
solenoid Resis- Between T12 (male) (1) and (2) 35 to 45 z
tance Between ground and each of T12 (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC2 and ATC3, and connect T-adapters to
Open or short circuit in wiring each female side.
2
harness a Coil resistance of solenoid
Resis- Between ATC2 (female) (19) and ATC3
(female) (23) 35 to 45 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ATC2, ATC3 and T12, and connect T-
3 (wire breakage or defective adapters to each female side.
contact of connector) Between ATC2 (female) (19) and T12 (female)
Max. 1 z
Resis- (1)
tance Between ATC3 (female) (23) and T12 (female)
(2) Max. 1 z

Hot short circuit in wiring 1. Turn starting switch to OFF position.

harness 2. Disconnect connector T12 and connect T-adapters to female side.
4 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between T12 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed).

40-570 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to radiator fan reverse solenoid

HM400-3M0 40-571
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW7LKB] Ground Fault of CAC Fan Rev. Sol. (HM300_3-DW7LKB-400-A-
Z0-A)

Action level Failure code Ground Fault of CAC Fan Reverse Solenoid
Failure
L01 DW7LKB (Transmission controller system)
Detail of • When driving CAC fan reverse solenoid, excessive current flows through circuit.
failure
Action of • Stops driving CAC fan reverse solenoid.
controller
Problem on
• CAC fan cannot rotate in reverse.
machine
• Output signal to CAC fan reverse solenoid can be checked with monitoring function
Related (Code: 03900).
information • Method of reproducing failure code: Turn starting switch to ON position and select CAC
fan reverse rotation.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect T17 and connect T-adapters to male side.
Defective CAC fan reverse
1 Between T17 (male) (1) and (2) 35 to 45 z
solenoid Resis-
Between chassis ground and each of connector
tance Min. 1 Mz
T17 (1) and (2)
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC2 and ATC3, and connect T-adapters to
Open circuit or short circuit in each female side.
2 wiring harness a Coil resistance of solenoid
Resis- Between ATC2 (female) (9) and ATC3 (female)
(3) 35 to 45 z
tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ATC2 and T12, and connect T-adapters to
3 either female side.
(contact with ground circuit)
Resis- Between ground and ATC2 (female) (9) or T17
(female) (1) Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
4 Short circuit in wiring harness 2. Disconnect connectors ATC2, ATC3 and T17, and connect T-
adapter to any of female sides.
Resis- Between ATC2 (female) (9) and ATC3 (female)
(3) or between T17 (female) (1) and (2). Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed).

Circuit diagram related to CAC fan reverse solenoid

40-572 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW7LKY] Hot Short of CAC Fan Rev. Sol. (HM300_3-DW7LKY-400-A-Z0-A)

Action level Failure code Hot Short of CAC Fan Reverse Solenoid
Failure
L01 DW7LKY (Transmission controller system)
Detail of • When controller does not drive CAC fan reverse solenoid, current flows through circuit.
failure
Action of • Stops driving CAC fan reverse solenoid.
controller
Problem on • CAC fan constantly rotates in reverse direction. If this failure occurs while fan is rotating in
machine normal direction, fan may be damaged due to sudden switching to reverse rotation.
• Output signal to CAC fan reverse solenoid can be checked with monitoring function
Related (Code: 03900).
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect T17 and connect T-adapters to male side.
Defective CAC fan reverse
1 Between T17 (male) (1) and (2) 35 to 45 z
solenoid Resis-
Between chassis ground and each of connector
tance Min. 1 Mz
T17 (1) and (2)
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector T17 and connect T-adapters to female side.
2 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between T17 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed).

Circuit diagram related to CAC fan reverse solenoid

HM400-3M0 40-573
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW7LKZ] Failure of CAC Fan Rev. Sol. (HM300_3-DW7LKZ-400-A-Z0-A)

Action level Failure code Failure of CAC Fan Reverse Solenoid

Failure
L01 DW7LKZ (Transmission controller system)
Detail of • When controller does not drive CAC fan reverse solenoid, circuit voltage remains
failure between 2.5 V and 7.0 V.
Action of • Stops driving CAC fan reverse solenoid.
controller
Problem on • Fuel consumption may increase since two pumps are constantly used.
machine
• Output signal to CAC fan reverse solenoid can be checked with monitoring function.
Related (Code: 03900)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect T17 and connect T-adapters to male side.
Defective CAC fan reverse
1 Between T17 (male) (1) and (2) 35 to 45 z
solenoid Resis-
Between chassis ground and each of connector
tance Min. 1 Mz
T17 (1) and (2)
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC2 and ATC3, and connect T-adapters to
Open circuit or short circuit in each female side.
2 wiring harness a Coil resistance of solenoid
Resis- Between ATC2 (female) (9) and ATC3 (female)
(3) 35 to 45 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ATC2, ATC3 and T17, and connect T-
3 (wire breakage or defective adapters to each female side.
contact of connector) Between ATC2 (female) (9) and T17 (female)
Max. 1 z
Resis- (1)
tance Between ATC3 (female) (3) and T17 (female)
(2) Max. 1 z

Hot short circuit in wiring 1. Turn starting switch to OFF position.

harness 2. Disconnect connector T12 and connect T-adapters to female side.
4 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between T17 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed).

Circuit diagram related to CAC fan reverse solenoid

40-574 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW7NKZ] Failure of Steering Pump Selector Sol. (HM300_3-

DW7NKZ-400-A-Z0-A)

Action level Failure code Failure of Steering Pump Selector Solenoid

Failure
L01 DW7NKZ (Retarder hoist controller system)
Detail of • When driving steering pump selector solenoid, no current flows or excessive current flows
failure through circuit. Or current flows when controller does not drive solenoid.
Action of • Stops driving steering pump selector solenoid for short circuit.
controller
Problem on • No change is observed or dump body speed becomes slow.
machine

k Before removing or installing solenoid connector, tilt up cab and fix it securely by
Related using lock bar.
information
• Method of reproducing failure code: Start engine, drive machine, and operate steering
wheel.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
Defective steering pump 3. Disconnect connector B09 and connect T-adapters to male side.
1
selector solenoid Between B09 (male) (1) and (2) 20 to 60 z
Resis-
Between ground and each of B09 (male) (1)
tance Min. 1 Mz
and (2)
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
3. Disconnect connector BRC2 and BRC3 and connect T-adapters to
Open circuit or short circuit in each female side.
2 wiring harness
a Coil resistance of solenoid
Resis- Between BRC2 (female) (18) and BRC3
(female) (23) 20 to 60 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector BRC2 and BRC3 and connect T-adapters to
Open circuit in wiring harness each female side.
3 (wire breakage or defective 3. Tilt up cab and fix it by using lock bar.
contact of connector) 4. Disconnect connector B09 and connect T-adapters to female side.
Between BRC2 (female) (18) and B09 (female)
Max. 1 z
Resis- (1)
tance Between BRC3 (female) (23) and B09 (female)
(2) Max. 1 z

1. Turn starting switch to OFF position.

2. Disconnect connector B09 and connect T-adapters to female side.
Ground fault in wiring harness 3. Lower tilted-up cab.
4 4. Disconnect connector BRC2 and connect T-adapters to female side.
(contact with ground circuit)
Resis- Between ground and BRC2 (female) (18) or
B09 (female) (1) Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC2 and BRC3 and connect T-adapters to
5 Short circuit in wiring harness each female side.
3. Tilt up cab and fix it by using lock bar.
4. Disconnect connector B09 and connect T-adapters to female side.
Resis- Between BRC2 (female) (18) and BRC3 (23), Min. 1 Mz
tance or between B09 (female) (1) and (2)

HM400-3M0 40-575
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector B09 and connect T-adapters to female side.
6 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between B09 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, retarder hoist controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
Reference
Defective retarder hoist 1. Turn starting switch to OFF position.
7
controller 2. Insert T-adapter into connectors BRC2 and BRC3.
3. Start engine.
Dump lever: HOLD Max. 4.5 V
Between BRC2 (18)
Voltage Dump lever: Between
and BRC3 (23) 20 to 30 V
RAISE and detent

Circuit diagram related to steering pump selector solenoid

40-576 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DWNJKZ] Failure of TCS Shut off Sol. (Front) (HM300_3-DWNJKZ-400-A-
Z0-A)

Action level Failure code Failure of TCS Shut off Solenoid (Front)
Failure
L03 DWNJKZ (Retarder hoist controller system)
Detail of • Current does not flow through front shutoff valve solenoid circuit or overcurrent flows
failure through it.
Action of • Continues retarder lever control.
controller • Stops TCS control (front wheel) (for open circuit or hot short circuit).
Problem on • Retarder does not work normally (for hot short circuit).
machine • TCS (L.H. front wheel) does not work (for open circuit or hot short circuit).

k Before removing or installing solenoid connector, tilt up cab and fix it securely by
using lock bar.
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Turn starting switch to ON position.

No. Cause
Defective TCS front shutoff
1
valve solenoid
Open circuit or short circuit in
2 wiring harness
Open circuit in wiring harness
3 (wire breakage or defective
contact of connector)
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
3. Disconnect connector B26 and connect T-adapters to male side.
Between B26 (male) (1) and (2) 10 to 30 z
Resis-
Between ground and each of B26 (male) (1)
tance Min. 1 Mz
and (2)
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
3. Disconnect connector BRC2 and BRC3 and connect T-adapters to
each female side.
a Coil resistance of solenoid
Resis- Between BRC2 (female) (8) and BRC3 (female)
(3) 10 to 30 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector BRC2 and BRC3 and connect T-adapters to
each female side.
3. Tilt up cab and fix it by using lock bar.
4. Disconnect connector B26, and connect T-adapters to female side.
Between BRC2 (female) (8) and B26 (female)
Max. 1 z
Resis- (1)
tance Between BRC3 (female) (3) and B26 (female)
(2) Max. 1 z

1. Turn starting switch to OFF position.

2. Disconnect connector B26 and connect T-adapters to female side.
Ground fault in wiring harness 3. Lower tilted-up cab.
4 4. Disconnect connector BRC2 and connect T-adapters to female side.
(contact with ground circuit)
Resis- Between ground and BRC2 (female) (8) or B26
(female) (1) Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC2 and BRC3 and connect T-adapters to
5 Short circuit in wiring harness each female side.
3. Tilt up cab and fix it by using lock bar.
4. Disconnect connector B26 and connect T-adapters to female side.
Resis- Between BRC2 (female) (8) and BRC3 (3), or Min. 1 Mz
tance between B26 (female) (1) and (2)

HM400-3M0 40-577
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector B26 and connect T-adapters to female side.
6 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between B26 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
7
controller performed).

Circuit diagram related to shutoff valve (front) solenoid

40-578 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DWNKKZ] Failure of TCS Shut off Sol. (Center) (HM300_3-DWNKKZ-
400-A-Z0-A)

Action level Failure code Failure of TCS Shut off Solenoid (Center)
Failure
L03 DWNKKZ (Retarder hoist controller system)
Detail of • Current does not flow through center shutoff valve solenoid circuit or overcurrent flows
failure through it.
Action of • Continues retarder lever control.
controller • Stops TCS control (front wheel) (for open circuit or hot short circuit).
Problem on • Retarder does not work normally (for hot short circuit).
machine • TCS (L.H. front wheel) does not work (for open circuit or hot short circuit).

k Before removing or installing solenoid connector, tilt up cab and fix it securely by
using lock bar.
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Turn starting switch to ON position.

No. Cause
Defective TCS center shutoff
1
valve solenoid
Open circuit or short circuit in
2 wiring harness
Open circuit in wiring harness
3 (wire breakage or defective
contact of connector)
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
3. Disconnect connector B27 and connect T-adapters to male side.
Between B27 (male) (1) and (2) 10 to 30 z
Resis-
Between ground and each of B27 (male) (1)
tance Min. 1 Mz
and (2)
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
3. Disconnect connector BRC2 and BRC3 and connect T-adapters to
each female side.
a Coil resistance of solenoid
Resis- Between BRC2 (female) (28) and BRC3
(female) (13) 10 to 30 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector BRC2 and BRC3 and connect T-adapters to
each female side.
3. Tilt up cab and fix it by using lock bar.
4. Disconnect connector B27 and connect T-adapters to female side.
Between BRC2 (female) (28) and B27 (female)
Max. 1 z
Resis- (1)
tance Between BRC3 (female) (13) and B27 (female)
(2) Max. 1 z

1. Turn starting switch to OFF position.

2. Disconnect connector B27 and connect T-adapters to female side.
Ground fault in wiring harness 3. Lower tilted-up cab.
4 4. Disconnect connector BRC2 and connect T-adapters to female side.
(contact with ground circuit)
Resis- Between ground and BRC2 (female) (28) or
B27 (female) (1) Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors BRC2 and BRC3 and connect T-adapters to
5 Short circuit in wiring harness each female side.
3. Tilt up cab and fix it by using lock bar.
4. Disconnect connector B27 and connect T-adapters to female side.
Resis- Between BRC2 (female) (28) and BRC3 (13), Min. 1 Mz
tance or between B27 (female) (1) and (2)

HM400-3M0 40-579
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector B27 and connect T-adapters to female side.
6 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between B27 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
7
controller performed).

Circuit diagram related to shutoff valve (front) solenoid

40-580 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX13KA] Disconnection of Hoist EPC Solenoid (HM400_3-DX13KA-

400-A-Z0-A)

Action level Failure code Disconnection of Hoist EPC Solenoid

Failure
L03 DX13KA (Retarder hoist controller system)
Detail of • When driving hoist EPC solenoid, no current flows through circuit.
failure
Action of • Stops driving hoist EPC solenoid.
controller
Problem on • Dump body does not move.
machine

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").

Related k Do not start engine when cab is tilted up.

information
• Output current value to hoist EPC solenoid can be checked with monitoring function.
(Code: 45601)
• Method of reproducing failure code: Start engine and set dump lever to any position other
than HOLD.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
1 Defective hoist EPC solenoid 3. Disconnect connector B04 and connect T-adapters to male side.
Resis- Between B04 (male) (1) and (2) 10 to 30 z
tance Between ground and each of B04 (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
Open or short circuit in wiring 3. Disconnect connector BRC3 and connect T-adapters to female side.
2
harness a Coil resistance of solenoid
Resis- Between BRC3 (female) (5) and (23) 10 to 30 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector BRC3 and connect T-adapters to female side.
Open circuit in wiring harness 3. Tilt up cab and fix it by using lock bar.
3 (wire breakage or defective 4. Disconnect connector B04 and connect T-adapters to female side.
contact of connector) Between BRC3 (female) (5) and B04 (female)
(1) Max. 1 z
Resis-
tance Between BRC3 (female) (23) and B04 (female)
(2) Max. 1 z
If no failure is found by above checks, retarder hoist controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
Reference
Defective retarder hoist 1. Turn starting switch to OFF position.
4
controller 2. Lower tilted-up cab.
3. Insert T-adapters into connector BRC3.
4. Start engine.
Between BRC3 (5) Dump lever: HOLD Max. 4.5 V
Voltage
and (23) Dump lever: FLOAT 20 to 30 V

HM400-3M0 40-581
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to hoist EPC solenoid

40-582 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX13KB] Ground Fault of Hoist EPC Solenoid (HM400_3-DX13KB-400-A-

Z0-A)

Action level Failure code Ground Fault of Hoist EPC Solenoid

Failure
L03 DX13KB (Retarder hoist controller system)
Detail of • When driving hoist EPC solenoid, excessive current flows through circuit.
failure
Action of • Stops driving hoist EPC solenoid.
controller
Problem on • Dump body does not move.
machine

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").

Related k Do not start engine when cab is tilted up.

information
• Output current value to hoist EPC solenoid can be checked with monitoring function.
(Code: 45601)
• Method of reproducing failure code: Start engine and set dump lever to any position other
than HOLD.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
1 Defective hoist EPC solenoid 3. Disconnect connector B04 and connect T-adapters to male side.
Resis- Between B04 (male) (1) and (2) 10 to 30 z
tance Between ground and each of B04 (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
3. Disconnect connector BRC3 and connect T-adapters to female
Open or short circuit in wiring side.
2
harness
a Coil resistance of solenoid
Resis- Between BRC3 (female) (5) and (23) 10 to 30 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector BRC3.
Ground fault in wiring harness 3. Tilt up cab and fix it by using lock bar.
3
(contact with ground circuit) 4. Disconnect connector B04 and connect T-adapters to female side.
Resis- Between B04 (female) (1) and ground Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
4 Short circuit in wiring harness 3. Disconnect connector BRC3.
4. Tilt up cab and fix it by using lock bar.
5. Disconnect connector B04 and connect T-adapters to female side.
Resis- Between B04 (female) (1) and (2) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
Reference
Defective retarder hoist 1. Turn starting switch to OFF position.
5
controller 2. Lower tilted-up cab.
3. Insert T-adapters into connector BRC3.
4. Start engine.
Between BRC3 (5) Dump lever: HOLD Max. 4.5 V
Voltage
and (23) Dump lever: FLOAT 20 to 30 V

HM400-3M0 40-583
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to hoist EPC solenoid

40-584 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX13KY] Hot Short of Hoist EPC Solenoid (HM400_3-DX13KY-400-A-Z0-A)

Action level Failure code Hot Short of Hoist EPC Solenoid

Failure
L03 DX13KY (Retarder hoist controller system)
Detail of • When controller does not drive hoist EPC solenoid, current flows through circuit.
failure
Action of • Stops driving hoist EPC solenoid.
controller
Problem on • Raising or lowering of dump body is possible.
machine

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").

Related k Do not start engine when cab is tilted up.

information
• Output current value to hoist EPC solenoid can be checked with monitoring function.
(Code: 45601)
• Method of reproducing failure code: Start engine and set dump lever to any position other
than HOLD.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
1 Defective hoist EPC solenoid 3. Disconnect connector B04 and connect T-adapters to male side.
Resis- Between B04 (male) (1) and (2) 10 to 30 z
tance Between ground and each of B04 (1) and (2) Min. 1 Mz
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector B04 and connect T-adapters to female side.
2 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between B04 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, retarder hoist controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
Reference
Defective retarder hoist 1. Turn starting switch to OFF position.
3
controller 2. Lower tilted-up cab.
3. Insert T-adapters into connector BRC3.
4. Start engine.
Between BRC3 (5) Dump lever: HOLD Max. 4.5 V
Voltage
and (23) Dump lever: FLOAT 20 to 30 V

HM400-3M0 40-585
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to hoist EPC solenoid

40-586 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol. (HM300_3-
DX16KA-400-A-Z0-A)

Action level Failure code Disconnection of Radiator Fan Pump EPC Solenoid
Failure
L03 DX16KA (Transmission controller system)
Detail of • When driving radiator fan EPC solenoid, no current flows through circuit.
failure
Action of • None in particular.
controller
Problem on • Radiator fan rotates at its maximum speed, thereby increasing fuel consumption and
machine damaging pump.
• Output signal to radiator fan EPC solenoid can be checked with monitoring function.
(Code: 41400 (mA))
Related k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
information CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine.

No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
Defective radiator fan EPC 3. Disconnect T14 and connect T-adapters to male side.
1
solenoid
Resis- Between T14 (male) (1) and (2) 5 to 10 z
tance Between ground and each of T14 (1) and (2) Min. 1 Mz
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
Open circuit or short circuit in 3. Disconnect connector ATC3 and connect T-adapters to female side.
2 wiring harness
a Coil resistance of solenoid
Resis- Between ATC3 (female) (18) and (3)
5 to 10 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
Open circuit in wiring harness 3. Tilt up cab (as mentioned above).
3 (wire breakage or defective 4. Disconnect connector T12 and connect T-adapters to female side.
contact of connector) Between ATC3 (female) (3) and T14 (female)
Max. 1 z
Resis- (1)
tance Between ATC3 (female) (18) and T14 (female)
(2) Max. 1 z
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed).

Circuit diagram related to radiator fan EPC solenoid

HM400-3M0 40-587
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. (HM300_3-
DX16KB-400-A-Z0-A)

Action level Failure code Ground Fault of Radiator Fan Pump EPC Solenoid
Failure
L03 DX16KB (Transmission controller system)
Detail of • When driving radiator fan EPC solenoid, excessive current flows through circuit.
failure
Action of • Stops driving radiator fan EPC solenoid.
controller
Problem on • Radiator fan rotates at its maximum speed, thereby increasing fuel consumption and
machine damaging pump.
• Output signal to radiator fan EPC solenoid can be checked with monitoring function.
(Code: 41400 (mA))
Related k Tilt
up cab, fix it securely by using lock bar, and check that lock lever is set to
information CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine.

No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
Defective radiator fan EPC 3. Disconnect T14 and connect T-adapters to male side.
1
solenoid
Resis- Between T14 (male) (1) and (2) 5 to 10 z
tance Between ground and each of T14 (1) and (2) Min. 1 Mz
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
Open circuit or short circuit in 3. Disconnect connector ATC3 and connect T-adapters to female side.
2 wiring harness a Coil resistance of solenoid
Resis- Between ATC3 (female) (18) and ATC3
(female) (3) 35 to 45 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
Ground fault in wiring harness 3. Tilt up cab (as mentioned above).
3 4. Disconnect connector T14 and connect T-adapters to female side.
(contact with ground circuit)
Resis- Between ground and ATC3 (female) (18) or T14
(female) (1) Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector T14 and connect T-adapters to female side.
4 Short circuit in wiring harness 3. Lower tilted-up cab.
4. Disconnect connector ATC3 and connect T-adapters to female side.
Resis- Between ATC3 (female) (18) and (3), or
between T14 (female) (1) and (2) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed).

40-588 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to radiator fan EPC solenoid

HM400-3M0 40-589
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. (HM300_3-
DX16KY-400-A-Z0-A)

Action level Failure code Hot Short of Radiator Fan Pump EPC Solenoid
Failure
L01 DX16KY (Transmission controller system)
Detail of • When controller does not drive radiator fan EPC solenoid, current flows through circuit.
failure
Action of • Stops driving radiator fan EPC solenoid.
controller
Problem on • Radiator may overheat due to reduced radiator fan speed.
machine
• Output signal to radiator fan EPC solenoid can be checked with monitoring function.
(Code: 41400 (mA))
Related k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
information CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine.

No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
Defective radiator fan EPC 3. Disconnect T14 and connect T-adapters to male side.
1
solenoid
Resis- Between T14 (male) (1) and (2) 5 to 10 z
tance Between ground and each of T14 (1) and (2) Min. 1 Mz
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector T14 and connect T-adapters to female side.
2 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between T14 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed).

Circuit diagram related to radiator fan EPC solenoid

40-590 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX29KA] Disconnection of CAC Fan Pump EPC Sol. (HM300_3-
DX29KA-400-A-Z0-A)

Action level Failure code Disconnection of CAC Fan Pump EPC Solenoid
Failure
L01 DX29KA (Transmission controller system)
Detail of • When driving CAC fan pump EPC solenoid, no current flows through circuit.
failure
Action of • Stops driving CAC fan pump EPC solenoid.
controller
Problem on • CAC fan rotates at its maximum speed, thereby increasing fuel consumption and
machine damaging pump.
• Output signal to CAC fan pump EPC solenoid can be checked with monitoring function.
Related (Code: 31645 (mA))
information • Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect T11 and connect T-adapters to male side.
Defective CAC fan pump
1 Between T11 (male) (1) and (2) 5 to 10 z
EPC solenoid Resis-
Between chassis ground and each of connector
tance Min. 1 Mz
T11 (1) and (2)
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
Open circuit or short circuit in
2 wiring harness a Coil resistance of solenoid
Resis- Between ATC3 (female) (28) and (13)
5 to 10 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ATC3 and T11, and connect T-adapters to
3 (wire breakage or defective each female side.
contact of connector) Between ATC3 (female) (28) and T11 (female)
Max. 1 z
Resis- (1)
tance Between ATC3 (female) (13) and T11 (female)
(2) Max. 1 z

Hot short circuit in wiring 1. Turn starting switch to OFF position.

harness 2. Disconnect connector T11 and connect T-adapters to female side.
4 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between T11 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed).

Circuit diagram related to CAC fan pump EPC solenoid

HM400-3M0 40-591
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX29KB] Ground Fault of CAC Fan Pump EPC Sol. (HM300_3-
DX29KB-400-A-Z0-A)

Action level Failure code Ground Fault of CAC Fan Pump EPC Solenoid
Failure
L01 DX29KB (Transmission controller system)
Detail of • When driving CAC fan pump EPC solenoid, excessive current flows through circuit.
failure
Action of • Stops driving CAC fan pump EPC solenoid.
controller
Problem on • CAC fan rotates at its maximum speed, thereby increasing fuel consumption and
machine damaging pump.
• Output signal to CAC fan pump EPC solenoid can be checked with monitoring function.
Related (Code: 31645 (mA))
information • Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect T11 and connect T-adapters to male side.
Defective CAC fan pump
1 Between T11 (male) (1) and (2) 5 to 10 z
EPC solenoid Resis-
Between chassis ground and each of connector
tance Min. 1 Mz
T11 (1) and (2)
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
Open circuit or short circuit in
2 wiring harness a Coil resistance of solenoid
Resis- Between ATC3 (female) (28) and ATC3
(female) (13) 5 to 10 z
tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ATC3 and T11, and connect T-adapters to
3 either female side.
(contact with ground circuit)
Resis- Between ground and ATC3 (female) (28) or T11
(female) (1) Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC3 and T11, and connect T-adapters to
4 Short circuit in wiring harness either female side.
Between ATC3 (female) (28) and ATC3
Resis- (female) (13) or between T11 (female) (1) and
Min. 1 Mz
tance (2).
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed).

Circuit diagram related to CAC fan pump EPC solenoid

40-592 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX29KY] Hot Short of CAC Fan Pump EPC Sol. (HM300_3-DX29KY-400-
A-Z0-A)

Action level Failure code Hot Short of CAC Fan Pump EPC Solenoid
Failure
L01 DX29KY (Transmission controller system)
Detail of • When controller does not drive CAC fan pump EPC solenoid, current flows through
failure circuit.
Action of • Stops driving CAC fan pump EPC solenoid.
controller
Problem on • CAC may overheat due to reduced CAC fan speed.
machine
• Output signal to CAC fan pump EPC solenoid can be checked with monitoring function.
Related (Code: 31645 (mA))
information • Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective CAC fan pump 2. Disconnect T11 and connect T-adapters to male side.
1
EPC solenoid Resis- Between T11 (male) (1) and (2) 5 to 10 z
tance Between ground and each of T11 (1) and (2) Min. 1 Mz
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector T11 and connect T-adapters to female side.
2 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between T11 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed).

Circuit diagram related to CAC fan pump EPC solenoid

HM400-3M0 40-593
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX30K4] Release Trouble of Retarder EPC Valve(FL) (HM400_3-

DX30K4-400-A-Z0-A)

Action level Failure code Release Trouble of Retarder EPC Valve (FL)
Failure
L03 DX30K4 (Retarder hoist controller system)
Detail of • When controller does not drive retarder EPC valve (front left) solenoid, controller detects
failure retarder pressure.
Action of • Continues retarder lever control.
controller • Stops TCS control (front).
Problem on • Retarder (front left) does not work normally.
machine • TCS (front) does not work.
Signal from retarder pressure sensor (center left) can be checked with monitoring function.
(Code: 91913 (Mpa) and 91915 (V)
Related Retarder lever not operated: 0.3 to 0.69 V, retarder lever at travel end: 3.3 to 4.1 V)
information • Method of reproducing failure code: Start engine and return retarder lever.
• Since T-adapter is not prepared for connector of retarder pressure sensor, measure
voltage at controller.
No. Cause Procedure, measuring location, criteria and remarks
• Check retarder (front left) oil piping, retarder EPC valve (front left),
Defective retarder (front left)
or shutoff valve (front).
1 circuit or retarder EPC valve
• For above check, see Testing and adjusting, "Measuring brake oil
(front left)
pressure".
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC1.
3. Turn starting switch to ON position.
Defective retarder pressure
2 Retarder lever: 0.3 to 0.69
sensor
Between BRC1 (19) and Released V
Voltage
(21) Retarder lever: 3.3 to 4.1
Full stroke V
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC3.
3. Turn starting switch to ON position.
Defective retarder hoist
3 Retarder lever:
controller Max. 4.5 V
Voltage Between BRC3 (37) and (3) Released
Retarder lever:
20 to 30 V
Full stroke

40-594 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid and retarder pressure sensor (front)

HM400-3M0 40-595
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX30KA] Disconnection of Retarder EPC Sol. (FL) (HM400_3-

DX30KA-400-A-Z0-A)

Action level Failure code Disconnection of Retarder EPC Solenoid (FL)

Failure
L03 DX30KA (Retarder hoist controller system)
Detail of • When driving retarder EPC valve (front left) solenoid, no current flows through circuit.
failure
Action of • Continues retarder lever control.
controller • Continues TCS control.
Problem on • Retarder (front left) does not work.
machine • TCS (front left) does not work.

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Start engine and pull retarder lever.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
Defective retarder EPC valve 3. Disconnect connector B18 and connect T-adapters to male side.
1 solenoid (front left)
Resis- Between B18 (male) (1) and (2) 10 to 30 z
tance Between ground and each of B18 (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
Open or short circuit in wiring 3. Disconnect connector BRC3 and connect T-adapters to female side.
2
harness a Coil resistance of solenoid
Resis- Between BRC3 (female) (37) and (3) 10 to 30 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector BRC3 and connect T-adapters to female side.
Open circuit in wiring harness 3. Tilt up cab and fix it by using lock bar.
3 (wire breakage or defective 4. Disconnect connector B18 and connect T-adapters to female side.
contact of connector) Between BRC3 (female) (37) and B18 (female)
(1) Max. 1 z
Resis-
tance Between BRC3 (female) (3) and B18 (female)
(2) Max. 1 z
If no failure is found by above checks, retarder hoist controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
Reference
1. Turn starting switch to OFF position.
Defective retarder hoist 2. Lower tilted-up cab.
4
controller 3. Insert T-adapters into connector BRC3.
4. Start engine.
Retarder lever:
Between BRC3 (37) Max. 4.5 V
Voltage Released
and (3) Retarder lever: Full
20 to 30 V
stroke

40-596 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid (FL)

HM400-3M0 40-597
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX30KB] Ground Fault of Retarder EPC Sol. (FL) (HM400_3-DX30KB-
400-A-Z0-A)

Action level Failure code Ground Fault of Retarder EPC Solenoid (FL)
Failure
L03 DX30KB (Retarder hoist controller system)
Detail of • When driving retarder EPC valve (front left) solenoid, excessive current flows through
failure circuit.
• Stops driving retarder EPC valve solenoid (front left).
Action of
• Continues retarder lever control.
controller
• Continues TCS control.
Problem on • Retarder (front left) does not work.
machine • TCS (front left) does not work.

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Start engine and pull retarder lever.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
Defective retarder EPC valve 3. Disconnect connector B18 and connect T-adapters to male side.
1 solenoid (front left)
Resis- Between B18 (male) (1) and (2) 10 to 30 z
tance Between ground and each of B18 (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
Open or short circuit in wiring 3. Disconnect connector BRC3 and connect T-adapters to female side.
2
harness a Coil resistance of solenoid
Resis- Between BRC3 (female) (37) and (3) 10 to 30 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector BRC3.
Ground fault in wiring harness 3. Tilt up cab and fix it by using lock bar.
3
(contact with ground circuit) 4. Disconnect connector B18 and connect T-adapters to female side.
Resis- Between B18 (female) (1) and ground Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
4 Short circuit in wiring harness 3. Disconnect connector BRC3.
4. Tilt up cab and fix it by using lock bar.
5. Disconnect connector B18 and connect T-adapters to female side.
Resis- Between B18 (female) (1) and (2) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
Reference
1. Turn starting switch to OFF position.
Defective retarder hoist 2. Lower tilted-up cab.
5
controller 3. Insert T-adapters into connector BRC3.
4. Start engine.
Retarder lever:
Between BRC3 (37) Max. 4.5 V
Voltage Released
and (3) Retarder lever: Full
20 to 30 V
stroke

40-598 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid (FL)

HM400-3M0 40-599
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX30KY] Hot Short of Retarder EPC Sol. (FL) (HM400_3-DX30KY-400-A-
Z0-A)

Action level Failure code Hot Short of Retarder EPC Solenoid (FL)
Failure
L03 DX30KY (Retarder hoist controller system)
Detail of • When controller does not drive retarder EPC valve (front left) solenoid, current flows
failure through circuit.
Action of • Continues retarder lever control.
controller • Stops TCS control (front).
Problem on • Retarder (front left) does not work normally.
machine • TCS (front) does not work.

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Start engine and return retarder lever.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
Defective retarder EPC valve 3. Disconnect connector B18 and connect T-adapters to male side.
1 solenoid (front left)
Resis- Between B18 (male) (1) and (2) 10 to 30 z
tance Between B18 (1), (2) and ground Min. 1 Mz
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector B18 and connect T-adapters to female side.
2 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between B18 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, retarder hoist controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
Reference
1. Turn starting switch to OFF position.
Defective retarder hoist 2. Lower tilted-up cab.
3
controller 3. Insert T-adapters into connector BRC3.
4. Start engine.
Retarder lever:
Between BRC3 (37) Max. 4.5 V
Voltage Released
and (3) Retarder lever: Full
20 to 30 V
stroke

40-600 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid (FL)

HM400-3M0 40-601
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX30MA] Malfunction of Retarder EPC Valve (FL) (HM400_3-

DX30MA-400-A-Z0-A)

Action level Failure code Malfunction of Retarder EPC Valve (FL)

Failure
L03 DX30MA (Retarder hoist controller system)
Detail of • When driving retarder EPC valve (front left) solenoid, controller does not detect retarder
failure pressure.
Action of • Continues retarder lever control.
controller • Continues TCS control.
Problem on • Retarder (front left) does not work normally.
machine • TCS (front left) does not work normally.
Signal from retarder pressure sensor (center left) can be checked with monitoring function.
(Code: 91913 (Mpa) and 91915 (V)
Related Retarder lever not operated: 0.3 to 0.69 V, retarder at travel end: 3.3 to 4.1 V)
information • Method of reproducing failure code: Start engine and pull retarder lever.
• Since T-adapter is not prepared for connector of retarder pressure sensor, measure
voltage at controller.
No. Cause Procedure, measuring location, criteria and remarks
• Check retarder (front left) oil piping, retarder EPC valve (front left),
Defective retarder (front left)
or shutoff valve (front).
1 circuit or retarder EPC valve
• For above check, see Testing and adjusting, "Measuring brake oil
(front left)
pressure".
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC1.
3. Turn starting switch to ON position.
Defective retarder pressure
2 Retarder lever: 0.3 to 0.69
sensor
Between BRC1 (19) and Released V
Voltage
(21) Retarder lever: 3.3 to 4.1
Full stroke V
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC3.
3. Turn starting switch to ON position.
Defective retarder hoist
3 Retarder lever:
controller Max. 4.5 V
Voltage Between BRC3 (37) and (3) Released
Retarder lever:
20 to 30 V
Full stroke

40-602 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid and retarder pressure sensor (front)

HM400-3M0 40-603
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX31K4] Release Trouble of Retarder EPC Valve(CR) (HM400_3-

DX31K4-400-A-Z0-A)

Action level Failure code Release Trouble of Retarder EPC Valve(CR)

Failure
L03 DX31K4 (Retarder hoist controller system)
Detail of • When controller does not drive retarder EPC valve (center right) solenoid, controller
failure detects retarder pressure.
Action of • Continues retarder lever control.
controller • Stops TCS control (center).
Problem on • Retarder (center right) does not work normally.
machine • TCS (center) does not work.

Signal from retarder pressure sensor (center right) can be checked with monitoring function.
(Code: 91920 (MPa) or 91922 (V)
Related Retarder lever not operated: 0.3 to 0.69 V, retarder lever at travel end: 3.3 to 4.1 V)
information • Method of reproducing failure code: Start engine and return retarder lever.
• Since T-adapter is not prepared for connector of retarder pressure sensor, measure
voltage at controller.

No. Cause Procedure, measuring location, criteria and remarks

• Check retarder (center right) oil piping, retarder EPC valve (center
Defective retarder (center
right), or shutoff valve (center).
1 right) circuit or retarder EPC
• For above check, see Testing and adjusting, "Measuring brake oil
valve (center right)
pressure".
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC1.
3. Turn starting switch to ON position.
Defective retarder pressure
2 Retarder lever: 0.3 to 0.69
sensor
Between BRC1 (13) and Released V
Voltage
(21) Retarder lever:
3.3 to 4.1 V
Full stroke
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC3.
3. Turn starting switch to ON position.
Defective retarder hoist
3 Retarder lever:
controller Max. 4.5 V
Voltage Between BRC3 (6) and (13) Released
Retarder lever:
20 to 30 V
Full stroke

40-604 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid (CR)

HM400-3M0 40-605
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX31KA] Disconnection of Retarder EPC Sol. (CR) (HM400_3-

DX31KA-400-A-Z0-A)

Action level Failure code Disconnection of Retarder EPC Solenoid (CR)

Failure
L03 DX31KA (Retarder hoist controller system)
Detail of • When driving retarder EPC valve (center right) solenoid, no current flows through circuit.
failure
Action of • Continues retarder lever control.
controller • Continues TCS control.
Problem on • Retarder (center right) does not work.
machine • TCS (center right) does not work.

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Start engine and pull retarder lever.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
Defective retarder EPC valve 3. Disconnect connector B28 and connect T-adapters to male side.
1 solenoid (center right)
Resis- Between B28 (male) (1) and (2) 10 to 30 z
tance Between ground and each of B28 (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
Open or short circuit in wiring 3. Disconnect connector BRC3 and connect T-adapters to female side.
2
harness a Coil resistance of solenoid
Resis- Between BRC3 (female) (6) and (13) 10 to 30 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector BRC3 and connect T-adapters to female side.
Open circuit in wiring harness 3. Tilt up cab and fix it by using lock bar.
3 (wire breakage or defective 4. Disconnect connector B28 and connect T-adapters to female side.
contact of connector) Between BRC3 (female) (6) and B28 (female)
(1) Max. 1 z
Resis-
tance Between BRC3 (female) (13) and B28 (female)
(2) Max. 1 z
If no failure is found by above checks, retarder hoist controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
Reference
1. Turn starting switch to OFF position.
Defective retarder hoist 2. Lower tilted-up cab.
4
controller 3. Insert T-adapters into connector BRC3.
4. Start engine.
Retarder lever:
Between BRC3 (6) Max. 4.5 V
Voltage Released
and (13) Retarder lever: Full
20 to 30 V
stroke

40-606 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid (CR)

HM400-3M0 40-607
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX31KB] Ground Fault of Retarder EPC Sol. (CR) (HM400_3-
DX31KB-400-A-Z0-A)

Action level Failure code Ground Fault of Retarder EPC Solenoid (CR)
Failure
L03 DX31KB (Retarder hoist controller system)
Detail of • When driving retarder EPC valve (center right) solenoid, excessive current flows through
failure circuit.
• Stops driving retarder EPC valve solenoid (center right).
Action of
• Continues retarder lever control.
controller
• Continues TCS control.
Problem on • Retarder (center right) does not work.
machine • TCS (center right) does not work.

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Start engine and pull retarder lever.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
Defective retarder EPC valve 3. Disconnect connector B28 and connect T-adapters to male side.
1 solenoid (center right)
Resis- Between B28 (male) (1) and (2) 10 to 30 z
tance Between ground and each of B28 (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
Open or short circuit in wiring 3. Disconnect connector BRC3 and connect T-adapters to female side.
2
harness a Coil resistance of solenoid
Resis- Between BRC3 (female) (6) and (13) 10 to 30 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector BRC3.
Ground fault in wiring harness 3. Tilt up cab and fix it by using lock bar.
3
(contact with ground circuit) 4. Disconnect connector B28 and connect T-adapters to female side.
Resis- Between B28 (female) (1) and ground Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
4 Short circuit in wiring harness 3. Disconnect connector BRC3.
4. Tilt up cab and fix it by using lock bar.
5. Disconnect connector B28 and connect T-adapters to female side.
Resis- Between B28 (female) (1) and (2) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
Reference
1. Turn starting switch to OFF position.
Defective retarder hoist 2. Lower tilted-up cab.
5
controller 3. Insert T-adapters into connector BRC3.
4. Start engine.
Retarder lever:
Between BRC3 (6) Max. 4.5 V
Voltage Released
and (13) Retarder lever: Full
20 to 30 V
stroke

40-608 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid (CR)

HM400-3M0 40-609
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX31KY] Hot Short of Retarder EPC Sol. (CR) (HM400_3-DX31KY-400-A-
Z0-A)

Action level Failure code Hot Short of Retarder EPC Solenoid (CR)
Failure
L03 DX31KY (Retarder hoist controller system)
Detail of • When controller does not drive retarder EPC valve (center right) solenoid, current flows
failure through circuit.
Action of • Continues retarder lever control.
controller • Stops TCS control (center).
Problem on • Retarder (center right) does not work normally.
machine • TCS (center) does not work.

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Start engine and return retarder lever.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
Defective retarder EPC valve 3. Disconnect connector B28 and connect T-adapters to male side.
1 solenoid (center right)
Resis- Between B28 (male) (1) and (2) 10 to 30 z
tance Between B28 (1), (2) and ground Min. 1 Mz
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector B28 and connect T-adapters to female side.
2 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between B28 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, retarder hoist controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
Reference
1. Turn starting switch to OFF position.
Defective retarder hoist 2. Lower tilted-up cab.
3
controller 3. Insert T-adapters into connector BRC3.
4. Start engine.
Retarder lever:
Between BRC3 (6) Max. 4.5 V
Voltage Released
and (13) Retarder lever: Full
20 to 30 V
stroke

40-610 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid (CR)

HM400-3M0 40-611
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX31MA] Malfunction of Retarder Valve (CR) (HM400_3-DX31MA-400-A-

Z0-A)

Action level Failure code Malfunction of Retarder Valve (CR)

Failure
L03 DX31MA (Retarder hoist controller system)
Detail of • When driving retarder EPC valve (center right) solenoid, controller does not detect
failure retarder pressure.
Action of • Continues retarder lever control.
controller • Continues TCS control.
Problem on • Retarder (center right) does not work normally.
machine • Retarder (center right) does not work normally.
Signal from retarder pressure sensor (center right) can be checked with monitoring function.
(Code: 91920 (MPa) or 91922 (V)
Related Retarder lever not operated: 0.3 to 0.69 V, retarder lever at travel end: 3.3 to 4.1 V)
information • Method of reproducing failure code: Start engine and pull retarder lever.
• Since T-adapter is not prepared for connector of retarder pressure sensor, measure
voltage at controller.
No. Cause Procedure, measuring location, criteria and remarks
• Check retarder (center right) oil piping, retarder EPC valve (center
Defective retarder (center
right), or shutoff valve (center).
1 right) circuit or retarder EPC
• For above check, see Testing and adjusting, "Measuring brake oil
valve (center right)
pressure".
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC1.
3. Turn starting switch to ON position.
Defective retarder pressure
2 Retarder lever: 0.3 to 0.69
sensor
Between BRC1 (13) and Released V
Voltage
(21) Retarder lever:
3.3 to 4.1 V
Full stroke
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC3.
3. Turn starting switch to ON position.
Defective retarder hoist
3 Retarder lever:
controller Max. 4.5 V
Voltage Between BRC3 (6) and (13) Released
Retarder lever:
20 to 30 V
Full stroke

40-612 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid and retarder pressure sensor (center)

HM400-3M0 40-613
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX32K4] Release Trouble of Retarder EPC Valve(CL) (HM400_3-

DX32K4-400-A-Z0-A)

Action level Failure code Release Trouble of Retarder EPC Valve (CL)
Failure
L03 DX32K4 (Retarder hoist controller system)
Detail of • When controller does not drive retarder EPC valve (center left) solenoid, controller detects
failure retarder pressure.
Action of • Continues retarder lever control.
controller • Stops TCS control (center).
Problem on • Retarder (center left) does not work normally.
machine • TCS (center) does not work.
Signal from retarder pressure sensor (center left) can be checked with monitoring function.
(Code: 91914 (Mpa) or 91916 (V)
Related Retarder lever not operated: 0.3 to 0.69 V, retarder lever at travel end: 3.3 to 4.1 V)
information • Method of reproducing failure code: Start engine and return retarder lever.
• Since T-adapter is not prepared for connector of retarder pressure sensor, measure
voltage at controller.
No. Cause Procedure, measuring location, criteria and remarks
• Check retarder (center left) oil piping, retarder EPC valve (center
Defective retarder (center left)
left), or shutoff valve (center).
1 circuit or retarder EPC valve
• For above check, see Testing and adjusting, "Measuring brake oil
(center left)
pressure".
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC1.
3. Turn starting switch to ON position.
Defective retarder pressure Retarder lever: 0.3 to 0.69
2 Released V
sensor
Voltage Between BRC1 (7) and (21)
Retarder lever:
3.3 to 4.1 V
Full stroke

1. Turn starting switch to OFF position.

2. Insert T-adapters into connector BRC3.
3. Turn starting switch to ON position.
Defective retarder hoist
3 Retarder lever:
controller Max. 4.5 V
Between BRC3 (16) and Released
Voltage
(13) Retarder lever:
20 to 30 V
Full stroke

40-614 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid and retarder pressure sensor (center)

HM400-3M0 40-615
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX32KA] Disconnection of Retarder EPC Sol. (CL) (HM400_3-

DX32KA-400-A-Z0-A)

Action level Failure code Disconnection of Retarder EPC Solenoid (CL)

Failure
L03 DX32KA (Retarder hoist controller system)
Detail of • When driving retarder EPC valve (center left) solenoid, no current flows through circuit.
failure
Action of • Continues retarder lever control.
controller • Continues TCS control.
Problem on • Retarder (center left) does not work.
machine • TCS (center left) does not work.

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Start engine and pull retarder lever.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
Defective retarder EPC valve 3. Disconnect connector B29 and connect T-adapters to male side.
1 solenoid (center left)
Resis- Between B29 (male) (1) and (2) 10 to 30 z
tance Between ground and each of B29 (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
3. Disconnect connector BRC3 and connect T-adapters to female
Open or short circuit in wiring side.
2
harness
a Coil resistance of solenoid
Resis- Between BRC3 (female) (16) and (13) 10 to 30 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector BRC3 and connect T-adapters to female
Open circuit in wiring harness side.
3 (wire breakage or defective 3. Tilt up cab and fix it by using lock bar.
contact of connector) 4. Disconnect connector B29 and connect T-adapters to female side.
Between BRC3 (female) (16) and B29 (female)
(1) Max. 1 z
Resis-
tance Between BRC3 (female) (13) and B29 (female)
(2) Max. 1 z
If no failure is found by above checks, retarder hoist controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
Reference
1. Turn starting switch to OFF position.
Defective retarder hoist 2. Lower tilted-up cab.
4
controller 3. Insert T-adapters into connector BRC3.
4. Start engine.
Retarder lever:
Between BRC3 (16) Max. 4.5 V
Voltage Released
and (13) Retarder lever: Full
20 to 30 V
stroke

40-616 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid (CL)

HM400-3M0 40-617
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX32KB] Ground Fault of Retarder EPC Sol. (CL) (HM400_3-DX32KB-
400-A-Z0-A)

Action level Failure code Ground Fault of Retarder EPC Solenoid (CL)
Failure
L03 DX32KB (Retarder hoist controller system)
Detail of • When driving retarder EPC valve (center left) solenoid, excessive current flows through
failure circuit.
• Stops driving retarder EPC valve solenoid (center left).
Action of
• Continues retarder lever control.
controller
• Continues TCS control.
Problem on • Retarder (center left) does not work.
machine • TCS (center left) does not work.

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Start engine and pull retarder lever.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
Defective retarder EPC valve 3. Disconnect connector B29 and connect T-adapters to male side.
1 solenoid (center left)
Resis- Between B29 (male) (1) and (2) 10 to 30 z
tance Between ground and each of B29 (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
Open or short circuit in wiring 3. Disconnect connector BRC3 and connect T-adapters to female side.
2
harness a Coil resistance of solenoid
Resis- Between BRC3 (female) (16) and (13) 10 to 30 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector BRC3.
Ground fault in wiring harness 3. Tilt up cab and fix it by using lock bar.
3
(contact with ground circuit) 4. Disconnect connector B29 and connect T-adapters to female side.
Resis- Between B29 (female) (1) and ground Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
4 Short circuit in wiring harness 3. Disconnect connector BRC3.
4. Tilt up cab and fix it by using lock bar.
5. Disconnect connector B29 and connect T-adapters to female side.
Resis- Between B29 (female) (1) and (2) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
Reference
1. Turn starting switch to OFF position.
Defective retarder hoist 2. Lower tilted-up cab.
5
controller 3. Insert T-adapters into connector BRC3.
4. Start engine.
Retarder lever:
Between BRC3 (16) Max. 4.5 V
Voltage Released
and (13) Retarder lever: Full
20 to 30 V
stroke

40-618 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid (CL)

HM400-3M0 40-619
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX32KY] Hot Short of Retarder EPC Sol. (CL) (HM400_3-DX32KY-400-A-
Z0-A)

Action level Failure code Hot Short of Retarder EPC Solenoid (CL)
Failure
L03 DX32KY (Retarder hoist controller system)
Detail of • When controller does not drive retarder EPC valve (center left) solenoid, current flows
failure through circuit.
Action of • Continues retarder lever control.
controller • Stops TCS control (center).
Problem on • Retarder (center left) does not work normally.
machine • TCS (center) does not work.

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Start engine and return retarder lever.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
Defective retarder EPC valve 3. Disconnect connector B29 and connect T-adapters to male side.
1 solenoid (center left)
Resis- Between B29 (male) (1) and (2) 10 to 30 z
tance Between B29 (1), (2) and ground Min. 1 Mz
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector B29 and connect T-adapters to female side.
2 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between B29 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, retarder hoist controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
Reference
1. Turn starting switch to OFF position.
Defective retarder hoist 2. Lower tilted-up cab.
3
controller 3. Insert T-adapters into connector BRC3.
4. Start engine.
Retarder lever:
Between BRC3 (6) Max. 4.5 V
Voltage Released
and (13) Retarder lever: Full
20 to 30 V
stroke

40-620 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid (CL)

HM400-3M0 40-621
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX32MA] Malfunction of Retarder EPC Valve (CL) (HM400_3-

DX32MA-400-A-Z0-A)

Action level Failure code Malfunction of Retarder EPC Valve (CL)

Failure
L03 DX32MA (Retarder hoist controller system)
Detail of • When driving retarder EPC valve (center left) solenoid, controller does not detect retarder
failure pressure.
Action of • Continues retarder lever control.
controller • Continues TCS control.
Problem on • Retarder (center left) does not work normally.
machine • Retarder (center left) does not work normally.
Signal from retarder pressure sensor (front left) can be checked with monitoring function.
(Code: 91914 (Mpa) or 91916 (V)
Related Retarder lever not operated: 0.3 to 0.69 V, retarder lever at travel end: 3.3 to 4.1 V)
information • Method of reproducing failure code: Start engine and pull retarder lever.
• Since T-adapter is not prepared for connector of retarder pressure sensor, measure
voltage at controller.
No. Cause Procedure, measuring location, criteria and remarks
• Check retarder (center left) oil piping, retarder EPC valve (center
Defective retarder (center left)
left), or shutoff valve (center).
1 circuit or retarder EPC valve
• For above check, see Testing and adjusting, "Measuring brake oil
(center left)
pressure".
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC1.
3. Turn starting switch to ON position.
Defective retarder pressure
2 Retarder lever: 0.3 to 0.69
sensor
Voltage Between BRC1 (7) and (21) Released V
Retarder lever:
3.3 to 4.1 V
Full stroke
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC3.
3. Turn starting switch to ON position.
Defective retarder hoist
3 Retarder lever:
controller Max. 4.5 V
Between BRC3 (16) and Released
Voltage
(13) Retarder lever:
20 to 30 V
Full stroke

40-622 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid and retarder pressure sensor (center)

HM400-3M0 40-623
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX33K4] Release Trouble of Retarder EPC Valve (FR) (HM400_3-
DX33K4-400-A-Z0-A)

Action level Failure code Release Trouble of Retarder EPC Valve (FR)
Failure
L03 DX33K4 (Retarder hoist controller system)
Detail of • When controller does not drive retarder EPC valve (front right) solenoid, controller detects
failure retarder pressure.
Action of • Continues retarder lever control.
controller • Stops TCS control (front).
Problem on • Retarder (front right) does not work normally.
machine • TCS (front) does not work.
Signal from retarder pressure sensor (front right) can be checked with monitoring function.
(Code: 91919 (MPa) or 91921 (V)
Related Retarder lever not operated: 0.3 to 0.69 V, retarder lever at travel end: 3.3 to 4.1 V)
information • Method of reproducing failure code: Start engine and return retarder lever.
• Since T-adapter is not prepared for connector of retarder pressure sensor, measure
voltage at controller.
No. Cause Procedure, measuring location, criteria and remarks
• Check retarder (front right) oil piping, retarder EPC valve (front
Defective retarder (front right)
right), or shutoff valve (front).
1 circuit or retarder EPC valve
• For above check, see Testing and adjusting, "Measuring brake oil
(front right)
pressure".
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC1.
Defective retarder pressure 3. Turn starting switch to ON position.
2
sensor 0.3 to 0.69
Between BRC1 Retarder lever: Released
Voltage V
(2) and (21)
Retarder lever: Full stroke 3.3 to 4.1 V
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC3.
Defective retarder hoist 3. Turn starting switch to ON position.
3
controller
Between BRC3 Retarder lever: Released Max. 4.5 V
Voltage
(27) and (3) Retarder lever: Full stroke 20 to 30 V

40-624 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid and retarder pressure sensor (front)

HM400-3M0 40-625
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX33KA] Disconnection of Retarder EPC Sol. (FR) (HM400_3-

DX33KA-400-A-Z0-A)

Action level Failure code Disconnection of Retarder EPC Solenoid (FR)

Failure
L03 DX33KA (Retarder hoist controller system)
Detail of • When driving retarder EPC valve (front right) solenoid, no current flows through circuit.
failure
Action of • Continues retarder lever control.
controller • Continues TCS control.
Problem on • Retarder (front right) does not work.
machine • TCS (front right) does not work.

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Start engine and pull retarder lever.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
Defective retarder EPC valve 3. Disconnect connector B19 and connect T-adapters to male side.
1 solenoid (front right)
Resis- Between B19 (male) (1) and (2) 10 to 30 z
tance Between ground and each of B19 (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
Open or short circuit in wiring 3. Disconnect connector BRC3 and connect T-adapters to female side.
2
harness a Coil resistance of solenoid
Resis- Between BRC3 (female) (27) and (3) 10 to 30 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector BRC3 and connect T-adapters to female side.
Open circuit in wiring harness 3. Tilt up cab and fix it by using lock bar.
3 (wire breakage or defective 4. Disconnect connector B19 and connect T-adapters to female side.
contact of connector) Between BRC3 (female) (27) and B19 (female)
(1) Max. 1 z
Resis-
tance Between BRC3 (female) (3) and B19 (female)
(2) Max. 1 z
If no failure is found by above checks, retarder hoist controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
Reference
1. Turn starting switch to OFF position.
Defective retarder hoist 2. Lower tilted-up cab.
4
controller 3. Insert T-adapters into connector BRC3.
4. Start engine.
Retarder lever:
Between BRC3 (27) Max. 4.5 V
Voltage Released
and (3) Retarder lever: Full
20 to 30 V
stroke

40-626 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid (FR)

HM400-3M0 40-627
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX33KB] Ground Fault of Retarder EPC Sol. (FR) (HM400_3-DX33KB-
400-A-Z0-A)

Action level Failure code Ground Fault of Retarder EPC Solenoid (FR)
Failure
L03 DX33KB (Retarder hoist controller system)
Detail of • When driving retarder EPC valve (front right) solenoid, excessive current flows through
failure circuit.
Action of • Continues retarder lever control.
controller • Continues TCS control.
Problem on • Retarder (front right) does not work.
machine • TCS (front right) does not work.

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Start engine and pull retarder lever.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
Defective retarder EPC valve 3. Disconnect connector B19 and connect T-adapters to male side.
1 solenoid (front right)
Resis- Between B19 (male) (1) and (2) 10 to 30 z
tance Between ground and each of B19 (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
3. Disconnect connector BRC3 and connect T-adapters to female
Open or short circuit in wiring side.
2
harness
a Coil resistance of solenoid
Resis- Between BRC3 (female) (27) and (3) 10 to 30 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector BRC3.
Ground fault in wiring harness 3. Tilt up cab and fix it by using lock bar.
3
(contact with ground circuit) 4. Disconnect connector B19 and connect T-adapters to female side.
Resis- Between B19 (female) (1) and ground Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
4 Short circuit in wiring harness 3. Disconnect connector BRC3.
4. Tilt up cab and fix it by using lock bar.
5. Disconnect connector B19 and connect T-adapters to female side.
Resis- Between B19 (female) (1) and (2) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
Reference
1. Turn starting switch to OFF position.
Defective retarder hoist 2. Lower tilted-up cab.
5
controller 3. Insert T-adapters into connector BRC3.
4. Start engine.
Retarder lever:
Between BRC3 (27) Max. 4.5 V
Voltage Released
and (3) Retarder lever: Full
20 to 30 V
stroke

40-628 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid (FR)

HM400-3M0 40-629
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX33KY] Hot Short of Retarder EPC Sol. (FR) (HM400_3-DX33KY-400-A-
Z0-A)

Action level Failure code Hot Short of Retarder EPC Solenoid (FR)
Failure
L03 DX33KY (Retarder hoist controller system)
Detail of • When controller does not drive retarder EPC valve (front right) solenoid, current flows
failure through circuit.
Action of • Continues retarder lever control.
controller • Stops TCS control (front).
Problem on • Retarder (front right) does not work normally.
machine • TCS (front) does not work.

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Start engine and return retarder lever.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
Defective retarder EPC valve 3. Disconnect connector B19 and connect T-adapters to male side.
1 solenoid (front right)
Resis- Between B19 (male) (1) and (2) 10 to 30 z
tance Between B19 (1), (2) and ground Min. 1 Mz
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector B19 and connect T-adapters to female side.
2 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between B19 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, retarder hoist controller is
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
Reference
1. Turn starting switch to OFF position.
Defective retarder hoist 2. Lower tilted-up cab.
3
controller 3. Insert T-adapters into connector BRC3.
4. Start engine.
Retarder lever:
Between BRC3 (27) Max. 4.5 V
Voltage Released
and (3) Retarder lever: Full
20 to 30 V
stroke

40-630 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid (FR)

HM400-3M0 40-631
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX33MA] Malfunction of Retarder EPC Valve (FR) (HM400_3-

DX33MA-400-A-Z0-A)

Action level Failure code Malfunction of Retarder EPC Valve (FR)

Failure
L03 DX33MA (Retarder hoist controller system)
• When driving retarder EPC valve (font right) solenoid, controller does not detect retarder
Detail of failure pressure.
Action of • Continues retarder lever control.
controller • Continues TCS control.
Problem on • Retarder (front right) does not work normally.
machine • Retarder (front right) does not work normally.
Signal from retarder pressure sensor (front right) can be checked with monitoring function.
(Code: 91919 (MPa) or 91921 (V)
Related Retarder lever not operated: 0.3 to 0.69 V, retarder lever at travel end: 3.3 to 4.1 V)
information • Method of reproducing failure code: Start engine and return retarder lever.
• Since T-adapter is not prepared for connector of retarder pressure sensor, measure
voltage at controller.
No. Cause Procedure, measuring location, criteria and remarks
• Check retarder (front right) oil piping, retarder EPC valve (front
Defective retarder (front right)
right), or shutoff valve (front).
1 circuit or retarder EPC valve
• For above check, see Testing and adjusting, "Measuring brake oil
(front right)
pressure".
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC1.
Defective retarder pressure 3. Turn starting switch to ON position.
2
sensor 0.3 to 0.69
Between BRC1 Retarder lever: Released
Voltage V
(2) and (21)
Retarder lever: Full stroke 3.3 to 4.1 V
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC3.
Defective retarder hoist 3. Turn starting switch to ON position.
3
controller
Between BRC3 Retarder lever: Released Max. 4.5 V
Voltage
(27) and (3) Retarder lever: Full stroke 20 to 30 V

40-632 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to retarder EPC solenoid and retarder pressure sensor (front)

HM400-3M0 40-633
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX34KA] Disconnection of Remote Cooling EPC Sol. (HM400_3-

DX34KA-400-A-Z0-A)

Action level Failure code Disconnection of Remote Cooling EPC Solenoid

Failure
L01 DX34KA (Retarder hoist controller system)
Detail of • When driving remote cooling valve EPC solenoid, no current flows through circuit.
failure
Action of • Keeps controlling remote cooling valve.
controller
Problem on • None in particular
machine

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Start engine and release retarder and service brake.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
Defective remote cooling 3. Disconnect connector B07 and connect T-adapter to male side.
1
valve EPC solenoid
Resis- Between B07 (male) (1) and (2) 4 to 10 z
tance Between ground and each of B07 (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
Open or short circuit in wiring 3. Disconnect connector BRC3, and connect T-adapter to female side.
2
harness a Coil resistance of solenoid
Resis- Between BRC3 (female) (7) and (3) 4 to 10 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector BRC3, and connect T-adapter to female side.
Open circuit in wiring harness 3. Tilt up cab and fix it by using lock bar.
3 (Wire breakage or defective 4. Disconnect connector B07 and connect T-adapter to female side.
contact of connector) Between BRC3 (female) (7) and B07 (female)
(1) Max. 1 z
Resis-
tance Between BRC3 (female) (3) and B07 (female)
(2) Max. 1 z
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

Circuit diagram related to remote cooling valve EPC solenoid

40-634 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX34KB] Ground Fault of Remote Cooling EPC Sol. (HM400_3-
DX34KB-400-A-Z0-A)

Action level Failure code Ground Fault of Remote Cooling EPC Solenoid
Failure
L01 DX34KB (Retarder hoist controller system)
Detail of • When driving remote cooling valve EPC solenoid, excessive current flows through circuit.
failure
Action of • Does not drive remote cooling valve EPC solenoid.
controller
Problem on • None in particular
machine

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Start engine.

No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
Defective remote cooling 3. Disconnect connector B07 and connect T-adapter to male side.
1
valve EPC solenoid
Resis- Between B07 (male) (1) and (2) 4 to 10 z
tance Between ground and each of B07 (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Lower tilted-up cab.
Open or short circuit in wiring 3. Disconnect connector BRC3, and connect T-adapter to female side.
2
harness a Coil resistance of solenoid
Resis- Between BRC3 (female) (7) and (3) 4 to 10 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector BRC3, and connect T-adapter to female side.
Ground fault in wiring harness 3. Tilt up cab and fix it by using lock bar.
3
(Contact with ground circuit) 4. Disconnect connector B07 and connect T-adapter to female side.
Resis- Between B07 (female) (1) and ground Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
4 Short circuit in wiring harness 2. Disconnect connector BRC3.
3. Tilt up cab and fix it by using lock bar.
Resis- Between B07 (female) (7) and (2) Min. 1 Mz
tance
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

HM400-3M0 40-635
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to remote cooling valve EPC solenoid

40-636 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX34KY] Hot Short of Remote Cooling EPC Sol. (HM400_3-DX34KY-
400-A-Z0-A)

Action level Failure code Hot Short of Remote Cooling EPC Solenoid
Failure
L01 DX34KY (Retarder hoist controller system)
Detail of • When does not driving remote cooling valve EPC solenoid, current flows through circuit.
failure
Action of • Keeps controlling remote cooling valve.
controller
Problem on • Retarder may overheat due to degraded cooling capability.
machine

k Before removing or installing solenoid connectors, tilt up cab and fix it securely by
using lock bar (see Testing and adjusting, "Cab tilt-up procedure").
Related
information k Do not start engine when cab is tilted up.

• Method of reproducing failure code: Turn starting switch to ON position and apply service
brake.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Tilt up cab and fix it by using lock bar.
Defective remote cooling 3. Disconnect connector B07 and connect T-adapter to male side.
1
valve EPC solenoid
Resis- Between B07 (male) (1) and (2) 4 to 10 z
tance Between ground and each of B07 (1) and (2) Min. 1 Mz
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector B07 and connect T-adapter to female side.
2 3. Turn starting switch to ON position and apply service brake.
(Contact with 24 V circuit)
Voltage Between B07 (1) and (2) Min. 4.5 V
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)

Circuit diagram related to remote cooling valve EPC solenoid

HM400-3M0 40-637
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH0KA] Disconnection of ECMV (Inter-Axle Diff.) (HM400_3-

DXH0KA-400-A-Z0-A)

Action level Failure code Disconnection of ECMV (Inter-Axle Differential)

Failure
L01 DXH0KA (Transmission controller system)
• When driving solenoid for inter-axle differential lock clutch, no current flows through
Detail of failure
circuit.
Action of • Stops driving solenoid for inter-axle differential lockup clutch.
controller
Problem on • Machine cannot get out of soft ground.
machine • Machine may buck during travel.
• Since controller detects open circuit only while it drives solenoid, perform check after
repair when controller drives solenoid.
• Output signal to solenoid for inter-axle differential lock clutch can be checked with
monitoring function. (Code: 31607 (mA))
Related
• Method of reproducing failure code: Turn starting switch to ON position, select "TCS
information
system check" in adjustment menu, then turn on inter-axle differential lockup.
k Tilt
up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector DIFF.PS (CN20) and connect T-adapters to
Defective inter-axle differential male side.
1
lock clutch ECMV solenoid
Between DIFF.PS (CN20) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and DIFF.PS (CN20) (male)
tance Min. 1 Mz
(1) or (2)
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
Open or short circuit in wiring
2 3. Disconnect connector ATC3 and connect T-adapters to female side.
harness
Resis- Between ATC3 (female) (15) and (23) 5 to 15 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
Open circuit in wiring harness 3. Tilt up cab (as mentioned above).
3 (wire breakage or defective 4. Disconnect connector DIFF.PS (CN20) and connect T-adapters to
contact of connector) female side.
Between ATC3 (female) (15) and DIFF.PS
(CN20) (female) (1) Max. 1 z
Resis-
tance Between ATC3 (female) (23) and DIFF.PS
(CN20) (female) (2) Max. 1 z
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed).

40-638 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to inter-axle differential lock clutch solenoid

HM400-3M0 40-639
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH0KB] Ground Fault of ECMV (Inter-Axle Diff.) (HM400_3-DXH0KB-

400-A-Z0-A)

Action level Failure code Ground Fault of ECMV (Inter-Axle Differential)

Failure
L01 DXH0KB (Transmission controller system)
Detail of • When driving solenoid for differential lock clutch, excessive current flows through circuit.
failure
• Stops driving solenoid for inter-axle differential lock clutch.
Action of • Even after failure is repaired, machine does not become normal until starting switch is
controller turned to OFF position once.
Problem on • Machine cannot get out of soft ground.
machine • Machine may buck during travel.
• Output signal to solenoid for inter-axle differential lock clutch can be checked with
monitoring function. (Code: 31607 (mA))
Related
information k Tilt up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector DIFF.PS (CN20) and connect T-adapters to
Defective inter-axle differential male side.
1
lock clutch ECMV solenoid
Between DIFF.PS (CN20) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and DIFF.PS (CN20) (male)
tance Min. 1 Mz
(1) or (2)
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
Open or short circuit in wiring
2 3. Disconnect connector ATC3 and connect T-adapters to female side.
harness
Resis- Between ATC3 (female) (15) and (23) 5 to 15 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
3. Tilt up cab (as mentioned above).
3 Ground fault in wiring harness 4. Disconnect connector DIFF.PS (CN20) and connect T-adapters to
female side.
Resis- Between ground and ATC3 (female) (15) or
DIFF.PS (CN20) (female) (1) Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC3 and connect T-adapters to female side.
4 Short circuit in wiring harness 4. Tilt up cab (as mentioned above).
5. Disconnect connector DIFF.PS (CN20) and connect T-adapters to
female side.
Resis- Between ATC3 (female) (15) and (23), or DIFF.
PS (CN20) (female) (1) and (2) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-640 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to inter-axle differential lock clutch

HM400-3M0 40-641
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH0KY] Hot Short of ECMV (Inter-Axle Diff.) (HM400_3-DXH0KY-400-A-

Z0-A)

Action level Failure code Hot Short of ECMV (Inter-Axle Differential)

Failure
L03 DXH0KY (Transmission controller system)
Detail of • When controller does not drive differential lock pressure control valve, current flows
failure through circuit.
• Stops driving differential lock pressure control valve.
Action of • Even after failure is repaired, machine does not become normal until starting switch is
controller turned to OFF position once.
Problem on • Inter-axle differential lock is activated and you feel heavy in turning steering wheel.
machine
• Output signal to solenoid for inter-axle differential lock clutch can be checked with
monitoring function. (Code: 31607 (mA))
Related k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
information CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").

• Method of reproducing failure code: Start engine.

No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector DIFF.PS (CN20) and connect T-adapters to
Defective inter-axle differential male side.
1
lock clutch ECMV solenoid Between DIFF.PS (CN20) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and DIFF.PS (CN20) (male)
tance Min. 1 Mz
(1) or (2)
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector DIFF.PS (CN20) and connect T-adapters to
Hot short circuit in wiring female side.
2 harness (contact with 24 V 4. Turn starting switch to ON position.
circuit)
a If open circuit failure code [DXH0KA] appears, there is no hot short.
(ECM solenoid of inter-axle differential lock clutch is defective.)
Voltage Between DIFF.PS (CN20) (female) (1) and (2) Max. 4.5 V
1.Turn starting switch to OFF position.
2.Disconnect connector DIFF.PS (CN20).
3.Lower tilted-up cab.
4.Disconnect connector ATC3 and connect T-adapters to female side.
Between ATC3 (female) (15) and No continuity
Continuity
every pin other than (15) (No sound is heard)
1. Turn starting switch to OFF position.
3 Short circuit in wiring harness 2. Disconnect connector ATC3 and connect T-adapters to female side.
3. Tilt up cab (as mentioned above).
4. Disconnect connectors J09 and DIFF.PS (CN20).
5. Connect T-adapter to either male or female side of connector J09.
Between J09 (female) (37) and No continuity
each pin other than pin (37) (No sound is heard)
Continuity
Between J09 (male) (37) and each No continuity
pin other than pin (37) (No sound is heard)
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

40-642 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to inter-axle differential lock clutch

HM400-3M0 40-643
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) (HM300_3-

DXH1KA-400-A-Z0-A)

Action level Failure code Disconnection of ECMV Solenoid (Lockup)

Failure
L03 DXH1KA (Transmission controller system)
Detail of • When driving lockup clutch solenoid, no current flows through circuit.
failure
• Maintains current gear speed during travel.
Action of • Disables lockup clutch.
controller • Even after failure is repaired, machine does not become normal until starting switch is
turned to OFF position once.
• Lockup clutch does not work.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.
• Since controller detects open circuit only while it drives solenoid, perform check after
repair when controller drives solenoid.
• Current value output to lockup solenoid can be checked with monitoring function (Code:
31609 (mA)).
Related • Method of reproducing failure code: Turn starting switch to ON position and wait for 5
information seconds (for 5 seconds after starting switch is turned to ON position, controller drives
solenoid and performs self check).
k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector L/U.PS (CN18) and connect T-adapters to
Defective lockup clutch male side.
1
solenoid Between L/U.PS (CN18) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and L/U.PS (CN18) (male) (1)
tance Min. 1 Mz
or (2)
1. Lower tilted-up cab.
Open circuit or short circuit in 2. Turn starting switch to OFF position.
2 wiring harness 3. Disconnect connector ATC3 and connect T-adapters to female side.
Resis- Between ATC3 (female) (27) and (23)
5 to 15 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
Open circuit in wiring harness 3. Tilt up cab (as mentioned above).
3 (wire breakage or defective 4. Disconnect connector L/U.PS (CN18) and connect T-adapters to
contact of connector) female side.
Between ATC3 (female) (27) and L/U.PS
Max. 1 z
Resis- (CN18) (female) (1)
tance Between ATC3 (female) (23) and L/U.PS
(CN18) (female) (2) Max. 1 z
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

40-644 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to lockup clutch solenoid

HM400-3M0 40-645
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) (HM300_3-

DXH1KB-400-A-Z0-A)

Action level Failure code Ground Fault of ECMV Solenoid (Lockup)

Failure
L03 DXH1KB (Transmission controller system)
Detail of • When driving lockup clutch solenoid, excessive current flows through circuit.
failure
• Maintains current gear speed during travel and disables lockup clutch.
Action of • Even after failure is repaired, machine does not become normal until starting switch is
controller turned to OFF position once.
• Lockup clutch does not work.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.
• Current value output to lockup solenoid can be checked with monitoring function (Code:
31609 (mA)).
• Method of reproducing failure code: Turn starting switch to ON position and wait for 5
Related seconds (for 5 seconds after starting switch is turned to ON position, controller drives
information solenoid and performs self check).
k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector L/U.PS (CN18) and connect T-adapters to
Defective lockup clutch male side.
1
solenoid Between L/U.PS (CN18) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and L/U.PS (CN18) (male) (1)
tance Min. 1 Mz
or (2)
1. Lower tilted-up cab.
Open circuit or short circuit in 2. Turn starting switch to OFF position.
2 wiring harness 3. Disconnect connector ATC3 and connect T-adapters to female side.
Resis- Between ATC3 (female) (27) and (23)
5 to 15 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
3. Tilt up cab (as mentioned above).
3 Ground fault in wiring harness 4. Disconnect connector L/U.PS (CN18) and connect T-adapters to
female side.
Resis- Between ground and ATC3 (female) (27) or L/
U.PS (CN18) (female) (1) Min. 1 Mz
tance
1. Lower tilted-up cab.
2. If no failure is found by check on cause 2, this check is not required.
3. Turn starting switch to OFF position.
4. Disconnect connector ATC3 and connect T-adapters to female side.
4 Short circuit in wiring harness 5. Tilt up cab (as mentioned above).
6. Disconnect connector L/U.PS (CN18) and connect T-adapters to
female side.
Resis- Between ATC3 (female) (27) and (23), or
between L/U.PS (CN18) (1) and (2) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-646 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to lockup clutch solenoid

HM400-3M0 40-647
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) (HM300_3-DXH1KY-

400-A-Z0-A)

Action level Failure code Hot Short of ECMV Solenoid (Lockup)

Failure
L03 DXH1KY (Transmission controller system)
Detail of • When controller does not drive lockup clutch solenoid, current flows through circuit.
failure
• Maintains current gear speed during travel and disables lockup clutch.
Action of • Even after failure is repaired, machine does not become normal until starting switch is
controller turned to OFF position once.
• Gear cannot shift.
Problem on • Lockup clutch remains engaged.
machine • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
than "N", gear does not engage until machine is stopped.
• Current value output to lockup solenoid can be checked with monitoring function (Code:
31609 (mA)).
Related • Method of reproducing failure code: Start engine.
information
k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector L/U.PS (CN18) and connect T-adapters to
Defective lockup clutch male side.
1
solenoid Between L/U.PS (CN18) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and L/U.PS (CN18) (male) (1)
tance Min. 1 Mz
or (2)
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector L/U.PS (CN18) and connect T-adapters to
Hot short circuit in wiring female side.
2 harness (contact with 24 V 4. Turn starting switch to ON position.
circuit) a If failure code [DXH1KA] for open circuit is displayed, wiring harness
does not short to power supply line (lockup clutch solenoid is
defective).
Voltage Between L/U.PS (CN18) (female) (1) and (2) Max. 4.5 V
1.Tilt up cab (as mentioned above).
2.Turn starting switch to OFF position.
3.Disconnect connector L/U.PS (CN18).
4.Lower tilted-up cab.
5.Disconnect connector ATC3 and connect T-adapters to female side.
Between ATC3 (female) (27) and No continuity
Continuity
each pin other than pin (27) (No sound is heard)
3 Short circuit in wiring harness 1. Turn starting switch to OFF position.
2. Disconnect connector ATC3.
3. Disconnect connectors J09 and L/U.PS (CN18).
4. Connect T-adapters to either male or female side of connector J09.
Between J09 (female) (14) and No continuity
each pin other than pin (14) (No sound is heard)
Continuity
Between J09 (male) (14) and each No continuity
pin other than pin (14) (No sound is heard)
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

40-648 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to lockup clutch solenoid

HM400-3M0 40-649
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH2KA] Disconnection of ECMV Solenoid (High) (HM300_3-

DXH2KA-400-A-Z0-A)

Action level Failure code Disconnection of ECMV Solenoid (High)

Failure
L03 DXH2KA (Transmission controller system)
Detail of • When driving Hi clutch ECMV solenoid, no current flows through circuit.
failure
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed.
controller • Disengages lockup clutch.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.
• Since controller detects open circuit only while it drives ECMV solenoid, perform check
after repair when controller drives ECMV solenoid.
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31600 (mA)).
Related • Method of reproducing failure code: Turn starting switch to ON position and wait for 5
information seconds (for 5 seconds after starting switch is turned to ON position, controller drives
solenoid and performs self check).
k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector H.PS (CN10) and connect T-adapters to male
Defective Hi clutch ECMV side.
1
solenoid Between H.PS (CN10) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and H.PS (CN10) (male) (1) or
tance Min. 1 Mz
(2)
1. Lower tilted-up cab.
Open circuit or short circuit in 2. Turn starting switch to OFF position.
2 wiring harness 3. Disconnect connector ATC3 and connect T-adapters to female side.
Resis- Between ATC3 (female) (6) and (13)
5 to 15 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
Open circuit in wiring harness 3. Tilt up cab (as mentioned above).
3 (wire breakage or defective 4. Disconnect connector H.PS (CN10) and connect T-adapters to
contact of connector) female side.
Between ATC3 (female) (6) and H.PS (CN10)
Max. 1 z
Resis- (female) (1)
tance Between ATC3 (female) (13) and H.PS (CN10)
(female) (2) Max. 1 z
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

40-650 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 1
Remedy taken when failure is detected
Gear speed when Action of controller
Failed clutch ON or OFF of lockup
failure is detected
(Selected clutch and gear speed) 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

Circuit diagram related to Hi clutch

HM400-3M0 40-651
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High) (HM300_3-DXH2KB-

400-A-Z0-A)

Action level Failure code Ground Fault of ECMV Solenoid (High)

Failure
L03 DXH2KB (Transmission controller system)
Detail of • When driving Hi clutch ECMV solenoid, excessive current flows through circuit.
failure
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed.
controller • Disengages lockup clutch.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31600 (mA)).
• Method of reproducing failure code: Turn starting switch to ON position and wait for 5
Related seconds (for 5 seconds after starting switch is turned to ON position, controller drives
information solenoid and performs self check).
k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector H.PS (CN10) and connect T-adapters to male
Defective Hi clutch ECMV side.
1
solenoid Between H.PS (CN10) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and H.PS (CN10) (male) (1) or
tance Min. 1 Mz
(2)
1. Lower tilted-up cab.
Open circuit or short circuit in 2. Turn starting switch to OFF position.
2 wiring harness 3. Disconnect connector ATC3 and connect T-adapters to female side.
Resis- Between ATC3 (female) (6) and (13)
5 to 15 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
3. Tilt up cab (as mentioned above).
3 Ground fault in wiring harness 4. Disconnect connector H.PS (CN10) and connect T-adapters to
female side.
Resis- Between ground and ATC3 (female) (6) or H.
PS (CN10) (female) (1) Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC3 and connect T-adapters to female side.
4 Short circuit in wiring harness 4. Tilt up cab (as mentioned above).
5. Disconnect connector H.PS (CN10) and connect T-adapters to
female side.
Resis- Between ATC3 (female) (6) and (13), or
between H.PS (CN10) (1) and (2) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-652 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 1
Remedy taken when failure is detected
Gear speed when Action of controller
Failed clutch ON or OFF of lockup
failure is detected
(Selected clutch and gear speed) 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

Circuit diagram related to Hi clutch

HM400-3M0 40-653
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH2KY] Hot Short of ECMV Solenoid (High) (HM300_3-DXH2KY-400-A-

Z0-A)

Action level Failure code Hot Short of ECMV Solenoid (High)

Failure
L03 DXH2KY (Transmission controller system)
Detail of • When controller does not drive Hi clutch ECMV solenoid, current flows through circuit.
failure
• Shifts up gear according to gear speed before failure as shown in Table 2 and holds that
Action of gear speed..
controller • Disengages lockup clutch.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31600 (mA)).
Related • Method of reproducing failure code: Start engine.
information
k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector H.PS (CN10) and connect T-adapters to male
Defective Hi clutch ECMV side.
1
solenoid Between H.PS (CN10) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and H.PS (CN10) (male) (1) or
tance Min. 1 Mz
(2)
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector H.PS (CN10) and connect T-adapters to
Hot short circuit in wiring female side.
2 harness (contact with 24 V 4. Turn starting switch to ON position.
circuit) a If failure code [DXH2KA] for open circuit is displayed, wiring harness
does not short to power supply line (Hi clutch ECMV solenoid is
defective).
Voltage Between H.PS (CN10) (female) (1) and (2) Max. 4.5 V
1.Tilt up cab (as mentioned above).
2.Turn starting switch to OFF position.
3.Disconnect connector H.PS (CN10).
4.Lower tilted-up cab.
5.Disconnect connector ATC3 and connect T-adapters to female side.
Between ATC3 (female) (6) and No continuity
Continuity
each pin other than pin (6) (No sound is heard)

3 Short circuit in wiring harness 1. Turn starting switch to OFF position.

2. Disconnect connector ATC3.
3. Tilt up cab (as mentioned above).
4. Disconnect connectors J09 and H.PS (CN10).
5. Connect T-adapters to either male or female side of connector J09.
Between J09 (female) (17) and No continuity
each pin other than pin (17) (No sound is heard)
Continuity
Between J09 (male) (17) and each No continuity
pin other than pin (17) (No sound is heard)
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

40-654 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low) (HM300_3-

DXH3KA-400-A-Z0-A)

Action level Failure code Disconnection of ECMV Solenoid (Low)

Failure
L03 DXH3KA (Transmission controller system)
Detail of • When driving Lo clutch ECMV solenoid, no current flows through circuit.
failure
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed..
controller • Disengages lockup clutch.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.
• Since controller detects open circuit only while it drives ECMV solenoid, perform check
after repair when controller drives ECMV solenoid.
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31601 (mA)).
Related • Method of reproducing failure code: Turn starting switch to ON position and wait for 5
information seconds (for 5 seconds after starting switch is turned to ON position, controller drives
solenoid and performs self check).
k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector L.PS (CN6) and connect T-adapters to male
Defective Lo clutch ECMV side.
1
solenoid Between L.PS (CN6) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and L.PS (CN6) (male) (1) or
tance Min. 1 Mz
(2)
1. Lower tilted-up cab.
Open circuit or short circuit in 2. Turn starting switch to OFF position.
2 wiring harness 3. Disconnect connector ATC3 and connect T-adapters to female side.
Resis- Between ATC3 (female) (37) and (3)
5 to 15 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
Open circuit in wiring harness 3. Tilt up cab (as mentioned above).
3 (wire breakage or defective 4. Disconnect connector L.PS (CN6) and connect T-adapters to female
contact of connector) side.
Between ATC3 (female) (37) and L.PS (CN6)
Max. 1 z
Resis- (female) (1)
tance Between ATC3 (female) (3) and L.PS (CN6)
(female) (2) Max. 1 z
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

HM400-3M0 40-655
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 1
Remedy taken when failure is detected
Gear speed when Action of controller
Failed clutch ON or OFF of lockup
failure is detected
(Selected clutch and gear speed) 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

Circuit diagram related to Lo clutch

40-656 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low) (HM300_3-DXH3KB-

400-A-Z0-A)

Action level Failure code Ground Fault of ECMV Solenoid (Low)

Failure
L03 DXH3KB (Transmission controller system)
Detail of • When driving Lo clutch ECMV solenoid, excessive current flows through circuit.
failure
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed.
controller • Disengages lockup clutch.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31601 (mA)).
• Method of reproducing failure code: Turn starting switch to ON position and wait for 5
Related seconds (for 5 seconds after starting switch is turned to ON position, controller drives
information solenoid and performs self check).
k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector L.PS (CN6) and connect T-adapters to male
Defective Lo clutch ECMV side.
1
solenoid Between L.PS (CN6) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and L.PS (CN6) (male) (1) or
tance Min. 1 Mz
(2)
1. Lower tilted-up cab.
Open circuit or short circuit in 2. Turn starting switch to OFF position.
2 wiring harness 3. Disconnect connector ATC3 and connect T-adapters to female side.
Resis- Between ATC3 (female) (37) and (3)
5 to 15 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
3. Tilt up cab (as mentioned above).
3 Ground fault in wiring harness 4. Disconnect connector L.PS (CN6) and connect T-adapters to female
side.
Resis- Between ground and ATC3 (female) (37) or L.
PS (CN6) (female) (1) Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC3 and connect T-adapters to female side.
4 Short circuit in wiring harness 4. Tilt up cab (as mentioned above).
5. Disconnect connector L.PS (CN6) and connect T-adapters to female
side.
Resis- Between ATC3 (female) (37) and (3), or
between L.PS (CN6) (1) and (2) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

HM400-3M0 40-657
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 1
Remedy taken when failure is detected
Gear speed when Action of controller
Failed clutch ON or OFF of lockup
failure is detected
(Selected clutch and gear speed) 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

Circuit diagram related to Lo clutch

40-658 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low) (HM300_3-DXH3KY-400-A-Z0-

A)

Action level Failure code Hot Short of ECMV Solenoid (Low)

Failure
L03 DXH3KY (Transmission controller system)
Detail of • When controller does not drive Lo clutch ECMV solenoid, current flows through circuit.
failure
• Shifts up gear according to gear speed before failure as shown in Table 2 and holds that
Action of gear speed.
controller • Disengages lockup clutch.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31601 (mA)).
Related • Method of reproducing failure code: Start engine.
information
k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
Defective Lo clutch ECMV 3. Disconnect connector L.PS (CN6) and connect T-adapters to male
1 side.
solenoid
Resis- Between L.PS (CN6) (male) (1) and (2) 5 to 15 z
tance Between L.PS (CN6) (male) (1) and (2) Min. 1 Mz
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector L.PS (CN6) and connect T-adapters to
Hot short circuit in wiring female side.
2 harness (contact with 24 V 4. Turn starting switch to ON position.
circuit)
a If open circuit failure code [DXH3KA] appears, there is no hot short.
(L clutch ECM solenoid is defective.)
Voltage Between L.PS (CN6) (female) (1) and (2) Max. 4.5 V
1.Tilt up cab (as mentioned above).
2.Turn starting switch to OFF position.
3.Disconnect connector L.PS (CN6).
4.Lower tilted-up cab.
5.Disconnect connector ATC3 and connect T-adapters to female side.
Between ATC3 (female) (37) and No continuity
Continuity
each pin other than (37) (No sound is heard)

3 Short circuit in wiring harness 1. Turn starting switch to OFF position.

2. Disconnect connector ATC3.
3. Tilt up cab (as mentioned above).
4. Disconnect connectors J09 and L.PS (CN6).
5. Connect T-adapter to either male or female side of connector J09.
Between J09 (female) (20) and No continuity
each pin other than pin (20) (No sound is heard)
Continuity
Between J09 (male) (20) and each No continuity
pin other than pin (20) (No sound is heard)
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

HM400-3M0 40-659
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to Lo clutch

40-660 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 2
Remedy taken when failure is detected
Gear speed when Failed clutch
Action of controller ON or OFF of lockup
failure is detected (Fill switch: ON)
(Selected clutch and gear speed) 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
No remedy is ―
N ANY NONE
taken

HM400-3M0 40-661
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) (HM300_3-DXH4KA-

400-A-Z0-A)

Action level Failure code Disconnection of ECMV Solenoid (1st)

Failure
L03 DXH4KA (Transmission controller system)
Detail of • When driving 1st clutch ECMV solenoid, no current flows through circuit.
failure
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed..
controller • Disengages lockup clutch.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.
• Since controller detects open circuit only while it drives ECMV solenoid, perform check
after repair when controller drives ECMV solenoid.
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31602 (mA)).
• Method of reproducing failure code: Turn starting switch to ON position and wait for 5
Related
seconds (for 5 seconds after starting switch is turned to ON position, controller drives
information
solenoid and performs self check).
• If repair is not completed, this failure code appears again.
k Tilt up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 1.PS (CN12) and connect T-adapters to male
Defective 1st clutch ECMV side.
1
solenoid Between 1.PS (CN12) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and 1.PS (CN12) (male) (1) or
tance Min. 1 Mz
(2)
1. Lower tilted-up cab.
Open circuit or short circuit in 2. Turn starting switch to OFF position.
2 wiring harness 3. Disconnect connector ATC3 and connect T-adapters to female side.
Resis- Between ATC3 (female) (16) and (13)
5 to 15 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
Open circuit in wiring harness 3. Tilt up cab (as mentioned above).
3 (wire breakage or defective 4. Disconnect connector 1.PS (CN12) and connect T-adapters to
contact of connector) female side.
Between ATC3 (female) (16) and 1.PS (CN12)
Max. 1 z
Resis- (female) (1)
tance Between ATC3 (female) (13) and 1.PS (CN12)
(female) (2) Max. 1 z
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

40-662 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 1
Remedy taken when failure is detected
Gear speed when Action of controller
Failed clutch ON or OFF of lockup
failure is detected
(Selected clutch and gear speed) 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

Circuit diagram related to 1st clutch

HM400-3M0 40-663
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) (HM300_3-DXH4KB-

400-A-Z0-A)

Action level Failure code Ground Fault of ECMV Solenoid (1st)

Failure
L03 DXH4KB (Transmission controller system)
Detail of • When driving 1st clutch ECMV solenoid, excessive current flows through circuit.
failure
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed..
controller • Disengages lockup clutch.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31602 (mA)).
• Method of reproducing failure code: Turn starting switch to ON position and wait for 5
Related seconds (for 5 seconds after starting switch is turned to ON position, controller drives
information solenoid and performs self check).
k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 1.PS (CN12) and connect T-adapters to male
Defective 1st clutch ECMV side.
1
solenoid Between 1.PS (CN12) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and 1.PS (CN12) (male) (1) or
tance Min. 1 Mz
(2)
1. Lower tilted-up cab.
Open circuit or short circuit in 2. Turn starting switch to OFF position.
2 wiring harness 3. Disconnect connector ATC3 and connect T-adapters to female side.
Resis- Between ATC3 (female) (16) and (13)
5 to 15 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
3. Tilt up cab (as mentioned above).
3 Ground fault in wiring harness 4. Disconnect connector 1.PS (CN12) and connect T-adapters to
female side.
Resis- Between ground and ATC3 (female) (16) or 1.
PS (CN12) (female) (1) Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC3 and connect T-adapters to female side.
4 Short circuit in wiring harness 4. Tilt up cab (as mentioned above).
5. Disconnect connector 1.PS (CN12) and connect T-adapters to
female side.
Resis- Between ATC3 (female) (16) and (13), or
between 1.PS (CN12) (female) (1) and (2) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-664 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 1
Remedy taken when failure is detected
Gear speed when Action of controller
Failed clutch ON or OFF of lockup
failure is detected
(Selected clutch and gear speed) 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

Circuit diagram related to 1st clutch

HM400-3M0 40-665
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) (HM300_3-DXH4KY-400-A-Z0-A)

Action level Failure code Hot Short of ECMV Solenoid (1st)

Failure
L03 DXH4KY (Transmission controller system)
Detail of • When controller does not drive 1st clutch ECMV solenoid, current flows through circuit.
failure
• Shifts up gear according to gear speed before failure as shown in Table 2 and holds that
Action of gear speed.
controller • Disengages lockup clutch.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31602 (mA)).
Related • Method of reproducing failure code: Start engine.
information
k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 1.PS (CN12) and connect T-adapters to male
Defective 1st clutch ECMV side.
1
solenoid
Between 1.PS (CN12) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and 1.PS (CN12) (male) (1) or
tance Min. 1 Mz
(2)
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 1.PS (CN12) and connect T-adapters to
Hot short circuit in wiring female side.
2 harness (contact with 24 V 4. Turn starting switch to ON position.
circuit) a If failure code [DXH4KA] for open circuit is displayed, wiring harness
does not short to power supply line (1st clutch ECMV solenoid is
defective).
Voltage Between 1.PS (CN12) (female) (1) and (2) Max. 4.5 V
1.Tilt up cab (as mentioned above).
2.Turn starting switch to OFF position.
3.Disconnect connector 1.PS (CN12).
4.Lower tilted-up cab.
5.Disconnect connector ATC3 and connect T-adapters to female side.
Between ATC3 (female) (16) and No continuity
Continuity
each pin other than pin (16) (No sound is heard)

3 Short circuit in wiring harness 1. Turn starting switch to OFF position.

2. Disconnect connector ATC3.
3. Tilt up cab (as mentioned above).
4. Disconnect connectors J09 and 1.PS (CN12).
5. Connect T-adapters to either male or female side of connector J09.
Between J09 (female) (28) and No continuity
each pin other than pin (28) (No sound is heard)
Continuity
Between J09 (male) (28) and each No continuity
pin other than pin (28) (No sound is heard)
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

40-666 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 1st clutch

HM400-3M0 40-667
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 2
Remedy taken when failure is detected
Gear speed when Failed clutch
Action of controller ON or OFF of lockup
failure is detected (Fill switch: ON)
(Selected clutch and gear speed) 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
No remedy is –
N ANY NONE
taken

40-668 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) (HM300_3-

DXH5KA-400-A-Z0-A)

Action level Failure code Disconnection of ECMV Solenoid (2nd)

Failure
L03 DXH5KA (Transmission controller system)
Detail of • When driving 2nd clutch ECMV solenoid, no current flows through circuit.
failure
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed..
controller • Disengages lockup clutch.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.
• Since controller detects open circuit only while it drives ECMV solenoid, perform check
after repair when controller drives ECMV solenoid.
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31603 (mA)).
Related • Method of reproducing failure code: Turn starting switch to ON position and wait for 5
information seconds (for 5 seconds after starting switch is turned to ON position, controller drives
solenoid and performs self check).
k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 2.PS (CN12) and connect T-adapters to male
Defective 2nd clutch ECMV side.
1
solenoid Between 2.PS (CN14) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and 2.PS (CN14) (male) (1) or
tance Min. 1 Mz
(2)
1. Lower tilted-up cab.
Open circuit or short circuit in 2. Turn starting switch to OFF position.
2 wiring harness 3. Disconnect connector ATC3 and connect T-adapters to female side.
Resis- Between ATC3 (female) (26) and (3)
5 to 15 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
Open circuit in wiring harness 3. Tilt up cab (as mentioned above).
3 (wire breakage or defective 4. Disconnect connector 2.PS (CN14) and connect T-adapters to
contact of connector) female side.
Between ATC3 (female) (26) and 2.PS (CN14)
Max. 1 z
Resis- (female) (1)
tance Between ATC3 (female) (3) and 2.PS (CN14)
(female) (2) Max. 1 z
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

HM400-3M0 40-669
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 1
Remedy taken when failure is detected
Gear speed when Action of controller
Failed clutch ON or OFF of lockup
failure is detected
(Selected clutch and gear speed) 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

Circuit diagram related to 2nd clutch

40-670 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) (HM300_3-DXH5KB-

400-A-Z0-A)

Action level Failure code Ground Fault of ECMV Solenoid (2nd)

Failure
L03 DXH5KB (Transmission controller system)
Detail of • When driving 2nd clutch ECMV solenoid, excessive current flows through circuit.
failure
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed..
controller • Disengages lockup clutch.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31603 (mA)).
Related
information k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 2.PS (CN14) and connect T-adapters to male
Defective 2nd clutch ECMV side.
1
solenoid
Between 2.PS (CN14) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and 2.PS (CN14) (male) (1) or
tance Min. 1 Mz
(2)
1. Lower tilted-up cab.
Open circuit or short circuit in 2. Turn starting switch to OFF position.
2 wiring harness 3. Disconnect connector ATC3 and connect T-adapters to female side.
Resis- Between ATC3 (female) (26) and (3)
5 to 15 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
3. Tilt up cab (as mentioned above).
3 Ground fault in wiring harness 4. Disconnect connector 2.PS (CN14) and connect T-adapters to
female side.
Resis- Between ground and ATC3 (female) (26) or 2.
PS (CN14) (female) (1) Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC3 and connect T-adapters to female side.
4 Short circuit in wiring harness 4. Tilt up cab (as mentioned above).
5. Disconnect connector 2.PS (CN14) and connect T-adapters to
female side.
Resis- Between ATC3 (female) (26) and (3), or
between 2.PS (CN14) (female) (1) and (2) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

HM400-3M0 40-671
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 1
Remedy taken when failure is detected
Gear speed when Action of controller
Failed clutch ON or OFF of lockup
failure is detected
(Selected clutch and gear speed) 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

Circuit diagram related to 2nd clutch

40-672 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) (HM300_3-DXH5KY-400-A-Z0-

A)

Action level Failure code Hot Short of ECMV Solenoid (2nd)

Failure
L03 DXH5KY (Transmission controller system)
Detail of • When controller does not drive 2nd clutch ECMV solenoid, current flows through circuit.
failure
• Shifts up gear according to gear speed before failure as shown in Table 2 and holds that
Action of gear speed..
controller • Disengages lockup clutch.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31603 (mA)).
Related • Method of reproducing failure code: Start engine.
information
k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 2.PS (CN14) and connect T-adapters to male
Defective 2nd clutch ECMV side.
1
solenoid Between 2.PS (CN14) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and 2.PS (CN14) (male) (1) or
tance Min. 1 Mz
(2)
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 2.PS (CN14) and connect T-adapters to
Hot short circuit in wiring female side.
2 harness (contact with 24 V 4. Turn starting switch to ON position.
circuit) a If failure code [DXH5KA] for open circuit is displayed, wiring harness
does not short to power supply line (2nd clutch ECMV solenoid is
defective).
Voltage Between 2.PS (CN14) (female) (1) and (2) Max. 4.5 V
1.Tilt up cab (as mentioned above).
2.Turn starting switch to OFF position.
3.Disconnect connector 2.PS (CN14).
4.Lower tilted-up cab.
5.Disconnect connector ATC3 and connect T-adapters to female side.
Between ATC3 (female) (26) and No continuity
Continuity
each pin other than pin (26) (No sound is heard)

3 Short circuit in wiring harness 1. Turn starting switch to OFF position.

2. Disconnect connector ATC3.
3. Tilt up cab (as mentioned above).
4. Disconnect connectors J09 and 2.PS (CN14).
5. Connect T-adapters to either male or female side of connector J09.
Between J09 (female) (31) and No continuity
each pin other than pin (31) (No sound is heard)
Continuity
Between J09 (male) (31) and each No continuity
pin other than pin (31) (No sound is heard)
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

HM400-3M0 40-673
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 2nd clutch

40-674 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 2
Remedy taken when failure is detected
Gear speed when Failed clutch
Action of controller ON or OFF of lockup
failure is detected (Fill switch: ON)
(Selected clutch and gear speed) 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
No remedy is –
N ANY NONE
taken

HM400-3M0 40-675
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) (HM300_3-DXH6KA-

400-A-Z0-A)

Action level Failure code Disconnection of ECMV Solenoid (3rd)

Failure
L03 DXH6KA (Transmission controller system)
Detail of • When driving 3rd clutch ECMV solenoid, no current flows through circuit.
failure
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed..
controller • Disengages lockup clutch.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.
• Since controller detects open circuit only while it drives ECMV solenoid, perform check
after repair when controller drives ECMV solenoid.
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31604 (mA)).
Related • Method of reproducing failure code: Turn starting switch to ON position and wait for 5
information seconds (for 5 seconds after starting switch is turned to ON position, controller drives
solenoid and performs self check).
k Tilt up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 3.PS (CN16) and connect T-adapters to male
Defective 3rd clutch ECMV side.
1
solenoid Between 3.PS (CN16) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and 3.PS (CN16) (male) (1) or
tance Min. 1 Mz
(2)
1. Lower tilted-up cab.
Open circuit or short circuit in 2. Turn starting switch to OFF position.
2 wiring harness 3. Disconnect connector ATC3 and connect T-adapters to female side.
Resis- Between ATC3 (female) (36) and (23)
5 to 15 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
Open circuit in wiring harness 3. Tilt up cab (as mentioned above).
3 (wire breakage or defective 4. Disconnect connector 3.PS (CN16) and connect T-adapters to
contact of connector) female side.
Between ATC3 (female) (36) and 3.PS (CN16)
Max. 1 z
Resis- (female) (1)
tance Between ATC3 (female) (23) and 3.PS (CN16)
(female) (2) Max. 1 z
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

40-676 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 1
Remedy taken when failure is detected
Gear speed when Action of controller
Failed clutch ON or OFF of lockup
failure is detected
(Selected clutch and gear speed) 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

Circuit diagram related to 3rd clutch

HM400-3M0 40-677
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) (HM300_3-DXH6KB-

400-A-Z0-A)

Action level Failure code Ground Fault of ECMV Solenoid (3rd)

Failure
L03 DXH6KB (Transmission controller system)
Detail of • When driving 3rd clutch ECMV solenoid, excessive current flows through circuit.
failure
• Shifts up gear according to gear speed before failure as shown in Table 1 and holds that
Action of gear speed..
controller • Disengages lockup clutch.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31604 (mA)).
• Method of reproducing failure code: Turn starting switch to ON position and wait for 5
Related seconds (for 5 seconds after starting switch is turned to ON position, controller drives
information solenoid and performs self check).
k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 3.PS (CN16) and connect T-adapters to male
Defective 3rd clutch ECMV side.
1
solenoid Between 3.PS (CN16) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and 3.PS (CN16) (male) (1) or
tance Min. 1 Mz
(2)
a Lower tilted-up cab.
Open circuit or short circuit in 1. Turn starting switch to OFF position.
2 wiring harness 2. Disconnect connector ATC3 and connect T-adapters to female side.
Resis- Between ATC3 (female) (36) and (23)
5 to 15 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
3. Tilt up cab (as mentioned above).
3 Ground fault in wiring harness 4. Disconnect connector 3.PS (CN16) and connect T-adapters to
female side.
Resis- Between ground and ATC3 (female) (36) or 3.
PS (CN16) (female) (1) Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC3 and connect T-adapters to female side.
4 Short circuit in wiring harness 4. Tilt up cab (as mentioned above).
5. Disconnect connector 3.PS (CN16) and connect T-adapters to
female side.
Resis- Between ATC3 (female) (36) and (23), or
between 3.PS (CN16) (1) and (2) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-678 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 1
Remedy taken when failure is detected
Gear speed when Action of controller
Failed clutch ON or OFF of lockup
failure is detected
(Selected clutch and gear speed) 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

Circuit diagram related to 3rd clutch

HM400-3M0 40-679
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) (HM300_3-DXH6KY-400-A-Z0-A)

Action level Failure code Hot Short of ECMV Solenoid (3rd)

Failure
L03 DXH6KY (Transmission controller system)
Detail of • When controller does not drive 3rd clutch ECMV solenoid, current flows through circuit.
failure
• Shifts up gear according to gear speed before failure as shown in Table 2 and holds that
Action of gear speed..
controller • Disengages lockup clutch.
Problem on • Once shift lever is set to "N" during travel, even if shift lever is moved to a position other
machine than "N", gear does not engage until machine is stopped.
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31604 (mA)).
Related • Method of reproducing failure code: Start engine.
information
k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 3.PS (CN16) and connect T-adapters to male
Defective 3rd clutch ECMV side.
1
solenoid
Between 3.PS (CN16) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and 3.PS (CN16) (male) (1) or
tance Min. 1 Mz
(2)
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector 3.PS (CN16) and connect T-adapters to
Hot short circuit in wiring female side.
2 harness (contact with 24 V 4. Turn starting switch to ON position.
circuit) a If failure code [DXH6KA] for open circuit is displayed, wiring harness
does not short to power supply line (3rd clutch ECMV solenoid is
defective).
Voltage Between 3.PS (CN16) (female) (1) and (2) Max. 4.5 V
1.Tilt up cab (as mentioned above).
2.Turn starting switch to OFF position.
3.Disconnect connector 3.PS (CN16).
4.Lower tilted-up cab.
5.Disconnect connector ATC3 and connect T-adapters to female side.
Between ATC3 (female) (36) and No continuity
Continuity
each pin other than pin (36) (No sound is heard)

3 Short circuit in wiring harness 1. Turn starting switch to OFF position.

2. Disconnect connector ATC3.
3. Tilt up cab (as mentioned above).
4. Disconnect connectors J09 and 3.PS (CN16).
5. Connect T-adapter to either male or female side of connector J09.
Between J09 (female) (34) and No continuity
each pin other than pin (34) (No sound is heard)
Continuity
Between J09 (male) (34) and each No continuity
pin other than pin (34) (No sound is heard)
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

40-680 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 3rd clutch

HM400-3M0 40-681
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 2
Remedy taken when failure is detected
Gear speed when Failed clutch
Action of controller ON or OFF of lockup
failure is detected (Fill switch: ON)
(Selected clutch and gear speed) 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
No remedy is –
N ANY NONE
taken

40-682 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH7KA] Disconnection of ECMV Solenoid

(Reverse) (HM300_3-DXH7KA-400-A-Z0-A)
Action level Failure code Disconnection of ECMV Solenoid (Reverse)
Failure
L03 DXH7KA (Transmission controller system)
Detail of • When driving R clutch ECMV solenoid, no current flows through circuit.
failure
Action of • Sets gear to NEUTRAL.
controller • Disengages lockup clutch.
Problem on • Machine cannot restart unless it is stopped once.
machine
• Since controller detects open circuit only while it drives ECMV solenoid, perform check
after repair when controller drives ECMV solenoid.
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31606 (mA)).
Related • Method of reproducing failure code: Turn starting switch to ON position and wait for 5
information seconds (for 5 seconds after starting switch is turned to ON position, controller drives
solenoid and performs self check).
k Tilt up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector R.PS (CN8) and connect T-adapters to male
Defective R clutch ECMV side.
1
solenoid Between R.PS (CN8) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and R.PS (CN8) (male) (1) or
tance Min. 1 Mz
(2)
1. Lower tilted-up cab.
Open circuit or short circuit in 2. Turn starting switch to OFF position.
2 wiring harness 3. Disconnect connector ATC3 and connect T-adapters to female side.
Resis- Between ATC3 (male) (5) and (23)
5 to 15 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
Open circuit in wiring harness 3. Tilt up cab (as mentioned above).
3 (wire breakage or defective 4. Disconnect connector R.PS (CN8) and connect T-adapters to female
contact of connector) side.
Between ATC3 (female) (5) and R.PS (CN8)
Max. 1 z
Resis- (female) (1)
tance Between ATC3 (female) (3) and R.PS (CN8)
(female) (2) Max. 1 z
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

HM400-3M0 40-683
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to R clutch

Table 1
Remedy taken when failure is detected
Gear speed when Action of controller
Failed clutch ON or OFF of lockup
failure is detected
(Selected clutch and gear speed) 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

40-684 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) (HM300_3-

DXH7KB-400-A-Z0-A)

Action level Failure code Ground Fault of ECMV Solenoid (Reverse)

Failure
L03 DXH7KB (Transmission controller system)
Detail of • When driving R clutch ECMV solenoid, excessive current flows through circuit.
failure
Action of • Sets gear to NEUTRAL.
controller • Disengages lockup clutch.
Problem on • Machine cannot restart unless it is stopped once.
machine
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31606 (mA)).
• Method of reproducing failure code: Turn starting switch to ON position and wait for 5
Related seconds (for 5 seconds after starting switch is turned to ON position, controller drives
information solenoid and performs self check).
k Tilt
up cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector R.PS (CN8) and connect T-adapters to male
Defective R clutch ECMV side.
1
solenoid
Between R.PS (CN8) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and R.PS (CN8) (male) (1) or
tance Min. 1 Mz
(2)
1. Lower tilted-up cab.
Open circuit or short circuit in 2. Turn starting switch to OFF position.
2 wiring harness 3. Disconnect connector ATC3 and connect T-adapters to female side.
Resis- Between ATC3 (male) (5) and (23)
5 to 15 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector ATC3 and connect T-adapters to female side.
3. Tilt up cab (as mentioned above).
3 Ground fault in wiring harness 4. Disconnect connector R.PS (CN8) and connect T-adapters to female
side.
Resis- Between ground and ATC3 (female) (5) or R.
PS (CN8) (female) (1) Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Lower tilted-up cab.
2. Turn starting switch to OFF position.
3. Disconnect connector ATC3 and connect T-adapters to female side.
4 Short circuit in wiring harness 4. Tilt up cab (as mentioned above).
5. Disconnect connector R.PS (CN8) and connect T-adapters to female
side.
Resis- Between ATC3 (female) (5) and (23), or
between R.PS (CN8) (female) (1) and (2) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

HM400-3M0 40-685
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to R clutch

Table 1
Remedy taken when failure is detected
Gear speed when Action of controller
Failed clutch ON or OFF of lockup
failure is detected
(Selected clutch and gear speed) 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

40-686 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) (HM300_3-DXH7KY-

400-A-Z0-A)

Action level Failure code Hot Short of ECMV Solenoid (Reverse)

Failure
L03 DXH7KY (Transmission controller system)
Detail of • When controller does not drive R clutch ECMV solenoid, current flows through circuit.
failure
Action of • Sets gear to NEUTRAL.
controller • Disengages lockup clutch.
Problem on • Machine cannot restart unless it is stopped once.
machine
• Current value output to ECMV solenoid can be checked with monitoring function (Code:
31606 (mA)).
Related • Method of reproducing failure code: Start engine.
information
k Tiltup cab, fix it securely by using lock bar, and check that lock lever is set to
CLOSE position (see Testing and adjusting, "Cab tilt-up procedure").
No. Cause Procedure, measuring location, criteria and remarks
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector R.PS (CN8) and connect T-adapters to male
Defective R clutch ECMV side.
1
solenoid Between R.PS (CN8) (male) (1) and (2) 5 to 15 z
Resis-
Between ground and R.PS (CN8) (male) (1) or
tance Min. 1 Mz
(2)
1. Tilt up cab (as mentioned above).
2. Turn starting switch to OFF position.
3. Disconnect connector R.PS (CN8) and connect T-adapters to female
Hot short circuit in wiring side.
2 harness (contact with 24 V 4. Turn starting switch to ON position.
circuit) a If failure code [DXH7KA] for open circuit is displayed, wiring harness
does not short to power supply line (R clutch ECMV solenoid is
defective).
Voltage Between R.PS (CN8) (female) (1) and ground Max. 4.5 V
1.Tilt up cab (as mentioned above).
2.Turn starting switch to OFF position.
3.Disconnect connector R.PS (CN8).
4.Lower tilted-up cab.
5.Disconnect connector ATC3 and connect T-adapters to female side.
Between ATC3 (female) (5) and No continuity
Continuity
each pin other than pin (5) (No sound is heard)

3 Short circuit in wiring harness 1. Turn starting switch to OFF position.

2. Disconnect connector ATC3.
3. Tilt up cab (as mentioned above).
4. Disconnect connectors J09 and R.PS (CN8).
5. Connect T-adapter to either male or female side of connector J09.
Between J09 (female) (3) and each No continuity
pin other than pin (3) (No sound is heard)
Continuity
Between J09 (male) (3) and each No continuity
pin other than pin (3) (No sound is heard)
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

HM400-3M0 40-687
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to R clutch

40-688 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Table 2
Remedy taken when failure is detected
Gear speed when Failed clutch
Action of controller ON or OFF of lockup
failure is detected (Fill switch: ON)
(Selected clutch and gear speed) 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
No remedy is –
N ANY NONE
taken

HM400-3M0 40-689
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor (HM400_3-

DY30MA-400-A-Z0-A)

Action level Failure code Malfunction 1 of Emergency Steering Motor

Failure
L01 DY30MA (Retarder hoist controller system)
• When manual emergency steering switch is in OFF position and controller does not drive
Detail of failure auto emergency steering relay 1, signal voltage of emergency steering pressure 1 is
above 0.56 V (oil pressure is above 0.7 MPa).
Action of • None in particular.
controller
Problem on • Emergency steering remains activated.
machine
• Signal from emergency steering pressure sensor 1 can be checked with monitoring
Related function.
information (Code: 07703 (Mpa) and 07705 (V), Emergency steering OFF with emergency steering
in straight-travel state: 0.3 to 0.56 V, Emergency steering ON: 2.0 to 2.3 V)
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Interchange R17 of auto emergency steering relay 1 with horn relay
Defective auto emergency R10.
1 steering relay 1 3. Turn starting switch to ON position.
If this failure code does not appear again, R17 of original auto
emergency steering relay 1 is defective.
1. Turn starting switch to OFF position.
2. Interchange R22 of manual emergency steering relay with stop lamp
Defective manual emergency relay R04.
2 steering relay 3. Turn starting switch to ON position.
If this failure code does not appear again, R22 of original manual
emergency steering relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors R17 and R22, and connect T-adapters to
each female side.
Hot short circuit in wiring 3. Turn starting switch to ON position.
3 harness Between R17 (female) (1) and (2) Max. 1 V
(contact with 24 V circuit) Between R22 (female) (5) and (6) Max. 1 V
Voltage Between R22 (female) (3) and (6) Max. 1 V
Between ground and M (1) or emergency
steering relay (76) Max. 1 V
Open circuit in wiring 1. Turn starting switch to OFF position.
harness (wire breakage or 2. Disconnect connector BRC3 and connect T-adapters to female side.
4 defective contact of Resis- Between BRC3 (female) (20) and ST (2)
connector) Max. 1 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector EST.
Defective manual emergency Emergency steering
5 steering switch Min. 1 Mz
Resis- Between EST (3) and switch: OFF
tance EST (4) Emergency steering
Max. 1 z
switch: ON
a Check that machine is in straight travel posture.
1. Turn starting switch to OFF position.
2. Insert T-adapters to connector B02.
Defective emergency 3. Turn starting switch to ON position.
6 steering pressure sensor
Emergency steering: 0.3 to 0.56
Between B02 (C) and OFF V
Voltage
(A)
Emergency steering: ON 2.0 to 2.3
V

40-690 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
7
controller performed.)

HM400-3M0 40-691
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to emergency steering motor

40-692 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor (HM400_3-

DY30MC-400-A-Z0-A)

Action level Failure code Malfunction 2 of Emergency Steering Motor

Failure
L03 DY30MC (Retarder hoist controller system)
• When manual emergency steering switch is turned to ON position or controller drives auto
Detail of emergency steering relay 1, signal voltage of emergency steering pressure 1 is below
failure 0.56 V (oil pressure is below 0.7 MPa).
Action of • None in particular.
controller
Problem on • Emergency steering is not activated.
machine
• Signal from emergency steering pressure sensor 1 can be checked with monitoring
Related function.
information (Code: 07703 (MPa) and 07705 (V))
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective auto 2. Interchange R17 of auto emergency steering relay 1 with horn relay R10.
1 emergency steering 3. Turn starting switch to ON position.
relay 1 If this failure code does not appear again, R17 of original auto emergency
steering relay 1 is defective.
1. Turn starting switch to OFF position.
2. Interchange R22 of manual emergency steering relay with side lamp relay
Defective manual
R11.
2 emergency steering
3. Turn starting switch to ON position.
relay
If this failure code does not appear again, R22 of original manual emergency
steering relay is defective.
1. Turn starting switch to OFF position.
Defective manual 2. Disconnect connector EST.
3 emergency steering Emergency steering
Between EST (3) and Min. 1 Mz
switch switch: OFF
Resistance EST (4)
Emergency steering
Max. 1 z
switch: ON
1. Turn starting switch to OFF position.
2. Check that system operating lamp is turned OFF, and then turn battery
disconnect switch to OFF position.
Open circuit in wiring 3. Remove fuse BT4-26.
harness (wire breakage 4. Set manual emergency steering switch to ON position.
4 or defective contact of
connector) a Coil resistance of R22 of manual emergency steering relay
a Path of manual emergency steering switch ST3 and ST4.
200 to 400
Resistance Between BT4-26 and ground
z
1. Turn starting switch to OFF position.
2. Disconnect connectors R17 and R22, and connect T-adapters to each
female side.
3. Disconnect terminals ER14 and M-2 of emergency steering motor.
Open circuit in wiring Between R17 (female) (3) and emergency steering
relay 1 (60) Max. 1 z
harness
5 Between R17 (female) (5) and BT1-4 Max. 1 z
(wire breakage or
defective contact of Between emergency relay 1 (59) and ground
connector) Max. 1 z
Resistance a Loose or rusted ground terminal ER4
Between M (1) and emergency steering relay 1 (76) Max. 1 z
Between ER18 and ground Max. 1 z
Between battery (+) (BT-2B) and emergency relay Max. 1 z
1 (77)

HM400-3M0 40-693
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector R17 , R22 and connect T-adapters to female side.
6
(contact with ground Between ground and R17 (female) (3) or R22
circuit) Resistance (female) (3) or emergency steering relay 1 (60) Min. 1 Mz

a Check that machine is in straight travel posture.

1. Turn starting switch to OFF position.
Defective emergency 2. Insert T-adapters to connector B02.
7 steering pressure 3. Turn starting switch to ON position.
sensor 1 Emergency steering: 0.3 to 0.56
Voltage Between B02 (C) and (A) OFF V
Emergency steering: ON 2.0 to 2.3 V
a Be ready with starting switch at OFF, and then turn starting switch to ON
position to perform troubleshooting.
Defective emergency
8 Between emergency Emergency steering
steering motor 1 Max. 1 V
Voltage steering motor 1 M (1) switch: OFF
and ER (18) Emergency steering
20 to 30 V
switch: ON
Defective retarder hoist If no failure is found by above checks, retarder hoist controller is defective.
9 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-694 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to emergency steering motor

HM400-3M0 40-695
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DY30ME] Emerg. Steering Long-Time Activated (HM400_3-DY30ME-

400-A-Z0-A)

Action level Failure code Emergency Steering Long-Time Activated

Failure
L02 DY30ME (Retarder hoist controller system)
Detail of • Signal voltage of emergency steering pressure 1 is above 0.56 V (oil pressure is above
failure 0.7 MPa) for continuous 60 seconds.
Action of • None in particular.
controller
Problem on
• None
machine
• Signal from emergency steering pressure sensor 1 can be checked with monitoring
Related function.
information (Code: 07703 (Mpa) and 07705 (V), Emergency steering OFF with emergency steering in
straight-travel state: 0.3 to 0.56 V, Emergency steering ON: 2.0 to 2.3 V)
No. Cause Procedure, measuring location, criteria and remarks

1 Steering Oil Pressure Low a If failure code [DHT8ZG] is displayed, perform troubleshooting for
[DHT8ZG].
If you set emergency steering switch to "ON" from necessity, stop
Long-period operation of
2 machine in safe place, set parking brake to "PARKING", and then set
manual emergency steering
emergency steering switch to "OFF".
Long-period operation of auto When auto emergency steering is in operation, stop machine in safe
3 emergency steering place and set parking brake to "PARKING".
a Check that machine is in straight travel posture.
1. Turn starting switch to OFF position.
Defective emergency steering 2. Insert T-adapters to connector B02.
4 pressure sensor 3. Turn starting switch to ON position.
0.3 to 0.56
Between B02 (C) Emergency steering: OFF
Voltage V
and (A)
Emergency steering: ON 2.0 to 2.3 V
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-696 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to emergency steering motor

HM400-3M0 40-697
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DY32MC] Malfunction 2 of Emerg. Steering Motor 2 (HM400_3-

DY32MC-400-A-Z0-A)

Action level Failure code Malfunction 2 of Emergency Steering Motor 2

Failure
L03 DY32MC (Retarder hoist controller system)
• When manual emergency steering switch is turned to ON position or controller drives auto
Detail of emergency steering relay 2, signal voltage of emergency steering pressure 2 is below
failure 0.56 V (oil pressure is below 0.7 MPa).
Action of • None in particular.
controller
Problem on • Emergency steering is not activated.
machine
• Signal from emergency steering pressure sensor 2 can be checked with monitoring
Related function.
information (Code: 07704 (Mpa) and 07706 (V))
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Interchange R21 of auto emergency steering relay 2 with horn relay
Defective auto emergency R10.
1 steering relay 2 3. Turn starting switch to ON position.
If this failure code does not appear again, R21 of original auto
emergency steering relay 2 is defective.
1. Turn starting switch to OFF position.
2. Interchange R22 of manual emergency steering relay with side lamp
Defective manual emergency relay R11.
2 steering relay 3. Turn starting switch to ON position.
If this failure code does not appear again, R22 of original manual
emergency steering relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector EST.
Defective manual emergency Emergency steering
3 steering switch Min. 1 Mz
Resis- Between EST switch: OFF
tance (3) and EST (4) Emergency steering
Max. 1 z
switch: ON
1. Turn starting switch to OFF position.
2. Remove fuse BT4-26.
Open circuit in wiring harness 3. Set manual emergency steering switch to ON position.
4 (wire breakage or defective
contact of connector) a Coil resistance of R22 of manual emergency steering relay
Resis- Between BT4-26 and ground Max. 290 ± 30
tance z

40-698 HM400-3M0
 40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors R21 and R22, and connect T-adapters to
each female side.
3. Disconnect terminals ER14 and M-2 of emergency steering motor.
Between R21 (female) (3) and emergency
relay (57) Max. 1 z
Open circuit in wiring harness Between R21 (female) (5) and BT1–4 Max. 1 z
5 (wire breakage or defective Between emergency relay 2 (56) and ground
contact of connector) Max. 1 z
Resis- a Loose or rusted ground terminal ER4
tance Between M (2) and emergency steering relay 2
(73) Max. 1 z
Between ER14 and ground Max. 1 z
Between battery (+) (BT-2B) and emergency
relay 2 (72) Max. 1 z

Ground fault in wiring 1. Turn starting switch to OFF position.

harness 2. Disconnect connector R21 and connect T-adapters to female side.
6
(contact with ground circuit) Resis- Between ground and R21 (female) (3) or R22
tance (female) (1) or emergency steering relay 2 (57) Min. 1 Mz
a Check that machine is in straight travel posture.
1. Turn starting switch to OFF position.
Defective emergency 2. Insert T-adapters to connector B20.
7 steering pressure sensor 2 3. Turn starting switch to ON position.
Emergency steering: OFF 0.3 to 0.56
Between B20 (C)
Voltage V
and (A)
Emergency steering: ON 2.0 to 2.3 V
a Be ready with starting switch at OFF, and then turn starting switch to
ON position to perform troubleshooting.
Defective emergency Between Emergency steering
8 steering motor 2 Max. 1 V
emergency switch: OFF
Voltage
steering motor 2 M Emergency steering
(1) and ER (14) 20 to 30 V
switch: ON
If no failure is found by above checks, retarder hoist controller is
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
9
controller performed.)

HM400-3M0 40-699
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to emergency steering motor 2

40-700 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Troubleshooting of electrical system (E-mode) (ALL-3840-001-A-01-A)

E-1 Engine does not start (Engine does not crank) (HM400_3R-A21-400-A-Z0-A)

Failure • Engine does not start (engine does not crank).

• Engine starting circuit has following 2 start lock mechanisms.
1. Start lock by password protection of machine monitor
2. Start lock by gear shift lever position (engine can start only when gear shift lever is in
NEUTRAL).
• If failure symptom "Battery relay operation sound is not heard" appears when starting
Related switch is turned to ON position, perform troubleshooting for E-1 as well.
information • If failure symptom "Machine monitor displays nothing" appears when starting switch is
turned to ON position, main power supply system may be defective. So, perform
troubleshooting for E-5 (lines connecting to terminal 82 of circuit breaker and fuse 3 in
fuse box BT2).
• Battery charge voltage sensed by transmission controller can be checked with monitoring
function. (Code: 04307 (V))
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
Loose terminal or open
1 Check terminals of starting motor, alternator, and battery relay, and ground
circuit at terminal
terminals ER2, ER4, ER5, ER6, ER15, etc.
1. Turn starting switch to OFF position.
Poor contact Between battery relay terminal 50 and ground
2 (grounding) between a Use machine frame as grounding point for
battery relay and frame Resistance Max. 1 z
measurement.
a Check for loosened or rusted terminal ER4.
a Be ready with starting switch at OFF, then perform troubleshooting without
Insufficient battery turning starting switch to ON position.
3 capacity Battery voltage (2 batteries) Min. 24 V
Specific gravity of electrolyte (each
battery) Min. 1.26
Defects of engine controller power supply and ACC signal are indicated with
Defective engine
4 failure code [DB2QKR]. If this code appears, perform troubleshooting for
controller system
causes 1 to 3 of [DB2QKR] first.
Defective transmission If failure code [DAQQKR] or [DAQRKR] is displayed, perform troubleshooting
5 controller system for [DAQQKR] or [DAQRKR].
Defective gear shift If failure code [DF10KA] or [DF10KB] is displayed, perform troubleshooting for
6 lever system [DF10KA] or [DF10KB].
1. Turn starting switch to ON position (to connect ACC).
Defective battery relay
7 system a If battery relay operation sound is not heard, go to checks on cause 19 and
after.
1. Turn starting switch to OFF position.
2. Remove fuse No. 23 (30 A) in fuse box BT4. (To prevent engine from
Defective starting starting during troubleshooting)
switch, shift lever 3. Insert T-adapter into connector 78.
switch, personal code 4. Turn starting switch to START position and hold it (two persons required
8 relay R19, engine start for this check).
relay R01, battery relay,
or wiring harness a If voltage is normal, go to checks on causes 15 and after.
Voltage Between 78 (1) and ground 20 to 30 V

HM400-3M0 40-701
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria, and remarks

a If no failure is found by check on cause 8, this check is not required.
1. Turn starting switch to OFF position.
Defective transmission
2. Disconnect connector R01 and connect T-adapter to female side.
9 controller or defective
3. Turn starting switch to ON position (to connect ACC).
wiring harness
a Check that gear shift lever is in NEUTRAL position.
Voltage Between R01 (female) (1) and ground 20 to 30 V
a If no failure is found by check on cause 9, this check is not required.
• Primary side of engine start relay R01
1. Turn starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn battery
disconnect switch to OFF position.
3. Disconnect connector ATC3, and connect T-adapter to female side.
Open circuit in wiring
harness 1 a To measure coil resistance of relay R01
200 to 400
10 (Wire breakage or Resistance Between ATC3 (female) (25) and ground
z
defective contact of
connector) a If no failure is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC3, R01, and JCA, and connect T-adapters to
each female side.
Between ATC3 (female) (25) and R01 (female) (1) Max. 1 z
Resistance Between R01 (female) (2) and JCA (female) (1) Max. 1 z
Between JCA (female) (16) and ground Max. 1 z
a If no failure is found by check on cause 9, this check is not required.
1. Turn starting switch to OFF position.
Ground fault 1 in wiring
2. Check that system operating lamp is not lit, and then turn battery
harness
11 disconnect switch to OFF position.
(Contact with ground 3. Disconnect connectors ATC3 and R01, and connect T-adapter to either
circuit) female side.
Between ground and ATC3 (female) (25) or R01
Resistance (female) (1) Min. 1 Mz

Defective transmission a If no failure is found by check on cause 9, this check is not required.
12 If check result on cause 9 is abnormal and those on causes 10 and 11 are
controller
normal, transmission controller is defective.
a If no failure is found by check on cause 8, this check is not required.
1. Check that system operating lamp is not lit, and then turn battery
disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect cable terminal B.
4. Turn starting switch to ON and START positions to perform
Defective starting troubleshooting again.
13 switch Between terminal B (on Starting switch: OFF. Min. 1 Mz
(Internal open circuit) switch side) and terminal
Starting switch: ON Max. 1 z
BR
Between terminal B (on Starting switch: OFF. Min. 1 Mz
Resistance switch side) and terminal Starting switch: ON
ACC Max. 1 z
Between terminal B (on Starting switch: OFF. Min. 1 Mz
switch side) and terminal Max. 1 z
Starting switch: START
C

40-702 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria, and remarks

a If no failure is found by check on cause 8, this check is not required.
1. Turn starting switch to OFF position.
2. Remove personal code relay R19 and engine start relay R01.
Defective personal 200 to 400
relay R19 and engine Between R19 (male) (1) and (2)
z
14 start relay R01 Between R19 (male) (3) and (6) Max. 1 z
(Internal open or short Between R19 (male) (3) and (5) Min. 1 Mz
circuit) Resistance
Between R01 (male) (1) and (2) 200 to 400
z
Between R01 (male) (3) and (6) Max. 1 z
Between R01 (male) (3) and (5) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector J13 or J26.
Defective alternator 3. Turn starting switch to ON position.
15
(Internal short circuit) Input from
Between ground and J13 (2) or J26
Voltage alternator Max. 1 V
(7)
generation
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector 78.
3. Remove fuse-24 (30 A, for engine controller) of fuse box BT4 (to prevent
engine from cranking during checks). (See "Fuse location table".)
4. Turn starting switch to START position to perform troubleshooting.
Between starting motor terminal B and Power
ground supply 20 to 30 V
Defective starting motor Starting
16 input to
(Internal defect) Between 78 (1) and ground 20 to 30 V
Voltage starting
motor
Input from
Between 78 (2) and ground alternator Max. 1 V
generation
When voltages of power supply, starting input to starting motor, and input from
alternator generation are normal, if starting motor does not rotate, starting
motor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors D01 and D09, and connect T-adapter to diode.
a Measure it with diode range of multimeter.
Defective diode D01 or No
D09 Between D01 (male) (1) (+) and (2) (-)
17 continuity
(Internal open or short Between D01 (male) (2) (+) and (1) (-) Continuity
circuit) Continuity No
Between D09 (male) (1) (+) and (2) (-)
continuity
Between D09 (male) (2) (+) and (1) (-) Continuity

HM400-3M0 40-703
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria, and remarks

• Battery relay
1. Turn starting switch to OFF position.
Resistance Between terminal 50 and ground Max. 1 z
• Battery relay
1. Turn starting switch to OFF position.
2. Turn starting switch to ON position.
a Check where 24 V power is reached to, and locate open section.
Between terminal 66 and terminal 50 20 to 30 V
Between terminal 53 and terminal 50 20 to 30 V
Voltage
Between terminal 69 and terminal 50 20 to 30 V
Between terminal 50 and ground Max. 1 V
• Starting motor
1. Turn starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn battery
disconnect switch to OFF position.
3. Insert T-adapters into connectors R19, R01, and 78.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to START position to perform troubleshooting.
Open circuit in wiring
a Check where 24 V power is reached to, and locate open section.
harness 2
Between terminal C of starting switch and ground 20 to 30 V
18 (Wire breakage or
defective contact of Between R19 (6) and ground 20 to 30 V
connector) Between R19 (3) and ground 20 to 30 V
Voltage
Between R01 (3) and ground 20 to 30 V
Between 78 (1) and ground 20 to 30 V
Between starting motor terminal B and ground 20 to 30 V
• Line of terminal C and power supply line
1. Turn starting switch to OFF position.
2. Disconnect connectors R01, R19, ATC1, MCM1, and 78.
3. Connect T-adapters to female sides of R01 and R19, and to male side of
78.
Between terminal C of starting switch and R19
(female) (6) Max. 1 z
Between R19 (female) (3) and R01 (female) (5) Max. 1 z
Between R01 (female) (3) and 78 (male) (1) Max. 1 z
Between R01 (female) (3) and ATC1 (female) (23) Max. 1 z
Resistance
Between R19 (female) (6) and MCM (female) (11) Max. 1 z
Between starting motor terminal B and battery relay
Max. 1 z
terminal 69
Between alternator terminal R and 78 (female) (2) Max. 1 z
Between alternator terminal E and ground Max. 1 z
Defective battery relay If voltage of terminal 69 only is unusual in battery relay checks on cause 18,
19 battery relay is defective.
(Does not turn ON.)
1. Turn starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn battery
Ground fault 2 in wiring disconnect switch to OFF position.
harness 3. Disconnect connectors R19, K0M2, IDJ, MCM1, BRC3, 78, and ATC1.
20 4. Connect T-adapters to female side of R19 and male side of 78.
(Contact with ground
circuit) Between R19 (female) (6) and ground Min. 1 Mz
Resistance Between R19 (female) (3) and ground Min. 1 Mz
Between 78 (male) (1) and ground Min. 1 Mz
Hot short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Insert T-adapter into connector 78.
21 3. Turn starting switch to ON position.
(Contact with 24 V
circuit) Voltage Between 78 (2) and ground Max. 1 V

40-704 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to engine starting circuit

HM400-3M0 40-705
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-2 Manual preheating system does not work (HM400_3R-FEM-400-A-Z0-A)

Failure Manual preheating system does not work.

a This troubleshooting describes procedures to be followed when manual preheating does
not function to heat electrical intake air heater (ribbon heater) mounting portion.
• This machine has "Automatic preheating" and "Manual preheating" functions. When either
preheating works, preheating monitor lights up. (When only preheating pilot lamp does not
Related light up, perform troubleshooting for "E-4 While preheating is working, preheating monitor
information does not light up").
• If failure symptom "Machine monitor displays nothing" or "Battery relay does not make
operating sound" appears when starting switch is turned to ON position, main electric
power supply system may be defective. In these cases, perform troubleshooting for E-5
and E-1 respectively.
• Before performing troubleshooting, check that no related failure code is displayed.
No. Cause Procedure, measuring location, criteria, and remarks
If slow-blow fuse SBF is blown out, circuit probably has ground fault. In this
1 Slow-blow fuse SBF case, perform check on cause 8 first.
1. Turn starting switch to OFF position.
Loose terminal or open
2 Check terminals of heater relay, battery relay, electrical intake air heater
circuit at terminal
(ribbon heater), etc.
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
a Heater relay coil resistance
Approx. 20
Resistance Between terminal R1 of starting switch and ground
z
a If slow-blow fuse (SBF) is blown, replace it in advance.
1. Turn starting switch to OFF position.
2. Turn battery disconnect switch to ON position.
3. Turn starting switch to ON position.
Open and short circuit Voltage Between heater relay terminal E12 and ground
3 20 to 30 V
in wiring harness
1. Turn starting switch to OFF position.
2. Disconnect heater relay terminal PHO.
a To prevent current from flowing through heater when starting switch is
turned to HEAT position
3. Turn starting switch to the HEAT position (connect R1).
Voltage Between heater relay terminal E11 and ground 20 to 30 V
1. Turn starting switch to OFF position.
a Check for loosened or rusted terminal ER4.
Continuity Between HR_BE of heater relay and ground Continuity
Defective heater relay
If no failure is found by check on cause 5 and heater relay operation sound is
4 (Does not engage) not heard, heater relay is defective.
(Terminal PH0)
1. Turn starting switch to OFF position.
2. Remove connector D15 and connect T-adapter to diode.
Defective diode D15
5 (Internal open or short a Measure it with diode range of multimeter.
circuit) No
Between D15 (male) (1) (+) and (2) (-)
Continuity continuity
Between D15 (male) (2) (+) and (1) (-) Continuity
Defective electrical 1. Turn starting switch to OFF position.
intake air heater (ribbon 2. Disconnect cable terminal RH.
6 heater)
Continuity Between terminal RH and ground Continuity
(Internal open circuit)

40-706 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria, and remarks

1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
Defective starting 3. Turn starting switch to OFF and the HEAT positions to perform
7 troubleshooting.
switch
OFF Min. 1 Mz
Resistance Between terminal B and terminal R1
HEAT Max. 1 z
a If no failure is found by check on cause 3, this check is not required.
a If slow-blow fuse is blown, replace it in advance.
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors MCM1 and D15, and terminals E11, E12, RH, and
harness 88.
8 Between heater relay terminal E12 (wiring harness
(Contact with ground
side) and ground Min. 1 Mz
circuit)
Between heater relay terminal E11 (wiring harness
Resistance side) and ground Min. 1 Mz
Between heater relay terminal RH (wiring harness
side) and ground Min. 1 Mz

HM400-3M0 40-707
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to engine preheating system

40-708 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-3 Automatic preheating system does not work (HM400_3R-FE1-400-A-Z0-A)

Failure Automatic preheating system does not work.

• Automatic preheating starts when coolant temperature is below -5°C.
(Monitoring code: 04107 “Coolant temperature”)
• If automatic preheating function does not work, check whether manual preheating
Related function works first.
information • Engine controller checks primary (coil) side of preheat relay (connector R07) and
generates failure code [CA2555] or [CA2556] if it is defective.
• Engine controller checks engine coolant temperature sensor and generates failure code
[CA144] or [CA145] if it is defective.
No. Cause Procedure, measuring location, criteria, and remarks
Defective circuit breaker If circuit breaker 62 is tripped, circuit probably has ground fault. In this case,
1 perform check on cause 6 first.
62
Defective fuse No. 11 in If fuse No. 11 in fuse box BT1 is blown, circuit probably has ground fault. In
2 this case, perform check on cause 6 first.
fuse box BT1
1. Turn starting switch to OFF position.
2. Replace auto preheat relay (connector R07) with horn relay (connector
Defective auto preheat
R10).
3 relay R07 (internal open
3. Turn starting switch to ON position.
or short circuit)
If automatic preheating starts when coolant temperature is below -5°C,
original auto preheat relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors MCM1, R07, and D15, and connect T-adapter to
female side of R07.
Open circuit or ground a If resistance is 1 Mz or higher, harness has open circuit. If it is 1 z or
4 fault in wiring harness below, harness has ground fault.
a Heater relay coil resistance
Approx. 20
Resistance Between R07 (female) (3) and ground
z
a If circuit breaker is tripped, reset it.
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Turn the battery disconnect switch to OFF position.
harness 3. Disconnect connectors R07 and MCM1, and connect T-adapter to female
5 (Wire breakage or side of R07.
defective contact of Between R07 (female) (5) and terminal 69 of
connector) battery relay Max. 1 z
Resistance
Between R07 (female) (3) and terminal E11 of
heater relay Max. 1 z
If circuit breaker is not tripped or fuse is not blown, this check is not required.

Ground fault in wiring a If circuit breaker is tripped, reset it.

harness 1. Turn starting switch to OFF position.
6 2. Disconnect connectors R07 and J02, and connect T-adapter to female
(Contact with ground
circuit) side of R07.
3. Remove fuses -1, -3, -7, -9, -13, and -15 in fuse box BT1.
Resistance Between R07 (female) (5) and ground Min. 1 Mz

HM400-3M0 40-709
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to engine preheating system

40-710 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-4 While preheating is working, preheating monitor does not light

up (HM400_3R-FE2-400-A-Z0-A)
Failure While preheating is working, preheating monitor does not light up.
• This machine has "Automatic preheating" and "Manual preheating" functions. When either
Related preheating works, preheating pilot lamp lights up.
information • Check whether manual preheating function works first.
• "Socket-type box" is available for monitor controller connector.
No. Cause Procedure, measuring location, criteria, and remarks

Open circuit in wiring 1. Turn starting switch to OFF position.

harness 2. Disconnect connectors MCM1 and R07, and connect T-adapters to each
female side.
1 (Wire breakage or Between terminal R1 of starting switch and MCM1
defective contact of Max. 1 z
connector) Resistance (female) (35)
Between R07 (female) (3) and MCM1 (female) (35) Max. 1 z
Defective monitor If no failure is found by above checks, monitor controller is defective.
2
controller

HM400-3M0 40-711
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to engine preheating system

40-712 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-5 All of LCD unit, LED unit and meter unit on machine monitor display
nothing (HM400_3-FH7-400-A-Z0-A)
Failure • All of LCD unit, LED unit, and meter unit on machine monitor display nothing.
• Display of rear view monitor is normal.
Related information • As T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
No. Cause Procedure, measuring location, criteria and remarks
Incorrect operation of battery Check that battery disconnect switch is at ON position.
1
disconnect switch
Incorrect operation of engine Check that engine shutdown secondary switch is at lower (OFF)
2 shutdown secondary switch position.
Defective circuit breaker (82 - If circuit breaker (82 - 84) is tripped, circuit probably has ground fault.
3 84) In this case, perform check on cause 8 first.
Defective fuse No. 9 in fuse If fuse is blown, circuit may have ground fault, etc. (See check on
4 cause 6.)
box BT2.
Defective fuse No. 3 in fuse
5 box BT2 and fuse No. 15 in If fuse is blown, circuit may have ground fault. (See check on cause 8.)
fuse box BT4
Defective continuous power
6 Perform troubleshooting for failure code [DAF3KK].
supply system
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector MCM1, and connect T-adapters to female
side.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
a Check that engine shutdown secondary switch is at lower (OFF)
position.
Between MCM1 (female) (43) and (2) 20 to 30 V
Voltage Between MCM1 (female) (31) and (2) 20 to 30 V
Between MCM1 (female) (24) and (3) 20 to 30 V
Open circuit in wiring harness
a If no failure is found by above checks, this check is not required.
7 (wire breakage or defective
contact of connector) 1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connectors MCM1 and ESS, and connect T-adapters to
each female side.
Between MCM1 (female) (24) and (43) Max. 1 z
Between MCM1 (female (24) and ESS
(female) (2) Max. 1 z
Between MCM1 (female (31) and ESS
Resis- (female) (1) Max. 1 z
tance
Between ESS (female) (1) and (4) Max. 1 z
Between ESS (female) (2) and (5) Max. 1 z
Between ESS (female) (2) and terminal ACC Max. 1 z
of starting switch

HM400-3M0 40-713
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
No. Cause
Ground fault in wiring harness
8 or BT2-10
(contact with ground circuit)
Defective starting switch
9 (internal defect)
10 Defective monitor controller
40-714
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector MCM1, and connect T-adapters to female
side.
3. Remove all fuses in fuse box BT2 and BT4.
Between ground and MCM1 (female) (1), (4)
Min. 1 Mz
Between ground and MCM1 (female) (24),
Resis- (43) or BT2-16 Min. 1 Mz
tance Between MCM1 (female) (31) and ground Min. 1 Mz
Between ground and BT2-3 or BT2-9. Min. 1 Mz
Between BT2-4 and ground Min. 1 Mz
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect terminal B of starting switch.
Between starting
switch terminals B and Starting switch: OFF Min. 1 Mz
Resis- ACC
tance Between starting
switch terminals B and Starting switch: ON Max. 1 z
ACC
If no failure is found by above checks, monitor controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to monitor controller

HM400-3M0 40-715
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-6 LCD unit on machine monitor displays nothing (HM300_3-FH8-400-A-Z0-A)

Failure • LCD unit on machine monitor displays nothing.

• Display of LED unit, meter unit, and rear view monitor is normal.
• Make harness checker. For details, see "Processing procedure of harness checker
for troubleshooting of machine monitor LCD unit" in General information on
Related information troubleshooting.
a Harness checker for troubleshooting of machine monitor LCD unit is simply referred
to as "harness checker".
No. Cause Procedure, measuring location, criteria and remarks
1. Set battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connectors of wiring harness between LCD unit of
machine monitor and monitor controller, and repeat connection and
1 Defective harness connector disconnection of connectors.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact
of connector.
a When using harness checker
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
Defective LCD unit of machine 3. Disconnect connector MCM3, and connect harness checker to
2
monitor female side.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between harness checker (5) and (3) 6.2 to 9.1 V
Voltage
Between harness checker (7) and (3) 6.2 to 9.1 V
a When performing troubleshooting by using new wiring harness
between machine monitor LCD unit and monitor controller
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
Open circuit in wiring harness
2. Turn starting switch to OFF position.
3 (wire breakage or defective 3. Replace wiring harness between LCD unit of machine monitor and
contact of connector) monitor controller with new one.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, wiring harness between LCD unit of
machine monitor and monitor controller is defective.
1. Set battery disconnect switch to ON position.
Defective LCD unit of machine 2. Turn starting switch to ON position.
4
monitor
If display of LED unit and meter unit is normal, LCD unit is defective.
1. Set battery disconnect switch to ON position.
2. Turn starting switch to ON position.
5 Defective monitor controller
If display of LED unit and meter unit is unusual, monitor controller is
defective.

40-716 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Wiring harness between monitor controller and LCD unit of machine monitor

Circuit diagram between monitor controller and LCD unit of machine monitor

HM400-3M0 40-717
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight

goes out or flickers) (HM300_3-FH9-400-A-Z0-A)
• Backlight of LCD unit on machine monitor is abnormal. (Backlight goes out or
Failure flickers.)
• Display of LED unit, meter unit, and rear view monitor is normal.
• Make harness checker. For details, see "Processing procedure of harness checker
for troubleshooting of machine monitor LCD unit" in General information on
Related information troubleshooting.
a Harness checker for troubleshooting of machine monitor LCD unit is simply referred
to as "harness checker".
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connectors of wiring harness between LCD unit of
machine monitor and monitor controller, and repeat connection
1 Defective harness connector
and disconnection of connectors.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact
of connector.
a When using harness checker
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
Defective LCD unit of machine 3. Disconnect connector MCM3, and connect harness checker for
2
monitor troubleshooting of LCD unit of machine monitor to female side.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between harness checker (4) and (3) Min. 0.3 V
Voltage
Between harness checker (7) and (3) 6.2 to 9.1 V
a When performing troubleshooting by using new wiring harness
between machine monitor LCD unit and monitor controller
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
Open circuit in wiring harness
2. Turn starting switch to OFF position.
3 (wire breakage or defective 3. Replace wiring harness between LCD unit of machine monitor and
contact of connector) monitor controller with new one.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, wiring harness between LCD unit of
machine monitor and monitor controller is defective.
1. Set battery disconnect switch to ON position.
Defective LCD unit of machine 2. Turn starting switch to ON position.
4
monitor
If display of LED unit and meter unit is normal, LCD unit is defective.
1. Set battery disconnect switch to ON position.
2. Turn starting switch to ON position.
5 Defective monitor controller
If display of LED unit and meter unit is unusual, monitor controller is
defective.

40-718 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Wiring harness between monitor controller and LCD unit of machine monitor

Circuit diagram between monitor controller and LCD unit of machine monitor

HM400-3M0 40-719
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-8 LCD on machine monitor does not display properly (HM300_3-FHA-400-A-Z0-A)

Failure • LCD on machine monitor does not display properly.

• Display of LED unit, meter unit, and rear view monitor is normal.
• Make harness checker. For details, see "Processing procedure of harness checker
for troubleshooting of machine monitor LCD unit" in General information on
Related information troubleshooting.
a Harness checker for troubleshooting of machine monitor LCD unit is simply referred
to as "harness checker".
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connectors of wiring harness between LCD unit of
machine monitor and monitor controller, and repeat connection and
1 Defective harness connector
disconnection of connectors.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact
of connector.
a When using harness checker
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
Defective LCD unit of machine 3. Disconnect connector MCM3, and connect harness checker for
2
monitor troubleshooting of LCD unit of machine monitor to female side.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between harness checker (1) and (3) Min. 0.3 V
Voltage
Between harness checker (2) and (3) Min. 0.3 V
a When performing troubleshooting by using new wiring harness
between machine monitor LCD unit and monitor controller
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
Open circuit in wiring harness
2. Turn starting switch to OFF position.
3 (wire breakage or defective 3. Replace wiring harness between LCD unit of machine monitor and
contact of connector) monitor controller with new one.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, wiring harness between LCD unit of
machine monitor and monitor controller is defective.
1. Set battery disconnect switch to ON position.
Defective LCD unit of machine 2. Turn starting switch to ON position.
4
monitor
If display of LED unit and meter unit is normal, LCD unit is defective.
1. Set battery disconnect switch to ON position.
2. Turn starting switch to ON position.
5 Defective monitor controller
If display of LED unit and meter unit is unusual, monitor controller is
defective.

40-720 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Wiring harness between monitor controller and LCD unit of machine monitor

Circuit diagram between monitor controller and LCD unit of machine monitor

HM400-3M0 40-721
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-9 Meter unit display on machine monitor is abnormal (HM300_3-FHB-400-A-Z0-A)

• Meter unit on machine monitor displays nothing.

• Pointer of meter on machine monitor does not swing.
Failure • Meter unit LCD display on machine monitor is abnormal.
• Backlight of meter unit on machine monitor is unusual.
• Display of LCD unit, LED unit, and rear view monitor is normal.
• As T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
Related information a If fuse BT2-9 or BT4-15 is blown, machine monitor displays nothing (see
troubleshooting E-5).
a T-adapter for machine monitor connector DPC3 (070-8) is newly developed.
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connectors of wiring harness between meter unit of
machine monitor and monitor controller, and repeat connection and
1 Defective harness connector
disconnection of connectors.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact
of connector.
Display abnormality record in the service mode of machine monitor. If
Defective CAN communication
2 failure code "DSJ0KR" of action level L01 is logged, perform
system
troubleshooting for failure code "DSJ0KR".
a When using T-adapter for connector DPC3 (070-8)
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector DPC3 and connect T-adapters to female
side.
Open circuit in wiring harness 4. Set battery disconnect switch to ON position.
3 (wire breakage or defective 5. Turn starting switch to ON position.
contact of connector) Between DPC3 (female) (1) and (4) 20 to 30 V
Between DPC3 (female) (2) and (4) 20 to 30 V
Between DPC3 (female) (3) and (4)
Voltage 1 to 4 V
a CAN communication line
Between DPC3 (female) (8) and (4)
1 to 4 V
a CAN communication line
If no failure is found by check on cause 3, meter unit of machine
monitor is defective.

Defective meter unit of
4 1. Set battery disconnect switch to ON position.
machine monitor
5 Defective monitor controller
a When not using T-adapter for connector DPC3 (070-8)
2. Turn starting switch to ON position.
If display of LCD unit and LED unit of machine monitor is normal,
meter unit of machine monitor is defective.
1. Set battery disconnect switch to ON position.
2. Turn starting switch to ON position.
If display of LCD unit and LED unit of machine monitor is unusual,
monitor controller is defective.

40-722 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Wiring harness between monitor controller and meter unit of machine monitor

HM400-3M0 40-723
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram between monitor controller and meter unit of machine monitor

40-724 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-10 Night lighting lamp of meter unit on machine monitor is

abnormal (HM300_3-FHC-400-A-Z0-A)
Failure • Night lighting lamp of meter unit on machine monitor is abnormal.
• Night lighting lamp of meter unit of machine monitor lights up only when clearance
lamp is turned on while monitor brightness selector switch is at the night mode.
• Check whether night lighting lamp of rear view monitor is also abnormal or not.
Related information • As T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
a T-adapter for machine monitor connector DPC3 (070-8) is newly developed.
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector of wiring harness connected to meter unit
of machine monitor and connector of night lighting switch, and
1 Defective harness connector
repeat connection and disconnection of connectors.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact
of connector.
a If night lighting lamp of rear view monitor lights up, this check is not
required.
1. Turn starting switch to OFF position.
Defective monitor brightness 2. Disconnect connector DTL and connect T-adapter to male side of
2 selector (night lighting) switch connector.
Between DTL Brightness selector
Min. 1 Mz
Resis- (female) (5) and (4) switch: OFF
tance Between DTL Brightness selector
(female) (5) and (4) Max. 1 z
switch: ON
a When using T-adapter for connector DPC3 (070-8)
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector DPC3 and connect T-adapters to female
side.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
6. Lighting up of clearance lamp
Between DPC3 (female) (1) and (4) 20 to 30 V
Between DPC3 (female) (2) and (4) 20 to 30 V
Open circuit in wiring harness Voltage Between DPC3 Night lighting switch:
(female) (5) and (4) Max. 0.2 V
3 (wire breakage or defective OFF.
contact of connector) Between DPC3 Night lighting switch:
(female) (5) and (4) 20 to 30 V
ON
a If no failure is found by above checks, this check is not required.
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connectors DPC3, DTL, and CM2, and connect T-
adapters to each female side.
Between DTL (female) (4) and DPC3 (female)
Max. 1 z
Resis- (5)
tance Between CM02 (female) (2) and DTL (female) Max. 1 z
(5)

HM400-3M0 40-725
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by check on cause 3, meter unit of machine
monitor is defective.
a When not using T-adapter for connector DPC3 (070-8)
Defective meter unit of 1. Set battery disconnect switch to ON position.
4 2. Turn starting switch to ON position.
machine monitor
3. Turn on night lighting switch.
If night lighting of LCD unit , LED unit, switch panel, and rear view
monitor of machine monitor is normal, meter unit of machine monitor is
defective.

Wiring harness between monitor controller and meter unit of machine monitor

40-726 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram between monitor controller and meter unit of machine monitor

HM400-3M0 40-727
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-11 LED unit lamp on machine monitor is abnormal (HM300_3-FHD-400-A-Z0-A)

Failure • LED unit lamp of machine monitor does not light up, or does not go out.
• As T-adapter for monitor controller connector is "socket-type box", operating voltage
Related information cannot be measured at monitor controller connector.
a T-adapter for machine monitor connector DPC2 (070-6) is newly developed.
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector of wiring harness connected to LED unit
of machine monitor and connector of monitor controller, and repeat
1 Defective harness connector
connection and disconnection of connectors.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact
of connector.
Display abnormality record in the service mode of machine monitor. If
Defective LIN communication failure code "DPQ2KR" of action level L01 is logged, perform
2
line troubleshooting for failure code "DPQ2KR".
Display abnormality record in the service mode of machine monitor. If
Defective 12 V power supply
3 failure code "DAFDKB" of action level L01 is logged, perform
system
troubleshooting for failure code "DAFDKB".
a When using T-adapter for connector DPC2 (070-6)
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector DPC2 and connect T-adapters to female
side.
Open circuit in wiring harness 4. Set battery disconnect switch to ON position.
4 (wire breakage or defective 5. Turn starting switch to ON position.
contact of connector) Between DPC2 (female) (1) and (2) 9.3 to 14.1
a 12 V power supply V
Between DPC2 (female) (3) and (2)
Voltage Approx. 9 V
a LIN communication line
Between DPC2 (female) (4) and (2)
4 to 6.1 V
a 5 V power supply
If no failure is found by check on cause 4, LED unit of machine monitor
is defective.
Defective LED unit of machine
5 a When not using T-adapter for connector DPC2 (070-6), if no failure
monitor
is found by checks on causes 3 and 4, replace LED unit of machine
monitor to check whether LED unit is defective.
If no failure is found by above checks, monitor controller may be
6 Defective monitor controller
defective.
Defective wiring harness If you cannot perform check on cause 4, take it that wiring harness is
7
defective.

40-728 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Wiring harness between monitor controller and LED unit of machine monitor

Circuit diagram between monitor controller and LED unit of machine monitor

HM400-3M0 40-729
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-12 Night lighting lamp of switch panel on machine monitor is abnormal

or switches does not operate properly (HM300_3-FHE-400-A-Z0-A)
• Night lighting lamp of switch panel on machine monitor does not light up, or does not
Failure go out.
• Switch of switch panel of machine monitor does not work.
• As T-adapter for monitor controller connector is "socket-type box", operating voltage
Related information cannot be measured at monitor controller connector.
a T-adapter for machine monitor connector OPM (070-6) is newly developed.
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector of wiring harness connected to switch
panel of machine monitor and connector of monitor controller, and
1 Defective harness connector
repeat connection and disconnection of connectors.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact
of connector.
Display abnormality record in the service mode of machine monitor. If
Defective LIN communication failure code "DPQ1KR" of action level L01 is logged, perform
2
line troubleshooting for failure code "DPQ1KR".
Display abnormality record in the service mode of machine monitor. If
Defective 12 V power supply
3 failure code "DAFDKB" of action level L01 is logged, perform
system
troubleshooting for failure code "DAFDKB".
a When using T-adapter for connector OPM (070-6)
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector OPM and connect T-adapters to female side.
4. Set battery disconnect switch to ON position.
Open circuit in wiring harness
5. Turn starting switch to ON position.
4 (wire breakage or defective Between OPM (female) (1) and (2) 9.3 to 14.1
contact of connector)
a 12 V power supply V
Between OPM (female) (3) and (2)
Voltage Approx. 9 V
a LIN communication line
Between OPM (female) (4) and (2)
4 to 6.1 V
a 5 V power supply
If no failure is found by check on cause 4, switch panel of machine
monitor is defective.
Defective switch panel of
5 a When not using T-adapter for connector OPM (070-6), if no failure
machine monitor
is found by checks on causes 2 and 3, replace switch panel of
machine monitor to check whether switch panel is defective.
If no failure is found by above checks, monitor controller may be
6 Defective monitor controller
defective.
Defective wiring harness If you cannot perform check on cause 4, take it that wiring harness is
7
defective.

40-730 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Wiring harness between monitor controller and switch panel of machine monitor

Circuit diagram between monitor controller and switch panel of machine monitor

HM400-3M0 40-731
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-13 2 switches operation of switch panel on machine monitor does not

function (HM300_3-FHF-400-A-Z0-A)
Failure • 2 switches operation of switch panel on machine monitor does not function.
• As T-adapter for monitor controller connector is "socket-type box", operating voltage
Related information cannot be measured at monitor controller connector.
a T-adapter for machine monitor connector OPM (070-6) is newly developed.
No. Cause
1 Defective harness connector
Defective LIN communication
2
line
Defective 12 V power supply
3 failure code "DAFDKB" of action level L01 is logged, perform
system
Open circuit in wiring harness
4 (wire breakage or defective
contact of connector)
Defective switch panel of
5 a When not using T-adapter for connector OPM (070-6), if no failure
machine monitor
6 Defective monitor controller
Defective wiring harness
7
Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector of wiring harness connected to switch
panel of machine monitor and connector of monitor controller, and
repeat connection and disconnection of connectors.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact
of connector.
Display abnormality record in the service mode of machine monitor. If
failure code "DPQ1KR" of action level L01 is logged, perform
troubleshooting for failure code "DPQ1KR".
Display abnormality record in the service mode of machine monitor. If
troubleshooting for failure code "DAFDKB".
a When using T-adapter for connector OPM (070-6)
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector OPM and connect T-adapters to female side.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
a "Simultaneous operation of up and down switch" denotes turning
on Up switch (A) and Down switch (B) at the same time. (See
description of LCD check function in Testing and adjusting,
"Special functions of machine monitor".)
Between OPM (female) (1) and (2) 9.3 to 14.1
V
a 12 V power supply
Between OPM (female) (3) and (2)
Approx. 9 V
a LIN communication line
Between OPM (female) (4) and (2)
4 to 6.1 V
Voltage a 5 V power supply
When Up and Down
Between OPM switches are not
(female) (5) and (2) operated Max. 0.2 V
simultaneously
When Up and Down
Between OPM
switches are operated Min. 2.2 V
(female) (5) and (2)
simultaneously
If no failure is found by check on cause 4, switch panel of machine
monitor is defective.
is found by checks on causes 2 and 3, replace switch panel of
machine monitor to check whether switch panel is defective.
If no failure is found by above checks, monitor controller may be
defective.
If you cannot perform check on cause 4, take it that wiring harness is
defective.

40-732 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Wiring harness between monitor controller and switch panel of machine monitor

Circuit diagram between monitor controller and switch panel of machine monitor

HM400-3M0 40-733
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-14 Switch panel buzzer of machine monitor is abnormal (HM300_3-FHG-400-A-Z0-A)

Failure • Switch panel buzzer of machine monitor does not sound or does not stop sounding.
• As T-adapter for monitor controller connector is "socket-type box", operating voltage
Related information cannot be measured at monitor controller connector.
a T-adapter for machine monitor connector OPM (070-6) is newly developed.
No. Cause
1 Defective harness connector
Defective LIN communication
2
line
Defective 12 V power supply
3 failure code "DAFDKB" of action level L01 is logged, perform
system
Open circuit in wiring harness
4 (wire breakage or defective
contact of connector)
Defective switch panel of
5 a When not using T-adapter for connector OPM (070-6), if no failure
machine monitor
6 Defective monitor controller
Defective wiring harness
7
Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector of wiring harness connected to switch
panel of machine monitor and connector of monitor controller, and
repeat connection and disconnection of connectors.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact
of connector.
Display abnormality record in the service mode of machine monitor. If
failure code "DPQ1KR" of action level L01 is logged, perform
troubleshooting for failure code "DPQ1KR".
Display abnormality record in the service mode of machine monitor. If
troubleshooting for failure code "DAFDKB".
a When using T-adapter for connector OPM (070-6)
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector OPM and connect T-adapters to female side.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between OPM (female) (1) and (2) 9.3 to 14.1
a 12 V power supply V
Between OPM (female) (3) and (2)
Approx. 9 V
a LIN communication line
Voltage Between OPM (female) (4) and (2)
4 to 6.1 V
a 5 V power supply
Between OPM When turning on
(female) (6) and (2) Max. 0.2 V
buzzer
Between OPM When turning off
(female) (6) and (2) 7 to 15 V
buzzer
If no failure is found by check on cause 4, switch panel of machine
monitor is defective.
is found by checks on causes 2 and 3, replace switch panel of
machine monitor to check whether switch panel is defective.
If no failure is found by above checks, monitor controller may be
defective.
If you cannot perform check on cause 4, take it that wiring harness is
defective.

40-734 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Wiring harness between monitor controller and switch panel of machine monitor

Circuit diagram between monitor controller and switch panel of machine monitor

HM400-3M0 40-735
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-15 Rear view monitor does not light up or backlight flickers
Z0-A)
Failure • Rearview monitor does not light up or backlight flickers
Related information
No. Cause
Defective fuse No. 28 in fuse
1 cause 4.)
box BT2
2 Defective harness connector
Open circuit in wiring harness
3 (wire breakage or defective
contact of connector)
Ground fault in wiring harness
4
(contact with ground circuit)
5 Defective rear view monitor
Defective wiring harness
6
40-736
(HM400_3-FHH-400-A-
Procedure, measuring location, criteria and remarks
If fuse is blown, circuit may have ground fault, etc. (See check on
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector (RMN1) of wiring harness connected to
rear view monitor, and repeat connection and disconnection of
connector.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact
of connector.
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector RMN1, and connect T-adapters to female
side.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between RMN1 (female) (1) and (2) 20 to 30 V
Voltage
Between RMN1 (female) (12) and (2) 20 to 30 V
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connectors RMN1 and ESS, and connect T-adapters to
each female side.
4. Remove fuse No. 28 in fuse box BT2.
Between RMN1 (female) (1) and BT2-28 Max. 1 z
Resis- Between RMN1 (female) (2) and ground Max. 1 z
tance Between RMN1 (female) (12) and ESS
(female) (4) Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector RMN1, and connect T-adapters to female
side.
3. Remove fuse No. 28 in fuse box BT2.
Resis- Between ground and RMN1 (female) (1) or
Min. 1 Mz
tance BT2-28
If no failure is found by above checks, rear view monitor may be
defective.
If you cannot perform check on cause 3, wiring harness may be
defective.
HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Wiring harness of rear view monitor

Circuit diagram related to rear view monitor power supply

HM400-3M0 40-737
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-16 Rear view monitor images are not displayed clearly (HM400_3-FHJ-400-A-Z0-A)

Failure • Rear view monitor images are not displayed clearly

• As T-adapter for monitor controller connector is "socket-type box", operating voltage
Related information cannot be measured at monitor controller connector.
a T-adapter for rear view monitor connector RMN2 (070-8) is newly developed.
No. Cause
1 Defective harness connector
Open circuit in wiring harness
2 (wire breakage or defective
contact of connector)
Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connectors (RMN1) and (RMN2) of wiring
harnesses connected to rear view monitor, and repeat connection
and disconnection of connectors.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact
of connector.
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector RMN1, and connect T-adapters to female
side.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between RMN1 (female) (1) and (2) 20 to 30 V
Voltage
Between RMN1 (female) (12) and (2) 20 to 30 V
a If no failure is found by above checks, this check is not required.
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connectors RMN1 and ESS, and connect T-adapters to
each female side.
4. Remove fuse No. 28 in fuse box BT2.
Between RMN1 (female) (1) and BT2-28 Max. 1 z
Resis- Between RMN1 (female) (2) and ground Max. 1 z
tance Between RMN1 (female) (12) and ESS
(female) (4) Max. 1 z

3 Defective rear view monitor
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Insert T-adapter into connector RMN1.
4. Disconnect connector RMN2 and connect T-adapters to male side.
5. Set battery disconnect switch to ON position.
6. Turn starting switch to ON position.
Between RMN2 (male) (1) and RMN1 (2) 8 ± 0.8 V
Voltage Between RMN2 (male) (5) and RMN1 (2) Max. 0.2 V
Between RMN2 (male) (8) and RMN1 (2) Max. 0.2 V

40-738 HM400-3M0

No. Cause
Open circuit in wiring harness
4 each female side.
(wire breakage or defective
contact of connector)
5 Defective rear view camera
Defective wiring harness or
6 monitor is probably defective.
rear view monitor
Wiring harness of rear view monitor
HM400-3M0
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector BMN and connect T-adapters to female side.
3. Turn starting switch to ON position.
Voltage Between BMN (female) (1) and (4) 8 ± 0.8 V
1. Turn starting switch to OFF position.
2. Disconnect connectors BMN and RMN2, and connect T-adapters to
3. Turn starting switch to ON position.
Between BMN (female) (1) and RMN2
(female) (1) Max. 1 z
Resis- Between BMN (female) (2) and RMN2
(female) (2) Max. 1 z
tance
Between BMN (female) (4) and each of RMN2
(female) (5) and (8) Max. 1 z
If no failure is found by above checks, rear view monitor may be
defective.
If T-adapter is not available, take it that wiring harness or rear view
40-739
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to rear view monitor power supply

40-740 HM400-3M0

E-17 Rear view monitor brightness cannot be adjusted
Failure • Brightness of rear view monitor cannot be adjusted.
Related information
No. Cause
Defective fuse No. 8 in fuse
1
box BT1
If normal conditions are restored, cause of failure is defective contact of
connector.
2 Defective harness connector
If normal conditions are restored, cause of failure is defective contact of
connector.
Open circuit in wiring harness
3 (wire breakage or defective
contact of connector)
4 Defective rear view monitor
HM400-3M0
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
(HM300_3-FHK-400-A-Z0-A)
Procedure, measuring location, criteria and remarks
If fuse is blown, circuit may have ground fault. (See check on cause 5.)
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector (RMN1) of wiring harness connected to
rear view monitor, and repeat connection and disconnection of
connector.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector (RM1) of wiring harness connected to rear
view monitor, and repeat connection and disconnection of
connector.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector RMN1, and connect T-adapters to female
side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between RMN1 Brightness adjustment
(female) (5) and (2) switch (+): OFF Max. 0.2 V
Between RMN1 Brightness adjustment
(female) (5) and (2) switch (+): ON 20 to 30 V
Voltage
Between RMN1 Brightness adjustment
(female) (6) and (2) switch (-): OFF Max. 0.2 V
Between RMN1 Brightness adjustment
(female) (6) and (2) switch (-): ON 20 to 30 V
a If no failure is found by above checks, this check is not required.
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connectors RMN1 and RM1, and connect T-adapters to
each female side.
4. Remove fuse-8 in fuse box BT1.
Between RM1 (female) (5) and BT1-8 Max.1 z
Between RM1 (female) (4) and RMN1 (female)
Resis- (5) Max.1 z
tance
Between RM1 (female) (6) and RMN1 (female)
(6) Max.1 z
If no failure is found by above checks, rear view monitor is defective.
40-741
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks

1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connectors RMN1 and RM1, and connect T-adapters to
Ground fault in wiring harness female side of RM1.
5 4. Remove fuse-8 in fuse box BT1.
(contact with ground circuit)
Between ground and RMN1 (female) (5) or
Min.1 Mz
Resis- BT1-8
tance Between RM1 (female) (4) and ground Min.1 Mz
Between RM1 (female) (6) and ground Min.1 Mz
1. Turn starting switch to OFF position.
2. Remove brightness adjustment switch.
Between RM1 Brightness adjustment
(female) (5) and (4) switch (+): OFF Min.1 Mz
Defective brightness Between RM1 Brightness adjustment
6 adjustment switch Max.1 z
Resis- (female) (5) and (4) switch (+): ON
tance Between RM1 Brightness adjustment
(female) (5) and (6) switch (-): OFF Min.1 Mz
Between RM1 Brightness adjustment
(female) (5) and (6) switch (-): ON Max.1 z
Defective brightness
If T-adapter is not available, take it that brightness adjustment switch,
7 adjustment switch, wiring
wiring harness, or rear view monitor is probably defective.
harness, or rear view monitor

Wiring harness of rear view monitor

40-742 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to brightness adjustment switch of rear view monitor

HM400-3M0 40-743
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-18 Night lighting lamp of rear view monitor is abnormal
Failure • Night lighting lamp of rear view monitor is abnormal
• Night lighting lamp of rear view monitor lights up only when clearance lamp is turned
Related information on while monitor brightness selector switch is at the night mode.
• Check whether night lighting lamp of meter unit of machine monitor is also unusual.
No. Cause
1 Defective harness connector
Defective monitor brightness
2 selector (night lighting) switch
Open circuit in wiring harness
3 (wire breakage or defective
contact of connector)
4 Defective rear view monitor
40-744
(HM300_3-FHL-400-A-Z0-A)
Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector (RMN1) of wiring harness connected to
rear view monitor and connector of night lighting switch, and repeat
connection and disconnection of connectors.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact
of connector.
a If night lighting lamp of meter unit lights up, this check is not
required.
1. Turn starting switch to OFF position.
2. Disconnect connector DTL and connect T-adapter to male side of
connector.
Between DTL Brightness selector
Min. 1 Mz
Resis- (female) (5) and (4) switch: OFF
tance Between DTL Brightness selector
(female) (5) and (4) Max. 1 z
switch: ON
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector RMN1, and connect T-adapters to female
side.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
6. Clearance lamp lights up.
Between RMN1 Night lighting switch:
(female) (8) and (2) Max. 0.2 V
OFF.
Voltage
Between RMN1 Night lighting switch:
(female) (8) and (2) 20 to 30 V
ON
a If no failure is found by above checks, this check is not required.
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connectors RMN1, DTL, and CM, and connect T-
adapters to each female side.
Between DTL (female) (4) and RMN1 (female)
Max. 1 z
Resis- (8)
tance Between CM (female) (2) and DTL (female)
(5) Max. 1 z
If no failure is found by check on cause 3, rear view monitor is
defective.
a When not using T-adapter for connector RMN1 (070-12)
1. Set battery disconnect switch to ON position.
2. Turn starting switch to ON position.
3. Turn on night lighting switch.
If night lighting of LCD unit , meter unit, LED unit, and switch panel of
machine monitor is normal, rear view monitor is defective.
HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Wiring harness of rear view monitor

Circuit diagram related to night lighting switch of rear view monitor

HM400-3M0 40-745
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-19 Rearview monitor does not display images while reverse linked
display function is enabled (HM300_3-FHM-400-A-Z0-A)
• Rearview monitor does not display images while reverse linked display function is
Failure
enabled
• Check whether guide line (see E-20) is appears on screen. If not, perform
troubleshooting for "E-20" first.
• For the setting procedure for the reverse linked display function, perform the
procedure in user menu of machine monitor "Monitor Setting ", "Rear View Monitor
Related information Setting ", "Reverse-interlock enabled mode "in order.
• Check whether rear view monitor does not display with shift lever is set to either "R1"
and "R2" while reverse linked display function is enabled.
• If reverse linked display function of rear view monitor does not work, check whether
rear view monitor displays images normally when function is not selected.
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connectors (RMN1) and (RMN2) of wiring
harnesses connected to rear view monitor and connector of shift
1 Defective harness connector lever switch, and repeat connection and disconnection of
connectors.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact
of connector.
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector RMN1, and connect T-adapters to female
side.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between RMN1 (7)
and (2) Shift lever: R1 20 to 30 V
Between RMN1 (7)
Voltage Shift lever: R2 20 to 30 V
and (2)
Between RMN1 (7)
and (2) Shift lever: N Max. 0.2 V
Open circuit in wiring harness
2 (wire breakage or defective a If no failure is found by above checks, this check is not required.
contact of connector) 1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connectors RMN1, D04, D05, and SF1, and connect T-
adapters to each female side.
Between D04 (female) (1) and RMN1 (female)
(7) Max. 1 z
Between D05 (female) (1) and RMN1 (female)
Max. 1 z
Resis- (7)
tance Between D04 (female) (2) and SF1 (female)
(4) Max. 1 z
Between D05 (female) (2) and SF1 (female) Max. 1 z
(3)

40-746 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks

a If no failure is found by check on cause 2, this check is not
required.
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connectors RMN1, D04, and D05, and connect T-
3 Defective diode adapters to each female side.
No
Between D04 (female) (1) (+) and (2) (-)
continuity
Resis- Between D04 (female) (2) (+) and (1) (-) Continuity
tance No
Between D05 (female) (1) (+) and (2) (-)
continuity
Between D05 (female) (2) (+) and (1) (-) Continuity
If no failure is found by check on cause 2, rear view monitor is
4 Defective rear view monitor
defective.

Wiring harness of rear view monitor

HM400-3M0 40-747
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to reverse linked function of rear view monitor

40-748 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-20 Guide line on rear view monitor is not displayed while guide line is
set (HM300_3-FHN-400-A-Z0-A)
Failure • Guide line on rear view monitor is not displayed while guide line is set
• For the setting procedure for the guide line, perform the procedure in user menu of
Related information machine monitor "Monitor Setting ", "Rear View Monitor Setting ", "Reference line" in
order.
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector (RMN1) connected to rear view monitor
and connector (MCM2) connected to monitor controller, and repeat
1 Defective harness connector
connection and disconnection of connectors.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact
of connector.
Display abnormality record in the service mode of machine monitor. If
Defective LIN communication failure code "DPQ3KR" of action level L01 is logged, perform
2
line troubleshooting for failure code "DPQ3KR".
If no failure is found by check on cause 2, rear view monitor is
3 Defective rear view monitor
defective.

Wiring harness of rear view monitor

HM400-3M0 40-749
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram between rear view monitor and monitor controller

40-750 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-21 Some items of gauges and caution lamps on machine monitor are
not displayed properly (HM300_3-FHP-400-A-Z0-A)
Failure Some gauges and caution lamps are not displayed normally.
• If mechanical system failure code is displayed, perform troubleshooting for that code
Related information
first.
No. Cause Procedure, measuring location, criteria and remarks
Perform troubleshooting for failure code related to defective sensor or
1 Defective sensor or switch
switch.
Defective CAN communication Perform troubleshooting for failure code related to defective CAN
2 system communication.
If no failure is found by above checks, machine monitor is defective.
3 Defective machine monitor
(Since this is an internal defect, troubleshooting cannot be performed.)

HM400-3M0 40-751
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-22 Fuel level gauge does not indicate correct level (HM400_3-FGB-400-A-Z0-A)

Failure Fuel gauge does not indicate correct level

• Input voltage from fuel level sensor can be checked with monitoring function.
Related information (Code: 04200 Fuel level sensor voltage)
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector M06 and connect T-adapters to male side.
Defective fuel level sensor Between M06 (male) (1) and (2) Approx. 4
1 FULL
(internal open or short circuit) z
Resis- a Fuel level sensor Approx. 85
tance characteristics EMPTY
z
Between M06 (male) (2) and ground Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector M06, and connect T-adapters to female
side.
3. Turn starting switch to ON position.

Open circuit, short circuit, or
2 ground fault in wiring harness
Open or short circuit in wiring
3 a Use fuel level sensor characteristics table for check on cause 1 as
harness
Open circuit in wiring harness
4 (wire breakage or defective
contact of connector)
a If voltage is 0 V, wiring harness has open circuit, ground fault, or
short circuit, and if voltage is 24 V, wiring harness has hot short
circuit.
a Voltage of approximately 3.3 V is applied to fuel level sensor signal
lines through resistor inside monitor controller.
Voltage Between M06 (female) (1) and (2) Approx.
3.3 V
a If no failure is found by check on cause 2, this check is not
required.
1. Turn starting switch to OFF position.
2. Disconnect connector MCM1, and connect T-adapters to female
side.
resistance criteria.
a If resistance is 1 Mz or higher, harness has open circuit. If it is 1 z
or below, harness has short circuit.
Resis- Between MCM1 (female) (8) and (9) Approx. 4
tance to 85 z
a If no failure is found by check on cause 2 or 3, this check is not
required.
1. Turn starting switch to OFF position.
2. Disconnect connectors MCM1 and M06, and connect T-adapters
to each female side.
Between MCM1 (female) (8) and M06 (female)
Max. 1 z
Resis- (1)
tance Between MCM1 (female) (9) and M06 (female)
(2) Max. 1 z

a If no failure is found by check on cause 2, this check is not

required.
Ground fault in wiring harness 1. Turn starting switch to OFF position.
5 2. Disconnect connectors MCM1 and M06, and connect T-adapters
(contact with ground circuit)
to either female side.
Resis- Between ground and MCM1 (female) (8) or Min. 1 Mz
tance M06 (female) (1)

40-752 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks

6 Short circuit in wiring harness
7 Defective monitor controller
1. Turn starting switch to OFF position.
2. Disconnect connectors MCM1 and M06, and connect T-adapters
to female side of MCM1.
a Check by using multimeter in continuity mode.
Between MCM1 (female) (8) and No continuity
Continuity
every pin other than (8) (No sound is heard)
If no failure is found by above checks, monitor controller is defective.

Circuit diagram related to fuel level sensor

HM400-3M0 40-753
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-23 Seat belt caution lamp indication is abnormal (HM300_3-FHQ-400-A-Z0-A)

Seatbelt caution lamp lights up even when seatbelt is fastened, or caution lamp does
Failure not light up when seatbelt is not fastened.
• If mechanical system failure code is displayed, perform troubleshooting for that code
Related information
first.
No. Cause
1 Defective fuse BT1-8
2 Defective seatbelt switch
Open circuit in wiring harness
3 (wire breakage or defective
contact of connector)
Ground fault in wiring harness
4 Between ground and MCM1 (female) (12) or
(contact with ground circuit)
5 Defective monitor controller
Procedure, measuring location, criteria and remarks
If fuse BT1-8 is blown, circuit probably has ground fault.
(Perform check on cause 4.)
1. Turn starting switch to OFF position.
2. Connect T-adapters to connector SBS (male).
3. Check switch itself.
When seatbelt is
Max. 1 z
Resis- Between SBS (male) fastened
tance (1) and (2) When seatbelt is not
Min. 1 Mz
fastened
1. Turn starting switch to OFF position.
2. Disconnect connectors MCM1 and SBS, and connect T-adapters to
each female side.
Between MCM1 (female) (12) and SBS
Resis- (female) (2) Max. 1 z
tance
Between SBS (female) (1) and fuse BT1-8 Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors MCM1 and SBS.
3. Connect T-adapters to MCM1.
Min. 1 Mz
Resis- SBS (female) (2)
tance Between ground and SBS (female) (1) or fuse
Min. 1 Mz
BT1-8
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector SBS.
3. Turn starting switch to ON position.
When seatbelt is
Between SBS (2) and fastened 20 to 30 V
Voltage
ground When seatbelt is not
Max. 1 V
fastened

Circuit diagram related to seatbelt switch

40-754 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-24 Machine monitor cannot be operated when starting switch is in OFF

position (HM300_3-FHR-400-A-Z0-A)
When switches are operated with starting switch in OFF position, service meter, travel
Failure odometer, and hazard lamp are not displayed.
• If mechanical system failure code is displayed, perform troubleshooting for that code
Related information
first.
No. Cause Procedure, measuring location, criteria and remarks
Defective continuous power
1 supply system of monitor Perform troubleshooting for failure code [DAF3KK].
controller

HM400-3M0 40-755
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-25 Alarm buzzer does not sound (HM400_3-KA3-400-A-Z0-A)

When starting switch is in ON position, even if emergency stop item caution lamp and
Failure centralized warning lamp light up, alarm buzzer does not sound.
• If mechanical system failure code is displayed, perform troubleshooting for that code
Related information
first.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors MCM1 and BZ2, and connect T-adapters to
Open circuit in wiring harness each female side.
1 (wire breakage or defective Between MCM1 (female) (2) and BZ2 (female)
Max. 1 z
contact of connector) Resis- (2)
tance Between MCM1 (female) (20) and BZ2
(female) (1) Max. 1 z

1. Turn starting switch to OFF position.

2. Disconnect connectors MCM1 and BZ2, and connect T-adapters to
2 Short circuit in wiring harness female side of BZ2.
Resis- Between BZ2 (female) (1) and (2)
Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BZ2.
3. Turn starting switch to ON position.
Under condition that
3 Defective monitor controller alarm buzzer does not Max. 1 V
Between BZ2 (1) and sound
Voltage
(2) For approx. 1 second
after starting switch is Min. 20 V
turned to ON position

40-756 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to alarm buzzer

HM400-3M0 40-757
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-26 Alarm buzzer does not stop sounding (HM300_3-KB3-400-A-Z0-A)

When starting switch is in ON position, centralized warning lamp lights up and alarm
Failure buzzer does not stop sounding.
• Buzzer sounding due to causes 2 to 7 is to avoid danger of wrong operation. If
Related information wrong operation is eliminated, buzzer stops sounding.
No. Cause Procedure, measuring location, criteria and remarks
• When failure is detected, centralized warning lamp lights up and
alarm buzzer sounds.
(Note: centralized warning lamp may not light up and alarm buzzer
1 Detection of failure may not sound depending on detected failure.)
• In this case, perform troubleshooting for displayed failure code
(also check abnormality record).
• When shift lever is in position other than "N", if starting switch is
Warning of neutral safety turned from OFF to ON position, current shift lever position pilot
2
lamp flashes, centralized warning lamp lights up and alarm buzzer
sounds.
• When starting engine with parking brake switch in "PARK" position,
if shift lever is moved to position other than "N", centralized
Warning of parking brake
3 warning lamp lights up and alarm buzzer sounds.
dragging
• If parking brake switch is set to "TRAVEL" position or shift lever is
moved to "N" position, buzzer stops sounding.
• When starting engine with dump body raised ( "Body Up Caution
"lamp of machine monitor lights up), if shift lever is moved to
position other than "N", centralized warning lamp lights up and
4 Warning of raised dump body
alarm buzzer sounds.
• If dump body is lowered or shift lever is moved to "N" position,
buzzer stops sounding.
• When this option setting is selected, if engine is started with dump
body raised ( "Body Up Caution "lamp of machine monitor lights
Warning due to "Body Up
5 up), centralized warning lamp lights up and alarm buzzer sounds.
Caution "setting (if equipped)
• If dump body is lowered, centralized warning lamp goes out and
alarm buzzer stops sounding.
• When hoist lever is in "RAISE" position, if the rear of machine is
tilted more than the safe lateral inclination angle, "Tilt Caution
"lamp of machine monitor and centralized warning lamp light up,
6 Tilt caution and alarm buzzer sounds.
• When hoist lever is moved to the position other than "RAISE" or
machine tilts within the safe lateral inclination angle, buzzer stops
sounding.
• If travel speed exceeds set travel speed or engine speed rises
abnormally high, centralized warning lamp lights up and alarm
buzzer sounds.
7 Warning of overrun
• If travel speed drops below set travel speed and engine speed
decreases within normal speed range, centralized warning lamp
goes out and alarm buzzer stops sounding.
• When engine starts, if accumulator pressure is low, "Brake Oil
Pressure "caution lamp of machine monitor (detection of
accumulator pressure drop) and centralized warning lamp light up
8 Low brake oil pressure and alarm buzzer sounds.
(Reference: After 30 seconds, failure code [2G42ZG] or [2G43ZG]
appears.)
• Check brake oil pressure circuit (accumulator oil pressure).
• When engine starts, if steering oil pressure is low, "Steering Oil
Pressure Low "caution lamp of machine monitor and centralized
Low steering oil pressure warning lamp light up, and alarm buzzer sounds.
9
(Reference: After 30 seconds, failure code [DHT8ZG] appears.)
• Check steering oil pressure circuit.

40-758 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks

• When radiator fan or aftercooler fan is rotating reverse, if shift lever
is moved to position other than "N" or dump body is raised, wrong
operation during fan reverse mode caution lamp of machine
Wrong operation during fan monitor and centralized warning lamp light up, and alarm buzzer
10
reverse mode sounds.
• If dump body is lowered or shift lever is moved to "N" position,
buzzer stops sounding.
• When "F1 Start at D Position Setting "is set, if shift lever is moved
to "D" position and accelerator pedal is depressed while brake is
applied, shift indicator (F1) flashes and centralized warning lamp
11 F1 stall alarm lights up, and alarm buzzer sounds.
• If accelerator pedal is released, alarm buzzer stops sounding.
• When setting torque converter to stalled state, disable "F1 Start at
D Position Setting "and move shift lever to "D" position.
• When controller is replaced, if initial setting is not performed
normally, centralized warning lamp lights up and alarm buzzer
12 Defective initial setting sounds.
• Perform correct initial setting.
• If no failure is found by above checks, monitor controller or any
Defective monitor controller or controller may be defective. (Since this is an internal defect,
13
each controller troubleshooting cannot be performed.)

HM400-3M0 40-759
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-27 Engine mode selector function does not operate properly
A-Z0-A)
When operating engine mode selector switch, engine mode selector function does not
Failure operate properly.
• If mechanical system failure code is displayed, perform troubleshooting for that code
Related information
first.
No. Cause
1 Defective fuse BT1-8
2 Defective engine mode switch
Open circuit in wiring harness
3 (wire breakage or defective
contact of connector)
Ground fault in wiring harness
4
(contact with ground circuit)
Hot short circuit in wiring
5
harness
Defective transmission
6
controller
Circuit diagram related to engine mode switch
40-760
(HM300_3-E22-400-
Procedure, measuring location, criteria and remarks
If fuse BT1-8 is blown, circuit probably has ground fault.
(Perform check on cause 4.)
1. Turn starting switch to OFF position.
2. Disconnect connector EGM and connect T-adapters to male side.
Resis- Between EGM (male) Switch: OFF Min. 1 Mz
tance (5) and (6) Switch: ON Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC1 and EGM, and connect T-adapters to
each female side.
3. Remove fuse BT1-8.
Between ATC1 (female) (12) and EGM
Resis- (female) (6) Max. 1 z
tance
Between EGM (female) (5) and fuse BT1-8 Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC1 and EGM, and connect T-adapters to
either female side.
3. Remove fuse BT1-8.
Between ground and ATC1 (female) (12) or
Min. 1 Mz
Resis- EGM (female) (6)
tance Between ground and EGM (female) (5) or fuse
Min. 1 Mz
BT1-8
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC1 and EGM, and connect T-adapters to
either female side.
3. Turn starting switch to ON position.
Between ground and ATC1 (female) (12) or
Voltage Max. 1 V
EGM (female) (6)
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector ATC1.
3. Turn starting switch to ON position.
Between ATC1 (12) Switch: ON 20 to 30 V
Voltage
and ground Switch: OFF Max. 1 V
HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-28 AISS function does not operate properly (HM300_3-FPQ-400-A-Z0-A)

Failure When operating AISS switch, AISS function does not work properly.
• If mechanical system failure code is displayed, perform troubleshooting for that code
first.
Related information • If brake lamp does not turn on and off according to operation of foot brake (service
brake) or parking brake pilot lamp does not light up and go out, perform
troubleshooting of them to repair them first.
No. Cause Procedure, measuring location, criteria and remarks
If fuse BT1-8 is blown, circuit probably has ground fault.
1 Defective fuse BT1-8
(Perform check on cause 4.)
1. Turn starting switch to OFF position.
2. Disconnect connector AISS and connect T-adapter to male side.
2 Defective AISS switch
Resis- Between AISS (male) Switch: OFF Min. 1 Mz
tance (5) and (6) Switch: ON Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC1 and AISS, and connect T-adapters to
Open circuit in wiring harness each female side.
3 (wire breakage or defective 3. Remove fuse BT1-8.
contact of connector) Between ATC1 (female) (18) and AISS
Resis- (female) (6) Max. 1 z
tance
Between AISS (female) (5) and fuse BT1-8 Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC1 and AISS, and connect T-adapters to
either female side.
Ground fault in wiring harness 3. Remove fuse BT1-8.
4
(contact with ground circuit) Between ground and ATC1 (female) (18) or
Min. 1 Mz
Resis- AISS (female) (6)
tance Between ground and AISS (female) (5) or fuse
Min. 1 Mz
BT1-8
1. Turn starting switch to OFF position.
2. Disconnect connectors ATC1 and AISS, and connect T-adapters to
Hot short circuit in wiring either female side.
5
harness 3. Turn starting switch to ON position.
Between ground and ATC1 (female) (18) or
Voltage Max. 1 V
AISS (female) (6)
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector ATC1.
Defective transmission 3. Turn starting switch to ON position.
6
controller
Between ATC1 (18) Switch: ON 20 to 30 V
Voltage
and ground Switch: OFF Max. 1 V

Circuit diagram related to AISS

HM400-3M0 40-761
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-29 Hoist lever does not operate properly (HM400_3-FPT-400-A-Z0-A)

Hoist lever does not operate properly

1) Hoist lever does not hold in RAISE position.
Failure
2) RAISE position detent of hoist lever is not canceled just before dump body reaches
set raised position.
• Failure codes [DW72KZ] and [DK54KX] indicate failures in kickout solenoid and
dump body positioner respectively. Therefore, when these codes are not displayed,
wiring is considered normal without breakage of solenoid coil, or open circuit or short
circuit of sensor.
• If detent condition is not canceled, hoist lever kickout may be regarded as normal
Related information (solenoid is energized and de-energized normally). Signals from dump body
positioner sensor are not probably sent to controller normally.
• When dump body does not rise at all, see troubleshooting for failure codes
[DK52KX] and [DK53L8] (troubleshooting for hoist lever potensiosensor).
• If kickout solenoid is defective, hoist lever must be replaced.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector LKO.
1 Defective hoist lever kickout 3. Start engine.
4. Set hoist lever to RAISE position, and then perform troubleshooting.
Voltage Between LKO (1) and (2) 20 to 30 V
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector BRC1 (or any connector on route to
dump body positioner sensor).
Defective dump body 3. Start engine.
2 positioner sensor 4. Set hoist lever to RAISE position, and perform troubleshooting
before dump body reaches set raised position.
Varies
Voltage Between BRC1 (14) and (4) between 0
to 5 V.
If no failure is found by above checks, retarder hoist controller may be
Defective retarder hoist defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)

Circuit diagram related to hoist lever and lever kickout solenoid

40-762 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to dump body positioner sensor

HM400-3M0 40-763
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-30 Turn signal lamp and winker lamp (hazard lamp) do not operate
properly (HM300_3-HS4-400-A-Z0-A)
Failure Turn signal lamp and winker lamp (hazard lamp) do not flash.
Description of circuit
1) When 24 V is applied to pin (3) of flasher, flasher always outputs repeated signals of
24 V and 0 V from pin (4).
2) Source of 24 V input to flasher pin (3) is switched by relay (R13). 24 V is supplied
from BT3 when turn signal lamp is turned on, and from BT2 when hazard lamp is turned
on.
3) Output from flasher is always (regardless of hazard switch operation) supplied to turn
switch connector CM (6) and pins (1) and (3) of hazard relay (R12).
Related information
4) When turn signal lamp is turned on, turn switch distribute flashing signal input to pin
(6) of connector CM to pin (8) for L.H. turn and pin (7) for R.H. turn.
5) When hazard switch is pressed, pins (5) and (6) of relay (HAZ) are connected with
each other, and hazard relay 1 (R12) and hazard relay 2 (R13) engage. Hazard relay 2
(R13) switches flasher power source from BT3 to BT2, and hazard relay 1 (R12)
connects flashing signal from flasher to both L.H. and R.H. turn signal lamps.
• Since T-adapter in not available for connectors FLS and MCM1, their operating
voltage cannot be measured.
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse BT3 (14) or BT2 If fuse BT3 (14) or BT2 (20) is blown, circuit probably has ground fault.
1 (20) (Perform check on cause 8.)
Lamp is probably defective. Check it directly or replace it with normal
2 Defective lamp
one for judgment.
Replace relay with other one for judgment.
• Replace relay R12 (6-pole) with any of relays R04, R05, R09, R11,
Defective hazard relay R12 or etc.
3
R13 • Replace relay R13 (5-pole) with any of relays R07, R10, etc.
a If hazard lamp operates normally, original relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors FLS and CM, and connect T-adapters to
female side of CM.
Open circuit in wiring harness Resis- Between FLS (female) (4) and CM
(female) (6) Max. 1 z
4 (wire breakage or defective tance
contact of connector) 1. Turn starting switch to OFF position.
2. Disconnect connector FLS.
3. Turn starting switch to ON position.
Voltage Between FLS (female) (3) and (1) 20 to 30 V
1. Turn starting switch to OFF position.
2. Disconnect connector CM, and connect T-adapters to female side.
3. Turn starting switch to ON position.
5 Defective flasher Pulse of
Voltage Between CM (female) (6) and ground voltage of 20
to 30 V and 0
V
1. Turn starting switch to OFF position.
2. Disconnect connector CM, and connect T-adapters to male side.
3. Operate turn switch (lever) to perform troubleshooting.
6 Defective turn switch Between CM (male) Right turn Max. 1 z
Resis- (6) and (7) Left turn Min. 1 Mz
tance Between CM (male) Left turn Max. 1 z
(6) and (8) Right turn Min. 1 Mz

40-764 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors HAZ, R12, R13, FLS, CM, MCM1, PR03,
PL03, CJR, B02, and B03.
3. Connect T-adapters to female side of connector of circuit to be
checked.
Between BT3-14 and R13 (female)(6) Max. 1 z
Between BT2-20 and R13 (female)(5) Max. 1 z
Between R13 (female) (5) and HAZ
(female) (5) Max. 1 z
Between HAZ (female) (6) and R13
(female) (1) Max. 1 z
Between R13 (female) (1) and R12
(female) (5) Max. 1 z
Between R13 (female) (3) and FLS
(female) (3) Max. 1 z
Between R12 (female) (4) and CM
(female) (7) Max. 1 z
Between CM (female) (7) and MCM1
(female) (16) Max. 1 z
Between R12 (female) (2) and CM
(female) (8) Max. 1 z
Between CM (female) (8) and MCM1
Open circuit in wiring harness (female) (15) Max. 1 z
7 (wire breakage or defective Between each of R12 (female) (1) and (3)
and FLS (female) (4) Max. 1 z
contact of connector)
Resis- Between CM (female) (7) and P02R
tance (female) (C) (front right) Max. 1 z
Between CM (female) (7) and P21
(female) (1) (rear right) Max. 1 z
Between CM (female) (8) and P02L
(female) (C) (front left) Max. 1 z
Between CM (female) (8) and P20
(female) (1) (rear left) Max. 1 z
Between P02R (female) (B) and ground
(front right) Max. 1 z
Between P02L (female) (B) and ground
(front left) Max. 1 z
Between P21 (female) (6) and ground
(ER10) (rear right) Max. 1 z
Between P20 (female) (6) and ground
(ER10) (rear left) Max. 1 z
Between R13 (female) (2) and ground
(ER2) Max. 1 z
Between R12 (female) (6) and ground
(ER2) Max. 1 z
Between FLS (female) (1) and ground Max. 1 z
(ER2)

HM400-3M0 40-765
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors HAZ, R12, R13, FLS, CM, MCM1, P02L,
P02R, P20, and P21.
3. Connect T-adapters to female side of connector of circuit to be
checked.
Between ground and BT3-14 or R13
(female) (6) Min. 1 Mz
Between ground and BT2-20, R13
(female) (5), or HAZ (female) (5) Min. 1 Mz

Ground fault in wiring harness Between ground and HAZ (female) (6),
R13 (female) (1), or R12 (female) (5) Min. 1 Mz
8
(contact with ground circuit)
Between ground and R13 (female) (3) or
Min. 1 Mz
Resis- FLS (female) (3)
tance Between ground and R12 (female) (4), CM
(female) (7), MCM1 (female) (16), P02R Min. 1 Mz
(female) (C), or P21 (female) (1)
Between ground and R12 (female) (2), CM
(female) (8), MCM1 (female) (15), P02L Min. 1 Mz
(female) (C), or P21 (female) (1)
Between ground and R12 (female) (1), (3),
FLS (female) (4). or CM (female) (6) Min. 1 Mz

40-766 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to turn signal lamp and winker lamp (hazard lamp)

HM400-3M0 40-767
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-31 None of headlamp, clearance lamp, and tail lamp lights (HM300_3-HQ1-400-A-Z0-
A)

Failure None of headlamp, clearance lamp, and tail lamp lights.

• Description of circuit
Related information 1. 24 V power is supplied from pin (6) of fuse BT3 to pins (1) and (4) of lighting
switch.
No. Cause Procedure, measuring location, criteria and remarks
If fuse BT3-6 is broken, circuit probably has ground fault. (Perfor check
1 Defective fuse BT3-6 on cause 4.)
1.Turn starting switch to OFF position.
2.Insert T-adapters into connectors CM, CJT, and CJR.
3.Turn starting switch to ON position.
Open circuit in wiring harness 4.Turn on lighting switch.
2 (wire breakage or defective Between CM (1) and ground 20 to 30 V
contact of connector)
Between CM (2) and ground 20 to 30 V
Voltage
Between CJT (4) and ground 20 to 30 V
Between CJR (4) and ground 20 to 30 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector CM, and connect T-adapters to male side.
Between CM (male)
(1) and (2) Max. 1 z
Lighting switch: 1st
3 Defective lighting switch Between CM (male) stage
Min. 1 Mz
Resis- (1) and (3)
tance Between CM (male)
(1) and (2) Max. 1 z
Lighting switch: 2nd
Between CM (male) stage
(1) and (3) Max. 1 z

1. Turn starting switch to OFF position.

2. Disconnect connectors CM, MCM1, P02R, P02L, P20, and P21,
Ground fault in wiring harness and connect T-adapters to each female side.
4 3. Remove fuse BT3-6.
(contact with ground circuit) Between ground and each of CM (female) (1)
Resis- and (4) Min. 1 Mz
tance
Between CM (female) (2) and ground Min. 1 Mz

40-768 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to night lighting

HM400-3M0 40-769
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-32 Clearance lamp does not light up (HM300_3-HQ5-400-A-Z0-A)

Failure Clearance lamp does not light up.

• This case assumes that tail lamp light up normally.
Related information • Check ground terminal ER16 for looseness and corrosion.

No. Cause Procedure, measuring location, criteria and remarks

If lamp (bulb) seems to be defective, visually check it or replace bulb
1 Defective lamp (bulb)
for judgment.
1. Turn starting switch to OFF position.
2. Disconnect connectors CM, P02R, and P02L, and connect T-
adapters to each female side.
Open circuit in wiring harness Between CM (female) (2) and P02R (female)
(A) Max. 1 z
2 (wire breakage or defective
contact of connector) Resis- Between CM (female) (2) and P02L (female) Max. 1 z
tance (A)
Between P02R (female) (B) and ground Max. 1 z
Between P02L (female) (B) and ground Max. 1 z

40-770 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to night lighting

HM400-3M0 40-771
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-33 Tail lamp does not light up (HM300_3-HQ6-400-A-Z0-A)

Failure Tail lamp does not light up.

• This case assumes that clearance lamps and head lamps (L.H. and R.H.) light up
Related information normally.
• Check ground terminal ER10 for looseness and corrosion.
No. Cause Procedure, measuring location, criteria and remarks
If lamp (bulb) seems to be defective, visually check it or replace bulb for
1 Defective lamp (bulb)
judgment.
1. Turn starting switch to OFF position.
2. Disconnect connectors CM, P20, and P21, and connect T-adapters
Open circuit in wiring harness to each female side.
2 (wire breakage or defective Between CM (female) (2) and P20 (female) (4) Max. 1 z
contact of connector) Resis- Between CM (female) (2) and P21 (female) (4) Max. 1 z
tance Between P20 (female) (6) and ground Max. 1 z
Between P21 (female) (6) and ground Max. 1 z

40-772 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to night lighting

HM400-3M0 40-773
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-34 Low beam of headlamp does not light up (HM300_3-HQ3-400-A-Z0-A)

Failure "Low beam" headlamp does not light up.

• This case assumes that high beam head lamp lights up normally.
• If clearance lamp and tail lamp do not light up, perform troubleshooting for E-31 or E-
32 first.
Related information • Check ground terminal ER2 for looseness and corrosion.
• Description of relay circuit
1. When lighting switch is set to "Head (Lo)", head lamp Lo relay (R16) engages,
allowing 24 V power from fuse BT3-4 to flow to head lamp from pin (3) of R16.
No. Cause Procedure, measuring location, criteria and remarks
If fuse BT3-4 is broken, circuit probably has ground fault. (Perform
1 Defective fuse BT3-4 check on cause 5.)
If lamp (bulb) seems to be defective, visually check it or replace bulb for
2 Defective lamp (bulb)
judgment.
1. Turn starting switch to OFF position.
Defective head lamp Lo relay 2. Interchange R16 and horn relay (R10).
3 (R16) 3. Turn starting switch to ON position.
4. Sound horn.
If horn does not sound, original head lamp Lo relay (R16) is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors P01R, P01L, CM, and R16, and connect T-
adapters to each female side.
Between P01R (female) (1) and R16 (female)
(3) Max. 1 z
Open circuit in wiring harness
Between P01R (female) (2) and ground Max. 1 z
4 (wire breakage or defective Between P01L (female) (1) and R16 (female)
contact of connector) Resis- (3) Max. 1 z
tance Between P01L (female) (2) and ground Max. 1 z
Between fuse BT3-4 and R16 (female)(5) Max. 1 z
Between CM (female) (3) and R16 (female) (1) Max. 1 z
Between R16 (female) (2) and ground Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors P01R, P01L, CM, MCM1, and R16, and
connect T-adapters to each female side.
Ground fault in wiring harness 3. Remove fuse BT3-4.
5
(contact with ground circuit) Between ground and P01R (female) (1), P01L
Min. 1 Mz
Resis- (female) (1), or R16 (female) (3)
tance Between ground and R16 (female) (5) or fuse
Min. 1 Mz
BT3-4

40-774 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to head lamp

HM400-3M0 40-775
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-35 High beam of headlamp does not light up (HM300_3-HQ4-400-A-Z0-A)

Failure "High beam" headlamp does not light up.

• This case assumes that low beam head lamp lights up normally..
• Description of relay circuit
1. When lighting switch is set to "Head (Hi)" from "Head (Lo)", voltage at pin MCM1
Related information
(18) of monitor controller becomes GND level and head lamp high relay (R14)
engages. R14 allows 24 V power from fuse BT3-2 to flow to both high beam
head lamp from pin (3) of R15.
No. Cause Procedure, measuring location, criteria and remarks
If fuse BT3-2 is blown, circuit probably has ground fault. (Perform check
1 Defective fuse BT3-2 on cause 4.)
If lamp (bulb) seems to be defective, visually check it or replace bulb for
2 Defective lamp (bulb)
judgment.
1. Turn starting switch to OFF position.
Defective head lamp Hi relay 2. Interchange R14 and horn relay (R10).
3 (R14) *1 3. Turn starting switch to ON position.
4. Sound horn.
If horn does not sound, original head lamp Hi relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors P03R, P03L, MCM1, R14, and CM, and
connect T-adapters to each female side.
3. Remove fuse BT3-2.
Between R14 (female) (5) and fuse BT3-2 Max. 1 z
Between R14 (female) (1) and CM (female) (3) Max. 1 z
Open circuit in wiring harness
Between MCM1 (female) (18) and R16
4 (wire breakage or defective (female) (2) Max. 1 z
contact of connector)
Resis- Between P03R (female) (1) and R16 (female)
(3) Max. 1 z
tance
Between P03L (female) (1) and R16 (female)
(3) Max. 1 z
Between P03R (female) (2) and ground Max. 1 z
Between P03L (female) (2) and ground Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors P03R, P03L, MCM1, R14, and CM, and
connect T-adapters to each female side.
Ground fault in wiring harness 3. Remove fuse BT3-2.
5
(contact with ground circuit) Between ground and P03R (female) (1), P03L
Min. 1 Mz
Resis- (female) (1), or R14 (female) (3)
tance Between ground and fuse BT3-2 or R14
(female) (5) Min. 1 Mz

1. Turn starting switch to OFF position.

Hot short circuit in wiring 2. Disconnect connector R14, and connect T-adapters to female side.
6 harness 3. Turn starting switch to ON position.
(contact with 24 V circuit) 4. Set lighting switch to "Head (Hi)".
Voltage Between R14 (female) (2) and ground Max. 1 V
*1: Passing lamp lights up even if relay is defective.

40-776 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to head lamp

HM400-3M0 40-777
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-36 Neither Low beam nor High beam of headlamp lights up (HM300_3-HQ2-400-A-
Z0-A)

Failure Neither "Low beam" nor "High beam" headlamp lights up.
Related information • This case assumes that clearance lamp and tail lamp light up normally.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector CM, and connect T-adapters to male side.
1 Defective lighting switch
Resis- Between CM (male) Righting switch: At 2nd
(1) and (3) stage Max. 1 z
tance
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors CM, R14, and R16, and connect T-adapters
2 (wire breakage or defective to each female side.
contact of connector) Resis- Between CM (female) (3) and R14 (female) (1) Max. 1 z
tance Between CM (female) (3) and R16 (female) (1) Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors R16 and CM, and connect T-adapter to
3 either female side.
(contact with ground circuit)
Resis- Between ground and CM (female) (3) or R16
(female) (1) Min. 1 Mz
tance

40-778 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to head lamp

HM400-3M0 40-779
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-37 High beams do not light up while passing switch is operated (HM300_3-
HQ8-400-A-Z0-A)

Failure High beams do not light up while passing switch is operated

• This case assumes that head lamp lights up normally (High beam head lamp lights
up).
• Description of relay circuit
Related information
1. When passing switch is turned on, passing relay (R15) engages, allowing 24 V
power from fuse BT3-2 to flow to pin (3) of R14 from pin (3) of R15. Then 24 V
power flows through same route when lighting high beam head lamp.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Interchange R15 and horn relay (R10).
1 Defective passing relay (R15) 3. Turn starting switch to ON position.
4. Sound horn.
If horn does not sound, original passing relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector CM, and connect T-adapters to male side.
2 Defective passing switch Passing switch:
Max. 1 z
Resis- Between CM (male) Turned on
tance (4) and (5) Passing switch:
Min. 1 Mz
Turned off
1. Turn starting switch to OFF position.
2. Disconnect connectors CM, R14, R15, and MCM1, and connect T-
adapters to each female side.
Open circuit in wiring harness Between CM (female) (5) and R15 (female) (1) Max. 1 z
3 (wire breakage or defective Between R14 (female) (5) and R15 (female)
Max. 1 z
contact of connector) Resis- (5)
tance Between R14 (female) (3) and R15 (female)
(3) Max. 1 z
Between R15 (female) (2) and ground Max. 1 z

40-780 HM400-3M0
 40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to head lamp

HM400-3M0 40-781
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-38 KOMTRAX does not operate properly (HM300_3-F50-400-A-Z0-A)

Failure KOMTRAX system does not operate normally.

• Perform following troubleshooting if administrator of KOMTRAX system requests to check
Related whether failure occurs in system on machine.
information • Even when KOMTRAX system is defective, no problem appears on machine.
• Check all results of troubleshooting on service menu display of machine monitor.
No. Cause Procedure, measuring location, criteria, and remarks
1. Turn starting switch to ON position.
Defective 2. Display "Terminal status" screen.
1
communication 1 Monitoring
Check item: Station set-up check Complete
display
1. Turn starting switch to ON position.
2. Display "GPS & Communication Status" screen.
N ###.##.## (Latitude)
Defective positioning by Monitoring
2 Check item: Positioning E ###.##.## (Longitude)
GPS display
Positioning in Progress
If latitude and longitude are not displayed within 5 minutes under the open
sky, contact KOMTRAX service hot line.
1. Turn starting switch to ON position.
2. Display "GPS & Communication Status" screen.
Defective Monitoring Satellite in View or No
3 communication display Check item: Communication
Satellite in View
environment If Communication Status does not display "Satellite in view" within 15 minutes
under the open sky, check whether the connector of TC330 or the antenna on
top of cab is properly connected.
1. Turn starting switch to ON position.
Defective 2. Display "GPS & Communication Status" screen.
4
communication 2 Monitoring Check item: Number of message(s)
0 to 60 (normally 0)
display not yet sent

a Select “01 Terminal Status” from “11 KOMTRAX

settings” in service menu of machine monitor.

a Select “02 GPS & Communication Status” from

“11 KOMTRAX settings” in service menu of
machine monitor.

40-782 HM400-3M0
 40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

Troubleshooting of hydraulic and mechanical system (H-mode) (ALL-

3840-001-A-02-A)

Information described in troubleshooting table (H-mode) (ALL-5170-010-A-00-A)

(Rev. 2011/03)

a The following information is summarized in the troubleshooting table. Before performing troubleshooting,
understand that information fully.
Failure Failure symptom that appears on machine
Related Information on occurred failure or troubleshooting
information
No. Cause Procedure, measuring location, criteria and remarks
1
2 Probable cause of failure <Contents of description>
(Each number is serial
3 number, not priority • Criteria to determine probable causes
4 sequence.) • Remarks for determination of probable cause
5

HM400-3M0 40-783
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

System chart of hydraulic and mechanical systems (HM400-PM10-054-K-00-A)

40-784 HM400-3M0
 40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

a This system chart shows simplified overall hydraulic circuit diagram and is intended to be used as
reference material for troubleshooting of hydraulic and mechanical systems.

HM400-3M0 40-785
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

Failure mode and cause table (HM300-5340-40D-A-00-A)

Component causing failure Power train Brake (dragging)

Power train pump main relief valve

Retarder pressure reducing valve

Torque converter relief valve

Transmission valve (ECMV)

Accumulator charge valve

Transmission clutch (*)

Lockup solenoid valve

Brake disc and plate

Troubleshooting No.
Brake pedal linkage

Brake accumulator
Power train pump

Torque converter

Brake (dragging)

Slack adjuster

Parking brake
Lockup clutch
Transmission

Brake valve
Failure
Machine does not start. q q q q q q q q H-1
Machine does not travel smoothly (engine
q q q H-2
hunts).
Lockup clutch is not disengaged. q q H-3
Abnormally large shocks result from starting of
q H-4
machine and gear shifting.
Machine does not upshift. q q q q q H-5
Machine lacks travel speed or power during
Power train system

travel in lockup drive mode through all gear q q q q H-6

speeds.
Machine lacks travel speed or power during
q q q H-7
travel in torque converter drive mode.
Machine lacks travel speed or power during
q q H-8
travel in specific gear speed.
Machine starts or gear speed shifts with long
q q q q H-9
time lag.
Torque converter oil temperature is high. q q q q H-10

Torque converter oil pressure is low q q q q H-11

Front brake does not work sufficiently. q q q q q q H-12

Center brake does not work sufficiently. q q q q q H-13

Steering wheel is heavy to turn. H-14

Steering system

Steering wheel does not move. H-15

Steering wheel swings. H-16

Dump body raise speed or power is slow. H-17

Work equipment system

Dump body does not move. H-18

Hydraulic drift of dump body is large. H-19

Radiator fan speed is abnormal (high, low, or

H-20
stationary).
Fan system

Aftercooler fan speed is abnormal (high, low, or

H-21
stationary)
Unusual noise is heard from around radiator
H-22
fan.
Abnormal noise is heard around aftercooler fan H-23

40-786 HM400-3M0
 40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

Component causing failure Steering Pump and motor

Aftercooler fan pump (hoist pilot pressure)

Troubleshooting No.
Steering and work equipment pump

Radiator fan motor (relief valve)

Hydraulic tank strainer

Aftercooler fan motor

Flow amplifier valve

Brake cooling pump

Brake control pump

Radiator fan pump

Steering cylinder

Steering valve

Engine

PTO
　
Failure
Machine does not start. q H-1
Machine does not travel smoothly (engine
q H-2
hunts).
Lockup clutch is not disengaged. H-3
Abnormally large shocks result from starting of
H-4
machine and gear shifting
Machine does not upshift. H-5
Machine lacks travel speed or power during
Power train system

travel in lockup drive mode through all gear q q H-6

speeds.
Machine lacks travel speed or power during
H-7
travel in torque converter drive mode.
Machine lacks travel speed or power during
H-8
travel in specific gear speed.
Machine starts or gear speed shifts with long
q H-9
time lag.
Torque converter oil temperature is high. q q H-10

Torque converter oil pressure is low. q H-11

Front brake does not work sufficiently. q H-12

Center brake does not work sufficiently. q H-13

Steering wheel is heavy to turn. q q q q q H-14

Steering system

Steering wheel does not move. q q q q q H-15

Steering wheel swings. q q H-16

Dump body raise speed or power is slow. q q q H-17

Work equipment system

Dump body does not move. q q q H-18

Hydraulic drift of dump body is large. H-19

Radiator fan speed is abnormal (high, low, or

q q H-20
stationary).
Aftercooler fan speed is abnormal (high, low, or
Fan system

H-21
stationary).
Unusual noise is heard from around radiator
q H-22
fan.
Unusual noise is heard from around aftercooler
q H-23
fan.

HM400-3M0 40-787
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

Component causing failure Hydraulic component

PC valve (steering and work equipment pump)

LS valve (steering and work equipment pump)

Self-pressure reducing valve (pilot pressure)

Aftercooler fan direction selector valve

Troubleshooting No.
Radiator fan direction selector valve
Flow amplifier valve (divider valve)

Aftercooler fan valve (relief valve)

Fan exterior
Radiator fan valve (relief valve)
Hoist valve (relief valve)
Pump suction piping

Hoist valve (spool)

Hoist EPC valve

Hoist cylinder
Failure
Machine does not start. q H-1
Machine does not travel smoothly (engine
q H-2
hunts).
Lockup clutch is not disengaged. H-3
Abnormally large shocks result from starting of
H-4
machine and gear shifting.
Machine does not upshift. H-5
Machine lacks travel speed or power during
Power train system

travel in lockup drive mode through all gear q H-6

speeds.
Machine lacks travel speed or power during
H-7
travel in torque converter drive mode.
Machine lacks travel speed or power during
H-8
travel in specific gear speed.
Machine starts or gear speed shifts with long
q H-9
time lag.
Torque converter oil temperature is high. q H-10

Torque converter oil pressure is low. q H-11

Front brake does not work sufficiently. q H-12

Center brake does not work sufficiently. q H-13

Steering wheel is heavy to turn. q q q H-14

Steering system

Steering wheel does not move. q H-15

Steering wheel swings. H-16

Dump body raise speed or power is slow. q q q q q q q q H-17

Work equipment system

Dump body does not move. q q q q q q q H-18

Hydraulic drift of dump body is large. q q H-19

Radiator fan speed is abnormal (high, low, or

q q H-20
stationary).
Fan system

Aftercooler fan speed is abnormal (high, low, or

q q H-21
stationary).
Unusual noise is heard from around radiator
q H-22
fan.
Unusual noise is heard around aftercooler fan. q H-23

40-788 HM400-3M0
 40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

(*)

Clutches to be used

Hi Lo 1st 2nd 3rd R

R2 q q

R1 q q

N
Gear speed

F1 q q

F2 q q

F3 q q

F4 q q

F5 q q

F6 q q

HM400-3M0 40-789
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-1 Machine does not start (HM400_3-BH0-400-A-Z0-A)

Failure Machine does not start with gear at any position.

• Check that transmission oil level is normal.
• If failure code related to input shaft speed sensor system or mechanical system is
displayed, perform troubleshooting for it first.
• Check that drive shaft, etc. are normal.
Related
• Check that parking brake is surely released.
information
• Engine speed can be checked with monitoring function. (Monitoring code: 01002)
• For the setting procedure of the engine mode by monitor operation, see Testing and
Adjusting, "Special functions of machine monitor", "Adjustment (Engine Mode Fixing)",
section 1.
No. Cause Procedure, measuring location, criteria and remarks
Defective power train pump Check strainer for clogging.
1
strainer
Air sucked in on suction side
2 Check suction piping for cracks, looseness, etc.
of power train pump
a Be ready with engine stopped, then perform troubleshooting with
engine running at low idle and rated speed.
2.45 ± 0.20 MPa
Low idle
Defective main relief valve of Main relief {25 ± 2.0 kg/cm2}
3 Engine speed
power train pump pressure 2.56 ± 0.20 MPa
2,000 rpm
{26.1 ± 2.0 kg/cm2}
When pressure cannot be adjusted to normal level, check main relief
valve for malfunction (setting of spring) and internal defect (defective
valve seat).
a Be ready with engine stopped, then perform troubleshooting with
engine running at 2,000 rpm.
Torque 0.86 ± 0.1 MPa
converter inlet Brake OFF
pressure {8.8 ± 1.0 kg/cm2}
Torque
converter 0.49 ± 0.1 MPa
Improper torque converter outlet Brake OFF
4 {5.0 ± 1.0 kg/cm2}
pressure (relief valve) pressure
Torque
converter 0.62 ± 0.1 MPa
outlet Brake ON
{6.3 ± 1.0 kg/cm2}
pressure
When pressure cannot be adjusted to normal level, check relief valve
for malfunction (setting of spring) and internal defect (defective valve
seat).
a Be ready with engine stopped, then perform troubleshooting with
engine at full speed.
5 Defective torque converter Torque Set Engine mode
converter stall Engine mode to "Power" with 1,858 ± 100 rpm
speed machine monitor.

40-790 HM400-3M0
 40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

No. Cause Procedure, measuring location, criteria and remarks

a Be ready with engine stopped, then perform troubleshooting with
engine at full speed.
Output Gear shift
pressure of lever position 2.55 ± 0.25 MPa
1 （F1)
Lo clutch {26 ± 2.5 kg/cm2}
(Gear speed)
ECMV
Output Gear shift
2.50 ± 0.25 MPa
pressure of Hi lever position 2 （F2）
clutch ECMV (Gear speed) {25.5 ± 2.5 kg/cm2}
Defective gear speed clutch
6 Output
ECMV Gear shift
pressure of lever position 2.55 ± 0.25 MPa
1 （F1)
1st clutch {26 ± 2.5 kg/cm2}
ECMV (Gear speed)
Output Gear shift
2.55 ± 0.25 MPa
pressure of R lever position R1
{26 ± 2.5 kg/cm2}
clutch ECMV (Gear speed)
* Combination of two gear speed clutches determines gear sped.
Check combination of two clutches to be used for selection of gear
speed by referring to Table 1.
• If measured pressure is low in check on cause 6, oil may leak
through clutch seal ring.
7 Defective gear speed clutch
• If measured pressure is normal in check on cause 6, clutch may
slip.
• If measured pressure is unusual in check on cause 3, disconnect
power train pump outlet hose, crank engine, and check that oil
8 Defective power train pump
flows out.
• Check line filter for foreign materials such as metal particles.
• If no failure is found by checks on causes 1 to 8, transmission may
9 Internal defect of transmission
have internal defect.
Table 1
Clutches to be used
Hi Lo 1st 2nd 3rd R
R2 q q
R1 q q
N
Gear speed

F1 q q
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q

HM400-3M0 40-791
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-2 Machine does not travel smoothly (engine hunts) (HM400_3-C61-400-A-Z0-A)

Failure Machine does not travel smoothly (engine hunts).

Related • Check that transmission oil level is normal.
information • If any failure code is displayed, perform troubleshooting for that failure code first.
No. Cause Procedure, measuring location, criteria and remarks
Defective power train pump Check strainer for clogging.
1
strainer
Air sucked in on suction side
2 Check suction piping for cracks, looseness, etc.
of power train pump
a Be ready with engine stopped, then perform troubleshooting with
engine running at low idle and rated speed.
2.45 ± 0.20 MPa
Engine speed Low idle
Defective main relief valve of Main relief {25 ± 2.0 kg/cm2}
3 power train pump pressure 2.56 ± 0.20 MPa
Engine speed 2,000 rpm
{26.1 ± 2.0 kg/cm2}
When pressure cannot be adjusted to normal level, check main relief
valve for malfunction (setting of spring) and internal defect (defective
valve seat).
• If measured pressure is low in check on cause 3, piston seal ring or
ring groove of gear speed clutch may wear.
4 Defective gear speed clutch
• If measured pressure is normal in check on cause 3, clutch may
slip.

40-792 HM400-3M0
 40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-3 Lockup clutch is not disengaged (HM400_3-AD1-400-A-Z0-A)

Failure Lockup clutch is not disengaged.

Related • Check that transmission oil level is normal.
information • If any failure code is displayed, perform troubleshooting for that failure code first.
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with
engine at full speed.
Malfunction of lockup When torque converter 2.01 ± 0.20 MPa
1
solenoid valve Output pressure of lockup clutch is engaged {20.5 ± 2.0 kg/cm2}
lockup solenoid When torque converter 0 MPa
lockup clutch is disengaged {0 kg/cm2}
Defective lockup clutch If measured pressure is normal in check on cause 1, lockup clutch may
2
be seized.

HM400-3M0 40-793
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-4 Abnormally large shocks result from starting of machine and gear
shifting (HM300_3-C10-400-A-Z0-A)
Failure Abnormally large shocks result from starting of machine and gear shifting.　
Related • If any failure code is displayed, perform troubleshooting for that failure code first.
information
No. Cause Procedure, measuring location, criteria and remarks
* It is difficult to determine whether shock you feel is large or small. so,
regard shocks as large in following cases.
• When you feel that shock increases significantly and suddenly
• When you feel that shock is larger than that of other machines of
same model
a Be ready with engine stopped, then perform troubleshooting with
engine at full speed.
Gear shift
Output pressure of lever position 2.55 ± 0.25 MPa
1 （F1)
Lo clutch ECMV {26 ± 2.5 kg/cm2}
(Gear speed)
Defective gear speed clutch Gear shift
1 Output pressure of lever position 2.50 ± 0.25 MPa
ECMV 2 （F2）
Hi clutch ECMV {25.5 ± 2.5 kg/cm2}
(Gear speed)
Gear shift
Output pressure of lever position 2.55 ± 0.25 MPa
1 （F1)
1st clutch ECMV {26 ± 2.5 kg/cm2}
(Gear speed)
Gear shift
Output pressure of lever position 2.55 ± 0.25 MPa
R1
R clutch ECMV {26 ± 2.5 kg/cm2}
(Gear speed)
* Combination of two gear speed clutches determines gear sped.
Check combination of two clutches to be used for selection of gear
speed by referring to Table 1.
Table 1
Clutches to be used
Hi Lo 1st 2nd 3rd R
R2 q q
R1 q q
N
Gear speed

F1 q q
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q

40-794 HM400-3M0
 40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-5 Machine does not upshift (HM400_3-EF1-400-A-Z0-A)

Failure Machine does not upshift.

Related • If any failure code is displayed, perform troubleshooting for that failure code first.
information
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with
engine running at low idle and rated speed.
2.45 ± 0.20 MPa
Engine speed Low idle
Defective main relief valve of Main relief {25 ± 2.0 kg/cm2}
1 power train pump pressure 2.56 ± 0.20 MPa
Engine speed 2,000 rpm
{26.1 ± 2.0 kg/cm2}
When pressure cannot be adjusted to normal level, check main relief
valve for malfunction (setting of spring) and internal defect (defective
valve seat).
a Be ready with engine stopped, then perform troubleshooting with
engine at full speed.
Malfunction of lockup solenoid When torque converter lockup 2.01 ± 0.20 MPa
2 Output
valve pressure of clutch is engaged {20.5 ± 2.0 kg/cm2}
lockup When torque converter lockup 0 MPa
solenoid clutch is disengaged {0 kg/cm2}
3 Malfunction of lockup clutch If machine upshifts in downhill travel, lockup clutch may slip.
a Be ready with engine stopped, then perform troubleshooting with
engine at full speed.
Output Gear shift
2.50 ± 0.25 MPa
pressure of Hi lever position 2 (F2)
{25.5 ± 2.5 kg/cm2}
clutch ECMV (Gear speed)
Output Gear shift
pressure of lever position 2.55 ± 0.25 MPa
1 (F1)
Lo clutch {26 ± 2.5 kg/cm2}
ECMV (Gear speed)
Output Gear shift
pressure of lever position 2.55 ± 0.25 MPa
1 (F1)
1st clutch {26 ± 2.5 kg/cm2}
ECMV (Gear speed)
Defective gear speed clutch
4 Output
ECMV Gear shift 2.38 ± 0.22 MPa
pressure of lever position 3 (F3)
2nd clutch {24.25 ± 2.25 kg/
(Gear speed) cm2}
ECMV
Output Gear shift 2.43 ± 0.22 MPa
pressure of lever position 5 (F5) {24.75 ± 2.25 kg/
3rd clutch
(Gear speed) cm2}
ECMV
Output Gear shift
2.55 ± 0.25 MPa
pressure of R lever position R1
{26 ± 2.5 kg/cm2}
clutch ECMV (Gear speed)
* Combination of two gear speed clutches determines gear speed.
Check combination of two clutches to be used for selection of gear
speed by referring to Table 1.
• If measured pressure is low in check on cause 4, piston seal ring or
ring groove of gear speed clutch may wear.
5 Defective gear speed clutch
• If measured pressure is normal in check on cause 4, clutch may
slip.

HM400-3M0 40-795
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

Table 1
Clutches to be used
Hi Lo 1st 2nd 3rd R
R2 q q
R1 q q
N

Gear speed
F1 q q
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q

40-796 HM400-3M0
 40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-6 Machine lacks travel speed or power during travel in lockup drive
mode through all gear speeds (HM400_3-D20-400-A-Z0-A)
Machine lacks travel speed or power during travel in lockup drive mode through all gear
Failure speeds.　
• Check that transmission oil level is normal.
• If any failure code is displayed, perform troubleshooting for that failure code first.
Related • Check that parking brake is surely released and retarder brake is not dragged.
information • Check that inflation pressure is normal.
• Engine speed can be checked with monitoring function. (Monitoring code: 01002)
No. Cause Procedure, measuring location, criteria and remarks
Defective power train pump Check strainer for clogging.
1
strainer
Air sucked in on suction side
2 Check suction piping for cracks, looseness, etc.
of power train pump
a Be ready with engine stopped, then perform troubleshooting with
engine running at low idle and rated speed.
2.45 ± 0.20 MPa
Engine speed Low idle
Defective main relief valve of Main relief {25 ± 2.0 kg/cm2}
3 power train pump pressure 2.56 ± 0.20 MPa
Engine speed 2,000 rpm
{26.1 ± 2.0 kg/cm2}
When pressure cannot be adjusted to normal level, check main relief
valve for malfunction (setting of spring) and internal defect (defective
valve seat).
a Be ready with engine stopped, then perform troubleshooting with
engine at full speed.
Defective lockup clutch When torque converter lockup 2.01 ± 0.20 MPa
4 Output
solenoid valve pressure of clutch is engaged {20.5 ± 2.0 kg/cm2}
solenoid When torque converter lockup 0 MPa
valve clutch is disengaged {0 kg/cm2}
• If measured pressure is low in check on cause 4, piston seal ring or
ring groove of gear speed clutch may wear.
5 Slippage of lockup clutch
• If measured pressure is normal in check on cause 4, clutch may
slip.
• If measured pressure is unusual in check on cause 3, disconnect
power train pump outlet hose, crank engine, and check that oil flows
6 Defective power train pump
out.
• Check line filter for foreign materials such as metal particles.
• If no failure is found by checks on causes 1 to 6 and torque
7 Lowered engine output converter stall speed (1,850 rpm for power mode) is below standard
value, engine performance may lower.

HM400-3M0 40-797
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-7 Machine lacks travel speed or power during travel in torque

converter drive mode (HM400_3-EF7-400-A-Z0-A)
Failure Machine lacks travel speed or power during travel in torque converter drive mode.
• Check that transmission oil level is normal.
• If any failure code is displayed, perform troubleshooting for that failure code first.
• Check that parking brake is surely released and retarder brake is not dragged.
Related • Check piping for oil leakage.
information • Engine speed can be checked with monitoring function. (Monitoring code: 01002)
• For the setting procedure of the engine mode by monitor operation, see Testing and
Adjusting, "Special functions of machine monitor", "Adjustment (Engine Mode Fixing)",
section 1.
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with
engine running at low idle and rated speed.
2.45 ± 0.20 MPa
Engine speed Low idle
Defective main relief valve of Main relief {25 ± 2.0 kg/cm2}
1 power train pump pressure 2.56 ± 0.20 MPa
Engine speed 2,000 rpm
{26.1 ± 2.0 kg/cm2}
When pressure cannot be adjusted to normal level, check main relief
valve for malfunction (setting of spring) and internal defect (defective
valve seat).
a Be ready with engine stopped, then perform troubleshooting with
engine running at 2,000 rpm.
Torque 0.86 ± 0.1 MPa
converter inlet Brake OFF
pressure {8.8 ± 1.0 kg/cm2}
Torque
converter 0.49 ± 0.1 MPa
Improper torque converter outlet Brake OFF
2 {5.0 ± 1.0 kg/cm2}
pressure (relief valve) pressure
Torque
converter 0.62 ± 0.1 MPa
outlet Brake ON
{6.3 ± 1.0 kg/cm2}
pressure
When pressure cannot be adjusted to normal level, check relief valve
for malfunction (setting of spring) and internal defect (defective valve
seat).
a Be ready with engine stopped, then perform troubleshooting with
engine at full speed.
3 Defective torque converter Torque Set Engine mode
converter stall Engine mode to "Power" with 1,858 ± 100 rpm
speed machine monitor.

40-798 HM400-3M0
 40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-8 Machine lacks travel speed or power during travel in specific gear
speed (HM400_3-A8E-400-A-Z0-A)
Failure Machine lacks travel speed or power during travel in specific gear speed.
Related • Check that transmission oil level is normal.
information • If any failure code is displayed, perform troubleshooting for that failure code first.
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with
engine at full speed.
Gear shift
Output pressure of lever position 2.50 ± 0.25 MPa
2 (F2)
Hi clutch ECMV {25.5 ± 2.5 kg/cm2}
(Gear speed)
Gear shift
Output pressure of lever position 2.55 ± 0.25 MPa
1 (F1)
Lo clutch ECMV {26 ± 2.5 kg/cm2}
(Gear speed)
Gear shift
Output pressure of lever position 2.55 ± 0.25 MPa
1 (F1)
1st clutch ECMV {26 ± 2.5 kg/cm2}
(Gear speed)
Defective gear speed clutch Gear shift 2.38 ± 0.22 MPa
1 Output pressure of lever position 3 (F3)
ECMV {24.25 ± 2.25 kg/
2nd clutch ECMV
(Gear speed) cm2}
Gear shift 2.43 ± 0.22 MPa
Output pressure of lever position 5 (F5) {24.75 ± 2.25 kg/
3rd clutch ECMV
(Gear speed) cm2}
Gear shift
Output pressure of lever position 2.55 ± 0.25 MPa
R1
R clutch ECMV {26 ± 2.5 kg/cm2}
(Gear speed)
• You may interchange ECMVs and check whether symptom
disappears or not for judgment.
* Combination of two gear speed clutches determines gear speed.
Check combination of two clutches to be used for selection of gear
speed by referring to Table 1.
• If measured pressure is low in check on cause 1, piston seal ring or
ring groove of gear speed clutch may wear.
2 Defective gear speed clutch
• If measured pressure is normal in check on cause 1, gear speed
clutch may slip.
Table 1
Clutches to be used
Hi Lo 1st 2nd 3rd R
R2 q q
R1 q q
N
Gear speed

F1 q q
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q

HM400-3M0 40-799
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-9 Machine starts or gear speed shifts with long time lag (HM400_3-C60-400-A-Z0-A)

Failure Machine starts or gear speed shifts with long time lag.
• Check that transmission oil level is normal.
Related • If any failure code is displayed, perform troubleshooting for that failure code first.
information • Check piping for oil leakage.
No. Cause Procedure, measuring location, criteria and remarks
Defective power train pump Check strainer for clogging.
1
strainer
Air sucked in on suction side
2 Check suction piping for cracks, looseness, etc.
of power train pump
a Be ready with engine stopped, then perform troubleshooting with
engine running at low idle and rated speed.
2.45 ± 0.20 MPa
Low idle
Defective main relief valve of Main relief {25 ± 2.0 kg/cm2}
3 Engine speed
power train pump pressure 2.56 ± 0.20 MPa
2,000 rpm
{26.1 ± 2.0 kg/cm2}
When pressure cannot be adjusted to normal level, check main relief
valve for malfunction (setting of spring) and internal defect (defective
valve seat).
a Be ready with engine stopped, then perform troubleshooting with
engine at full speed.
Output Gear shift
2.50 ± 0.25 MPa
pressure of Hi lever position 2 (F2)
{25.5 ± 2.5 kg/cm2}
clutch ECMV (Gear speed)
Output Gear shift
pressure of lever position 2.55 ± 0.25 MPa
1 (F1)
Lo clutch {26 ± 2.5 kg/cm2}
(Gear speed)
ECMV
Output Gear shift
pressure of lever position 2.55 ± 0.25 MPa
1 (F1)
1st clutch {26 ± 2.5 kg/cm2}
ECMV (Gear speed)
Defective gear speed clutch Output Gear shift 2.38 ± 0.22 MPa
4 pressure of lever position
ECMV 3 (F3) {24.25 ± 2.25 kg/
2nd clutch
(Gear speed) cm2}
ECMV
Output Gear shift 2.43 ± 0.22 MPa
pressure of lever position 5 (F5) {24.75 ± 2.25 kg/
3rd clutch
(Gear speed) cm2}
ECMV
Output Gear shift
2.55 ± 0.25 MPa
pressure of R lever position R1
{26 ± 2.5 kg/cm2}
clutch ECMV (Gear speed)
• You may interchange ECMVs and check whether symptom
disappears or not for judgment.
* Combination of two gear speed clutches determines gear sped.
Check combination of two clutches to be used for selection of gear
speed by referring to Table 1.
• If measured pressure is low in check on cause 4, piston seal ring or
ring groove of gear speed clutch may wear.
5 Defective gear speed clutch
• If measured pressure is normal in check on cause 4, gear speed
clutch may slip.
• If If failure symptom does not disappear after main relief valve is
properly adjusted in check on cause 3, power train pump may be
6 Defective power train pump
defective.
Check line filter for foreign material such as aluminum powder.

40-800 HM400-3M0
 40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

Table 1
Clutches to be used
Hi Lo 1st 2nd 3rd R
R2 q q
R1 q q
N

Gear speed
F1 q q
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q

HM400-3M0 40-801
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-10 Torque converter oil temperature is high (HM400_3-AM0-400-A-Z0-A)

Failure Torque converter oil temperature is high.

• Check that transmission oil level is normal.
• If any failure code is displayed, perform troubleshooting for that failure code first.
Related
• If torque converter oil temperature rises when torque converter is stalled and lowers when
information
gear shift lever returned to NEUTRAL position, machine is normal. Overload operation
causes this failure.
No. Cause Procedure, measuring location, criteria and remarks
Defective power train pump Check strainer for clogging.
1
strainer
Air sucked in on suction side
2 Check suction piping for cracks, looseness, etc.
of power train pump
a Be ready with engine stopped, then perform troubleshooting with
engine running at low idle and rated speed.
2.45 ± 0.20 MPa
Low idle
Defective main relief valve of Main relief {25 ± 2.0 kg/cm2}
3 Engine speed
power train pump pressure 2.56 ± 0.20 MPa
2,000 rpm
{26.1 ± 2.0 kg/cm2}
When pressure cannot be adjusted to normal level, check main relief
valve for malfunction (setting of spring) and internal defect (defective
valve seat).
If failure symptom does not disappear after main relief valve is properly
4 Defective power train pump adjusted in check on cause 3, power train pump may be defective.
Check line filter for foreign material such as aluminum powder.
a Be ready with engine stopped, then perform troubleshooting with
engine running at 2,000 rpm and with foot brake pedal depressed
and released.
Torque 0.86 ± 0.1 MPa
converter inlet Brake OFF
pressure {8.8 ± 1.0 kg/cm2}

Defective torque converter Torque 0.49 ± 0.1 MPa

5 converter outlet Brake OFF
relief valve {5.0 ± 1.0 kg/cm2}
pressure
Torque 0.62 ± 0.1 MPa
converter outlet Brake ON
pressure {6.3 ± 1.0 kg/cm2}
When pressure cannot be adjusted to normal level, check relief valve
for malfunction (setting of spring) and internal defect (defective valve
seat).
Defective torque converter If no failure is found by checks on causes 1 to 5, torque converter may
6
have internal defect.

40-802 HM400-3M0
 40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-11 Torque converter oil pressure is low (HM400_3-AM1-400-A-Z0-A)

Failure Torque converter oil pressure is low.

• Check that transmission oil level is normal.
Related • If any failure code is displayed, perform troubleshooting for that failure code first.
information • Check piping for oil leakage.
No. Cause Procedure, measuring location, criteria and remarks
Defective power train pump Check strainer for clogging.
1
strainer
Air sucked in on suction side
2 Check suction piping for cracks, looseness, etc.
of power train pump
a Be ready with engine stopped, then perform troubleshooting with
engine running at low idle and rated speed.
2.45 ± 0.20 MPa
Low idle
Defective main relief valve of Main relief {25 ± 2.0 kg/cm2}
3 Engine speed
power train pump pressure 2.56 ± 0.20 MPa
2,000 rpm
{26.1 ± 2.0 kg/cm2}
When pressure cannot be adjusted to normal level, check main relief
valve for malfunction (setting of spring) and internal defect (defective
valve seat).
If failure symptom does not disappear after main relief valve is properly
4 Defective power train pump adjusted in check on cause 3, power train pump may be defective.
Check line filter for foreign material such as aluminum powder.
a Be ready with engine stopped, then perform troubleshooting with
engine running at 2,000 rpm and with foot brake pedal depressed
and released.
Torque 0.86 ± 0.1 MPa
converter inlet Brake OFF
pressure {8.8 ± 1.0 kg/cm2}

Defective torque converter Torque 0.49 ± 0.1 MPa

5 converter outlet Brake OFF
relief valve {5.0 ± 1.0 kg/cm2}
pressure
Torque 0.62 ± 0.1 MPa
converter outlet Brake ON
pressure {6.3 ± 1.0 kg/cm2}
When pressure cannot be adjusted to normal level, check relief valve
for malfunction (setting of spring) and internal defect (defective valve
seat).
Defective torque converter If no failure is found by checks on causes 1 to 5, torque converter may
6
have internal defect.

HM400-3M0 40-803
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-12 Front brake does not work sufficiently (HM400_3-FL4-400-A-Z0-A)

Failure Front brake does not work sufficiently.

• Check that transmission oil level is normal.
Related • If any failure code is displayed, perform troubleshooting for that failure code first.
information • Check that inflation pressure is normal.
No. Cause Procedure, measuring location, criteria and remarks
Air sucked in on suction side
1 Check suction piping for cracks, looseness, etc.
of brake control pump
a Be ready with engine stopped, then perform troubleshooting with
engine at full speed.
Defective accumulator charge 11.77(+0.98/0) MPa
2 Charge valve Charge valve cut-in pressure
valve {120(+10/0) kg/cm2}
operating
pressure 20.59 ± 0.98 MPa
Charge valve cut-in pressure
{210 ± 10 kg/cm2}
If brakes went out immediately after engine is stopped, accumulator
Defective front brake may be short of charged gas.
3
accumulator (Reference) Charged gas pressure: 4.4 ± 0.15 MPa {45 ± 1.5 kg/cm2 } at
20 ± 5 °C
a Be ready with engine stopped, then perform troubleshooting with
engine at full speed.
4 Defective front brake valve Brake 4.9 ± 0.49 MPa
actuating Brake pedal: Depressed
pressure {50 ± 5.0 kg/cm2}

a Be ready with engine stopped, then perform troubleshooting with

Defective pressure reducing engine at full speed.
5 Brake
valve of front brake retarder 4.22 ± 0.49 MPa
actuating Retarder lever: Operated
pressure {43 ± 5.0 kg/cm2}
Defective slack adjuster of If brake starts to work with time lag or large depressing effort is required
6 to obtain specified braking force, slack adjuster may be defective.
front brake
• If measured pressure is low in checks on causes 4 and 5, brake
Defective front wheel brake piston seal ring or ring groove may be defective.
7 • If measured pressure is normal in checks on causes 4 and 5, brake
valve
disc may slip

40-804 HM400-3M0
 40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-13 Center brake does not work sufficiently (HM400_3-FL5-400-A-Z0-A)

Failure Center brake does not work sufficiently.

• Check that transmission oil level is normal.
Related • If any failure code is displayed, perform troubleshooting for that failure code first.
information • Check that inflation pressure is normal.
No. Cause Procedure, measuring location, criteria and remarks
Air sucked in on suction side
1 Check suction piping for cracks, looseness, etc.
of brake control pump
a Be ready with engine stopped, then perform troubleshooting with
engine at full speed.
Defective accumulator charge 11.77 (+0.98/0) MPa
2 Charge valve Charge valve cut-in pressure
valve {120 (+10/0) kg/cm2}
operating
pressure 20.59 ± 0.98 MPa
Charge valve cut-in pressure
{210 ± 10 kg/cm2}
If brakes went out immediately after engine is stopped, accumulator
Defective center brake may be short of charged gas.
3
accumulator (Reference) Charged gas pressure: 4.4 ± 0.15 MPa {45 ± 1.5 kg/cm 2 }
at 20 ± 5 °C
a Be ready with engine stopped, then perform troubleshooting with
engine at full speed.
4 Defective center brake valve Brake 4.9 ± 0.49 MPa
actuating Brake pedal: Depressed
pressure {50 ± 5.0 kg/cm2}

a Be ready with engine stopped, then perform troubleshooting with

Defective pressure reducing engine at full speed.
5 Brake
valve of center brake retarder 4.22 ± 0.49 MPa
actuating Retarder lever: Operated
pressure {43 ± 5.0 kg/cm2}
Defective slack adjuster of If brake starts to work with time lag or large depressing effort is required
6 to obtain specified braking force, slack adjuster may be defective.
center brake
• If measured pressure is low in checks on causes 4 and 5, brake
piston seal ring or ring groove may be defective.
7 Defective center wheel brake • If measured pressure is normal in checks on causes 4 and 5, brake
disc may slip

HM400-3M0 40-805
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-14 Steering wheel is heavy to turn (HM400_3-LQ0-400-A-Z0-A)

Failure Steering wheel is heavy to turn.

• Check that oil level in hydraulic tank is normal.
• If any failure code is displayed, perform troubleshooting for that failure code first.
• Steering pressure can be checked with monitoring function. (Monitoring code: 95302)
• Check that play of steering wheel is normal. (Max. 150 mm)
Related • Check that hinge pin, etc. are properly greased.
information • Before starting troubleshooting, adjust tire inflation to proper pressure.
• For the setting procedure of the steering pump swash plate angle by monitor operation,
see Testing and Adjusting, "Special functions of machine monitor", "Adjustment (Steering
Pump Displacement Fixing)".
No. Cause Procedure, measuring location, criteria and remarks
Air sucked in on suction side
1 of steering and work Check suction piping for cracks, looseness, etc.
equipment pump
Defective strainer of steering
2 Check strainer for clogging.
and work equipment pump
a Be ready with engine stopped, then perform troubleshooting with
engine running at full speed.
Defective relief valve of flow Set pump swash
3 amplifier valve Steering relief Steering plate angle to 20.59 ± 0.98 MPa
pressure cylinder: At maximum using
stroke end {210 ± 10 kg/cm2}
monitor panel.
a Be ready with engine stopped, then perform troubleshooting with
engine running at full speed.
4 Defective steering valve Set pump swash
Steering relief Steering plate angle to 20.59 ± 0.98 MPa
pressure cylinder: At maximum using
stroke end {210 ± 10 kg/cm2}
monitor panel.
Malfunction of flow amplifier If measured pressure is normal in check on cause 3, flow amplifier
5 valve spool valve spool may malfunction.
PC valve may malfunction or has internal defect. Check PC valve for
6 Malfunction of PC valve trapped spool or setting of spring.
LS valve may malfunction or has internal defect. Check LS valve for
7 Malfunction of LS valve trapped spool or setting of spring.
a Be ready with engine stopped, then perform troubleshooting with
engine running at full speed.
Set pump swash
Steering relief Steering plate angle to 20.59 ± 0.98 MPa
pressure cylinder: At maximum using
8 Defective steering cylinder {210 ± 10 kg/cm2}
stroke end monitor panel.
If measured relief pressure is low, disconnect hydraulic hose from
steering cylinder head end, and relieve steering cylinder hydraulically at
its stroke end. If oil flows out from cylinder, cylinder piston ring is
defective.
If measured relief pressure is low in check on causes 3 and 4, steering
Defective steering and work and work equipment pump may be defective.
9 equipment pump
Check line filter for foreign material such as aluminum powder.

40-806 HM400-3M0
 40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-15 Steering wheel does not move (HM400_3-L91-400-A-Z0-A)

Failure Steering wheel does not move.

• Check that oil level in hydraulic tank is normal.
• If any failure code is displayed, perform troubleshooting for that failure code first.
• Steering pressure can be checked with monitoring function. (Monitoring code: 95302)
Related • Check that play of steering wheel is normal. (Max. 150 mm)
information • Check that hinge pin, etc. are properly greased.
• For the setting procedure of the steering pump swash plate angle by monitor operation,
see Testing and Adjusting, "Special functions of machine monitor", "Adjustment (Steering
Pump Displacement Fixing)".
No. Cause Procedure, measuring location, criteria and remarks
1 Defective PTO If dump body does not move either, PTO may be defective.
Air sucked in on suction side
2 of steering and work Check suction piping for cracks, looseness, etc.
equipment pump
Defective strainer of steering
3 and work equipment pump Check strainer for clogging.

a Be ready with engine stopped, then perform troubleshooting with

engine running at full speed.
Defective relief valve of flow Set pump swash
4 amplifier valve Steering relief Steering plate angle to 20.59 ± 0.98 MPa
pressure cylinder: At maximum using
stroke end {210 ± 10 kg/cm2}
monitor panel.
a Be ready with engine stopped, then perform troubleshooting with
engine running at full speed.
5 Defective steering valve Set pump swash
Steering relief Steering plate angle to 20.59 ± 0.98 MPa
pressure cylinder: At maximum using
stroke end {210 ± 10 kg/cm2}
monitor panel.
Malfunction of flow amplifier If measured pressure is normal in check on cause 3, flow amplifier
6 valve spool valve spool may malfunction.
a Be ready with engine stopped, then perform troubleshooting with
engine running at full speed.
Set pump swash
Steering relief Steering plate angle to 20.59 ± 0.98 MPa
pressure cylinder: At maximum using
7 Defective steering cylinder {210 ± 10 kg/cm2}
stroke end monitor panel.
If measured relief pressure is low, disconnect hydraulic hose from
steering cylinder head end, and relieve steering cylinder hydraulically
at its stroke end. If oil flows out from cylinder, cylinder piston ring is
defective.
If measured relief pressure is low in checks on causes 4 and 5, steering
Defective steering and work and work equipment pump may be defective.
8 equipment pump
Check line filter for foreign material such as aluminum powder.

HM400-3M0 40-807
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-16 Steering wheel swings (HM400_3-L92-400-A-Z0-A)

Failure Steering wheel swings.

• Check that oil level in hydraulic tank is normal.
• Check that play of steering wheel is appropriate (20 to 50 mm).
• If any failure code is displayed, perform troubleshooting for that failure code first.
Related • Steering pressure can be checked with monitoring function. (Monitoring code: 95302)
information • For the setting procedure of the steering pump swash plate angle by monitor operation,
see Testing and Adjusting, "Special functions of machine monitor", "Adjustment (Steering
Pump Displacement Fixing)".
No. Cause Procedure, measuring location, criteria and remarks
1 Improper oil Check oil for deterioration.
a Be ready with engine stopped, then perform troubleshooting with
engine running at full speed.
Set pump swash
Steering relief Steering plate angle to 20.59 ± 0.98 MPa
pressure cylinder: At maximum using
2 Defective steering cylinder stroke end
{210 ± 10 kg/cm2}
monitor panel.
If measured relief pressure is low, disconnect hydraulic hose from
steering cylinder head end, and relieve steering cylinder hydraulically
at its stroke end. If oil flows out from cylinder, cylinder piston ring is
defective.
Malfunction of steering valve If no failure is found by check on cause 2, steering valve may be
3
defective.

40-808 HM400-3M0
 40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-17 Dump body raise speed or power is slow (HM400_3-D40-400-A-Z0-A)

Failure Dump body raise speed or power is slow.

• Check that oil level in hydraulic tank is normal.
• If any failure code is displayed, perform troubleshooting for that failure code first.
Related • Flow amplifier valve relief pressure (steering pressure) can be checked with monitoring
information function. (Monitoring code: 95302)
• Check that hoist lever moves smoothly.
No. Cause Procedure, measuring location, criteria and remarks
Air sucked in on suction side
1 of work equipment and Check suction piping for cracks, looseness, etc.
steering pump
Defective strainer of work
2 Check strainer for clogging.
equipment and steering pump
a Be ready with engine stopped, then perform troubleshooting with
engine running at full speed.
Defective relief valve of flow Set pump swash
3 amplifier valve Steering relief Steering plate angle to 20.59 ± 0.98 MPa
pressure cylinder: At maximum using {210 ± 10 kg/cm2}
stroke end monitor panel.
If no failure is found by check on cause 3, flow divider valve may
Defective flow divider valve of malfunction.
4 flow amplifier valve
Check whether valve spool is locked inside valve body.
a Be ready with engine stopped, then perform troubleshooting with
engine at 2,000 rpm.
Control Engine at 2,000 3.4 ± 0.49 MPa
Defective self-pressure pressure of rpm {35 ± 5 kg/cm2}
5 reducing valve self-pressure
reducing Hoist lever:
valve Neutral Engine at low idle 2.6 ± 0.49 MPa
(Hoist pilot (Reference) {27 ± 5 kg/cm2}
pressure)
If measured pressure is normal in check on cause 5, flow amplifier EPC
valve may malfunction.
6 Malfunction of hoist EPC valve
Check strainer on inlet side of self-pressure reducing valve for metal
particles.
Defective pilot pump for hoist If measured pressure is normal in check on cause 5, pilot pump in hoist
7 EPC valve circuit may be defective.
EPC valve
a Be ready with engine stopped, then perform troubleshooting with
engine running at full speed (1,800 rpm).
Defective relief valve of hoist Set pump swash
8
valve Hoist relief Hoist cylinder: plate angle to 28.4 ± 0.98 MPa
pressure At stroke end maximum using {290 ± 10 kg/cm2}
monitor panel.
Malfunction of hoist valve If measured pressure is abnormally low in check on cause 8, main
9 main spool spool of hoist valve may malfunction.
PC valve may malfunction or has internal defect. Check PC valve for
10 Malfunction of PC valve trapped spool or setting of spring.
LS valve may malfunction or has internal defect. Check LS valve for
11 Malfunction of LS valve trapped spool or setting of spring.

HM400-3M0 40-809
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

No. Cause Procedure, measuring location, criteria and remarks

12 Defective hoist cylinder
a Be ready with engine stopped, then perform troubleshooting with
engine running at full speed (1,800 rpm).
Set pump swash
Hoist relief Hoist cylinder: plate angle to 28.4 ± 0.98 MPa
pressure At stroke end maximum using {290 ± 10 kg/cm2}
monitor panel.
If measured relief pressure is low, disconnect hydraulic hose at hoist
cylinder head end. If oil flows out from cylinder when cylinder is stalled
at its stroke end, cylinder piston ring is defective.

40-810 HM400-3M0
 40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-18 Dump body does not move (HM400_3-D41-400-A-Z0-A)

Failure Dump body does not move.

• Check that oil level in hydraulic tank is normal.
• If any failure code is displayed, perform troubleshooting for that failure code first.
Related • Flow amplifier valve relief pressure (steering pressure) can be checked with monitoring
information function. (Monitoring code: 95302)
• Check that hoist lever moves smoothly.
No. Cause Procedure, measuring location, criteria and remarks
1 Defective PTO If dump body does not move either, PTO may be defective.
Air sucked in on suction side
2 of work equipment and Check suction piping for cracks, looseness, etc.
steering pump
Defective strainer of work
3 equipment and steering pump Check strainer for clogging.

a Be ready with engine stopped, then perform troubleshooting with

engine running at full speed.
Defective relief valve of flow Set pump swash
4 amplifier valve Steering relief Steering plate angle to 20.59 ± 0.98 MPa
pressure cylinder: At maximum using
stroke end {210 ± 10 kg/cm2}
monitor panel.
a Be ready with engine stopped, then perform troubleshooting with
engine at 2,000 rpm.
Control Engine at 2,000 3.4 ± 0.49 MPa
Defective self-pressure pressure of rpm {35 ± 5 kg/cm2}
5 reducing valve self-pressure
reducing Hoist lever:
valve Neutral Engine at low idle 2.6 ± 0.49 MPa
(Hoist pilot (Reference) {27 ± 5 kg/cm2}
pressure)
If measured pressure is normal in check on cause 5, flow amplifier EPC
6 Malfunction of hoist EPC valve valve may malfunction.
If measured pressure is normal in check on cause 5, pilot pump in hoist
Defective pilot pump for hoist EPC valve circuit may be defective.
7
EPC valve Check strainer on inlet side of self-pressure reducing valve for metal
particles.
a Be ready with engine stopped, then perform troubleshooting with
engine running at full speed (1,800 rpm).
Defective relief valve of hoist Set pump swash
8
valve Hoist Relief Hoist cylinder: plate angle to 28.4 ± 0.98 MPa
Pressure At stroke end maximum using {290 ± 10 kg/cm2}
monitor panel.
Malfunction of hoist valve If measured pressure is abnormally low in check on cause 8, main
9 main spool spool of hoist valve malfunctions.
a Be ready with engine stopped, then perform troubleshooting with
engine running at full speed (1,800 rpm).
Set pump swash
Hoist relief 28.4 ± 0.98 MPa
Hoist cylinder: plate angle to
10 Defective hoist cylinder pressure
At stroke end maximum using {290 ± 10 kg/cm2}
monitor panel.
If measured relief pressure is low, disconnect hydraulic hose at hoist
cylinder head end. If oil flows out from cylinder when cylinder is stalled
at its stroke end, cylinder piston ring is defective.

HM400-3M0 40-811
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-19 Hydraulic drift of dump body is large (HM300_3-D42-400-A-Z0-A)

Failure Hydraulic drift of dump body is large.

Related • If any failure code is displayed, perform troubleshooting for that failure code first.
information
No. Cause Procedure, measuring location, criteria and remarks
When dump body is raised and hydraulic hose is disconnected from
Defective sealing of hoist hoist cylinder head end, if oil does not flow out of cylinder and hoist
1 valve main spool cylinder drifts hydraulically, sealing of spool may be defective. Check
spool for damage, etc.
a Raise dump body, stop engine, and then perform troubleshooting.
2 Defective hoist cylinder When dump body is raised and hydraulic hose is disconnected from
hoist cylinder head end, if oil flows out of cylinder, piston ring of cylinder
is defective.

40-812 HM400-3M0
 40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-20 Radiator fan speed is abnormal (high, low, or stationary) (HM400_3-FTP-400-A-

Z0-A)

Failure Radiator fan speed is abnormal (high, low, or does not rotate).
• When engine is started for first time after hydraulic oil replacement, fan may temporarily
rotates at higher speeds but this is normal.
• If any failure code is displayed, perform troubleshooting for that failure code first.
Related • Fan speed can be checked with monitoring function. (Monitoring code: 10014)
information • Hydraulic oil temperature (steering oil temperature) can be checked with monitoring
function (monitoring code: 32701).
• For the setting procedure of the fan mode by monitor operation, see Testing and
Adjusting, "Special functions of machine monitor", "Adjustment (Fan Mode Fixing)".
No. Cause Procedure, measuring location, criteria and remarks
a Start engine and perform check.
Engine: Low idle 700 to 750 rpm
1 Defective engine speed Engine speed Engine: High idle
2,200 to 2,250 rpm
(P-mode)
If engine speed is not increased to specification, perform
troubleshooting for "S-5 Engine runs rough or is unstable".
a Set engine speed to 2,000 rpm, and perform check.
2 Defective fan speed Hydraulic oil temperature:
Radiator fan Min. 50 °C 1230(+100/–50) rpm
speed
Fan mode: MAX
Defective PTO (fan pump
3 Fan pump drive of PTO may be defective.
drive)
a Be ready with engine stopped, then perform troubleshooting with
Malfunction of radiator fan engine at full speed.
4 motor (relief valve) Fan motor 17.7 ± 0.98 MPa
drive pressure Fan mode MAX
{180 ± 10 kg/cm2}
If pressure does not reach specified value after relief valve is adjusted
5 Defective radiator fan pump in check on cause 4, fan pump may have internal defect.
Check strainer at direction selector valve inlet for metal particles.
a Release remaining pressure from hydraulic tank and piping, and
Malfunction of radiator fan then perform troubleshooting with engine stopped.
6 motor (direction selector • Check for stuck or seized spool in direction selector valve body
valve) (spool should move smoothly).
• Take out direction selector spool from valve body and check it for
defects and dirt.
If no failure is found by checks on causes 1 to 6, radiator fan motor may
7 Defective radiator fan motor
have internal defect.

HM400-3M0 40-813
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-21 Aftercooler fan speed is abnormal (high, low, or stationary) (HM400_3-FTP-

400-A-Z1-A)

Failure Aftercooler fan speed is abnormal (high, low, or stationary).

• When engine is started for first time after hydraulic oil replacement, fan may temporarily
rotates at higher speeds but this is normal.
• If any failure code is displayed, perform troubleshooting for that failure code first.
Related • Aftercooler fan speed can be checked with monitoring function. (Monitoring code: 10015)
information • Hydraulic oil temperature (steering oil temperature) can be checked with monitoring
function (monitoring code: 32701).
• For the setting procedure of the fan mode by monitor operation, see Testing and
Adjusting, "Special functions of machine monitor", "Adjustment (Fan Mode Fixing)".
No. Cause Procedure, measuring location, criteria and remarks
a Start engine and perform check.
Engine: Low idle 700 to 750 rpm
1 Defective engine speed Engine speed Engine: High idle
2,200 to 2,250 rpm
(P-mode)
If engine speed is not increased to specification, perform
troubleshooting for "S-5 Engine runs rough or is unstable".
a Set engine speed to 2,000 rpm, and perform check.
2 Defective fan speed Hydraulic oil temperature:
Aftercooler fan Min. 50 °C 2,325 (-250/+100) rpm
speed
Fan mode: 100 %
Defective PTO (fan pump
3 Fan pump drive of PTO may be defective.
drive)
a Be ready with engine stopped, then perform troubleshooting with
Malfunction of aftercooler fan engine at full speed.
4 motor (relief valve) Fan motor 15.8 ± 0.98 MPa
drive pressure Fan mode MAX
{161 ± 10 kg/cm2}
If pressure does not reach specified value after relief valve is adjusted
Defective aftercooler fan in check on cause 4, fan pump may have internal defect.
5 pump
Check strainer of self-pressure reducing valve inlet for metal particles.
a Release remaining pressure from hydraulic tank and piping, and
Malfunction of aftercooler fan then perform troubleshooting with engine stopped.
6 motor (direction selector • Check for stuck or seized spool in direction selector valve body
valve) (spool should move smoothly).
• Take out direction selector spool from valve body and check it for
defects and dirt.
Defective aftercooler fan If no failure is found by checks on causes 1 to 6, fan motor may have
7
motor internal defect.

40-814 HM400-3M0
 40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-22 Unusual noise is heard from around radiator fan (HM300_3-FTQ-400-A-Z0-A)

Failure Unusual noise is heard from around radiator fan.

Related
information
No. Cause Procedure, measuring location, criteria and remarks
Loosening of fan and fan Check fan and fan motor for rattling due to loose installation or for
1 motor mounting portions foreign mater in their mounting portions.
2 Interference with shroud Check fan for interference with shroud.
If no failure is found by checks on causes 1 and 2, fan motor may have
3 Internal defect of fan motor
internal defect.

HM400-3M0 40-815
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-23 Unusual noise is heard from around aftercooler fan (HM300_3-FTQ-400-A-Z1-A)

Failure Abnormal sound is heard around aftercooler fan.

Related
information
No. Cause Procedure, measuring location, criteria and remarks
Loosening of fan and fan Check fan and fan motor for rattling due to loose installation or for
1 motor mounting portions foreign mater in their mounting portions.
2 Interference with shroud Check fan for interference with shroud.
If no failure is found by checks on causes 1 and 2, fan motor may have
3 Internal defect of fan motor
internal defect.

40-816 HM400-3M0
 40 Troubleshooting
Troubleshooting of engine (S-mode)

Troubleshooting of engine (S-mode) (ALL-3840-001-A-03-A)

Information mentioned in troubleshooting table (S mode) (PC400-5170-010-A-00-A)

(Rev. 2011/04 125T4)

a Troubleshooting Table collectively carries the following information. Carry out troubleshooting work after
fully grasping its contents.
Failure Problem on engine
Related Information related to the detected failure or troubleshooting
information
Probable cause Contents of check and remarks Remedy
1 <Contents of description>
2 Probable causes for
trouble (Each number is • Contents of check to judge • Actions to eliminate probable
3 serial number, not priority probable causes causes of trouble
4 sequence.) • Remarks required for
5 judgment

1. Gauze filter for feed pump

a This figure shows the location of gauze filter (1) for the feed pump explained in this manual.

HM400-3M0 40-817
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-1 When starting switch is turned to START position, engine is not

cranked (PC400-A26-400-A-Z0-A)
Failure When starting switch is turned to START position, engine is not cranked
• See E mode (E-1) for troubleshooting the electrical system.
Related information • If any failure code is displayed, carry out troubleshooting for it first.

No. Cause Detail of work, remarks Remedy

Defective starting circuit wiring •
1 system
Defective starting motor
2 (safety relay section)
3 Broken flywheel ring gear
Cracked EGR cooler
4 (Reference: coolant in exhaust
gas)
When starting switch is turned to START
Diagnose and take
position, starting motor pinion is not pushed
remedies for E-1
out
• Grating noise is heard from starting motor
pinion
(When starting switch is turned to START
position, starting motor pinion is pushed
out)
• Starting motor pinion disengages during
operation
(When starting switch is turned to START
position, starting motor pinion is pushed Diagnose and take
out) remedies for E-1
• Ratting noise is heard and starting motor
does not turn.
(When starting switch is turned to START
position, starting motor pinion is pushed
out)
(Reference: Rattling noise is caused when
starting motor pinion is repeatedly pushed
out and pulled in.)
• If grating noise is heard from starting motor
pinion and the starting motor does not Replace if damaged
crank, visually check the flywheel ring gear.
• Remove EGR cooler inlet and outlet gas
piping and check if coolant containing
antifreeze flows out Replace EGR cooler
and drain water from
a Water can normally be condensed in the engine cylinders
exhaust gas, so make sure the water is
coolant or not.

40-818 HM400-3M0
 40 Troubleshooting
Troubleshooting of engine (S-mode)

S-2 The engine cranks but exhaust smoke does not come out (PC400-A27-400-A-Z0-
A)

Failure The engine cranks but exhaust smoke does not come out
Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
• When fuel tank is inspected, it is found to
1 Insufficient fuel in tank be empty Add fuel
Flush air breather hole
Air breather hole in fuel tank
2 • Air breather hole in fuel tank cap is clogged in fuel tank cap and
cap is clogged
clean surrounding area
• Check used hours of fuel filter. If used
3 Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
may be clogged element

Foreign material in fuel • Rust and water are found when fuel tank is Replace fuel
4
drained
• When air bleeding operation for fuel system Perform air bleeding
is performed, air comes out operation
5 Air in fuel piping system
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
6 (Reference: See Testing and adjusting,
system piping related parts
"Bleeding air from fuel system")
Check leakage from common rail pressure
limiter according to "Measuring fuel delivery,
return and leakage" in "Testing and adjusting".
7 Defective common rail Replace common rail
a Common rail is normal if the leakage from
common rail pressure limiter is Max.10
(CC/min)
a Check "Defective common rail" described
above first.
If the pressure doesn't rise during cranking
8 Defective supply pump when checking common rail pressure on Replace supply pump
machine monitor, the supply pump is
defective.
a Common rail pressure can be checked with
monitoring function. (Code: 36400 (MPa))
• When priming pump is operated, no
9 Defective priming pump Replace priming pump
resistance is felt or it is heavy
Clogging of feed pump gauze • Gauze filter is clogged Clean or replace
10 gauze filter
filter
• Common rail pressure does not go down Loosen injection piping
when when pressure is checked with and high pressure
Improper bleeding of common
11 rail or injection piping monitoring function and then stopped piping mounting nuts
(Code: 36400 Common rail pressure) on common rail and
(pressure will not decrease if air is present) bleed air

HM400-3M0 40-819
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-3 Fuel is injected but engine does not start (incomplete combustion,
engine seems to start but does not) (PC400-A28-400-A-Z0-A)
Fuel is injected but engine does not start (incomplete combustion, engine seems to start
Failure but does not)
Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
• Specific gravity of electrolyte and voltage of Add electrolyte or
1 Defective battery
battery are low charge battery
• When fuel tank is inspected, it is found to
2 Insufficient fuel in tank be empty Add fuel
Flush air breather hole
Air breather hole in fuel tank
3 • Air breather hole in fuel tank cap is clogged in fuel tank cap and
cap is clogged
clean surrounding area
• Check used hours of fuel filter. If used
4 Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
may be clogged element

Foreign material in fuel
5
6 Air in fuel piping system
Leakage from fuel piping
7 (Reference: See Testing and adjusting,
system
8 Defective priming pump
Clogging of feed pump gauze
9 • Gauze filter is clogged
filter
10 Clogged air cleaner element
11 Defective intake air heater
12 Worn valves or rocker arms
13 Defective piston ring
Defective injector
14 (clogged injector, defective
injection)
15 Defective engine controller
• Rust and water are found when fuel tank is Replace fuel
drained
• When air bleeding operation for fuel system Perform air bleeding
is performed, air comes out operation
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Correct or replace fuel
piping related parts
"Bleeding air from fuel system")
• When priming pump is operated, no
Replace priming pump
resistance is felt or it is heavy
Clean or replace
gauze filter
• Air cleaner dust indicator is at a caution Test and adjust air
level cleaner element
• During pre-heating operation, intake air
heater mount is cold
• When engine is preheated or when Replace intake air
temperature is low, preheating monitor heater
does not indicate properly
• Check valve clearance
(Reference: For details, see Testing and
adjusting, "Testing and adjusting valve Replace valve or
clearance") rocker arm
• While engine is running, unusual noise is
heard around cylinder head
• Testing compression pressure
Replace piston ring or
(Reference: See Testing and adjusting,
piston
"Testing compression pressure")
• When a certain cylinder is cut out, engine
speed does not change
Replace Injector
(Note: see "Handling cylinder cutout mode
operation" section of Testing and adjusting)
• Since this is an internal defect, Replace engine
troubleshooting cannot be performed. controller.

40-820 HM400-3M0
 40 Troubleshooting
Troubleshooting of engine (S-mode)

S-4 Engine startability is poor (PC400-A10-400-A-Z0-A)

Failure Engine startability is poor.

• If any failure code is displayed, carry out troubleshooting for it first.
• The common rail fuel injection system (CRI) controls the fuel injection timing
Related information electrically. Accordingly, even if the engine is cranked properly, the engine may not
start until the crankshaft rotates two turns under the most disadvantageous
condition. This phenomenon does not mean a problem, however.
No. Cause Detail of work, remarks Remedy
• Specific gravity of electrolyte and voltage of Add electrolyte or
1 Defective battery
battery are low charge battery
• When fuel tank is inspected, it is found to
2 Insufficient fuel in tank be empty Add fuel
• Non-specified fuel is being used.
• Fuel suitable for ambient temperature is not
used Use proper fuel
Improper fuel used (Reference: When engine starts in warm specified in Operation
3
temperatures but not in low temperatures) and Maintenance
• Wax is found when clear bowl of fuel Manual
prefilter is checked (milky)
Flush air breather hole
Air breather hole in fuel tank
4 • Air breather hole in fuel tank cap is clogged in fuel tank cap and
cap is clogged
clean surrounding area
• Check used hours of fuel filter. If used
5 Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
may be clogged element

Foreign material in fuel
6
7 Air in fuel piping system
Leakage from fuel piping
8 (Reference: See Testing and adjusting,
system
9 Defective common rail
10 Defective supply pump
Clogging of feed pump gauze
11
filter
12 Clogged air cleaner element
13 Defective intake air heater
• Rust and water are found when fuel tank is Replace fuel
drained
• When air bleeding operation for fuel system Perform air bleeding
is performed, air comes out operation
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Correct or replace fuel
piping related parts
"Bleeding air from fuel system")
Check leakage from common rail pressure
limiter according to "Measuring fuel delivery,
return and leakage" in "Testing and adjusting".
Replace common rail
a Common rail is normal if the leakage from
common rail pressure limiter is Max.10
(CC/min)
a Check "Defective common rail" described
above first.
If the pressure doesn't rise during cranking
when checking common rail pressure on Replace supply pump
machine monitor, the supply pump is
defective.
a Common rail pressure can be checked with
monitoring function. (Code: 36400 (MPa))
Clean or replace
• Gauze filter is clogged
gauze filter
• Air cleaner dust indicator is at a caution Check, clean air
level cleaner element
• During pre-heating operation, intake air
heater mount is cold
• When engine is preheated or when Replace intake air
temperature is low, preheating monitor heater
does not indicate properly

HM400-3M0 40-821
40 Troubleshooting
Troubleshooting of engine (S-mode)
No. Cause
Cracks in EGR cooler
14 (Reference: coolant in exhaust
gas)
15 Defective injector
16 Defective engine controller
Defective contact of valve with
17
valve seat
18 Defective piston ring
40-822
Detail of work, remarks Remedy
• Remove EGR cooler inlet and outlet gas
piping and check if coolant containing
antifreeze flows out Replace EGR cooler
and drain water from
a Water can normally be condensed in the engine cylinders
exhaust gas, so make sure the water is
coolant or not.
• When exhaust manifold is touched
immediately after starting engine,
temperature of some cylinders is low
• When a certain cylinder is cut out, engine Replace injector
speed does not change
(Reference: See Testing and adjusting,
"Handling of cylinder cut-out operation".)
• Since this is an internal defect, Replace engine
troubleshooting cannot be performed. controller.
• Measure the compression pressure (see
standard values table)
(Reference: See Testing and adjusting,
"Testing compression pressure") Correct or replace
• Test the valve clearances
valve or valve seat
(Reference: For details, see Testing and
adjusting, "Testing and adjusting valve
clearance")
• Open the exhaust gas color measuring hole
before the KDPF and check the color of the
exhaust gas.
(Reference: See Testing and adjusting,
"Testing exhaust gas color".) Replace piston ring or
• Measure the compression pressure (see piston
standard values table)
(Reference: See Testing and adjusting,
"Testing compression pressure")
• Check piston rings and piston ring grooves
HM400-3M0
 40 Troubleshooting
Troubleshooting of engine (S-mode)

S-5 Engine does not pick up smoothly (HM400_3R-A30-400-A-Z0-A)

Failure Engine does not pick-up smoothly.

Related • If any failure code is displayed, perform troubleshooting for that code first.
information
No. Cause Point to check, remarks Remedy
1 Insufficient fuel in tank • Fuel tank is empty. Add fuel.
Flush air breather hole
Clogged air breather hole in
2 • Air breather hole in fuel tank cap is clogged. in fuel tank cap and
fuel tank cap clean surrounding
area.
• Check used hours of fuel filter. If used
Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
3
may be clogged. element.

Foreign material in fuel
4
5 Air in fuel piping system
Leakage from fuel piping
6 (Reference: See Testing and adjusting,
system
7 Defective common rail
8 Defective supply pump
Clogging of feed pump gauze • Gauze filter is clogged.
9
filter
10 Defective injector
Seizure or damage in
11 turbocharger
• Rust and water are found in fuel drained Replace fuel.
from fuel tank.
• Air is bled during air bleeding of fuel system. Perform air bleeding.
(Reference: See Testing and adjusting, Repair or replace fuel
"Bleeding air from fuel system".) piping.
• Fuel leaks from fuel piping.
Repair or replace fuel
piping related parts.
"Testing fuel circuit for leakage".)
• Check for fuel leakage from common rail
pressure limiter. See Testing and adjusting,
"Testing fuel discharge, return and leakage".
Replace common rail.
a Common rail is normal when leakage from
common rail pressure limiter is max. 10
(CC/min).
a Be sure to check for "Defective common
rail" above first.
• Supply pump is defective if common rail
pressure displayed on machine monitor Replace supply pump.
does not increase during cranking.
a Common rail pressure can be checked with
monitoring function. (Code: 36400 (MPa))
Clean or replace gauze
filter.
• Some cylinder is found to be cool when
exhaust manifolds are touched by hand
immediately after engine is started.
• When engine is run in cylinder cutout mode
Replace injector.
with some cylinder cut out, engine speed
does not change.
(Reference: See Testing and adjusting,
"Handling cylinder cutout mode operation".)
• Unusual noise is heard from turbocharger.
• Check whether turbocharger shaft rotates. Replace turbocharger.
(Move turbocharger vanes with hand in axial
and radial directions to make judgment.)

HM400-3M0 40-823
40 Troubleshooting
Troubleshooting of engine (S-mode)
No. Cause
12 Incorrect valve clearance
13 Defective engine controller
Defective contact between
14
valve and valve seat
15 Defective piston ring
40-824
Point to check, remarks Remedy
• When engine is cranked, unusual noise is
heard from around cylinder head.
• Check valve clearance. Adjusting valve
(Reference: See Testing and adjusting, clearance
"Testing and adjusting valve clearance".)
• Since this is an internal defect, Replace engine
troubleshooting cannot be performed. controller.
• Measure compression pressure (see
Standard value table).
(Reference: See Testing and adjusting, Correct contact
"Testing compression pressure".) between valve and
• Check valve clearance. valve seat or replace
(Reference: See Testing and adjusting, them.
"Testing and adjusting valve clearance".)
• Open exhaust color inspection hole that is
just upstream of KDPF, and check exhaust
gas.
(Reference: See Testing and adjusting,
"Testing exhaust gas color".) Replace piston ring or
• Measure compression pressure (see piston.
Standard value table).
(Reference: See Testing and adjusting,
"Testing compression pressure".)
• Check piston ring and piston ring groove.
HM400-3M0
 40 Troubleshooting
Troubleshooting of engine (S-mode)

S-6 Engine stops during operation (HM400_3R-AF0-400-A-Z0-A)

Failure Engine stops during operation.

Related • If any failure code is displayed, perform troubleshooting for that code first.
information
No. Cause Point to check, remarks Remedy
1 Insufficient fuel in tank • Fuel tank is empty. Add fuel.
Flush air breather hole
Clogged air breather hole in
2 • Air breather hole in fuel tank cap is clogged. in fuel tank cap and
fuel tank cap clean surrounding
area.
• Check used hours of fuel filter. If used
Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
3
may be clogged. element.

Foreign material in fuel
4
5 Air in fuel piping system
Leakage from fuel piping
6 (Reference: See Testing and adjusting,
system
7 Defective priming pump
Clogging of feed pump gauze • Gauze filter is clogged.
8
filter
9 Defective supply pump
Defective air intake hose
10 (from air cleaner to
turbocharger inlet)
11 Defective air intake manifold
Defective boost piping and
connections
12
(from turbocharger outlet to
intake manifold)
Defective exhaust gas piping • Check exhaust gas piping for damage and
13 (from exhaust manifold to
muffler inlet)
Damaged valve or rocker arm
14
Broken or seized piston
15
connecting rod
Broken or seized crankshaft
16 bearing
Defective wiring harness of
17 engine controller power
supply
• Rust and water are found in fuel drained Replace fuel.
from fuel tank.
• Air is bled during air bleeding of fuel system. Perform air bleeding.
(Reference: See Testing and adjusting, Repair or replace fuel
"Bleeding air from fuel system".) piping.
• Fuel leaks from fuel piping.
Repair or replace fuel
piping related parts.
"Testing fuel circuit for leakage".)
• No resistance is felt or large effort is
Replace priming pump.
required when operating priming pump.
Clean or replace gauze
filter.
• See Testing and adjusting, "Testing fuel Replace supply pump
discharge, return and leakage". or pressure limiter.
• Visually check air intake hose for breakage. Replace air intake
hose.
• Check air intake manifold for internal Replace air intake
breakage. manifold.
Correct or replace
• Air leaks from boost piping.
boost piping.
exhaust gas leakage. Replace exhaust gas
(Check soot on heat insulation cover and piping.
heat insulation plate.)
• Check valve and rocker arm.
(Unusual noise is heard and engine stops Replace valve or
suddenly.) rocker arm.
• Metal particles are found in oil drained from
oil pan.
• Remove oil pan and check piston and
Replace piston and
connecting rod.
connecting rod.
(Reference: Unusual noise is heard and
engine stops suddenly, or stops due to
overheat.)
• Metal particles are found in oil drained from
oil pan. Replace crankshaft
• Remove oil pan and check crankshaft main main bearing.
bearing
• Check wiring harness of engine controller
Repair wiring harness
power supply.
of engine controller
(Reference: See Troubleshooting, "Failure
power supply.
code [CA343]".)

HM400-3M0 40-825
40 Troubleshooting
Troubleshooting of engine (S-mode)

No. Cause Point to check, remarks Remedy

Defective starting switch
18 wiring
19 Defective hydraulic system
Perform
• Check starting switch wiring harness. troubleshooting for E-1
and take remedies.
• See H mode "H-6 Machine lacks travel Perform
speed or power during travel in lockup drive troubleshooting for H-6
mode through all gear speeds". and take remedies.

40-826 HM400-3M0
 40 Troubleshooting
Troubleshooting of engine (S-mode)

S-7 Engine runs rough or is unstable (PC400-A40-400-A-Z0-A)

Failure Engine runs rough or is unstable

Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
• When fuel tank is inspected, it is found to
1 Insufficient fuel in tank be empty Add fuel
Flush air breather hole
Air breather hole in fuel tank
2 • Air breather hole in fuel tank cap is clogged in fuel tank cap and
cap is clogged
clean surrounding area
• Check used hours of fuel filter. If used
3 Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
may be clogged element

Foreign material in fuel
4
5 Air in fuel piping system
Leakage from fuel piping
6 (Reference: See Testing and adjusting,
system
7 Leakage in boost system
Clogging of feed pump gauze
8 • Gauze filter is clogged
filter
Defective mass air flow and
9 temperature sensor
• Rust and water are found when fuel tank is Replace fuel
drained
• When air bleeding operation for fuel system Perform air bleeding
is performed, air comes out operation
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Correct or replace fuel
piping related parts
"Bleeding air from fuel system")
• Check for leaks from boost system (KVGT Correct or replace
outlet to aftercooler, aftercooler to air intake parts around boost
manifold) piping
Clean or replace
gauze filter
• Replace sensor and check if problem is
corrected Replace mass air flow
(Failure code may not be issued if the and temperature
sensor is covered with dust.) sensor

HM400-3M0 40-827
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-8 Engine lacks power (HM400_3M0-A60-400-A-Z0-A)

Failure Engine lacks power.

Related • If any failure code is displayed, perform troubleshooting for that code first.
information
No. Cause Point to check, remarks Remedy
1 Insufficient fuel in tank • Fuel tank is empty. Add fuel.
Flush air breather hole in
Clogged air breather
2 • Air breather hole in fuel tank cap is clogged. fuel tank cap and clean
hole in fuel tank cap
surrounding area.
• Check used hours of fuel filter. If used beyond
Clogged fuel filter specified hours, fuel filter element may be Replace fuel filter
3
element clogged. element.

Foreign material in fuel • Rust and water are found in fuel drained from Replace fuel.
4
fuel tank.
• Air is bled during air bleeding of fuel system. Perform air bleeding.
5 Air in fuel piping system (Reference: See Testing and adjusting, Repair or replace fuel
"Bleeding air from fuel system".) piping.
• Fuel leaks from fuel piping.
Leakage from fuel Repair or replace fuel
6 (Reference: See Testing and adjusting, "Testing
piping system piping related parts.
fuel circuit for leakage".)
• See Testing and adjusting, "Testing fuel Replace supply pump or
7 Defective supply pump
discharge, return and leakage". pressure limiter.
Clogging of feed pump Clean or replace gauze
8 • Gauze filter is clogged.
gauze filter filter.
Clogged air cleaner • Air cleaner dust indicator indicates that dust is Check and clean air
9
element at caution level. cleaner element.
• Check air cleaner and rectifying wire net for Correct or replace air
10 Defective air cleaner
deformation. cleaner.
Defective air intake
hose
11 • Visually check air intake hose for breakage. Replace air intake hose.
(from air cleaner to
turbocharger inlet)
Defective air intake • Check air intake manifold for internal breakage. Replace air intake
12
manifold manifold.
Defective boost piping
and connections
Correct or replace boost
13 (from turbocharger • Air leaks from boost piping.
piping.
outlet to intake
manifold)
Defective installation of • Air leaks from mounting part of charge pressure Correct installation of
14 charge pressure sensor charge pressure sensor.
sensor.
Defective exhaust gas • Check exhaust gas piping for damage and
piping exhaust gas leakage. Replace exhaust gas
15 (Check soot on heat insulation cover and heat piping.
(from exhaust manifold
to muffler inlet) insulation plate.)
Gas leakage from EGR
16 • Gas leaks from EGR piping. Replace EGR piping.
piping
Check intake and
exhaust system
(from turbocharger • Measure boost pressure.
Repair or replace
17 outlet to intake (Reference: See Testing and adjusting, "Testing
defective part.
manifold, and from boost pressure".)
exhaust manifold to
muffler inlet)
• Unusual noise is heard from turbocharger.
Seizure or damage in • Check whether turbocharger shaft rotates. Replace turbocharger.
18 turbocharger (Move turbocharger vanes with hand in axial
and radial directions to make judgment.)

40-828 HM400-3M0
 40 Troubleshooting
Troubleshooting of engine (S-mode)

No. Cause Point to check, remarks Remedy

• When engine is cranked, unusual noise is heard
from around cylinder head.
Incorrect valve • Check valve clearance. Adjusting valve
19
clearance (Reference: See Testing and adjusting, "Testing clearance
and adjusting valve clearance".)
• Some cylinder is found to be cool when exhaust
manifolds are touched by hand immediately
after engine is started.
• When engine runs in cylinder cutout mode with
20 Defective injector Replace injector.
some cylinder cut out, engine speed does not
change.
(Reference: See Testing and adjusting,
"Handling cylinder cutout mode operation".)
Defective engine • Since this is an internal defect, troubleshooting Replace engine
21 cannot be performed.
controller controller.
• Measure compression pressure (see Standard
value table).
Defective contact (Reference: See Testing and adjusting, "Testing Correct contact between
22 between valve and compression pressure".) valve and valve seat or
valve seat • Check valve clearance. replace them.
(Reference: See Testing and adjusting, "Testing
and adjusting valve clearance".)
• Check the exhaust gas.
(Reference: See Testing and adjusting, "Testing
exhaust gas color".)
• Measure compression pressure (see Standard Replace piston ring or
23 Defective piston ring value table). piston.
(Reference: See Testing and adjusting, "Testing
compression pressure".)
• Check piston ring and piston ring groove.

HM400-3M0 40-829
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-9 Exhaust smoke is black (HM400_3M0-AH1-400-A-Z0-A)

Failure Exhaust smoke is black.

Related • If any failure code is displayed, perform troubleshooting for that code first.
information
No. Cause Point to check, remarks Remedy
Use proper fuel specified
1 Improper fuel used • Fuel other than specified one is used. in Operation and
Maintenance Manual.
Foreign material in fuel • Rust and water are found in fuel drained from Replace fuel.
2
fuel tank.
• Check air cleaner and rectifying wire net for Correct or replace air
3 Defective air cleaner
deformation. cleaner.
Defective exhaust gas • Check exhaust gas piping for damage and
piping exhaust gas leakage. Replace exhaust gas
4 (Check soot on heat insulation cover and heat piping.
(from exhaust manifold
to muffler inlet) insulation plate.)
Defective installation of • Air leakage from installed position of charge Correct installation of
5 charge (boost) pressure (boost) pressure sensor charge (boost) pressure
sensor sensor.
Defective boost piping
and connections
Correct or replace boost
6 (from turbocharger • Air leaks from boost piping.
piping.
outlet to intake
manifold)
Gas leakage from EGR
7 piping • Gas leaks from EGR piping. Replace EGR piping.
• Unusual noise is heard from turbocharger.
Seizure or damage in • Check whether turbocharger shaft rotates.
8 turbocharger Replace turbocharger.
(Move turbocharger vanes with hand in axial
and radial directions to make judgment.)
• Some cylinder is found to be cool when exhaust
manifolds are touched by hand immediately
after engine is started.
• When engine runs in cylinder cutout mode with
9 Defective injector Replace injector.
some cylinder cut out, engine speed does not
change.
(Reference: See Testing and adjusting,
"Handling cylinder cutout mode operation".)
• Measured fuel return rate is excessive.
Defective fuel return (Reference: See Testing and adjusting, "Testing Correct or replace fuel
10 piping fuel discharge, return and leakage".) return piping.
• Check fuel return piping for clogging.
• When engine is cranked, unusual noise is heard
from around cylinder head.
Incorrect valve • Check valve clearance. Adjusting valve
11
clearance (Reference: See Testing and adjusting, "Testing clearance
and adjusting valve clearance".)

40-830 HM400-3M0
 40 Troubleshooting
Troubleshooting of engine (S-mode)

No. Cause Point to check, remarks Remedy

• Measure compression pressure (see Standard
value table).
Defective contact (Reference: See Testing and adjusting, "Testing Correct contact between
12 between valve and compression pressure".) valve and valve seat or
valve seat • Check valve clearance. replace them.
(Reference: See Testing and adjusting, "Testing
and adjusting valve clearance".)
• Check the exhaust gas.
(Reference: See Testing and adjusting, "Testing
exhaust gas color".)
• Measure compression pressure (see Standard Replace piston ring or
13 Defective piston ring value table). piston.
(Reference: See Testing and adjusting, "Testing
compression pressure".)
• Check piston ring and piston ring groove.

HM400-3M0 40-831
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-10 Engine oil consumption is excessive (HM400_3M0-B10-400-A-Z0-A)

Failure Engine oil consumption is excessive.

Related • If any failure code is displayed, perform troubleshooting for that code first.
information
No. Cause Point to check, remarks Remedy
Dust sucked from air • When intake piping between air cleaner and Clean or replace intake
1 intake system engine is removed, dust is found inside. piping.
• Measured blowby pressure exceeds standard
value.
Broken or worn piston • Measure compression pressure (see Standard Replace piston ring or
2 ring value table). correct its installation.
(Reference: See Testing and adjusting, "Testing
compression pressure".)
Oil leakage outside
3 • Check for oil leakage. Repair oil leaks.
engine
Oil leakage from oil filter • Check oil filter for oil leakage. Reinstall or replace oil
4
filter.
Oil leakage from oil Correct installation of oil
5 • Check oil piping for oil leakage.
piping piping or replace it.
Oil leakage from oil
6 • Check oil drain plug for oil leakage. Retighten oil drain plug.
drain plug
Correct installation of oil
7 Oil leakage from oil pan • Check oil pan for oil leakage.
pan or replace it.
Oil leakage from Correct installation of
8 • Check cylinder head for oil leakage. cylinder head or replace
cylinder head
it.
Worn or damaged rear • Oil in clutch chamber or damper chamber on Correct installation of
9 rear oil seal or replace it.
oil seal machine increases.
• Turbocharger blower inlet and outlet, and
turbine outlet are dirty with oil.
Oil leakage from
10 • Check whether turbocharger shaft rotates. Replace turbocharger.
turbocharger
(Move turbocharger vanes with hand in axial
and radial directions to make judgment.)
• Oil is in coolant.
• Remove oil cooler and check for oil leakage
Oil leakage from oil outside oil cooler. Replace oil cooler.
11
cooler • Check oil cooler for oil leakage by applying air
pressure.
Oil leakage from EGR • When EGR valve is removed, outlet port is
12 Replace EGR valve.
valve stem found to be dirty with oil.
• Check valve guide and stem seal.
Worn or damaged valve • Remove cylinder head, and check inside Replace valve guide and
13 guide or stem seal diameter of guide and stem seal for damage. stem seal.
(Reference: See "Maintenance standards".)

40-832 HM400-3M0
 40 Troubleshooting
Troubleshooting of engine (S-mode)

S-11 Oil becomes contaminated quickly (HM400_3M0-B20-400-A-Z0-A)

Failure Oil becomes contaminated quickly.

Related • If any failure code is displayed, perform troubleshooting for that code first.
information
No. Cause Point to check, remarks Remedy
Use proper fuel specified
1 Improper fuel used • Fuel other than specified one is used. in Operation and
Maintenance Manual.
Use proper oil specified
2 Improper oil used • Oil other than specified one is used. in Operation and
Maintenance Manual.
• Check exhaust gas color (see standard value
table). Perform troubleshooting
Exhaust smoke is
3 (Reference: See Testing and adjusting, "Testing for "S-9 Exhaust smoke
black.
exhaust gas color".) is black".
• Measured blowby pressure exceeds standard Perform following
4 Excessive blowby gas
value. checks.
Defective seal on • Rotate turbocharger shaft and check for play.
5 turbocharger turbine (Move turbocharger vanes with hand in axial Replace turbocharger.
side and radial directions to make judgment.)
• Remove EGR valve and check stem seal,
guide, and stem.
6 Worn EGR valve guide • When EGR valve is removed, outlet port is Replace EGR valve.
found to be dirty with oil.
• Check oil level for excessive refilling.
Refill with oil to correct oil
7 Excessive refilling of oil (If oil level is excessive, oil will reach high
temperatures and early deteriorates.) level.
• Visually check oil cooler element for
contamination. Clean or replace oil
8 Dirty oil cooler element (Contaminated oil cooler element can increased cooler element.
oil temperature.)
• Measured blowby pressure exceeds standard
value.
• Blowby pressure is still high.
Broken or worn piston Replace piston ring or
9 ring • Measure compression pressure (see Standard
value table). correct its installation.
(Reference: See Testing and adjusting, "Testing
compression pressure".)
• Check valve guide and stem seal.
Worn or damaged valve • Remove cylinder head, and check inside Replace valve guide and
10 guide or stem seal diameter of guide and stem seal for damage. stem seal.
(Reference: See "Maintenance standards".)

HM400-3M0 40-833
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-12 Fuel consumption is excessive (HM400_3R-B70-400-A-Z0-A)

Failure Fuel consumption is excessive.

Related • If any failure code is displayed, perform troubleshooting for that code first.
information
No. Cause Point to check, remarks Remedy
Replace injector.
• Measure spill rate from injector.
Excessive spill of fuel from (Reference: See Testing and adjusting, Lots of dusts are is
1 injector "Testing fuel discharge, return and probably in fuel. Check
leakage".) storage management
of fuel.
• Check fuel return piping for clogging.
Correct or replace fuel
2 Clogged fuel return piping (Injection rate may be increased due to
return piping.
clogged fuel return piping.)
• Some cylinder is found to be cool when
exhaust manifolds are touched by hand
immediately after engine is started.
• When engine is run in cylinder cutout mode
3 Defective injector Replace injector.
with some cylinder cut out, engine speed
does not change.
(Reference: See Testing and adjusting,
"Handling cylinder cutout mode operation".)
Fuel leakage from cylinder • Check for increased oil level. Repair defective parts.
4
head • Check for smell of diesel fuel.
• Check for increased engine oil level and
Fuel leakage from feed pump smell of diesel fuel. Replace feed pump oil
5
oil seal • Check feed pump oil seal. seal.
6 Fuel leakage outside engine • Check for fuel leakage outside engine. Repair defective parts.

40-834 HM400-3M0
 40 Troubleshooting
Troubleshooting of engine (S-mode)

S-13 Oil is in coolant (or coolant spurts or coolant level goes down) (PC400-
B40-400-A-Z0-A)

Failure Oil is in coolant (or coolant spurts or coolant level goes down)
Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
Perform
troubleshooting for "S-
1 Milky engine oil • Engine oil level rises and oil is milky
16 Water mixes into
engine oil (milky)".
Damaged oil cooler element Replace oil cooler
2 • Check oil cooler element
element
• Coolant in radiator has excessive air
bubbles and blows back.
3 Damaged cylinder head • Overhaul engine and perform a pressure Replace cylinder head
tightness test on cylinder head to check for
abnormalities
• Coolant in radiator has excessive air
Damaged cylinder head bubbles and blows back. Replace cylinder head
4 gasket • Overhaul engine and check cylinder head gasket
gasket for abnormalities
• Engine oil level rises and oil is milky
Cracks or pitting in cylinder • Disassemble engine and check for cracks Replace cylinder block
5
block or pitting in cylinder block

HM400-3M0 40-835
40 Troubleshooting
Troubleshooting of engine (S-mode)
S-14 Oil pressure drops
Failure Oil pressure drops
• If any failure code is displayed, carry out troubleshooting for it first.
Related information • Confirm if machine has been operated on a slope steeper than specified in the
Operation and Maintenance Manual.
No. Cause
1 Lack of oil in oil pan
Defective oil pressure sensor,
2 wiring harness
3 Fuel in oil
4 Water in oil
5 Clogged oil filter
6 Clogged oil strainer
Crushed or clogged hydraulic
7 •
piping
8 Defective oil pump
Defective regulator valve
9
10 Defective oil pump relief valve
Cracks in oil pump suction
11 piping
Defective seal between oil
12 pump and oil pump suction
piping
13 Defective boost oil pump
Defective boost oil pump relief •
14
valve
Oil leakage from EGR
15 hydraulic piping
16 Worn main journal bearing
17 Worn pin journal bearing
Worn idler bushing, damaged
18 idler gear
Breakage or falling off of
19 piston cooling nozzle
40-836
(PC400-10D-400-A-Z0-A)
Detail of work, remarks Remedy
• Oil level in oil pan is low
• Oil pressure monitor indicates low oil Add oil
pressure when operating on slopes
Replace oil pressure
• Check oil pressure sensor, wiring harness,
sensor, wiring harness,
and connector
or connector
If oil is contaminated
with fuel, carry out
• Perform oil analysis and check for fuel in oil
troubleshooting for "S-
• Engine oil smells of diesel fuel
15 Fuel mixes into
engine oil"
If oil is contaminated
• Perform oil analysis and check for water in with water, carry out
oil troubleshooting for "S-
• Oil is milky 16 Water mixes into
engine oil (milky)"
• Check oil filter
(Reference: Oil filter has been used beyond
the specified period, oil heavily Replace oil filter
deteriorated, etc.)
• Water in oil can cause oil filter blockage
• Check oil strainer Clean oil strainer
Replace hydraulic
Hydraulic piping is crushed or clogged
piping
• Check oil pump
(worn or damaged gear) Replace oil pump
• Oil pump rotation is heavy or it has play
• Check valve spring for fatigue or damage Replace regulator
valve
• Valve and spring of oil pump relief valve is Replace oil pump relief
fatigued, damaged. valve
• Check around oil pump suction piping Replace oil pump
(cracked piping) suction piping
• Check seal Replace seal
Replace boost oil
• Check boost oil pump
pump
Check boost oil pump relief valve for fatigue Replace boost oil
or damage on valve and spring pump relief valve
Replace EGR
• Check EGR hydraulic piping
hydraulic piping
• Check main journal bearing
Replace main journal
• Metallic powders are found in oil drained
bearing
from oil pan
• Check pin journal bearing
Replace pin journal
• Metallic powders are found in oil drained
bearing
from oil pan
Replace idler bushing
• Check idler bushing and idler gear
or idler gear
Replace piston cooling
• Check piston cooling nozzle
nozzle
HM400-3M0
 40 Troubleshooting
Troubleshooting of engine (S-mode)

S-15 Fuel mixes into engine oil (PC400-B31-400-A-Z0-A)

Failure Fuel mixes into engine oil (smells of diluted diesel fuel)
Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
• When exhaust manifold is touched
immediately after starting engine,
temperature of some cylinders is low
1 Defective injector • When a certain cylinder is cut out, engine Replace Injector
speed does not change
(Reference: See Testing and adjusting,
"Handling of cylinder cut-out operation".)
Fuel leakage from injector or
2 • Check injector or O-ring Replace injector O-ring
O-ring (spill circuit)
Defective seal between
• Check seal between injector and injection
3 injector and injection piping, Repair or replace
piping, and check injection piping for cracks
cracks in injection piping
• Confirm that fuel no longer mixes into oil
4 Defects in supply pump Replace supply pump
after supply pump is replaced

HM400-3M0 40-837
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-16 Water mixes into engine oil (milky) (PC400-B32-400-A-Z0-A)

Failure Water mixes into engine oil (milky)

• If oil mixes into the coolant, perform troubleshooting for "S-13 Oil mixes into coolant"
• If any failure code is displayed, carry out troubleshooting for it first.
When engine starting and stopping is frequently repeated in low outside
temperatures, the KCCV may cause condensation of water vapor in the blow-by gas
Related information leading to milky oil or emulsification inside the engine, but this is normal. This is not
a problem if coolant is not leaking.
If coolant leakage is suspected by such as drop of coolant level in a short time, carry
out the following troubleshooting procedures.
No. Cause Detail of work, remarks Remedy
• Coolant containing antifreeze flows out
when EGR cooler outlet gas piping are
removed.
(Make sure the water is coolant or not. It
may be condensate water)
1 Cracks in EGR cooler Replace EGR cooler
(Reference: If cracks are found in the EGR
cooler, this may be caused by low coolant
level in the cooling system. When replacing
the EGR cooler, check for leaks from
coolant system piping and radiator.)
• Check oil cooler element and O-ring
Damaged oil cooler element or Replace oil cooler
2 • Pressure-tightness test of oil cooler shows
O-ring element or O-ring
oil leakage
Leakage from water pump • Check for leaks from water pump Replace water pump
3
mechanical seal mechanical seal mechanical seal
Clogged water pump drain • Check water pump drain hole Clean water pump
4
hole drain hole
Replace cylinder head
Broken cylinder head or • Disassemble engine and check cylinder
5 or cylinder head
cylinder head gasket head and cylinder head gasket
gasket
• Engine oil level rises and oil is milky
Cracks or pitting in cylinder • Disassemble engine and check for cracks Replace cylinder block
6
block or pitting in cylinder block

40-838 HM400-3M0
 40 Troubleshooting
Troubleshooting of engine (S-mode)

S-17 Coolant temperature rises too high (overheating) (HM400_3R-AL0-400-A-Z0-A)

Failure Coolant temperature rises too high (overheating).

Related • If any failure code is displayed, perform troubleshooting for that code first.
information
No. Cause
Clogged radiator core
1 Clean radiator core.
2 Malfunction of thermostat
Defective coolant
3 displayed, but measured value of radiator
temperature gauge
Increased fuel injection rate
4
5 Low coolant level
6 Leakage of coolant
7 Breakage of water pump
Overheating due to increased
EGR ratio (EGR amount
8 against fresh air amount)
caused by air cleaner
deformation
Defective cylinder head or
9 cylinder head gasket
10 Defective piston ring
Point to check, remarks Remedy
• Check radiator core for clogging, and check
fin for crush.
• Thermostat does not open at cracking
temperature.
a Thermostat cracking temperature: 76.5 ± 2° Replace thermostat.
C
(Full open temperature: 90°C)
• Error related to coolant temperature is Replace coolant
temperature sensor,
monitor or wiring
coolant temperature is normal.
harness.
Perform
• Fuel injection rate is high. troubleshooting for "S-
12 Fuel consumption is
excessive".
• Check coolant level for lowering Refill with coolant
• Check water leakage from coolant piping Replace coolant piping
• Visually check water pump
(Check shaft seal for water leakage,
Replace water pump.
impeller for damage, and shaft for
breakage.)
• Check air cleaner and rectifying wire net for Repair or replace air
deformation. cleaner.
• Check radiator coolant for excessive Perform
bubbles and spurt back troubleshooting for "S-
13 Oil is in coolant".
• Check the exhaust gas.
(Reference: See Testing and adjusting,
"Testing exhaust gas color".)
• Measure compression pressure (see Replace piston ring or
Standard value table). piston.
(Reference: See Testing and adjusting,
"Testing compression pressure".)
• Check piston ring and piston ring groove.

HM400-3M0 40-839
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-18 Unusual noise is heard (HM400_3R-BA1-400-A-Z0-A)

Failure Unusual noise is heard.

• Check whether noise source is in or outside engine before starting troubleshooting.
• Engine runs in low-temperature mode while it is not warmed up sufficiently. Accordingly,
engine sound becomes slightly larger. This does not indicate abnormality, however.
Related • When engine accelerates, it switches into acceleration mode and its sound becomes
information slightly large further for up to approximately 3 to 5 seconds. This does not indicate
abnormality, however.
• If any failure code is displayed, perform troubleshooting for that code first.
No. Cause Point to check, remarks Remedy
• Gas leaks from piping between cylinder
head and exhaust manifold, between
exhaust manifold and turbocharger, or Repair or replace
1 Gas leakage from piping
between turbocharger outlet and muffler. defective parts.
• Gas leaks from EGR piping or air intake
piping.
Vibration of exhaust piping or • Visually check for vibration. Check and retighten
2 piping brackets.
exhaust bellows
• Check whether turbocharger shaft rotates.
Seizure or damage in
3 turbocharger (Move turbocharger vanes with hand in axial Replace turbocharger.
and radial directions to make judgment.)
Clean or replace
4 Damage inside muffler • Check inside muffler.
muffler.
• Some cylinder is found to be cool when
exhaust manifolds are touched by hand
immediately after engine is started.
• When engine is run in cylinder cutout mode
5 Defective injector Replace injector.
with some cylinder cut out, engine speed
does not change.
(Reference: See Testing and adjusting,
"Handling cylinder cutout mode operation".)
• Check valve clearance.
6 Incorrect valve clearance (Reference: See Testing and adjusting, Adjusting valve
"Testing and adjusting valve clearance".) clearance
Seized pin bushing, front Repair or replace
7 bearing or main bearing • Check for metal particles in oil pan.
damaged parts.
• If metal particles is found in oil pan or oil
filter, overhaul engine and check piston ring
and cylinder liner.
Worn piston ring or cylinder Replace piston ring or
8 • Measure compression pressure (see
liner cylinder liner.
Standard value table).
(Reference: See Testing and adjusting,
"Testing compression pressure".)
• Overhaul engine and check valves and Replace valve or
9 Damaged valve or rocker arm rocker arm parts. rocker arm.
10 Damaged idler gear • Overhaul engine and check idler gear parts. Replace idler gear.

40-840 HM400-3M0
 40 Troubleshooting
Troubleshooting of engine (S-mode)

S-19 Vibration is excessive (HM300_3-BC0-400-A-Z0-A)

Failure Vibration is excessive.

• If unusual noise is heard and vibration is excessive, perform troubleshooting for "S-18
Related Unusual noise is heard", too.
information • If any failure code is displayed, perform troubleshooting for that code first.
No. Cause Point to check, remarks Remedy
• Visually check engine mounting bolts for
Loose engine mounting bolts Retighten bolts or
1 looseness and cushions for cracks and
or defective cushions replace cushions.
hardening.
• Visually check vibration (viscous) damper Replace engine
2 Damaged vibration damper
for discoloration. damper.
Defective output shaft or • Check output shaft for damage and damper Replace defective
3 internal defect of damper parts.
for internal defect.
Misalignment and facial
runout at connection between • Measure misalignment and facial runout at Replace defective
4 engine and hydraulic pump connection from engine to output shaft. parts.
are out of standard range.
• Some cylinder is found to be cool when
exhaust manifolds are touched by hand
immediately after engine is started.
• When engine is run in cylinder cutout mode
5 Defective injector Replace injector.
with some cylinder cut out, engine speed
does not change.
(Reference: See Testing and adjusting,
"Handling cylinder cutout mode operation".)
Worn main bearing or • If metal particles are found in oil pan or oil Repair or replace
6 connecting rod bearing filter, overhaul engine. damaged parts.
• If metal particles are found in oil pan or oil Repair or replace
7 Stuck valve or rocker arm filter, open cylinder head cover and check damaged parts.
valves and rocker arms.
• If metal particles are found in oil pan or oil
Replace camshaft
8 Worn camshaft bushing filter, overhaul engine and check camshaft
bushings.
bushings.

HM400-3M0 40-841
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-20 Air cannot be bled from fuel circuit (HM400_3R-A29-400-A-Z0-A)

Failure Air cannot be bled from fuel circuit.

Related • If any error code is displayed, carry out troubleshooting for it first.
information
No. Cause Detail of work, remarks Remedy
• When fuel feed pump switch is turned ON,
1 Insufficient fuel in tank pump operating sound is heard. Add fuel
• Check drain valve of fuel prefilter for
Loose drain valve of fuel
2 loosening Close drain valve
prefilter
(Air leaking in due to loose drain valve)
• Check used hours of fuel filter. If used
Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
3
may be clogged element
• When air bleeding operation for fuel system
is performed, air comes out Correct or replace fuel
4 Air in fuel piping system
(Reference: See Testing and adjusting, piping
"Bleeding air from fuel system")
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
5 (Reference: See Testing and adjusting,
system piping related parts
"Checking fuel system for leakage")

40-842 HM400-3M0
SHOP MANUAL

ARTICULATED DUMP TRUCK

HM400-3M0
Model Serial Number

HM400-3M0 5001 and up

50 Disassembly and assembly

7 50 Disassembly and assembly

HM400-3M0 50-1
50 Disassembly and assembly
Table of contents

Table of contents (ALL-0310-002-A-00-A)

50 Disassembly and assembly ........................................................................................................... 50-1
Table of contents ........................................................................................................................ 50-2
Related information on disassembly and assembly ........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-19
Engine and cooling system ........................................................................................................ 50-37
Removal and installation of supply pump assembly............................................................... 50-37
Removal and installation of injector assembly....................................................................... 50-41
Removal and installation of cylinder head assembly.............................................................. 50-48
Removal and installation of radiator assembly ...................................................................... 50-60
Removal and installation of radiator core assembly ............................................................... 50-65
Removal and installation of cooling fan and fan motor assembly for radiator............................ 50-67
Removal and installation of aftercooler assembly .................................................................. 50-69
Removal and installation of cooling fan and fan motor assembly for aftercooler ....................... 50-73
Removal and installation of engine assembly ....................................................................... 50-75
Removal and installation of engine front oil seal .................................................................... 50-84
Removal and installation of engine rear oil seal..................................................................... 50-88
Removal and installation of output shaft assembly ................................................................ 50-94
Disassembly and assembly of output shaft assembly ............................................................ 50-99
Removal and installation of air cleaner assembly ................................................................ 50-102
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly...................... 50-104
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly..................... 50-106
Removal and installation of fire prevention cover on exhaust pipe ........................................ 50-109
Power train............................................................................................................................. 50-113
Removal and installation of transmission and front differential assembly ............................... 50-113
Disconnection and connection of front differential assembly and transmission
assembly ........................................................................................................... 50-125
Disassembly and assembly of front differential assembly..................................................... 50-127
Disassembly and assembly of torque converter assembly ................................................... 50-142
Disassembly and assembly of transmission assembly......................................................... 50-149
Removal and installation of center differential assembly ...................................................... 50-189
Disassembly and assembly of center differential assembly .................................................. 50-193
Removal and installation of rear differential assembly.......................................................... 50-207
Disassembly and assembly of rear differential assembly ..................................................... 50-209
Removal and installation of front final drive and brake assembly........................................... 50-219
Disassembly and assembly of front final drive and brake assembly ...................................... 50-221
Removal and installation of center final drive and brake assembly ........................................ 50-233
Disassembly and assembly of center final drive and brake assembly.................................... 50-235
Removal and installation of rear final drive assembly........................................................... 50-245
Disassembly and assembly of rear final drive assembly....................................................... 50-246
Removal and installation of center axle assembly ............................................................... 50-251
Removal and installation of rear axle assembly................................................................... 50-255
Steering system...................................................................................................................... 50-258
Disassembly and assembly of steering cylinder assembly ................................................... 50-258
Undercarriage and frame......................................................................................................... 50-264
Removal and installation of front suspension cylinder assembly ........................................... 50-264
Removal and installation of rear suspension cylinder assembly............................................ 50-266
Disassembly and assembly of suspension cylinder assembly .............................................. 50-268
Removal and installation of equalizer bar assembly ............................................................ 50-270
Removal and installation of front wheel assembly ............................................................... 50-272
Removal and installation of rear (front side) wheel assembly................................................ 50-276
Removal and installation of rear (back side) wheel assembly ............................................... 50-277
Removal and installation of hitch frame assembly ............................................................... 50-278
Disassembly and assembly of hitch frame assembly ........................................................... 50-285
Hydraulic system .................................................................................................................... 50-290

50-2 HM400-3M0
 50 Disassembly and assembly
Table of contents

Removal and installation of flow amplifier valve assembly.................................................... 50-290

Removal and installation of hoist valve assembly ................................................................ 50-293
Disassembly and assembly of hoist valve assembly............................................................ 50-297
Disassembly and assembly of hoist cylinder assembly ........................................................ 50-301
Body...................................................................................................................................... 50-307
Removal and installation of dump body assembly ............................................................... 50-307
Cab and its attachments .......................................................................................................... 50-310
Removal and installation of operator's cab assembly........................................................... 50-310
Removal and installation of operator's cab glass (adhered glass) ......................................... 50-315
Removal and installation of operator's seat assembly.......................................................... 50-321
Removal and installation of seat belt .................................................................................. 50-323
Electrical system .................................................................................................................... 50-324
Removal and installation of machine monitor assembly ....................................................... 50-324
Removal and installation of engine controller assembly ....................................................... 50-326
Removal and installation of retarder and hoist controller assembly ....................................... 50-328
Removal and installation of transmission controller assembly .............................................. 50-329
Removal and installation of KOMTRAX terminal assembly .................................................. 50-330
Air conditioner unit .................................................................................................................. 50-331
Removal and installation of air conditioner unit assembly..................................................... 50-331
Removal and installation of air conditioner compressor assembly......................................... 50-336
Removal and installation of air conditioner condenser ......................................................... 50-338

HM400-3M0 50-3
50 Disassembly and assembly
Related information on disassembly and assembly
Related information on disassembly and assembly
How to read this manual (ALL-0320-011-A-00-A)
Removal and installation of TTTT assembly
Special tools
• The special tools required for removal and
installation work are described in the list as
symbols such as A1, ..., X1. Part number, part
name, necessity, and quantity are described.
• Mark used in the column of necessity are
explained below.
t: Tools are not substituted, must always be
equipped (used).
q: Tools extremely useful if available or tools
that can be substituted with commercially
available tools.
• For details and the sketches of the special tools,
see "Special tool list" and "Sketches of special
tools."
Removal
• In "Removal" section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
• The general tools required for "Removal" are
listed as [1], [2], ..., without description of part
number, part name, and quantity.
• Marks used in "Removal" section are explained
below.
k: This mark shows safety-related precautions
which must be followed when performing the
work.
a : This mark gives knowledge or precautions
when performing the work.
[*1]: This mark indicates that knowledge or
precautions for the assembly installation work are
given in the "Installation" section.
6 : This mark shows the amount of oil or
coolant to be drained.
4 : This mark shows the weight of the part
or equipment.
Installation
• The work procedure of "Installation" is in the
reversed order to removal unless otherwise
specified.
• For knowledge and precautions required for
"Installation", a [*1] mark is assigned to the
"Removal" work procedure to indicate the work
item of the installation knowledge or precaution.
50-4
(ALL-3851-001-A-00-A)
(Rev.2013.05)
• The general tools required for "Installation" are
listed as [1], [2], ..., without description of part
number, part name, and quantity.
• Marks used in "Installation" section are
explained below.
k: This mark shows safety-related precautions
which must be followed when performing the
work.
a : This mark gives knowledge or precautions
when performing the work.
4 : This mark shows the weight of the part
or equipment.
2 : This mark shows a specific coating
agent to be used.
3 : This mark shows the specified
tightening torque.
5 : This mark shows the amount of oil or
coolant to be added.
• For details of oil or coolant to be
added after installation, see
Specification "Table of fuel, coolant
and lubricants".
Disassembly and assembly of TTTT assembly
Special tools
• The special tools required for disassembly and
assembly work are described in the list as
symbols such as A1, ..., X1. Part number, part
name, necessity, and quantity are described.
• Mark used in the column of necessity are
explained below.
t: Tools are not substituted, must always be
equipped (used).
q: Tools extremely useful if available or tools
that can be substituted with commercially
available tools.
• For details and the sketches of the special tools,
see "Special tool list" and "Sketches of special
tools."
Disassembly
• "Disassembly" describes the work procedure as
well as the precautions, knowledge, and drain
amounts of oil and coolant required for the work.
• The general tools required for "Disassembly" are
listed as [1], [2], ..., without description of part
number, part name, and quantity.
HM400-3M0
 50 Disassembly and assembly
Related information on disassembly and assembly

• Marks used in the section of "Disassembly" are

explained below.
k: This mark shows safety-related precautions
which must be followed when performing the
work.

a : This mark gives knowledge or precautions

when performing the work.

6 : This mark shows the amount of oil or

coolant to be drained.

4 : This mark shows the weight of the part

or equipment.
Assembly
• "Assembly" describes the work procedure as
well as the precautions, knowledge, and drain
amounts of oil and water required for the work.
• The general tools required for "Assembly" are
listed as [1], [2], ..., without description of part
number, part name, and quantity.
• Marks used in the section of "Assembly" are
explained below.
k: This mark shows safety-related precautions
which must be followed when performing the
work.

a : This mark gives knowledge or precautions

when performing the work.

4 : This mark shows the weight of the part

or equipment.
2 : This mark shows a specific coating
agent to be used.
3 : This mark shows the specified
tightening torque.

5 : This mark shows the amount of oil or

coolant to be added.
• For details of oil or coolant to be
added after installation, see
Specification "Table of fuel, coolant
and lubricants".

HM400-3M0 50-5
50 Disassembly and assembly
Related information on disassembly and assembly

Coating materials list (ALL-3540-071-A-00-A)

(Rev.2012.11)

a The coating materials such as adhesives, liquid gasket, and grease used for disassembly and assembly
are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.

Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube cushions, and cork plugs from coming
out.
• Use for plastic (except polyethylene,
20 g Polyethy- polypropylene, tetrafluoroethylene and
LT-1B 790-129-9050 (contained 2 lene vinyl chloride), rubber, metal, and non-
pieces) container metal parts which require immediate
and strong adhesion.
• Features: Resistance to heat and
Polyethy- chemicals
LT-2 790-129–9180 50 g lene • Use to prevent bolts and plugs from
container coming loose and as sealant.
Adhesive:
790-129-9060 1 kg • Use to bond and seal metal, glass and
LT-3 Set of adhesive Can plastics.
Hardener:
and hardener 500 g
Polyethy-
LT-4 790-129-9040 250 g lene • Use to seal plugs for blank holes.
container
• Heat-resistant seal used to repair
Holts MH705 790-129-9120 75 g Tube engines
• Instantaneous adhesive
Polyethy- • Curing time: From 5 sec. to 3 min.
ThreeBond 1735 790-129-9140 50 g lene • Use mainly to bond metals, rubbers,
container plastics, and woods.
• Instantaneous adhesive
2g Polyethy- • Quick-curing type (max. strength is
Aron Alpha 201 790-129-9130 (contained 5 lene obtained after 30 minutes)
pieces) container • Use mainly to bond rubbers, plastics,
and metals.
• General-purpose instantaneous
adhesive with excellent resistance to
Loctite 499 428-99-80070 20 cc Tube heat and impact
• Use on the bushing mounting faces of
axle supports.
Polyethy- • Features: Resistance to heat and
Loctite 648-50 79A-129-9110 50 cc lene chemicals
container • Use to bond high-temperature fit parts.

50-6 HM400-3M0
 50 Disassembly and assembly
Related information on disassembly and assembly

Liquid gasket
Komatsu code Part No. Capacity Container Main features and applications
• Use to seal various threaded parts,
LG-5 Polyethy- pipe joints, and flanges.
790-129-9080 1 kg lene
ThreeBond 1110F • Use to seal taper plugs, elbows, and
container nipples for hydraulic piping.
• Features: Silicon-based heat and cold-
LG-6 resistant sealant.
790-129-9160 250 g Tube • Use to seal flange surface and
ThreeBond 1215 threaded parts.
• Use to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-curing
LG-7 sealant
790-129-9170 150 g Tube • Use to seal flywheel housing, intake
ThreeBond 1207C manifold, oil pan, thermostat housing,
etc.
LG-8 • Features: Silicon-based heat, vibration,
419-15-18131 100 g Tube and shock-resistant sealant.
ThreeBond 1207B • Use to seal transfer case, etc.
• Use for rough surfaces such as the
LG-9 circle gear top seal which is not
790-129-9310 200 g Tube clamped by bolts, gaps in the weld
ThreeBond 1206D which must be caulked, etc.
• Can be coated with paint.
• Use as lubricant or sealant when the
LG-10
790-129-9320 200 g Tube radiator hoses are put on.
ThreeBond 1206E • Can be coated with paint.
• Feature: Can be used together with
LG-11 solid gaskets.
790-129-9330 200 g Tube
ThreeBond 1121 • Use for covers of the transmission case
and steering case etc.
ThreeBond 1211 790-129-9090 100 g Tube • Liquid gasket used to repair engine

Molybdenum disulfide lubricant

Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent galling and seizure of
press-fitted parts, shrinkage-fitted
LM-P 09940-00040 200 g Tube parts, and threaded parts.
• Use to lubricate linkages, bearings, etc.
• Spray type
• Thin molybdenum disulfide films are
made on metal surfaces to prevent the
LM-S 09995-00250 190 g Can metals from galling.
• Use for the drive shaft splines, needle
bearings, various link pins, bolts, etc.

HM400-3M0 50-7
50 Disassembly and assembly
Related information on disassembly and assembly

Seizure prevention compound

Komatsu code Part No. Capacity Container Main features and applications
• Feature: Seizure and galling prevention
compound with metallic super-fine-
LC-G grain, etc.
— — Can
NEVER-SEEZ • Use for the mounting bolt in the high
temperature area of the exhaust
manifold and the turbocharger, etc.

Grease
Komatsu code Part No. Capacity Container Main features and applications
SYG2-400LI-A
G2-LI SYGA-16CNLI • Lithium grease with extreme pressure
G0-LI(*) SYG0-400LI-A Various Various lubrication performance, general
*: For cold districts (*) purpose type.
SYG0-16CNLI (*)
• Use for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows- • Do not use this grease for rolling
disulfide grease type bearings like swing circle bearings,
SYG2-400M-A 400 g x 20 container etc. and spline.
LM-G(G2-M) SYGA-16CNM 16 kg Can • Use this grease for work equipment
pins only when installing them, but
do not use it afterward.
Hyper white SYG2-400T • Higher seizure resistance, heat
grease Bellows-
SYG2-16CNT 400 g type resistance, and waterproof than
G2-T molybdenum disulfide grease
SYG0-400T(*) 16 kg container
G0-T(*) • Not conspicuous on machine since
SYG0-16CNT(*) Can color is white.
*: For cold districts
Biogrease
SYG2-400B
G2-B Bellows-
SYGA-16CNB • Since this grease is biodegradable in
G2-BT(*) 400 g type
SYG2-400BT(*) container short period, it has less impact on
*: For use at high 16 kg microorganisms, animals, and plants.
SYGA-16CNBT Can
temperature and
(*)
under high load
• Feature: Silicon-based grease with
wider operating temperature range and
G2-S superior thermal oxidative stability to
— 200 g Tube prevent deterioration of rubber and
ThreeBond 1855 plastic.
• Use for oil seals of the transmission,
etc.
• Feature: Urea (organic) grease with
heat resistance and long life, inclusion
type.
G2-U-S
427-12-11871 2 kg Can • Use for rubber, bearing and oil seal in
ENS grease
damper.
Caution: Do not mix with lithium
grease.

50-8 HM400-3M0
 50 Disassembly and assembly
Related information on disassembly and assembly

Primer
Komatsu code Part No. Capacity Container Main features and applications
Glass • Use to accelerate hardening of
Loctite 712 428-99-80080 100 ml
container instantaneous adhesive.
SUNSTAR Paint • Use as primer for cab side.
Glass (Effective period: 4 months after
Surface Primer 20 ml
container manufacture)
580 SUPER
417-926-3910
SUNSTAR Glass • Use as primer for glass side.
Glass (Effective period: 4 months after
Primer 580 20 ml

For adhered window glass

container manufacture)
SUPER
• Use as primer for painted cab sheet
SUNSTAR Paint metal surface.
Glass
Surface Primer 22M-54-27230 20 ml (Effective period: 4 months after
container
435-95 manufacture)
• Use as primer for black ceramic-
SUNSTAR coated glass surface and for hard
PRIMER 435-41 22M-54-27240 150 ml Steel can polycarbonate-coated surface.
for glass (Effective period: 4 months after
manufacture)
• Use as primer for sash (alumite
SUNSTAR sash Glass surface treatment).
primer GP-402 22M-54-27250 20 ml (Effective period: 4 months after
container
manufacture)

Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use "S" as adhesive for glass in
For adhered window glass

high temperature months (during

SUNSTAR Polyethy- summer) and "W" in low
Penguin Seal 580 417-926-3910 320 ml lene temperature months (during winter).
SUPER "S" or "W" container (Effective period: 4 months after
manufacture)
• Use as adhesive for glass.
Sika Japan Cartridge (Effective period: 6 months after
20Y-54-39850 310 ml
Sikaflex 256HV manufacture)
SUNSTAR Ecocart • Use as adhesive for glass.
Penguin Super 22M-54-27210 320 ml (special (Effective period: 6 months after
560 container) manufacture)

Caulking material
Komatsu code Part No. Capacity Container Main features and applications
SUNSTAR • Use to seal glass-to-glass joint.
For adhered window glass

Penguin Seal 417-926-3920 330 ml Cartridge (Effective period: 4 months after

No.2505 manufacture)
• Use to seal front window.
SEKISUI Silicone Cartridge (Effective period: 6 months after
20Y-54-55130 333 ml
Sealant 83 manufacture)

• Translucent white seal used for joint

GE TOSHIBA seals between glasses
SILICONES 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after
TOSSEAL381 manufacture)

HM400-3M0 50-9
50 Disassembly and assembly
Related information on disassembly and assembly

Special tools list (HM400_3R-3530-061-A-00-A)

a Tools with part number 79*T-***-**** are not supplied (to be locally manufactured).
a Necessity
t: Tools are not substituted, must always be equipped (used).
q: Tools extremely useful if available or tools that can be substituted with commercially available tool.
a New/Redesign
N: Tools with new part numbers, newly developed for this model.
R: Tools, with advanced part numbers, developed by improving existing tools for other models.
Blank: Tools already available for other models that can be used without any modification.
a Tools marked with Q in the Sketch column have the sketches. (See "Sketches of special tools")

New/Redesign
Necessity

Sketch
Sym- Details of work and

Q'ty
Work Part No. Part name
bol remarks

Removal and 1 795-630-5500 Standard puller t 1

Removal of supply
installation of supply 2 01010-81090 Bolt t 2 pump gear
pump assembly 3 01643-31032 Washer t 2
Removal and
Angle tightening Angle tightening of
installation of cylinder 4 790-331-1110 t 1
wrench cylinder head bolt
head assembly
Removal and
installation of cooling Installation of cooling
fan and fan motor 5 790-101-3501 Puller q 1
fan and removal of nut
assembly for radiator
Removal and A 792-420-1120 Flange t 2 Centering of engine
installation of engine 7 assembly and
assembly 01050-61225 Bolt t 8 transmission assembly
Removal of engine
8 795-931-1100 Seal puller t 1
front oil seal
795T-521-1111 Push tool t 1 Q Removal of engine
Removal and 9 01050-31655 Bolt t 3 front oil seal
installation of engine (sleeveless seal)
front oil seal 01050-31635 Bolt t 3
795T-521-1150 Push tool t 1 Q Removal of engine
10 front oil seal (sleeved
01050-31635 Bolt t 3 seal)

50-10 HM400-3M0
 50 Disassembly and assembly
Related information on disassembly and assembly

New/Redesign
Necessity

Sketch
Sym- Details of work and

Q'ty
Work Part No. Part name
bol remarks

Removal of engine rear

11 795-931-1100 Seal puller t 1
oil seal
Angle tightening Tightening of flywheel
12 790-331-1110 q 1
wrench bolt
795T-421-1260 Push tool t 1 Q Press-fitting of engine
1301050-31640 Bolt t 4 rear seal (sleeveless
Removal and seal)
installation of engine A 01643-31645 Washer t 4
rear oil seal 795T-421-1240 Push tool t 1 Q
14 01050-31645 Bolt t 4
01643-31645 Washer t 4 Engine rear seal
795T-421-1231 Push tool t 1 Q (sleeved seal)
15 02050-31645 Bolt t 4
01643-31645 Washer t 4
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 fit of shaft
1 01580-01613 Nut t 1 bearing
Removal and
installation of output 01643-31645 Washer t 2
shaft assembly Puller (294 kN {30
790-101-2102 t 1
ton})
B 790-101-1102 Hydraulic pump t 1
792-420-1120 Flange t 2 Centering of engine
2 assembly and
01050-61225 Bolt t 8 transmission assembly
Removal and 792-420-1120 Flange t 2
installation of Centering of engine
transmission and 2 assembly and
front differential 01050-61225 Bolt t 8 transmission assembly
assembly
790-501-5200 Unit repair stand t 1
1 790-901-2110 Bracket t 1 For AC110 V and 220 V
792T-413-1110 Plate t 1 Q
Removal and
2 792-103-5110 Wrench t 1 installation of pump
bearing locknut
790-101-3201 Bearing puller t 1 Removal of input shaft
3 turbine side bearing
Disassembly and 790-101-2501 Push-puller t 1
assembly of torque C 790-101-5401 Push tool kit (C) t 1 • Removal of retainer
converter assembly 790-101-5471 • Plate 1 guide bearing
• Removal of housing
790-101-5451 • Plate 1
4 bearing
790-101-5491 • Plate 1 • Installation of
790-101-5421 • Grip 1 retainer guide
01010-51240 • Bolt 1 bearing
790-201-2700 Push tool (C) t 1 Installation of housing
5 bearing
790-201-2770 • Spacer 1
6 792T-413-1120 Push tool t 1 Q

HM400-3M0 50-11
50 Disassembly and assembly
Related information on disassembly and assembly

New/Redesign
Necessity

Sketch
Sym- Details of work and

Q'ty
Work Part No. Part name
bol remarks

790-101-3101 Bearing puller t 1 Removal of 3rd clutch

1 side bearing
790-101-2501 Push-puller t 1
1 792T-375-1100 Plate t 1 Q
2 792T-375-1200 Plate t 1 Q Removal of R clutch
2 3 792T-375-1300 Plate t 1 Q side gear and needle
4 01010-81230 Bolt t 6 bearing assembly
5 01643-31232 Washer t 6
790-201-2800 Push tool (D) t 1 • Installation of
790-201-2880 • Spacer 1 differential clutch
bearing
790-201-2850 • Spacer 1 • Installation of front
3 shaft bearing
Disassembly and
• Installation of
assembly of
D 792T-415-1410 Push tool t 1 Q differential clutch
transmission
bearing outer race
assembly
790-101-5401 Push tool kit (C) t 1 • Installation of
790-101-5481 • Plate 1 bearing outer race
to gear
4 790-101-5421 • Grip 1
• Installation of oil
01010-51240 • Bolt 1 seal to bearing
cage
Installation of
differential clutch ring
5 792T-415-1420 Push tool t 1 Q gear and gear
assembly
Installation of bearing
6 793T-623-1170 Push tool t 1 Q to spacer

50-12 HM400-3M0
 50 Disassembly and assembly
Related information on disassembly and assembly

New/Redesign
Necessity

Sketch
Sym- Details of work and

Q'ty
Work Part No. Part name
bol remarks

• Installation of side
carrier output shaft
bearing (for front
differential)
1 792T-423-1120 Push tool t 1 Q • Installation of input
shaft cage bearing
inner race (for rear
differential)
790-101-5201 Push tool kit (B) t 1 • Installation of case
790-101-5231 • Plate 1 assembly
2 790-101-5331 • Plate 1 • Installation of
790-101-5221 • Grip 1 differential carrier
bearing inner race
01010-51225 • Bolt 1
Installation of cage oil
3 792T-422-1710 Push tool t 1 Q
seal
790-101-5401 Push tool kit (C) t 1 • Installation of pinion
Disassembly and 790-101-5461 • Plate 1 case bearing outer
assembly of front race (outside)
790-101-5521 • Plate 1
differential assembly • Installation of pinion
790-101-5481 • Plate 1 case oil seal and
790-101-5421 • Grip 1 bearing outer race
4
(outside)
• Installation of pinion
H case bearing outer
01010-51240 • Bolt 1
race (inside)
• Installation of pinion
case oil seal
790-201-2800 Push tool (D) t 1 Installation of bevel
pinion bearing inner
race
5
790-201-2840 • Spacer 1 (front differential,
center differential, and
rear differential)
Installation of speed
6 792T-415-1410 Push tool t 1 Q detection gear (for front
differential)
792T-423-1360 Plate t 1 Q
Push tool kit (C) t 1 Installation of cage oil
7 790-101-5021
seal
01010-50816 • Bolt 1
Removal and 792T-423-1140 Push tool t 1 Q
Grip t 1 Installation of cage
installation of center 8 790-101-5421
dust seal
differential assembly 01010-51240 Bolt t 1
Removal and
installation of coupling
19 09003-07280 Nut wrench t 1
holding nut

HM400-3M0 50-13
50 Disassembly and assembly
Related information on disassembly and assembly

New/Redesign
Necessity

Sketch
Sym- Details of work and

Q'ty
Work Part No. Part name
bol remarks

790-501-5200 Unit repair stand t 1 For AC110 V and 220 V

9 790-901-2110 Bracket t 1
792T-423-1310 Plate t 1 Q
Removal of preload
adjustment nut and
adjustment of bearing
10 792-103-0901 Wrench t 1 preload (for center
differential and rear
differential)
• Installation of input
shaft bearing inner
race (for center
differential)
• Installation of
bushing to
differential gear (for
11 792T-423-1320 Push tool t 1 Q center differential)
• Installation of bevel
pinion bearing
(differential side)
Disassembly and (for center
assembly of center H differential and rear
differential assembly differential)
Installation of input
shaft bearing inner
12 792T-423-1110 Push tool t 1 Q race (for center
differential)
790-101-5401 Push tool kit t 1 • Installation of dust
790-101-5451 • Plate 1 seal in transfer
790-101-5481 • Plate 1 case cage (for
center differential)
14 790-101-5421 • Grip 1 • Installation of dust
seal in transfer
01010-51240 • Bolt 1 case cage (for rear
differential)
792T-423-1140 Push tool t 1 Q
Installation of oil seal in
15 790-101-5421 Grip t 1 transfer case cage
01010-51240 Bolt t 1
790-201-2700 Push tool (C) t 1 Installation of bevel
pinion bearing inner
18 race
790-201-2740 • Spacer 1 (for center differential
and rear differential)

50-14 HM400-3M0
 50 Disassembly and assembly
Related information on disassembly and assembly

New/Redesign
Necessity

Sketch
Sym- Details of work and

Q'ty
Work Part No. Part name
bol remarks

790-501-5200 Unit repair stand t 1

9 790-901-2110 Bracket t 1 For AC110 V and 220 V
792T-423-1310 Plate t 1 Q
Removal of preload
adjustment nut and
bearing preload
10 792-103-0901 Wrench t 1 adjustment
(for center differential
and rear differential)
11 792T-423-1320 Push tool t 1 Q
Disassembly and 792T-422-1260 Push tool t 1 Q
assembly of rear H
16 790-101-5421 Grip t 1 Installation of oil seal
differential assembly
01010-51240 Bolt t 1
790-101-5401 Push tool kit t 1
Installation of dust seal
790-101-5481 • Plate 1
17 in transfer case cage
790-101-5421 • Grip 1 (for rear differential)
01010-51240 • Bolt 1
790-201-2700 Push tool (C) t 1 Installation of bevel
pinion bearing inner
18 race
790-201-2740 • Spacer 1 (for center differential
and rear differential)
Holding of front brake
792T-427-1110 Fixture t 3 Q assembly
Holding of center brake
1 792T-427-1210 Fixture t 3 　 Q
assembly
01010-61435 Bolt t 3
01010-62440 Bolt t 3
792T-422-1220 Plate t 1 Q
Installation of oil seal
2 790-101-5421 Grip t 1
(front and center)
01010-51240 Bolt t 1
Disassembly and
assembly of front final Installation of bearing
drive and brake 3 792T-423-1330 Push tool t 1 Q inner race to hub (front,
assembly center, and rear)
J Installation of bearing
Disassembly and
assembly of center 4 792T-422-1240 Push tool t 1 Q inner race to tube
(front, center, and rear)
final drive and brake
assembly 792-520-2110 Installer t 1 • Installation of large
diameter floating
seal (front and
center)
5 • Installation of small
790-434-1620 Installer t 1
diameter floating
seal (front and
center)
Installation of bushing
6 792T-423-1340 Plate t 1 Q (front and center)

HM400-3M0 50-15
50 Disassembly and assembly
Related information on disassembly and assembly

New/Redesign
Necessity

Sketch
Sym- Details of work and

Q'ty
Work Part No. Part name
bol remarks

7
792T-423-1350 Push tool t 1 Q Installation of protector
Disassembly and t 1 Installation of sleeve
790-201-2100 Push tool kit
assembly of rear final J 8
drive assembly 790-201-2480 • Plate 1 Installation of oil seal
10 792T-423-1330 Push tool t 1 Q Installation of bearing
Front
suspen-
791-863-1110 Push tool t 1 sion
Disassembly and cylinder
assembly of Rear Installation
suspension cylinder P suspen- of dust
792-201-3141 Push tool t 1 sion seal
assembly
cylinder
790-101-5221 Grip t 1
01010-51225 Bolt t 1
792T-446-1120 Push tool t 1 Q
790-101-2310 Block t 2
790-101-2390 Leg t 2
790-101-2750 Adapter (18 mm) t 2
Press fit of hitch frame
2 790-101-2360 Plate t 2 bearing
Removal and 02215-11622 Nut t 2
installation of hitch Q Puller (300 kN {30
frame assembly 790-101-2102 t 1
ton})
790-101-1102 Pump t 1
792T-446-1130 Plate t 1 Q
792T-446-1140 Plate t 1 Q Press fit of rear retainer
6 and rear frame dust
790-110-5421 Grip t 1 seal
01010-51240 Bolt t 1
1 792T-446-1110 Push tool t 1 Q Press fit of hitch frame
3 792T-446-1150 Push tool t 1 Q bearing
792T-446-1150 Push tool t 1 Q
790-101-5401 • Plate 1
Disassembly and 4 790-101-5431 • Plate 1 Press fit of dust seal
assembly of hitch Q 790-101-5421 • Grip 1
frame assembly 01010-51240 • Bolt 1
790-101-5201 Push tool kit t 1
790-101-5311 • Plate 1 Press fit of lower hinge
5 pin dust seal
790-101-5221 • Grip 1
01010-51225 • Bolt 1

50-16 HM400-3M0
 50 Disassembly and assembly
Related information on disassembly and assembly

New/Redesign
Necessity

Sketch
Sym- Details of work and

Q'ty
Work Part No. Part name
bol remarks

790-502-1003 Cylinder repair stand t 1 Disassembly and

1 assembly of hydraulic
790-101-1102 Hydraulic pump t 1 cylinder
Removal and
2 790-102-3802 Wrench assembly t 1 installation of cylinder
head
790-102-4300 Wrench assembly t 1 Removal and
3 installation of piston
790-102-4310 Pin t 2
790-720-1000 Expander t 1
For steering cylinder
4 796-720-1670 Ring t 1 and hoist cylinder
07281-01279 Clamp t 1
Disassembly and
assembly of steering Push tool (outer
U
cylinder assembly diameter: 135mm
792T-461-1110 inner diameter: t 1 Q
5 130mm length: For steering cylinder
35mm)
790-101-5021 Grip t 1
01010-50816 Bolt t 1
Plate (outside
diameter of dust seal
790-201-1970 t 1
press fitting portion:
6 146mm) For steering cylinder
790-101-5021 Grip t 1
01010-50816 Bolt t 1

HM400-3M0 50-17
50 Disassembly and assembly
Related information on disassembly and assembly

New/Redesign
Necessity

Sketch
Sym- Details of work and

Q'ty
Work Part No. Part name
bol remarks

790-502-1003 Cylinder repair stand t 1 Disassembly and

1 assembly of hydraulic
790-101-1102 Hydraulic pump t 1 cylinder
Removal and
2 790-102-3802 Wrench assembly t 1 installation of cylinder
head
790-102-4300 Wrench assembly t 1 Removal and
3 installation of piston
790-102-4310 Pin t 2
790-720-1000 Expander t 1 • For steering
Disassembly and
796-720-1670 Ring t 1 cylinder and hoist
assembly of hoist U
cylinder assembly 4 07281-01279 Clamp t 1 cylinder
796-720-1680 Ring t 1 • For No. 1 hoist
Clamp t cylinder
07281-01289 1
792T-461-1120 Push tool t 1 Q
7 790-101-5021 Grip t 1 For hoist cylinder
01010-50816 Bolt t 1
792T-461-1130 Plate t 1 Q
8 790-101-5021 Grip t 1 For hoist cylinder
01010-50816 Bolt t 1
Removal and 2 793-498-1210 Lifter (suction cup) t 2
installation of
Removal of operator's
operator's cab glass X
3 20Y-54-13180 Stopper rubber t 2 cab glass
(adhered window
glass)

50-18 HM400-3M0
 50 Disassembly and assembly
Related information on disassembly and assembly

Sketches of special tools (HM400_3R-3531-066-A-00-A)

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.

A9 Push tool

A10 Push tool

HM400-3M0 50-19
50 Disassembly and assembly
Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.

A13: Push tool

A14 Push tool

50-20 HM400-3M0
 50 Disassembly and assembly
Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.

A15 Push tool

C1: Plate

HM400-3M0 50-21
50 Disassembly and assembly
Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.

C6 Push tool

D2–1 Plate

50-22 HM400-3M0
 50 Disassembly and assembly
Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.

D2–2 Plate

D2–3 Plate

HM400-3M0 50-23
50 Disassembly and assembly
Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.

D3 and H6 Push tools

D5: Push tool

50-24 HM400-3M0
 50 Disassembly and assembly
Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.

D6 Push tool

H1: Push tool

HM400-3M0 50-25
50 Disassembly and assembly
Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.

H3 Push tool

H7 Plate

50-26 HM400-3M0
 50 Disassembly and assembly
Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.

H8 and H15 Push tools

H9 Plate

HM400-3M0 50-27
50 Disassembly and assembly
Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.

H11 Push tool

H12 Push tool

50-28 HM400-3M0
 50 Disassembly and assembly
Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.

H16 Push tool

J1: Fixture

HM400-3M0 50-29
50 Disassembly and assembly
Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.

J1: Fixture

J2 Plate

50-30 HM400-3M0
 50 Disassembly and assembly
Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.

J3 and J10 Push tools

J4 Push tool

HM400-3M0 50-31
50 Disassembly and assembly
Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.

J6 Plate

J7: Push tool

50-32 HM400-3M0
 50 Disassembly and assembly
Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.

Q1 Push tool

Q2 Push tool

HM400-3M0 50-33
50 Disassembly and assembly
Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.

Q3 and Q4 Push tools

Q6 Plate

50-34 HM400-3M0
 50 Disassembly and assembly
Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.

Q6 Plate

U5 Push tool

HM400-3M0 50-35
50 Disassembly and assembly
Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.

U7 Push tool

U8 Plate

50-36 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

Engine and cooling system (ALL-R401-001-K-00-A)

Removal and installation of supply pump assembly (HM400_3R-AD70-924-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

1 795-630-5500 Puller t 1
A 2 01010-81090 Bolt t 2
3 01643-31032 Washer t 2

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)

a Ask a qualified person for collecting, adding and

filling operations of the refrigerant (air 2. Collect the refrigerant (air conditioner gas:
conditioner gas: R134a). R134a) from the air conditioner circuit.
a Never release the refrigerant (air conditioner 3. Remove air conditioner compressor assembly
gas: R134a) to the atmosphere. (2a). For details, see "Removal and installation
of air conditioner compressor assembly". [*1]
k If refrigerant gas (air conditioner gas: R134a)
a When removing the air conditioner
gets in your eyes, you may lose your sight.
compressor assembly, the mounting bolt
And if it touches your skin, you may suffer
interferes with the refrigerant piping.
from frostbite. Put on protective eyeglasses,
Therefore, disconnect the refrigerant piping.
gloves and working clothes with long
sleeves while collecting the refrigerant or
filling the air conditioner circuit with the
refrigerant.

Removal (HM400_3M0-AD70-520-K-00-A)

1. Open engine hood (1).

a Be sure to lock it with lock (2).

4. Remove cover (3) of the front of the engine.

5. Rotate the crankshaft in the positive direction
(clockwise viewing from damper (4)), and align
center position (a) between marks 2/5TOP and
3/4TOP of damper (4) with pointer (5).

HM400-3M0 50-37
50 Disassembly and assembly
Engine and cooling system

a Check that the hole of forcing tap of drive 12.Disconnect tube (18) between the fuel feed
gear is matched with the hole (b) of cover (3) pump and supply pump.
mounting bolt. (if it is not matched, turn
crankshaft 1 turn in the same direction.)
a As described above, the pump shaft key is
located at a position 15 deg. clockwise from
the top.
6. Remove mounting nut (6). [*2]
a Take care not to drop the parts into the gear
case.

13.Remove blowby tube (19).

14.Cut harness clips (20) (2 pieces).
15.Remove clamp (21) and disconnect tube (22).
16.Disconnect fuel hose (23).

17.Disconnect harnesses G (24), PCV2 (25), and

PCV1 (26).
18.Remove oil tube (28).
19.Remove clamps (29), (30), and (31). [*3]
7. Remove U-clamp (8) and mounting bolts (9) (3
pieces), and remove oil filler pipe (10).
8. Remove clamp (11), and remove oil level gauge
(12).
9. Remove clamp (13), and remove tube (14).

20.Remove fuel spray prevention caps (32) (4

pieces), and remove fuel high-pressure pipes
(33) and (34). [*4]

10.Remove joint bolts (15) and (16), and

disconnect the fuel hose.
11.Remove fuel filter (17) together with the bracket.

50-38 HM400-3M0

21.Remove clamps (35) (3 pieces), and remove oil
tube (36), (38) and fuel piping (37). [*5]
22.Remove joint bolt (39), and disconnect the fuel
piping.
23.Remove brackets (40) and (41). [*6]
24.Remove mounting bolts (42) (4 pieces).
a To prevent supply pump assembly (43) from
falling off, screw in mounting bolt (42) by 2 or
3 threads.
25.Set tools A1, A2, and A3 according to the
following, screw in the center bolt of tool A1, and
remove gear (44) from the shaft.
26.Remove mounting bolts (42) remaining as
described above, and remove supply pump
assembly (43). [*7]
a If tool A1 is removed, gear (44) falls off. Keep
the tool mounted until supply pump assembly
(43) is installed.
HM400-3M0
50 Disassembly and assembly
Engine and cooling system
Installation (HM400_3R-AD70-720-K-00-A)
• Perform installation in the reverse order to
removal.
1. Check of connections of fuel high-pressure
piping
a Check that the inside of the injector sleeve is
free from dirt.
k Do not bend the fuel high-pressure pipe
to correct before installing.
k Check the following items before
installing the fuel high-pressure pipe. If
the fuel high-pressure pipe has any defect,
replace it with a new one since fuel may
leak.
• Make sure with visual check that the taper
seal part of the connection ((a) part: 2mm
area from the tip-end) is free from
longitudinal slits (b) or pits (c).
• Make sure that end (d) (2mm from the tip
end) is free from steps you can feel by your
fingernail. (Namely, this portion must be free
from fatigue.)
2. Check for fuel leakage
a Check installed supply pump (1) for fuel
leakage according to the following
procedure.
50-39
50 Disassembly and assembly
Engine and cooling system

a Clean the engine and the parts around it and [*2]

degrease them in advance so that you can
3 Mounting nut (6):
check it easily for fuel leakage.
176 to 196 Nm {18 to 20 kgm}
1) Spray color checker (developer) on the
connection of the supply pump and fuel high- [*3], [*4], [*5], [*6], [*7]
pressure pipe. 1. Install the following parts and finger-tighten the
2) Start the engine, keep its speed at 1,000 rpm mounting bolts.
or below, and stop it when its speed is • Supply pump assembly (43)
stabilized. • Fuel high-pressure pipes (33) and (34)
3) Check the supply pump and fuel high- • Bracket (41)
pressure pipe for fuel leakage. 2. Tighten fuel high-pressure pipes (33) and (34) to
a Check the fuel high-pressure circuit for the specified torque.
fuel leakage focusing on the area where 3 Sleeve nut on common rail side:
the color checker is sprayed.
39.2 to 44.1 Nm {4.0 to 4.5 kgm}
a If any fuel leakage is detected, repair it
3 Sleeve nut on supply pump side
and perform the checks from Step 1)
again. 39.2 to 44.1 Nm {4.0 to 4.5 kgm}
4) Start the engine and keep it running at low 3. Tighten supply pump mounting bolts (42) to the
idle. specified torque.
5) Check the supply pump and fuel high- 2 Mounting bolt (42):
pressure pipe for fuel leakage.
Liquid adhesive (LT-2)
a Check the fuel high-pressure circuit for 4. Install bracket (41) to the specified torque.
fuel leakage focusing on the area where 5. Finger-tighten the mounting bolts of fuel high-
the color checker is sprayed. pressure pipe clamps (29), (30), and (31).
6. Tighten the mounting bolts of fuel high-pressure
a If any fuel leakage is detected, repair it
pipe clamps (29), (30), and (31) to the specified
and perform the checks from Step 1)
torque.
again.
6) Start the engine and keep it running at high 3 Mounting bolt of fuel high-pressure
idle. pipe clamps (29), (30), and (31):
7) Check the supply pump and fuel high- 9.8 ± 1 Nm {1 ± 0.1 kgm}
pressure pipe for fuel leakage.
a Tighten the mounting bolts in order of (31),
a Check the fuel high-pressure circuit for (30), and (29).
fuel leakage focusing on the area where
• Filling of refrigerant (R134a)
the color checker is sprayed.
Refill the air conditioner circuit with
a If any fuel leakage is detected, repair it refrigerant (air conditioner gas: R134a).
and perform the checks from Step 1) Refill amount: 875 ± 25 g
again. • Refilling with air conditioner compressor oil
8) Start the engine and keep it running at high See Air conditioner, "Handling of compressor
idle, then perform the torque converter stall. oil".
9) Check the supply pump and fuel high-
pressure pipe for fuel leakage.
a Check the fuel high-pressure circuit for
fuel leakage focusing on the area where
the color checker is sprayed.
a If any fuel leakage is detected, repair it
and perform the checks from Step 1)
again.
a If no fuel leakage is detected, check is
completed.
[*1]
a Install air conditioner compressor assembly (2a).
For details, see"Removal and installation of air
conditioner compressor assembly".

50-40 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

Removal and installation of injector assembly (HM400-AE60-924-K-00-A)

k In order to prevent serious or death k Do not give a large impact to the machine
accidents due to falling of the cab, following when tilting up the cab.
precautions must be observed when tilting
the cab. k When lowering the cab by using the cab
power tilt (optional), do it gradually adjusting
• Precautions before starting cab-tilting operation the descending speed without decreasing
the oil pressure at a breath.
k Cab-tilting operation must be performed on a
flat ground.
k The lock bar is equipped in the inner left side
corner of the engine hood. Be sure to return
k Set the machine to the straight-travel
the bar to the original place after using it.
condition to prevent the interference
between the cab and body, then fix the front
k Set the lock bar to the front and rear frames
and rear frames by using the articulation
to lock them.
lock.
k Turn the battery disconnect switch to the
k Place the machine on a level ground, set the
OFF position and remove the key.
parking brake switch to ON position by
pressing "P", and apply the parking brake. k If you drain the coolant when it is still hot,
you may be scalded. Wait until the coolant
k Operate the dump lever lock knob to lock the
temperature drops before starting the work.
dump lever.
a When removing and installing the fuel piping,
k Chock the wheels to prevent the machine take extreme care not to allow foreign matters to
from moving. enter the fuel piping. If dust, etc. sticks to any
part, wash that part thoroughly with clean fuel.
k When dismounting the cab, always lock the
lock pin at the rear mounting part of cab a Note the connector numbers and installed
before starting the work. positions before disconnecting wiring harnesses
and hoses.
k Do not perform the cab-tilting operation Removal (HM400_3M0-AE60-520-K-00-A)
when it is strongly windy.
1. Open engine hood (1).
• Precautions for cab-tilting operation
k Do not perform the cab-tilting operation
when the dump body is loaded.

k Do not place yourself under the cab as long

as the cab-tilting operation is continued.

k Fix the cab securely by using the lock bar

before tilting up the cab.

k Installthe lock bar from the side of the cab

without entering into a space below the cab.

k Do not go in or out the cab when tilting up

k Check that lock (2) is set securely.
the cab.

k Do not operate the gear shift lever and dump

lever when tilting up the cab.

k Do not start the engine when tilting up the

cab.

k When you are forced to start the engine for

inspection purpose, check that no person is
under the cab.

HM400-3M0 50-41
50 Disassembly and assembly
Engine and cooling system

4. Tilt up operator's cab assembly (6). For details,

see Testing and adjusting, "Cab tilt up
procedure".
a Check that lock lever (7) is in CLOSE
position and operator's cab assembly (6) is
securely fixed with lock bar (8).

2. Remove cover (3), open drain plug (4), and drain

coolant.

6 Radiator (coolant): 114 l

5. Disconnect hoses (9), (10), and (11) from the

fuel prefilter.

3. Remove cover (5).

6. Loosen clamp (12), and disconnect hose (13).

50-42 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

7. Remove clamps (14) and (15).

12.Tube between exhaust manifold and EGR

8. Remove clamps (16) (2 pieces), and disconnect (Exhaust Gas Recirculation) cooler
connector T01 (17). 1) Remove fuel tubes (20) (2 pieces).
2) Remove fuel filter head assembly (21).

9. Sling engine hood support (19).

10.Remove mounting bolts (18) (4 pieces each) on 13.Oil filter head assembly
the right and left sides of engine hood support 1) Remove oil filter head tubes (22) (2 pieces).
(19). 2) Remove oil filter head assembly (23).
11.Sling engine hood support (19), and remove it.
a Remove engine hood support (19) together
with the radiator reservoir tank and fuel
prefilter.

4 Engine hood support (19): 80 kg

HM400-3M0 50-43
50 Disassembly and assembly
Engine and cooling system

14.Remove priming pump (24). 18.Fuel high-pressure pipe

Remove common rail bracket (28), related
clamp (29), and fuel high-pressure pipes (30) (6
pieces). [*1]

15.Remove priming pump bracket (25).

19.Cylinder head cover

Remove the mounting bolts of each cylinder
head cover (31), and remove the covers. [*2]

16.Remove oil filter bracket (26).

20.Rocker arm and shaft assembly

1) Remove the mounting bolts (3 pieces) to
remove rocker arm and shaft assembly (32).
[*3]
a When installing rocker arm, loosen
locknut (33) and loosen adjustment screw
(34) 2 to 3 turns so that an excessive
force is not applied to push rod (35).
17.Remove air intake connector (27).

50-44 HM400-3M0

21.Fuel injector [*4]
1) Remove nuts (37) (2 pieces) of solenoid
valve on fuel injector (36).
a Loosen nuts (37) alternately.
2) Pull out spring clamp (38).
3) Remove bolt of clamp (39).
4) Loosen the bolt of holder (44) of fuel injector
(43).
5) Insert L-shaped small bar [1] under
connector (46) of fuel injector (45), and pull
out fuel injector (45) slowly by using the bar
as a leverage.
a Prior to insertion, move the high-pressure
pipe to the outside to prevent interference
between the injector and the taper seal
part of the high-pressure pipe.
HM400-3M0
50 Disassembly and assembly
Engine and cooling system
a When pulling out the fuel injector (45), do
not try to nip at the solenoid valve at the
top of the fuel injector with pliers and
such.
Installation (HM400_3R-AE60-720-K-00-A)
• Perform installation in the reverse order to
removal.
[*1]
1. Before installing the fuel high-pressure pipe,
check it for the following.
The fuel high-pressure pipe having any defect
can cause fuel leakage. Accordingly, replace the
fuel high-pressure pipe with a new one.
• Make sure with visual check that the taper
seal part of the connection ((a) part: 2 mm
area from the tip-end) is free from
longitudinal slits (b) or pits (c).
• Make sure that part (d) (end of taper seal: 2
mm from the tip-end) is free from steps you
can feel by your fingernail. (Namely, this
portion must be free from fatigue.)
2. Finger-tighten sleeve nuts (1) and (2)
approximately 2 turns, and then tighten the
threaded portion of the fuel injector by using a
wrench.
a If it is difficult to fit the the sleeve nut to
threaded portion, use the regular wrench to
rotate the threaded portion while pressing the
sleeve nut edge by using another wrench,
etc.
50-45
50 Disassembly and assembly
Engine and cooling system

a Tighten the sleeve nut by using wrench-type

torque wrench [1].
3 Sleeve nut for fuel high-pressure pipe:
39.2 to 49 Nm {4 to 5 kgm}

[*3]
1. Install rocker arm and shaft assembly (10), and
tighten mounting bolts (11), (12), and (13).
a Note that mounting bolts (11), (12), and (13)
3. Lightly fasten clamps (3), (4), (5), and (6) by have different stem lengths.
hand, check that each part is installed smoothly Mounting bolt (11): 120 mm
as intended, and then fasten the clamps to the Mounting bolt (12): 90 mm
specified torque.
Mounting bolt (13): 75.2 mm
a Install clamps (3), (4) and (5) after the intake
a Check that the ball of the adjustment screw is
manifold has been installed.
set in the push rod socket securely.
3 Clamp mounting bolt:
3 Rocker arm mounting bolt:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
93 to 103 Nm {9.5 to 10.5 kgm}

[*2] 2. Adjust the valve clearance according to the

Install cylinder head cover (9) with O-ring attached. following procedure.

a Tighten the bolt in the front side of the intake a As the valve clearance, adjust the clearance
manifold lightly since it is tightened together with between the crosshead and rocker arm to
the wiring harness clamp. the following valve.

3 Cylinder head cover: a Valve clearance (cold)

29.4 to 34.3 Nm {3.0 to 3.5 kgm} Intake valve: 0.35 ± 0.02 mm
Exhaust valve: 0.57 ± 0.02 mm
a Adjust the valve clearance of each cylinder
by cranking the engine in the firing order of 1,
5, 3, 6, 2, and 4.
1) Rotate the crankshaft in the positive direction
and align "1.6TOP" stamp line (e) of vibration
damper (14) with pointer (15) while checking
the movement of the valve.

50-46 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

a Lightly tighten sleeve nut on the common

rail side as well and take care not to tilt
the fuel high-pressure pipe.
5) Tighten holder (21) to the specified torque.
a While pulling the high-pressure fuel pipe
in the opposite direction of the fuel
injector, tighten bolt (22).
3 Holder mounting bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
a After tightening the holder, remove the
fuel high-pressure pipe, and install the
2) Insert feeler gauge [1] between rocker arm fuel injectors sequentially as described
(16) and crosshead (17) and adjust previously.
adjustment screw (18) to a degree that the
feeler gauge moves lightly.
3) Tighten locknut (19) at this position to fix
adjustment screw (18).
3 Adjustment screw lock nut:
53 to 64.7 Nm {5.4 to 6.6 kgm}
a After tightening the locknut, check the
valve clearance again.

[*4]
1. Install fuel injector assembly according to the
following procedure.
a Check that there is no dirt inside the injector • Refilling with coolant
sleeve. Refill with coolant to the specified level
1) Install O-ring and gasket to the fuel injector. through the coolant filler port of the radiator.
2) Insert holder (21) to fuel injector (20). Direct Run the engine to circulate the coolant
injector connector (24) to the insertion hole of through the piping. Then check the coolant
the fuel high-pressure pipe, and insert the level again.
fuel injector together with the holder.
3) Install the spherical washer to bolt (22) and 5 Radiator: 114 l
lightly tighten holder (21).
2 Spherical washer: Engine oil
(E030)
4) Insert high-pressure pipe sleeve (23) through
the high-pressure pipe insertion portion, align
it with injector connector (24), and tighten it
lightly.

HM400-3M0 50-47
50 Disassembly and assembly
Engine and cooling system

Removal and installation of cylinder head assembly (HM400_3R-A100-924-K-00-A)

a Special tools k Do not start the engine when tilting up the

cab.

Necessity
Sym-

Q'ty
Part No. Part name k When you are forced to start the engine for
bol inspection purpose, check that no person is
under the cab.
Angle tightening
A 4 790–331–1110 t 1
wrench k Do not give a large impact to the machine
when tilting up the cab.
k In order to prevent serious or death
accidents due to falling of the cab, following
k When lowering the cab by using the cab
precautions must be observed when tilting
power tilt (optional), do it gradually adjusting
the cab.
the descending speed without decreasing
• Precautions before starting cab-tilting operation the oil pressure at a breath.

k Cab-tilting operation must be performed on a
flat ground.
k Set the machine to the straight-travel
condition to prevent the interference
between the cab and body, then fix the front
and rear frames by using the articulation
lock.
k Place the machine on a level ground, set the
parking brake switch to ON position by
pressing "P", and apply the parking brake.
k Operate the dump lever lock knob to lock the
dump lever.
k The lock bar is equipped in the inner left side
corner of the engine hood. Be sure to return
the bar to the original place after using it.
k Set the lock bar to the front and rear frames
to lock them.
k Turn the battery disconnect switch to OFF
position, and remove the key. (For details,
see Testing and adjusting, "Handling battery
disconnect switch".)
k If you drain the coolant when it is still hot,
you may be scalded. Wait until the coolant
temperature drops before starting the work.

k Chock the wheels to prevent the machine
from moving.
k Do not perform the cab-tilting operation
when it is strongly windy.
• Precautions for cab-tilting operation
k Do not perform the cab-tilting operation
when the dump body is loaded.
k Do not get under the cab during cab tilting
up operation.
a When removing and installing the fuel piping,
take extreme care not to allow foreign matters to
enter the fuel piping. If dust, etc. sticks to any
part, wash that part thoroughly with clean fuel.
a Note the connector numbers and installed
positions before disconnecting wiring harnesses
and hoses.
Removal (HM400_3M0-A100-520-K-00-A)
1. Open engine hood (1).

k Fix the cab securely by using the lock lever

before tilting up the cab.

k Installthe lock lever from the side of the cab

without entering into a space below the cab.

k Do not go in or out the cab when tilting up

the cab.

k Do not operate the gear shift lever and dump

lever when tilting up the cab.
k Check that lock (2) is set securely.

50-48 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

4. Tilt up operator's cab assembly (6). For details,

see Testing and adjusting, "Cab tilt up
procedure".
a Check that lock lever (7) is in CLOSE
position and operator's cab assembly (6) is
securely fixed with lock bar (8).

2. Remove cover (3), open drain plug (4), and drain

coolant.

6 Radiator (coolant): 114 l

5. Disconnect hoses (9), (10), and (11) from the

fuel prefilter.

3. Remove cover (5).

6. Remove clamp (12).

7. Loosen clamps (13) and (14) (2 pieces each),
and remove hose (15).
8. Loosen clamps (16) and (17) (2 pieces each),
and remove hose (18).

HM400-3M0 50-49
50 Disassembly and assembly
Engine and cooling system

13.Remove mounting bolts (25) (4 pieces each) on

the right and left sides of engine hood support
(26).
14.Sling engine hood support (26), and remove it.
a Remove engine hood support (26) together
with the radiator reservoir tank and fuel
prefilter.

4 Engine hood support (26): 80 kg

9. Loosen clamp (19), and disconnect hose (20).

10.Remove clamps (21) and (22).

15.Remove turbo housing cover (27) and fire

prevention cover (28) for the exhaust pipe. [*1]

11.Remove clamps (23) (2 pieces), and disconnect

connector T01 (24).

16.Remove clamps (29) and (30). [*2]

12.Sling engine hood support (26).

50-50 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

19.Tube between exhaust manifold and EGR

(Exhaust Gas Recirculation) cooler
1) Remove fuel tubes (35) (2 pieces).
2) Remove fuel filter head assembly (36).

17.Remove mounting bolts (31) (4 pieces), and

remove exhaust pipe (32). [*8]

20.Oil filter head assembly

1) Remove oil filter head tubes (37) (2 pieces).
2) Remove oil filter head assembly (38).

18.Turbocharger lubrication tube

1) Remove turbocharger lubrication tube (33).

21.Remove blowby tube (39).

2) Remove turbocharger drain tube (34).

22.Remove priming pump (40).

HM400-3M0 50-51
50 Disassembly and assembly
Engine and cooling system

23.Remove priming pump bracket (41). 2) Remove mounting bolts (24 pieces), sling
intake manifold (45) and remove it. [*3]

24.Remove oil filter bracket (42).

27.Sling exhaust manifold assembly (45a), and
remove it. [*4]

25.Remove air intake connector (43).

28.Disconnect injector harness (46) and supply

pump harness (47), and reposition them.

26.Intake manifold
1) Remove brackets (44) (5 pieces).

50-52 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

29.Remove common rail bracket (48), related

clamp (49), and fuel high-pressure pipes (50) (6
pieces). [*5]

33.Rocker arm and shaft assembly

a Remove the mounting bolts (3 pieces) to
remove rocker arm and shaft assembly (54).
30.Remove fuel return tube (51). [*6] [*9]
• When installing rocker arm, loosen
locknut (55) and loosen adjustment screw
(56) 2 to 3 turns so that an excessive
force is not applied to push rod (57).

31.Remove coolant return (air bleeding) tube (52).

[*7]

34.Fuel injector [*10]

1) Remove nuts (59) (2 pieces) of solenoid
valve on fuel injector (58).
• Loosen nuts (59) alternately.
2) Pull out spring clamp (60).
3) Remove bolt of clamp (61).

32.Cylinder head cover

Remove the mounting bolts of each cylinder
head cover (53), and remove the covers. [*8]

4) Loosen the bolt of holder (66) of fuel injector

(65).

HM400-3M0 50-53
50 Disassembly and assembly
Engine and cooling system
5) Insert L-shaped small bar [1] under
connector (68) of fuel injector (67), and pull
out fuel injector (67) slowly by using the bar
as a leverage.
6) When pulling out the fuel injector (67), do not
try to nip at the solenoid valve at the top of
the fuel injector with pliers and such.
35.Push rod [*11]
Remove push rod (69).
36.Cylinder head assembly and crosshead
1) Remove crosshead (70). [*12]
2) Remove mounting bolt (71) and auxiliary bolt,
and remove cylinder head (72). [*13]
3) Remove respective cylinder head gaskets.
50-54
Installation (HM400_3R-A100-720-K-00-A)
• Perform installation in the reverse order to
removal.
[*1]
a Install fire prevention cover (28) of the exhaust
pipe. For details see "Removal and installation
of fire prevention cover of exhaust pipe".
[*2]
a Tighten mounting nuts of clamps (63) and (64)
according to the following procedure.
1. Tighten mounting nut (64a) to 13.7 Nm {1.4
kgm}.
2. Tighten mounting nut (64b) to 39.2 to 49.0 Nm {4
to 5 kgm}.
3. Slightly return mounting nut (64a) in the
loosening direction.
[*3]
a Tighten the bolts in the order of (1) to (24).
3 Intake manifold mounting bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
HM400-3M0

[*4]
a Tighten the exhaust manifold mounting bolts in
the following order.
1. Tighten the bolts in the order of (1) to (3).
2. Tighten the other bolts in the order of [4] to [24].
3 Exhaust manifold mounting bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
[*5]
1. Check the following items before installing the
fuel high-pressure pipe.
The fuel high-pressure pipe having any defect
can cause fuel leakage. Accordingly, replace the
fuel high-pressure pipe with a new one.
• Make sure with visual check that the taper
seal part of the connection ((a) part: 2 mm
area from the tip-end) is free from
longitudinal slits (b) or pits (c).
• Make sure that part (d) (end of taper seal: 2
mm from the tip-end) is free from steps you
can feel by your fingernail. (Namely, this
portion must be free from fatigue.)
HM400-3M0
50 Disassembly and assembly
Engine and cooling system
2. Finger-tighten sleeve nuts (1) and (2)
approximately 2 turns, and then tighten the
threaded portion of the fuel injector by using a
wrench.
a If it is difficult to fit the the sleeve nut to
threaded portion, use the regular wrench to
rotate the threaded portion while pressing the
sleeve nut edge by using another wrench,
etc.
a Tighten the sleeve nut by using wrench-type
torque wrench [1].
3 Sleeve nut for fuel high-pressure pipe:
39.2 to 49 Nm {4 to 5 kgm}
3. Lightly fasten clamps (3), (4), (5), and (6) by
hand, check that each part is installed smoothly
as intended, and then fasten the clamps to the
specified torque.
a Install clamps (3), (4), and (5) after the intake
manifold has been installed.
3 Clamp mounting bolt:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
50-55
50 Disassembly and assembly
Engine and cooling system

[*6]
3 Fuel return tube joint bolt:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
[*9]
1. Install rocker arm and shaft assembly (10), and
tighten mounting bolts (11), (12), and (13).
a Note that mounting bolts (11), (12), and (13)
have different stem lengths.
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
set in the push rod socket securely.
3 Rocker arm mounting bolt:
93 to 103 Nm {9.5 to 10.5 kgm}

[*7]
3 Coolant return tube joint bolt (air
bleeding):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

2. Adjust the valve clearance according to the

[*8]
Install cylinder head cover (9) with O-ring attached.
a Tighten the bolt in the front side of the intake
manifold lightly since it is tightened together with
the wiring harness clamp.
3 Cylinder head cover:
29.4 to 34.3 Nm {3.0 to 3.5 kgm}
following procedure.
a As the valve clearance, adjust the clearance
between the crosshead and rocker arm to
the following valve.
a Valve clearance (cold)
Intake valve: 0.35 ± 0.02 mm
Exhaust valve: 0.57 ± 0.02 mm
a Adjust the valve clearance of each cylinder
by cranking the engine in the firing order of 1,
5, 3, 6, 2, and 4.
1) Rotate the crankshaft in the positive direction
and align "1.6TOP" stamp line (e) of vibration
damper (14) with pointer (15) while checking
the movement of the valve.

50-56 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

a Lightly tighten sleeve nut on the common

rail side as well and take care not to tilt
the fuel high-pressure pipe.
5) Tighten holder (21) to the specified torque.
a While pulling the high-pressure fuel pipe
in the opposite direction of the fuel
injector, tighten bolt (22).
3 Holder mounting bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
a After tightening the holder, remove the
fuel high-pressure pipe, and install the
2) Insert feeler gauge [1] between rocker arm fuel injectors sequentially as described
(16) and crosshead (17) and adjust previously.
adjustment screw (18) to a degree that the
feeler gauge moves lightly.
3) Tighten locknut (19) at this position to fix
adjustment screw (18).
3 Adjustment screw lock nut:
53 to 64.7 Nm {5.4 to 6.6 kgm}
a After tightening the locknut, check the
valve clearance again.

[*10]
1. Install fuel injector assembly according to the
following procedure.
a Check that there is no dirt inside the injector [*11]
sleeve. Install push rods (25).
1) Install O-ring and gasket to the fuel injector.
a Check that the push rod is fitted in the cam
2) Insert holder (21) to fuel injector (20). Direct
follower securely.
injector connector (24) to the insertion hole of
the fuel high-pressure pipe, and insert the
fuel injector together with the holder.
3) Install the spherical washer to bolt (22) and
lightly tighten holder (21).
2 Spherical washer: Engine oil
(E030)
4) Insert high-pressure pipe sleeve (23) through
the high-pressure pipe insertion portion, align
it with injector connector (24), and tighten it
lightly.

HM400-3M0 50-57
50 Disassembly and assembly
Engine and cooling system

[*12] • The number of tightening times reaches 6

times (the punch number indicating the
a Adjust the crosshead according to the following
tightening times is 5) or less
procedure.
• Bolt stem length (allowable value) (b)
1. Loosen the locknut and slightly return the Short bolt: Max. 170.8 mm
adjustment screw. Long bolt: Max. 205.8 mm
2. While pressing the top of crosshead (26) lightly,
screw in the adjustment screw.
3. After the adjustment screw touches the valve
stem, screw in it further by 20 deg.
4. At this position, tighten the locknut.
3 Lock nut:
58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}

3. Install cylinder head assembly (29) and tighten

the mounting bolts and auxiliary bolts.
2 Mounting bolt:
Molybdenum disulfide lubricant (LM-
P)

[*13]
a Install the cylinder head according to the
following procedure.
1. Check that the cylinder head mounting face and
inside of the cylinders are free from dirt and
foreign material, and then set cylinder head
gasket (27).
a When installing the gasket, check that the
grommets are not fall off or lost and the
gasket has been installed securely.

a Tighten in order of [1] to [6] by using tool A4.

3 Mounting bolt:
1st time: 137 to 157 Nm {14 to 16
kgm}
2nd time: 284 to 294 Nm {29.0 to 30.0
kgm}
3rd time: By using tool A7, retighten
the bolt by 90 deg. (+30 deg./0).

2. Before tightening the cylinder head mounting

bolt, check the following items.
a Check the cylinder head mounting bolt. If it is
out of the standard, do not reuse the
mounting bolt but replace it.

50-58 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

• Refilling with coolant

Refill with coolant to the specified level through
the coolant filler port of the radiator. Run the
engine to circulate the coolant through the piping.
Then check the coolant level again.

5 Radiator: 114 l

a When not using tool A4, put marks "g" and

"h" on the bolt and cylinder head with paint,
and then retighten the bolts by 90 deg. (+30
deg./0).
a After tightening bolts [1] to [6], tighten bolt [7].
a After tightening the bolts, put a punch mark
on each bolt head to indicate the number of
tightening.
a Do not put a mark on a new bolt.
a The number of tightening times reaches 6 ( 5
punch marks on bolt head) or less.
3 Bolt [7]:
66.6 ± 7.4 Nm {6.8 ± 0.8 kgm}

HM400-3M0 50-59
50 Disassembly and assembly
Engine and cooling system

Removal and installation of radiator assembly (HM400_3R-B220-924-K-00-A)

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)

k If you drain the coolant when it is still hot,

you may be scalded. Wait until the coolant
temperature drops before starting the work.

k Loosen the cap of the hydraulic tank

gradually, and release the pressure
remaining inside the hydraulic tank.

Removal (HM400_3R-B220-520-K-00-A)

1. Remove mounting bolts (1) (8 pieces), and

remove cover (2). 4. Open engine hood (6).
2. Remove plug (3), and install hose (4).
a Be sure to turn lock (7) to LOCK position.
a Hose (4) is fixed as the special tool to the
back side of cover (2).
3. Loosen drain plug (5), and drain the hydraulic
oil.

6 Hydraulic tank: 167 l

5. Remove covers (8) and (9) on the bottom of the

engine.
6. Loosen drain plug (10) to drain the coolant.

50-60 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

10.Remove mounting bolts (16) (4 pieces), and

6 Radiator: 114 l
remove cover (17).

11.Remove 4 mounting bolts (18), and remove

guard (4).

7. Loosen clamps (11) (2 pieces), and disconnect

radiator lower hose (12). [*1]

12.Loosen clamp (19a).

13.Disconnect connectors MAF (19b) and T05
(19c).

8. Remove cover (13).

14.Remove air cleaner assembly mounting bolts

(19d) (4 pieces), and remove air cleaner
assembly (19e). [*2]

9. Remove mounting bolts (15) (4 pieces) of guard

(14).

HM400-3M0 50-61
50 Disassembly and assembly
Engine and cooling system
15.Remove clamps (20) and (21).
16.Remove mounting bolts (22) (4 pieces) and
remove air conditioner condenser (23).
a Fix air conditioner condenser (23) to the
machine.
17.Disconnect hoses (23a) and (23b) from water
separator assembly (23c).
50-62
18.Remove clamp (23c) and remove water
separator assembly (23d) together with bracket
(23e).
19.Remove clamps (24) (3 pieces), and disconnect
hose (25).
a Pull out hose (25) downward.
20.Remove clamp (26), and disconnect hose (27).
21.Remove clamps (28) (2 pieces), and disconnect
hose (29).
22.Remove clamp (34) from radiator assembly (33),
and disconnect hoses (35), (36), (37), and (38).
23.Remove U-clamps (39) (2 pieces) and loosen
clamps (40) (2 pieces).
24.Remove U-clamps (41) (2 pieces) and loosen
clamps (42) (2 pieces).
25.Disconnect hoses (43) and (44) from tube (45).
26.Remove fan guard (46).
HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

27.Remove clamp (47) and disconnect connector 32.Remove rods (56) on the right and left sides and
(48). cushion mounting bolt (57). [*3]
28.Remove the mounting bolts (3 pieces) and
remove belt cover (49) of the air conditioner
compressor.
a This is to prevent interference of belt cover
(49) with the radiator.
29.Remove mounting bolts (50) (2 pieces), and
remove cover (51).
30.Disconnect hoses (52), (53), and (54).
a Place an oil container under the hose.
a Plug the disconnected hose and the
mounting port to prevent oil leakage and dust
entry.
33.Remove radiator assembly mounting bolts (58)
(2 pieces each on right and left sides), and
plates (59) (1 piece each on right and left sides).
[*4]

34.Install eyebolt, sling radiator assembly (33), and

remove it.

4 Radiator assembly (33): 300 kg

31.Remove plate (55). (right side only)

HM400-3M0 50-63
50 Disassembly and assembly
Engine and cooling system

Installation (HM400_3R-B220-720-K-00-A) [*2]

• Perform installation in the reverse order to 3 Clamp (16):
removal.
[*1] 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
a Do not apply adhesive to hose fittings.
3 Mounting nut of rod (56):
a Use a neutral detergent if it is hard to instal the
hose. 54 to 88 Nm {5.5 to 9.0 kgm}
• Installed dimension (a) of rod (56): 313 mm
a Installed dimension of hose clamp (11) is shown
in the following figure.
• B: Bulge
• C: Clamp
• H: Hose
• T: Tube
• Clearance (L1) between the bulge and inner
clamp: Max. 5 mm
• Distance (L2) between hose end and outer
clamp: 5 to 10 mm
• Hose installed dimension (L3): 60 mm
a Position 2 clamps so that their clamp screws are
180 deg. apart.
[*4]
a Position fastening portions (c1) and (c2) of
clamps (2 pieces) to the direction where they are 3 Radiator assembly mounting bolt (58):
fastened from same direction. 245 to 309 Nm {25.0 to 31.5 kgm}
3 Clamp (11) of the hose between radiator • Refilling with coolant
bottom and oil cooler: Refill with coolant to the specified level through
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} the coolant filler port of the radiator. Run the
engine to circulate the coolant through the piping.
Then check the coolant level again.

5 Radiator: 114 l
• Refilling with oil
Refill with oil through the oil filler port of the
hydraulic tank to the specified level. Run the
engine to circulate the oil through the piping.
Then check the oil level again.

5 Hydraulic tank: 167 l

50-64 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

Removal and installation of radiator core assembly (HM400_3R-B222-924-K-00-A)

Removal (HM400_3R-B222-520-K-00-A)

1. Remove the radiator assembly (33). For details,

see "Removal and installation of radiator
assembly."

4 Radiator assembly (33): 300 kg

6. Loosen clamps (68) (4 pieces), and remove

mounting bolts (69)(2 pieces) and (70) (2 pieces).
[*3]
7. Remove tube (71), hose and bracket together as
a unit.

2. Remove mounting bolt (60) from radiator

assembly (33), then remove cooling fan for
radiator and fan motor assembly (61). [*1]

8. Fix radiator assembly (33) securely to lift truck,

and remove radiator assembly top cover (72).

3. Remove mounting bolts (62) (8 pieces) from

radiator assembly (33), then remove cooling fan
shroud assembly (63) for radiator.

9. Remove right radiator core assembly (73).

4. Loosen clamps (64) (2 pieces) of radiator

assembly (33), and remove hose (65).
5. Loosen clamps (66) (2 pieces) of radiator
assembly (33), and remove hose (67). [*2]

HM400-3M0 50-65
50 Disassembly and assembly
Engine and cooling system

• B: Bulge
• C: Clamp
• H: Hose
• T: Tube
• Distance (L1) between bulge and inner clamp:
Max. 5 mm
• Distance (L2) between hose end and outer
clamp: 5 to 10 mm
• Hose installed dimension (L3): 60 mm
a Position 2 clamps so that their clamp screws are
180 deg. apart.
a Position fastening portions (c1) and (c2) of 2
10.Remove left radiator core assembly (74).
clamps to the direction where they are fastened
from same direction.
3 Clamp (11) of hose between radiator
bottom part to the oil cooler:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

Installation (HM400_3R-B222-720-K-00-A)

• Perform installation in the reverse order to

removal.
[*1]
a Clearance (e) between the outer periphery of the
radiator cooling fan and shroud must meet the
following dimension along the whole
circumference.
• Clearance (e): 10 ± 3 mm

[*2], [*3]
a Do not apply adhesive to hose fittings.
a Use a neutral detergent if it is hard to install the
hose.
a The following figure shows the installed
dimension of the hose clamp (11).

50-66 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

Removal and installation of cooling fan and fan motor assembly for
radiator (HM400_3R-B5L0-924-K-00-A)
a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

A 5 790-101-3501 Puller q 1
Removal (HM400_3R-B5L0-520-K-00-A)

1. Remove radiator assembly (33). For details, see

"Removal and installation of radiator assembly".

4 Radiator assembly (33):

4. Disconnect wiring connectors T12 (63) and B13
300 kg
(64).
5. Remove oil tube fixing clamps (65) and (66) (3
places each).
6. Disconnect oil tube fixing clamps (67), (68), and
(69).

2. Remove mounting bolt (60) from radiator

assembly (33), then remove cooling fan for
radiator and fan motor assembly (61). [*1]

7. Sling radiator cooling fan and fan motor

assembly (61), and turn them over.
8. After turning the assembly over, remove bolts
(70) and (71) and lock plate (72). [*2]

3. Remove cover (62).

9. By using tool A5, remove radiator cooling fan

mounting nut (73). [*3]

HM400-3M0 50-67
50 Disassembly and assembly
Engine and cooling system

[*3]
3 Radiator cooling fan mounting nut (73):
441 to 539 Nm {45 to 55 kgm}
a Degrease the key slot before installing the
radiator cooling fan.
• Key slot on the radiator cooling fan
• Woodruff key insertion keyway on shaft
[*4]
3 Fan motor assembly mounting bolt (75):
98 to 123 Nm {10.0 to 12.5 kgm}
10.Remove mounting bolts (75) of fan motor
assembly (74). [*4]
a Place a wood block under fan motor
assembly (74) not to fall off and get
damaged.

Installation (HM400_3R-B5L0-720-K-00-A)

• Perform installation in the reverse order to

removal.
[*1]
a Clearance (e) between the outer periphery of the
radiator cooling fan and shroud must meet the
following dimension along the whole
circumference.
• Clearance (e): 10 ± 3 mm

[*2]
3 Clamping bolt of lock plate (72):
59 to 74 Nm {6.0 to 7.5 kgm}

50-68 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

Removal and installation of aftercooler assembly (HM400_3R-A9A0-924-K-00-A)

k Place the machine on a level ground, Set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)
k Loosen the cap of the hydraulic tank
gradually, and release the pressure
remaining inside the hydraulic tank.
4. Remove the air cleaner assembly. For details,
see "Removal and installation of air cleaner
assembly".
5. Remove mounting bolts (1) (9 pieces) to remove
net (2).

Removal (HM400_3R-A9A0-520-K-00-A)

1. Remove mounting bolts (1a) (8 pieces) to

remove cover (1).
2. Remove plug (1c), and install hose (1d).
a Hose (1d) is fixed as the special tool to the
back side of cover (1b).
3. Loosen drain plug (1e), and drain the hydraulic
oil.

6 Hydraulic tank:
167 l
6. Remove plate (3).
7. Remove covers (4) and (5).

8. Remove mounting bolts (6) (2 pieces), and

remove bracket (7).
9. Loosen clamp (8) and, remove hose (9).
10.Loosen clamp (10) and, disconnect hose (11).

HM400-3M0 50-69
50 Disassembly and assembly
Engine and cooling system

11.Remove U-bolt (12) of the aftercooler inlet port 16.Remove clamp (20) and disconnect wiring
hose, and remove brackets (13) and (14). harness (21).

12.Remove clamp (15) on the left side of the 17.Remove mounting bolt (22) on the bottom of the
aftercooler and disconnect hose (16). [*1] shroud.
13.Remove mounting bolt (17).

18.Sling aftercooler core assembly (23) and

14.Remove mounting bolts (18) (2 pieces). remove it.

4 Aftercooler core assembly:

100 kg

15.Remove mounting bolts (19) (3 pieces).

50-70 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

19.Remove shroud (24). 24.Remove mounting bolts (32) (8 pieces).

20.Remove cover mounting bolts (25) (2 pieces), 25.Sling aftercooler cooling fan and fan motor
and remove cover (26). assembly (33), and remove them.

4 Aftercooler cooling fan and fan motor

assembly:
95 kg

21.Remove cover (27).

Installation (HM400-A9A0-720-K-00-A)

• Perform installation in the reverse order to

removal.
[*1]
a Do not apply adhesive to hose fittings.
a Use a neutral detergent if it is hard to install the
hose.
a Installed dimension of hose clamps are is shown
22.Disconnect hoses (28), (29), and (30).
in the following figure.
23.Disconnect connector DT10 (31).
• B: Bulge

HM400-3M0 50-71
50 Disassembly and assembly
Engine and cooling system

• C: Clamp
• H: Hose
• T: Tube
• Clearance (L1) between the bulge and inner
clamp: Max. 5 mm
• Distance (L2) between hose end and outer
clamp: 5 to 10 mm
• Hose installed dimension (L3): 60 mm
a Position 2 clamps so that their clamp screws are
180 deg. apart.
a Position fastening portions (c1) and (c2) of
clamps (2 pieces) to the direction where they are
fastened from same direction. • Refilling with oil
Refill with oil through the oil filler port of the
3 Clamp (11) of the hose between radiator hydraulic tank to the specified level. Run the
bottom and oil cooler: engine to circulate the oil through the piping.
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} Then check the oil level again.

5 Hydraulic tank: 167 l

[*2]
a Clearance between the outer periphery of the
aftercooler fan and shroud must meet the
following dimension along the whole
circumference.
• Clearance (e): 7 ± 2.5 mm

50-72 HM400-3M0

Removal and installation of cooling fan and fan motor assembly for
aftercooler (HM400_3R-B5L0-924-K-01-A)
Removal (HM400-B5L0-520-K-01-A)
1. Remove the aftercooler assembly. For details,
see "Removal and installation of aftercooler
assembly".
2. Remove cover (1).
3. Remove tube clamps (2) to (5).
4. Disconnect harness connectors CN-T17 (6),
CN-T11 (7), and CN-B01 (8).
5. Disconnect connector bracket (9).
6. Disconnect hydraulic tubes (10) to (12).
7. Remove bolt (13), and remove lock plate (14).
[*1]
a Bolt (13) also serves as a aftercooler
mounting bolt.
HM400-3M0
50 Disassembly and assembly
Engine and cooling system
8. Remove aftercooler fan mounting bolts (15) (3
pieces), then remove aftercooler fan (16). [*2]
9. Remove boss mounting nut (17). [*3]
10.Remove boss (18).
11.Remove mounting bolts (20) (3 pieces) of fan
motor assembly (19). [*4]
a Place a wood block under fan motor
assembly (19) to prevent it not to fall off and
get damaged.
12.Remove frame assembly (21).
Installation (HM400-B5L0-720-K-01-A)
• Perform installation in the reverse order to
removal.
a Degrease key slot (a) on the boss and key slot
(b) on the shaft before installing the aftercooler
fan.
50-73
50 Disassembly and assembly
Engine and cooling system

[*1]
a Perform hole alignment by using both sides of
lock plate (14), use the side which requires less
adjustment for positioning, and retighten boss
mounting nut (13).
3 Lock plate mounting bolt (14):
59 to 74 Nm {6 to 7.5 kgm}
[*2]
3 Aftercooler fan mounting bolt (15):
59 to 74 Nm {6 to 7.5 kgm}
[*3]
3 Boss mounting nut (17):
98 to 127.5 Nm {10 to 13 kgm}
[*4]
3 Fan motor assembly mounting bolt (20):
59 to 74 Nm {6 to 7.5 kgm}

50-74 HM400-3M0

Removal and installation of engine assembly
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
792-420-1120 Flange t 2
A 7
01050-61225 Bolt t 2
k In order to prevent serious or death
accidents due to falling of the cab, following
precautions must be observed when tilting
the cab.
• Precautions before starting cab-tilting
operation
k Cab-tilting operation must be performed on a
flat ground.
k Set the machine to the straight-travel
condition to prevent the interference
between the cab and body, then fix the front
and rear frames by using the articulation
lock.
k Set the parking brake switch to ON position
by pressing P, and apply the parking brake.
k Operate the dump lever lock knob to lock the
dump lever.
k Chock the wheels to prevent the machine
from moving.
k Do not perform the cab-tilting operation
when it is strongly windy.
k Before dismounting cab, be sure to lock the
lock pin in the rear mount of cab.
• Precautions for cab-tilting operation
k Do not perform the cab-tilting operation
when the dump body is loaded.
k Do not get under the cab during cab tilting
up operation.
k Fix the cab securely by using the lock lever
before tilting up the cab.
k Installthe lock lever from the side of the cab
without entering into a space below the cab.
k Do not go in or out the cab when tilting up
the cab.
HM400-3M0
50 Disassembly and assembly
Engine and cooling system
(HM400_3R-A000-924-K-00-A)
k Do not operate the gear shift lever and dump
lever when tilting up the cab.
k Do not start the engine when tilting up the
cab.
k When you are forced to start the engine for
inspection purpose, check that no person is
under the cab.
k Do not give a large impact to the machine
when tilting up the cab.
k When lowering the cab by using the cab
power tilt (optional), do it gradually adjusting
the descending speed without decreasing
the oil pressure at a breath.
k The lock bar is equipped in the inner left side
corner of the engine hood. Be sure to return
the bar to the original place after using it.
k Set the lock bar to the front and rear frames
to lock them.
k Stop the engine, turn the battery disconnect
switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)
k Loosen the cap of the hydraulic tank
gradually, and release the pressure
remaining inside the hydraulic tank.
k If you drain the coolant when it is still hot,
you may be scalded. Wait until the coolant
temperature drops before starting the work.
a Ask a qualified person for collecting, adding and
filling operations of the refrigerant (air
conditioner gas: R134a).
a Never release the refrigerant (air conditioner
gas: R134a) to the atmosphere.
k If refrigerant gas (air conditioner gas: R134a)
gets in your eyes, you may lose your sight.
And if it touches your skin, you may suffer
from frostbite. Put on protective eyeglasses,
gloves and working clothes with long
sleeves while collecting the refrigerant or
filling the air conditioner circuit with the
refrigerant.
a When removing and installing the fuel piping,
take extreme care not to allow foreign matters to
enter the fuel piping. If dust, etc. sticks to any
part, wash that part thoroughly with clean fuel.
50-75
50 Disassembly and assembly
Engine and cooling system

a Note the connector numbers and installed

positions before disconnecting wiring harnesses
and hoses.
Removal (HM400_3M0-A000-520-K-00-A)

1. Remove mounting bolts (1) (8 pieces), and

remove cover (2).
2. Remove plug (3), and install hose (4).
a Hose (4) is fixed to the back side of cover (2)
as the special tool .
3. Loosen drain plug (5), and drain the hydraulic
oil.

6 Hydraulic tank:
167 l

5. Tilt up operator's cab assembly (8). For details,

see Testing and adjusting, "Cab tilt up
procedure".

k Check that lock lever (9) is in CLOSE

position and operator's cab assembly (8)
is securely fixed with lock bar (10).

4. Open engine hood (6).

a Be sure to lock it with lock (7).

50-76 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

6. Collect the refrigerant (air conditioner gas:

R134a) from the air conditioner circuit.
Refrigerant to be collected: 875 ± 25 g
7. Remove cover (11) on the bottom of the engine.
8. Loosen drain plug (12), and drain the coolant.

6 Radiator: 114 l

13.Disconnect hose (16) from the left side of the

engine.

14.Remove clamp (17), and remove cover (18).

9. Remove the air cleaner assembly. For details,

see "Removal and installation of air cleaner
assembly".
10.Remove the radiator assembly. For details, see
"Removal and installation of radiator assembly".
11.Remove the air conditioner compressor
assembly. For details, see "Removal and
installation of air conditioner compressor
assembly".
15.Remove cover (19).
a When removing the air conditioner
compressor assembly, the mounting bolt
interferes with the refrigerant piping.
Therefore, disconnect the refrigerant piping.
a Remove the receiver drier assembly, and fix
it to the machine.
12.Disconnect hoses (13), (14), and (15) from the
fuel prefilter.

16.Remove clamps (20) (2 pieces).

17.Disconnect ground (21), connectors J3P (22),
and J2P (23) [*1]

HM400-3M0 50-77
50 Disassembly and assembly
Engine and cooling system

a Loosen hexagonal socket head bolt (4 mm),

and remove connector J2P (23).

22.Remove mounting bracket (30) of the air

conditioner compressor.
18.Remove clamp (24), and disconnect connector
T06 (25).

23.Loosen clamps (31) (2 pieces), and disconnect

hose (32). [*2]
19.Remove clamps (26) (4 pieces).
20.Remove U-clamps (27), and remove bracket
(28).

24.Remove clamp (33).

25.Loosen clamps (34) and (35) (2 pieces each),
and remove hose (36). [*3]
26.Loosen clamps (37) and (38) (2 pieces each),
21.Remove clamps (29) (2 pieces) of the fuel hose.
and remove hose (39). [*4]

50-78 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

27.Loosen clamp (40), and disconnect hose (41). 35.Disconnect connector 78 (53).

28.Disconnect alternator wiring connectors 80 (42), 36.Remove clamps (54) and (55).
E1 (43), and 85 (43a).
29.Remove clamp (44), and disconnect hose (45).
30.Remove mounting bolts (46) (4 pieces), and
disconnect tube (47) for the inlet port hose. [*5]

37.Remove clamps (56) (2 pieces), and disconnect

connector T01 (57).

31.Remove clamp (48).

32.Disconnect heater hose (49).
33.Disconnect starting motor wiring STR (50) and
(51).
34.Disconnect ground cable (52).

38.Sling engine hood support (59).

HM400-3M0 50-79
50 Disassembly and assembly
Engine and cooling system

39.Remove mounting bolts (58) (4 pieces each) on

the right and left sides of engine hood support
(59).
40.Sling engine hood support (59), and remove it.
a Remove engine hood support (59) together
with the radiator reservoir tank and fuel
prefilter.

4 Engine hood support (59): 80 kg

43.Remove mounting bolts (65) (4 pieces), and pull

out exhaust pipe (66) from the turbo housing.
[*8]

44.Remove clamps (67) and (68).

45.Remove clamps (69) and (70).
46.Remove clamps (71) and (72).
47.Disconnect hose (73).

41.Remove turbo housing cover (61) and fire

prevention cover (62) for the exhaust pipe. [*6]

48.Remove clamp (74) and U-clamp (75).

49.Disconnect the following hoses from the
hydraulic pump.
• Coupling (76) and tube (77)
• Hose (78)
42.Remove clamps (63) and (64). [*7] • Hose (79)
• Hose (80)
a Place an oil container under the hose.
a Plug the disconnected hose and the
mounting port to prevent oil leakage and dust
entry.

50-80 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

50.Remove mounting bolts (81) (4 pieces), and

remove triple type gear pump assembly (82).
a Remove triple type gear pump assembly (82)
so as to secure the work space for removal
of the coupling yoke mounting bolt of the
output shaft.

54.Sling engine assembly (88), and remove it.

a Check that all piping and wiring are
disconnected.

4 Engine assembly (88): 1,900 kg

51.Remove mounting bolts (83) (4 pieces), and

remove coupling yoke (85) of output shaft (84)
from the engine side. [*9]

Installation (HM400_3R-A000-720-K-00-A)

• Perform installation in the reverse order to

removal.
[*1]
52.Remove front engine mount bolts (86) from the
right and left sides. [*10] 3 Mounting hexagonal socket head bolt (4
53.Remove rear engine mount bolts (87) from the mm) of connector J2P (23):
right and left sides. [*11] 3 ± 1 Nm {0.3 ± 0.1 kgm}
[*2]
a Do not apply adhesive to hose fittings.
a Use a neutral detergent if it is hard to install the
hose.
a Installed dimension of hose clamp (11) is shown
in the following figure.
• B: Bulge
• C: Clamp
• H: Hose
• T: Tube
• Clearance (L1) between the bulge and inner
clamp: Max. 5 mm
• Distance (L2) between hose end and outer
clamp: 5 to 10 mm
• Hose installed dimension (L3): 60 mm

HM400-3M0 50-81
50 Disassembly and assembly
Engine and cooling system
a Position 2 clamps so that their clamp screws are
180 deg. apart.
a Position fastening portions (c1) and (c2) of
clamps (2 pieces) to the direction where they are
fastened from same direction.
3 Clamp (11) of the hose between radiator
bottom and oil cooler:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*3]
3 Clamps (34) and (35):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*4]
3 Clamps (37) and (38):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*5]
a Install a new gasket to tube (47).
[*6]
a Install fire prevention cover (62) of the exhaust
pipe. For details see "Removal and installation
of fire prevention cover of exhaust pipe".
[*7]
a Tighten mounting nuts of clamps (63) and (64)
according to the following procedure.
1. Tighten mounting nut (64a) to 13.7 Nm {1.4
kgm}.
50-82
2. Tighten mounting nut (64b) to 39.2 to 49.0 Nm {4
to 5 kgm}.
3. Slightly return mounting nut (64a) in the
loosening direction.
[*8]
a Install a new gasket to exhaust pipe (66) on the
muffler side.
2 Mounting bolt (65):
Seizure prevention compound (LC-G)
[*9]
Drive shaft mounting bolt
a When the engine assembly, transmission, torque
converter assembly, or drive shaft is removed,
use tool A7 to perform lateral centering of the
engine and transmission according to the
following procedure.
1. Install tool A7 to the engine side coupling and
torque converter side coupling.
2. Apply scale [1] to the right and left sides of tool
A7.
3. Measure the right and left clearances (a) and (b)
between scale [1] and tool A7.
a Check that the largest clearance is within 3mm
on both sides. (If the clearance is not parallel,
check that the clearance at the widest point is
within 3mm.)
a If the clearance is 3mm or wider, reposition the
engine mounts for the engine assembly to adjust
the clearance.
HM400-3M0

a When installing the drive shaft, check the
direction of the drive shaft (on the engine (ENG)
side and torque converter (TC) side) and make
sure that the convex portion of the spider cap is
completely fitted in the groove of the mating
yoke before tightening mounting bolt (83). ("T/C"
mark (P) is printed on the spider on the torque
converter side.)
2 Mounting bolt (83):
Liquid adhesive (LT-2)
3 Mounting bolt (83):
98 to 123 Nm {10.0 to 12.5 kgm}
a Measure dimension (c) between the flywheel
housing and coupling end after the drive shaft
between the engine and transmission has been
installed. If dimension (c) is out of the following
range, adjust the dimension within the standard
value by moving position of the mount of the
engine assembly.
• Dimension between flywheel housing and
coupling end
(c): 207 to 210 mm
HM400-3M0
50 Disassembly and assembly
Engine and cooling system
[*10], [*11]
a Never use an impact wrench for tightening the
engine mounting bolt.
3 Front engine mounting bolt (86):
662 to 829 Nm {67.5 to 84.5 kgm}
3 Rear engine mounting bolt (87):
662 to 829 Nm {67.5 to 84.5 kgm}
• Filling of refrigerant (R134a)
Refill the air conditioner circuit with refrigerant
(air conditioner gas: R134a).
Refill amount: 875 ± 25 g
• Refilling with air conditioner compressor oil
See Air conditioner, "Handling of compressor oil".
• Refilling with coolant
Refill with coolant to the specified level through
the coolant filler port of the radiator. Run the
engine to circulate the coolant through the piping.
Then check the coolant level again.
5 Radiator: 114 l
• Refilling with oil
Refill with oil through the oil filler port of the
hydraulic tank to the specified level. Run the
engine to circulate the oil through the piping.
Then check the oil level again.
5 Hydraulic tank: 167 l
50-83
50 Disassembly and assembly
Engine and cooling system

Removal and installation of engine front oil seal (HM400_3R-A350-924-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

8 795-931-1100 Seal puller t 1

795T-521-1111 Push tool t 1
9 01050-31655 Bolt t 3
A
01050-31635 Bolt t 3
795T-521-1150 Push tool t 1
10
01050-31635 Bolt t 3

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)

k If you drain the coolant when it is still hot,

you may be scalded. Wait until the coolant
temperature drops before starting the work.

k Loosen the cap of the hydraulic tank

gradually, and release the pressure
remaining inside the hydraulic tank.

Removal (HM400_3R-A350-520-K-00-A)

1. Remove mounting bolts (1) (8 pieces), and

remove cover (2). 4. Open engine hood (6).
2. Remove plug (3), and install hose (4).
a Be sure to turn lock (7) to LOCK position.
a Hose (4) is fixed as the special tool to the
back side of cover (2).
3. Loosen drain plug (5), and drain the hydraulic
oil.

6 Hydraulic tank:
167 l

50-84 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

5. Remove cover (8) on the bottom of the engine.
6. Loosen drain plug (9), and drain the coolant.
6 Radiator:
114 l
11.By using tool A8, install front oil seal (12). [*2]
1) Drill a hole of approximately 3 mm in
diameter in front oil seal (12).
2) Set tool A8 in the drilled hole. (Tip: Drill type)
3) Use impacts of the slider hammer (SH) for
the removal. (Apply impact evenly so that the
front oil seal is not tilted.)
a Remove all the chips.
a If the seal is sleeved, cut and remove sleeve
(14) with a chisel and a hammer.
a Be careful not to damage crankshaft (13).

• Tool A8

7. Remove the air cleaner assembly. For details,

see "Removal and installation of air cleaner
assembly".
8. Remove the air conditioner condenser assembly.
For details, see "Removal and installation of air
conditioner condenser assembly".
9. Remove the radiator assembly. For details, see
"Removal and installation of radiator assembly".
10.Remove inner mounting bolts (10) (6 pieces),
and remove damper assembly (11). [*1]
Left: Sleeveless seal Right: Sleeved seal
a Put mark (a) on the damper and front cover.

HM400-3M0 50-85
50 Disassembly and assembly
Engine and cooling system

1) Apply the larger inside diameter side (b) of

plastic inner tube (15) to the end of
crankshaft (13).
a Be careful not to put the wrong end.
2) Put sleeve (14) of front oil seal (14) to the
end surface of crankshaft (13).
Press-fit sleeve (14) together with front oil
seal (12) by tightening the bolts (3 pieces)
evenly until the end face of tool A10 reaches
the end face of crankshaft (13).
Left: Sleeveless seal Right: Sleeved seal

Installation (HM400_3R-A350-720-K-00-A)

• Perform installation in the reverse order to

removal.
[*1]
a Set damper assembly (11) on the mounting
position, align it with the dowel pin, and tighten
mounting bolts (10) (6 pieces).
3 Damper assembly mounting bolt (11):
245 to 309 Nm {25.0 to 31.5 kgm}
[*2]
1. Preparatory work for front oil seal installation
a Check the wear of the crankshaft and select
either a "sleeveless seal" or a "sleeved seal"
to install it.
If the wear condition of the crankshaft is
glossy and no scratch (when touched by a
finger, wear depth is 10 µm or less), install
"sleeveless seal (A)". In other cases, install
"sleeved seal (B)".
(14): Shows the sleeve.
(15): Shows the inner plastic tube/installation
guide.
3) Remove tool A10 and replace it with tool A9.
a Do not remove installation guide (15) from
4) Press-fit sleeve (14) together with front oil
front oil seal (12) before installing it.
seal (12) by tightening the bolts (35 mm) (3
a Handle the front oil seal (12) and sleeve (14) pieces) evenly until the end face of tool A9
as an assembly and never separate them reaches the end face of crankshaft (13).
from each other.
a Installed dimension (c) of front oil seal (12)
2. Installation of front oil seal (sleeveless type)
from end face of crankshaft (13): 9.2 to 10.1
a Before installing the front oil seal, check that mm
end face corners and seal lip sliding surface
a Be careful not to damage the seal lip by
of the crankshaft and the housing are free
using a tool set, etc. when press-fitting front
from flaw, burr, sharp edge or rust.
oil seal (12).
a When installing the front oil seal, do not apply
a After press-fitting front oil seal (12), remove
oil or grease to the crankshaft and seal lip.
the red sealant layer from its outer periphery.
Thoroughly wipe off oil or grease from the
crankshaft.
a Never remove inner plastic tube (15) of the
supplied front oil seal until the front oil seal is
installed.

50-86 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

• Refilling with coolant

Refill with coolant to the specified level through
the coolant filler port of the radiator. Run the
engine to circulate the coolant through the piping.
Then check the coolant level again.

5 Radiator:
114 l
• Refilling with oil
Refill with oil through the oil filler port of the
hydraulic tank to the specified level. Run the
engine to circulate the oil through the piping.
Then check the oil level again.

5 Hydraulic tank:
167 l

HM400-3M0 50-87
50 Disassembly and assembly
Engine and cooling system

Removal and installation of engine rear oil seal (HM400_3R-A510-924-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

11 795-931-1100 Seal puller t 1

Angle tightening
12 790-331-1110 q 1
wrench
795T-421-1260 Push tool t 1
13 01050-31640 Bolt t 4
01643-31645 Washer t 4
A 795T-421-1240 Push tool t 1
14 01050-31645 Bolt t 4
01643-31645 Washer t 4
795T-421-1231 Push tool t 1
15 02050-31645 Bolt t 4
01643-31645 Washer t 4

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)

k Loosen the cap of the hydraulic tank

gradually, and release the pressure
remaining inside the hydraulic tank.

Removal (HM400_3R-A510-520-K-00-A)
4. Open engine hood (6).
1. Remove mounting bolts (1) (8 pieces), and
remove cover (2). a Be sure to turn lock (7) to LOCK position.
2. Remove plug (3), and install hose (4).
a Hose (4) is fixed as the special tool to the
back side of cover (2).
3. Loosen drain plug (5), and drain the hydraulic
oil.

6 Hydraulic tank:
167 l

50-88 HM400-3M0

5. Tilt up operator's cab assembly (8). For details,
see Testing and adjusting, "Cab tilt up
procedure".
k Check that lock lever (9) is in CLOSE
position and operator's cab assembly (8)
is securely supported with lock bar (10).
6. Remove the output shaft assembly. For details,
see "Removal and installation of output shaft
assembly".
7. Remove flywheel (11) according to the following
procedure.
1) Remove flywheel (11) mounting bolt (1 piece)
and install guide bolt.
2) By using eyebolt [1], sling flywheel (11) and
remove mounting bolts (8 pieces).
3) Pull out flywheel (11) from the dowel pin of
crankshaft (13), move it to your side, and
sling it.
HM400-3M0
50 Disassembly and assembly
Engine and cooling system
k Since the flywheel may drop at this time,
be sure not to hold it with your hands.
4 Flywheel (11):
60 kg
8. Remove rear oil seal (sleeveless seal).
a Slightly tap rear oil seal (14) to unstick it from
flywheel housing (12).
a Be careful not to damage the rear oil seal
contact surfaces on flywheel housing (12)
and crankshaft (13).
1) Drill several holes of approximately 3mm in
diameter on rear oil seal (14).
2) Select the drill type (DT) for the tip of tool
A11.
3) Insert tip of tool A11 to the hole drilled in step
1) and remove rear oil seal by using impact
power of slide hammer (SH).
a Apply impact evenly so that rear oil seal (14)
is not tilted.
9. Remove rear oil seal (sleeved seal).
1) Select the puller type (PT) for the tip of tool
A11.
2) Hang tip of tool A11 on metal ring of rear oil
seal (14), and pull out rear oil seal by using
impact power of slide hammer (SH).
3) Cut and remove sleeve (15) by using a chisel
and a hammer.
Left: Sleeveless seal Right: Sleeved seal
50-89
50 Disassembly and assembly
Engine and cooling system
• Tool A11
Installation (HM400_3R-A510-720-K-00-A)
• Perform installation in the reverse order to
removal.
1. Preparatory work for rear oil seal installation
a Check the wear of the crankshaft and select
either a "sleeveless seal" or a "sleeved seal"
to install it.
If the wear condition of the crankshaft is
glossy and no scratch (when touched by a
finger, wear depth is 10 µm or less), install
"sleeveless seal (A)". In other cases, install
"sleeved seal (B)".
(15): Shows the sleeve.
(16): Shows the inner plastic tube/installation
guide.
a Do not remove installation guide (16) from
rear oil seal (14) before installing it.
a Handle the rear oil seal (14) and sleeve (15)
as an assembly and never separate them
from each other.
50-90
a Clean, degrease, and dry contacting surface
(a) against flywheel housing (12).
a Clean, degrease, and dry the seal lip sliding
surface (peripheral surface of the
crankshaft).
2. Installation of rear oil seal (sleeveless seal).
a Before installing the rear oil seal, check that
end face corners and lip sliding surface of
the crankshaft and the housing are free from
flaw, burr, sharp edge or rust.
a When installing the rear oil seal, do not apply
oil or grease to the crankshaft and seal lip.
Thoroughly wipe off oil or grease from the
crankshaft.
a Never remove inner plastic tube (16) of the
sleeveless oil seal until the oil seal is
installed.
1) Apply the larger inside diameter side (b) of
plastic inner tube (16) to the end of
crankshaft (13).
a Be careful not to put the wrong end.
HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

2) Push in rear oil seal (14) until its metal ring
passes over large inside diameter side (b) of
inner plastic tube (16).
a Push in rear oil seal (14) while slightly
tapping its metal ring by using a plastic
hammer.
3) After pushing in rear oil seal (14), remove
inner plastic tube (16).
a Be careful not to damage the seal lip
when removing inner plastic tube (16).
3. Installation of rear oil seal (sleeved seal).
a When installing the rear oil seal, do not apply
oil or grease to the crankshaft and seal lip.
Thoroughly wipe off oil or grease from the
crankshaft.
1) Set sleeve (15) together with rear oil seal
(14) to tool A14.
2 Contact face of sleeve (15):
Liquid gasket (LG-7)

2) Put sleeve (15) of rear oil seal (14) to the end

4) Press-fit rear oil seal (14) by tightening the
surface of crankshaft (13).
bolts (4 pieces) evenly until the end face of
Press-fit sleeve (15) together with rear oil
tool A13 reaches the end face of crankshaft
seal (14) by tightening the bolts (4 pieces)
(13).
evenly until the end face of tool A14 reaches
a Tighten the bolts without washers until the end face of crankshaft (13).
tool A13 reaches the bottom, and then
a Tighten tool A14 together with the
install washers (2 pieces) to the bolts to
washers with the bolts.
tighten the bolts.
a Be careful not to damage the seal lip on
the front side by using a tool set, etc.
when press-fitting rear oil seal (14).
a After press-fitting rear oil seal (14),
remove the red sealant layer from its
outer periphery.

HM400-3M0 50-91
50 Disassembly and assembly
Engine and cooling system

3) Remove tool A14 and replace it with tool 2 Threaded part and seat surface of
A15. bolt:
4) Press-fit sleeve (15) together with rear oil Engine oil (EO30)
seal (14) by tightening the bolts (4 pieces)
evenly until the end face of tool A15 reaches 4 Flywheel (11):
the end face of crankshaft (13).
60 kg
a Tighten the bolts without washers until
tool A15 reaches the bottom, and then
install washers (2 pieces) to the bolts to
tighten the bolts.
a Installed dimension (c) of rear oil seal (14)
from end face of crankshaft (13): 13.2 ±
0.2 mm
a Be careful not to damage the seal lip by
using a tool set, etc. when press-fitting
rear oil seal (14).
a After press-fitting rear oil seal (14),
remove the red sealant layer from its
outer periphery. 2) Tighten the flywheel mounting bolts
according to the following procedure.
3 Flywheel mounting bolt
1st time: 118 ± 4.9 Nm {12 ± 0.5
kgm}
2nd time: 2nd time: By using tool
A12, tighten the bolts by 90 deg.
(+30 deg./0) in the order of [1] to
[8].

a When not using tool A12, put mark (f) on

the flywheel with paint, and then retighten
the bolts by 90 deg. (+30 deg./0) in the
order of [1] to [8].
4. Install the flywheel.
a After tightening, put a punch mark (g) on
1) By using eyebolt [1], sling flywheel (11) and
each bolt head to indicate the number of
install it to crankshaft (13).
tightening.
a Install the flywheel while aligning the
a When a new bolt is used, do not put a
dowel pin of crankshaft (13) with the pin
punch mark on its head.
hole of flywheel (11).
a The bolt which has 5 punch marks must
a Take care that flywheel (11) does not
be replaced without being reused.
touch the speed sensor.

50-92 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

3) After installing the flywheel, measure the

facial runout and radial runout by using dial
gauge [2].
a Facial runout: Max. 0.20 mm
a Radial runout: Max. 0.13 mm

5. Install the output shaft assembly. For details, see

"Removal and installation of output shaft
assembly".
• Refilling with oil
Refill with oil through the oil filler port of the
hydraulic tank to the specified level. Run the
engine to circulate the oil through the piping.
Then check the oil level again.

5 Hydraulic tank:
167 l

HM400-3M0 50-93
50 Disassembly and assembly
Engine and cooling system

Removal and installation of output shaft assembly (HM400_3R-CB30-924-K-00-A)

a Special tools k Do not place yourself under the cab during

the cab-tilting operation.

Necessity
Sym-

Q'ty
Part No. Part name k Fix the cab securely by using the lock lever
bol
before tilting up the cab.

790-201-2210 Plate t 1 k Installthe lock lever from the side of the cab
790-201-2740 Spacer t 1 without entering into a space below the cab.
791-600-1120 Bolt t 1
790-101-2540 Washer t 1 k Do not go in or out the cab when tilting up
1 01580-01613 Nut t 1 the cab.
B 01643-31645 Washer t 2
k Do not operate the gear shift lever and dump
Puller (294 kN {30
790-101-2102 t 1 lever when tilting up the cab.
ton})
790-101-1102 Hydraulic pump t 1
k Do not start the engine when tilting up the
792-420-1120 Flange t 2
2 cab.
01050-61225 Bolt t 8
k When you are forced to start the engine for
k In order to prevent serious or death inspection purpose, check that no person is
accidents due to falling of the cab, following under the cab.
precautions must be observed when tilting
the cab. k Do not give a large impact to the machine
when tilting up the cab.
• Precautions before starting cab-tilting operation
k Cab-tilting operation must be performed on a k When lowering the cab by using the cab
flat ground. power tilt (optional), do it gradually adjusting
the descending speed without decreasing
k Set the machine to the straight-travel the oil pressure at a breath.
condition to prevent the interference
k The lock bar is equipped in the inner left side
between the cab and body, then fix the front
and rear frames by using the articulation corner of the engine hood. Be sure to return
lock. the bar to the original place after using it.

k Set the parking brake switch to ON position k Stop the engine, turn the battery disconnect
by pressing "P", and apply the parking brake. switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
k Lock the lever by using the dump lever lock "Handling battery disconnect switch".)
knob.
k Loosen the cap of the hydraulic tank
k Chock the wheels to prevent the machine gradually, and release the pressure
from moving. remaining inside the hydraulic tank.

k When dismounting the cab, always lock the k Set the lock bar to the front and rear frames
lock pin at the rear mounting part of cab to lock them.
before starting the work.
Removal (HM400_3R-CB30-520-K-00-A)
k Do not perform the cab-tilting operation 1. Remove mounting bolts (1a) (8 pieces), and
when it is strongly windy. remove cover (1b).
2. Remove plug (1c), and install hose (1d).
k Before dismounting cab, be sure to lock the
lock pin in the rear mount of cab. a Hose (1d) is fixed as the special tool to the
back side of cover (1b).
• Precautions for cab-tilting operation 3. Loosen drain plug (1e), and drain the hydraulic
oil.
k Do not perform the cab-tilting operation
when the dump body is loaded. 6 Hydraulic tank: 167 l

50-94 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

5. Tilt up operator's cab assembly (3). For details,

see Testing and adjusting, "Cab tilt up
procedure".
a Check that lock lever (4) is in the CLOSE
position and operator's cab assembly (3) is
securely supported with lock bar (5).

4. Open engine hood (1).

a Be sure to turn lock (2) to LOCK position.

6. Remove clamp (5a).

7. Remove bracket (6).
8. Disconnect hoses (7), (8), and (9).

HM400-3M0 50-95
50 Disassembly and assembly
Engine and cooling system

9. Remove clamp (10).

10.Remove coupling (11).
11.Remove tube (12).
12.Remove pump assembly mounting bolts (13) (4
pieces), and remove pump assembly (14).

18.Remove bracket (22).

19.Remove coupling (24) and oil seal cage (25)
from output shaft assembly (23).

13.Remove tube (15).

14.Remove guard (16).

20.Remove snap ring (26).

15.Sling drive shaft (17) between the engine and

transmission, and remove mounting bolts (18)
and (19) (4 pieces each). [*1]
16.Remove drive shaft (17) between the engine
and transmission.[*2]
17.Remove coupling yoke (21) from output shaft
assembly (20).[*3]

21.Install guide bolt [2], sling cover (27), and

remove it by using tool [3]. [*4]

50-96 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

4 Cover (27):
25 kg

2 Mounting bolt of drive shaft between

engine and transmission:
22.Remove output shaft assembly (28) by using Liquid adhesive (LT-2)
forcing screw [1] and guide bolt [2].
3 Mounting bolt of drive shaft between
engine and transmission:
4 Output shaft assembly:
98 to 123 Nm {10.0 to 12.5 kgm}
90 kg
[*3]
For ENS grease charging procedure, see
"Disassembly and assembly of output shaft
assembly".
2 Spline:
ENS grease
a Remove other greases completely before using
ENS grease. It must not be mixed with other
greases. (The grease gun used for ENS grease
must discriminated from others.)
a ENS grease part No.:
23.Remove bearing (29).[*5] 427-12-11871 (2 kg can)
2 Bearing cover mounting bolt:
Liquid adhesive (LT-2)
3 Bearing cover mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
[*4]
Install cover (27) according to the following
procedure.
1. Sling cover (27).
2. Set tool B1 on the output shaft.
3. By using tool B1, press-fit the bearing inner
portion of the cover to the output shaft, and then
Installation (HM400_3R-CB30-720-K-00-A) install cover (27).
• Perform installation in the reverse order to 2 Mounting surface of cover (27):
removal. Liquid gasket (LG-6)
[*1], [*2]
• When installing drive shaft, check that key slot of
spider cap is completely fitted to key slot of the
mating yoke before tightening bolt.
a By using tool B2, perform centering of the
engine and torque converter.

HM400-3M0 50-97
50 Disassembly and assembly
Engine and cooling system

2 Mounting bolt of output shaft assembly:

Liquid adhesive (LT-2)
3 Mounting bolt of output shaft assembly:
98 to 123 Nm {10.0 to 12.5 kgm}
[*5]
2 Whole circumference of inside diameter
surface of bearing and outside diameter
surface of shaft
ENS grease (G2-U-S):
• Refilling with oil
Refill with oil to the specified level through the oil
filler port of the hydraulic tank. Run the engine to
circulate the oil through the piping. Then check
the oil level again.

5 Hydraulic tank:
167 l

50-98 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

Disassembly and assembly of output shaft assembly (HM400_3R-CB30-926-K-00-A)

a Put marks to indicate their mating position on the flange and outer body for installation purpose.

Disassembly (HM400_3R-CB30-530-K-00-A)

1. Oil cage assembly

Remove oil seal (1) from cage (2).
2. Cover assembly
Remove bearing (3) from cover (4).
3. Damper assembly (5)
1) Before disassembling, mark the assembly positions of flange (6), body assembly (7), and outer body
(10) to allow well-balanced reassembling.
2) Remove body assembly (7) large rubber (8), and small rubber (9) from outer body (10).
3) Remove bearing (11) from flywheel.

HM400-3M0 50-99
50 Disassembly and assembly
Engine and cooling system

Assembly (HM400_3R-CB30-710-K-00-A)

1. Press-fit bearing (11) in flywheel by using the

4 Cover assembly:
push tool.
35 kg
2 Flywheel hole and bearing inner 6. Install oil seal (1) in cage (2).
diameter part:
2 Outer periphery of oil seal and
ENS grease
insertion portion of cover
2. Assembly of damper assembly
Liquid adhesive (Loctite 648)
1) Apply adhesive to the mating surfaces of
outer body (10) and one side of flange (6), 2 Oil seal lip:
and then assemble them. ENS grease (G2-U-S):
2 Flange mating face: 7. Install the cage assembly to the cover assembly.
Liquid gasket (LG-6) 2 Mounting bolt:
2 Mounting bolt: Liquid adhesive (LT-2)
Liquid adhesive (LT-2) 3 Mounting bolt:
3 Mounting bolt: 98 to 123 Nm {10.0 to 12.5 kgm}
59 to 74 Nm {6.0 to 7.5 kgm}
2) Install dump body assembly (7).
3) Install large rubber (8) and small rubber (9).
a Place large rubber (8) at the load side at
assembly.
a Apply the grease before installation.
2 Outer body, body assembly, and
rubber:
ENS grease (G2-U-S):
4) Install flange (6).
2 Flange mating face:
Liquid gasket (LG-6)
2 Mounting bolt:
Liquid adhesive (LT-2)
3 Mounting bolt:
59 to 74 Nm {6.0 to 7.5 kgm}
a Align the outer dump body, dump body
assembly, rubber, and flange at the
marking positions, and assemble them.
3. Install damper assembly (5) to the flywheel.
2 Dump body assembly shaft spline:
ENS grease (G2-U-S):
2 Mounting bolt:
Liquid adhesive (LT-2)
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
4. Press-fit bearing (3) in cover (4).
2 Bearing:
ENS grease (G2-U-S):
5. Install the cover assembly to the flywheel.

50-100 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

• Procedure for filling with ENS grease

1. ENS grease part No.: 427-12-11871
2. Places to fill ENS grease and amount (total
amount: approximately 225 g)
a: 60 % pack (30 g)
b: Apply grease to all periphery of bearing inner-
diameter and shaft outer-diameter.
c: Apply grease to 3 places at 20 mm intervals
on labyrinth circumference.
d: 60 % pack (30 g)
e: Section B-B (R part)
f: Full pack (35 g)
g: Apply grease between grease lip and dust lip.
h: 50% pack (30 g)
i: Full pack (20g)
j: Apply grease to all periphery of spline.
k: Full pack (25g)
l: Full pack (30g)
m: 90 % pack (25g)

HM400-3M0 50-101
50 Disassembly and assembly
Engine and cooling system

Removal and installation of air cleaner assembly (HM400_3R-A910-924-K-00-A)

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".) 3. Remove four mounting bolts (5) of guard (4).
4. Remove four mounting bolts (6), and remove
Removal (HM400-A910-520-K-00-A) cover (7).
1. Open engine hood (1).

5. Remove four mounting bolts (8), and remove

guard (4).
a Be sure to place lock (2) to LOCK position.

6. Loosen clamp (9). [*1]

2. Remove cover (3). 7. Disconnect connectors MAF (10) and T05 (11).

50-102 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

8. Remove four air cleaner assembly mounting

bolts (12), and remove air cleaner assembly (13).
[*1]

Installation (HM400-A910-720-K-00-A)

• Perform installation in the reverse order to

removal.
[*1]
3 Clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

HM400-3M0 50-103
50 Disassembly and assembly
Engine and cooling system

Removal and installation of EGR (Exhaust Gas Recirculation) valve

assembly (HM400_3M0-A9K1-924-K-00-A)
k Place the machine on a level ground, set the
parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".) 3. Remove clamps (7), (8), and (9).

Removal (HM400_3M0-A9K1-520-K-00-A)

1. Open engine hood (1).

4. Remove mounting bolts (10) (4 pieces).

5. Remove joint bolts (11) (2 pieces).
6. Remove tubes (12), (13), (14), and (15). [*1]

k Check that lock (2) is set securely.

7. Remove mounting bolts (16) (8 pieces). [*2]

8. Remove EGR valve assembly mounting bolts
(17) (4 pieces), and remove bypass valve (18)
2. Disconnect connectors SBP (3), BP (4), SGER
and EGR valve assembly (19).
(5), and EGR (6).

50-104 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

Installation (HM400_3M0-A9K1-720-K-00-A)

• Perform installation in the reverse order to

removal.
[*1]
3 Sleeve nut of tubes (!2), (13), (14), and
(15):
24 to 27 Nm {2.5 to 2.8 kgm}
[*2]
3 Mounting bolt (16):
44.1 to 53.9 Nm {4.5 to 5.5 kgm}

HM400-3M0 50-105
50 Disassembly and assembly
Engine and cooling system

Removal and installation of EGR (Exhaust Gas Recirculation) cooler

assembly (HM400_3M0-A9L0-924-K-00-A)
k Place the machine on a level ground, set the a Work space for removal and installation of
parking brake switch to ON position by EGR cooler assembly inlet tube is securely
pressing "P", and apply the parking brake. obtained by tilting up the operator's cab
assembly (3).
k Chock the wheels to prevent the machine
from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)

k If you drain the coolant when it is still hot,

you may be scalded. Wait until the coolant
temperature drops before starting the work.

Removal (HM400_3M0-A9L0-520-K-00-A)

1. Open engine hood (1).

a Be sure to lock it with lock (2).

3. Remove cover (6) on the bottom of the engine.

4. Loosen drain plug (7), and drain the coolant.

6 Radiator: 114 l

2. Tilt up operator's cab assembly (3). For details,

see Testing and adjusting, "Cab tilt up
procedure".

k Check that lock lever (4) is in CLOSE

position and operator's cab assembly (3)
is securely fixed with lock bar (5).

50-106 HM400-3M0

5. Remove the air cleaner assembly (8). For details,
see "Removal and installation of air cleaner
assembly".
6. Remove the aftercooler core assembly (9). For
details, see "Removal and installation of
aftercooler assembly."
7. Remove clamp (10) and (10a), and disconnect
radiator outlet hose (11).
8. Disconnect fuel tank breather hose (12).
9. Remove drain tube (13) on the bottom of
turbocharger. [*1]
HM400-3M0
50 Disassembly and assembly
Engine and cooling system
10.Remove heat insulation plates (14) and (15).
11.Loosen clamps (16), (17), and (18).
12.Disconnect tubes for air bleeding (19) (2 pieces).
[*2]
13.Disconnect upper tube (20) and lower tube (21).
[*3]
14.Remove mounting bolts (22) (4 pieces) and (23)
(4 pieces), and disconnect EGR cooler
assembly (25) and tubes on the front and rear.
[*4]
a Remove mounting bolts (23) (4 pieces) from
rear side of the engine.
15.Remove mounting bolts (24) (4 pieces), and
remove EGR cooler assembly (25).
50-107
50 Disassembly and assembly
Engine and cooling system

Installation (HM400_3M0-A9L0-720-K-00-A)

• Perform installation in the reverse order to

removal.
[*1]
a Install a new gasket to drain tube (13).
[*2]
3 Air bleeding tube (19) joint bolt:
19.6 to 29.4 Nm {2 to 3 kgm}
[*3]
a Install new O-rings and gasket to upper tube (20)
and lower tube (21).
[*4]
2 Mounting bolt (23):
Seizure prevention compound (LC-G)
3 Mounting bolt (22):
44.1 to 53.9 Nm {4.5 to 5.5 kgm}
3 Mounting bolt (23):
44.1 to 53.9 Nm {4.5 to 5.5 kgm}
• Refilling with coolant
Refill with coolant to the specified level through
the coolant filler port of the radiator. Run the
engine to circulate the coolant through the piping.
Then check the coolant level again.

5 Radiator:
114 l

50-108 HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

Removal and installation of fire prevention cover on exhaust pipe (HM400_3R-

A9D7-924-K-00-A)

k In order to prevent serious or death
accidents due to falling of the cab, following
precautions must be observed when tilting
the cab.
• Precautions before starting cab-tilting
operation
k Cab-tilting operation must be performed on a
flat ground.
k Set the machine to the straight-travel
condition to prevent the interference
between the cab and body, then fix the front
and rear frames by using the articulation
lock.
k Set the parking brake switch to ON position
by pressing "P", and apply the parking brake.
k Operate the dump lever lock knob to lock the
dump lever.
k Chock the wheels to prevent the machine
from moving.
k Do not perform the cab-tilting operation
when it is strongly windy.
k Do not give a large impact to the machine
when tilting up the cab.
k When lowering the cab by using the cab
power tilt (optional), do it gradually adjusting
the descending speed without decreasing
the oil pressure at a breath.
k The lock bar is equipped in the inner left side
corner of the engine hood. Be sure to return
the bar to the original place after using it.
k Set the lock bar to the front and rear frames
to lock them.
k Stop the engine, turn the battery disconnect
switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)
a Note the connector numbers and installed
positions before disconnecting wiring harnesses
and hoses.
• Visually check the exhaust pipe fire
prevention cover. If it is damaged, replace it
according to the following procedure.
Removal (HM400_3R-A9D7-520-K-00-A)

k Before dismounting cab, be sure to lock the 1. Open engine hood (1).
lock pin in the rear mount of cab.
a Be sure to turn lock (2) to LOCK position.
• Precautions for cab-tilting operation

k Do not perform the cab-tilting operation

when the dump body is loaded.

k Do not place yourself under the cab during

the cab-tilting operation.

k Fix the cab securely by using the lock lever

before tilting up the cab.

k Install the lock lever from the side of the cab

without entering into a space below the cab.

k Do not go in or out the cab when tilting up

the cab.

k Do not operate the gear shift lever and dump

lever when tilting up the cab.

k Do not start the engine when tilting up the

cab.

k When you are forced to start the engine for

inspection purpose, check that no person is
under the cab.

HM400-3M0 50-109
50 Disassembly and assembly
Engine and cooling system
2. Tilt up operator's cab assembly (3). For details,
see Testing and adjusting, "Cab tilt up
procedure".
k Check that lock lever (4) is in CLOSE
position and operator's cab assembly (3)
is securely supported with lock bar (5).
3. Remove clamps (6) and (7).
50-110
4. Loosen clamp (7a), and disconnect hose (7b).
5. Remove clamps (8) (2 pieces) and disconnect
connector T01 (9).
6. Sling engine hood support (11).
7. Remove mounting bolts (10) (4 pieces each) on
the right and left sides of engine hood support
(11).
8. Sling engine hood support (11), and remove it.
a Remove engine hood support (11) together
with the radiator reservoir tank and fuel
prefilter.
4 Engine hood support (11): 80 kg
HM400-3M0
 50 Disassembly and assembly
Engine and cooling system

a Check that there is no clearance between (b)

turbo housing cover (12) and exhaust pipe
fire prevention cover (13).
a Check that there is no clearance between (c)
the muffler and exhaust pipe fire prevention
cover (13).
3. Tighten each belt (14) and ribbon (15).
a Adjust the length of ribbon (15) so that its end
does not hit, and securely tie it.

9. Remove turbo housing cover (12) and fire

prevention cover (13) for the exhaust pipe. [*1]

Installation (HM400_3R-A9D7-720-K-00-A)

• Perform installation in the reverse order to

removal.
[*1]
1. Install turbo housing cover (12) to the
turbocharger.
2. Set exhaust pipe fire prevention cover (13) to the
exhaust pipe.
4. Completely block contacting face (d) of exhaust
a Install the cover with seam line (a) facing pipe fire prevention cover (13) to prevent
upward. clearance, and tighten belt (14).
a Make sure that turbo housing cover (12) and a Fold ends (e) of each belt (14) to fix them.
exhaust pipe fire prevention cover (13) are
overlapped.

HM400-3M0 50-111
50 Disassembly and assembly
Engine and cooling system

50-112 HM400-3M0
 50 Disassembly and assembly
Power train

Power train (ALL-C100-001-K-00-A)

Removal and installation of transmission and front differential

assembly (HM400_3R-RA1P-924-K-00-A)
a Special tools k Installthe lock lever from the side of the cab
without entering into a space below the cab.

Necessity
Sym-

Q'ty
Part No. Part name k Do not go in or out the cab when tilting up
bol
the cab.

792-420-1120 Flange t 2 k Do not operate the gear shift lever and dump
B 2
01050-61225 Bolt t 8 lever when tilting up the cab.

k In order to prevent serious or death
accidents due to falling of the cab, following
precautions must be observed when tilting
the cab.
• Precautions before starting cab-tilting operation
k Cab-tilting operation must be performed on a
flat ground.
k Set the machine to the straight-travel
condition to prevent the interference
between the cab and body, then fix the front
and rear frames by using the articulation
lock.
k Set the parking brake switch to ON position
by pressing "P", and apply the parking brake.
k Lock the lever by using the dump lever lock
knob.
k Chock the wheels to prevent the machine
from moving.
k When dismounting the cab, always lock the
lock pin at the rear mounting part of cab
before starting the work.
k Do not perform the cab-tilting operation
when it is strongly windy.
k Do not start the engine when tilting up the
cab.
k When you are forced to start the engine for
inspection purpose, check that no person is
under the cab.
k Do not give a large impact to the machine
when tilting up the cab.
k When lowering the cab by using the cab
power tilt (optional), do it gradually adjusting
the descending speed without decreasing
the oil pressure at a breath.
k The lock bar is equipped in the inner left side
corner of the engine hood. Be sure to return
the bar to the original place after using it.
k Set the lock bar to the front and rear frames
to lock them.
k Stop the engine, turn the battery disconnect
switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)
k Loosen the cap of the hydraulic tank
gradually, and release the pressure
remaining inside the hydraulic tank.

k If you disconnect the heater hose when the

k Before dismounting cab, be sure to lock the
lock pin in the rear mount of cab. coolant in radiator is still hot, you may be
scalded. Wait until the coolant temperature
• Precautions for cab-tilting operation drops before starting the work.

k Do not perform the cab-tilting operation a Ask a qualified person for collecting, adding and
when the dump body is loaded. filling operations of the refrigerant (air
conditioner gas: R134a).
k Do not place yourself under the cab during
a Never release the refrigerant (air conditioner
the cab-tilting operation.
gas: R134a) to the atmosphere.
k Fix the cab securely by using the lock lever
before tilting up the cab.

HM400-3M0 50-113
50 Disassembly and assembly
Power train

k If refrigerant gas (air conditioner gas: R134a)

gets in your eyes, you may lose your sight.
And if it touches your skin, you may suffer
from frostbite. Put on protective eyeglasses,
gloves and working clothes with long
sleeves while collecting the refrigerant or
filling the air conditioner circuit with the
refrigerant.

a Note the connector numbers and installed

positions before disconnecting wiring harnesses
and hoses.
Removal (HM400_3R-RA1P-520-K-00-A) 4. Open engine hood (1e).
1. Remove mounting bolts (1) (8 pieces), and a Be sure to turn lock (1f) to LOCK position.
remove cover (1a).
2. Remove plug (1b), and install hose (1c).
a Hose (1c) is fixed as the special tool to the
back side of cover (1a).
3. Loosen drain plug (1d), and drain the hydraulic
oil.

6 Hydraulic tank:
167 l

5. Collect the refrigerant (air conditioner gas:

R134a) from the air conditioner circuit.
a Refrigerant to be collected:
875 ± 25 g
6. Drain oil from the transmission and brake oil
tank.

6 Transmission and brake oil tank:

125 l
7. Drain oil from the front differential case.

6 Front differential case:

26 l
8. Sling operator's cab assembly (1) and remove it.
For details, see "Removal and installation of
operator's cab assembly".

50-114 HM400-3M0
 50 Disassembly and assembly
Power train

4 Operator's cab assembly:

1,150 kg

12.Remove water drain tube (3a).

13.Remove right bracket (3b) and left bracket (3c).

9. Sling the engine hood support and remove it.

For details, see "Removal and installation of
injector assembly".

10.Remove cover (2).

11.Remove mounting bolts (3) (4 pieces). [*1]

14.Sling exhaust pipe assembly (4) and remove it.

4 Exhaust pipe assembly (4):

35 kg

HM400-3M0 50-115
50 Disassembly and assembly
Power train

15.Remove covers (5), (6), (7), (8), and (9).
16.Open cover (10).
23.Disconnect hoses (37), (38), (39), and (40).
24.Remove mounting bolt (41), and disconnect
tube (42).
25.Disconnect tubes (43), (44), (45), and (46).
26.Remove clamp (47).

17.Disconnect connectors (11) and (12), clamp and

ground cable.
18.Disconnect hoses (13) to (23) and install oil
stopper. 27.Remove clamp (48).
28.Disconnect connectors (49) and (50).
a Prepare an oil container in advance.
29.Disconnect terminal (51).
19.Remove clamps (24) and (25).
30.Disconnect tube (52).
20.Remove cover (26).

31.Sling mount (53) of exhaust pipe assembly.

21.Remove clamps (27) to (35).
22.Remove U-clamps (36) (2 pieces).

50-116 HM400-3M0
 50 Disassembly and assembly
Power train

38.Disconnect connectors (65) and (66), and pull

them out of the hole.

32.Disconnect connector (54).

33.Remove clamp (55).
39.Remove mount (53) of exhaust pipe assembly.

34.Remove clamps (56), (57), and (58).

35.Disconnect connectors (59), (60), and (61). 40.Remove clamp (66), spacer (67) and bracket
(68).

36.Remove clamps (62) and (63).

37.Remove clamp (64). 41.Loosen clamps (69) (4 pieces), and remove
hose (70).
a Prepare an oil container in advance.
42.Remove coupling (71), and remove tubes (72)
and (73).

HM400-3M0 50-117
50 Disassembly and assembly
Power train

43.Remove clamps (74), (75), (76), (77), (78), and 49.Remove tube (92).
(79). 50.Remove clamp (93).
44.Disconnect connector (80).
45.Disconnect hoses (81), (82), (83), (84), (85), and
(86).
a Prepare an oil container in advance.
46.Disconnect tube (87).
47.Disconnect tubes (88), (89), and (90).

51.Disconnect connectors (94), (95), (96), (97), (98),

(99), and (100).
52.Remove clamps (101), (102), (103), (104), (105),
(106), (107), (108), and (109).
53.Remove clamp (110).
54.Remove hoses (111) and (112).
a Prepare an oil container in advance.

48.Remove clamp (91).

50-118 HM400-3M0

55.Remove clamp (113) under the vertical main
bar.
56.Remove clamp (114).
57.Remove bracket (115).
58.Disconnect hoses (116), (117), and (118).
a Prepare an oil container in advance.
59.Remove clamp (119).
60.Remove coupling (120).
61.Remove tube (121).
62.Remove pump assembly mounting bolts (122)
(4 pieces), and remove pump assembly (123).
63.Disconnect hose (124).
HM400-3M0
50 Disassembly and assembly
Power train
64.Remove mounting bolts (125) (4 pieces), and
remove coupling yoke (127) of output shaft (126)
from the engine side.
65.Remove tube (128).
a Prepare an oil container in advance.
66.Remove guard (129).
67.Sling drive shaft assembly (130) between the
engine and transmission, and remove mounting
bolts (131) (4 pieces).
68.Remove drive shaft assembly (130) between the
engine and transmission. [*2]
69.Disconnect hose (132).
50-119
50 Disassembly and assembly
Power train

70.Open undercover (133). 74.Remove clamp (143).

71.Remove clamps (134), (135), and (136). 75.Disconnect tubes (144) and (145).
72.Remove brackets (137) and (138). 76.Disconnect hoses (146), (147), (148), and (149).

73.Disconnect hoses (139), (140), (141), and (142). 77.Disconnect every wiring attached to vertical
main bar (150), sling vertical main bar (150), and
remove it.

4 Vertical main bar:

45 kg

50-120 HM400-3M0
 50 Disassembly and assembly
Power train

78.Remove couplings (151) and (152), and remove
tube (153).
79.Remove tubes (154) and (155).
80.Disconnect hoses (156), (157), (158), and (159).
81.Remove couplings (160) and (161), and remove
tube (162).
82.Remove U-clamp (163).
83.Remove tube (164).
84.Remove the front wheel assembly. For details,
see "Removal and installation of front wheel
assembly". [*3]
85.Disconnect hoses (165), (166), (167), (168), and
(169) under the left fender.
86.Remove clamp (170).
87.Remove U-clamp (171), and remove tube (172).
88.Remove tube (173).

89.Remove bracket (174), U-clamp (175), and

elbow (176).

90.Disconnect cover (177) under the right fender.

HM400-3M0 50-121
50 Disassembly and assembly
Power train

91.Disconnect hose (178). 97.Sling drive shaft assembly (189) on the both
sides (between front differential and front final
drive), and disconnect drive shaft assembly
(189) on the front differential side. [*4]

92.Disconnect hoses (179), (180), (181), and (182).

98.Remove yoke (190).

93.Disconnect the hose at (183) and (184).

99.Sling drive shaft assembly (191) between the

transmission and hitch frame.

94.Disconnect tube (185).

95.Remove coupling (186), and remove tube (187).
96.Remove covers (188) (2 pieces).

50-122 HM400-3M0

100.Disconnect drive shaft assembly (191) at the
transmission side. [*5]
101.Remove transmission and front differential
assembly mounting bolts (192) (2 pieces on the
center right and left sides). [*6]
102.Remove transmission and front differential
assembly mounting bolts (193) (2 pieces on the
front right and left sides). [*7]
103.Remove transmission and front differential
assembly mounting bolts (194) (8 pieces on the
rear right and left sides). [*8]
HM400-3M0
50 Disassembly and assembly
Power train
104.Sling transmission and front differential
assembly (195) and remove them. [*9]
4 Transmission and front differential
assembly:
2,300 kg
Installation (HM400_3R-RA1P-720-K-00-A)
• Perform installation in the reverse order to
removal.
[*1]
2 Threaded portion and seat surface of
mounting bolt:
Seizure prevention compound (LC-G)
[*2]
• When installing drive shaft, check that key slot of
spider cap is completely fitted to key slot of the
mating yoke before tightening bolt.
a By using tool B2, perform centering of the
engine and torque converter.
50-123
50 Disassembly and assembly
Power train
2 Mounting bolt of drive shaft between
engine and transmission:
Liquid adhesive (LT-2)
3 Mounting bolt of drive shaft between
engine and transmission:
98 to 123 Nm {10.0 to 12.5 kgm}
[*3]
Install the front wheel assembly. For details, see
"Removal and installation of front wheel assembly".
[*4]
• When installing drive shaft, check that key slot of
spider cap is completely fitted to key slot of the
mating yoke before tightening bolt.
2 Mounting bolt for drive shaft between
transmission and hitch frame:
Liquid adhesive (LT-2)
3 Mounting bolt for drive shaft between
transmission and hitch frame:
98 to 123 Nm {10.0 to 12.5 kgm}
[*5]
• When installing drive shaft, check that key slot of
spider cap is completely fitted to key slot of the
mating yoke before tightening bolt.
2 Mounting bolt for drive shaft between
transmission and hitch frame:
Liquid adhesive (LT-2)
3 Mounting bolt for drive shaft between
transmission and hitch frame:
157 to 196 Nm {16 to 20 kgm}
[*6]
3 Center side mount bolt:
235 to 285 Nm {23.5 to 29.5 kgm}
[*7]
• Standard shim thickness (b) for front side
mounting bolt: 1 mm
• Standard shim thickness (c) for rear side
mounting bolt: 2 mm.
50-124
3 Front side mounting bolt:
1,150 to 1,440 Nm {118 to 147 kgm}
[*8]
3 Rear side mounting bolt:
235 to 285 Nm {23.5 to 29.5 kgm}
[*9]
4 Transmission and front differential
assembly:
2,300 kg
• Filling of refrigerant (R134a)
Refill the air conditioner circuit with refrigerant
(air conditioner gas: R134a).
Refill amount: 875 ± 25g
• Refilling with air conditioner compressor oil
See Air conditioner, "Handling of compressor oil".
• Refilling with oil
Refill with oil through the oil filler port of the
hydraulic tank to the specified level. Run the
engine to circulate the oil through the piping.
Then check the oil level again.
5 Hydraulic tank:
167 l
• Refilling with oil
Refill with oil through the oil filler ports of the
transmission and brake oil tank to the specified
level. Run the engine to circulate the oil through
the piping. Then check the oil level again.
5 Transmission and brake oil tank:
125 l
• Refilling with oil
Refill with oil through the oil filler port of the front
differential case to the specified level. Run the
engine to circulate the oil through the piping.
Then check the oil level again.
5 Front differential case:
26 l
HM400-3M0
 50 Disassembly and assembly
Power train

Disconnection and connection of front differential assembly and

transmission assembly (HM400-RA1P-925-K-00-A)
Disconnection (HM400_3R-RA1P-510-K-00-A)

1. Bracket
Remove brackets (1a) and (1b).
2. Piping
Remove hoses and pipings (2a) to (3f).
a Record their currently installed positions.
3. Pumps
1) Remove pumps (4a) for driving torque
converter, transmission, aftercooler fan, and
center brake cooling motors.
2) Remove center brake, radiator fan, and
brake charge pumps (4b).

5. Front differential assembly

Sling front differential assembly (7) and remove
it. [*2]

4 Front differential assembly:

450 kg

Connection (HM400-RA1P-730-K-00-A)

[*1]
Adjust the speed sensor. For details, see Testing
and adjusting, "Adjusting transmission speed
sensor."
[*2]
4. Remove cover (5) and remove transmission
2 Front differential mounting bolt:
front output shaft speed sensor (6). [*1]
Adhesive (LT-2)

HM400-3M0 50-125
50 Disassembly and assembly
Power train

3 Front differential mounting bolt:

490 to 608 Nm {50 to 62 kgm}

50-126 HM400-3M0
 50 Disassembly and assembly
Power train

Disassembly and assembly of front differential assembly (HM400-DC70-926-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

1 792T-423-1120 Push tool t 1

790-101-5201 Push tool kit (B) t 1
790-101-5231 • Plate 1
2 790-101-5331 • Plate 1
790-101-5221 • Grip 1
01010-51225 • Bolt 1
3 792T-423-1130 Push tool t 1 2. Bevel gear fall-prevention bolt
790-101-5401 Push tool kit (C) t 1 Remove bevel gear fall-prevention bolt (4).
H
790-101-5461 • Plate 1
790-101-5521 • Plate 1
4
790-101-5481 Plate 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-201-2800 Push tool (C) t 1
5
790-201-2840 • Spacer t 1
6 792T-415-1410 Push tool t 1

Disassembly (HM400-DC70-530-K-00-A)

1. Speed sensor and top cover

1) Remove right and left speed sensor covers
(1). 3. Input shaft coupling and holder
Remove holder (5), and remove coupling gear
assembly (6).

2) Remove speed sensors (2a) and (2b) on

right and left sides.
3) Remove top cover (3). 4. Pinion and case assembly
1) Remove mounting bolts (7a).
2) Pull out pinion case assembly (7), by using
forcing screws [1].
a Check and record the number and
thickness of the shims.

HM400-3M0 50-127
50 Disassembly and assembly
Power train

3] Remove seals (14) and (15), bearing (16),

and bearing outer race (13b) from case
(10).

3) Disassemble the pinion and case assembly

according to the following procedure.
1] Remove case assembly (10) from pinion
assembly (11).
5. Right and left output shaft couplings
Remove couplings (17) on right and left sides.
a Check and record the number and thickness
of the shims.

6. Differential assembly
1) Sling differential gear case (18), and hold it.
2) Remove mounting bolts (19a) from side
carrier and shaft assembly (19) at bevel gear
side.
a Bracket (20) is tightened together with.

2] Remove spacer (12) and bearing (13a).

50-128 HM400-3M0
 50 Disassembly and assembly
Power train

3) Sling the differential gear case by using lifting

tool, hold it, and remove side carrier on the
bevel gear side and shaft assembly (19) by
using forcing screw [1].
a Check and record the number and
thickness of the shims.

k Make up a team with 2 persons when

removing side carrier and shaft
assembly (19).

a For disassembling of side carrier and

shaft assembly, see step 8.
5) Sling differential gear assembly (22) and
remove it.

7. Disassembly of differential gear assembly

1) Remove 12 mounting bolts (23a), and
remove case and bearing assembly (23).
a Before removing, put a match mark on
the case on the bearing assembly (23)
4) Hold the differential gear case, and remove side, and the case of bevel gear
side carrier (at the opposite side) and shaft assembly side.
assembly (20) by using forcing screw [2].
a Note the number and thickness of the
shims, and the upward/downward
direction of side carrier.

HM400-3M0 50-129
50 Disassembly and assembly
Power train
2) Remove bearing (25) from case (24) by
using puller [3].
3) Remove washer (26a).
4) Remove differential side gear (27a).
5) Remove pinion gear assembly (28) as a unit.
6) Remove 4 each of washers (28b), pinion
gears (28c) and bushings (28d) from shaft
(28a).
50-130
7) Remove differential side gear (27b).
8) Remove washer (26b).
9) Disassemble the bevel gear assembly
according to the following procedure.
1] Turn over bevel gear and case assembly
(29).
2] Remove bearing (30a) from bevel gear
and case assembly (29) by using puller
[4].
3] Remove mounting bolts (31a), and
remove case (31) from bevel gear (32).
HM400-3M0

8. Disassembly of side carrier and shaft assembly
1) Disassemble the side carrier (at bevel gear
side) and shaft assembly according to the
following procedure.
1] Remove seal (33).
2] Remove shaft and bearing assembly
(34).
3] Remove bearing (35a) by using push tool
[5].
HM400-3M0
50 Disassembly and assembly
Power train
4] Remove bearing (37) and bearing outer
races (30b) and (35b) from case (36).
a Bearings (37) is divided into inner and
outer races when the shaft is removed
(pulled out).
2) Disassemble the side carrier (at opposite
side to bevel gear) and shaft assembly
according to the following procedure.
1] Remove seal (38).
2] Remove shaft and bearing assembly
(39).
50-131
50 Disassembly and assembly
Power train

1] Install bearing outer races (30b), (35b),

and (37b) to case (36).

3] Remove bearing (40a) by using push tool

[5].

2] By using tool H1, press-fit bearing (35a)

to shaft (43).

3) Remove bearing (42) and bearing outer

races (30b) and (40b) from case (41).
a Bearings (42) is divided into inner and
3] After attaching the standard shims
outer races when the shaft is removed
(thickness and number of shims checked
(pulled out).
at disassembly), install coupling (17). By
using tool H2, press-fit case assembly
(45) to the shaft and bearing assembly by
pushing holder (44).

Assembly (HM400_3R-DC70-710-K-00-A)

a If no tool is specified to mount seals and

assemble parts (especially, in the input shaft
section), use a push tool having an appropriate
diameter.
1. Assembly of side carrier and shaft assembly
1) Assemble the side carrier and shaft
assembly on the bevel gear side according
to the following procedure.
2) Adjust shims for the bearing according to the
following procedure.
1] Measure the starting tangential force in
the tangential direction of the bolt hole of
the case.
a Standard tangential force:
Max. 21.5 N {2.2 kg}

50-132 HM400-3M0
 50 Disassembly and assembly
Power train

2] When the starting tangential force is large,

increase shims, and decrease shims
when it is small. Then measure the
starting tangential force again.
a When the starting tangential force is
large, disassemble shaft and bearing
assembly (34) and case assembly
(45), and increase shims. Then
proceed to Steps 1) - 3].

4) Assemble the side carrier and shaft

assembly on the opposite side of the bevel
gear according to the following procedure.
1] Install bearing outer races (25b), (40b),
and (42b) to case (41).

3) By using tool H3, press-fit seal (33).

a Insert seal (33) so that dimension A is 4.6
± 0.2 mm.
2 Seal periphery:
Adhesive (SEALEND 242 or
equivalent)
2 Seal lip:
Grease (G2-LI) 2] By using tool H1, press-fit bearing (40a)
to shaft (46).

3] After inserting the standard shims

(thickness and number of shims checked
at disassembly), install coupling (18). By
using tool H2, press-fit case assembly
(48) to the shaft and bearing assembly
(39) by pushing holder (47).

HM400-3M0 50-133
50 Disassembly and assembly
Power train
5) Adjust shims for the bearing according to the
following procedure as you did for the side
carrier on the bevel side.
1] Measure the starting tangential force in
the tangential direction of the bolt hole of
the case.
a Standard tangential force:
Max. 24.5 N {2.5 kg}
2] When the starting tangential force is large,
increase shims, and decrease shims
when it is small. Then measure the
starting tangential force again.
a When the starting tangential force is
large, disassemble shaft and bearing
assembly (39) and case assembly
(48), and increase shims. Then
proceed to Step 4)-3].
6) By using tool H3, press-fit seal (38).
a Insert seal (38) so that dimension (A) is
4.6 ± 0.2 mm.
2 Seal periphery:
Adhesive (SEALEND 242
equivalent)
2 Seal lip:
Grease (G2-LI)
50-134
a For installation of the right and left side
carriers and shaft assembly to the main body,
see Step 3.
2. Differential gear assembly
1) Assemble the differential gear assembly
according to the following procedure.
1] Install case (31) to bevel gear (32).
2 Mounting bolt:
Liquid adhesive (LT-2)
3 Mounting bolt:
245 to 309 Nm {25.0 to 31.5
kgm}
2] Shrink-fit bearing inner race (30a) to case
(31).
a Shrink fit temperature:
Approximately 120°C for 30 minutes
or
3] Turn over the case and bevel gear
assembly.
4] Install washer (26b) in the case.
5] Install differential side gear (27b).
HM400-3M0

6] Install 4 each of bushings (28d), pinion
gears (28c) and washers (28b) to shaft
(28a).
7] Install pinion gear assembly (28) as a
unit.
8] Install differential side gear (27a).
9] Install washer (26a).
10]Shrink-fit bearing (25) in case (24).
• Bearing shrink fit temperature:
120 °C for 30 minutes.
a After installation, drip Axle Oil
(AXO80) to the bearing.
HM400-3M0
50 Disassembly and assembly
Power train
11]Install case and bearing assembly (23).
a Align the match marks when installing.
3 Mounting bolt:
245 to 309 Nm {25.0 to 31.5
kgm}
3. Side carrier and shaft assembly
1) While slinging the differential gear case,
mount the standard shims (their thickness
and numbers are checked during
disassembly) and install side carrier and
shaft assembly (19) on the bevel gear side.
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
2) Continued from the above posture, mount
the standard shims (their thickness and
numbers are checked during disassembly) to
50-135
50 Disassembly and assembly
Power train

side carrier and shaft assembly (20) on the 3 Mounting bolt:

opposite side and install the assembly. 490 to 608 Nm {50 to 62 kgm}
3 Mounting bolt:
157 to 196 Nm {16 to 20 kgm}

5. Pinion and case assembly

1) Assemble the pinion and case assembly
3) Preload adjustment of side bearing according to the following procedure.
1] Measure the starting torque in the 1] By using tool H4, install bearing outer
tangential direction of the outside of the race (16b) to case (11).
bevel gear. 2] By using tool H4, install bearing outer
race (13b) to case (11).
a Starting torque:
9.8 to 24.5 N {1.0 to 2.5 kg}
2] When the value measured is greater than
the standard starting torque, increase the
thickness and number of shims. The
value is normal when it is within the
standard starting torque.
a The right and left shims may be
interchanged after adjusting the tooth
contact or backlash. However, it is
prohibited to change the sum of
thickness and numbers of the right
and left shims.
4) After the preload adjustment, be sure to 3] Set bearing (13a) and spacer (12) to
tighten the bolts to the specified torque pinion (10).
described in Step 1). 4] By using tool H5, insert bearing (13a) into
pinion (10).

4. Right and left output shaft couplings

Install right and left couplings (17). 2) By using tool H5, press-fit case assembly
2 Mounting bolt: (11) to pinion (10).
Liquid adhesive (LT-2) a Never use the press for pushing.

50-136 HM400-3M0
 50 Disassembly and assembly
Power train

a When press-fitting bearing (16a), apply a Press-fit the seal flush with the case
tool H5 to it. as indicated in the figure while paying
• Press-fitting force: attention to its installation direction.
0 to 8134 N {0 to 830 kg}
a Rotate case assembly (11) when press-
fitting it.

3) Mount the standard shims (their thickness

and numbers are checked during
disassembly), and install pinion and case
assembly (9).
a Tighten them with 3 mounting bolts.
a After adjusting the tooth contact, tighten
every mounting bolt.
3 Mounting bolt:
245 to 309 Nm {25.0 to 31.5 kgm}

1] By using push tool H4, press-fit seal (15)

to case (11).
2 Seal periphery:
Adhesive (SEALEND 242 or
equivalent)
2 Seal lip:
6. Input shaft coupling and holder
Grease (G2-LI)
1) By using tool H6, press-fit speed detecting
a Press-fit the seal flush with the case gear (8) to coupling (7).
as indicated in the figure while paying
a Press-fit the gear flush with the coupling.
attention to its installation direction.
a Standard dimension (a) = 110 mm
must result from the installation.
2] By using push tool H4, press-fit seal (14)
to case (11).
2 Seal periphery:
Adhesive (SEALEND 242 or
equivalent)
2 Seal lip:
Grease (G2-LI)

HM400-3M0 50-137
50 Disassembly and assembly
Power train

2) Install coupling and gear assembly (6) and a Conduct the adjustment in 3 to 4
install holder (5). locations. Fix the pinion gear during
the measurement.
2 Coupling and gear tip (contact
surface with inner bearing):
Molybdenum disulfide lubricant
(LM-P)
2 Holder mounting bolt:
Liquid adhesive (LT-2)
3 Holder mounting bolt:
824 to 1,030 Nm {84 to 105 kgm}

2) Adjust the tooth contact according to the

following procedure.
1] Adjust travel of the bevel pinion by
increasing or decreasing shims (52)
between differential case and bearing
case.

7. Adjusting the tooth contact and backlash

• Adjust the backlash and, at the same time,
adjust the tooth contact.
1) Adjust the backlash according to the
following procedure.
1] Increase or decrease shims (31a) and
(31b) of the right and left carrier
assemblies to move the bevel gear. At
this time, be sure not to change the total
thickness and numbers of the right and
left shims to avoid changing the preload • When the backlash is below the
to the bearing. standard value
Loosen the adjustment nut on the
bevel gear side, then tighten the left
side adjustment nut by that amount.
(Advance in direction (A))
• When the backlash exceeds the
standard value
Loosen the left side adjustment nut,
then tighten the adjustment nut on the
bevel gear side by that amount.
(Advance in direction (B))

2] Apply dial gauge [14] vertically to the

reverse tooth surface in the outer end of
the bevel gear, and adjust the tooth
surface so that move of the gauge pointer
is 0.3 to 0.46 mm.

50-138 HM400-3M0
 50 Disassembly and assembly
Power train

a Tooth contact pattern will be as shown

in the next figure.
• Decrease shims of the bevel pinion to
advance the bevel pinion in direction
(C).
• Advance the bevel gear in direction
(D).

2] Checking tooth contact

Thinly apply red lead to 7 to 8 tooth
surfaces of the bevel gear, then rotate the
bevel gear back and forth to check the
tooth contact patterns left on the bevel
gear.
a The center of the tooth contact must
be the position indicated below. When the bevel pinion is too close to
• Central portion of tooth height the bevel gear
• The position where tooth length from
a Tooth contact pattern will be as shown
small end (C) is (x)
in the next figure.
(Approximately 33 % of the tooth
length) • Increase shims of the bevel pinion to
advance the bevel pinion in direction
a Width (y) of the tooth contact must be (E).
30 to 60 % of the tooth length. • Advance the bevel gear in direction
a Check that addendum (A), dedendum (F).
(B), small end (C) and large end (D)
are not exposed to strong contact.

When the bevel gear is too close to the

bevel pinion
3] Adjusting tooth contact a Tooth contact pattern will be as shown
When an appropriate tooth contact in the next figure.
pattern is not obtained in the check,
• Decrease shims of the bevel pinion to
repeat adjustment referring to the
advance the bevel pinion in direction
following.
(C).
a After adjusting the tooth contact, • Advance the bevel gear in direction
check the backlash again. (D).
• Correct the tooth contact according to
the following procedure.
When the bevel pinion is excessively
distanced from the bevel gear

HM400-3M0 50-139
50 Disassembly and assembly
Power train

9. Speed sensor and top cover

When the bevel gear is excessively
distanced from the bevel pinion 1) Install top cover (3).

a Tooth contact pattern will be as shown 2 Top cover:

in the next figure. Liquid adhesive (LT-515)
• Increase shims of the bevel pinion to 3 Top cover mounting bolts:
advance the bevel pinion in direction
157 to 196 Nm {16 to 20 kgm}
(E).
Install speed sensors (2a) and (2b).
• Advance the bevel gear in direction
(F).

2) Install speed sensor cover (1).

a After adjustment of the tooth contact,

apply adhesive referring to the
following items. Be sure to observe
the specified torque.
• Mounting bolts for the right and left
bevel gear side carriers
• Pinion and case assembly
• Input shaft
8. Bevel gear fall-prevention bolt
Install bevel gear fall-prevention bolt (4).
a Apply the bolt tip to the bevel gear back face
and return the bolt by 3/4 turn, then secure a Install speed sensors (2a) and (2b) according
the bolt with the lock nut. to the following procedure.
2 Bolt: 1) Finger-tighten the speed sensor until its tip
Liquid gasket (LG-5) lightly touches surface of the addendum of
the gear.
3 Lock nut:
196 to 245 Nm {20 to 25 kgm} a Turin it gently without pushing it hard to
the addendum.

50-140 HM400-3M0
 50 Disassembly and assembly
Power train

2) When the speed sensor touches the

addendum surface of the gear, rotate it by
360 deg. counterclockwise from that position.
3) Rotate the speed sensor clockwise, and
tighten lock nut (53b) at the position where
position mark (P) of positioning nut (53a)
becomes parallel to the lateral direction of
the machine.
(a) direction: Left side of machine
(b) direction: Right side of machine
3 Lock nut (53b):
84 to 132 Nm {8.5 to 13.5 kgm}

HM400-3M0 50-141
50 Disassembly and assembly
Power train

Disassembly and assembly of torque converter assembly (HM400-CD00-926-K-00-A)

a Special tools 2) Place torque converter housing (3) on block

[3] with the pump side down.

Necessity
3) Remove mounting bolts (2) which have been
Sym-

Q'ty
Part No. Part name remained in Step (1), and remove torque
bol
converter assembly (4) by using eyebolts [4].

790-501-5200 Unit repair stand t 1

1 790-901-2110 Bracket t 1
792T-413-1110 Plate t 1
2 792-103-5110 Wrench t 1
790-101-3201 Bearing puller t 1
3
790-101-2501 Push puller t 1
790-101-5401 Push tool kit (C) t 1
C 790-101-5471 • Plate 1
790-101-5451 • Plate 1
4
790-101-5491 • Plate 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1 3. Turbine and clutch assembly
790-201-2700 Push tool (C) t 1
5 1) Set torque converter assembly (4) to tool C1.
790-201-2770 • Spacer 1
6 792T-413-1120 Push tool t 1

Disassembly (HM400-CD00-530-K-00-A)

1. PTO assembly
By using eyebolt [1], mount forcing screw [2] in
position, and remove PTO assembly (1).

2) Remove pump side mounting bolt (5).

2. Torque converter assembly

1) Loosen all mounting bolts (2). Leave
approximately 3 bolts in position, but remove
all other bolts.

3) By using eyebolts [5], remove turbine and

clutch assembly (6).
a For disassembling details, see Step 7
"Disassembly of the turbine and clutch
assembly".

50-142 HM400-3M0
 50 Disassembly and assembly
Power train

4. Stator assembly 3) Remove the mounting bolts, retainer (11),

Lift and remove stator assembly (7) . and guide (12).
a For disassembling details, see Step 8
"Disassembly of the stator assembly".

4) By using push tool C4, remove bearing (13)

from guide (12).
5. Pump assembly
1) By using tool C2, loosen and remove nut (8).

6. Stator shaft
1) Remove the plug, and remove inner race
2) Using puller [6], remove inner race (9) and (15) from stator shaft (14) by using a pushrod
pump assembly (10). or others.
a When installing the plug again, do not
apply adhesive (LT-2).
2) Remove bushing (16).
3) Remove seal ring (17).

HM400-3M0 50-143
50 Disassembly and assembly
Power train

7. Disassembly of the turbine and clutch assembly 5) Remove the mounting bolts and lift off
1) By using forcing screw [8], remove input housing assembly (23).
shaft (18). 6) Remove piston (24) from the housing
2) By using tool C3, remove bearing (19). assembly, and remove two seal rings (25).

3) Remove snap ring (20) to remove plate (21). 7) By using tool C4, remove bearing (26) from
the housing.
8) Remove two seal rings (27).
9) Remove pin (28).

4) Using forcing screw [10], remove turbine

(22).

10)Remove disc (30) from case (29).

50-144 HM400-3M0
 50 Disassembly and assembly
Power train

2) Install bushings (34) and (33) to race (32).

a Expansion-fit the bushings.
a Apply oil (TO30) to the sliding surfaces.
a Take care not to forget to insert balls.

8. Disassembly of the stator assembly

1) Remove the mounting bolts and stator (31)
from race (32).

3) Install stator (31) to race (32).

2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
58.8 to 73.5 Nm {6 to 7.5 kgm}
a Make sure that stator rotates in correct
direction.
Rotating in clockwise direction when
2) Remove bushings (33) and (34) from race viewed from input side: Idle turns
(32). Rotating in counterclockwise direction
3) Remove race (35) and free wheel (36) from when viewed from input side: Locked
race (32).

2. Assembly of turbine and clutch assembly

Assembly (HM400-CD00-710-K-00-A) 1) Set turbine (22) and case (29) to push tool
[12].
1. Assembly of stator assembly
a Use a block to prevent case (29) from
1) Install free wheel (36) and race (35) to race
touching turbine (22).
(32).
a Install the free wheel by facing its arrow
marking of the cage edge to the input
side.
a Apply oil (TO30) to the sliding surfaces of
the races.

HM400-3M0 50-145
50 Disassembly and assembly
Power train

2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98.1 to 122.6 Nm {10 to 12.5 kgm}

2) Install disc (30).

a Apply oil (TO30) to the sliding surfaces.

7) By using tool C5, press-fit bearing (26).

3) Install pin (28).

a Install pin (28) to the housing by
expansion fit.
4) Install two seal rings (27) and two seal rings
8) Install plate (21) and snap ring (20).
(25) to piston (24) and housing (23).
2 Seal ring:
Grease (G2-LI)
5) Install the piston to housing assembly (23).
a Apply oil (TO30) to the sliding surface of
the piston.
a Mount the seal ring without being
pinched.

9) Using the push tool, press fit bearing (19) to

input shaft (18).
10)Install input shaft (18) to the housing.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
269.7 to 308.9 Nm {27.5 to 31.5
kgm}
6) Sling housing assembly (23) and install it to
case (29).

50-146 HM400-3M0
 50 Disassembly and assembly
Power train

3. Stator shaft 2) Set guide (12) and retainer (11) and tighten
• Hereafter, assembly of the torque converter the mounting bolts.
1) Set stator shaft (14) to tool C1 and turn it 2 Mounting bolt:
over.
Adhesive (LT-2)
2) By using the push tool, install bushing (16)
by expansion fit. 3 Mounting bolt:
a Press-fit the bushing by facing the 58.8 to 73.5 Nm {6 to 7.5 kgm}
chamfered surface of bushing periphery
to the stator shaft.

3) Set pump assembly (10) and inner race (9).

3) Install seal ring (17). a Drop 10 cc of oil (TO30) onto the bearing
and rotate the bearing by 10 turns.
2 Seal ring:
Grease (G2-LI)
4) By using the push tool, press fit inner race
(15).

4) By using push tool C5, press-fit inner race

(9).

4. Pump assembly
1) By using tool C4, press fit bearing (13) to
guide (12).

HM400-3M0 50-147
50 Disassembly and assembly
Power train

5) By using tool C2, tighten nut (8). 7. Torque converter assembly

2 Nut: 1) Set torque converter housing (3) to block [3].
2) By using eyebolts [4], set torque converter
Adhesive (LT-2)
assembly (4) to torque converter housing (3)
3 Nut: and tighten the mounting bolts.
441.3 to 490.3 Nm {45 to 50 kgm} 2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98.1 to 122.6 Nm {10 to 12.5 kgm}

5. Stator assembly
Install stator assembly (7).
• For the assembly, see "Step 1 Assembly of
stator assembly."
8. PTO assembly
Fit the O-ring and install PTO assembly (1), by
using eyebolts [1].

6. Turbine and clutch assembly

By using eyebolts [5], set turbine and clutch
assembly (6) to the pump side and tighten the
mounting bolts.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
49.0 to 58.8 Nm {5 to 6 kgm}

50-148 HM400-3M0
 50 Disassembly and assembly
Power train

Disassembly and assembly of transmission assembly (HM400-CF00-926-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

790-101-3101 Bearing puller t 1

1
790-101-2501 Push puller t 1
1 792T-375-1100 Plate t 1
2 792T-375-1200 Plate t 1
2 3 792T-375-1300 Plate t 1
4 01010-81230 Bolt t 6
5 01643-31232 Washer t 6
790-201-2800 Push tool (D) t 1
D 790-201-2880 • Spacer 1
3
790-201-2850 • Spacer 1
792T-415-1410 Push tool t 1
790-101-5401 Push tool kit (C) t 1
790-101-5481 • Plate 1
4
790-101-5421 • Grip 1
01010-51240 • Bolt 1
5 792T-415-1420 Push tool t 1
6 793T-623-1170 Push tool t 1
Disassembly (HM400-CF00-530-K-00-A)

1. Piping
Remove hose and piping from transmission
assembly (1).
2. Harness assembly
Remove wiring harness assembly from
transmission assembly (1).
3. Transmission shaft speed sensor
Remove transmission input shaft speed sensor
(4), intermediate shaft speed sensor (5) (inside
of cover), and rear output shaft speed sensor (6).
a For the front output shaft speed sensor, see
the "Disengaging and reengaging the front
8. Transmission control valve,
differential gear and transmission systems"
main relief valve, valve seat, and tube
section.
1) Remove transmission control valve
4. Torque converter oil temperature sensor
assembly (12), main relief valve assembly
Remove torque converter oil temperature
(13), valve seat (14), and tube (225).
sensors (7) and (8).
2) Disconnect the other relating tubes.
5. Torque converter oil pressure sensor
Remove torque converter oil pressure sensor a Cover the oil hole on the mounting surface
(230). with a piece of tape to prevent entering of
6. Strainer foreign material.
Remove strainer (9).
7. Mounting bracket and trunnion
Remove trunnion (10) (rear side).

HM400-3M0 50-149
50 Disassembly and assembly
Power train

11.Cover
Remove covers (18) (on the 1st clutch side) and
9. Coupling (19) (on the 2nd clutch side).
1) Remove rear coupling (15).
a Check the thickness and quantity of the
shims on the cover (19) side.

2) Remove input coupling (27).

12.Bearing cage
1) Using forcing screw [1], remove bearing case
(20).
a Note the number and thickness of the
shims.

10.Snap ring of front output shaft

Remove snap ring (16).

50-150 HM400-3M0
 50 Disassembly and assembly
Power train

2) Remove bearing outer race (38b), dust seal 14.Shroud

(67), and oil seal (68) from bearing cage (66). Remove shroud (90).
a For details of bearing inner race (38a),
see "step 21. Disassembly and assembly
of differential lockup clutch assembly".

15.Differential lock-up clutch assembly

Remove differential lockup clutch assembly (22).
a For disassembling of the differential lock-up
clutch assembly, see Step 21.
13.Transmission case assembly (on opposite side
of torque converter)
Place the transmission with the torque converter
side down and remove the transmission case
assembly (21) (on the opposite side of the
torque converter).

k If the transmission is not placed with the

torque converter side down, it cannot be
disassembled. Be sure to set it with the
torque converter side down.
a Be sure to install the transmission system
with its torque converter side down. If its
torque converter side is placed upward, 16.FH and 1st clutch assembly, and 2nd and 3rd
internal parts of transmission system may be clutch assembly
damaged. Simultaneously sling and remove FH and 1st
clutch assembly (23), and 2nd and 3rd clutch
a For further disassembly of the transmission
assembly (24).
case, see "step 27".
a For disassembling of 2nd and 3rd clutch
assembly, see Step 22. For disassembling of
FH and 1st clutch assembly, see Step 23.

HM400-3M0 50-151
50 Disassembly and assembly
Power train

17.R and FL clutch assembly

Remove R and FL clutch assembly (25). 1] Remove snap ring (201), and then
remove bearing, spacer, and snap ring
a For disassembling of the R and FL clutch assembly (202).
assembly, see Step 24.

18.Cage assembly 2] Remove snap ring (203) from bearing,

spacer, and snap ring assembly (202).
1) By using forcing screw [2], remove cage Then, remove bearing (205) from spacer
assembly (26). (204).

2) Disassemble the cage assembly according

to the following procedure. 3] Remove bearing outer race (38b) from
cage (207).

50-152 HM400-3M0

2) Disassemble the gear, shaft, and ring gear
19.PTO assembly
Remove PTO assembly (28).
a For further disassembly of the PTO assembly,
see "step 27".
20.Torque converter assembly
Remove 12 mounting bolts used to install the
torque converter assembly (29) to the
transmission, then remove torque converter
assembly.
a For disassembling of torque converter
assembly, see "Disassembly and assembly
of the torque converter assembly" section.
21.Disassembly of differential lockup clutch
assembly
1) By using forcing screws [3], remove gear,
shaft, and ring gear assembly (30).
HM400-3M0
50 Disassembly and assembly
Power train
assembly according to the following
procedure.
1] By using push tool [15], remove shaft and
ring gear assembly (31).
2] Remove shaft and snap ring assembly
(32), ring gear assembly (33), bearings
(34) [inner races (34-1a) and (34-2a), and
spacer (34-3)].
a Bearing (34) [Inner races (34-1), (34-
2), (34-3)] is a set part.
a For bearing outer race (34-1b), (34-
2b), see Step 4].
50-153
50 Disassembly and assembly
Power train

3] Remove snap rings (36) and (68) from 4) Remove snap ring (41).
shaft (35).
a Snap ring (68) is used to dam the oil.

5) Remove 12 mounting bolts to remove carrier

assembly (42).

4] Remove gear (37), bearing (34) [Outer

races (34-1b), (34-2b)], and bearing inner
race (38a).

6) Disassemble the carrier assembly according

to the following procedure.
1] Remove ring (43).
2] Drive out shaft (44) toward ball (45) and
3) Remove snap ring (39), then remove sun remove shaft (44), gear (46), ball (45),
gear (40). two bearings (47), and two thrust
washers (48).

50-154 HM400-3M0
 50 Disassembly and assembly
Power train

9) Remove end plate (55), seven discs (56),

seven plates (57), and seven wave springs
(58) from the differential clutch.

7) Remove front shaft and hub assembly (49).

10)By using the tapped hole, remove piston

assembly (59).

8) Disassemble front shaft and hub assembly

(49) according to the following procedure.
1] Remove seal rings (53) and (54).
2] Remove snap ring (50) , then remove hub
(52) and bearing inner race (64a) from 11)Remove seal ring (61) from piston (60).
shaft (51) .

HM400-3M0 50-155
50 Disassembly and assembly
Power train

12)Disassemble the housing assembly a For bearing outer race (73b), see
according to the following procedure. "Disassembly of transmission case
Remove seal ring (63), bearing outer race assembly on opposite side of torque
(64b), and bearing inner race (65a) from converter".
housing (62).
a For bearing outer race (65b), see
"Disassembly of transmission case
assembly on torque converter side".

3) Remove (half-splitting) spacer (74) and thrust

washer (75).

4) Remove gear and needle bearing assembly

(76).
22.Disassembly of the 2nd and 3rd clutch assembly
(At 2nd clutch side)
1) Remove three seal rings (71).

5) Remove needle bearing (78) from gear (77).

2) By using puller [4], remove spacer (226) and

bearing inner race (73a) together. After
removal of (half-splitting) spacer (227),
remove gear (72).

50-156 HM400-3M0
 50 Disassembly and assembly
Power train

6) By using a C-clamp, jig [5], etc., compress 8) Using the hanging tap, remove thrust
the clutch spring and remove snap ring (79). washers (84) and piston assembly (86).
a For the 2nd clutch, eyebolt holes are
provided on the gear for slinging, you can
insert spacers having appropriate
thickness at the clutch side to compress
the spring by using that eyebolt holes and
tool [5].

7) Remove end plate (80), 14 plates (81), 13

discs (82), and 13 wave springs (83) from the
2nd clutch.

9) Remove seal rings (88) and (89) from piston

(87).

(At 3rd clutch side)

10)By using tool D1, remove bearing inner race
(100a) and spacer (101) together.

HM400-3M0 50-157
50 Disassembly and assembly
Power train

a For details of bearing outer race (100b),

see "Disassembling the transmission
case assembly at torque converter side".

14)Using C-clamp [7], etc., compress the clutch

spring and remove snap ring (107).
a If the C-clamp is unavailable, push the
11)Remove snap ring (102), then remove thrust end plate section similar to the 2nd clutch
washer (103). and compress the clutch spring. (For
example, hook a crosspiece in the shaft
screw hole and press down the end plate
from crosspiece position by using
spacer.)

12)Remove gear and needle bearing assembly

(104).

13)Remove needle bearing (106) from gear

(105).
15)Remove end plate (108), eight plates (109),
seven discs (110), and seven wave springs
(111) from the 3rd clutch.

50-158 HM400-3M0
 50 Disassembly and assembly
Power train

2) By using puller [4], remove gear (122) and

bearing inner race (123a) together.
a For bearing outer race (123b), see
"Disassembly of transmission case
assembly on opposite side of torque
converter".

16)Remove thrust washer (112) and piston

assembly (113).

3) Remove snap ring (124) and thrust washer

(125).

17)Remove seal rings (115) and (116) from

piston (114).

4) Remove gear and needle bearing assembly

(126).

23.Disassembly of the 1st and FH clutch assembly

(At 1st clutch side)
1) Remove three seal rings (121).

HM400-3M0 50-159
50 Disassembly and assembly
Power train

5) Remove two needle bearings (128) from

7) Remove end plate (130), 13 plates (131), 12
gear (127).
discs (132), and 12 wave springs (133) from
the 1st clutch.

6) Using C-clamp [8], etc., compress the clutch

spring and remove snap ring (129).
a If the C-clamp is unavailable, push the
end plate section similar to the 2nd clutch
and compress the clutch spring. (For
example, hook a crosspiece in shaft
screw hole and press down the end plate
from crosspiece position by using
spacer.)

8) Using the hanging tap, remove thrust washer

(134) and piston assembly (136).

50-160 HM400-3M0
 50 Disassembly and assembly
Power train

9) Remove seal rings (138) and (139) from

a Turn the three forcing screws equally.
piston (137).
If only one screw is turned too much, the
gear may slant causing damage to the
shaft.
a Do not use an impact wrench when
turning forcing screws.

(At FH clutch side)

10)By using three forcing screws [8], remove
gear and needle bearing assembly (140)
together with bearing inner race (141a),
spacer (142), and thrust washer (143).
a For details of the bearing outer race, see 11)Remove needle bearing (145) from gear
"Disassembling the transmission case (144).
assembly at torque converter side".

12)Using C-clamp [9], etc., compress the clutch

spring and remove snap ring (146).
a If the C-clamp is unavailable, push the
end plate section similar to the 2nd clutch
and compress the clutch spring. (For
example, hook a crosspiece in shaft
screw hole and press down the end plate
from crosspiece position by using
spacer.)

HM400-3M0 50-161
50 Disassembly and assembly
Power train

15)Remove seal rings (154) and (155) from

piston (153).

13)Remove end plate (147), 10 plates (148),

nine discs (149), and nine wave springs
(150) from the FH clutch. 24.Disassembly of the R and FL clutch assembly
(R clutch side)
1) Remove three seal rings (161).

2) By using tool D2, remove gear and needle

bearing assembly (162) together with
bearing inner race (163a), spacer (164), and
thrust washer (165).
a For details of the bearing outer race, see
"Disassembling the transmission case
assembly at opposite side of torque
converter".

14)Using the hanging tap, remove thrust washer

(151) and piston assembly (152).

50-162 HM400-3M0
 50 Disassembly and assembly
Power train

5) Remove end plate (169), 12 plates (170), 11

3) Remove two needle bearings (167) from
discs (171), and 11 wave springs (172) from
gear (166).
the R clutch.

4) By using C-clamp [11], etc., compress the

clutch spring and remove snap ring (168).
a If the C-clamp is unavailable, push the
end plate section similar to the 2nd clutch
and compress the clutch spring. (For
example, hook a crosspiece in shaft
screw hole and press down the end plate
from crosspiece position by using
spacer.)

6) Remove thrust washer (173) and piston

assembly (174).

7) Remove seal rings (176) and (177) from

piston (175).

HM400-3M0 50-163
50 Disassembly and assembly
Power train
(FL clutch side)
8) By using push puller [4], remove gear (178)
and bearing inner race (179a) together.
9) Remove (half-splitting) spacer (180) and
thrust washer (181). Then, remove gear and
needle bearing assembly (182).
10)Remove two needle bearings (184) from
gear (183).
50-164
11)By using C-clamp [11], etc., compress the
clutch spring and remove snap ring (185).
a If the C-clamp is unavailable, push the
end plate section similar to the 2nd clutch
and compress the clutch spring. (For
example, hook a crosspiece in shaft
screw hole and press down the end plate
from crosspiece position by using
spacer.)
12)Remove end plate (186), 12 plates (187), 11
discs (188), and 11 wave springs (189) from
the FL clutch.
HM400-3M0
 50 Disassembly and assembly
Power train

1) Remove holder (213), and then remove gear

(214), bearings (215) and (216), snap ring
(217), and collar (218).
2) Remove bearing outer races (73b), (123b),
and (163b).

13)Remove thrust washer (190) and piston

assembly (191).

26.Disassembly of transmission case assembly (on

torque converter side)
Remove bearing outer races (64b), (100b), and
(141b) from the case.

14)Remove seal rings (193) and (194) from

piston (192).

27.Disassembly of PTO case assembly

Disassemble the three idle gears according in
the following procedure.
1) Remove nut (219), and then remove PTO
gear and bearing inner race assembly (220).

25.Disassembly of transmission case assembly (on

opposite side of torque converter)

HM400-3M0 50-165
50 Disassembly and assembly
Power train

2) Remove bearing inner race (222a) from PTO

gear and bearing inner race assembly (221). 1. Assembly of PTO case assembly
1) Install bearing outer race (222c), spacer
(222b), and bearing (222a), then fix them
with plate (224) and snap ring (223).

3) Remove snap ring (223) and plate (224),

then remove bearing (222a), spacer (222b),
and bearing outer race (222c).
2) Place bearing inner race (222d) in position,
install PTO gear (221) and tighten them with
nut (219).
2 Threaded portion of nut:
Loctite (LT-2)
3 Nut:
313.8 to 392.3 Nm {32 to 40 kgm}

Assembly (HM400-CF00-710-K-00-A)

• Precautions for assembly

a Clean all parts and check them for dirt or
damage before assembling.
a Apply engine oil to the sliding surfaces of each
part and install them.
a Dip the discs in clean oil (TO30) for at least 2 2. Assembly of transmission case assembly (on
minutes before installing. torque converter side)
a Install seal ring (a) for the piston with the Install bearing outer races (64b), (100b), and
pressure receiving side (side b) directed to (141b) to the case.
housing (c) as shown in the figure.

50-166 HM400-3M0
 50 Disassembly and assembly
Power train

4. Assembly of FL clutch assembly

(FL clutch side)
1) Install seal rings (193) and (194) to piston
(192).
a Install the seal ring by facing its pressure-
receiving side to the housing.

3. Assembly of transmission case assembly (on

opposite side of torque converter)
1) Install bearing outer races (73b), (123b), and
(163b).

2) Install piston assembly (191) and thrust

washer (190).
2 Apply oil (TO30) to the periphery
and contact surfaces of the seal
rings

2) Fit collar (218) and install bearings (215) and

(216) to gear (214) by expansion fit.
a Install them in correct assembling
directions.
3) Install snap ring (217).
4) Install gear assembly (214) by shrink fit.
a Shrink-fit temperature: Approximately 120
°C for 30 minutes 3) Install 12 plates (187), 11 discs (188), 11
5) Install holder (213) and tighten the bolts wave springs (189), and end plate (186) of
2 Bolt: FL clutch.
Loctite (LT-2) a Dip the discs in clean oil (T030) for at
least 2 minutes before installing.
3 Bolt:
245 to 309 Nm {25 to 31.9 kgm}

HM400-3M0 50-167
50 Disassembly and assembly
Power train

4) Install two needle bearings (184) to gear

(183).

8) Install gear and needle bearing assembly

5) Temporarily install gear and needle bearing
assembly (182), and align disc grooves.
a While pushing down, rotate the gear to
the right and left, and gradually insert it so
that it does not interfere with disc teeth.
(182), and then install thrust washer (181)
and (half-splitting) spacer (180).
a If it is difficult to install gear and needle
bearing assembly (182), repeat from Step
5) again.
a It is also allowed to install gear and
needle bearing assembly (182) first, and
then compress the clutch spring and
install snap ring (180) by using C-clamp
[11].

6) Temporarily remove gear and needle bearing

assembly (182).
7) By using C-clamp [11], etc., compress the
clutch spring and install snap ring (185).
a If the C-clamp is unavailable, push the 9) Install gear (178), then install bearing inner
end plate section similar to the 2nd clutch race (179a) by shrink fit.
and compress the clutch spring. (For
a Shrink-fit temperature: Approximately 120
example, hook a crosspiece in the shaft
°C for 30 minutes
screw hole and press down the end plate
from crosspiece position by using
spacer.)

50-168 HM400-3M0
 50 Disassembly and assembly
Power train

a For bearing outer race (179b), see a Dip the discs in clean oil (T030) for at
"Disassembly of transmission case least 2 minutes before installing.
assembly on opposite side of torque
converter".

(R clutch side)
10)Install seal rings (176) and (177) to piston
(175).
a Install the seal ring by facing its pressure-
receiving side to the housing.

13)Install two needle bearings (167) to gear

(166).

11)Install piston assembly (174) and thrust

washer (173).
2 Apply oil (TO30) to the periphery
and contact surfaces of the seal
rings

14)Temporarily install gear and needle bearing

assembly (162), and align disc grooves.
a While pushing down, rotate the gear to
the right and left, and gradually insert it so
that it does not interfere with disc teeth.

12)Install 12 plates (170), 11 discs (171), 11

wave springs (172), and end plate (169) of R
clutch.

HM400-3M0 50-169
50 Disassembly and assembly
Power train

a Shrink-fit temperature: Approximately 120

°C for 30 minutes
a For bearing outer race (163b), see
"Assembly of transmission case
assembly on opposite side of torque
converter".

15)Temporarily remove gear and needle

bearing assembly (162).
16)By using C-clamp, jig [11], etc., compress
the clutch spring and install snap ring (168).
a If the C-clamp is unavailable, push the
end plate section similar to the 2nd clutch
and compress the clutch spring. (For 19)Install three seal rings (161).
example, hook a crosspiece in shaft
screw hole and press down the end plate
from crosspiece position by using
spacer.)

5. Assembly of 1st and FH clutch assembly

(At FH clutch side)
1) Install seal rings (154) and (155) to piston
(153).
a Install the seal ring by facing its pressure-
receiving side to the housing.

17)Install gear and needle bearing assembly

(162), and then install thrust washer (165)
and spacer (164).
2) Install piston assembly (152) and thrust
a If it is difficult to install gear and needle washer (151).
bearing assembly (162), repeat from Step
14) again. a Using the hanging tap, install piston
18)Install bearing inner race (163a) by shrink fit. assembly (152), taking extreme care that
the seal rings will not be caught.

50-170 HM400-3M0
 50 Disassembly and assembly
Power train

2 Apply oil (TO30) to the periphery

and contact surfaces of the seal
rings.
3) Install 10 plates (148), nine discs (149), nine
wave springs (150), and end plate (147) from
the FH clutch.

5) Temporarily install gear and needle bearing

assembly (140), and align disc grooves.
a While pushing down, rotate the gear to
the right and left, and gradually insert it so
that it does not interfere with disc teeth.

a Dip the discs in clean oil (T030) for at

least 2 minutes before installing.

6) Temporarily remove gear and needle bearing

assembly (140).
7) By using C-clamp [9], etc., compress the
clutch spring and install snap ring (146).
a If the C-clamp is unavailable, push the
end plate section similar to the 2nd clutch
and compress the clutch spring. (For
example, hook a crosspiece in the shaft
screw hole and press down the end plate
from crosspiece position by using
spacer.)

4) Install needle bearing (145) to gear (144).

HM400-3M0 50-171
50 Disassembly and assembly
Power train

11)Install piston assembly (136) and thrust

8) Install gear and needle bearing assembly
(140), and then install thrust washer (143)
and spacer (142).
a If it is difficult to install gear and needle
bearing assembly (140), repeat from Step
5) again.
washer (134).
a Using the hanging tap, install piston
assembly (136), taking extreme care that
the seal rings will not be caught.
2 Apply oil (TO30) to the periphery
and contact surfaces of the seal
rings.

9) Install bearing inner race (141a) by shrink fit.

a Shrink-fit temperature: Approximately 120
°C for 30 minutes
a For the bearing outer race, see
"Assembly of transmission case
assembly on opposite side of torque
converter". (At 1st clutch side)

12)Install 12 plates (131), 11 discs (132), 11

wave springs (133) pieces, and end plate
(130) to the 1st clutch.
a Dip the discs in clean oil (T030) for at
least 2 minutes before installing.

10)Install seal rings (138) and (139) to piston

(137).
a Install the seal ring by facing its pressure-
receiving side to the housing.

50-172 HM400-3M0
 50 Disassembly and assembly
Power train

15)Temporarily remove gear and needle

bearing assembly (126).
16)By using C-clamp, jig [8], etc., compress the
clutch spring and install snap ring (129).
a If the C-clamp is unavailable, push the
end plate section similar to the 2nd clutch
and compress the clutch spring. (For
example, hook a crosspiece in shaft
screw hole and press down the end plate
from crosspiece position by using
spacer.)

13)Install two needle bearings (128) to gear

(127).

14)Temporarily install gear and needle bearing

assembly (126), and align disc grooves.
a While pushing down, rotate the gear to
the right and left, and gradually insert it so
that it does not interfere with disc teeth.

17)Install gear and needle bearing assembly

(126).
a When it is difficult to assemble, repeat
from Step (13) again.

HM400-3M0 50-173
50 Disassembly and assembly
Power train

18)Install thrust washer (125) and snap ring
(124).
a Replace the snap ring with a new one.
a Install the snap ring by opening it to f 87
mm maximum against f 85 mm of the
spline outer diameter.
6. Assemble of 2nd and 3rd clutch assembly
(At 3rd clutch side)
1) Install seal rings (115) and (116) to piston
(114).
a Install the seal ring by facing its pressure-
receiving side to the housing.

2) Install piston assembly (113) and thrust

19)Install gear (127).
washer (112).
20)Install bearing inner race (123a) by shrink fit.
2 Apply oil (TO30) to the periphery
a Shrink-fit temperature: Approximately 120
and contact surfaces of the seal
°C for 30 minutes
rings.
a For bearing outer race (123b), see
"Disassembly of transmission case
assembly on opposite side of torque
converter".

3) Install eight plates (109), seven discs (110),

seven wave springs (111), and end plate
(108) to the 3rd clutch.

21)Install three seal rings (121). a Dip the discs in clean oil (TO30) for at
least 2 minutes before installing.

50-174 HM400-3M0
 50 Disassembly and assembly
Power train

7) By using C-clamp [7], etc., compress the

clutch spring and install snap ring (107).
a If the C-clamp is unavailable, push the
end plate section similar to the 2nd clutch
and compress the clutch spring. (For
example, hook a crosspiece in the shaft
screw hole and press down the end plate
from crosspiece position by using
spacer.)

4) Install needle bearing (106) to gear (105).

5) Temporarily install gear and needle bearing

assembly (104), and align disc grooves.
a While pushing down, rotate the gear to
the right and left, and gradually insert it so
that it does not interfere with disc teeth.
6) Temporarily remove gear and needle bearing
assembly (104).

8) Install gear and needle bearing assembly

(104).
a If it is difficult to install the gear and
needle bearing assembly, repeat from
Step 5) again.
9) Install thrust washer (103) and snap ring
(102).

HM400-3M0 50-175
50 Disassembly and assembly
Power train

10)Install spacer (101), and shrink-fit bearing

inner race (100a).
a Shrink-fit temperature: Approximately 120
°C for 30 minutes

13)Install 14 plates (81), 13 discs (82), 13 wave

springs (83), and end plate (80) to the 2nd
clutch.
a Dip the discs in clean oil (TO30) for at
(At 2nd clutch side) least 2 minutes before installing.
11)Install seal rings (88) and (89) to piston (87).
a Install the seal ring by facing its pressure-
receiving side to the housing.

12)Install piston assembly (86) and thrust

washer (84).
a Using the hanging tap, install piston
assembly (86), taking extreme care that
the seal rings will not be caught.
2 Apply oil (TO30) to the periphery
and contact surfaces of the seal
rings.
14)Install needle bearing (78) to gear (77).

50-176 HM400-3M0
 50 Disassembly and assembly
Power train

15)Temporarily install gear and needle bearing

18)Install gear and needle bearing assembly
assembly (76), and align disc grooves.
(76).
a While pushing down, rotate the gear to
a When it is difficult to assemble, repeat
the right and left, and gradually insert it so
from Step (13) again.
that it does not interfere with disc teeth.

19)Install gear (72), spacer (227) (half-splitting),

16)Temporarily remove gear and needle and spacer (226) (splined).
bearing assembly (76).
17)By using C-clamp, jig [5], etc., compress the 2 Gear (72) splines:
clutch spring and install snap ring (79). Molybdenum disulfide grease (LM-
S)
a For the 2nd clutch, eyebolt holes are
provided on the gear for slinging, you can
insert spacers having appropriate
thickness at the clutch side to compress
the spring by using that eyebolt holes and
tool [5].

20)Install bearing inner race (73a) by shrink fit.

a Shrink-fit temperature: Approximately 120
°C for 30 minutes

HM400-3M0 50-177
50 Disassembly and assembly
Power train

21)Install three seal rings (71).

3] Install seal ring (63).
a Install the seal ring by facing its
pressure-receiving side to the
housing.

7. Assembly of differential clutch assembly

1) Assemble the housing assembly according
to the following procedure.
1] Using tool D3, press-fit bearing inner race
2) Install seal ring (61) to piston (60).
(65a) to housing (62).
2 Apply grease (G2-LI) to the seal
a For bearing outer race (65b), see
rings.
"Disassembly of transmission case
assembly on torque converter side". a Install the seal ring by facing its pressure-
receiving side to the housing.

2] Using tool D3, press-fit bearing outer race

(64b) to housing (62). 3) Install piston assembly (59).
a Using the hanging tap, install piston
assembly (59), taking extreme care that
the seal rings will not be caught.

50-178 HM400-3M0

4) Assemble front shaft and hub assembly (49)
according to the following procedure.
1] Using tool D3, press-fit bearing inner race
(64a) to shaft (51).
2] Install hub (52) to shaft (51), then install
snap ring (50).
3] Install seal rings (53) and (54).
2 Apply grease (G2-LI) to the seal
rings.
5) Install front shaft and hub assembly (49).
HM400-3M0
50 Disassembly and assembly
Power train
6) Install seven plates (57), seven discs (56),
seven wave springs (58), and end plate (55)
to the differential clutch.
a Dip the discs in clean oil (TO30) for at
least 2 minutes before installing.
7) Assemble the carrier assembly according to
the following procedure.
1] Place gear (46), two bearings (47), and
two thrust washers (48) in specified
positions. Drive shaft (44) halfway, install
ball (45), and fully drive shaft (44).
a First, adjust the position (direction) of
the hole to put the ball in.
2] Install ring (43).
50-179
50 Disassembly and assembly
Power train

10)Install sun gear (40) and snap ring (39).

8) Install carrier assembly (42) in position.

2 Mounting bolt: 11)Assemble the gear, shaft, and ring gear
assembly according to the following
Loctite (LT-2)
procedure.
3 Mounting bolt: 1] Install snap rings (68) and (36) to shaft
98 to 122.5 Nm {10 to 12.5 kgm} (35).
a Snap ring (68) is used to dam the oil.

9) Install snap ring (41).

50-180 HM400-3M0
 50 Disassembly and assembly
Power train

a The abutment joint of snap rings must

be placed as shown in the figure.
OP: oil hole CG: abutment joint

5] By using tool D5, press-fit ring gear (33)

together with bearing inner race (34-2a)
to the snap ring side of shaft and snap
ring assembly (32).
2] By using tool D3, press-fit bearing inner
race (38a) to gear.
a For details of bearing outer race (38b),
see "Bearing cage".

6] Install spacer (34-3) to shaft and ring gear

assembly (69).

3] By using tool D4, press-fit bearing outer

race (34-2b) to gear (37).
a Bearing (34) [Inner races (34-1a), (34-
2a), (34-2b), and (34-3)] is a set part.

7] By using tool D5, press-fit gear assembly

(70) together with bearing inner race (34-
1a) to the snap ring side of shaft and
snap ring assembly (32).

4] Install shaft and snap ring assembly (32)

to ring gear (33).
2 Ring gear spring part:
Molybdenum disulfide grease
(LM-G)

HM400-3M0 50-181
50 Disassembly and assembly
Power train

2 Mounting bolt:
Loctite (LT-2)
3 Mounting bolt:
98.1 to 122.6 Nm {10 to 12.5 kgm}
a For assembly of PTO assembly, see
"Assembly of PTO assembly".

12)Install gear, shaft, and ring gear assembly

(30) in position.

10.Cage assembly
1) Assemble the cage assembly according to
the following procedure.
1] Install bearing outer race (38b) to cage
(207).

8. Torque converter assembly

Install torque converter assembly (29).
2 Mounting bolt:
Loctite (LT-2)
3 Mounting bolt:
98.1 to 122.6 Nm {10 to 12.5 kgm}
a For assembly of torque converter assembly,
see "Disassembly and assembly of torque
converter assembly".

2] By using tool D6, press-fit bearing (205)

to spacer (204) and install snap ring
(203).

9. PTO assembly
Install the O-ring and PTO assembly (28).
2 O-ring on the mating surface:
Grease (G2-LI)

50-182 HM400-3M0

11.FL clutch assembly
3] Install bearing, spacer, and snap ring
assembly (202), and then install snap ring
(201).
12.1st and FH clutch assembly, 2nd and 3rd clutch
2) Install cage assembly (26).
2 O-ring on the mating surface:
Grease (G2-LI)
HM400-3M0
50 Disassembly and assembly
Power train
Install R. FL clutch assembly (25).
a For assembly of R. FL clutch assembly, see
Step 4.
2 Apply grease (G2-LI) to the seal rings
(at three places) before installing
transmission case assembly (21) (on
the opposite side of the torque
converter).
a Check that the seal rings (at three places)
are not installed with their mouths expanded.
assembly
Sling the 1st and FH clutch assembly (23), 2nd
and 3rd clutch assembly (24) at the same time,
and install them.
a For assembly of 1st and FH clutch assembly,
see Step 5. For assembly of 2nd and 3rd
clutch assembly, see Step 6.
2 Apply grease (G2-LI) to the seal rings
(at six places) before installing
transmission case assembly (21) (on
the opposite side of the torque
converter).
a Check that the seal rings (at three places)
are not installed with their mouths expanded.
50-183
50 Disassembly and assembly
Power train

a For assembly of the transmission case (on

the opposite side of the torque converter),
see "3".

13.Differential lock-up clutch assembly

Install differential lock clutch assembly (22).
a For assembly of differential lock-up clutch
assembly, see Step 7.
16.Bearing cage
1) Bearing cage (2nd side)
Install outer race (129) to bearing cage (128).

14.Shroud
Install shroud (90).
a Lightly touch the shroud to the housing, and
then separate the shroud 1 mm away from
the housing and install it.
2) Bearing cage (rear output side)
By using tool D4, press-fit oil seal (68) to
bearing cage (66).
a Distance from cage end surface (f) = 28.5
± 0.2 mm

15.Transmission case assembly (on opposite side

of torque converter)
Install transmission case assembly (21) (on the
opposite side of the torque converter). 3) By using tool D4, press-fit oil seal (67) to
bearing cage (66).
3 Mounting bolt:
a Distance from cage end surface (g) =
98.1 to 122.6 Nm {10 to 12.5 kgm}
13.5 ± 0.2 mm

50-184 HM400-3M0
 50 Disassembly and assembly
Power train

a If the variation in measurements at 3

points is greater than 0.15 mm, check for
incorrect bearing assembling or other
causes. Take a corrective action, and
measure clearance (f) again.
7) Assemble shims having thickness of average
value of clearances (f) obtained in Step 6)
above minus the following dimensions.
a Reduction in thickness: 0.10 to 0.15 mm
a Allowable range of shim thickness
(reference): 1.70 to 30.0 mm
8) Rotating the output shaft, tighten the
4) Install bearing outer race (38b). mounting bolts of bearing cage (19) to the
following torque.
3 Mounting bolt:
98 to 122 Nm {10.0 to 12.5 kgm}
9) Measure the rotating torque of the output
shaft, and check that the increment in the
rotating torque over that obtained in Step 5)
is within the following range of value.
a Increment in the rotating torque:
2.94 to 9.81 Nm {0.3 to 1.0 kgm}

17.Bearing cage installation procedure, and

preload adjustment procedure of taper roller
bearings
1) Operate the differential lock-up clutch by
using a compressed air.
a Operate it until the following shim
adjustment completes.
2) Tighten mounting bolts of bearing cages (19)
and (20) with the following torque, but
without inserting shims.
10)Measure clearance (a) between cage (20)
3 Mounting bolt: and the rear transmission case at 3 points
8.8 to 10.8 Nm {0.9 to 1.1 kgm} (equally spaced on the periphery), and
3) Rotate the output shaft for 20 turns. calculate their mean value.
4) Check that the tightening torque of mounting
bolts does not change. If changed, repeat a If the variation in measurements at 3
Steps (2) and (3). points is greater than 0.15 mm, check for
5) Loosen the mounting bolts of bearing cage incorrect bearing assembling or other
(19) and measure the rotating torque of the causes. Take a corrective action, and
measure clearance (a) again.
output shaft.
11)Assemble shims having thickness of
a Rotating torque: 14.7 to 25.5 Nm {1.5 to average value of (a) obtained in Step 10)
2.6 kgm} above minus the following dimensions.
6) Measure clearance (f) between bearing cage
(19) and rear transmission case at 3 points a Reduction in thickness: 0.05 to 0.10 mm
(equally spaced on the periphery) and a Allowable range of shim thickness
calculate their mean value. (reference): 1.50 to 3.15 mm
12)Rotating the output shaft, tighten the
mounting bolts of bearing cage (20) to the
following torque.

HM400-3M0 50-185
50 Disassembly and assembly
Power train

3 Mounting bolt:
98 to 122 Nm {10.0 to 12.5 kgm}
13)Measure the rotating torque of the output
shaft, and check that the increment in the
rotating torque over that obtained in Step 9)
is within the following range of value.
a Increment in the rotating torque:
2.94 to 9.81 Nm {0.3 to 1.0 kgm}

19.Coupling
1) Fit O-ring and holder, and install rear
coupling (15).
3 Mounting bolt:
824 to 1,030 Nm {84 to 105 kgm}

14)Install cover (18) (1st clutch side).

2) Install input coupling (27).

2 O-ring mating portion:
Grease (G2-LI)
3 Mounting bolt:
18.Snap ring of front output shaft
245.2 to 308.9 Nm {25 to 31.5 kgm}
Install snap ring (16).

20.Transmission control valve, torque converter

valve, valve sheet, tubes
1) Install upper tube (225) of the transmission.
a Connect these tubes in the correct
direction.

50-186 HM400-3M0

2) Fit the O-rings and install valve seat (14),
transmission control valve assembly (12),
and main relief valve assembly (13).
3 Two mounting bolts (* mark)
34 to 44 Nm {3.5 to 4.5 kgm}
3) Connect the other relating tubes.
21.Front differential assembly
Engage the front differential gear assembly. For
details, see "Disconnection and connection of
the front differential gear and transmission
systems" section.
22.Mount brackets and trunnion
Install mounting bracket (11) (on the front
differential side) and trunnion (10) (on the rear
side).
2 Mounting bolt of mounting bracket
(11) (on front differential side):
Loctite (LT-2)
HM400-3M0
50 Disassembly and assembly
Power train
3 Mounting bolt of mounting bracket
(11) (on front differential side):
455 to 565 Nm {46.5 to 58.5 kgm}
23.Strainer
Install strainer (9).
24.Torque converter oil pressure sensor
Install torque converter oil pressure sensor (230).
2 Threaded portion of oil pressure
sensor:
Liquid gasket (LG-5)
3 Oil pressure sensor:
29.4 (+4.9/0) Nm {3 (+0.5/0) kgm}
25.Torque converter oil temperature sensor
Install torque converter oil temperature sensors
(6) and (7).
2 Threaded portion:
Liquid gasket (LG-5)
3 Threaded portion:
15.7 to 19.2 Nm {1.6 to 2.0 kgm}
26.Transmission shaft speed sensor
Install transmission input shaft speed sensor (4),
intermediate shaft speed sensor (5), and rear
output shaft speed sensor (5).
a For the adjustment procedure and bolt
tightening torques, see the Testing and
Adjusting of the manual.
a For the front output shaft speed sensor, see
the "Disconnection and connection of the
front differential gear and transmission
systems" section.
27.Torque converter and transmission charge pump
Install the torque converter and transmission
charge pump (3).
28.Harness assembly
Install wiring harness assembly.
29.Piping
Install hoses and pipings.
50-187
50 Disassembly and assembly
Power train

50-188 HM400-3M0
 50 Disassembly and assembly
Power train

Removal and installation of center differential assembly (HM400_3R-DCH1-924-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

792T-423-1360 Plate t 1
7 790-101-5021 Push tool kit (C) t 1
01010-50816 • Bolt 1
H 792T-423-1140 Push tool t 1
8 790-101-5421 Grip t 1
01010-51240 Bolt t 1
19 09003-07280 Nut wrench t 1 3. Drive shaft between the hitch frame and center
differential
k Place the machine on a level ground, set the
Remove the guard, and sling and disconnect the
parking brake switch to ON position by
center differential side of drive shaft (2) between
pressing "P", and apply the parking brake.
the hitch frame and center differential. [*1]
k Chock the wheels to prevent the machine
4 Drive shaft between hitch frame and
from moving.
center differential (center differential
k Set the lock bar to the front and rear frames side alone):
to lock them. 35 kg
a Take care so that the drive shaft spider cap
k Raise the dump body assembly fully and
does not fall off.
insert a lock pin.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)

k Loosen the cap of the hydraulic tank

gradually, and release the pressure
remaining inside the hydraulic tank.

Removal (HM400_3R-DCH1-520-K-00-A)

1. Draining oil
Drain oil from the center differential case and 4. Drive shaft between center differential and rear
from the center final drive case. differential
Remove the guard, and disconnect drive shaft
6 Center differential case: (3) between the center differential and rear
43 l differential by slinging at the center differential
side. [*2]
6 Center final drive case:
5l
2. Sun gear and drive shaft
Remove the center final drive cover, and pull out
sun gear and drive shaft (1) (on both sides) to
the outside.

HM400-3M0 50-189
50 Disassembly and assembly
Power train

5. Transfer output side cage and coupling
assembly
Remove mounting bolt (4) to remove cage and
coupling assembly (5). [*3]
a For further disassembly, see Step 9 below.
k Since the transfer case side is heavy,
slings may come off and the assembly
may drop. So add slings to the transfer
case side.
4 Center differential assembly:
380 kg

6. Transfer output shaft

Pull out and remove shaft (6). [*4]
9. Disassembly of cage and coupling assembly
1) Remove cover (16).
2) By using tool H19, remove nut (17).
3) Remove holder (18).

7. Piping and wiring harness

1) Disconnect hoses (8) and (9).
2) Remove tubes (10) to (13).

4) By using push tool [1], remove coupling (20)

from cage (19).

8. Center differential assembly

1) Leave 2 to 3 bolts in position, but remove all
other mounting bolts.
2) Sling center differential assembly (15) and 5) Remove seals (23) and (24), bearing (25),
remove remaining mounting bolts. spacer (21), and bearing (26) from cage (19).
3) By using forcing screw [2] (M14 x 2), pull the
center differential assembly to the front side.
[*5]

50-190 HM400-3M0
 50 Disassembly and assembly
Power train

Installation (HM400_3R-DCH1-720-K-00-A)
2. By using tools H7 and H8, press-fit seals (24)
and (23) into cage(19).
• Perform installation in the reverse order to
removal. a Press-fit seal (24) so that dimension (A) is 10
[*1] ± 0.5 mm.

a When installing drive shaft, check that key of a Press-fit seal (23) until it becomes flush with
spider cap is completely fitted to key groove of the cage end face.
the mating yoke before tightening bolt. 2 Seal periphery:
2 Mounting bolts of drive shaft between Liquid gasket (LG-5 or LG-11)
hitch frame and center differential:
2 Seal lip part:
Liquid adhesive (LT-2)
Grease (G2-LI)
3 Mounting bolts of drive shaft between
hitch frame and center differential:
157 to 198 Nm {16 to 20 kgm}
[Target: 177 Nm {18 kgm}]
[*2]
a When installing drive shaft, check that key of
spider cap is completely fitted to key groove of
the mating yoke before tightening bolt.
2 Mounting bolts of drive shaft locating
between center differential and rear
differential:
Liquid adhesive (LT-2) 3. By using push tool [2], press-fit coupling (20) into
3 Mounting bolts of drive shaft locating bearing inner race (25a).
between center differential and rear
differential:
98 to 123 Nm {10.0 to 12.5 kgm}
[Target: 113.0 Nm {11.5 kgm}]
[*3]
Assembly of cage and coupling assembly
1. Install bearing outer races (25b) and (26b) and
inner race (25a) to cage (19).

4. Install spacer (21).

5. Install bearing inner race (26a).

HM400-3M0 50-191
50 Disassembly and assembly
Power train

a Do not press-fit directly by using the push

5 Transmission case:
tool, etc.
6. Install holder (18). Only necessary quantity
7. By using the tool, tighten nut (17). • Refilling with oil
Refill with oil through the oil filler port of the
3 Nut: hydraulic tank to the specified level. Run the
372 to 490 Nm {38 to 50 kgm} engine to circulate the oil through the piping.
8. Install cover (16). Then check the oil level again.
3 Nut:
5 Hydraulic tank:
54 to 79 Nm {6.0 to 7.5 kgm}
Only necessary quantity

[*4]
2 Splines of transfer output shaft (6):
Molybdenum disulfide lubricant (LM-P)
[*5]
3 Center differential mounting bolt:
157 to 198 Nm {16 to 20 kgm}
[Target: 177 Nm {18 kgm}]
k After installation, bleed air from brake circuit.
For details, see Testing and adjusting
"Bleeding air from brake circuit".

• Refilling with oil

Refill with oil through the oil filler port of the
center differential case to the specified level.
Then check the oil level again.

5 Center differential case:

43 l
• Refilling with oil
Refill with oil through the oil filler port of the
center final drive case to the specified level.
Then check the oil level again.

5 Center final drive case:

5l
• Refilling with oil
Refill with oil through the oil filler port of the
transmission case to the specified level. Run the
engine to circulate the oil through the piping.
Then check the oil level again.

50-192 HM400-3M0
 50 Disassembly and assembly
Power train

Disassembly and assembly of center differential assembly (HM400-DCH1-926-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

790-501-5200 Unit repair stand t 1

9 790-901-2110 Bracket t 1
792T-423-1310 Plate t 1
10 792-103-0901 Wrench t 1
11 792T-423-1320 Push tool t 1
12 792T-423-1110 Push tool t 1
790-101-5401 Push tool kit t 1 4. Cage
790-101-5451 • Plate 1
H 1) By using forcing screw [1] (M12 x 1.75),
14 790-101-5481 • Plate 1 remove cage assembly (4).
790-101-5421 • Grip 1
01010-51240 • Bolt 1 a Note the number and thickness of the
792T-423-1140 Push tool t 1 shims.
15 790-101-5421 Grip t 1
01010-51240 Bolt t 1
790-201-2700 Push tool (C) t 1
18
790-201-2740 • Spacer t 1
Disassembly (HM400-DCH1-530-K-00-A)

1. Set the center differential gear assembly on tool

H9.

2) Remove side seal (5), oil seal (6), and

bearing outer race (7b) from cage (12).

2. Cover
Remove cover (1).

5. Transfer input shaft and gear assembly

1) Remove transfer input shaft and gear
assembly (8).

3. Transfer input coupling and holder

Remove holder (2), and remove coupling (3).

HM400-3M0 50-193
50 Disassembly and assembly
Power train

2) Disassemble transfer input shaft and gear 7. Transfer case

assembly (8) according to the following 1) By using forcing screw [1] (M12 x 1.75),
procedure. remove transfer case assembly (16).
• Remove bearing (7a), spacer (11), and
gear (12) from transfer input shaft (9).

6. Input shaft holder

a Insert a wooden block so that the bevel
pinion does not drop.
1) Remove holder (13).
a Note the number and thickness of the
shims.

2) Remove bearing outer race (10b) and

bearing (18) from transfer case (17).

2) Remove holder (14) and key (15).

8. Input gear and spacer

50-194 HM400-3M0
 50 Disassembly and assembly
Power train

1) Remove cover (50).

10.Pinion assembly
2) Remove spacer (19) and input gear (20). 1) Remove pinion assembly (24).
a Check the spacer identification marks (A
to J).

2) Disassemble the pinion assembly according

to the following procedure.
9. Cage assembly Remove bearing (21a) from pinion (25).
1) By using forcing screw [1] (M12 x 1.75),
remove cage assembly (21).
a Note the number and thickness of the
shims.

11.Differential gear assembly

a Sling the differential gear case in advance.
1) Remove snap rings (26a) and (26b), and
then remove spacers (27a) and (27b).
2) Remove bearing outer race (23b) from cage 2) Remove gears (28a) and (28b) and keys
(22). (29a) and (29b).

HM400-3M0 50-195
50 Disassembly and assembly
Power train

7) Disassemble the differential gear case

assembly according to the following
procedure.
1] Remove 12 mounting bolts (34a), and
remove case and bearing assembly (34).
a Before removing, put a match mark on
the case of case and bearing
assembly and on the case of case
and bevel gear assembly.
2] Remove bushing (34b) and coupling
(34c).

3) Remove locks (30a) and (30b).

4) By using tool H10, loosen adjustment nuts
(31a) and (31b) so that they can be rotated
by hands.
5) Loosen four bolts (32a) and (32b) at each of
right and left sides.
6) Sling the differential gear case assembly,
and remove bearing caps (33a) and (33b)
and adjustment nuts (31a) and (31b). Then,
remove the differential gear case assembly.
a Take care not to drop the outer race of
bearing during handling.
3] By using puller [2], remove bearing (36a)
from case (35).

4] Remove washer (37a).

5] Remove differential side gear (38a).
6] Remove pinion gear assembly (39) as a
unit.

50-196 HM400-3M0

7] Remove four each of washers (39b),
pinion gears (39c) and bushings (39d)
from shaft (39a).
8] Remove differential side gear (38b).
9] Remove washer (37b).
8) Disassemble the bevel gear assembly
according to the following procedure.
1] Turn over case and bevel gear assembly
(40).
2] Remove bushing (38c) and coupling
(38d).
3] By using puller [2], remove bearing (41)
from case and bevel gear assembly (40).
4] Remove mounting bolts (42), and remove
case (43) from bevel gear (44).
HM400-3M0
50 Disassembly and assembly
Power train
Assembly (HM400-DCH1-710-K-00-A)
a If no tool is specified to mount seals and
assemble parts (especially, in the input shaft
section), use a push tool having an appropriate
diameter.
1. Differential gear case assembly
1) Assemble the differential gear case
assembly according to the following
procedure.
1] Install case (43) to bevel gear (44).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
245 to 309 Nm {25 to 31.5 kgm}
2] Shrink-fit bearing (41) to case and bevel
gear assembly (40).
a Shrink-fit temperature: Approximately
120°C for 30 minutes
50-197
50 Disassembly and assembly
Power train
3] Install bushing (38c) and coupling (38d)
as a unit.
a By using tool H11, press-fit the
bushing and coupling as a unit.
a Do not hit the bushing directly to insert
it.
4] Turn over case and bevel gear assembly
(40).
5] Install washer (37b).
6] Install differential side gear (38b).
7] Install four each of washers (39b), pinion
gears (39c) and bushings (39d) to shaft
(39a).
50-198
8] Install pinion gear assembly (39) as a
unit.
9] Install differential side gear (38a).
10]Install washer (37a).
11]Shrink-fit bearing (36a) to case (35).
a Shrink-fit temperature: Approximately
120°C for 30 minutes
12]Install bushing (34c) and coupling (34d)
as a unit following the same procedure as
Step 3].
a By using tool H11, press-fit the
bushing and coupling as a unit.
a Do not hit the bushing directly to insert
it.
13]Install case and bearing assembly (34).
HM400-3M0
 50 Disassembly and assembly
Power train

3 Mounting bolt:
245 to 309 Nm {25 to 31.5 kgm}

4. Adjusting bearing preload

1) By using tool H10, rotate adjustment nuts
2. Assembly of differential body
1) Differential gear assembly
1] Install nuts (31a) and (31b) fitting them to
the groove of differential case (45).
2] Sling gear case assembly (46), install the
outer race to the bearing, then install
them to differential case (45).
2) Install a spring balance to the ring gear and
(31a) and (31b) until the ring gear hits the
pinion gear. Continue the adjustment until
backlash is eliminated.
a Hit the ring gears lightly with a copper
hammer while rotating the bearing, so
that the bearing has enough contact to
other parts.
a Apply sufficient amount of oil to the
bearing.
a When you loosened the adjustment nut
on one side by a turn, you must tighten
the adjustment nut on the other side by a
turn.
measure the free turning force at this time.
Starting tangential force: 11.8 to 17.7 N {1.2
N to 1.8 kg}

3. Cap
1) Install adjustment nuts (31a) and (31b) and
caps (33a) and (33b), and tighten bolts (32a)
and (32b) lightly.
2) By using tools [5] and [6], tighten bolts (32a)
and (32b).
3 Bolt:
824 to 1,040 Nm {84 to 105 kgm}

HM400-3M0 50-199
50 Disassembly and assembly
Power train

5. Speed sensing gear 7. Assembly of the bevel pinion assembly

1) Install gears (28a) and (28b) and keys (29a) Assemble the bevel pinion assembly according
and (29b). to the following procedure.
2) Install spacers (27a) and (27b). • By using tool H11, press-fit bearing inner
3) Secure them with snap rings (26a) and (26b). race (21a) to pinion (25).

8. Preload adjustment of bevel pinion support

bearing
1) Install pinion assembly (24).

6. Assembly of transfer case

Install bearing outer race (10b) and bearing
outer race (18b) to transfer case (17).
2) Cage assembly
1] Install bearing outer race (23b) to cage
(22).

50-200 HM400-3M0
 50 Disassembly and assembly
Power train

4) Transfer case
2] Install cage assembly (21).
Install transfer case assembly (16).
a Install the assembly after confirming that
the bearing of the pinion is correctly
installed.

3) Input gear and spacer

Install input gear (20) and spacer (19).
a Install the shims as checked in the
disassembly. 5) Bearing
Stampe- By using tool H18, press-fit bearing inner
MD shim
thickness Spacer part d letter Spacer width race (18a).
number on dimension
range
spacer
0.013 to
56B-23-16910 A 25.887 ± 0.025
0.113
0.114 to
56B-23-16920 B 25.787 ± 0.025
0.213
0.214 to
56B-23-16930 C 25.687 ± 0.025
0.313
0.314 to
56B-23-16940 D 25.587 ± 0.025
0.413
0.414 to
56B-23-16950 E 25.487 ± 0.025
0.513
0.514 to
56B-23-16960 F 25.387 ± 0.025
0.613
0.614 to
56B-23-16970 G 25.287 ± 0.025
0.713
0.714 to
56B-23-16980 H 25.187 ± 0.025
0.813
0.814 to
56B-23-16990 J 25.087 ± 0.025
0.913

HM400-3M0 50-201
50 Disassembly and assembly
Power train

a Rotating tangential force (torque)

Starting torque:
8 to 14 Nm {0.8 to 1.4 kgm}
(Insert a wrench to the shaft end bolt
when measuring the above.)

6) Input shaft holder

1] Install holder (14) and key (15).

9. Adjusting the tooth contact and backlash

• Adjust the backlash and, at the same time,
adjust the tooth contact.
1) Adjust the backlash according to the
following procedure.
1] Move the bevel gear with adjustment nuts
(28) and (29). At this time, rotate the nuts
on the both side the same number of
turns in the same direction to prevent
2] Mount the standard shims (their thickness
changing the preload applied to the
and numbers are checked during
bearing.
disassembly), and install holder (13).
3 Mounting bolt:
824 to 1,030 Nm {84 to 105
kgm}
a Determine the thickness and number
of shims after implementing "Adjusting
the tooth contact and backlash" in
Step 9.

2] Apply dial gauge [11] vertically to the

reverse tooth surface in the outer end of
the bevel gear, and adjust the tooth
surface while rotating the adjustment nut
so that move of the gauge pointer is 0.3
to 0.4 mm.
a Conduct the adjustment in three to
four locations. Fix the pinion gear
7) Measuring rotating torque during the measurement.
By using push-pull scale [14], measure the
rotating tangential force (torque) of the input
shaft, and check that it matches the following
value.

50-202 HM400-3M0
 50 Disassembly and assembly
Power train

2) Adjust the tooth contact according to the

following procedure. 1] Checking tooth contact
Apply thin film of red lead to seven to
1] Adjust the travel of bevel pinion with
eight tooth surfaces of the bevel gear,
shims (65) between differential case (64)
then rotate the bevel gear back and
and transfer case (17).
forth to check the tooth contact
2] Adjusting tooth contact
patterns left on the bevel gear.
a See "Adjusting tooth contact" in Step
a The center of the tooth contact
3.
shall be the position indicated
below.
• Central portion of tooth height
• The position where tooth length
from small end (C) is (x)
(approximately 33% of tooth
length)
a Width (y) of the tooth contact must
be 30 to 60% of the tooth length.
a Check that addendum (A),
dedendum (B), small end (C) and
large end (D) are not exposed to
strong contact.
3] Adjustment of tooth contact between
bevel gear and bevel pinion
• When the backlash is below the
standard value
Loosen the adjustment nut on the
bevel gear side, then tighten the left
side adjustment nut by that amount.
(Advance in direction (A).)
• When the backlash is beyond the
standard value
Loosen the adjustment nut on the left
side, then tighten the adjustment nut
on the bevel gear side by that amount.
(Advance in direction (B).)
2] Adjusting tooth contact
When an appropriate tooth contact
pattern is not obtained in the check,
repeat adjustment referring to the
following.
a After adjusting the tooth contact,
check the backlash again.
When the bevel pinion is excessively
distanced from the bevel gear

HM400-3M0 50-203
50 Disassembly and assembly
Power train

a Tooth contact pattern will be as shown

in the next figure.
• Decrease shims of the bevel pinion to
advance the bevel pinion in direction
(C).
• Advance the bevel gear in direction
(D).

When the bevel gear is excessively

distanced from the bevel pinion
a Tooth contact pattern will be as shown
in the next figure.
• Increase shims of the bevel pinion to
advance the bevel pinion in direction
(E).
When the bevel pinion is too close to • Advance the bevel gear in direction
the bevel gear (F).
a Tooth contact pattern will be as shown
in the next figure.
• Increase shims of the bevel pinion to
advance the bevel pinion in direction
(E).
• Advance the bevel gear in direction
(F).

10.Assembly of transfer input shaft

1) Assemble the transfer input shaft assembly
according to the following procedure.
• Install gear (12) and spacer (11) to
transfer input shaft (9) and press-fit
bearing inner race (7a) by using tools D11
and D12.
When the bevel pinion is too close to
the bevel gear
a Tooth contact pattern will be as shown
in the next figure.
• Decrease shims of the bevel pinion to
advance the bevel pinion in direction
(C).
• Advance the bevel gear in direction
(D).

11.Transfer input shaft and gear assembly

Install transfer input shaft and gear assembly (8).

50-204 HM400-3M0

12.Cage
1) Install bearing outer race (7b) to cage (10)
and press-fit oil seal (6) by using tool H15.
a Press-fit oil seal (6) so that clearance (c)
between its outside surface and the end
surface of cage (10) becomes within 10 ±
0.5 mm.
2) By using tool H14, press fit side seal (5) to
cage (10).
a Making the side seal flush with the cage
end face by using this tool serves as the
position alignment.
3) Install the regular shims and install cage
assembly (4).
HM400-3M0
50 Disassembly and assembly
Power train
13.Preload adjustment of transfer input shaft
bearing
1) Install input shaft and gear assembly (8) to
transfer case (17) without using shims, and
tighten eight mounting bolts (64) of cage
assembly (12) to 113.0 Nm {11.5 kgm}.
a Tighten mounting bolt (64) repeatedly
while turning the bearing until the
assembly becomes stable.
2) Sling the coupling by using a crane and
measure its end play after the adjustment by
using dial gauge [11]. Select shim thickness
so that the measured end play becomes 0 to
0.05 mm.
3) After confirming the shim thickness, remove
the input shaft, gear assembly (8) and cage
assembly (12) once.
14.Transfer input coupling and holder
Install coupling (3) and install holder (2).
50-205
50 Disassembly and assembly
Power train

2 Coupling and splined end (A): a Rotate the bolt until its tip touches the bevel
Grease (LM-P) gear back face and then return the bolt by 3/
4 turn, then secure the bolt with the lock nut.
2 Seal lip (B):
2 Bolt:
Grease (G2-LI)
Liquid gasket (LG-5)
2 Seal periphery surface (C):
3 Lock nut:
Adhesive (SEALEND 242 or
equivalent) 196 to 245 Nm {20 to 25 kgm}

2 Holder mounting bolt:

Adhesive (LT-2)
3 Holder mounting bolt:
824 to 1,030 Nm {84 to 105 kgm}

a For disassembly and assembly of the center

axle transfer output section, see "Removal
and installation of center differential
assembly".

15.Cover
Install cover (1).

16.Bevel gear fall-prevention bolt

Install bevel gear fall-prevention bolt (47).

50-206 HM400-3M0
 50 Disassembly and assembly
Power train

Removal and installation of rear differential assembly (HM400_3R-DCD0-924-K-00-A)

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".) 5. Rear differential assembly
1) Leave 2 to 3 bolts in position, but remove all
Removal (HM400_3R-DCD0-520-K-00-A) other mounting bolts (4).
1. Remove the dump body assembly. For details, 2) Sling rear differential assembly (5).
see "Removal and installation of dump body 3) Remove remaining mounting bolts (4), and
assembly". install forcing screw [1] and guide bolts [2].
2. Draining oil
Drain oil from the rear differential case and from
the rear final drive case.

6 Rear differential case:

39 l

6 Rear final drive case:

5.5 l
3. Sun gear and drive shaft
Remove the rear final drive cover, and pull out
sun gear and drive shaft (1) (on both sides) to
the outside.
4. Drive shaft between center differential and rear
differential
1) Remove guard (2).
2) Disconnect drive shaft (3) between the
center differential and rear differential by
slinging at the rear differential side. [*1]
4) While pulling rear differential assembly (5)
forward by using forcing screw [1] (M14 x 2),
change the sling application positions
(increase the positions) and remove the
assembly. [*2]
a Support the assembly from the bottom
also by using mission jack [3] and such.
a Since rear side of installed rear
differential assembly (5) hangs down
somewhat, it is difficult to pull out the
assembly. So pull out the assembly out
through the front side carefully and
slowly.
4 Rear differential assembly:
260 kg

HM400-3M0 50-207
50 Disassembly and assembly
Power train

5 Rear differential case:

39 l
• Refilling with oil
Refill with oil through the oil filler port of the rear
differential case to the specified level. Then
check the oil level again.

5 Rear final drive case:

5.5 l
• Refilling with oil
Refill with oil through the oil filler port of the
transmission case to the specified level. Run the
engine to circulate the oil through the piping.
Then check the oil level again.

5 Transmission case:
Only necessary quantity
• Refilling with oil
Refill with oil through the oil filler port of the
hydraulic tank to the specified level. Run the
engine to circulate the oil through the piping.
Then check the oil level again.

5 Hydraulic tank:
Installation (HM400_3R-DCD0-720-K-00-A) Only necessary quantity
• Perform installation in the reverse order to
removal.
[*1]
a When installing drive shaft, check that key of
spider cap is completely fitted to the groove of
the mating yoke before tightening mounting bolt.
2 Mounting bolts of drive shaft locating
between center differential and rear
differential:
Liquid adhesive (LT-2)
3 Mounting bolts of drive shaft locating
between center differential and rear
differential:
98 to 123 Nm {10.0 to 12.5 kgm}
[Target: 113.0 Nm {11.5 kgm}]
[*2]
3 Rear differential mounting bolts:
157 to 196 Nm {16 to 20 kgm}
[Target: 177 Nm {18 kgm}]
k After the installation, bleed air from the brake
circuit. For details, see Testing and adjusting
"Bleeding air from brake circuit".

• Refilling with oil

Refill with oil through the oil filler port of the rear
differential case to the specified level. Then
check the oil level again.

50-208 HM400-3M0
 50 Disassembly and assembly
Power train

Disassembly and assembly of rear differential assembly (HM400-DCD0-926-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

790-501-5200 Unit repair stand t 1

9 790-901-2110 Bracket t 1
792T-423-1310 Plate t 1
10 792-103-0901 Wrench t 1
11 792T-423-1320 Push tool t 1
792T-422-1260 Push tool t 1
16 790-101-5421 Grip t 1
H
01010-51240 Bolt t 1
790-101-5401 Push tool kit t 1
790-101-5481 • Plate 1
17
790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-201-2700 Push tool (C) t 1
18
790-201-2740 • Spacer t 1

Disassembly (HM400-DCD0-530-K-00-A)

1. Set the rear differential gear assembly on tool

H9.
2. Input coupling and holder
2) Remove side seal (6) and oil seal (7) from
Remove holder (1), and remove coupling (2). the pinion and cage assembly.

3. Pinion and cage assembly

1) By using forcing screw [1], remove pinion 3) Remove pinion assembly (8) from cage
and cage assembly (3). assembly (9).

a Note the number and thickness of the

shims.

4) Disassembly of the pinion assembly

HM400-3M0 50-209
50 Disassembly and assembly
Power train

Remove spacer (11) and bearing inner race

(12a) from pinion (10).

5) Disassembly of the cage assembly

Remove bearing (14) and bearing outer race
(12b) from cage (13).
a The inner race of bearing (14) has been
removed in Step 3 above.

5) Disassemble the differential gear case

assembly according to the following
procedure.
1] Remove 12 mounting bolts (34a), and
remove case and bearing assembly (34).
a Before removing, put a match mark on
the case of case and bearing
assembly and on the case of case
4. Differential gear assembly and bevel gear assembly.
a Sling the differential gear case in advance.
1) Remove locks (26) and (27).
2) By using tool H10, loosen adjustment nuts
(28) and (29) so that they can be rotated by
hands.
3) Loosen four bolts (30).
4) Sling the differential gear assembly, and
remove bearing caps (31) and (32) and
adjustment nuts (28) and (29). Then, remove
the differential gear case assembly.
a Take care not to drop the outer race of
bearing during handling.
2] By using puller [2], remove bearing (36a)
from case (35).

50-210 HM400-3M0

3] Remove washer (37a).
4] Remove differential side gear (38a).
5] Remove pinion gear assembly (39) as a
unit.
6] Remove four each of washers (39b),
pinion gears (39c) and bushings (39d)
from shaft (39a).
7] Remove differential side gear (38b).
8] Remove washer (37b).
HM400-3M0
50 Disassembly and assembly
Power train
6) Disassemble the bevel gear assembly
according to the following procedure.
1] Turn over case and bevel gear assembly
(40).
2] By using puller [2], remove bearing (41)
from case and bevel gear assembly (40).
3] Remove mounting bolts , and remove
case (43) from bevel gear (44).
Assembly (HM400_3R-DCD0-710-K-00-A)
a If no tool is specified to mount seals and
assemble parts (especially, in the input shaft
section), use a push tool having an appropriate
diameter.
1. Differential gear case assembly
1) Assemble the differential gear case
assembly according to the following
procedure.
1] Install case (43) to bevel gear (44).
50-211
50 Disassembly and assembly
Power train

2 Mounting bolt: 7] Install pinion gear assembly (39) as a

Liquid adhesive (LT-2) unit.
8] Install differential side gear (38a).
3 Mounting bolt: 9] Install washer (37a).
245 to 309 Nm {25.0 to 31.5
kgm}
2] Shrink-fit bearing (41) to case and bevel
gear assembly (40).
a Shrink fit temperature: Approximately
120 °C for 30 minutes

10]Shrink-fit bearing (36a) to case (35).

a Shrink fit temperature: Approximately
120 ℃ for 30 minutes

3] Turn over case and bevel gear assembly

(40).
4] Install washer (37b).
5] Install differential side gear (38b).

11]Install case and bearing assembly (34).

3 Mounting bolt (34a):
245 to 309 Nm {25.0 to 31.5
kgm}

6] Install 4 each of washers (39b), pinion

gears (39c) and bushings (39d) to shaft
(39a).

2. Assembly of differential body

1) Differential gear assembly
1] Install nuts (28) and (29) fitting them to
the groove of differential case (61).

50-212 HM400-3M0
 50 Disassembly and assembly
Power train

2] Sling gear case assembly (62), install the

outer race to the bearing, then install
them to differential case (61).

3. Cap
1) Install caps (31) and (32), and tighten bolt
(30) lightly.
2) By using tools [5] and [6], tighten bolt (30).
3 Bolt:
824 to 1,030 Nm {84 to 105 kgm}

5. Assembly of pinion and cage assembly

Assemble the pinion and cage assembly
according to the following procedure.
1) Assembly of cage assembly
Install bearing outer races (12b) and (14b) to
the cage.

4. Adjusting bearing preload

1) By using tool H10, rotate adjust rings (28)
and (29) until the ring gear hits the pinion
gear. Continue the adjustment until backlash
is eliminated.
a Hit the ring gears lightly with a copper
hammer while rotating the bearing, so
that the bearing has enough contact to
other parts. 2) Assembly of pinion assembly
Install bearing inner race (12a) to pinion (10).
a Apply sufficient amount of oil to the
bearing. a Install bearing inner race (12a) by
employing shrink fit or press fit by using
a When you loosened the adjust ring on
tool H11.
one side by a turn, you must tighten the
adjust ring on the other side by a turn.
2) Install a spring balance to the ring gear and
measure the free turning force at this time.
Starting tangential force: 11.8 to 17.7 N {1.2
to 1.8 kg}

HM400-3M0 50-213
50 Disassembly and assembly
Power train
3) Stand pinion assembly (8), insert spacer (11)
to pinion assembly and install cage assembly
(9).
4) By using tool H18, install bearing inner race
(14a) while rotating cage assembly (9).
a Never use the press for pushing.
50-214
a Apply oil to bearing inner race (14a).
5) By using tool H16, press-fit oil seal (7).
a Press-fit oil seal (7) so that clearance (c)
between its outside diameter surface and
the end surface of cage (13) becomes 10
± 0.5 mm.
6) By using tool H17, press-fit side seal (5).
a Press-fit side seal (5) so that its outside
diameter surface becomes fthe same
level with the end surface of cage (13).
HM400-3M0
 50 Disassembly and assembly
Power train

6. Pinion and cage assembly

Mount the standard shims (their thickness and
numbers are checked during disassembly), and
install pinion and cage assembly (3).
a Determine the thickness and number of
shims after implementing "Adjusting the tooth
contact and backlash" in Step 8.

8. Adjusting the tooth contact and backlash

• Adjust the backlash and, at the same time,
adjust the tooth contact.
1) Adjust the backlash according to the
following procedure.
1] Move the bevel gear with adjustment nuts
(28) and (29). At this time, rotate the nuts
7. Input coupling and holder on the both side the same number of
Install coupling (2) and install holder (1). turns in the same direction to prevent
changing the preload applied to the
2 Coupling end face (A portion): bearing.
Molybdenum disulfide lubricant (LM-
P)
2 Seal lip part (B):
Grease (G2-LI)
2 Holder mounting bolt:
Liquid adhesive (LT-2)
3 Holder mounting bolt:
824 to 1,030 Nm {84 to 105 kgm}

2] Apply dial gauge [11] vertically to the

reverse tooth surface in the outer end of
the bevel gear, and adjust the tooth
surface while rotating the adjustment nut
so that move of the gauge pointer is 0.3
to 0.46 mm.

HM400-3M0 50-215
50 Disassembly and assembly
Power train
a Conduct the adjustment in 3 to 4
locations. Fix the pinion gear during
the measurement.
2) Adjust the tooth contact according to the
following procedure.
1] Adjust the travel of bevel pinion with
shims (65) between differential case (64)
and transfer case (17).
2] Adjusting tooth contact
a See "Adjusting tooth contact" in Step
3.
3] Adjustment of tooth contact between
bevel gear and bevel pinion
• When the backlash is below the
standard value
Loosen the adjustment nut on the
bevel gear side, then tighten the left
side adjustment nut by that amount.
(Advance in direction (A))
• When the backlash exceeds the
standard value
Loosen the left side adjustment nut,
then tighten the adjustment nut on the
bevel gear side by that amount.
(Advance in direction (B))
50-216
1] Checking tooth contact
Thinly apply red lead to 7 to 8 tooth
surfaces of the bevel gear, then rotate
the bevel gear back and forth to check
the tooth contact patterns left on the
bevel gear.
a The center of the tooth contact
must be the position indicated
below.
• Center of tooth height
• The position where tooth length
from small end (C) is (x)
(approximately 33% of tooth
length)
a Width (y) of the tooth contact must
be 30 to 60% of the tooth length.
a Check that addendum (A),
dedendum (B), small end (C) and
large end (D) are not exposed to
strong contact.
2] Adjusting tooth contact
When an appropriate tooth contact
pattern is not obtained in the check,
repeat adjustment referring to the
following.
a After adjusting tooth contact,
check the backlash again.
When the bevel pinion is excessively
distanced from the bevel gear
HM400-3M0
 50 Disassembly and assembly
Power train

a Tooth contact pattern will be as shown

in the next figure.
• Decrease shims of the bevel pinion to
advance the bevel pinion in direction
(C).
• Advance the bevel gear in direction
(D).

When the bevel gear is excessively

distanced from the bevel pinion
a Tooth contact pattern will be as shown
in the next figure.
• Increase shims of the bevel pinion to
advance the bevel pinion in direction
(E).
When the bevel pinion is too close to • Advance the bevel gear in direction
the bevel gear (F).
a Tooth contact pattern will be as shown
in the next figure.
• Increase shims of the bevel pinion to
advance the bevel pinion in direction
(E).
• Advance the bevel gear in direction
(F).

9. Bevel gear fall-prevention bolt

Install bevel gear fall-prevention bolt (66).
a Rotate the bolt tip until it touches the bevel
gear back face and then return the bolt by 3/
4 turn, then secure the bolt with the lock nut.
2 Bolt:
Liquid gasket (LG-5)
When the bevel gear is too close to the
bevel pinion 3 Lock nut:
a Tooth contact pattern will be as shown 196 to 245 Nm {20 to 25 kgm}
in the next figure.
• Decrease shims of the bevel pinion to
advance the bevel pinion in direction
(C).
• Advance the bevel gear in direction
(D).

HM400-3M0 50-217
50 Disassembly and assembly
Power train

50-218 HM400-3M0
 50 Disassembly and assembly
Power train

Removal and installation of front final drive and brake assembly (HM400_3R-
RA1Q-924-K-00-A)

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)

k Loosen the cap of the hydraulic tank

gradually, and release the pressure
remaining inside the hydraulic tank.

Removal (HM400_3R-RA1Q-520-K-00-A)

1. Draining oil
Drain oil from the front final drive case.

6 Front final drive case:

5.5 l
2. Remove the front wheel assembly. For details,
see "Removal and installation of front wheel
assembly".
3. Drive shaft between the front differential and
front final drive
Disconnect drive shaft (1) between the front
differential and front final drive at the front
differential side. [*1]
5. Front final drive, brake and side drive shaft
assembly
Sling front final drive, brake and side drive shaft
assembly (6) and remove it.
a Take care in the removal not to allow falling
off of the side drive shaft at the spline in the
center of the shaft.

4 Front final drive, brake and side drive

shaft assembly:
610 kg

4. Brake cooling tube and brake drive hose

Disconnect brake cooling tubes (4) (2 pieces)
and brake drive hose (5).

Installation (HM400_3R-RA1Q-720-K-00-A)

• Perform installation in the reverse order to

removal.
[*1]

HM400-3M0 50-219
50 Disassembly and assembly
Power train

3 Front wheel mounting bolts:

824 to 1,030 Nm {84 to 105 kgm}
[Target: 926.0 Nm {94.5 kgm}]
[*2]
• When installing drive shaft, check that key slot of
spider cap is completely fitted to key slot of the
mating yoke before tightening bolt.
2 Mounting bolts of drive shaft between
front differential and front final drive:
Liquid adhesive (LT-2)
3 Mounting bolts of drive shaft between
front differential and front final drive:
98 to 123 Nm {10.0 to 12.5 kgm}
k After the installation, bleed air from the brake
circuit. For details, see Testing and adjusting
"Bleeding air from brake circuit".

• Refilling with oil

Refill with oil through the oil filler port of the front
final drive case to the specified level. Then
check the oil level again.

5 Front final drive case:

5.5 l
• Refilling with oil
Refill with oil through the oil filler port of the
transmission case to the specified level. Run the
engine to circulate the oil through the piping.
Then check the oil level again.

5 Transmission case:
Only necessary quantity
• Refilling with oil
Refill with oil through the oil filler port of the
hydraulic tank to the specified level. Run the
engine to circulate the oil through the piping.
Then check the oil level again.

5 Hydraulic tank:
Only necessary quantity

50-220 HM400-3M0
 50 Disassembly and assembly
Power train

Disassembly and assembly of front final drive and brake assembly (HM400-
RA1Q-926-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

792T-427-1110 Fixture t 3
1 01010-61435 Bolt t 3
01010-62440 Bolt t 3
792T-422-1220 Plate t 1
2 790-101-5421 Grip t 1
J 01010-51240 Bolt t 1
3 792T-423-1330 Push tool t 1
4 792T-422-1240 Push tool t 1
792-520-2110 Installer t 1
5
790-434-1620 Installer t 1
6 792T-423-1340 Plate t 1
Disassembly (HM400-RA1Q-530-K-00-A)

1. Drive shaft
Remove drive shaft (1).
a Take care not to drop the cap (yoke) from the
drive shaft during removal.

2. Cover and shaft

Remove cover (2), and remove snap ring (3). 3. Set the assembly by facing its brake side
Then, remove shaft (4) to the opposite side. downward.
4. Sun gear
a Drain the remaining oil from the case.
Remove sun gear (5).
a Take care not to expand snap ring (3)
excessively when removing it. Do not reuse
the snap ring if its inside diameter is 51.4 mm
or more after removal or if 0.3 mm or larger
step is found when the ring is placed on a flat
surface. (Replace it with a new one.)

HM400-3M0 50-221
50 Disassembly and assembly
Power train

5. Carrier assembly
1) Remove carrier assembly (6).

7. Plate
Remove plate (12) by using forcing screw [1].

2) Disassemble the carrier assembly according

to the following procedure.
1] Remove shaft (7).
a Take care not to lose ball (8).
2] Remove planetary gear (9) and bearing
(10).

8. Retainer and shims

1) By using tool J1, fix inner gear (13) and outer
gear (14).
a Set tools J1 at three points (equally
spaced) on circumference of inner gear
(13).
a To avoid a damage to floating seals,
always mount tools J1 before removing
retainer (15).
2) Remove the mounting bolts, and remove
retainer (15) and shims.

6. Thrust washer
Remove thrust washer (11).

9. Ring gear
Remove ring gear (16).

50-222 HM400-3M0
 50 Disassembly and assembly
Power train

1) Disassemble the ring gear according to the

following procedure.
1] Remove mounting bolts (17), and remove
holder (18).
2] Remove inner hub (20) from ring gear
(19).

11.Set the assembly by facing its brake side

upward.
12.Brake assembly
1) Remove brake assembly (24) from shaft
(23).
a Put a matchmark in advance.
10.Floating seal cage and floating seal
Remove floating seal cage (21) [including a half
part of floating seal (22a)].
a Use an M10 (long) forcing screw to remove
the cage.

2) Disassemble the brake assembly according

to the following procedure.
1] Remove tools J1.

HM400-3M0 50-223
50 Disassembly and assembly
Power train

2] Remove cylinder assembly (25).

3) Remove damper (end plate) (30), plate (31),

3] Disassemble the cylinder assembly and disc (32).
according to the following procedure. a Check the position of plate notch.
1] Remove piston (27) from cylinder
(26).

2] Remove seal rings (28) and (29) from

cylinder (26) and piston (27).

13.Hub (inner gear) and outer gear

1) Remove outer gear (34) from hub (inner
gear) (33).

50-224 HM400-3M0
 50 Disassembly and assembly
Power train

2) Remove floating seal and cage assembly

5) Remove floating seal (37b) from outer gear
(36), bearing outer races (46a) and (42a),
(38).
and floating seal (22b) from hub (inner gear)
(35).

14.Shaft (tube) assembly

Remove bearing (42), retainer (43), seal (44),
3) Remove floating seal (37a) and seal sleeve
and bushing (45) from shaft (tube) (41).
(40a) from floating seal and cage assembly
(36).

4) Remove cover (39) from outer gear (38), and

remove seal (40).

HM400-3M0 50-225
50 Disassembly and assembly
Power train

a Ensure that dirt is not sticking to seal

Assembly (HM400-RA1Q-710-K-00-A)
surface (a).
a If no tool is specified to mount seals and
2 Seal surface (a):
assemble parts (especially, in the input shaft
section), use a push tool having an appropriate Engine oil
diameter.
1. Shaft (tube) assembly
1) Install retainer (43) to shaft (tube) (41), and
install bearing (42) by using tool J4.

2) By using tool J2, install seal (40) to outer

gear (38).

2) Install bushing (44) and seal (45) to shaft

(tube) (41).
a Distance (c) between shaft (tube) end
and bushing end = 29 +/- 0.2 mm
2 Seal periphery:
Adhesive (SEALEND 242 or
equivalent)
2 Seal lip:
Grease (G2-LI)
a Distance (b) between shaft (tube) step 3) Install cover (39) to outer gear (38).
and bushing end = 5 +/- 0.2 mm

4) By using tool J6, install sleeve (40a) for seal

to cage (47).
2. Hub (inner gear) and outer gear
a End (c) of sleeve must be flush with end
1) By using tool J5, install floating seal (37b) to
face (P) of cage when installed.
outer gear (38).
a Measure seal height (A) (at 4 points on
the circumference) from outer gear and
make sure that the deviation among four
measurements is within 1 mm.

50-226 HM400-3M0
 50 Disassembly and assembly
Power train

5) By using tool J5, install floating seal (37a) to 8) Install floating seal and cage assembly (36)
cage (47). to hub (inner gear) (35).
a Measure seal height (A) (at 4 points on
the circumference) from outer gear and
make sure that the deviation among four
measurements is within 1 mm.
a Ensure that dirt is not sticking to seal
surface (a).
2 Seal surface (a):
Engine oil

9) Install outer gear (34) to hub (inner gear)

(33).
a Take care not to damage to the floating
seals and not to peel them during
installation.

6) Install bearing outer races (42a) and (46a) to

hub (inner gear) (35).

3. Brake assembly
1) Install disc (32), plate (31), and damper (end
plate) (30).
a When installing the plate, align notches at
six places on circumference.

7) By using tool J5, install floating seal (22b) to

hub (inner gear) (35).

HM400-3M0 50-227
50 Disassembly and assembly
Power train

2] Install piston (27) on cylinder (26).

2) Assemble the brake assembly according to

the following procedure. 2] Install cylinder assembly (25).
1] Assemble the brake assembly according
3 Cylinder mounting bolts:
to the following procedure.
157 to 196 Nm {16 to 20 kgm}
1] Install seal rings (28) and (29) on
cylinder (26) and piston (27).
a Measure seal height (A) (at 4
points on the circumference) from
outer gear and make sure that the
deviation among four
measurements is within 1 mm.
a Ensure that dirt is not sticking to
seal surface (a).
2 Seal surface (a):
Engine oil

3] Install tool J1.

3) Install brake assembly (24) to shaft (23).

50-228 HM400-3M0
 50 Disassembly and assembly
Power train

4. Set the assembly by facing its brake side 6. Ring gear

downward. 1) Assemble the ring gear according to the
5. Floating seal cage and floating seal following procedure.
1) By using tool J5, install floating seal (22a) to 1] By using tool J3, press-fit bearing (46)
cage (21). into inner hub (20).
a Measure seal height (A) (at 4 points on
the circumference) from outer gear and
make sure that the deviation among four
measurements is within 1 mm.
a Ensure that dirt is not sticking to seal
surface (a).
2 Seal surface (a):
Engine oil

2] Install holder (18) and tighten mounting

bolts (17).
2 Threaded portion of holder
mounting bolts:
Adhesive (LT-2)
3 Holder mounting bolt:
27 to 34 Nm {2.8 to 3.5 kgm}

2) Install floating seal cage (21) [including a half

split of floating seal (22a)].

2) Install ring gear (16).

HM400-3M0 50-229
50 Disassembly and assembly
Power train
7. Retainer and shims
1) Adjust the bearing preload according to the
following procedure.
1] Temporarily install retainer (15) with bolts
without inserting shims.
2] Remove tool J1 at 3 points, and tighten
bolts.
3] Tie up and secure the brake assembly to
forklift truck [1] or others.
4] Tighten every other retainer mounting
bolts, four bolts in total, while rotating
inner gear (13) 20 to 30 turns.
a Tighten the retainer mounting bolts
uniformly with 78.5 ± 4.9 Nm {8 ± 0.5
kgm} until the specified value is met.
a If the retainer mounting bolts are
tightened without rotating inner gear
(13), the bearings may not match and
the correct preload may not apply.
50-230
5] By using depth micrometer [2], measure
distance (c) between shaft end face and
retainer (15) end face.
a Measure the distance at two points
and use their average.
6] Remove retainer (15), and measure
thickness (a) of the retainer. Add "0.3
mm" to "Difference of measured values
(b) = (c - a)" and use it as the thickness of
shims.
2) Insert shims selected in the above step,
install retainer (15), and tighten the mounting
bolts.
a Tighten the mounting bolts uniformly to
the same torque while rotating inner gear
(13).
2 Threaded portion of retainer
mounting bolts:
Adhesive (LT-2)
3 Retainer mounting bolt:
157 to 196 Nm {16 to 20 kgm}
a After tightening the mounting bolts, rotate
inner gear (13) to check that the gear
rotates smoothly.
HM400-3M0
 50 Disassembly and assembly
Power train

8. Shaft 11.Carrier assembly

Install shaft (4).
1) Assemble the carrier assembly according to
the following procedure.
1] Install bearing (10) and planetary gear
(9).
2] Install shaft (7).
a Be sure to install balls (8).

9. Plate
Install plate (12).

2) Install carrier assembly (6) in position.

10.Thrust washer
Install thrust washer (11).

HM400-3M0 50-231
50 Disassembly and assembly
Power train

3 Drive shaft mounting bolts:

98 to 123 Nm {10 to 12.5 kgm}

12.Sun gear
Install sun gear (5). Install snap ring (3).
a Do not reuse snap ring (3) and replace it with
a new one if its inner diameter is 51.4 mm or
more after removal or if 0.3-mm or larger step
is found when the ring is placed on a flat
surface.

13.Cover
Install cover (2).
3 Cover mounting bolts:
98 to 123 Nm {10 to 12.5 kgm}

14.Drive shaft
Install drive shaft (1).
2 Threaded portion of retainer mounting
bolts:
Adhesive (LT-2)

50-232 HM400-3M0
 50 Disassembly and assembly
Power train

Removal and installation of center final drive and brake assembly (HM400_3R-
RA1R-924-K-00-A)

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Raise the dump body assembly fully and

insert a lock pin.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)

k Loosen the cap of the hydraulic tank

gradually, and release the pressure
remaining inside the hydraulic tank.

Removal (HM400_3R-RA1R-520-K-00-A)

1. Draining oil
Drain oil from the center final drive case.
5. Sun gear and drive shaft
6 Center final drive case:
Remove the center final drive cover, and remove
5l sun gear and drive shaft (4).
2. Jack up of center axle
Jack up the center axle.
3. Rear (front side) wheel
Remove rear (front side) wheel assembly (1).
For details, see "Removal and installation of rear
(front side) wheel assembly". [*1]

4 Rear (front side) wheel assembly:

800 kg

6. Center final drive assembly

Sling center final drive assembly (5) and remove
it.

4 Center final drive assembly:

600 kg

4. Brake cooling tube and brake drive hose

Disconnect brake cooling tubes (2) (2 pieces)
and brake drive hose (3).

HM400-3M0 50-233
50 Disassembly and assembly
Power train

Installation (HM400_3R-RA1R-720-K-00-A)

• Perform installation in the reverse order to

removal.
[*1]
3 Rear wheel mounting bolts:
824 to 1,030 Nm {84 to 105 kgm}
[Target: 926.0 Nm {94.5 kgm}]
k After the installation, bleed air from the brake
circuit. For details, see Testing and adjusting
"Bleeding air from brake circuit".

• Refilling with oil

Refill with oil through the oil filler port of the
center final drive case to the specified level.
Then check the oil level again.

5 Center final drive case:

5l
• Refilling with oil
Refill with oil through the oil filler port of the
transmission case to the specified level. Run the
engine to circulate the oil through the piping.
Then check the oil level again.

5 Transmission case:
Only necessary quantity
• Refilling with oil
Refill with oil through the oil filler port of the
hydraulic tank to the specified level. Run the
engine to circulate the oil through the piping.
Then check the oil level again.

5 Hydraulic tank:
Only necessary quantity

50-234 HM400-3M0
 50 Disassembly and assembly
Power train

Disassembly and assembly of center final drive and brake

assembly (HM400-RA1R-926-K-00-A)
a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

792T-427-1110 Fixture t 3
1 01010-61435 Bolt t 3
01010-62440 Bolt t 3
792T-422-1220 Plate t 1
2 790-101-5421 Grip t 1
J 01010-51240 Bolt t 1
3 792T-423-1330 Push tool t 1
4 792T-422-1240 Push tool t 1
792-520-2110 Installer t 1
5
790-434-1620 Installer t 1
6 792T-423-1340 Plate t 1
Disassembly (HM400-RA1R-530-K-00-A)

a The sun gear has been removed at removal of

final drive and brake assembly.
1. Set the assembly by facing its brake side
downward.
2. Carrier assembly
1) Remove carrier assembly (1).
3. Retainer and shims
1) By using tool J1, fix inner gear (6) and outer
gear (7).
a Set tools J1 at three points (equally
spaced) on circumference of inner gear
(6).
a To avoid a damage to floating seals,
always mount tools J1 before removing
retainer (8).
2) Remove the mounting bolts, and remove
retainer (8) and shims.

2) Disassemble the carrier assembly according

to the following procedure.
1] Remove shaft (2).
a Take care not to lose ball (3).
2] Remove planetary gear (4) and bearing
(5).

4. Ring gear
Remove ring gear (9).

HM400-3M0 50-235
50 Disassembly and assembly
Power train

1) Disassemble the ring gear according to the

following procedure.
1] Remove mounting bolts (10), and remove
holder (11).
2] Remove inner hub (13) from ring gear
(12).

6. Set the assembly by facing its brake side

upward.
7. Brake assembly
1) Remove brake assembly (17) from shaft
(16).
a Put a matchmark in advance.
5. Floating seal cage and floating seal
Remove floating seal cage (14) [including a half
split of floating seal (15a)].
a Use an M10 (long) forcing screw to remove
the cage.

2) Disassemble the brake assembly according

to the following procedure.
1] Remove tools J1.

50-236 HM400-3M0
 50 Disassembly and assembly
Power train

2] Remove cylinder assembly (18).

3) Remove damper end plate (23), plate (24),

3] Disassemble the cylinder assembly and disc (25).
according to the following procedure. a Check the position of plate notch.
1] Remove piston (20) from cylinder
(19).

2] Remove seal rings (21) and (22) from

cylinder (19) and piston (20).

8. Hub (inner gear) and outer gear

1) Remove outer gear (27) from hub (26).

HM400-3M0 50-237
50 Disassembly and assembly
Power train

2) Remove floating seal and cage assembly

5) Remove floating seal (30b) from outer gear
(29), bearing outer races (39a) and (35a),
(31).
and floating seal (15b) from hub (inner gear)
(28).

9. Shaft tube assembly

Remove bearing (35) and retainer (36) from
3) Remove floating seal (30a) and seal sleeve
shaft (34).
(33a) from floating seal and cage assembly
(29).

Assembly (HM400-RA1R-710-K-00-A)

4) Remove cover (32) from outer gear (31), and
remove seal (33).
a If no tool is specified to mount seals and
assemble parts (especially, in the input shaft
section), use a push tool having an appropriate
diameter.
1. Shaft (tube) assembly
1) Install retainer to shaft (tube) (34), and install
bearing (35) by using tool J4.

50-238 HM400-3M0
 50 Disassembly and assembly
Power train

2. Hub (inner gear) and outer gear

3) Install cover (32) to outer gear (31).
1) By using tool J5, install floating seal (30b) to
outer gear (31).
a Measure seal height (A) (at 4 points on
the circumference) from outer gear and
make sure that the deviation among four
measurements is within 1 mm.
a Ensure that dirt is not sticking to seal
surface (a).
2 Seal surface (a):
Engine oil

4) By using tool J6, install sleeve (33a) for seal

to cage (37).
a End face (c) of sleeve must be flush with
end face (P) of cage when installed.
2 Sleeve mounting face:
Axle oil (AXO80) or molybdenum
disulfide lubricant (LM-P)

2) By using tool J2, install seal (33) to outer

gear (31).
a The seal surface must be flush with the
outer gear end face.
2 Seal periphery:
Liquid gasket (LG-8)
2 Seal lip:
Grease (G2-LI)
5) By using tool J5, install floating seal (30a) to
cage (37).
a Measure the seal height (A) against the
cage (at four points in circumference) and
make sure that the deviation among four
measurements is within 1 mm.
a Ensure that dirt is not sticking to seal
surface (a).

HM400-3M0 50-239
50 Disassembly and assembly
Power train

2 Seal surface (a):

Engine oil

9) Install outer gear (26) to hub (inner gear)

(27).
a Take care not to damage to the floating
6) Install bearing outer races (35a) and (39a) to seals and not to peel them during
hub (inner gear) (28). installation.

7) By using tool J5, install floating seal to hub 3. Brake assembly

(inner gear).
a Measure the seal height (A) against the
hub (at four points in circumference) and
make sure that the deviation among four
measurements is within 1 mm.
1) Install disc (25), plate (24), and damper (end
plate) (23).
a When installing the plate, align notches at
six places on circumference.

8) Install floating seal and cage assembly (29)

to hub (inner gear) (28).

50-240 HM400-3M0
 50 Disassembly and assembly
Power train

2) Assemble the brake assembly according to 2] Install cylinder assembly (18).

the following procedure.
3 Cylinder mounting bolts:
1] Assemble the brake assembly according
157 to 196 Nm {16 to 20 kgm}
to the following procedure.
1] Install seal rings (21) and (22) to
cylinder (19) and piston (20).

3] Install tool J1.

3) Install brake assembly (17) to shaft (16).

2] Install piston (20) on cylinder (19).

HM400-3M0 50-241
50 Disassembly and assembly
Power train

4. Set the assembly by facing its brake side

downward.
5. Floating seal cage and floating seal
1) By using tool J5, install floating seal (15a) to
cage (14).
2) Install floating seal cage (14) [including a half
split of floating seal (15a)].
a Measure seal height (A) (at 4 points on
circumference) from the gear, hub and
retainer at position (a), and make sure
that the standard height is 2 mm.

6. Ring gear
1) Assemble the ring gear according to the
following procedure.
1] By using tool J3, press-fit bearing (39)
into inner hub (13).

2] Install holder (11) and tighten mounting

bolts (10).
2 Threaded portion of holder
mounting bolts:
Adhesive (LT-2)
3 Holder mounting bolt:
27 to 34 Nm {2.8 to 3.5 kgm}

2) Install ring gear (9).

50-242 HM400-3M0
 50 Disassembly and assembly
Power train

7. Retainer and shims

1) Adjust the bearing preload according to the
following procedure.
1] Temporarily install retainer (8) with bolts
without inserting shims.
2] Remove tool J1 at three points, and
tighten bolts.
3] Tighten every other retainer mounting
bolts, four bolts in total, while rotating
inner gear (6) 20 to 30 turns.
a Tighten the retainer mounting bolts
uniformly with 73.5 ± 0.98 Nm {7.5 ±
0.1 kgm} until the specified value is
met.
a If the retainer mounting bolts are
tightened without rotating inner gear
8. Carrier assembly
(6), the bearings may not match and
the correct preload may not apply.
2) Insert shims of an appropriate thickness,
install retainer (8), and tighten the mounting
bolts.
a Tighten the mounting bolts uniformly to
the same torque while rotating outer gear
(6).
2 Threaded portion of retainer
mounting bolts:
Adhesive (LT-2)
3 Retainer mounting bolt:
157 to 196 Nm {16 to 20 kgm}
a After tightening the mounting bolts, rotate
inner gear (6) to check that the gear
rotates smoothly.
1) Assemble the carrier assembly according to
the following procedure.
1] Install bearing (5) and planetary gear (4).
2] Install shaft (2).
a Be sure to install balls (3).

4] By using depth micrometer [1], measure

distance (c) between shaft end face and
retainer (8) end face.
a Measure the distance at 2points and
calculate their average.
5] Remove retainer (8), and measure
thickness (a) of the retainer. Add "0.3
mm" to "Difference of measured values
(b) = (c - a)" and use it as the thickness of
shims.

HM400-3M0 50-243
50 Disassembly and assembly
Power train

2) Install carrier assembly (1) in position.

a Install the sun gear at the installation of

the final drive assembly.

50-244 HM400-3M0
 50 Disassembly and assembly
Power train

Removal and installation of rear final drive assembly (HM400-DFH0-924-K-00-A)

k Set the parking brake switch to ON position,

and chock the wheels.

k Set the lock bar to the front and rear frames

to lock them.

k Turn the battery disconnect switch to the

OFF position and remove the key.

k Loosen the oil filler cap of the hydraulic tank

to release the internal pressure in the tank.

Removal (HM400_3R-DFH0-520-K-00-A)
6. Rear final drive assembly
1. Remove the dump body assembly. For details,
Sling the rear final drive assembly and remove it.
see "Removal and installation of dump body
assembly".
2. Draining oil 4 Rear final drive assembly:
Drain oil from the rear final drive case. 350 kg

6 Rear final drive case:

Installation (HM400_3R-DFH0-720-K-00-A)

5.5 l • Perform installation in the reverse order to

3. Jack up of rear axle removal.
Jack up the rear axle. [*1]
4. Rear wheel 3 Rear wheel mounting bolts:
Remove rear (rear side) wheel assembly (1). For 824 to 1,030 Nm {84 to 105 kgm}
details, see "Removal and installation of rear
(rear side) wheel assembly". [*1] [Target: 926.0 Nm {94.5 kgm}]
• Refilling with oil
4 Rear wheel assembly: Refill with oil through the oil filler port of the rear
800 kg differential case to the specified level. Then
check the oil level again.

5 Rear final drive case:

5.5 l
• Refilling with oil
Refill with oil through the oil filler port of the
transmission case to the specified level. Run the
engine to circulate the oil through the piping.
Then check the oil level again.

5 Transmission case:
Only necessary quantity
• Refilling with oil
5. Sun gear and drive shaft Refill with oil through the oil filler port of the
Remove the rear final drive cover, and pull out hydraulic tank to the specified level. Run the
sun gear and drive shaft (4). engine to circulate the oil through the piping.
Then check the oil level again.

5 Hydraulic tank:
Only necessary quantity

HM400-3M0 50-245
50 Disassembly and assembly
Power train

Disassembly and assembly of rear final drive assembly (HM400-DFH0-926-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

7 792T-423-1350 Push tool t 1

790-201-2100 Push tool kit t 1
J 8
790-201-2480 • Plate t 1
10 792T-423-1330 Push tool t 1
Disassembly (HM400-DFH0-530-K-00-A)

a The sun gear has been removed at removal of

3. Retainer and shims
final drive assembly.
Remove the mounting bolts, and remove
1. Set the assembly by facing its brake side retainer (6) and shims.
downward.
2. Carrier assembly
1) Remove carrier assembly (1).

4. Ring gear
Remove ring gear (7).

2) Disassemble the carrier assembly according

to the following procedure.
1] Remove shaft (2).
a Take care not to lose ball (3).
2] Remove planetary gear (4) and bearing
(5).

1) Disassemble the ring gear according to the

following procedure.
1] Remove bearing (8) from ring gear (7).

50-246 HM400-3M0
 50 Disassembly and assembly
Power train

2] Remove mounting bolts (9), and remove

holder (10).
3] Remove inner hub (12) from ring gear
(11).

Assembly (HM400-DFH0-710-K-00-A)

a If no tool is specified to mount seals and

5. Hub (inner gear) and outer gear
1) Remove seal (14) and bearing outer races
(8a) and (16a) from hub (13).
assemble parts (especially, in the input shaft
section), use a push tool having an appropriate
diameter.
1. Install tube (20) to axle housing (21) and tighten
mounting bolts (20a) (25 pieces).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
490 to 608 Nm {50 to 62 kgm}

6. Shaft (tube) assembly

Remove bearing (16) and retainer (17) from
shaft (15).
7. Retainer assembly
Remove retainer (17) and, remove protector (18)
and sleeve (19). 2. Retainer assembly
Install protector (18) to retainer (22) by using
push tool [4].
a Press-fit it until the surface becomes flush to
the retainer (A).

HM400-3M0 50-247
50 Disassembly and assembly
Power train

3. Shaft (tube) assembly

4) Install seal (14) to hub (tube) (13) by using
1) Install retainer (17) on shaft (tube) (15). tool J8.
a Check that O-ring (18) is installed to a Press-fit the seal until it firmly contacts
retainer (17). the hub end surface.
2 Seal lip surface: Grease (G2–LI)

2) Install bearing (16) to shaft (tube) (15) by

using tool J10.
5) Sling wheel hub assembly (24) and install it
to the tube.

4. Hub
1) Install bearing outer race (8a) to hub (13). 5. Ring gear
2) Turn over hub (13) and install bearing outer
1) Assemble the ring gear according to the
race (16a) to it.
following procedure.
3) Install bearing (23) to hub (13).
1] Press-fit bearing (8) to inner hub (12) by
2 Bearing: Axle oil using tool J7.
2 Bearing: Axle oil

50-248 HM400-3M0
 50 Disassembly and assembly
Power train

a Tighten the retainer mounting bolts

uniformly to 78.5 ± 4.9 Nm {8 ± 0.5
kgm} until the specified value is met.
a If the retainer mounting bolts are
tightened without rotating the inner
gear, the bearings may not match and
the correct preload may not apply.
3] Measure distance (c) by using depth
micrometer [1] between shaft end face
and retainer (6) end face.
a Measure the distance at 2 points, and
calculate their average.
2] Install plate (10) and tighten mounting 4] Remove retainer (6), and measure
bolts (9). thickness (a) of the retainer. Add 0.3 mm
2 Threaded part of holder to difference of measured values (b) = (c -
mounting bolts: a) and use it as the thickness of shims.
2) Insert shims of an appropriate thickness,
Adhesive (LT-2) install retainer (6), and tighten the mounting
3 Holder mounting bolt: bolts.
27 to 34 Nm {2.8 to 3.5 kgm} a Tighten the mounting bolts evenly until
the tightening torque of the bolt becomes
constant while rotating the outer gear.
2 Threaded part of retainer mounting
bolts:
Adhesive (LT-2)
3 Retainer mounting bolt:
157 to 196 Nm {16 to 20 kgm}
a After tightening the mounting bolts, rotate
the inner gear to check that the gear
rotates smoothly.

2) Install ring gear (7).

7. Carrier assembly
1) Assemble the carrier assembly according to
6. Retainer and shims the following procedure.
1) Adjust the bearing preload according to the 1] Install bearing (5) and planetary gear (4).
following procedure. 2] Install shaft (2).
1] Temporarily install retainer (6) with bolts
without inserting shims. a Be sure to install balls (3).
2] Tighten every other retainer mounting
bolts (4 pieces in total) while rotating the
inner gear 20 to 30 turns.

HM400-3M0 50-249
50 Disassembly and assembly
Power train

2) Install carrier assembly (1).

a Install the sun at the installation of the

final drive assembly.

50-250 HM400-3M0
 50 Disassembly and assembly
Power train

Removal and installation of center axle assembly (HM400_3R-DAK5-924-K-00-A)

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".) 4. Piping and wiring harness
1) Disconnect harness connectors (2) to (4).
Removal (HM400_3R-DAK5-520-K-00-A)
a Disconnect wiring harness clamps (5)
1. Remove the dump body assembly. For details, and (6), and .move wiring harness to the
see "Removal and installation of dump body left side.
assembly". 2) Remove right and left speed sensors (7) and
2. Jack up of frame (8). [*2]
1) Jack up the rear frame and support it by
using stand [1].
2) Jack up the center axle and rear axle by
using jacks [2] and [3].

3) Disconnect hydraulic hoses (9) and (10) from

valve (11).
4) Remove hydraulic tubes (12) to (15).

3. Rear (front side) wheel

Remove rear (front side) wheel assembly (1).
For details, see "Removal and installation of rear
(front side) wheel assembly". [*1]

4 Rear (front side) wheel assembly:

800 kg

5) Remove hydraulic hoses (16) to (20).

a Above is necessary to protect the center
axle from damage due to interference
when sling and lower the assembly by
using a sling.

HM400-3M0 50-251
50 Disassembly and assembly
Power train

5. Drive shaft between center differential and rear 9. Center axle and arm assembly
differential 1) Sling center axle and arm assembly (27).
1) Remove guard (21). 2) Remove support (retainer) plate (28) for the
2) Remove the guard, sling drive shaft (22) center axle arm support pin, then lower and
between the center differential and rear remove rear axle and arm assembly (27).
differential, and remove it. [*3]
6. Drive shaft between the hitch frame and center 4 Center axle and arm assembly:
differential 2,200 kg
1) Remove guard (23).
2) Disconnect drive shaft (24) between the hitch
frame and center differential by slinging at
the center differential side. Then hang the
drive shaft from the rear frame and fix it in
that state. [*4]

4 Drive shaft between the hitch

frame and center differential:
85 kg

7. Lateral rod
Remove lateral rod (25). [*5]

4 Lateral rod: Installation (HM400_3R-DAK5-720-K-00-A)

60 kg • Perform installation in the reverse order to
8. Equalizer bar spring removal.
Disconnect equalizer bar spring (26). [*6] [*1]
3 Rear wheel mounting bolts:
824 to 1,030 Nm {84 to 105 kgm}
[*2]
• Install speed sensors (7) and (8) according to
the following procedure.

50-252 HM400-3M0
 50 Disassembly and assembly
Power train

1. Finger-tighten the speed sensor until its tip

lightly touches surface of the addendum of
the gear.
a Turin it gently without pushing it hard to
the addendum.
2. When the speed sensor touches the
addendum surface of the gear, rotate it by
360° counterclockwise from that position.
3. Rotate the speed sensor clockwise, and
tighten lock nut (29b) at the position where
position mark (P) of positioning nut (29a)
becomes parallel to the lateral direction of
the machine.
(a) direction: Left side of machine [*5], [*6]
(b) direction: Right side of machine a Install center axle and arm assembly so that
3 Lock nut (29b): dimensions (X), (Z) and (Y) match the values
shown below.
84 to 132 Nm {8.5 to 13.5 kgm}
Distance (X) between rear suspension cylinder
pins: 574 mm
Clearance (Z) between rear axle top surface and
rear frame bottom surface: 130 mm
Dimension (Y) between rear frame top surface
and equalizer spring top surface: 201 mm

[*3]
a When installing drive shaft, check that key of
spider cap is completely fitted to key groove of
the mating yoke before tightening bolt.
2 Mounting bolts of drive shaft locating
between center differential and rear
differential: k After the installation, bleed air from the brake
Liquid adhesive (LT-2) circuit. For details, see Testing and adjusting
"Bleeding air from brake circuit".
3 Mounting bolts of drive shaft locating
between center differential and rear a Adjust length of suspension cylinder. For details
differential: see, Testing and adjusting, "Testing and
98 to 123 Nm {10.0 to 12.5 kgm} adjusting suspension cylinder".
[*4] • Refilling with oil
Refill with oil through the oil filler port of the
a When installing the lateral rod, align tap hole (a)
transmission case to the specified level. Run the
with center line of bearing (30) as shown in the engine to circulate the oil through the piping.
figure below. Then check the oil level again.

5 Transmission case:
Only necessary quantity
• Refilling with oil
Refill with oil through the oil filler port of the
hydraulic tank to the specified level. Run the

HM400-3M0 50-253
50 Disassembly and assembly
Power train

engine to circulate the oil through the piping.

Then check the oil level again.

5 Hydraulic tank:
Only necessary quantity

50-254 HM400-3M0
 50 Disassembly and assembly
Power train

Removal and installation of rear axle assembly (HM400_3R-DAC0-924-K-00-A)

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)
k Release nitrogen gas from the rear
suspension cylinder. For details, see Testing
and adjusting, "Testing and adjusting
suspension cylinder".
4. Drive shaft between center differential and rear
differential
1) Remove guard (2).
2) Remove the guard, sling drive shaft (3)
between the center differential and rear
differential, and remove it. [*2]

Removal (HM400_3R-DAC0-520-K-00-A)

1. Remove the dump body assembly. For details,

see "Removal and installation of dump body
assembly".
2. Jack up of frame
1) Jack up the rear frame and support it by
using stand [1].
2) Jack up the center axle and rear axle by
using jacks [2] and [3].

5. Lateral rod
Remove lateral rod (4). [*3]

4 Lateral rod:
60 kg

3. Rear (rear side) wheel

Remove rear (rear side) wheel assembly (1). For
details, see "Removal and installation of rear
(rear side) wheel assembly". [*1]

4 Rear (rear side) wheel assembly:

800 kg
6. Bracket (left)
Remove bracket (left) (5).

HM400-3M0 50-255
50 Disassembly and assembly
Power train
7. Rear axle and arm assembly
1) Sling rear axle and arm assembly (6).
2) Remove support (retainer) plate (7) for the
rear axle arm support pin.
3) Remove bottom pin (9) of rear suspension
cylinder (8), and lower and remove rear axle
and arm assembly (6). [*4]
4 Rear axle and arm assembly:
2,200 kg
50-256
Installation (HM400_3R-DAC0-720-K-00-A)
• Perform installation in the reverse order to
removal.
[*1]
3 Rear wheel mounting bolts:
824 to 1,030 Nm {84 to 105 kgm}
[*2]
a When installing drive shaft, check that key of
spider cap is completely fitted to key groove of
the mating yoke before tightening bolt.
2 Mounting bolts of drive shaft locating
between center differential and rear
differential:
Liquid adhesive (LT-2)
3 Mounting bolts of drive shaft locating
between center differential and rear
differential:
98 to 123 Nm {10.0 to 12.5 kgm}
[*3]
a When installing lateral rod, align tap hole (a) with
center line of bearing (15) as shown in the figure
below.
HM400-3M0
 50 Disassembly and assembly
Power train

a Adjust length of the rear suspension cylinder.

For details see, Testing and adjusting, "Testing
and adjusting suspension cylinder".

[*4]
a Install rear axle and arm assembly so that
dimensions (X), (Z) and (Y) match the values
shown below.
Distance (X) between rear suspension cylinder
pins: 574 mm
Clearance (Z) between rear axle top surface and
rear frame bottom surface: 130 mm
Dimension (Y) between rear frame top surface
and equalizer spring top surface: 201 mm

• Refilling with oil

Refill with oil through the oil filler port of the
transmission case to the specified level. Run the
engine to circulate the oil through the piping.
Then check the oil level again.

5 Transmission case:
Only necessary quantity
• Refilling with oil
Refill with oil through the oil filler port of the
hydraulic tank to the specified level. Run the
engine to circulate the oil through the piping.
Then check the oil level again.

5 Hydraulic tank:
Only necessary quantity
• Filling rear suspension cylinder with nitrogen gas
and adjusting cylinder length

HM400-3M0 50-257
50 Disassembly and assembly
Steering system

Steering system (ALL-F000-001-K-00-A)

Disassembly and assembly of steering cylinder assembly (HM400-F6L0-926-K-00-A)

a Special tools 5) By using tool U2, loosen cylinder head nuts

and remove cylinder head assembly (3).

Necessity
Sym-

Q'ty
Part No. Part name
bol

790-502-1003 Cylinder repair stand t 1

1
790-101-1102 Hydraulic pump t 1
2 790-102-3802 Wrench assembly t 1
790-102-4300 Wrench assembly t 1
3
790-102-4310 Pin t 2
790-720-1000 Expander t 1
4 796-720-1670 Ring t 1
07281-01279 Clamp t 1
Push tool (outside
U diameter: 135 mm, 6) Pull out and remove cylinder head and piston
792T-461-1110 t 1
inside diameter: 130 rod assembly (4) from cylinder (5).
5 mm, length: 35 mm)
790-101-5021 Grip t 1 a When the piston rod assembly is pulled
out of the cylinder, oil flows out. So
01010-50816 Bolt t 1
prepare a container to receive the oil.
Plate (outside
diameter of dust seal 7) Remove cylinder (5) from tool U1.
790-201-1970 t 1
press-fitting part: 146
6 mm)
790-101-5021 Grip t 1
01010-50816 Bolt t 1

Disassembly (HM400-F6L0-530-K-00-A)

a Take care not to damage the rod packing, dust

seals, piston rings, wear rings and others during
disassembly.
1. Piston rod assembly
1) Remove the piping from the cylinder
assembly.
2) Remove mounting bolts (1a), and remove 8) Disassemble the piston rod assembly
collar assembly (1). according to the following procedure.
3) Remove check valve (1b).
1] Set piston rod assembly (4) on tool U1.
a Place an oil container under the cylinder
to receive oil.

2] Remove lock screw (6b) of the piston

assembly.
4) Set cylinder assembly (2) on tool U1. Screw size: M12, Pitch=1.75 mm

50-258 HM400-3M0
 50 Disassembly and assembly
Steering system

7] Remove cap (9), remove nine balls (10),

a If screw (6b) is punched securely and
and remove plunger (11).
hard to remove, tighten it further once.
Then tap its threaded portion with tap
[1] and remove the screw.

2. Disassembly of piston assembly

1) Remove wear ring (12).
3] By using tool U3, remove piston 2) Remove piston ring (13).
assembly (6). 3) Remove the O-ring and backup ring (14).
• When tool U3 is not used, use drilled
holes (DH) (φ10-mm in 2 places) to
loosen the piston assembly.

3. Disassembly of cylinder head assembly

1) Remove the O-ring and backup ring (15).
2) Remove O-ring (16).
4] Remove head assembly (7). 3) Remove rod packing (17).
5] Remove collar (8). 4) Remove bushing (18).
6] Remove plate (8a). 5) Remove dust seal (19).

HM400-3M0 50-259
50 Disassembly and assembly
Steering system

4. Disassembly of collar assembly 2. Assembly of head assembly

1) Remove ring (20). 1) Press-fit bushing (18) by using tool U5.
2) Remove dust seal (21). 2) Install rod packing (17).
3) By using tool U6, press-fit dust seal (19).
4) Install O-ring (16).
5) Install the backup ring and O-ring (15).

Assembly (HM400_3R-F6L0-710-K-00-A)

a Take care not to damage packings, dust seals,

O-rings, etc.
a Clean all parts so that dust do not enter in piping
ports and pin insertion holes after assembling.
a When inserting the backup ring, do not insert it
forcibly but warm it in hot water at approximately
50 to 60 °C, and then install it.
a Check all parts thoroughly for dust and
scratches, and apply engine oil to the sliding
surface before assembling.
1. Assembly of collars
1) Install dust seal (21).
2) Install ring (20).
3. Assembly of piston assembly
1) By using the expander of tool U4, expand
piston ring (13).
a Set the piston ring on tool U4, and rotate
the handle 8 to 10 turns to expand the
piston ring.
2) Remove piston ring (13) from tool U4, and
install it to piston (6a).

50-260 HM400-3M0
 50 Disassembly and assembly
Steering system

3) By using the ring of tool U4, compress the 2) Set pin plunger (11) on the piston rod, mount
piston ring. 9 balls (10), and secure them with cap (9).
a Make sure that the plunger end has a
certain play.

4) Install the backup ring and O-ring (14).

5) Install wear ring (12).
a Take care not to expand the ring mating 3) Install plate (8a).
part excessively. 4) Install collar (8).
5) Install head assembly (7).
2 Ring groove:
Grease (G2-LI)

6) Assemble piston assembly (6) according to

the following procedure.
4. Piston rod assembly
• When reusing piston rod assembly (4)
1) Set piston rod assembly (4) on tool U1. and piston assembly (6):
a Clean them thoroughly and remove all
chips and dirt.
1] Screw in piston assembly (6). By using
tool U3, tighten piston assembly (6) until
screw holes (H) are aligned.

HM400-3M0 50-261
50 Disassembly and assembly
Steering system

a Remove burrs and sharp edges from

threaded part by using a file.

4] Tighten screw (6b).

• When either or both of rod and piston are
new:
1] Screw in piston assembly (6) until it
reaches rod end surface [B]. By using
tool U3, tighten it to the specified torque.
5] Punch 4 places of threaded part (a) with
2 Female thread side of screw
(b):
Adhesive (Loctite No. 262)
3 Screw:
58.9 to 73.6 Nm {6.0 to 7.5 kgm}
punch.
a After punching, check that the
threaded parts do not loosen to the
return torque 41.2 Nm {4.2 kgm}.

2] Make one threaded hole for screw

mounting.
a Drill a hole in horizontal into the V-
groove where piston (6a) and rod (2)
mesh with each other.
• Drilling dimensions (mm)
Tap drill Tap hole Tapping
Tap
diameter depth depth
10.3 27 12 x 1.75 20
3] After drilling, remove all dirt and clean the
hole thoroughly.

7) Remove piston rod assembly (4) from tool

U1.

50-262 HM400-3M0
 50 Disassembly and assembly
Steering system

3 Plug:
83.4 to 102.9 Nm {8.5 to 10.5 kgm}

5. Piston rod assembly

1) Set cylinder (5) on tool U1.
2) Install cylinder head and piston rod assembly
(4) to cylinder (5).
3) By using tool U2, tighten cylinder head
assembly (3).
3 Cylinder head nuts:
981 ± 98 Nm {100 ± 10 kgm}

4) Tighten mounting bolts (1a) of collar (1).

5) Install plug (1b).
a Clean threaded portion of the plug and
degrease it, dry it, and apply liquid
adhesive to the entire threaded portion.
a Use the Loctite's Primer T.
2 Threaded portion of plug:
Liquid gasket (LG-5)

HM400-3M0 50-263
50 Disassembly and assembly
Undercarriage and frame

Undercarriage and frame (ALL-DT00-001-K-00-A)

Removal and installation of front suspension cylinder assembly (HM400_3R-

E140-924-K-00-A)

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".) 2) Disconnect tube (4) and hose (5).

k Release nitrogen gas from the front

suspension cylinder. For details, see Testing
and adjusting, "Testing and adjusting
suspension cylinder".

Removal (HM400_3R-E140-520-K-00-A)

1. Front wheel assembly

Remove the front wheel assembly. For details,
see "Removal and installation of front wheel
assembly". [*1]

4 Front wheel assembly:

3) Sling the front suspension cylinder.
800 kg 4) Remove top and bottom pins (6) and (7), and
remove front suspension cylinder assembly
(8).

2. Front suspension cylinder

1) Remove covers (2) and (3).
Installation (HM400-E140-720-K-00-A)

• Perform installation in the reverse order to

removal.
[*1]

50-264 HM400-3M0
 50 Disassembly and assembly
Undercarriage and frame

3 Front wheel mounting bolts:

824 to 1,030 Nm {84 to 105 kgm}
[Target: 926 Nm {94.5 kgm}]
Charging of nitrogen gas and adjusting cylinder
length
a Charge the suspension cylinder with nitrogen
gas and adjust the cylinder length. For details,
see Testing and adjusting, "Testing and
adjusting suspension cylinder".

HM400-3M0 50-265
50 Disassembly and assembly
Undercarriage and frame

Removal and installation of rear suspension cylinder assembly (HM400_3R-E141-

924-K-00-A)

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".) 3. Rear suspension cylinder
By using balancing bar [3], remove top and
k Release nitrogen gas from the rear bottom pins (3) and (4), and remove rear
suspension cylinder. For details, see Testing suspension cylinder assembly (5).
and adjusting, "Testing and adjusting
suspension cylinder".

Removal (HM400_3R-E141-520-K-00-A)

1. Jack up
1) Jack up the rear frame and rear axle by using
jacks [1] and [2].
2) Lower lateral rod (1) and pull it out to your
side. [*1]

k Since you cannot sling the lateral rod,

bind it to prevent its falling. Then
remove it while watching your step.
Installation (HM400-E141-720-K-00-A)

4 Lateral rod: • Perform installation in the reverse order to

60 kg removal.
[*1]
a When installing lateral rod, align tap hole (a) with
center line of bearing (6) as shown in the figure
below.

2. Bracket
Remove bracket (2).

Charging of nitrogen gas and adjusting cylinder

length

50-266 HM400-3M0
 50 Disassembly and assembly
Undercarriage and frame

a Charge the suspension cylinder with nitrogen

gas and adjust the cylinder length. For details,
see Testing and adjusting, "Testing and
adjusting suspension cylinder".

HM400-3M0 50-267
50 Disassembly and assembly
Undercarriage and frame

Disassembly and assembly of suspension cylinder assembly (HM400-E139-926-K-

00-A)

a Special tools 2) Remove O-ring (8) and backup ring (8a).

3) Remove bushing (9), buffer ring (10),

Necessity
packing (11), backup ring (11a), and dust
Sym-

Q'ty
Part No. Part name seal (12) from flange assembly (3).
bol
Assembly (HM400-E139-710-K-00-A)
791-863-1110 Push tool t 1 1. Assembly of flange
792-201-3141 Push tool t 1
P 1) Install buffer ring (10) to flange assembly (3).
790-101-5221 Grip t 1 2) Install packing (11) and backup ring (11a) in
01010-51225 Bolt t 1 a set to flange assembly (3).
Disassembly (HM400-E139-530-K-00-A) a Be sure to face part (R) of backup ring
(11a) in the correct direction when
subassembling packing (11) and backup
ring (11a).
Be sure to face part (R) surface towards
the buffer ring.

1. Preparation
1) Release nitrogen gas from the suspension
cylinder. For details, see Testing and
adjusting, "Testing and adjusting suspension
cylinder".
2) Drain the oil from oil chamber (13). 3) Install bushing (9) to flange assembly (3).
4) By using tool P install dust seal (12) to flange
6 Front suspension cylinder : assembly (3).
7.8 l 2 Periphery of dust seal (12):
Adhesive (LT-2)
6 Rear suspension cylinder: 5) Install O-ring (8) and backup ring (8a) in a set
2.4 l to flange assembly (3).
3) Remove cover (1).
2 Periphery of packing (11):
2. Removal of cylinder rod
Antirust agent (ENEOS P1300 or
1) Remove mounting bolts (2a).
equivalent)
2) Pull out cylinder rod (2) and flange assembly
6) Install cylinder rod (2) to flange assembly (3).
(3) in a unit.
2. Assembly of cylinder rod assembly
3. Removal of piston assembly
1) Install boss (7) and ball (6) to cylinder rod (2).
1) Remove mounting bolts (4a).
3. Assembly of piston assembly
2) Pull out piston assembly (4).
4. Disassembly of piston assembly 1) Install wear ring (5) to piston (4).
4. Assembly of cylinder rod assembly
1) Remove wear ring (5) from piston (4).
5. Disassembly of cylinder rod assembly 1) Install piston assembly (4) to the cylinder rod
assembly.
1) Remove ball (6) and boss (7) from cylinder
2) Tighten piston mounting bolts (4a) to the
rod (2).
specified torque.
6. Disassembly of flange assembly
1) Remove flange assembly (3) from cylinder 3 Piston mounting bolts (4a):
rod (2). 58.8 to 73.5 Nm {6.0 to 7.5 kgm}

50-268 HM400-3M0
 50 Disassembly and assembly
Undercarriage and frame

3) Install cylinder rod assembly (2) to the

cylinder.
4) Install flange assembly (3) to the cylinder.
5) Tighten mounting bolts (2a) of flange
assembly (3) to the specified torque.
3 Flange assembly mounting bolts
(2a):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
5. Install cover (1) to the cylinder.
6. Refill with oil from oil chamber (13).
• Refilling with oil
Refill with oil through the oil filler port of the
front suspension cylinder to the specified
level. Then check the oil level again.

5 Front suspension cylinder :

7.8 l
• Refilling with oil
Refill with oil through the oil filler port of the
rear suspension cylinder to the specified
level. Then check the oil level again.

5 Rear suspension cylinder:

2.4 l
a Adjust the oil level. For details, see Testing
and Adjusting, "Testing and adjusting
suspension cylinders".
7. Charging nitrogen gas
Fill suspension cylinders with nitrogen gas. For
details, see Testing and Adjusting, "Testing and
adjusting suspension cylinders".

HM400-3M0 50-269
50 Disassembly and assembly
Undercarriage and frame

Removal and installation of equalizer bar assembly (HM400_3R-E3A2-924-K-00-A)

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)
k Release nitrogen gas from the rear
suspension cylinder. For details, see Testing
and adjusting, "Testing and adjusting
suspension cylinder".
Removal (HM400_3R-E3A2-520-K-00-A)
3. Remove the rear wheels (front and rear) on the
equalizer removal side. For details, see
"Removal and installation of rear wheel
assembly".
4. Remove pin (5) of the rear suspension cylinder
bottom side, and lay down cylinder (6) in the rear
side of the machine.

1. Remove the dump body assembly. For details,

see "Removal and installation of dump body
assembly".
2. Remove the hoist cylinder
1) Disconnect hoses (1) and (2).
a Plug the hoses to prevent leakage of oil.

k Pull and hold the hoist cylinder into

the inside of the machine. (Be sure to
pull and hold the hoist cylinder into
the inside of the machine to prevent its
5. Remove mounting bolts (8) (4 pieces) on top of
falling (swinging) to the outside when
cushion (7) mounted to the equalizer bar.
the bottom side pin is removed.)

6. Sling the equalizer bar.

2) Sling the hoist cylinder, and tilt it in the
7. Remove mounting bolts (10a) (3 pieces) and
direction at right angle to the machine.
(10b) (3 pieces) of plate (9) in the center of the
3) Remove bottom side pin (3) and remove
equalizer bar. [*3]
hoist cylinder (4). [*2]
8. By using forcing screw [1], remove bushing (11).
4 Hoist cylinder:
230 kg

50-270 HM400-3M0

9. Sling equalizer bar (12) and remove it.
4 Equalizer bar:
220 kg
Installation (HM400_3R-E3A2-720-K-00-A)
• Perform installation in the reverse order to
removal.
[*1]
Fill suspension cylinders with nitrogen gas. For
details, see "Testing and adjusting suspension
cylinders".
[*2]
3 Bottom side pin mounting bolt:
157 to 196 Nm {16 to 20 kgm}
[*3]
a Do necessary adjustment in the installation so
that the difference of the dimensions between
the machine and equalizer bar, namely between
(a) and (b) and between (c) and (d), is
respectively within 2mm.
3 Plate mounting bolt (10a) (thread
diameter: 14 mm)
157 to 196 Nm {16 to 20 kgm}
3 Plate mounting bolt (10b) (thread
diameter: 24 mm)
824 to 1,030 Nm {84 to 105 kgm}
HM400-3M0
50 Disassembly and assembly
Undercarriage and frame
a Install so that dimensions (X), (Z) and (Y) match
the values shown below.
Distance (X) between rear suspension cylinders:
574 mm
Clearance (Z) between rear axle top surface and
rear frame top surface: 130 mm
Dimension (Y) between rear frame top surface
and equalizer spring top surface: 201 mm
• Adjusting dump body
a Adjust the dump body positioner. For details, see
Testing and adjusting, "Adjusting dump body
positioner sensor".
• Refilling with oil
Refill with oil through the oil filler port of the
hydraulic tank to the specified level. Run the
engine to circulate the oil through the piping.
Then check the oil level again.
a Move the dump body up and down and then
check the level again.
5 Hydraulic tank:
Only necessary quantity
• Charging of nitrogen gas and adjusting cylinder
length
a Release nitrogen gas from the rear suspension
cylinder and adjust cylinder length. For details,
see Testing and adjusting, "Testing and
adjusting suspension cylinder".
50-271
50 Disassembly and assembly
Undercarriage and frame

Removal and installation of front wheel assembly (HM400_3R-DW20-924-K-00-A)

k In order to prevent serious or death k Do not give a large impact to the machine
accidents due to falling of the cab, following when tilting up the cab.
precautions must be observed when tilting
the cab. k When lowering the cab by using the cab
power tilt (optional), do it gradually adjusting
• Precautions before starting cab-tilting operation the descending speed without decreasing
the oil pressure at a breath.
k Cab-tilting operation must be performed on a
flat ground.
k The lock bar is equipped in the inner left side
corner of the engine hood. Be sure to return
k Set the machine to the straight-travel
the bar to the original place after using it.
condition to prevent the interference
between the cab and body, then fix the front
k Turn the battery disconnect switch to OFF
and rear frames by using the articulation
position, and remove the key.
lock.
k Set the lock bar to the front and rear frames
k Set the parking brake switch to ON position
to lock them.
by pressing "P", and apply the parking brake.
Removal (HM400_3R-DW20-520-K-00-A)
k Lock the lever by using the dump lever lock
knob. 1. Open engine hood (1).

k Chock the wheels to prevent the machine

from moving.

k Do not perform the cab-tilting operation

when it is strongly windy.

k Before dismounting cab, be sure to lock the

lock pin in the rear mount of cab.

• Precautions for cab-tilting operation

k Do not perform the cab-tilting operation
when the dump body is loaded.
k Check that lock (2) is set securely.
k Do not place yourself under the cab during
the cab-tilting operation.

k Fix the cab securely by using the lock lever

before tilting up the cab.

k Installthe lock lever from the side of the cab

without entering into a space below the cab.

k Do not go in or out the cab when tilting up

the cab.

k Do not operate the gear shift lever and dump

lever when tilting up the cab.
2. Tilt up operator's cab assembly (3). For details,
k Do not start the engine when tilting up the see Testing and adjusting, "Cab tilt up
cab. procedure".
Check that lock lever (4) is in CLOSE position
k When you are forced to start the engine for and operator's cab assembly (3) is securely
inspection purpose, check that no person is supported with lock bar (B).
under the cab.

50-272 HM400-3M0
 50 Disassembly and assembly
Undercarriage and frame

1) Remove tire house covers (5), (6), (7), (8),

(9) and mudguard (10).

2) Remove handrails (11) and (12).

3. Remove cover (4).

3) Sling left fender assembly (13) and remove

it.

4 Left fender assembly: 120 kg

4. Jack up the front (sub) frame and set support

stands [1].

4) Sling left front wheel assembly (14) and

remove mounting bolt (15). [*1]
5) Sling left front wheel assembly (14) and
remove it.

4 Front wheel assembly: 800 kg

5. Removal and installation of left front wheel

assembly

HM400-3M0 50-273
50 Disassembly and assembly
Undercarriage and frame

6. Removal and installation of right front wheel 4) Remove covers (21) to (24).
assembly
1) Loosen the belt of cover (16) and flip the fire
prevention cover. [*2]

5) Remove mounting bolts (25) (4 pieces), and

disconnect muffler assembly (27) from
exhaust pipe (26). [*4]
2) Remove bracket (17).

6) Remove cover (28).

3) Remove bolts (18) (4 pieces) and (19) (2
pieces), and remove exhaust pipe (20).

7) Remove mounting bolts (29) (4 pieces).

50-274 HM400-3M0
 50 Disassembly and assembly
Undercarriage and frame

8) Remove tire house covers (30), (31), (32), 11)Sling right front wheel assembly (40) and
(33), (34), (35) and mudguard (36). remove mounting bolts (41). [*3]
12)Sling right front wheel assembly (40) and
remove it.

4 Right front wheel assembly: 800 kg

9) Remove handrails (37) and (38) from the

right fender assembly.

Installation (HM400_3R-DW20-720-K-00-A)

• Perform installation in the reverse order to

removal.
[*1], [*3]
3 Front wheel mounting bolts (15) and (41):
824 to 1,030 Nm {84 to 105 kgm}
[*2]
a Install fire prevention cover (28) of the exhaust
pipe. For details see "Removal and installation
10)Sling and remove right fender (39) together of fire prevention cover of exhaust pipe".
with the muffler assembly.

4 Right fender: 250 kg

HM400-3M0 50-275
50 Disassembly and assembly
Undercarriage and frame

Removal and installation of rear (front side) wheel assembly (HM400_3R-DW40-924-

K-00-A)

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)

Removal (HM400-DW40-520-K-00-A)

1. Remove the dump body assembly. For details,

see "Removal and installation of dump body
assembly".
a When a forklift is used for the removal, work
of Step 1 is not necessary.
2. Jack up of center axle
Jack up the center axle.
3. Rear (front side) Tire and rim assembly
Set slings to the rear (front side) Tire and rim
assembly, remove mounting bolts, then sling
and remove rear (front side) Tire and rim
assembly (1).

4 Rear (front side) Tire and rim

assembly (29.5R25 AAE-2)
AA (1piece):
777 kg

Installation (HM400-DW40-720-K-00-A)

• Perform installation in the reverse order to

removal.
3 Rear (font side) wheel mounting bolt:
824 to 1,030 Nm {84 to 105 kgm}

50-276 HM400-3M0
 50 Disassembly and assembly
Undercarriage and frame

Removal and installation of rear (back side) wheel assembly (HM400_3R-DW40-924-

K-01-A)

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)

Removal (HM400-DW40-520-K-01-A)

1. Remove the dump body assembly. For details,

see "Removal and installation of dump body
assembly".
a When a forklift is used for the removal, work
of Step 1 is not necessary.
2. Jack up of rear axle
Jack up the rear axle.
3. Rear (rear side) Tire and rim assembly
Set slings to the rear (rear side) Tire and rim
assembly, remove mounting bolts, then sling
and remove rear (rear side) Tire and rim
assembly (1).

4 Rear (rear side) Tire and rim assembly

(29.5R25 AAE-2)
AA (1piece):
777 kg

Installation (HM400-DW40-720-K-01-A)

• Perform installation in the reverse order to

removal.
[*1]
3 Rear (font side) wheel mounting bolt:
824 to 1,030 Nm {84 to 105 kgm}

HM400-3M0 50-277
50 Disassembly and assembly
Undercarriage and frame

Removal and installation of hitch frame assembly (HM400_3R-H1P0-924-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

792T-446-1120 Push tool t 1

790-101-2310 Block t 2
790-101-2390 Leg t 2
790-101-2750 Adapter (18 mm) t 2
2 790-101-2360 Plate t 2
02215-11622 Nut t 2
Q Puller (300 kN 3) Disconnect hoses (3a) and (3b).
790-101-2102 t 1
{30ton})
790-101-1102 Pump t 1
792T-446-1130 Plate t 1
792T-446-1140 Plate t 1
6
790-110-5421 Grip t 1
01010-51240 Bolt t 1

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.
4) Disconnect wiring connectors (4a) to (4d).
k Raise the dump body assembly fully and 5) Disconnect ground cable (4e).
insert a lock pin.

k Turn the key switch ON, shift dump lever

LOWER position, and release the remaining
pressure in hoist hydraulic circuit. Never
start the engine at this time.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)

k Loosen the oil filler cap of the hydraulic tank

gradually to release the internal pressure in 6) Disconnect hoses (5a) and (5b).
the tank.
a Disconnect hose clamps (6a) and (6b), as
Removal (HM400_3R-H1P0-520-K-00-A) well.
1. Hose and wiring harness
1) Remove covers (1a) and (1b).
2) Remove bracket (2).

50-278 HM400-3M0
 50 Disassembly and assembly
Undercarriage and frame

1) Release the parking brake.

2) Remove cover (11).

7) Open cover (7).

8) Remove cover (8).
3) Remove spring bracket (12) for pad
expansion. [*2]
4) Remove mounting bolt (13a) for plate (13),
and remove parking brake and cylinder
assembly (14). [*3]

9) Disconnect hose (9).

a Disconnect hose clamp (9a), as well.

3. Drive shaft between the hitch frame and center

differential
Remove the guard, sling drive shaft (20)
between the hitch frame and center differential
and remove it. [*4]

4 Drive shaft between the hitch frame

and center differential:
80 kg

10)Disconnect hoses (10a) to (10c).

4. Parking brake disc and coupling assembly

2. Parking brake assembly

HM400-3M0 50-279
50 Disassembly and assembly
Undercarriage and frame

Remove the coupling holder, and remove

parking brake disc and coupling assembly (16).
[*5]

4 Parking brake and coupling assembly:

55 kg

7. Steering cylinder
Remove head side pin (19) and disconnect
steering cylinder (20). (On both sides) [*7]

5. Parking brake bracket

Remove parking brake bracket (17).

4 Parking brake bracket:

55 kg

8. Jack up of machine
1) Operator's cab side in the front
1] Sling the front side by using crane (chain
[1], etc.).
2] Support the bottom of the frame in the
rear side with a stand for safety.

6. Drive shaft between transmission and hitch

frame
Remove the guard, and disconnect drive shaft
(18) between the transmission and hitch frame
on the transmission side. [*6]

4 Drive shaft between transmission and

hitch frame:
55 kg

2) Dump body side in the rear

1] Support the end of the dump body in the
rear side with block [2], etc.
2] For the sake of safety, Support the
bottom of the frame in the front side with
a jack for safety.

50-280 HM400-3M0

9. Hinge pin
1) By using jacks [3] and [4], move up and
down finely the rear portion of the front frame
and the front portion of the rear frame until
centering of the hinge pin is completed.
10.Disconnecting of front from rear
2) Remove plate (21) and anti-pin drop plate
(21A), and lower and remove (pull out) upper
hinge pin (22).
3) Remove pin bushing (21B) upward.
4) By using a jack, remove lower hinge pin (23)
upward. [*8]
HM400-3M0
50 Disassembly and assembly
Undercarriage and frame
By using the fork lift and crane at the front
portion of the front frame, move the front frame
side forward and disconnect it from the rear
frame side.
k Check that levelness around the hinge
pin is sufficiently maintained until the
moment the rear frame of the front frame
side is disconnected from the hitch frame.
k Check that clearances (a) and (b) are
provided between the rear frame of the
front frame side and hitch frame. Then
disconnect the front frame side from the
rear frame side.
k The rear frame of the front frame side and
the hitch frame should be always
supported by stands, etc. until the
moment they are disconnected from each
other. Accordingly, move the rear frame of
the front side forward together with stand.
50-281
50 Disassembly and assembly
Undercarriage and frame

11.Hitch frame assembly

1) Remove rear seal and retainer (large)
assembly (24). [*9]

2) By using forcing screw [5], remove end

retainer (25). [*10]

12.Remove retainer (50) and dust seal (51) from

the rear frame.

3) Sling hitch frame assembly (26) and remove

it while drawing it forward. [*11]
a When drawing the assembly forward,
hold bearing inner race (26a) to prevent
its coming off.
a Pushing the side end of hitch frame (25)
by using a thin small puller will make the
pullout easier.
a While drawing the assembly forward, add
(change) the sling application positions to Installation (HM400_3R-H1P0-720-K-00-A)
ensure a well balanced slinging. • Perform installation in the reverse order to
removal.

50-282 HM400-3M0

[*1]
a Bleed air from the brake circuit. For details, see
Testing and adjusting "Bleeding air from brake
circuit".
[*2]
a Measure wear of the pad and adjust the pad
clearance. For details, see Testing and adjusting,
""Testing wear of parking brake pad".
[*3]
2 Plate mounting bolt:
Liquid adhesive (LT-2)
3 Plate mounting bolt:
824 to 1,030 Nm {84 to 105 kgm}
[*4]
a Before installing, check that the yoke of the drive
shaft between the hitch frame and center
differential and the yoke of the drive shaft
between the center differential and rear
differential are shifted from each other by 45 ± 6
deg.
2 Mounting bolts of drive shaft between
hitch frame and center differential:
Liquid adhesive (LT-2)
3 Mounting bolts of drive shaft between
hitch frame and center differential:
157 to 198 Nm {16 to 20 kgm}
[Target 177 Nm {18 kgm}]
[*5]
2 Coupling spline area:
Molybdenum disulfide grease (LM-G)
2 Coupling bolt:
Liquid adhesive (LT-2)
3 Coupling bolt:
824 to 1,030 Nm {84 to 105 kgm}
[*6]
a Before installing, check that the yoke of the drive
shaft between the hitch frame and center
differential and the yoke of the drive shaft
between the center differential and rear
differential are shifted from each other by 45 ± 6
deg.
a When installing the drive shaft, check that the
convex portion of the spider cap is completely
fitted to the groove of the mating yoke before
tightening the mounting bolt.
2 Mounting bolt for drive shaft between
transmission and hitch frame:
Liquid adhesive (LT-2)
HM400-3M0
50 Disassembly and assembly
Undercarriage and frame
3 Mounting bolt for drive shaft between
transmission and hitch frame:
157 to 198 Nm {16 to 20 kgm}
[Target 177 Nm {18 kgm}]
[*7], [*8]
k When aligning the mounting holes for the pin,
never insert your fingers in the holes.
a When installing the steering cylinder, adjust the
clearance between the hitch frame and steering
cylinder.
• Standard shim thickness: 2.5mm
• Available shims and thickness: 1.5 mm and
0.5 mm
• Top and bottom of the cylinder head side and
bottom side (8 places in total)
• Adjust clearance between the hitch frame
and steering cylinder to 0.5 mm or less by
using shims.
[*9]
a When installing rear seal (27) to rear retainer
(28), be sure to use push tool [6] suitable for the
diameter.
[*10]
a Oscillation bearing adjustment procedure
1. Measure thickness (t) of end retainer (25) in 2
places (measure in 2 places equally spaced on
the circumference)
2. Tighten 3 mounting bolts (30) to the following
torque without attaching shims (29).
3 Mounting bolt:
68.6 Nm {7.0 kgm}
3. Measure dimension (d) by using a micrometer.
4. Rotate hitch frame (31) 5 to 6 times, and then
repeat Steps 2) and 3) again.
a Repeat above Steps 2) to 4) until the
measured value of dimension (d) becomes
constant.
5. Combine shims so that difference in the above
measurements, namely (e) = (d -t), is 0 to 0.15
mm.
50-283
50 Disassembly and assembly
Undercarriage and frame

6. After the above adjustment is completed, tighten

mounting bolt (30) (every bolt) to the following
torque.
3 Mounting bolt:
385.0 Nm {39.5 kgm} (Target)

[*11]
a After installing the hitch frame assembly, install
bearing inner race (26a) by using tool Q2.

[*12]
a By using tool Q6, install dust seal (51).

50-284 HM400-3M0
 50 Disassembly and assembly
Undercarriage and frame

Disassembly and assembly of hitch frame assembly (HM400-H1P0-926-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

1 792T-446-1110 Push tool t 1

3 792T-446-1150 Push tool t 1
792T-446-1150 Push tool t 1
790-101-5401 • Plate 1
4 790-101-5431 • Plate 1
Q 790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-101-5201 Push tool kit t 1 3. Center shaft
790-101-5311 • Plate 1 1) Remove center shaft and bearing assembly
5 (8) from hitch frame (7).
790-101-5221 • Grip 1
01010-51225 • Bolt 1
Disassembly (HM400_3R-H1P0-530-K-00-A)

1. Coupling
Remove coupling holder (1), and remove
coupling (2).

2) Remove rear bearing (10) and front bearing

inner race (11a) from center shaft (9).

2. Rear retainer
1) By using forcing screw [1], remove rear
retainer assembly (3).

4. Disassembly of hitch frame

1) Remove front cage assembly (13) from hitch
frame (12).
2) Remove ring (14), front bearing outer race
(11b), rings (15) and (16) from hitch frame
(12).
3) Remove dust seal (18) from front cage (17).
2) Remove ring (5), dust seal (6), grease fitting
(19) and nipple (20) from retainer (4).

HM400-3M0 50-285
50 Disassembly and assembly
Undercarriage and frame

No. Manufacturer Grease brand

1 NIPPECO LTD. Highrex HD-2
2 SHELL Super Duty Grease2
3 ESSO RONEX MP
4 BP Energrease LS-EP2
1. Assembly of top and bottom hinge pins of hitch
frame
a Adjust the shim according to the following
procedure.
1) By using tools Q4 and Q5, install dust seals
(30) and (29) to hitch frame (12).
4) Remove retainers (21), (22), shim (23), and Tool Q4: For dust seal (29)
(24) Tool Q5: For dust seal (30)
5) Remove bearings (25) and (26) from the 2) By using tools Q4 and Q5, install dust seals
hinge. (28) and (27) to retainers (22) and (21).
6) Remove dust seals (27), (28), (29), and (30) Tool Q4: For dust seal (27)
from retainers (21), (22), and hitch frame Tool Q5: For dust seal (28)
(12). 2 Dust seal lip:
Grease (G2-LI)
3) By using tool Q3, install bearings (25) and
(26) to the hitch frame.
a Since bearings (25) and (26) are
assemble parts, do not change the
combination of bearing and spacer.
2 Bearing inner surface:
Molybdenum disulfide lubricant
(LM-P)

7) Remove bearing (40) and spacer (41) from

hitch frame (12).

4) Adjust the shim and then install retainers (21)

Assembly (HM400_3R-H1P0-710-K-00-A)
a Clean each part, and check for dirt or dent.
a Use the push tool according to the seal diameter
to install the seal.
a Select the hub grease with which each part is
filled from the following items.
and (22).
1] Measure thickness (a) and (b) of
retainers (21) and (22) of the hitch frame.
2] Install retainer (21) to the top of the hitch
frame with the mounting bolts (5 pieces).
3 Retainer mounting bolt:
98.1 Nm {10 kgm} ± 10%
3] Install retainer (22) to the bottom of the
hitch frame with the mounting bolts (4
pieces).

50-286 HM400-3M0
 50 Disassembly and assembly
Undercarriage and frame

3 Retainer mounting bolt: a Fill the Internal space of the bearing (40)
58.8 Nm {6 kgm} ± 10% with the hub grease (described
4] Measure the clearance dimensions (d) previously).
and (e) between retainers (21) and (22) 2 Internal space of bearing (40):
and the hinge plate.
Filling with hub grease 100%
5] Combine shims (22) and (23) so that the
(1,195 g)
clearance is 0.02 to 0.12 mm smaller than
difference (f) between dimensions (d) and
(a), and than difference (g) between
dimensions (e) and (b).
f = (d – a)
g = (e – b)
• Shim thickness and type: 0.1 mm and
0.5 mm
• Standard shim thickness of retainer
(21): 2 mm
• Standard shim thickness of retainer
(22): 1 mm
6] Set the shim selected on retainers (21)
and (22) and tighten all the retainer
mounting bolts. 3) Install ring (15) and front bearing outer race
(11b) to the front side of hitch frame (12).
2 Retainer mounting bolt:
Liquid adhesive (LT-2) 2 Internal space (A) of ring (15):
Filling with grease (G2-LI) 100%
3 Retainer mounting bolt:
(127 g)
157 to 196 Nm {16 to 20 kgm}
2 Labyrinth (L1) and (L2)
Grease (G2-LI)
2 Internal space of front bearing
outer race (11b):
Filling with grease (G2-LI) 100%
(68 g)
4) Install ring (14).
2 Internal space (C) of ring (14):
Filling with grease (G2-LI) 100%
(123 g)
5) Install ring (16) to the rear side of hitch frame
(12).
2 Internal space (B) of ring (16):
Filling with grease (G2-LI) 100%
(147 g)

2. Assembly of hitch frame

1) Install spacer (41) to hitch frame (12).
2) By using tool Q1, press-fit bearing (40).
3. Center shaft

HM400-3M0 50-287
50 Disassembly and assembly
Undercarriage and frame

1) By using tool Q3, press-fit front bearing inner

race (11a) to center shaft (9).
2) By using general push tool, press-fit rear
bearing inner race (11-1) to center shaft (9).
2 Bearing surfaces (RF1) and (RF2):
Grease (G2-LI) (to be applied
lightly after press-fitting the inner
race)

5. Ring and front cage assembly

1) By using tool Q4, install dust seal (18) to
front cage (17).
2) Install O-ring to front cage (17), and then
install them to hitch frame (12).
2 Lip of dust seal (18):
Grease (G2-LI)
2 Internal space (C) of dust seal (18):
3) The manufacturing numbers (PN) are Filling with grease (G2-LI) 100%
marked on inner races (10-1), (10-2), and (25 g)
outer race (10-3) of the ball bearing (10).
2 Periphery (G) of dust seal (18) and
a Align marks (A) of the inner race and labyrinth (L4)
outer race for installation. Filling with grease (G2-LI) 100%
2 Internal space (BB) of bearing (10):
Grease (G2-LI) 58 g
a Be sure to apply correct amount of
grease since the incorrect amount of
grease may cause bearing overheat.

6. Coupling
Install coupling (2) and coupling holder (1).
2 Coupling spline area:
Molybdenum disulfide grease (LM-G)
2 Coupling bolt:
4. Assembly of center shaft and bearing assembly
Liquid adhesive (LT-2)
Carefully install the center shaft and bearing
assembly (8) to hitch frame (7) from its rear 3 Coupling bolt:
position. 824 to 1,030 Nm {84 to 105 kgm}

50-288 HM400-3M0
 50 Disassembly and assembly
Undercarriage and frame

7. Rear retainer
1) By using tool Q4, press-fit dust seal (6) to
rear retainer (4).
2 Lip of dust seal (6):
Grease (G2-LI)
2) Install ring (5) and O-ring to rear retainer (4).
2 Groove (D) of ring (5):
Filling with grease (G2-LI) 100%
(85 g)
2 Labyrinth (L5):
Filling with grease (G2-LI) 100%
3) Install nipple (20) and grease fitting (19) to
rear retainer (4).
4) Install rear retainer assembly (4) to hitch
frame (12).
2 Mounting bolt:
Liquid adhesive (LT-2)
3 Mounting bolt:
59 to 74 Nm {6.0 to 7.5 kgm}
a Fill the inside of retainer assembly (4)
with the grease from grease fitting (19).
2 Inside of retainer assembly (4):
Grease (G2-LI) (200 g)
2 Labyrinth (L5):
Filling with grease (G2-LI) (100%)

HM400-3M0 50-289
50 Disassembly and assembly
Hydraulic system

Hydraulic system (ALL-C000-001-K-00-A)

Removal and installation of flow amplifier valve assembly (HM400_3R-F5D7-924-K-00-A)

k In order to prevent serious or death
accidents due to falling of the cab, following
precautions must be observed when tilting
the cab.
• Precautions before starting cab-tilting operation
k Cab-tilting operation must be performed on a
flat ground.
k Set the machine to the straight-travel
condition to prevent the interference
between the cab and body, then fix the front
and rear frames by using the articulation
lock.
k Set the parking brake switch to ON position
by pressing "P", and apply the parking brake.
k Lock the lever by using the dump lever lock
knob.
k Do not give a large impact to the machine
when tilting up the cab.
k When lowering the cab by using the cab
power tilt (optional), do it gradually adjusting
the descending speed without decreasing
the oil pressure at a breath.
k The lock bar is equipped in the inner left side
corner of the engine hood. Be sure to return
the bar to the original place after using it.
k Stop the engine, turn the battery disconnect
switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)
k Loosen the cap of the hydraulic tank
gradually, and release the pressure
remaining inside the hydraulic tank.

k Chock the wheels to prevent the machine k Set the lock bar to the front and rear frames
from moving. to lock them.

k Do not perform the cab-tilting operation

Removal (HM400_3R-F5D7-520-K-00-A)

when it is strongly windy. 1. Remove mounting bolts (1a) (8 pieces), and

remove cover (1b).
k Before dismounting cab, be sure to lock the 2. Remove plug (1c), and install hose (1d).
lock pin in the rear mount of cab.
a Hose (1d) is fixed as the special tool to the
• Precautions for cab-tilting operation back side of cover (1b).
3. Loosen drain plug (1e), and drain the hydraulic
k Do not perform the cab-tilting operation oil.
when the dump body is loaded.
6 Hydraulic tank:
k Do not place yourself under the cab during 167 l
the cab-tilting operation.

k Fix the cab securely by using the lock lever

before tilting up the cab.

k Installthe lock lever from the side of the cab

without entering into a space below the cab.

k Do not go in or out the cab when tilting up

the cab.

k Do not operate the gear shift lever and dump

lever when tilting up the cab.

k Do not start the engine when tilting up the

cab.

k When you are forced to start the engine for

inspection purpose, check that no person is
under the cab.

50-290 HM400-3M0
 50 Disassembly and assembly
Hydraulic system

k Check that lock lever (4) is in CLOSE

position and operator's cab assembly (3)
is securely supported with lock bar (3a).

4. Open engine hood (1).

6. Remove covers (5), (6), and (7) under the front

left side fender.

a Be sure to turn lock (2) to LOCK position.

7. Remove clamps (8), (9), (10), (11), (12), (13),

(14), and (15).

5. Tilt up operator's cab assembly (3). For details,

see Testing and adjusting, "Cab tilt up
procedure".

HM400-3M0 50-291
50 Disassembly and assembly
Hydraulic system

8. Disconnect hoses (16), (17), (18), (19), (20), (21), Installation (HM400_3R-F5D7-720-K-00-A)
and (22).
• Perform installation in the reverse order to
a Prepare an oil container in advance. removal.
9. Disconnect tube (23). • Refilling with oil
10.Disconnect tubes (24), (25), and (26). Refill with oil to the specified level through the oil
filler port of the hydraulic tank. Run the engine to
circulate the oil through the piping. Then check
the oil level again.

5 Hydraulic tank:
167 l

11.Disconnect hoses (27) and (28).

12.Disconnect hoses (29), (30), (31), and (32).

13.Disconnect tubes (33) and (34).
14.Remove mounting bolts (35) (4 pieces), and
sling flow amplifier valve assembly (36) and
remove it.

4 Flow amplifier valve assembly:

35 kg

50-292 HM400-3M0
 50 Disassembly and assembly
Hydraulic system

Removal and installation of hoist valve assembly (HM400_3R-M5J0-924-K-00-A)

k In order to prevent serious or death
accidents due to falling of the cab, following
precautions must be observed when tilting
the cab.
• Precautions before starting cab-tilting operation
k Cab-tilting operation must be performed on a
flat ground.
k Set the machine to the straight-travel
condition to prevent the interference
between the cab and body, then fix the front
and rear frames by using the articulation
lock.
k Set the parking brake switch to ON position
by pressing "P", and apply the parking brake.
k Lock the lever by using the dump lever lock
knob.
k Do not give a large impact to the machine
when tilting up the cab.
k When lowering the cab by using the cab
power tilt (optional), do it gradually adjusting
the descending speed without decreasing
the oil pressure at a breath.
k The lock bar is equipped in the inner left side
corner of the engine hood. Be sure to return
the bar to the original place after using it.
k Stop the engine, turn the battery disconnect
switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)
k Loosen the cap of the hydraulic tank
gradually, and release the pressure
remaining inside the hydraulic tank.

k Chock the wheels to prevent the machine k Set the lock bar to the front and rear frames
from moving. to lock them.

k Do not perform the cab-tilting operation

Removal (HM400_3R-M5J0-520-K-00-A)

when it is strongly windy. 1. Remove mounting bolts (1a) (8 pieces) to

remove cover (1b).
k Before dismounting cab, be sure to lock the 2. Remove plug (1c), and install hose (1d).
lock pin in the rear mount of cab.
a Hose (1d) is fixed as the special tool to the
• Precautions for cab-tilting operation back side of cover (1b).
3. Loosen drain plug (1e), and drain the hydraulic
k Do not perform the cab-tilting operation oil.
when the dump body is loaded.
6 Hydraulic tank:
k Do not place yourself under the cab during 167 l
the cab-tilting operation.

k Fix the cab securely by using the lock lever

before tilting up the cab.

k Installthe lock lever from the side of the cab

without entering into a space below the cab.

k Do not go in or out the cab when tilting up

the cab.

k Do not operate the gear shift lever and dump

lever when tilting up the cab.

k Do not start the engine when tilting up the

cab.

k When you are forced to start the engine for

inspection purpose, check that no person is
under the cab.

HM400-3M0 50-293
50 Disassembly and assembly
Hydraulic system

k Check that lock lever (4) is in CLOSE

position and operator's cab assembly (3)
is securely supported with lock bar (3a).

4. Open engine hood (1).

6. Remove left front wheel assembly (5). For

details, see "Removal and installation of front
wheel assembly".
7. Remove covers (6), (7), (8), (9), and (10) under
the front left side fender.
8. Remove covers (11) and (12).

a Be sure to turn lock (2) to LOCK position.

9. Remove flow amplifier valve assembly (13). For

details, see "Removal and installation of flow
amplifier valve assembly".
a Prepare an oil container in advance.

5. Tilt up operator's cab assembly (3). For details,

see Testing and adjusting, "Cab tilt up
procedure".

50-294 HM400-3M0
 50 Disassembly and assembly
Hydraulic system

10.Remove clamps (14) and (15).

11.Remove coupling (16) and block (17), and
remove tube (18).

12.Disconnect hoses (19), (20), and (21).

17.Disconnect tube (27) from hydraulic tank

assembly (30).

13.Disconnect hoses (22), (23), and (24).

14.Loosen hose clamps (25) (4 pieces).
15.Remove clamp (26) from tube (27).
16.Remove block (28) and disconnect tube (29).

18.Disconnect tubes (31) and (32).

HM400-3M0 50-295
50 Disassembly and assembly
Hydraulic system

Installation (HM400_3R-M5J0-720-K-00-A)

• Perform installation in the reverse order to

removal.
• Refilling with oil
Refill with oil to the specified level through the oil
filler port of the hydraulic tank. Run the engine to
circulate the oil through the piping. Then check
the oil level again.

5 Hydraulic tank:
167 l

19.Attach sling [1] such as lever block to bracket

(33) and sling hoist valve assembly (34).
20.Remove the mounting bolt, sling and lower hoist
valve assembly (34).

4 Hoist valve assembly (34):

35 kg

50-296 HM400-3M0

Disassembly and assembly of hoist valve assembly
Disassembly (HM400-M5J0-530-K-00-A)
1. Valve body assembly
1) RAISE position
1] Remove cover (15) from valve body (1).
a When removing the RAISE portion
first, as cover (15) is pressed by the
force of spring (16), carefully remove
the components so that they are not
splattered.
2] Remove retainer (18), spring (16),
retainer (17), and spool (2) in this order.
a As retainer (18) has dowel pin (19),
carefully remove the retainer without
loosing the pin.
2) LOWER position
1] Remove cover (22) from valve body (1).
2. Suction relief valve assembly
HM400-3M0
50 Disassembly and assembly
Hydraulic system
(HM400-M5J0-926-K-00-A)
a When removing the RAISE portion
first, as cover (22) is pressed by the
force of spring (24), carefully remove
the components so that they are not
splattered.
2] Remove retainer (26), spring (24),
retainer (25), spring (23), and retainer
(27) in this order.
a Retainer (26), spring (24), and retainer
(25) are integrated with bolts (30) as a
unit.
3] Remove cover (22) from valve body (1).
3) Check valve
1] Remove plug (5) from valve body (1).
2] Remove spring (4) and check valve (3) in
this order.
4) Plugs
Remove two plugs (11) and (13) from valve
body (1).
50-297
50 Disassembly and assembly
Hydraulic system

Remove suction relief valve assembly (32) from

valve body (1).
3. Relief valve assembly
Remove relief valve assembly (36) from valve
body (1).

50-298 HM400-3M0

Assembly (HM400-M5J0-710-K-00-A)
• Clean all parts, and correct defects such as
burrs in advance.
• Apply engine oil to the sliding surfaces of each
part and install them.
• Replace all O-rings with new ones.
1. Valve body assembly
1) LOWER position
1] Secure retainer (26), spring (24), and
retainer (25) with bolts (30).
a Check that washer (31) is installed.
3 Mounting bolt:
27 to 34 Nm {2.8 to 3.5 kgcm}
2] Install retainer (27), spring (23), retainer
(25), spring (24), and retainer (26) in this
order to valve body (1).
3] Install O-ring (28) to cover (22), and
secure them to the body with bolts (29).
3 Mounting bolt:
27 to 34 Nm {2.8 to 3.5 kgcm}
HM400-3M0
50 Disassembly and assembly
Hydraulic system
2) RAISE position
1] Install dowel pin (19) to cover (15).
2] Install retainer (18) to cover (15).
a Align the dowel pin hole of retainer
(18) with the dowel pin, and install
them securely in position.
3] Install spool (2) to valve body (1).
a Hold the spool in horizontal and lightly
insert it into the dump body.
If it is hard to insert the spool, do not
force to insert it. Slightly pull out the
spool, and then try to insert it again.
4] Install retainer (17) and spring (16).
5] Fit O-ring (20) to cover (15), and secure
them to the valve body with bolts (21).
3 Mounting bolt:
27 to 34 Nm {2.8 to 3.5 kgcm}
3) Check valve
1] Install check valve (3) and spring (4) in
this order to valve body (1).
50-299
50 Disassembly and assembly
Hydraulic system

2] Install O-ring (6) to plug (5), and install

them to valve body (1).
2 Threaded portion of plug:
Adhesive (LT-2)
3 Plug:
343 to 392 Nm {35 to 40 kgcm}
4) Plugs
1] Install O-ring (12) to plug (11), and install
them to valve body (1).
3 Plug:
177 to 196 Nm {18 to 20 kgcm}
2] Install O-ring (14) to plug (13), and install
them to valve body (1). (2 places)
3 Plug:
58.8 to 78.4 Nm {6 to 8 kgcm}
2. Relief valve assembly
Install O-ring (37) to relief valve assembly (36),
and install them to valve body (1).
3 Plug:
176.5 to 196 Nm {18 to 20 kgcm}
3. Suction relief valve assembly
1) Install backup ring (34) and O-ring (33) to the
end of suction relief valve assembly (32).
2) Install O-ring (35) to suction relief valve
assembly (32), and install them to valve body
(1).
3 Plug:
176.5 to 196 Nm {18 to 20 kgcm}

50-300 HM400-3M0
 50 Disassembly and assembly
Hydraulic system

Disassembly and assembly of hoist cylinder assembly (HM400-M5K0-926-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

790-502-1003 Cylinder repair stand t 1

1
790-101-1102 Hydraulic pump t 1
2 790-102-3802 Wrench assembly t 1
790-102-4300 Wrench assembly t 1
3
790-102-4310 Pin t 2
790-720-1000 Expander t 1
4 796-720-1670 Ring t 1
U 5) Pull out and remove cylinder head and piston
07281-01279 Clamp t 1
rod assembly (4) from cylinder (5).
792T-461-1120 Push tool t 1
7 790-101-5021 Grip t 1 a When the piston rod assembly is pulled
01010-50816 Bolt t 1 out of the cylinder, oil flows out. So
792T-461-1130 Plate t 1 prepare a container to receive the oil.
8 790-101-5021 Grip t 1 6) Remove cylinder (5) from tool U1.
01010-50816 Bolt t 1
Disassembly (HM400-M5K0-530-K-00-A)

a Take care not to damage the rod packing, dust

seals, piston rings, wear rings and others during
disassembly.
1. Piston rod assembly
1) Remove the piping from the cylinder
assembly.
2) Remove mounting bolts (1a), and remove
collar assembly (1).
a Place an oil container under the cylinder
to receive oil. 7) Disassemble the piston rod assembly
according to the following procedure.
1] Set piston rod assembly (4) on tool U1.

3) Set cylinder assembly (2) on tool U1.

4) By using tool U2, loosen cylinder head nuts
and remove cylinder head assembly (3). 2] Remove lock screw (6) of the piston
assembly.
Screw size: M12, Pitch=1.75 mm

HM400-3M0 50-301
50 Disassembly and assembly
Hydraulic system
a If screw (6) is punched securely and
hard to remove, tighten it further once.
Then tap its threaded portion with tap
[1] and remove the screw.
3] By using tool U3, remove piston
assembly (7).
• When tool U3 is not used, use drilled
holes (DH) (φ10-mm in 2 places) to
loosen the piston assembly.
4] Remove head assembly (8).
5] Remove collar (9).
50-302
2. Disassembly of piston assembly
1) Remove ring (10).
2) Remove wear ring (11).
3) Remove piston ring (12).
4) Remove the O-ring and backup ring (13).
3. Disassembly of cylinder head assembly
1) Remove the O-ring and backup ring (15).
2) Remove O-ring (16).
3) Remove rod packing (17).
4) Remove bushing (18).
5) Remove dust seal (19).
4. Disassembly of collar assembly
1) Remove snap ring (20).
2) Remove dust seal (21).
HM400-3M0
 50 Disassembly and assembly
Hydraulic system

Assembly (HM400_3R-M5K0-710-K-00-A)

a Take care not to damage packings, dust seals,

O-rings, etc.
a Clean all parts so that dust do not enter in piping
ports and pin insertion holes after assembling.
a When inserting the backup ring, do not insert it
forcibly but warm it in hot water at approximately
50 to 60°C, and then install it.
a Check all parts thoroughly for dust and
scratches, and apply engine oil to the sliding
surface before assembling.
1. Assembly of collars 3. Assembly of piston assembly
1) Install dust seal (21). 1) By using the expander of tool U4, expand
2) Install snap ring (20). piston ring (12).
a Set the piston ring on tool U4, and rotate
the handle 8 to 10 turns to expand the
piston ring.
2) Remove piston ring (12) from tool U4, and
install it to piston (6a).

2. Assembly of head assembly

1) Press-fit bushing (18) by using tool U5.
2) Install rod packing (17).
3) By using tool U6, press-fit dust seal (19).
4) Install O-ring (16).
5) Install the backup ring and O-ring (15). 3) By using the ring of tool U4, compress the
piston ring.

HM400-3M0 50-303
50 Disassembly and assembly
Hydraulic system

4) Install the backup ring and O-ring (13). 4) Assemble piston assembly (7) according to
5) Install wear ring (11). the following procedure.
a Take care not to expand the ring mating • When reusing piston rod assembly (2)
part excessively. and piston assembly (7):

2 Ring groove: a Clean them thoroughly and remove all

chips and dirt.
Grease (G2-LI)
6) Install ring (10). 1] Screw in piston assembly (7). By using
tool U3, tighten piston assembly (7) until
screw holes (H) are aligned.
a Remove burrs and sharp edges from
threaded part by using a file.

4. Piston rod assembly

1) Set piston rod assembly (2) on tool U1.

2] Tighten screw (14).

2 Screw part female screw side:
Adhesive (Loctite No. 262)
3 Screw:
58.9 to 73.6 Nm {6.0 to 7.5 kgm}
3] Punch 4 thread places (a) of screw (14)
with punch.
a After punching, check that the
threaded parts do not loosen to the
return torque 41.2 Nm {4.2 kgm}.
2) Install collar (9).
((2): Piston rod assembly, (7): Piston
3) Install head assembly (8).
assembly)

50-304 HM400-3M0
 50 Disassembly and assembly
Hydraulic system

• When either or both of piston rod 4] Tighten screw (14).

assembly (2) and piston assembly (7) are
new:
1] Screw in piston assembly (7) until it
reaches rode end (B), and then tighten to
the specified torque by using the tool.
3 Piston assembly:
294 ± 29.4 Nm {30 ± 3.0 kgm}
2 Screw part female screw side:
Adhesive (Loctite No. 262)
3 Screw:
58.9 to 73.6 Nm {6.0 to 7.5 kgm}
5] Punch 4 thread places (a) of screw (14)
with punch.

a After tightening the piston, make sure a After punching, check that the
that plunger (5a) has a play. threaded parts do not loosen to the
return torque 41.2 Nm {4.2 kgm}.

2] Make one threaded hole for tightening

screw (14).
a Drill a hole in horizontal into the V-
groove where piston (6a) and the
threads of piston rod assembly (2)
mesh with each other.
• Drilling dimensions (mm)
Tap drill Tap hole Tapping
Tap
diameter depth depth
10.3 27 12 x 1.75 20
3] After drilling, remove all dirt and clean the
hole thoroughly.
5) Remove piston rod assembly (2) from tool
U1.

HM400-3M0 50-305
50 Disassembly and assembly
Hydraulic system

5. Piston rod assembly

1) Set cylinder (5) on tool U1.
2) Install cylinder head and piston rod assembly
(4) to cylinder (5).
3) By using tool U2, tighten cylinder head
assembly (3).
3 Cylinder head nuts:
1.06 ± 0.11 kNm {108 ± 10.8 kgm}

4) Tighten mounting bolts (1a) of collar (1).

50-306 HM400-3M0
 50 Disassembly and assembly
Body

Body (HM300-M510-001-K-00-A)

Removal and installation of dump body assembly (HM400_3R-M510-924-K-00-A)

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".) 5. Sling the dump body assembly (4 positions).

Removal (HM400_3R-M510-520-K-00-A)

1. Sling the head side of the hoist cylinder.

2. Remove pins (1) on the head side of the right
and left hoist cylinders. [*1]

k When the head-side pin is removed, the

hoist cylinder swings outward. Lock the
hoist cylinder inwardly by using the lever
block [1] etc.
a Since the piston rod on the cylinder head
side is damaged, do not use any sling other
than nylon sling. 6. Remove 2 body hinge pins (3) on the right and
left sides. [*3]
When using metal sling [2], be sure to attach
it to the cylinder. a Since shims are installed, check and record
3. While lowering the crane, loosen lever block [1] their thickness, quantity and mounting
and place the hoist cylinder on the tire. positions.
a Put a block [3] etc. between the hoist cylinder
and the tire.

7. Remove the side way swing prevention brackets

(5) on the right and left sides of the dump body.
4. Disconnect body potentiometer linkage (2) on [*4]
the side of the body. [*2]

HM400-3M0 50-307
50 Disassembly and assembly
Body

8. Sling dump body assembly (4) and remove it. [*5]

[*5]
4 Dump body assembly:
4,500 kg
Installation (HM400_3R-M510-720-K-00-A)
• Perform installation in the reverse order to
removal.
[*1]
k When aligning the mounting holes for the pin,
never insert your fingers in the holes.
3 Cylinder head pin mounting bolt:
157 to 196 Nm {16 to 20 kgm}
[*2]
a Adjust the dump body positioner sensor. For
details, see Testing and adjusting, "Adjusting
dump body positioner sensor".
[*3]
k When aligning the mounting holes for the pin,
never insert your fingers in the holes.
a By using shims, adjust the dump body mount
according to the following procedure.
1. Insert spacer [1] of thickness (x1) to the top end
of dump body (4).
(1 place each on right and left)
a Standard clearance (x1) between dump body
and frame: 58 mm
2. Measure the clearance (x2) between mounting
face (a) of the bottom mount and the top face of
rear frame (6).
a Measure the clearance on right and left sides
of (A), (B), and (C) (6 places).
3. Calculate the shim thickness on right and left
sides of (A), (B), and (C) (6 places).
• Shim thickness = (x2 - 26) mm
a Standard height of bottom mount: 26 mm
4. Install shim (7) calculated in Step 3 to the
clearance between mounting face (a) of the
bottom mount and top face of the bottom mount.
• Standard shim thickness: 4 mm
• Types and thickness of shims: 1.0 and 3.2
mm
5. Remove spacer [1] and check that all 6 places
on the bottom face of the bottom mount are in
contact with the rear frame top face.

3 Hinge pin mounting bolt:

157 to 196 Nm {16 to 20 kgm}
[*4]
a Check clearance (t) between dump body rolling
prevention bracket (5) and rear frame (6).
• Clearance (t): 1 to 2 mm

50-308 HM400-3M0
 50 Disassembly and assembly
Body

HM400-3M0 50-309
50 Disassembly and assembly
Cab and its attachments
Cab and its attachments (ALL-K000-001-K-00-A)
Removal and installation of operator's cab assembly
k In order to prevent serious or death
accidents due to falling of the cab, following
precautions must be observed when tilting
the cab.
• Precautions before starting cab-tilting operation
k Cab-tilting operation must be performed on a
flat ground.
k Set the machine to the straight-travel
condition to prevent the interference
between the cab and body, then fix the front
and rear frames by using the articulation
lock.
k Set the parking brake switch to ON position
by pressing "P", and apply the parking brake.
k Lock the lever by using the dump lever lock
knob.
k Chock the wheels to prevent the machine
from moving.
k When dismounting the cab, always lock the
lock pin at the rear mounting part of cab
before starting the work.
k Do not perform the cab-tilting operation
when it is strongly windy.
k Before dismounting cab, be sure to lock the
lock pin in the rear mount of cab.
• Precautions for cab-tilting operation
k Do not perform the cab-tilting operation
when the dump body is loaded.
k Do not place yourself under the cab during
the cab-tilting operation.
k Fix the cab securely by using the lock lever
before tilting up the cab.
k Installthe lock lever from the side of the cab
without entering into a space below the cab.
k Do not go in or out the cab when tilting up
the cab.
k Do not operate the gear shift lever and dump
lever when tilting up the cab.
k Do not start the engine when tilting up the
cab.
50-310
(HM400_3R-K000-924-K-00-A)
k When you are forced to start the engine for
inspection purpose, check that no person is
under the cab.
k Do not give a large impact to the machine
when tilting up the cab.
k When lowering the cab by using the cab
power tilt (optional), do it gradually adjusting
the descending speed without decreasing
the oil pressure at a breath.
k The lock bar is equipped in the inner left side
corner of the engine hood. Be sure to return
the bar to the original place after using it.
k Set the lock bar to the front and rear frames
to lock them.
k Stop the engine, turn the battery disconnect
switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)
k Loosen the cap of the hydraulic tank
gradually, and release the pressure
remaining inside the hydraulic tank.
k If you disconnect the heater hose when the
coolant in radiator is still hot, you may be
scalded. Wait until the coolant temperature
drops before starting the work.
a Ask a qualified person for collecting, adding and
filling operations of the refrigerant (air
conditioner gas: R134a).
a Never release the refrigerant (air conditioner
gas: R134a) to the atmosphere.
k If refrigerant gas (air conditioner gas: R134a)
gets in your eyes, you may lose your sight.
And if it touches your skin, you may suffer
from frostbite. Put on protective eyeglasses,
gloves and working clothes with long
sleeves while collecting the refrigerant or
filling the air conditioner circuit with the
refrigerant.
a Note the connector numbers and installed
positions before disconnecting wiring harnesses
and hoses.
Removal (HM400_3R-K000-520-K-00-A)
1. Open engine hood (1).
HM400-3M0
 50 Disassembly and assembly
Cab and its attachments

a Be sure to turn lock (2) to LOCK position.

a Confirm the destinations of hoses in
advance.
a Prepare an oil container in advance.
a Plug the hose in advance.
a When removing the hose from the brake
valve (BV) side and steering valve (SV) side,
place a matchmark on the hose clamping
position to prevent increase of noise due to
sag of the hose.

2. Tilt up operator's cab assembly (3). For details,

see Testing and adjusting, "Cab tilt up
procedure".

k Check that lock lever (4) is in CLOSE

position and operator's cab assembly (3)
is securely supported with lock bar (3a).

3. Disconnect ground (4a).

4. Collect the refrigerant (air conditioner gas:
R134a) from the air conditioner circuit.
Refrigerant to be collected: 875 ± 25 g
5. Disconnect air conditioner hoses (5) and (6). [*1]
a Plug both the air conditioner hose and air
conditioner unit with a piece of tape to cut off
external air.
6. Disconnect heater hoses (7) and (8).
a Prepare a container.

HM400-3M0 50-311
50 Disassembly and assembly
Cab and its attachments
7. Disconnect hoses (9) to (13) from steering valve
(SV).
8. Disconnect hoses (14) to (18) from brake valve
(BV).
9. Disconnect connectors (19) to (26).
• (19): CN-J01, (20): CN-J02
• (21): CN-J03, (22): CN-J04
• (23): CN-J05, (24): CN-J06
• (25): CN-J07, (26): CN-J08
• (27): CN-J09, (27a): CN-J10
50-312
10.Fix cylinder (28) temporarily to prevent it from
tilting, and then remove pin (29).
a Retract cylinder (28) in advance.
a Since shims are installed, check and record
their thickness, quantity and mounting
positions in advance.
11.Return the operator's cab assembly (3) back to
the horizontal posture.
12.Sling the operator's cab assembly by using
plates (P) on the right and left.
13.Remove pins (30) on the right and left sides. [*2]
a Since shims are installed, check and record
their thickness, quantity and mounting
positions in advance.
HM400-3M0

14.Sling operator's cab assembly (3), and remove
it.
4 Operator's cab assembly:
1,150 kg
Installation (HM400_3R-K000-720-K-00-A)
• Perform installation in the reverse order to
removal.
[*1]
a When installing the hose for the air conditioner
circuit, be careful that any dirt, dusts and water
do not enter into the hose.
a Check that the O-ring (70) is installed for the air
conditioner hose connection before installation
a Check that the O-ring is not damaged or
deteriorated.
a When connecting the refrigerent piping, apply
compressor oil (DENSO: ND-OIL8, VALEO
THERMAL SYSTEMS: ZXL100PG (equivalent
to PAG46)) for new refrigerant (R134a) to O-ring.
3 Air conditioner pipe tightening torque
Thread size Tightening torque
16 x 1.5 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
19.6 to 24.5 Nm {2.0 to 2.5 kgm}
22 x 1.5
24 x 1.5 29.4 to 34.3 Nm {3.0 to 3.5 kgm}
HM400-3M0
50 Disassembly and assembly
Cab and its attachments
[*2]
a By using shims, adjust the clearance between
operator's cab (3) and mount (26) to (a)
dimension on the both sides of right and left.
• Standard clearance (a): 0.2 mm (one side)
• Types and thickness of shims: 0.5 mm, 1.0
mm, 2.3 mm
• Filling of refrigerant (R134a)
Refill the air conditioner circuit with refrigerant
(R134a).
a Filling quantity: 875 ± 25 g
• Refilling of air conditioner compressor oil
See Air conditioner, "Handling of compressor oil".
• Refilling with coolant
Refill with coolant to the specified level through
the coolant filler port of the radiator. Run the
engine to circulate the coolant through the piping.
Then check the coolant level again.
5 Radiator: Only necessary quantity
• Refilling with oil
Refill with oil through the oil filler port of the
hydraulic tank to the specified level. Run the
engine to circulate the oil through the piping.
Then check the oil level again.
5 Hydraulic tank: Only necessary
quantity
• Refilling with oil
50-313
50 Disassembly and assembly
Cab and its attachments

Refill with oil through the oil filler port of the

brake oil tank to the specified level. Run the
engine to circulate the oil through the piping.
Then check the oil level again.

5 Brake oil tank: Only necessary

quantity
a Bleed air from the brake circuit. For details,
see Testing and adjusting "Bleeding air from
brake circuit".

50-314 HM400-3M0
 50 Disassembly and assembly
Cab and its attachments

Removal and installation of operator's cab glass (adhered glass) (HM400_3R-

K183-924-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

2 793-498-1210 Lifter (suction cup) t 2

x
3 20Y-54-13180 Stopper rubber t 2

a Among the glasses on 4 sides of the operator's

cab, the stuck type is 4 glasses from (1) to (4) in
the figure.
a This section describes the replacement
procedure of the stuck type glass.
(1): Front glass
(2): Left side rear window glass
(3): Rear glass
(4): Right side sash assembly (frame of sash is
adhered)
a If seal cutter is not available, adhesive and
the dam rubber may be cut by moving a wire
lateral direction. For doing this, make a hole
in the dam rubber through adhesive by using
a drill and pass the extra fine wire (piano wire,
etc) [2] through the hole. Pinch the both ends
of the extra fine wire passed through the hole
with a plier [3] (or loop it around to fix).
Since frictional heat can break the wire,
apply lubricant to the wire from time to time
during this work.
(Figure shows the operator's cab on a wheel
loader.)

a If the glass is broken in small pieces, it may

be removed with a cutter knife [4] and a flat-
head screwdriver.
a Cut off the dam rubber and adhesive with
cutter knife [4] while expanding the cut with a
flat-head screwdriver.
(Figure shows the operator's cab on a wheel
Removal (HM300-K183-520-K-00-A)
loader.)

a Remove the glass to be replaced according to

the following procedure.
1. By using seal cutter [1], cut the adhesive
between broken glass (7) and operator's cab
(metal sheet) (8).

HM400-3M0 50-315
50 Disassembly and assembly
Cab and its attachments

2. Remove the glass. 2. Remove oil, dust, dirt, etc. from the adhesion
surfaces on cab (8) and glass (9) with white
Installation (HM400_3R-K183-720-K-00-A)
gasoline.
Overview of installation procedure
a Clean them thoroughly since insufficient
Preparation (cleaning) cleaning induces defective adhesion.
O a Clean all the black part on the back of the
Application of primer
window glass.
• Cab side: SUNSTAR 435-95
• Glass side: SUNSTAR 435-40 a After cleaning, leave them for more than 5
Dry the primer for 5 minutes minimum and minutes for natural drying.
O start the next process within 24 hours. (Figure shows the operator's cab on a wheel
Paste the dam rubber (cab side) loader.)
O
Glass position alignment
O
Apply adhesive (SUNSTAR Industrial Sealant
Petaseal 551) (Cab side)
O Within 5 minutes
Adhering glass

a Keep pressing down the glass for 10 hours

minimum.
Preparation
1. Remove the remaining adhesive and dam
rubber from the sheet metal (adhesion surfaces) Application of primer
of the operator's cab by using a cutter knife [4]
1. Apply primer (10).
and scraper [5].
a Do not use an primer if it is passed the
a Note that removal of the adhesive and dam
expiration date which is 4 months after its
rubber left on the sheet metal surface is
production date.
sufficient if they become uninfluential to the
bonding effect of new adhesive. You must a Make sure to use primer within 2 hours after
avoid damaging the coating surface by opening its cap.
excessive scraping.
a Even when it is plugged again immediately
(If the painted surfaces are damaged, after opening, be sure to use it within 24
adhesion will be lowered.) hours after opening.
(Figure shows the operator's cab on a wheel
(A primer must be disposed in 24 hours after
loader.)
opening.)
1) Stir both primers for paint surface and for
glass thoroughly before use.

50-316 HM400-3M0
 50 Disassembly and assembly
Cab and its attachments

a If a primer was chilled-stored in a

depository, leave it at least half a day in
room temperature before stirring it.
(If you open the lid of a primer
immediately after having been chilled-
stored, the primer will dew-condense. So
it must be exposed to room temperature
for a sufficient period of time.)
2) When reusing a brush (11) for applying a
primer, clean it with white gasoline before
use.
a Check again that the brush is free from
stains or fouling after cleaning. a (9): Glass
a 2 brushes must be prepared separately,
one for the primer for paint surface and
another for glass.

4) Apply a glass primer to all circumferences

within the black coating surface of glass (9).
(a): Min. 30 mm
3) Apply a primer for coating surface uniformly
to the entire coating range of operator's cab 2 Primer for glass:
(8). SUNSTAR 435-40
(a): Min. 30 mm a Black coating of the glass prevents light
2 Cab side (coating) primer: aging.
SUNSTAR 435-95 a 2 times are the upper limit of primer
a 2 times are the upper limit of primer application.
application. (Application beyond 2 times cause
(Application beyond 2 times cause degradation.)
degradation.)
a Do not use wrong primer for coating.
If, for instance, a wrong glass primer is
applied, wipe it out completely with white
gasoline.
a Leave the primer for 5 minutes minimum
for natural drying, then bond the dam
rubber within 24 hours.
(Figure shows the operator's cab on a
Hydraulic Excavator.)

a (8): Cab

HM400-3M0 50-317
50 Disassembly and assembly
Cab and its attachments

a (8): Cab
a Do not use wrong primer for coating.
If a wrong primer such as paint surface a (a): Applying range of primer (described
primer is applied, wipe it out completely previously)
by using white gasoline. a (15): Adhesive (to be described later)
Bonding of dam rubber
1. Attach dam rubber (double-coated adhesion
tape) (6) along the edge of the operator's cab
(8).
a Do not remove the release tape on glass-
adhering side of the dam rubber until
installation of the window glass is started.
a When sticking the dam rubber, do not touch
the cleaned surface.
a Care should be taken not to float the dam
rubber in each sticking corner.

Window glass position alignment

1. Perform position alignment of window glasses to
be replaced.
1) Check the clearance between the glass and
the operator 's cab on the right, left, upper,
and lower sides, and then position the glass
so that it is centered.
2) Stick tapes [6] between glass (9) and
operator's cab (8). Draw positioning line (n)
on each tape.
a Attach tape [6] in 3 positions of the right,
left and bottom side of the window glass
a When bonding dam rubber (6) around a
to ensure correct alignment.
window, use care to prevent its overlapping
3) Cut the tape between glass (9) and
in the meeting area of the starting and ending
operator's cab (8) with a cutter knife, etc. and
points. Or provide a clearance of 5 mm or so
then remove the glass.
in meeting area (e).
1) Attach dam rubber (6) for glass to the a Do not remove the release tape on glass-
position indicated in the figure. bonding side of dam rubber until
installation of glass is started.
a (Figure shows the operator's cab on a (Figure shows the operator's cab on a
Hydraulic Excavator.) Hydraulic Excavator.)

50-318 HM400-3M0

Application of adhesive
1. Preparations for applying adhesive.
• Adhesive:
SUNSTART Industrial Sealant Petaseal
551
a Do not use an adhesive if it is passed the
expiration date which is 4 months after its
production date.
a Adhesives must be stored at 25°C or lower in
a dark and cool place.
a Never heat an adhesive beyond 30°C.
a When reusing the adhesive, remove the
hardened adhesive at the nozzle tip
completely.
1) Set adhesive cartridge (12) on caulking gun
[7].
a A better workability is obtainable from a
power caulking gun.
2) Cut the tip of adhesive nozzle (14) to
dimensions (q) and (r) as shown in the figure.
• Dimension (q): 10 mm
• Dimension (r): 15 mm
HM400-3M0
50 Disassembly and assembly
Cab and its attachments
3) Remove the protective tape on the glass-
bonding side of dam rubber.
2. Apply adhesive.
a Apply adhesive (15) to dam rubber (6) of
operator's cab (8) in conformity with
dimensions (s) and (t) indicated in the figure.
• Dimension (s): 10 mm
• Dimension (t): 15 mm
2 Adhesive:
SUNSTART Industrial Sealant
Petaseal 551
a Thickness of applied adhesive (15) must be
higher than that of dam rubber (6).
a Height of applied adhesive must be even.
a (a): Applying range of primer (described
previously)
a After the adhesive is applied, you must install
the glass within 5 minutes.
Installation of glass
1. Install the glass.
1) Install glass (9) aligning it to the lines drawn
on the tapes in the process of "Position
alignment of glass".
a Since the glass cannot be removed and
installed again, install it with utmost
caution.
50-319
50 Disassembly and assembly
Cab and its attachments

2) After installing glass (9), press entire

circumferential area until it adheres firmly to
the dam rubber.
a Press the corners of the glass firmly.
(Figure shows the operator's cab on a
Hydraulic Excavator.)

2) Make the glass and dam rubber stick

together by clamping them with expanded
styrene foam [9] and rubber band [10] and
maintain them in that state for 10 hours
minimum.
(Figure shows the operator's cab on a
Hydraulic Excavator.)
a You can perform this work efficiently by
pulling glass (9) from the inside of the
operator's cab with suction cup X2.

3. After installing the glass, remove any excess of

the primer and adhesive on the operator's cab
and glass.
a Wipe off adhesives before it is dried up by
a Wipe off overflowed adhesives.
using of white gasoline.
2. Fix the glass.
1) For right side glass (1) after installing it in the a When cleaning the glass, do not give an
operator's cab, install stopper rubber X3 for impact to it.
fixation in 2 portions (v) at the bottom of the
glass.
(Figure shows the operator's cab on a
Hydraulic Excavator.)

50-320 HM400-3M0
 50 Disassembly and assembly
Cab and its attachments

Removal and installation of operator's seat assembly (HM300-K2Q0-924-K-00-A)

k Place the machine on a level ground, and

apply the parking brake.

k Set the lock bar to the front and rear frames,

and chock the wheels.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.

Removal (HM400_3R-K2Q0-520-K-00-A)

1. Upper seat assembly

1) Disconnect connector SBS (1).
2) Disconnect clamp (2). 2. Suspension assembly
1) Disconnect connector ASS (8).
2) Remove clamp (9).

3) Remove cover mounting pins (3) (12 pieces).

4) Pull out pin (4) and remove weight
adjustment knob (5).
3) Remove mounting bolts (11) (4 pieces) of
suspension assembly (10).
a Mounting bolt (11): Hexagonal socket
head bolt (M8) [*1]
4) Remove suspension assembly (10).
a Since a crane is not usable in ROPS cab,
make up a team with 2 persons when
removing suspension assembly (10).

4 Suspension assembly (10): 25 kg

5) Remove mounting bolts (7) (4 pieces) of

upper seat assembly (6).
6) Remove upper seat assembly (6).
a Since a crane is not usable in the ROPS
cab, make up a team with 2 persons
when removing upper seat assembly (6).

4 Upper seat assembly (6): 30 kg

Installation (HM400_3R-K2Q0-720-K-00-A)

• Perform installation in the reverse order to

removal.

HM400-3M0 50-321
50 Disassembly and assembly
Cab and its attachments

[*1]
3 Suspension assembly mounting bolt
(11):
27 to 34 Nm {2.8 to 3.5 kgm}

50-322 HM400-3M0
 50 Disassembly and assembly
Cab and its attachments

Removal and installation of seat belt (HM400_3R-K2Q3-924-K-00-A)

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".) Installation (HM400_3R-K2Q3-720-K-00-A)

Removal (HM400_3R-K2Q3-520-K-00-A) • Perform installation in the reverse order to

removal.
1. Disconnect connector SBS (1) on the left side of [*1]
the operator's seat.
3 Mounting bolt (2):
37.2 to 41.2 Nm {3.8 to 4.2 kgm}
[*2]
3 Mounting bolt (4):
37.2 to 41.2 Nm {3.8 to 4.2 kgm}

2. Remove mounting bolts (2). [*1]

3. Remove seat belt catch (3).

4. Remove mounting bolt (4) on the right side of

the operator's seat. [*2]
5. Remove seat belt reel (5).

HM400-3M0 50-323
50 Disassembly and assembly
Electrical system

Electrical system (HM400_3R-RA1D-001-K-00-A)

Removal and installation of machine monitor assembly (HM400_3R-Q170-924-K-00-A)

k Place the machine on a level ground, set the
parking brake switch to ON position by
pressing "P", and apply the parking brake.
k Chock the wheels to prevent the machine
from moving.
k Set the lock bar to the front and rear frames
to lock them.
2) Pull out cover (1) in the direction of the arrow
(s) until the tabs (N) in seven places are
disengaged.
a Since the wiring harness of switches (3)
to (5) is connected to the back side of
cover (1), take care when pulling it out.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)

Removal (HM400_3R-Q170-520-K-00-A)

1. Remove cover (1) according to the following

procedure.
1) Remove clips (2a) and (2b) on right and left
sides.
a Remove the clip by pushing the button at
the center of the clip in the direction of the
arrow (p).
a After removing the clip, return the button
at the center of the clip to its original
position by pushing it in the direction of
the arrow (q).

3) Float cover (1) a little, then disconnect

connectors CN-HAZ (3a), CN-EST (4a) and
CN-RM1 (5a) of switches (3) to (5).
4) Remove cover (1).

50-324 HM400-3M0
 50 Disassembly and assembly
Electrical system

2. Remove bolts (8a) and (8b) from back side of Installation (HM300-Q170-720-K-00-A)
machine monitor (7) by tilting steering wheel (6)
downward. • Perform installation in the reverse order to
3. Disconnect wiring harness connectors (9) to removal.
(11).
4. Remove four mounting bolts (12), and remove
machine monitor (7) and machine monitor
bracket (13) as a unit.

5. Remove eight mounting screws (14), and

disconnect machine monitor (7) from machine
monitor bracket (13).

HM400-3M0 50-325
50 Disassembly and assembly
Electrical system

Removal and installation of engine controller assembly (HM400_3R-AP70-924-K-00-A)

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)

Removal (HM400_3R-AP70-520-K-00-A)

1. Open engine hood (1).

a Be sure to turn lock (2) to LOCK position.

3. Remove clamp (6) from the left side of the

engine, and remove cover (7).

4. Remove cover (8).

2. Tilt up operator's cab assembly (3). For details,

see Testing and adjusting, "Cab tilt up
procedure".

k Check that lock lever (4) is in CLOSE

position and operator's cab assembly (3)
is securely supported with lock bar (5).

5. Disconnect connector J3P (9).

50-326 HM400-3M0
 50 Disassembly and assembly
Electrical system

6. Disconnect connectors J1P (10) and J2P (11).

[*1]
a Loosen hexagonal socket head bolt (4mm),
and remove connectors J1P (10) and J2P
(11).

7. Disconnect ground cable (12).

8. Remove mounting bolts (13) (4 pieces), and
remove engine controller assembly (14).

Installation (HM400_3R-AP70-720-K-00-A)

• Perform installation in the reverse order to

removal.
a When the engine controller assembly is
replaced, write the following compensation
value into the engine controller. For details,
see Testing and adjusting, "Writing offset
value at replacement of injector and engine
controller".
• Write the injector compensation value written on
the old engine controller to the new engine
controller.
• If the compensation value is not correctly written,
an engine trouble can result.
[*1]
3 Mounting hexagonal socket head bolts
(4mm) of connectors J1P (10) and J2P
(11):
3 ± 1 Nm {0.3 ± 0.1 kgm}

HM400-3M0 50-327
50 Disassembly and assembly
Electrical system

Removal and installation of retarder and hoist controller

assembly (HM400_3R-RA1M-924-K-00-A)
k Place the machine on a level ground, set the
parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".) Installation (HM300-RA1M-720-K-00-A)

Removal (HM400_3R-RA1M-520-K-00-A) • Perform installation in the reverse order to

removal.
1. Fold operator's seat (1) forward.

2. Remove cover (3).

3. Disconnect harness connectors (4) to (6).

a Loosen the locks in the center of each
connector (4 mm hexagonal socket head
bolt) in advance.
4. Remove mounting bolts (7) (4 pieces).
5. Remove the retarder and hoist controller
assembly (8).

50-328 HM400-3M0
 50 Disassembly and assembly
Electrical system

Removal and installation of transmission controller assembly (HM400_3R-CV10-

924-K-00-A)

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".) Installation (HM300-CV10-720-K-00-A)

Removal (HM400_3R-CV10-520-K-00-A) • Perform installation in the reverse order to

removal.
1. Fold operator's seat (1) forward.

2. Remove cover (3).

3. Disconnect harness connectors (4) to (6).

a Loosen the lock in the center of each
connector (4 mm hexagonal head bolt) in
advance.
4. Remove mounting bolts (7) (4 pieces).
5. Remove transmission controller assembly (8).

HM400-3M0 50-329
50 Disassembly and assembly
Electrical system

Removal and installation of KOMTRAX terminal assembly (HM400_3R-Q210-924-K-00-A)

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".) Installation (HM300-Q210-720-K-00-A)

Removal (HM300-Q210-520-K-00-A) • Perform installation in the reverse order to

removal.
1. Remove bolts (1) (2 pieces).
2. Remove cover (2).

3. Disconnect wiring harness clamps (3) and (4).

4. Disconnect wiring harness connectors (5) to (8).
5. Remove bolts (9) (4 pieces).
6. Remove KOMTRAX terminal (10).

50-330 HM400-3M0

Air conditioner unit (ALL-K500-001-K-03-A)
Removal and installation of air conditioner unit assembly
k In order to prevent serious or death
accidents due to falling of the cab, following
precautions must be observed when tilting
the cab.
• Precautions before starting cab-tilting operation
k Cab-tilting operation must be performed on a
flat ground.
k Set the machine to the straight-travel
condition to prevent the interference
between the cab and body, then fix the front
and rear frames by using the articulation
lock.
k Set the parking brake switch to ON position
by pressing "P", and apply the parking brake.
k Lock the lever by using the dump lever lock
knob.
k Chock the wheels to prevent the machine
from moving.
k Do not perform the cab-tilting operation
when it is strongly windy.
• Precautions for cab-tilting operation
k Do not perform the cab-tilting operation
when the dump body is loaded.
k Do not place yourself under the cab during
the cab-tilting operation.
k Fix the cab securely by using the lock lever
before tilting up the cab.
k Installthe lock lever from the side of the cab
without entering into a space below the cab.
k Do not go in or out the cab when tilting up
the cab.
k Do not operate the gear shift lever and dump
lever when tilting up the cab.
k Do not start the engine when tilting up the
cab.
k When you are forced to start the engine for
inspection purpose, check that no person is
under the cab.
k Do not give a large impact to the machine
when tilting up the cab.
HM400-3M0
50 Disassembly and assembly
Air conditioner unit
(HM400_3R-K540-924-K-00-A)
k When lowering the cab by using the cab
power tilt (optional), do it gradually adjusting
the descending speed without decreasing
the oil pressure at a breath.
k The lock bar is equipped in the inner left side
corner of the engine hood. Be sure to return
the bar to the original place after using it.
k Stop the engine, turn the battery disconnect
switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".)
a Ask a qualified person for collecting, adding and
filling operations of the refrigerant (air
conditioner gas: R134a).
a Never release the refrigerant (air conditioner
gas: R134a) to the atmosphere.
k If refrigerant gas (air conditioner gas: R134a)
gets in your eyes, you may lose your sight.
And if it touches your skin, you may suffer
from frostbite. Put on protective eyeglasses,
gloves and working clothes with long
sleeves while collecting the refrigerant or
filling the air conditioner circuit with the
refrigerant.
k If you disconnect the radiator hose and
heater hose when the coolant in radiator is
still hot, you may be scalded. Wait until the
coolant temperature drops before starting
the work.
Removal (HM400_3R-K540-520-K-00-A)
1. Open engine hood (1).
a Be sure to set lock (1a) securely.
50-331
50 Disassembly and assembly
Air conditioner unit
2. Tilt up operator's cab assembly (2). For details,
see Testing and adjusting, "Cab tilt up
procedure".
k Check that lock lever (2b) is in CLOSE
position and operator's cab assembly (2)
is securely supported with lock bar (2a).
3. Collect the refrigerant (air conditioner gas:
R134a) from the air conditioner circuit.
Refrigerant to be collected: 875 ± 25g
4. Disconnect air conditioner hoses (3) and (4). [*1]
5. Disconnect heater hoses (5) and (6).
a Note the current installation positions of the
hoses.
50-332
6. Return the operator's cab assembly (1) back to
the horizontal posture.
7. Remove mounting bolt (7) to remove auxiliary
seat (8).
8. Fold operator's seat assembly (9) forward.
9. Remove cover (10).
10.Remove cover (11).
a Before removing cover (11), remove 12 V
wiring harness connector (12) and audio
wiring harness (13) on the back side.
a Disconnect audio wiring harness (13)
according to the following procedure.
1) Open cap (13a).
2) Remove nut (13b).
3) Pull out audio wiring harness (13).
HM400-3M0
 50 Disassembly and assembly
Air conditioner unit

13.Remove covers (16) to (18).

11.Disconnect wiring harness connectors CN-ASS

(14) and CN-SBS (15). 14.Disconnect fuse box (45).
12.Disconnect wiring harness clamps (15a) and 15.Remove ducts (46) to (50).
(15b).

HM400-3M0 50-333
50 Disassembly and assembly
Air conditioner unit

16.Open fresh air duct inspection cover (51). 21.Disconnect wiring harness connectors (60) and
(61).

17.Remove filter (52).

22.Remove air conditioner unit assembly mounting
bolts (56) to (58) (6 pieces).
(Bolt installation position)
Front: 2 pieces (56)
Right, left, and front 1 piece each (57)
Rear: 2 pieces (58)
23.Remove air conditioner unit assembly (59).

18.Remove fresh air duct mounting bolts (53) (4

pieces).
19.Remove clip (54).
20.Remove fresh air duct (55).

50-334 HM400-3M0
 50 Disassembly and assembly
Air conditioner unit

• Refilling with coolant

Refill with coolant to the specified level through
the coolant filler port of the radiator. Run the
engine to circulate the coolant through the piping.
Then check the coolant level again.

5 Radiator: Only necessary quantity

Installation (HM400_3R-K540-720-K-00-A)

• Perform installation in the reverse order to

removal.
[*1]
a When installing the hose for the air conditioner
circuit, take care not to allow invasion of dirt,
dusts and water into the hose.
a Check that the O-ring (70) is installed for the air
conditioner hose connection before installation
a Check that the O-ring is not damaged or
deteriorated.
a When connecting the refrigerent piping, apply
compressor oil (DENSO: ND-OIL8, VALEO
THERMAL SYSTEMS: ZXL100PG (equivalent
to PAG46)) for new refrigerant (R134a) to the O-
ring.
3 Air conditioner pipe tightening torque
Thread size Tightening torque
16 x 1.5 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
22 x 1.5 19.6 to 24.5 Nm {2.0 to 2.5 kgm}
24 x 1.5 29.4 to 34.3 Nm {3.0 to 3.5 kgm}

• Filling of refrigerant (R134a)

Refill the air conditioner circuit with refrigerant
(R134a).
a Refill amount: 875 ± 25 g
• Refilling with air conditioner compressor oil
See Air conditioner, "Handling of compressor oil".

HM400-3M0 50-335
50 Disassembly and assembly
Air conditioner unit

Removal and installation of air conditioner compressor assembly (HM400-

K590-924-K-00-A)

k Stop the machine on a level ground and k If refrigerant gas (air conditioner gas:
apply the parking brake. R134a) gets in your eyes, you may lose
your sight. And if it touches your skin,
k Set the lock bar to the frame and chock the you may suffer from frostbite.
wheels. Accordingly, put on the protective
eyeglasses, gloves and working suits
k Turn the battery disconnect switch to the
with long sleeves while you are collecting
OFF position and remove the key.
or filling with the refrigerant (R134a).
Removal (HM400_3R-K590-520-K-00-A) 3. Remove cover (3).
1. Open engine hood (1).

4. Remove clamp (4).

5. Disconnect connector J33 (5).
a Check that lock (2) is set securely. 6. Remove cover (6).

2. Collect the refrigerant (air conditioner gas: 7. Remove cover (7).

R134a) from the air conditioner circuit. [*1] 8. Disconnect connector CM (8).
a Never release the refrigerant (air conditioner
gas: R134a) to the atmosphere.
a Ask a qualified person for collecting, adding,
and filling operations of the refrigerant (air
conditioner gas: R134a).
Refrigerant to be collected: 875 ± 25 g

50-336 HM400-3M0

9. Loosen belt tension adjustment nut (9) and
remove air conditioner compressor drive belt
(10). [*2]
10.Remove air cleaner assembly mounting bolts
(11) (2 pieces), and remove air conditioner
hoses (12) and (13). [*3]
11.Remove mounting bolts (14) (4 pieces) and
remove air conditioner compressor assembly
(15). [*4]
Installation (HM400_3R-K590-720-K-00-A)
• Perform installation in the reverse order to
removal.
[*1]
a When installing the hose for the air conditioner
circuit, take care not to allow invasion of dirt,
dusts and water into the hose.
HM400-3M0
50 Disassembly and assembly
Air conditioner unit
a Check that the O-ring is installed for the air
conditioner hose connection before installation.
a Check that the O-ring is not damaged or
deteriorated.
a When connecting the refrigerent piping, apply
compressor oil (DENSO: ND-OIL8, VALEO
THERMAL SYSTEMS: ZXL100PG (equivalent
to PAG46)) for new refrigerant (R134a) to O-ring.
[*2]
a After installing the compressor belt, press
(approximately 10 kg) the area around the
center between the compressor pulley and drive
pulley to adjust the compressor belt so that it
deflects approximately 9 mm.
[*3]
3 Air conditioner hose assembly mounting
bolt (11):
8 to 12 Nm {0.8 to 1.2 kgm}
[*4]
3 Mounting bolt (15):
27 to 34 Nm {2.8 to 3.5 kgm}
k If mounting bolts (9) are overtightened, the
air conditioner compressor may be damaged
inside. Strictly observe the specified
tightening torque.
• Filling of refrigerant (R134a)
Refill the air conditioner circuit with refrigerant
(R134a).
Refill amount: 875 ± 25 g
50-337
50 Disassembly and assembly
Air conditioner unit

Removal and installation of air conditioner condenser (HM400_3R-K580-924-K-00-A)

k Place the machine on a level ground, set the

parking brake switch to ON position by
pressing "P", and apply the parking brake.

k Chock the wheels to prevent the machine

from moving.

k Set the lock bar to the front and rear frames

to lock them.

k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see Testing and adjusting,
"Handling battery disconnect switch".) 2. Collect the refrigerant (air conditioner gas:
R134a) from the air conditioner circuit.
a Ask a qualified person for collecting, adding and Refrigerant to be collected: 875 ± 25 g
filling operations of the refrigerant (air 3. Disconnect air conditioner refrigerant coolant
conditioner gas: R134a). piping (3) (2 pieces). [*1]
4. Remove mounting bolts (4) (4 pieces) and
a Never release the refrigerant (air conditioner remove air conditioner condenser (5).
gas: R134a) to the atmosphere.
k If refrigerant gas (air conditioner gas: R134a)
gets in your eyes, you may lose your sight.
And if it touches your skin, you may suffer
from frostbite. Put on protective eyeglasses,
gloves and working clothes with long
sleeves while collecting the refrigerant or
filling the air conditioner circuit with the
refrigerant.

Removal (HM400_3R-K580-520-K-00-A)

1. Open engine hood (1).

a Be sure to turn lock (2) to LOCK position. Installation (HM400_3R-K580-720-K-00-A)

• Perform installation in the reverse order to

removal.
[*1]
a When installing the hose for the air conditioner
circuit, be careful that any dirt, dusts and water
do not enter into the hose.
a When installing the air conditioner hoses, check
that O-rings (70) are fitted to each of their
fittings.
a Check that O-ring (70) is free from flaws and
deterioration.
a When connecting the refrigerant pipes, apply
compressor oil for new refrigerant (R134a)
(SANDEN: SP-20PAG oil) to O-ring (70).

50-338 HM400-3M0
 50 Disassembly and assembly
Air conditioner unit

3 Air conditioner pipe tightening torque

Thread size Tightening torque
16 x 1.5 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
22 x 1.5 19.6 to 24.5 Nm {2.0 to 2.5 kgm}
24 x 1.5 29.4 to 34.3 Nm {3.0 to 3.5 kgm}
• Filling of refrigerant (R134a)
Refill the air conditioner circuit with refrigerant
(R134a).
Refill amount: 875 ± 25 g
• Refilling with air conditioner compressor oil
See Air conditioner, "Handling of compressor oil".

HM400-3M0 50-339
50 Disassembly and assembly
Air conditioner unit

50-340 HM400-3M0
SHOP MANUAL

ARTICULATED DUMP TRUCK

HM400-3M0
Model Serial Number

HM400-3M0 5001 and up

60 Maintenance standard
8 60 Maintenance standard

HM400-3M0 60-1
60 Maintenance standard
Table of contents

Table of contents (ALL-0310-002-A-00-A)

60 Maintenance standard................................................................................................................... 60-1
Table of contents ........................................................................................................................ 60-2
Engine and cooling system .......................................................................................................... 60-3
Engine mount ...................................................................................................................... 60-3
Output shaft......................................................................................................................... 60-4
Radiator fan pump................................................................................................................ 60-5
Radiator fan motor ............................................................................................................... 60-7
Aftercooler fan motor ............................................................................................................ 60-8
Power train............................................................................................................................... 60-10
Drive shaft ......................................................................................................................... 60-10
Torque converter and transmission mount ............................................................................ 60-12
Torque converter ................................................................................................................ 60-13
Transmission ..................................................................................................................... 60-16
Transmission control valve.................................................................................................. 60-24
Forward and reverse clutch ECMV and gear speed clutch ECMV ........................................... 60-25
Lockup clutch ECMV .......................................................................................................... 60-26
Differential lock clutch ECMV .............................................................................................. 60-27
Main relief valve, torque converter relief valve, and main flow selector valve............................ 60-28
Differential ......................................................................................................................... 60-30
Axle .................................................................................................................................. 60-33
Final drive ......................................................................................................................... 60-35
Steering system........................................................................................................................ 60-40
Steering column................................................................................................................. 60-40
Steering cylinder ................................................................................................................ 60-41
Emergency steering pump .................................................................................................. 60-42
Brake system ........................................................................................................................... 60-43
Slack adjuster .................................................................................................................... 60-43
Brake ................................................................................................................................ 60-45
Parking brake .................................................................................................................... 60-48
Undercarriage and frame........................................................................................................... 60-50
Suspension ....................................................................................................................... 60-50
Suspension cylinder ........................................................................................................... 60-54
Oscillation hitch ................................................................................................................. 60-56
Hydraulic system ...................................................................................................................... 60-58
Steering and hoist pump ..................................................................................................... 60-58
Pump for driving torque converter, transmission, aftercooler fan, and center brake cooling
motors ................................................................................................................. 60-61
Center brake cooling pump ................................................................................................. 60-63
Brake charge pump ............................................................................................................ 60-64
Center brake cooling remote pump ...................................................................................... 60-65
Center brake cooling remote motor ...................................................................................... 60-66
Hoist valve ........................................................................................................................ 60-68
Hoist cylinder..................................................................................................................... 60-70

60-2 HM400-3M0
 60 Maintenance standard
Engine mount

Engine and cooling system (ALL-R401-001-K-00-A)

Engine mount (HM400_3M0-H320-034-K-00-A)

HM400-3M0 60-3
60 Maintenance standard
Output shaft

Output shaft (HM400-CB30-034-K-00-A)

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between dimension Shaft Hole clearance clearance
1 flywheel and bearing 0 0 -0.030 to
80 0.02
+0.013 -0.030 -0.013
Clearance between -0.009 0 -0.003 to
2 40 0.10 Replace
shaft and bearing -0.025 -0.012 0.025
Clearance between 0 -0.006 -0.028 to
3 120 ―
bearing and cover -0.015 -0.028 0.009
Clearance between +0.012 0 -0.027 to
4 bearing and shaft 65 0.025
-0.007 -0.015 0.007
Wear of oil seal Repair or
Standard dimension Tolerance replace
5 contact surface of
coupling 95 94.7
Standard backlash Allowable backlash
6 Backlash of spline
0.070 to 0.217 0.4
Replace
Deformation of Initial dimension: Lo Repair limit (Min. width: L)
7 rubber 85 (large), 58 (small) 76 (large), 52 (small)
Appearance No crack

60-4 HM400-3M0
 60 Maintenance standard
Radiator fan pump

Radiator fan pump (HM400-B450-034-K-00-A)

HM400-3M0 60-5
60 Maintenance standard
Radiator fan pump

Servo valve (HM400-B4H0-034-K-00-A)

60-6 HM400-3M0
 60 Maintenance standard
Radiator fan motor

Radiator fan motor (HM400-B5L0-034-K-01-A)

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
Free length Load at Load at Replace
Installed
x Outside installed Free length installed spring if
1 Check valve spring length
diameter length length damaged or
13.7 N 11.0 N deformed
16.4 x 8.9 11.5 —
{1.4 kg} {1.12 kg}

HM400-3M0 60-7
60 Maintenance standard
Aftercooler fan motor

Aftercooler fan motor (HM400-B5L0-034-K-00-A)

60-8 HM400-3M0
 60 Maintenance standard
Aftercooler fan motor

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
Free length Load at Load at
Installed
x Outside installed Free length installed
1 Spool return spring length Replace
diameter length length
spring if
58.8 N 47.1 N damaged or
44.84 x 12 33 —
{6 kg} {4.8 kg} deformed
44.1 N 35.3 N
2 Spool return spring 35 x 8.5 34 —
{4.5 kg} {3.6 kg}

HM400-3M0 60-9
60 Maintenance standard
Drive shaft

Power train (ALL-C100-001-K-00-A)

Drive shaft (HM400-D510-034-K-00-A)

Front frame side (HM400-D520-034-K-00-A)

60-10 HM400-3M0
 60 Maintenance standard
Drive shaft

Rear frame side (HM400-D540-034-K-00-A)

HM400-3M0 60-11
60 Maintenance standard
Torque converter and transmission mount

Torque converter and transmission mount (HM400_3R-H340-034-K-00-A)

60-12 HM400-3M0
 60 Maintenance standard
Torque converter

Torque converter (HM400-CD00-034-K-00-A)

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between dimension clearance clearance
Shaft Hole
1 PTO gear and
bearing +0.018 0 -0.030 to
50 — Replace
+0.002 -0.012 -0.002
Clearance between 0 +0.004 -0.018 to
2 90 —
bearing and case -0.015 -0.018 -0.019

HM400-3M0 60-13
60 Maintenance standard
Torque converter

60-14 HM400-3M0
 60 Maintenance standard
Torque converter

Unit: mm
No. Item Criteria Remedy
Outside diameter of Standard dimension Tolerance Repair limit
1 oil seal contact 0
surface of coupling 95 94.8
-0.087
Inside diameter of +0.025
2 seal ring contact 35 35.5
surface of input shaft 0
Standard Tolerance Standard Allowable
Clearance between dimension clearance clearance
Shaft Hole
3 clutch housing and
piston (outside) -0.5 +0.097 0.500 to
420 0.87
-0.7 0 0.797
Clearance between
-0.110 +0.081 0.110 to
4 clutch housing and 295 0.30
piston (inside) -0.190 0 0.271

Inside diameter of Standard dimension Tolerance Repair limit

5 seal ring contact +0.040
surface of retainer 135 135.5
0
Inside diameter of +0.030 Replace
6 seal ring contact 70 70.5
surface of sleeve 0
Inside diameter of
7 free wheel rolling 127.844 ±0.013 127.874
surface of race
Outside diameter of
8 free wheel rolling 108.883 ±0.013 108.853
surface of stator shaft
Inside diameter of +0.015
9 sliding surface of 109 109.08
bushing 0
Thickness of sliding 0
10 surface of bushing 5 4.5
-0.1
Thickness of clutch
11 5.4 ±0.1 4.9
disc
Backlash between
12 input shaft and PTO 0.17 to 0.45
gear

HM400-3M0 60-15
60 Maintenance standard
Transmission

Transmission (HM400-CF00-034-K-00-A)

60-16 HM400-3M0
 60 Maintenance standard
Transmission

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between dimension Shaft Hole clearance clearance
1 bearing and case +0.032 0 -0.047 to
70 — Replace
+0.002 -0.015 -0.002
Clearance between R
0 -0.036 -0.061 to
2 idler gear and 125 —
bearing -0.018 -0.061 -0.018

HM400-3M0 60-17
60 Maintenance standard
Transmission

60-18 HM400-3M0
 60 Maintenance standard
Transmission

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between
dimension Shaft Hole clearance clearance
1 FL/R clutch bearing
and case (front) 0 0 -0.040 to
160 —
-0.025 -0.040 0.025
Clearance between
0 0 -0.040 to
2 FL/R clutch bearing 160 —
and case (rear) -0.025 -0.040 0.025
Clearance between 0 0 -0.040 to
3 FH/1st clutch bearing 160 —
and case (front) -0.025 -0.040 0.025
Clearance between
0 0 -0.040 to
4 FH/1st clutch bearing 160 —
and case (rear) -0.025 -0.040 0.025
Clearance between 0 -0.012 -0.052 to
5 2nd/3rd clutch bearing 160 —
and case (front) -0.025 -0.052 0.013
Clearance between
0 -0.017 -0.052 to
6 2nd/3rd clutch bearing 160 —
and case (rear) -0.025 -0.052 0.008
Clearance between
differential lockup 0 -0.014 -0.060 to
7 clutch bearing and 230 —
-0.030 -0.060 0.016
case (front)
Clearance between
differential lockup 0 +0.014 -0.060 to
8 clutch bearing and 230 —
-0.030 -0.060 0.016
case (rear)
Clearance between 0 +0.018 -0.007 to
9 front output bearing 140 —
and cage -0.018 -0.007 0.036 Replace
Clearance between +0.045 0 -0.065 to
10 front output bearing 90 —
and spacer +0.023 -0.020 0.023
Standard dimension Tolerance Repair limit
Width of seal ring
11 groove of input shaft +0.18
2.5 2.7
+0.10
Width of seal ring +0.076
12 groove of input shaft 3.2 3.5
0
Inside diameter of seal
ring contact surface of +0.050
input/upper/lower shaft 50 50.1
0
13 (rear)
Width of input/upper/ +0.076
lower shaft seal ring 3.2 3.5
groove (rear) 0
Inside diameter of seal +0.040
ring contact surface of 140 140.1
0
14 sleeve
Width of seal ring +0.15
groove of sleeve 4.5 5.0
+0.10
Inside diameter of seal +0.035
ring contact surface of 85 85.1
front output shaft 0
15
Width of seal ring +0.15
groove of front output 3.0 3.3
shaft +0.10
Outside diameter of oil 0
16 seal contact surface of 120 119.8
rear coupling -0.087

HM400-3M0 60-19
60 Maintenance standard
Transmission

FL and R clutches (HM400-CF80-034-K-00-A)

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between dimension clearance clearance
Shaft Hole
1 FL/R shaft and
bearing (front) +0.071 0 -0.086 to
75 —
+0.061 -0.015 -0.061
Clearance between +0.071 0
FL/R shaft and -0.086 to —
2 75
bearing (rear) +0.061 -0.015 -0.061
Standard dimension Tolerance Repair limit
Clutch Thick-
3 plate 2.0 ±0.05 1.8
ness
Distortion — 0.05 0.15
Thick-
Clutch 3.2 ±0.08 2.75
4 ness
disc — Replace
Distortion 0.10 0.25
Load of wave spring
5 1,270 N {130 kg} ±115 N {±11.7 kg} 1,090 N {111 kg}
[Test height: 3.8 mm]
Thickness of thrust
6 washer 4 ±0.2 3.7
(FL clutch)
Thickness of thrust
7 washer 4 ±0.2 3.7
(R clutch)
End play of FL clutch
8 gear 0.14 to 0.86
End play of R clutch
9 gear 0.17 to 0.83

60-20 HM400-3M0
 60 Maintenance standard
Transmission

FH and 1st clutches (HM400-CF82-034-K-00-A)

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between dimension clearance clearance
Shaft Hole
1 FH/1st shaft and
bearing (front) +0.071 0 -0.086 to
75 —
+0.051 -0.015 -0.051
Clearance between +0.071 0
FH/1st shaft and -0.086 to —
2 75
bearing (rear) +0.051 -0.015 -0.051
Standard dimension Tolerance Repair limit
Clutch Thick-
3 plate 2.0 ±0.05 1.8
ness
Distortion — 0.05 0.15
Thick-
Clutch 3.2 ±0.08 2.75
4 ness
disc — Replace
Distortion 0.10 0.25
Load of wave spring
5 1,270 N {130 kg} ±115 N {±11.7 kg} 1,090 N {111 kg}
[Test height: 3.8 mm]
Thickness of thrust
6 washer 4 ±0.2 3.7
(FH clutch)
Thickness of thrust
7 washer 4 ±0.2 3.7
(1st clutch)
End play of FH clutch
8 gear 0.17 to 0.83
End play of 1st clutch
9 gear 0.15 to 0.85

HM400-3M0 60-21
60 Maintenance standard
Transmission

2nd and 3rd clutches (HM400-CFK0-034-K-00-A)

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between dimension clearance clearance
Shaft Hole
1 2nd/3rd shaft and
bearing (front) +0.071 0 -0.086 to
75 —
+0.051 -0.015 -0.051
Clearance between +0.071 0
2nd/3rd shaft and -0.086 to —
2 75
bearing (rear) +0.051 -0.015 -0.051
Standard dimension Tolerance Repair limit
Clutch Thick-
3 plate 2.0 ±0.05 1.8
ness
Distortion — 0.05 0.15
Thick-
Clutch 3.2 ±0.08 2.75
4 ness
disc — Replace
Distortion 0.10 0.25
Load of wave spring
5 1,270 N {130 kg} ±115 N {±11.7 kg} 1,090 N {111 kg}
[Test height: 3.8 mm]
Thickness of thrust
6 washer 4 ±0.2 3.7
(3rd clutch)
Thickness of thrust
7 washer 4 ±0.2 3.7
(2nd clutch)
End play of 3rd clutch
8 gear 0.15 to 0.85
End play of 2nd
9 clutch gear 0.15 to 0.85

60-22 HM400-3M0
 60 Maintenance standard
Transmission

Differential lockup clutch (HM400-DD30-034-K-00-A)

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between
dimension Shaft Hole clearance clearance
1 front housing and
bearing +0.052 0 -0.077 to
170 —
+0.027 -0.025 -0.027
Clearance between +0.065 0
output gear and -0.090 to —
2 170
bearing +0.040 -0.025 -0.040
Clearance between 0 -0.012 -0.052 to
3 130 —
housing and bearing -0.018 -0.052 -0.006
Clearance between
+0.012 0 -0.027 to
4 front output shaft and 75 —
bearing +0.007 -0.015 -0.007
Clearance between
0 -0.050 -0.090 to
5 output gear and 150 —
bearing (front) -0.015 -0.090 -0.035
Clearance between 0 -0.028
output gear and -0.068 to —
6 150
bearing (rear) -0.015 -0.068 -0.013 Replace
Clearance between +0.028 0
rear output shaft and -0.043 to —
7 100
bearing +0.013 -0.015 -0.013
Standard dimension Tolerance Repair limit
Clutch
8 plate Thickness 2.0 ±0.05 1.8
Distortion — 0.05 0.15
Clutch Thickness 3.2 ±0.10 2.75
9
disc Distortion — 0.20 0.25
Load of wave spring
10 1,480 N {151 kg} 440 N {45 kg} 1,260 N {128 kg}
[Test height: 3.2 mm]
Inside diameter of +0.030
seal ring contact 70 70.1
surface of carrier 0
11
Width of seal ring
groove of front output 2.1 ±0.05 2.3
shaft

HM400-3M0 60-23
60 Maintenance standard
Transmission control valve

Transmission control valve (HM400-CJA0-034-K-00-A)

60-24 HM400-3M0
 60 Maintenance standard
Forward and reverse clutch ECMV and gear speed clutch
ECMV

Forward and reverse clutch ECMV and gear speed clutch ECMV (HM300-CJJ0-
034-K-00-A)

a ECMV: Abbreviation for Electronic Control Modulation Valve

a Do not disassemble this since it needs to be adjusted for maintaining the performance after reassembly.

HM400-3M0 60-25
60 Maintenance standard
Lockup clutch ECMV

Lockup clutch ECMV (HM300-CDT8-034-K-00-A)

a ECMV: Abbreviation for Electronic Control Modulation Valve

a Do not disassemble this since it needs to be adjusted for maintaining the performance after reassembly.

60-26 HM400-3M0
 60 Maintenance standard
Differential lock clutch ECMV

Differential lock clutch ECMV (HM300-DD31-034-K-00-A)

a ECMV: Abbreviation for Electronic Control Modulation Valve

a Do not disassemble this since it needs to be adjusted for maintaining the performance after reassembly.

HM400-3M0 60-27
60 Maintenance standard
Main relief valve, torque converter relief valve, and main
flow selector valve

Main relief valve, torque converter relief valve, and main flow selector
valve (HM300-C156-034-K-00-A)

60-28 HM400-3M0
 60 Maintenance standard
Main relief valve, torque converter relief valve, and main
flow selector valve

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between dimension clearance clearance
Shaft Hole
1 main relief valve and
valve body -0.035 +0.013 0.035 to
28 0.078
-0.045 0 0.058
Clearance between
torque converter -0.035 +0.013 0.035 to
2 relief valve and valve 22 0.078
-0.045 0 0.058
body
Clearance between -0.035 +0.013
main flow selector 0.035 to
3 25 0.078
valve and valve body -0.045 0 0.058
Clearance between -0.020 +0.052
check valve and 0.020 to
4 25 0.113
valve body -0.041 0 0.093
Standard dimension Repair limit
Load at Load at
Installed
Main relief valve Free length installed Free length installed
5 length Replace
spring (outside) length length
271.5 N 257.9 N
108 79.8 104.8
{27.7 kg} {26.3 kg}
Main relief valve 346.9 N 329.6 N
6 spring (inside) 108 79.8 104.8
{35.4 kg} {33.6 kg}
Torque converter 162.5 N 154.4 N
7 relief valve spring 50 41.5 48.5
{16.5 kg} {15.7 kg}
Poppet spring 21.4 N 20.3 N
8 43.9 22 42.6
(Main relief) {2.19 kg} {2.08 kg}
Poppet spring
5.7 N 5.4 N
9 (Torque converter 26 19 25.2
{0.581 kg} {0.552 kg}
relief)
Main flow selector 96.7 N 91.9 N
10 valve spring 95 55.5 92.2
{9.87 kg} {9.38 kg}
3.97 N 3.82 N
11 Check valve spring 45 30 43.7
{0.41 kg} {0.39 kg}

HM400-3M0 60-29
60 Maintenance standard
Differential

Differential (HM300-DC10-001-K-60-A)

Front differential (HM400-DC70-034-K-00-A)

Unit: mm
No. Item Criteria Remedy
Backlash between
1 bevel gear and bevel 0.42 to 0.65 (circumferential direction on outside of bevel gear) Adjust
pinion
Wear of oil seal Standard dimension Tolerance Repair limit
2 contact surface of 0
coupling 110 109.9 Repair or
-0.087
Wear of oil seal replace
0
3 contact surface of 95 94.9
coupling -0.087
Thickness of side
4 4 ±0.05 3.5 Replace
gear thrust washer

60-30 HM400-3M0
 60 Maintenance standard
Differential

Center differential (HM400-DCH1-034-K-00-A)

Unit: mm
No. Item Criteria Remedy
Wear of oil seal Standard dimension Tolerance Repair limit
1 contact surface of 0 Replace
coupling 95 94.9
-0.087
Backlash between
2 bevel gear and bevel 0.42 to 0.65 (circumferential direction on outside of bevel gear) Adjust
pinion
Thickness of side
3 4 ±0.05 3.5 Replace
gear thrust washer

HM400-3M0 60-31
60 Maintenance standard
Differential

Rear differential (HM400-DCD0-034-K-00-A)

Unit: mm
No. Item Criteria Remedy
Wear of oil seal Standard dimension Tolerance Repair limit
Repair or
1 contact surface of 0
90 89.9 replace
coupling -0.087
Thickness of side
2 4 ±0.05 3.5 Replace
gear thrust washer
Backlash between
3 bevel gear and bevel 0.42 to 0.65 (circumferential direction on outside of bevel gear) Adjust
pinion

60-32 HM400-3M0
 60 Maintenance standard
Axle

Axle (HM300-DA00-001-K-00-A)

Center axle (HM400_3R-DAK5-034-K-00-A)

HM400-3M0 60-33
60 Maintenance standard
Axle

Rear axle (HM400_3R-DAC0-034-K-00-A)

60-34 HM400-3M0
 60 Maintenance standard
Final drive

Final drive (HM300-DF10-034-K-00-A)

Front final drive (HM400-DFD0-034-K-00-A)

HM400-3M0 60-35
60 Maintenance standard
Final drive

Unit: mm
No. Item Criteria Remedy
Repair or
1 Straightness of shaft Repair limit: 0.7 TIR
replace
Backlash between
2 planetary gear and 0.19 to 0.53
ring gear
Backlash between
planetary gear and Replace
3 0.19 to 0.43
sun gear
Standard dimension Tolerance Repair limit
4 Thickness of spacer
12 ±0.1 11.5
Wear in outside
diameter of bearing +0.040
5 insertion portion of 200 200
+0.015
ring gear hub
Repair
Wear in outside
diameter of bearing -0.030
6 170 169.83
insertion portion of -0.055
axle tube
Clearance between Standard Tolerance Standard Allowable
shaft (outside dimension Shaft Hole clearance clearance
7 Replace
diameter) and 0 +0.39 0.409 to
bushing 65 0.41
-0.019 +0.32 0.320

a TIR: Abbreviation for Total Indicator Reading. It shows the difference between the maximum value and the
minimum value of the indicator measurement readings.

60-36 HM400-3M0
 60 Maintenance standard
Final drive

Center final drive (HM400-DFJ6-034-K-00-A)

Unit: mm
No. Item Criteria Remedy
Repair or
1 Straightness of shaft Repair limit: 1.5 TIR
replace
Backlash between
2 planetary gear and 0.19 to 0.53
ring gear
Backlash between
planetary gear and Replace
3 0.19 to 0.43
sun gear
Standard dimension Tolerance Repair limit
4 Thickness of spacer
26 ±0.1 25.5
Wear in outside
diameter of bearing +0.040
5 insertion portion of 200 200
+0.015
ring gear hub
Repair
Wear in outside
diameter of bearing -0.030
6 170 169.83
insertion portion of -0.055
axle tube

a TIR: Abbreviation for Total Indicator Reading. It shows the difference between the maximum value and the
minimum value of the indicator measurement readings.

HM400-3M0 60-37
60 Maintenance standard
Final drive

Rear final drive (HM400-DFH0-034-K-00-A)

60-38 HM400-3M0
 60 Maintenance standard
Final drive

Unit: mm
No. Item Criteria Remedy
Repair or
1 Straightness of shaft Repair limit: 1.5 TIR
replace
Backlash between
2 planetary gear and 0.19 to 0.53
ring gear
Backlash between
planetary gear and Replace
3 0.19 to 0.43
sun gear
Standard dimension Tolerance Repair limit
4 Thickness of spacer
26 ±0.1 25.5
Wear in outside
diameter of bearing +0.040
5 200 200
insertion portion of +0.015
axle tube Repair
Wear in outside
diameter of bearing -0.030
6 170 169.83
insertion portion of -0.055
axle tube

a TIR: Abbreviation for Total Indicator Reading. It shows the difference between the maximum value and the
minimum value of the indicator measurement readings.

HM400-3M0 60-39
60 Maintenance standard
Steering column

Steering system (ALL-F000-001-K-00-A)

Steering column (HM300-F171-034-K-00-A)

60-40 HM400-3M0
 60 Maintenance standard
Steering cylinder

Steering cylinder (HM400-F6L0-034-K-00-A)

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between dimension clearance clearance
Shaft Hole
1 piston rod and
bushing –0.030 +0.259 0.093 to
70 0.635
–0.076 +0.063 0.335
Clearance between –0.030 +0.174
piston rod mounting 0.130 to
2 65 1.0
pin and bushing –0.076 +0.100 0.250
Replace
Clearance between
cylinder bottom –0.030 +0.174 0.130 to
3 mounting pin and 65 1.0
–0.076 +0.100 0.250
bushing
Standard dimension Tolerance Repair limit
4 Cylinder bore +0.1
120 —
0

HM400-3M0 60-41
60 Maintenance standard
Emergency steering pump

Emergency steering pump (HM400-F940-034-K-00-A)

Unit: mm
No. Item Criteria Remedy
Model Tolerance Repair limit
1 Side clearance
SBL (1) 21 0.10 to 0.15 0.19
Clearance between
plain bearing inside
2 diameter and gear SBL (1) 21 0.06 to 0.119 0.20
shaft outside Replace
diameter
Standard Repair limit
Model Tolerance
dimension
3 Driving depth of pin
0
SBL (1) 21 10 —
-0.5
4 Torque of spline shaft 2.0 to 4.9 Nm {0.2 to 0.5 kgm}
Discharge Discharge
Standard Allowable
Rotating pressure
Oil: EO10-CD Model discharge discharge —
— speed (rpm) (MPa) {kg/
(l/min) (l/min)
Oil temperature: 45 to cm2}
55 °C SBL (1) 21 3,500 20.6 {210} 67.6 62.4

60-42 HM400-3M0
 60 Maintenance standard
Slack adjuster

Brake system (ALL-G000-001-K-00-A)

Slack adjuster (HM300-G310-001-K-60-A)

Front slack adjuster (HM400-G320-034-K-00-A)

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between dimension Shaft Hole clearance clearance
1 body and piston -0.030 +0.074 0.030 to
55 0.25
-0.076 0 0.150
Standard dimension Repair limit
Replace
Load at
Installed Allowable
Free length installed Free length
2 Slack adjuster spring length load
length
36.6 N
198 69.3 — —
{3.7 kg}

HM400-3M0 60-43
60 Maintenance standard
Slack adjuster

Center slack adjuster (HM400-G322-034-K-00-A)

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between dimension Shaft Hole clearance clearance
1 body and piston -0.030 +0.074 0.030 to
55 0.25
-0.076 0 0.150
Standard dimension Repair limit
Replace
Load at
Installed Allowable
Free length installed Free length
2 Slack adjuster spring length load
length
39.8 N
198 58 — —
{4.1 kg}

60-44 HM400-3M0
 60 Maintenance standard
Brake

Brake (HM300-G160-001-K-60-A)

Front brake (HM400-G16H-034-K-00-A)

HM400-3M0 60-45
60 Maintenance standard
Brake

Unit: mm
No. Item Criteria Remedy
Backlash between Standard backlash Repair limit
1 outer gear and plate 0.52 to 0.90 1.5
Backlash between
2 hub gear and disc 0.52 to 0.90 1.5
Standard dimension Repair limit
3 Thickness of plate
2.4 2.15
4 Thickness of disc 5.1 4.6
5 Thickness of damper 6.9 5.1
6 Thickness of damper 3.4 2.5 Replace
Distortion of friction Standard distortion Repair limit
7
surface of disc Max. 0.45 0.7
Distortion of friction
8 surface of plate and Max. 0.50 0.7
damper
Assembled thickness Standard dimension Repair limit
9 of plate, disc and
damper 52.9 45.9

60-46 HM400-3M0
 60 Maintenance standard
Brake

Center brake (HM400-G16J-034-K-00-A)

Unit: mm
No. Item Criteria Remedy
Backlash between Standard backlash Repair limit
1 outer gear and plate 0.52 to 0.90 1.5
Backlash between
2 hub gear and disc 0.52 to 0.90 1.5
Standard dimension Repair limit
3 Thickness of plate
2.4 2.15
4 Thickness of disc 5.1 4.6
5 Thickness of damper 6.9 5.1
6 Thickness of damper 3.4 2.5 Replace
Distortion of friction Standard distortion Repair limit
7
surface of disc Max. 0.45 0.7
Distortion of friction
8 surface of plate and Max. 0.50 0.7
damper
Assembled thickness Standard dimension Repair limit
9 of plate, disc and
damper 97.9 84.9

HM400-3M0 60-47
60 Maintenance standard
Parking brake

Parking brake (HM400-GJ20-034-K-00-A)

60-48 HM400-3M0
 60 Maintenance standard
Parking brake

Unit: mm
No. Item Criteria Remedy
Facial runout of Standard dimension Repair limit Repair or
1 replace
disc 0.4 0.8
Repair if there
is extreme
flaw or
uneven wear.
Min. 20
2 Thickness of disc 25 However,
thickness
must be at
least 20 mm.
Below 20
Thickness of pad Replace
3 (including 21.5 11.5
thickness of plate)
Standard
dimension of Standard Allowable
Tolerance
plate clearance clearance
0
Clearance between 22.3
-0.3 Repair or
4 plate and brake
Standard replace
assembly
dimension of Tolerance 1.0 ± 0.4 1.5
brake assembly
+0.4
23.0
-0.1

HM400-3M0 60-49
60 Maintenance standard
Suspension

Undercarriage and frame (ALL-DT00-001-K-00-A)

Suspension (HM300-E000-001-K-00-A)

Front suspension (HM400-E140-034-K-00-A)

60-50 HM400-3M0
 60 Maintenance standard
Suspension

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between dimension Shaft Hole clearance clearance
1 pin and bushing -0.030 +0.046 0.030 to
60 0.3 Replace
-0.076 0 0.122
Clearance between -0.030 +0.046 0.030 to
2 pin and bushing 60 0.3
-0.076 0 0.122

HM400-3M0 60-51
60 Maintenance standard
Suspension

Center and rear suspensions (HM400-E141-034-K-00-A)

60-52 HM400-3M0
 60 Maintenance standard
Suspension

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between dimension Shaft Hole clearance clearance
1 pin and bushing -0.030 +0.046 0.030 to
60 0.3
-0.076 0 0.122
Replace
Clearance between -0.030 +0.046 0.030 to
2 pin and bushing 60 0.3
-0.076 0 0.122
Clearance between -0.030 +0.046 0.030 to
3 pin and bushing 60 0.3
-0.076 0 0.122

HM400-3M0 60-53
60 Maintenance standard
Suspension cylinder

Suspension cylinder (HM400-E139-001-K-00-A)

Front suspension cylinder (HM400-E150-034-K-00-A)

a These figures show the front left suspension cylinder.

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between dimension clearance clearance
Shaft Hole
1 piston rod and
bushing -0.043 +0.24 0.103 to
160 0.4 Replace
-0.106 +0.06 0.346
Clearance between -0.015 +0.115
cylinder and wear 0.015 to
2 200 0.8
ring -0.061 0 0.176

60-54 HM400-3M0
 60 Maintenance standard
Suspension cylinder

Rear suspension cylinder (HM400-E170-034-K-00-A)

a These figures show the rear left suspension cylinder.

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between dimension clearance clearance
Shaft Hole
1 piston rod and
bushing -0.036 +0.235 0.096 to
110 0.4 Replace
-0.090 +0.060 0.325
Clearance between 0 +0.100
2 cylinder and wear 150 0 to 0.31 0.8
ring -0.21 0

HM400-3M0 60-55
60 Maintenance standard
Oscillation hitch

Oscillation hitch (HM400-H1P0-034-K-00-A)

60-56 HM400-3M0
 60 Maintenance standard
Oscillation hitch

Unit: mm
No. Item Criteria Remedy
Standard shim
1 2
thickness
Standard shim
2 1.5
thickness
Standard Tolerance Standard Allowable
Clearance between dimension Shaft Hole clearance clearance
3 bushing and front
-0.036 +0.054 0.036 to
frame 115 —
-0.090 0 0.144
Clearance between -0.036 +0.054 0.036 to
4 shaft and bushing 85 0.5
-0.058 0 0.112
Clearance between -0.036 0 0.016 to
5 shaft and bearing 85 0.5
-0.058 -0.020 0.058
Clearance between -0.036 +0.054 0.036 to
6 shaft and bushing 85 0.5
-0.058 0 0.112
Clearance between -0.036 +0.054 0.036 to
7 85 —
front frame and shaft -0.058 0 0.112
Standard shim
8 2
thickness
Clearance between +0.036 +0.054 -0.036 to
9 85 —
pin and bushing +0.058 0 0.112
Clearance between -0.036 0 0.016 to
10 pin and bearing 85 0.5
-0.058 -0.020 0.058 Replace
Clearance between -0.036 +0.054 0.036 to
11 85 —
pin and bushing -0.058 0 0.112
Clearance between 0 0
hitch frame and -0.040 to —
12 150
bearing -0.018 -0.040 0.018
Clearance between 0 0
hitch frame and -0.040 to —
13 340
bearing -0.057 -0.040 0.057
Clearance between 0 -0.017
rear frame and -0.080 to —
14 460
bearing -0.045 -0.080 0.028
Clearance between -0.020 +0.063
rear frame and 0.020 to —
15 435
bearing -0.083 0 0.146
Clearance between 0 -0.017
rear frame and 0.080 to —
16 420
bearing -0.045 -0.080 0.028
Clearance between -0.056 0 0.021 to —
17 bearing and hitch 300
-0.108 -0.035 0.108
frame
Standard shim
18 3
thickness

HM400-3M0 60-57
60 Maintenance standard
Steering and hoist pump

Hydraulic system (D65-PM10-001-K-00-A)

Steering and hoist pump (HM400-C200-034-K-00-A)

60-58 HM400-3M0
 60 Maintenance standard
Steering and hoist pump

Servo valve (HM300-F2J0-034-K-00-A)

HM400-3M0 60-59
60 Maintenance standard
Steering and hoist pump

60-60 HM400-3M0
 60 Maintenance standard
Pump for driving torque converter, transmission,
aftercooler fan, and center brake cooling motors

Pump for driving torque converter, transmission, aftercooler fan, and

center brake cooling motors (HM400-RA13-034-K-00-A)

HM400-3M0 60-61
60 Maintenance standard
Pump for driving torque converter, transmission,
aftercooler fan, and center brake cooling motors

Unit: mm
No. Item Criteria Remedy
Model Tolerance Repair limit
SAR (3) 56
1 Side clearance SAR (1) 28
0.10 to 0.15 0.19
SAR (1) 12
SAR (1) 12
Clearance between SAR (3) 56 0.06 to 0.149
plain bearing inside SAR (1) 28 0.06 to 0.119
2 diameter and gear SAR (1) 12 0.20 Replace
shaft outside 0.06 to 0.144
diameter SAR (1) 12
Standard Repair limit
Model Tolerance
dimension
SAR (3) 56 14
3 Driving depth of pin SAR (1) 28 0
—
SAR (1) 12 10 -0.5
SAR (1) 12
4 Torque of spline shaft 12.9 to 26.5 Nm {1.3 to 2.7 kgm}
Discharge
Standard Allowable
Rotating pressure
Model discharge (l discharge (l
Discharge speed (rpm) (MPa) {kg/
/min) /min)
cm2} —
— Oil: EO10-CD
SAR (3) 56 134 123
Oil temperature: 45 to 2.9 {30}
55 °C SAR (1) 28 68 59
2,500
SAR (1) 12
25.5 {250} 26 24
SAR (1) 12

60-62 HM400-3M0
 60 Maintenance standard
Center brake cooling pump

Center brake cooling pump (HM400-B453-034-K-00-A)

Unit: mm
No. Item Criteria Remedy
Model Tolerance Repair limit
1 Side clearance
SAR (3) 63 0.10 to 0.15 0.19
Clearance between
plain bearing inside
2 diameter and gear SAR (3) 63 0.06 to 0.149 0.20
shaft outside Replace
diameter
Standard Repair limit
Model Tolerance
dimension
3 Driving depth of pin
0
SAR (3) 63 14 —
-0.5
4 Torque of spline shaft 6.9 to 11.8 Nm {0.7 to 1.2 kgm}
Discharge Discharge
Standard Allowable
Rotating pressure
Oil: EO10-CD Model discharge discharge —
— speed (rpm) (MPa) {kg/
(l/min) (l/min)
Oil temperature: 45 to cm2}
55 °C SAR (3) 63 2,500 2.9 {30} 151 138

HM400-3M0 60-63
60 Maintenance standard
Brake charge pump

Brake charge pump (HM400_3R-G237-034-K-00-A)

Unit: mm
No. Item Criteria Remedy
Model Tolerance Repair limit
1 Side clearance
SAR (1) 18 0.10 to 0.15 0.19
Clearance between
plain bearing inside
2 circumference and SAR (1) 18 0.06 to 0.119 0.20
gear shaft outside Replace
circumference
Standard Repair limit
Model Tolerance
dimension
3 Driving depth of pin
0
SAR (1) 18 10 —
-0.5
4 Torque of spline shaft 2.0 to 4.9 Nm {0.2 to 0.5 kgm}
Discharge Discharge
Standard Allowable
Rotating pressure
Oil: EO10-CD Model discharge discharge —
— speed (rpm) (MPa {kg/
(l/min) (l/min)
Oil temperature: 45 to cm2})
55°C SAR (1) 18 3,500 24.5 {250} 59 54

60-64 HM400-3M0
 60 Maintenance standard
Center brake cooling remote pump

Center brake cooling remote pump (HM400-B454-034-K-00-A)

Unit: mm
No. Item Criteria Remedy
Model Tolerance Repair limit
1 Side clearance
SAL (2) 50 0.10 to 0.15 0.19
Clearance between
plain bearing inside
2 diameter and gear SAL (2) 50 0.06 to 0.125 0.20
shaft outside Replace
diameter
Standard Repair limit
Model Tolerance
dimension
3 Driving depth of pin
0
SAL (2) 50 12 —
-0.5
4 Torque of spline shaft 2.9 to 6.9 Nm {0.3 to 0.7 kgm}
Discharge Discharge
Standard Allowable
Rotating pressure
Oil: EO10-CD Model discharge discharge —
— speed (rpm) (MPa) {kg/
(l/min) (l/min)
Oil temperature: 45 to cm2}
55 °C SAL (2) 50 3,000 2.9 {30} 144 132

HM400-3M0 60-65
60 Maintenance standard
Center brake cooling remote motor

Center brake cooling remote motor (HM400_3R-GD7C-034-K-00-A)

60-66 HM400-3M0
 60 Maintenance standard
Center brake cooling remote motor

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
Free length Load at Load at
Installed
x Outside installed Free length installed
1 Spool return spring length Replace
diameter length length
spring if
58.8 N 47.1 N damaged or
44.84 x 12 33 —
{6 kg} {4.8 kg} deformed
44.1 N 35.3 N
2 Spool return spring 36.4 x 8.5 34 —
{4.5 kg} {3.6 kg}

HM400-3M0 60-67
60 Maintenance standard
Hoist valve

Hoist valve (HM400_3R-M5J0-034-K-00-A)

60-68 HM400-3M0
 60 Maintenance standard
Hoist valve

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
Free length Load at Load at
Installed
Spool return spring x Outside installed Free length installed
1 length
(RAISE) diameter length length
155.8 N 124.6 N
51.3 x 34.5 50 — Replace
{15.9 kg} {12.7 kg}
spring if
Spool return spring 124.5 N 99.6 N damaged or
2 34.2 x 36 32 —
(FLOAT) {12.7 kg} {10.2 kg} deformed
Spool return spring 1005.5 N 804.4 N
3 73 x 36.5 53 —
(LOWER) {102.6 kg} {82.1 kg}
44.1 N 35.3 N
4 Check valve spring 32.6 x 10.9 24.5 —
{4.5 kg} {3.6 kg}

HM400-3M0 60-69
60 Maintenance standard
Hoist cylinder

Hoist cylinder (HM400-M5K0-034-K-00-A)

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between dimension clearance clearance
Shaft Hole
1 piston rod and
bushing -0.036 +0.235 0.096 to
95 0.625
-0.090 +0.060 0.325
Clearance between -0.030 0
piston rod supporting 0.015 to
2 70 1.0
pin and bushing -0.076 -0.015 0.076 Replace
Clearance between
-0.030 0 0.015 to
3 cylinder supporting 70 1.0
pin and bushing -0.076 -0.015 0.076
Standard dimension Tolerance Repair limit
4 Cylinder bore +0.1
135 —
0

60-70 HM400-3M0
SHOP MANUAL

ARTICULATED DUMP TRUCK

HM400-3M0
Model Serial Number

HM400-3M0 5001 and up

80 Appendix
9 80 Appendix

HM400-3M0 80-1
80 Appendix
Table of contents

Table of contents (ALL-0310-002-A-00-A)

80 Appendix...................................................................................................................................... 80-1
Table of contents ........................................................................................................................ 80-2
Air conditioner components ......................................................................................................... 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-7
Outline of refrigeration cycle.................................................................................................. 80-8
Air conditioner unit ............................................................................................................. 80-10
Dual pressure switch .......................................................................................................... 80-15
Air conditioner controller ..................................................................................................... 80-16
Compressor....................................................................................................................... 80-17
Condenser ........................................................................................................................ 80-18
Receiver drier .................................................................................................................... 80-19
Outer temperature sensor (outside air temperature sensor) ................................................... 80-20
Procedure for testing and troubleshooting ............................................................................ 80-21
Circuit diagram and arrangement of connector pins............................................................... 80-23
System diagram................................................................................................................. 80-25
Input and output signals of the air conditioner controller ......................................................... 80-26
Parts and connectors layout................................................................................................ 80-28
Testing air leakage (duct) .................................................................................................... 80-33
Testing with self-diagnosis function ...................................................................................... 80-36
How to open the electrical system abnormality record screen in service mode of the machine
monitor ................................................................................................................ 80-37
Testing vent (mode) changeover.......................................................................................... 80-39
Testing FRESH/RECIRC air changeover.............................................................................. 80-40
Testing (dual) pressure switch for refrigerant......................................................................... 80-41
Testing relays .................................................................................................................... 80-43
Troubleshooting chart 1 ...................................................................................................... 80-45
Troubleshooting chart 2 ...................................................................................................... 80-46
Information in troubleshooting table ..................................................................................... 80-49
Failure code list related to air conditioner.............................................................................. 80-50
Failure code [879AKA] A/C Inner sensor Open Circuit ........................................................... 80-51
Failure code [879AKB] A/C Inner sensor Short Circuit ........................................................... 80-52
Failure code [879BKA] A/C Outer sensor Open Circuit .......................................................... 80-53
Failure code [879BKB] A/C Outer sensor Short Circuit .......................................................... 80-55
Failure code [879CKA] Ventilating sensor Open Circuit ......................................................... 80-57
Failure code [879CKB] Ventilating sensor Short Circuit.......................................................... 80-58
Failure code [879EMC] Ventilating Damper Abnormality ........................................................ 80-59
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-60
Failure code [879GKX] Refrigerant Abnormality .................................................................... 80-61
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-63
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-65
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-68
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-70
Troubleshooting with gauge pressure................................................................................... 80-72
Connection of service tool................................................................................................... 80-75
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-77
Handling of compressor oil.................................................................................................. 80-79

80-2 HM400-3M0
 80 Appendix
Precautions for refrigerant

Air conditioner components (ALL-K500-001-K-02-A)

Precautions for refrigerant (ALL-K512-012-K-00-A)

k Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before
disconnecting the air conditioner hoses to replace the air conditioner unit or condenser, the air
conditioner compressor, receiver drier, etc.

a Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a). (Only registered person can work.)
a Never release the refrigerant (R134a) to the atmosphere.
k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skin,
you may suffer from frostbite. Put on protective eyeglasses, gloves and working clothes with long
sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant.

HM400-3M0 80-3
80 Appendix
Air conditioner component

Air conditioner component (HM400-K500-04D-K-00-A)

80-4 HM400-3M0
 80 Appendix
Air conditioner component

1. Compressor
2. Condenser
3. Receiver drier
4. Hot water piping
5. Hot water return piping
6. Refrigerant piping
7. Dual pressure switch
8. Sight glass
9. Air conditioner controller
10. Air conditioner unit
11. Recirculation air filter
12. Fresh air filter
13. Machine monitor
14. Control panel
A. Front window defroster vent
HM400-3M0 80-5
80 Appendix
Air conditioner component

B. Face vents
C. Air vent for assistant's seat
D. Rear vents
E. Foot vents
Specifications (HM400-K500-030-K-00-A)

Refrigerant R134a
Refrigerant refilling level (g) 875 ± 25

80-6 HM400-3M0
 80 Appendix
Configuration and function of refrigeration cycle

Configuration and function of refrigeration cycle (ALL-K500-042-K-00-A)

Cycle Compression Condensation Expansion Evaporation

(Component) (Compressor) (Condenser) (Expansion valve) (Evaporator)
In operator's cab In operator's cab
Engine
Location compartment Front of radiator (Built in air conditioner (Built into air
unit) conditioner unit)
Circulates Lowers temperature
By evaporating
refrigerant gas and Condenses and pressure of
refrigerant, absorb
increases its refrigerant to refrigerant liquid and
heat from the air
temperature and discharge heat gas for easy
around the evaporator,
Function pressure so that it absorbed in evaporation with
and cools the
can be liquefied evaporator. throttle. Controls flow
surrounding air.
easily in condenser. (condensation of rate, too.
(Evaporation of
(Compression of refrigerant) (Throttle action of
refrigerant)
refrigerant) refrigerant)
Gas o gas Gas o liquid Liquid, gas o gas
State of Liquid o liquid, gas
refrigerant Adiabatic Constant pressure Constant pressure
Adiabatic expansion
compression change change

HM400-3M0 80-7
80 Appendix
Outline of refrigeration cycle

Outline of refrigeration cycle (HM300-K500-04A-K-00-A)

• Regeneration cycles are composed of the following four processes. Refrigerant circulates around the
system repeatedly changing its phase from liquid o gas o liquid.

Compression (Compressor)
• The compressor sucks in the refrigerant that has been vaporized in the evaporator and compresses it into
a state where it can be easily liquefied at the ambient temperature.
• The gaseous refrigerant sucked into the compressor cylinder is compressed to a temperature and
pressure at which it can be easily liquefied when cooled to the ambient temperature.

Condensation (Condenser)
• The condenser cools and liquefies the high pressure and high-temperature gaseous refrigerant sent from
the compressor.
• The heat released to the outside from the condenser is called condensation heat.
• The amount of condensation heat is the sum total of the heat absorbed by the evaporator from the air in
the cab and the quantity of the work applied (the value converted into a heat quantity) by compression of
the compressor.
• The refrigerant liquefied in the condenser is sent to the receiver drier, where moisture is removed.
• In the compression cycle, the gaseous refrigerant and liquid refrigerant coexist.
• The temperature (condensation temperature) and the pressure (condensation pressure) at which the
gaseous refrigerant is liquefied are proportional to each other.
Reference: The pressure varies depending on the condensation temperature of the refrigerant.

Expansion (Expansion valve)

• The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant can be
easily evaporated by the throttle action (*1).
• The action of reducing the liquid refrigerant pressure to a level where it can be easily evaporated before it
is sent to the evaporator is called expansion.
• The expansion valve, which reduces the refrigerant pressure, also adjusts the refrigerant flow rate
simultaneously.
• The quantity of the liquid refrigerant that can be evaporated in the evaporator depends on the amount of
heat (refrigeration load) to be removed under the specific evaporation temperature (evaporation pressure).
• The expansion valve controls the refrigerant feed rate so that the optimum quantity of liquid refrigerant is
supplied to the evaporator.
(*1) Throttle action
• If there is a narrow section in the passage through which liquid is flowing at a constant rate, a resistance to
the flow will be generated.
The liquid expands when it passes through the narrow section and rushes into the passage where the
sectional area is larger, and consequently, its pressure and temperature are reduced.
• No heat is transferred from or to the outside during the throttle action.

Evaporation (Evaporator)
• The evaporator evaporates the liquid refrigerant (superheated vapor).
• The refrigerant evaporates, while absorbing an amount of heat necessary for evaporation (evaporation
heat) from the air around the cooling fins (air in the cab).
• After the heat has been removed, the cooled air is sent into the cab by the blower fan, reducing the
temperature inside the cab.
• The mist refrigerant that has been sent from the expansion valve coexists with the evaporated refrigerant
in the evaporator
• The temperature (evaporation temperature) and the pressure (evaporation pressure) at which the liquid
refrigerant is evaporated are proportional to each other.
• The compressor sucks in the evaporated refrigerant in order to keep the pressure level in the evaporator
as low as possible so that the liquid refrigerant can be evaporated at a much lower temperature.

Relationship between refrigerant and defective air conditioning

• The refrigerant circulates in the refrigeration circuit while repeating the refrigeration cycle to expel the heat
from inside the cab.
• If there is an insufficient quantity of refrigerant, all of it will be evaporated while it is passing through the
evaporator. This causes evaporator efficiency to deteriorate, which will result in defective air conditioning.

80-8 HM400-3M0
 80 Appendix
Outline of refrigeration cycle

• If there is excessive refrigerant, not all of it will be evaporated and part of it will be sucked into the
compressor in liquid form, which will cause the compressor to compress the liquid and may damage the
components.
• If water gets into the refrigeration circuit, it will freeze at a small hole in the expansion valve, lower the
refrigerant flow, and may result in defective air conditioning.

HM400-3M0 80-9
80 Appendix
Air conditioner unit

Air conditioner unit (ALL-K540-041-K-00-A)

a This air conditioner unit is auto temperature control type.

A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to compressor)

80-10 HM400-3M0
 80 Appendix
Air conditioner unit

C: Hot water inlet

D: Hot water outlet
E: Recirculation air hole
F: Fresh air hole
G: Front air vents
H: Rear air vents
J: Foot level air vents
K: Defroster vents
1. Evaporator
2. Heater core
3. Expansion valve
4. Blower fan, blower motor
5. Air mix servomotor
6. Air mix door
7. Vent (mode) changeover servomotor
Vent (mode) changeover door
8. Rear door
9. Foot door
10. Defroster door
11. FRESH/RECIRC air changeover servomotor
12. FRESH/RECIRC air changeover door
13. Power transistor
14. Evaporator temperature sensor
15. Insidel air temperature sensor
a The door is the same as the damper.
Functions (HM300-K540-042-K-00-A)
Outline
• The air conditioner unit consists of the evaporator (1) and heater core (2), and is used to cool down or
warm up the air in the cab.

Temperature control
• Whenever a temperature control switch is operated on the machine monitor, temperature setting data is
sent to the air conditioner controller, which is located behind the operator seat. The air conditioner
controller controls the air mix servomotor (5) and changes the angle of the air mix door (6) in order to
adjust the temperature.

Over-cooling (Freezing) prevention

• Evaporator temperature sensor (14) varies its electrical resistance according to temperature.
• The air conditioner controller detects the temperature of the evaporator (1) by converting the changes in
the resistance of the evaporator temperature sensor (14) into voltage changes.
• The air conditioner controller performs control to prevent freezing of the evaporator (1) by operating the
compressor clutch relay (*) to stop the compressor.
*: See "Parts and connectors layout" for details regarding the compressor clutch relay.

Air flow adjustment

• Whenever an air flow control switch is operated on the machine monitor, air flow setting data is sent to the
air conditioner controller. The air conditioner controller controls blower motor (4) using power transistor
(13) in order to adjust the air flow.

HM400-3M0 80-11
80 Appendix
Air conditioner unit

Vent (mode) changeover

• Whenever a vent switch is operated on the machine monitor, mode data is sent to the air conditioner
controller. The air conditioner controller controls mode changeover servomotor (7) to adjust the opening
angle of mode changeover doors (8) to (10) and thus perform vent changeover.

FRESH/RECIRC air changeover

• Whenever a FRESH/RECIRC air changeover switch is operated on the machine monitor, FRESH/
RECIRC air changeover setting data is sent to the air conditioner controller. The air conditioner controller
controls FRESH/RECIRC air changeover servomotor (11) to open and close FRESH/RECIRC air
changeover door (12).
a When the cab door is opened, the air conditioner is automatically set to the FRESH air mode and the
changeover of the mode by using the changeover switch is disabled.After the cab door is closed, the air
conditioner automatically returns to the set mode.

Automatic air conditioner

• Inside air temperature sensor (15) varies its electrical resistance according to remperature inside cab. The
air conditioner controller detects the internal temperature by converting the changes in the resistance of
inside air temperature sensor (15) into voltage changes.
The air conditioner controller checks the voltage of inside air temperature sensor (15) and controls the
internal temperature so that it matches the setting made on the machine monitor.
Data from the outside air temperature sensor is also taken into consideration when adjusting the internal
temperature.
a The door is the same as the damper.
Functions of major components (ALL-K540-001-K-00-A)

a For details of the numbers in the following sentence, see “Air conditioner unit”.

Evaporator (ALL-K549-042-K-00-A)
• Evaporator (1) is cooled by the low-pressure, low-temperature refrigerant gas being sent from expansion
valve (3).
• Air from blower motor (4) is cooled and dehumidified when passing through the evaporator fins.

Heater core (ALL-K547-042-K-00-A)

• Heater core (2) is warmed by the hot water (engine coolant) being sent from the engine. Air from blower
motor (4) is warmed when passing through fins of the heater core (2).

Evaporator temperature sensor (ALL-K5FF-042-K-00-A)

• Evaporator temperature sensor (14) is installed to evaporator (1) with the holder. Its resistance changes in
accordance with the temperature change of the evaporator. The air conditioner controller determines the
temperature of evaporator (1) from voltage changes of evaporator temperature sensor (14) to prevent
freeze of the evaporator.

Servomotor (ALL-K5D2-042-K-00-A)

a Servomotors are used to adjust the temperature (air mix) and to perform vent (mode) changeover.

80-12 HM400-3M0
 80 Appendix
Air conditioner unit

• When a switch on the machine monitor is operated, the air conditioner controller applies 24V power
between servomotor terminal B (6) and servomotor terminal A (7). (Rotation direction switches according
to the polarity of supply voltage.) )
• The servomotor contains a variable resistor, and its resistance value changes as the motor rotates.
• The air conditioner controller applies a voltage of 5 V to the variable resistor and determines the motor
rotation angle from the potential difference.
• When the door (damper) reaches the position specified by each switch, the air conditioner controller stops
the supply of current to the servomotor, then the corresponding door stops.
• When the air conditioner controller cannot recognize the potential difference that corresponds to the
command to the servomotor, it generates a air conditioner failure code to inform the machine monitor of
failure in air conditioner system. Failure code [879EMC] or [879FMC] is displayed on the electrical system
failure record screen of the machine monitor.
a FRESH/RECIRC air changeover servo motor does not feature a variable resistance, and therefore,
does not have a self-diagnosis function.
a Do not try to drive a servomotor by supplying power directly between servomotor terminals (6) and (7)
during inspection.

Expansion valve (ALL-K548-041-K-00-A)

A: When evaporator outlet temperature is high

B: When evaporator outlet temperature is low
C: From capacitor (high-pressure refrigerant)
D: To compressor (low-pressure refrigerant)
1. Expansion valve
1a. Needle valve
1a-1. Diaphragm
1a-2. Thermoprobe
1b. Spring
2. Refrigerant gas

HM400-3M0 80-13
80 Appendix
Air conditioner unit

3. Evaporator

Structure
• Box-type expansion valve (1) consists of needle valve (1a), spring (1b), etc.
• Refrigerant gas (2) is sealed in the diaphragm chamber (hatched area) outside diaphragm (1a-1) of
needle valve (1a).

Function (ALL-K548-042-K-00-A)
• The expansion valve (1) converts high-pressure and high-temperature liquid refrigerant from the receiver
drier to low-pressure, low-temperature misty refrigerant through the throttle action.
• It controls the flow rate of refrigerant by changing the level of throttling depending on the temperature in
the cab.
• The temperature of the air blown out of the air vent is adjusted depending on the flow rate of refrigerant
circulating in the evaporator (3).

Operation (ALL-K548-044-K-00-A)
• Thermoprobe (1a-2) senses the refrigerant temperature after it passes through the evaporator (3).
• After the refrigerant passes through evaporator (3), its temperature is transferred to the refrigerant gas (2)
in the diaphragm chamber (hatched area) through the thermoprobe (1a-2).
• The pressure of the refrigerant gas (2) sealed in the diaphragm chamber (hatched area) changes in
response to the temperature change of the thermoprobe (1a-2), which therefore changes the force (Fg)
pushing the needle valve (1a).
• The opening level of the needle valve (1a) is determined based on the balance between the reaction force
exerted by the spring (1b) in a rightward direction, and the force (Fg) of the refrigerant gas (2) pushing the
needle valve (1a) through the diaphragm (1a-1) in a leftward direction.
• The refrigerant flow rate flowing from the receiver drier to evaporator (3) is determined based on the
opening level of needle valve (1a).

When evaporator (3) outlet temperature is high: [When not cooled yet: Condition (A) in the figure]
• The pressure of the refrigerant gas (2) in the diaphragm chamber is high and the volume is increased.
• The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is increased, and the needle valve
(1a) moves leftward.
• As a result, the opening level of the needle valve (1a) is increased and the refrigerant flow rate to the
evaporator (3) is increased to improve cooling capacity. (Condition (A) in previous figure)

When evaporator (3) outlet temperature is low: [When cooled already: Condition (B) in the figure]
• The pressure of the refrigerant gas (2) in the diaphragm chamber is low and the volume is decreased.
• The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is reduced, and the needle valve
(1a) is moved rightward by the reaction force of spring (1b).
• The opening level of the needle valve (1a) is reduced and the refrigerant flow rate to the evaporator (3) is
reduced to lower the cooling capacity. (Condition (B) in previous figure)

80-14 HM400-3M0
 80 Appendix
Dual pressure switch

Dual pressure switch (HM300-K5FG-044-K-00-A)

a The dual pressure switch is installed on the receiver drier.

• The dual pressure switch turns "OFF" when the refrigerant circuit pressure becomes abnormally low or
abnormally high.
• When the dual pressure switch turns "OFF", the air conditioner controller turns the compressor clutch
relay "OFF". As a result, the compressor's magnet clutch is released and air conditioner components are
protected.
Function (ALL-K5FG-042-K-00-A)

a LA or lower: Abnormally low pressure

a HA or higher: Abnormally high pressure
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}

HM400-3M0 80-15
80 Appendix
Air conditioner controller

Air conditioner controller (ALL-K5G4-041-K-00-A)

a See "System Diagrams" for details regarding input/output signals.

80-16 HM400-3M0
 80 Appendix
Compressor

Compressor (ALL-K590-041-K-00-A)

A: Refrigerant inlet (from air conditioner unit)

B: Refrigerant outlet (to condenser)
1. Pulley
2. Magnetic clutch
3. Relief valve
Specification (ALL-K590-044-K-00-A)

Number of cylinders - Bore x Stroke (mm) 10 - 32 x 20.8

Piston capacity (cc/rev) 157.3
Max. allowable speed (rpm) 6,000
Compressor oil DENSO: ND-OIL8 (For R134a)
Compressor oil refill capacity (cc) 180
Function (ALL-K590-042-K-00-A)

• The compressor circulates the refrigerant and compresses the gaseous refrigerant from the evaporator
into a misty refrigerant at high pressure and high temperature so that it will be easily regenerated
(liquefied) at the normal temperature.
• Calling into account of the evaporator temperature and refrigerant pressure, the air conditioner controller
activates magnetic clutch (2) built in the compressor.
• When magnetic clutch (2) is engaged, the power of the engine rotates the compressor shaft along with
pulley (1) to drive the compressor.

HM400-3M0 80-17
80 Appendix
Condenser

Condenser (HM300-K580-041-K-00-A)

1. Condenser
A: Refrigerant inlet (from compressor)
B: Refrigerant outlet (to receiver drier)
Specifications (HM300-K580-030-K-00-A)

Fin pitch (mm) 3.95

Height x width x thickness (mm) 357.4 x 540 x 16
Max. working pressure (MPa {kg/cm2} 3.5 {36}

Function (PC400-K580-042-K-00-A)

• The condenser cools and liquefies the high pressure and high temperature misty refrigerant sent from the
compressor.
a If the fin is crushed or is clogged with dust, heat exchange efficiency is reduced and complete liquefaction
of refrigerant becomes impossible.
If the heat exchange efficiency is reduced, pressure in the refrigerant circulation circuit will be increased,
applying extra load to the engine or reducing the cooling effect. Take extreme care not to crush or damage
the fins when hangling it or performing daily inspection.

80-18 HM400-3M0
 80 Appendix
Receiver drier

Receiver drier (PC400-K5E2-041-K-00-A)

A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to air conditioner unit)

HM400-3M0 80-19
80 Appendix
Outer temperature sensor (outside air temperature
sensor)

Outer temperature sensor (outside air temperature sensor) (ALL-K55C-041-K-00-A)

1. Connector
2. Sensor
Functions (HM300-K55C-042-K-00-A)
Outline
• The outside (air) temperature sensor is installed in the cooling unit.
• The outside air temperature sensor has feature of change in resistance by temperature change, therefore,
can detect the ambient temperature.
• The air conditioner controller detects the ambient temperature by converting the changes in the resistance
of the outside air temperature sensor into voltage changes.
• Only when performing automatic air conditioning, the air conditioner controller controls the blower motor
and the air mix servomotor with the data of the outside air temperature sensor in order to adjust the
temperature and air flow.

80-20 HM400-3M0
 80 Appendix
Procedure for testing and troubleshooting

Procedure for testing and troubleshooting (HM400-K500-422-K-00-A)

The air conditioner is provided with self-diagnosis functionality in order to provide for inspection of its main
components. Specifically, the operation of sensors and servomotors can be examined.
If a troubled section is detected, every part of that section must be inspected.
1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. Narrow down the sections with the self-diagnosis function (See “Check with self-diagnosis”).
If, however, the entire air conditioner unit fails to operate, inspect for problems with the supply of power to
the air conditioner controller and with CAN communication between the machine monitor and the air
conditioner controller.
If any part of the air conditioner unit can operate, it will indicate that the air conditioner controller is
receiving power normally and that CAN communication between the machine monitor and the air
conditioner controller is normal.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.

Basic testing and troubleshooting sequence

*1: By error display or abnormal display on "Electrical Systems" screen on the machine monitor.
*2: Simple checking of refrigerant volume through sight glass.
Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding with
the inspection.
A) If the continuous stream of bubbles can be seen, the system contains insufficient refrigerant.
B) If the bubbles can be seen intermittently, the refrigerant volume is sufficient.

HM400-3M0 80-21
80 Appendix
Procedure for testing and troubleshooting

C) If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant or no
refrigerant at all.
The above should be treated as general guidelines as certain exceptions do exist.
See "Troubleshooting with gauge pressure" and use gauge pressure to determine whether or not the
condition is normal.
S: Sight glass condition
R: Receiver drier internal condition
LR: Liquid refrigerant

*3: If any leakage of refrigerant is occurring, the compressor oil circulating within the air conditioner circuit will
definitely be leaking from the same point.
In such a case, retighten in accordance with the table of retightening torques from "Precautions for
disconnecting and connecting air conditioner piping."
*4: Start the engine and perform the check with the air conditioner switch set to ON.

80-22 HM400-3M0
 80 Appendix
Circuit diagram and arrangement of connector pins

Circuit diagram and arrangement of connector pins (HM300-K500-051-K-00-A)

HM400-3M0 80-23
80 Appendix
Circuit diagram and arrangement of connector pins

a Diffuser servomotor means vent (mode) changeover servomotor.

a SERVOMOTOR OF INSIDE/OUTSIDE AIR means FRESH/RECIRC air changeover servomotor.
a Frost sensor means evaporator temperature sensor.

80-24 HM400-3M0
 80 Appendix
System diagram

System diagram (HM300-K5F0-051-K-00-A)

a This air conditioner unit is auto temperature control type.

HM400-3M0 80-25
80 Appendix
Input and output signals of the air conditioner controller

Input and output signals of the air conditioner controller (HM300-K5G4-03C-K-00-A)

Controller side connector: AMP 025 - 32PM

Wiring harness connector: ACECU
AMP025 - 32PF
Input/Output
Pin No. Symbol Signal name
signal
1 +Bback Backup power supply Input
2 – (*1) –
3 SS Sunlight sensor (Not used) Input
4 THOUT Outside air temperature sensor Input
5 THF Evaporator temperature sensor Input
6 THI Inside air temperature sensor Input
7 POT5 V Servomotor potentiometer power supply(5 V) Output
8 BWFB Blower feedback signal Input
9 PTRB Power transistor control signal Output
10 CAN_H CAN communication signal (H) Input/output
11 CAN_L CAN communication signal (L) Input/output
12 – (*1) –
13 MRFA SERVOMOTOR OF INSIDE/OUTSIDE AIR terminal A Output
14 MRFB SERVOMOTOR OF INSIDE/OUTSIDE AIR terminal B Output
15 MAMA Air mix servomotor terminal A Output
16 MAMB Air mix servomotor terminal B Output
17 +24 V 24 V power supply Input
18 – (*1) –
19 SAM Air mix servomotor potentiometer signal Input
20 SVI Vent (mode) changeover servomotor potentiometer signal Input
21 PRESS SW Dual pressure switch Input
22 – (*1) –
23 – (*1) –
24 – (*1) –
25 GNDS Sensor GND Input
26 GND GND Input
27 – (*1) –
28 – (*1) –
29 RLCC Compressor clutch relay Output
30 – (*1) –
31 MV1A Vent (mode) changeover servomotor terminal A Output
32 MV1B Vent (mode) changeover servomotor terminal B Output
*1: Never connect these pins. Malfunctions or failures may occur.
Functions (HM300-K5G4-042-K-00-A)

• Operation of air conditioner controller

1. Performing CAN communication with the machine monitor, the air conditioner controller controls the air
conditioner unit by inputting switches associated with air conditioning.
2. The air conditioner controller controls three servomotors located inside the air conditioner unit in order to
adjust the temperature (airmix), perform vent (mode) changeover, and perform FRESH/RECIRC air
changeover.
3. The air conditioner controller controls the ON/OFF condition of the compressor clutch relay (i.e., a switch
for activating the compressor).
4. The air conditioner controller controls the air flow volume using the power transistor.
a The power transistor has an overcurrent prevention fuse in it.
5. The air conditioner controller detects the evaporator temperature using the evaporator temperature
sensor.

80-26 HM400-3M0
 80 Appendix
Input and output signals of the air conditioner controller

6. In order to prevent freezing of the evaporator, the air conditioner controller controls the compressor by
turning the compressor clutch relay ON and OFF.
a When the dual pressure switch detects a pressure abnormality (i.e., turns OFF), the air conditioner
controller turns the compressor clutch relay OFF, and therefore, the compressor stops operating.
7. In the automatic air conditioning mode, the air conditioner controller controls the air temperature inside the
cab to the set temperature based on data from the outside air temperature sensor and inside air
temperature sensor, and controls the air flow rate.
8. The controller has a self-diagnosis function. If any abnormality is detected, the control notifies it to the
machine monitor by the CAN communication. Then, failure code [879***] is displayed on the "Electrical
Systems" (electrical systems abnormality record) screen in the service mode of the machine monitor.

HM400-3M0 80-27
80 Appendix
Parts and connectors layout

Parts and connectors layout (HM400-K500-055-K-00-A)

• Four fuses relating to the air conditioner are located in the fuse box at the rear of the operator's seat.
• The air conditioner unit is installed behind the rear cover at the rear of the operator's seat.
k Park the machine on a level ground, set the parking switch to "PARK", and then chock the wheels.

k Turn the battery disconnect switch to the "OFF" position and pull out the key.

a Note connector numbers and installed positions before disconnecting wiring and hoses.
Item No. to
Connector No. Remarks Location be referred
to
AC01 Intermediate connector At the rear of cab 2.
AC02 Intermediate connector At the rear of cab 2.
CM Air conditioner compressor Engine 7.
ACECU Air conditioner controller At the rear of cab 2.
DPC1* Machine monitor At the front of cab 5.
DPC2* Machine monitor At the front of cab 5.
DPC3 Machine monitor At the front of cab 5.
CM04* Machine monitor At the front of cab 5.
BT1–BT4 Fuse box At the rear of cab 1.
Engine
HLS Dual pressure switch 6.
(Above receiver drier)
OTS Outside air temperature sensor Cooling unit 8.
CCR Relay At the right rear of cab 2.
[2] Power transistor Air conditioner unit 3.
[5]* FRESH/RECIRC air changeover
Air conditioner unit 3.
servomotor
[6]* Inside air temperature sensor Air conditioner unit 3.
Evaporator temperature sensor (frost
[7]* Air conditioner unit 3.
sensor)
*: Connectors that are not involved in the troubleshooting
Details (HM400-K500-055-K-01-A)

1. To remove fuses in the fuse boxes BT1 to BT4, remove the cover of respective fuse boxes at the rear of
the operator's seat.
• BT1-14 (20 A): Fuse for blower (fan) power supply
• BT1-16 (10 A): Fuse for air conditioner compressor
• BT4-18 (5 A): Fuse for air conditioner controller and primary side power supply of magnetic clutch relay
of air conditioner compressor
• BT2-2 (5 A): Fuse for air conditioner power supply (backup power supply) and FRESH/RECIRC air
changeover

2. Air conditioner controller: *1

80-28 HM400-3M0
 80 Appendix
Parts and connectors layout

• AC01: Intermediate connector (see Note 1.)

• AC02: Intermediate connector
• ACECU: Air conditioner controller connector

3. Air conditioner unit

a Connectors [2], [5], [6], and [7] are not labeled.
a Photo shows the rear face of the air conditioner unit (no connectors can be disconnected with the unit
installed on the machine.)
[2]: Connector for power transistor (*2)
[5]: Connector for FRESH/RECIRC air changeover servomotor
[6]: Inside air temperature sensor connector
[7]: Evaporator temperature sensor connector
*2: Power transistor

4. Relay
• CCR: Connector for magnetic clutch relay of air conditioner compressor (see Note 2.)

5. Machine monitor
• DPC1–3: Machine monitor connector

HM400-3M0 80-29
80 Appendix
Parts and connectors layout

6. Dual pressure switch

a Open the engine hood.
• HLS: Dual pressure switch connector

7. Air conditioner compressor

a Open the engine hood.
• CM: Connector for air conditioner compressor

8. Outside air temperature sensor

OTS: Outside air temperature sensor connector

80-30 HM400-3M0
 80 Appendix
Parts and connectors layout

Note 1: Procedure for disconnecting connectors AC01 and AC02

1. Remove rear cover (1).

2. Remove ducts (2) to (4).

3. Remove the relay and fuse box (5).

4. Use a large screwdriver to remove connector AC02 from the clip.

5. Similarly, use a large screwdriver to remove connector AC01 from the clip.
6. Disconnect connectors AC01 and AC02.

HM400-3M0 80-31
80 Appendix
Parts and connectors layout

Note 2: Location of connector CCR

1. Remove cover (5).

80-32 HM400-3M0
 80 Appendix
Testing air leakage (duct)

Testing air leakage (duct) (HM300-K5D0-001-K-00-A)

k Park the machine on a level ground, set the parking switch to "PARK", and then chock the wheels.

k Turn the battery disconnect switch to the OFF position and remove the key.

Testing (HM300-K5D0-360-K-00-A)

1. Remove covers (1) to (5).

HM400-3M0 80-33
80 Appendix
Testing air leakage (duct)

2. Check rear ducts (6) and (7) for dislocation.

3. Check face duct (8) and defroster duct (9) for dislocation.
a Condition with rear ducts (6) and (7) removed

4. Check face duct (10) and defroster duct (11) for dislocation.

80-34 HM400-3M0
 80 Appendix
Testing air leakage (duct)

5. Check defroster duct (12) for dislocation.

a Be sure to check the ends (inside cover (3)) of the duct for dislocation.

6. Check face duct (13) for dislocation.

a Condition with defroster duct (12) removed

7. Check outside air duct (14) for dislocation.

HM400-3M0 80-35
80 Appendix
Testing with self-diagnosis function

Testing with self-diagnosis function (HM300-Q19Y-001-K-00-A)

Function (HM300-Q19Y-042-K-00-A)

On the air conditioner operation screen of the machine monitor, the system performs self-diagnosis to the
communication with the air conditioner controller, FRESH/RECIRC air temperature sensor, outside (air)
temperature sensor, evaporator temperature sensor, temperature control, vent (mode) changeover, and
refrigerant pressure with the pressure switch, and if a problem is detected, the "Air conditioner system
condition monitor" is displayed.

a Even if the cause of a detected problem is restored to normal, the self-diagnosis failure condition will not
automatically be reset. To reset the failure condition, the starter switch must be set to OFF.
a On the "Electrical System" screen in the service mode of the machine monitor, the system performs self-
diagnosis for various sensors. If a problem is detected, failure information is displayed.
a FRESH/RECIRC air changeover servomotor is not checked with self-diagnosis function.

80-36 HM400-3M0
 80 Appendix
How to open the electrical system abnormality record
screen in service mode of the machine monitor

How to open the electrical system abnormality record screen in service

mode of the machine monitor (HM300-Q19Y-100-K-00-A)
• Overview of machine monitor operating procedure
Normal screen
O While pressing [R], press [1], [2], and [3] in this order.
Service menu (Mode)
O Press [R] twice. Press "check mark" (4).
03 Abnormality record
O Press [R] once. Press "check mark" (4).
02 Electrical Systems screen
• Detailed description of machine monitor operating procedure
1. On the normal operation screen, while pressing "friangle mark" [R] (6), press number key [1], [2], and [3]
in this order.

2. On the service menu screen, press the "triangle mark" [R] twice, and then select "03 Abnormality
Record".
3. Press the "check mark" (described previously) to confirm.

4. On the abnormality record screen, press the "triangle mark" [R] once, and then select "02 Electrical
Systems".
5. Press the "check mark" (described previously) to confirm.

HM400-3M0 80-37
80 Appendix
How to open the electrical system abnormality record
screen in service mode of the machine monitor

a For details, see the failure code list related to air conditioner
Failure code Failure (Displayed on screen) Remarks
879AKA A/C Inner Sensor Open Circuit
*
879AKB A/C Inner Sensor Short Circuit
879BKA A/C Outer Sensor Open Circuit
879BKB A/C Outer Sensor Short Circuit
879CKA Ventilating Sensor Open Circuit
*
879CKB Ventilating Sensor Short Circuit
879EMC Ventilation Dumper Abnormality *
879FMC Air Mix Dumper Abnormality *
879GKX Refrigerant Abnormality
DAZ9KQ A/C Model Selection Abnormality See Chapter 40,
"Troubleshooting by failure
DAZQKR CAN2 Discon (Aircon ECU) code"
**
*: Troubleshooting cannot be performed while the controller is mounted on the machine since the connector
cannot be checked.
**: Troubleshooting is not performed by the air conditioner unit but by the machine monitor.
a The A/C inner sensor means the inside (air) temperature sensor.
a The A/C outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The ventilation damper means the vent (mode) changeover damper (door).
a The air mix damper means the temperature adjustment (air mix) damper (door).

80-38 HM400-3M0
 80 Appendix
Testing vent (mode) changeover

Testing vent (mode) changeover (HM300-K5FR-001-K-00-A)

k Place the machine on a level ground, turn parking brake switch to PARK position, and chock
wheels.

a Note the connector numbers and installed positions before disconnecting wiring harnesses and hoses.
Testing (HM300-K5FR-360-K-00-A)

1. Remove the rear cover.

2. Remove rear ducts (1) and (2).
3. Remove face duct (3).

4. Turn the battery disconnect switch to the ON position.

5. Start the engine and switch on the air conditioner.
6. Operate the FRESH/RECIRC air changeover switch on the machine monitor.
7. Check the opening and closing motion of face door (5) of air conditioner unit (4).

8. After finishing the test, switch off the air conditioner.

HM400-3M0 80-39
80 Appendix
Testing FRESH/RECIRC air changeover

Testing FRESH/RECIRC air changeover (HM300-K5D2-001-K-00-A)

k Park the machine on a level ground, set the parking switch to "PARK", and then chock the wheels.

• FRESH/RECIRC air is selected by changing the door (damper) angle in the air conditioner unit with the
servo motor. Check the opening and closing operations of the door (damper) visually.
a The system does not have self-diagnosis function for FRESH/RECIRC air changeover servo motor.
Testing (HM300-K5D2-360-K-00-A)

1. Open recirculation air filter (1) and remove recirculation air filter (2).

2. Start the engine and switch on the air conditioner.

3. Operate the FRESH/RECIRC air changeover switch on the machine monitor.
4. Visually check the opening and closing motions of FRESH/RECIRC air changeover door (3).

5. After finishing the test, switch off the air conditioner.

80-40 HM400-3M0
 80 Appendix
Testing (dual) pressure switch for refrigerant

Testing (dual) pressure switch for refrigerant (HM300-K5FG-001-K-00-A)

k Park the machine on a level ground, set the parking switch to "PARK", and then chock the wheels.

k Turn the battery disconnect switch to the "OFF" position and pull out the key.

a Note connector numbers and installed positions when disconnecting wiring and hoses.
• If the self-diagnosis (electrical system abnormality record screen of machine monitor) displays
[879GKX]"Refrigerant error", check dual pressure switch connector HLS.
• To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF.
• The dual pressure switch is ON when the refrigerant pressure is normal, and OFF when it is abnormal.
a As the refrigerant pressure will drop when the ambient temperature is below 0 °C , there is a possibility
that the dual pressure switch is OFF. In such a case, the dual pressure switch is actually normal (i.e.,
not defective).
Testing (HM400-K5FG-360-K-00-A)

1. Open the engine hood.

2. Disconnect dual pressure switch connector HLS.

3. Check that the resistor between the terminals on the switch side of connector HLS is shorted (ON). (If not
shorted (OFF), the dual pressure switch has detects a refrigerant pressure abnormality.)
a When the dual pressure switch is OFF, connect a pressure gauge to the high-pressure side of the air
conditioner compressor and check the refrigerant pressure. See "Connection of service tool" and
"Troubleshooting with gauge pressure."
a If the refrigerant pressure is normal, the dual pressure switch is defective.
• (Dual) pressure switch

LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
k When replacing the dual pressure switch, refrigerant must be collected in advance.

HM400-3M0 80-41
80 Appendix
Testing (dual) pressure switch for refrigerant

a If the resistor between the terminals on the switch side of connector HLS is shorted (ON), perform "A-2
Troubleshooting for compressor and refrigerant system".

80-42 HM400-3M0
 80 Appendix
Testing relays

Testing relays (HM300-K5FE-001-K-00-A)

a If the air conditioner compressor is normal (air is cooled), the relays are normal. Accordingly, the test can
be omitted.
• Compressor clutch relay CCR:
Turns the air conditioner compressor (clutch) ON/OFF.
a See Step 2 on "Parts and connectors layout".
Testing (HM300-K5FE-360-K-00-A)

1. Remove cover (1).

2. Check the condition of contact of connector CCR. (Check whether the connector is partially
disconnected.)
3. Turn the starting switch ON (do not start the engine) and turn the main power of the air conditioner ON.
When the air conditioner is turned ON, the compressor relay will activate if it is normal. Check whether its
clicks.
a The air conditioner controller will not turn on the compressor clutch relay in the following cases.
1) When the evaporator temperature is below 3 °C (depending on the input voltage from the evaporator
temperature sensor).
2) When the pressure switch detects abnormality (it is turned OFF).

• Checking relay unit

a Since no T-adapter is available, it is impossible to check the relay while the voltage is applied to the coil
actually.
1. Connector (CCR) for compressor clutch relay
1) The coil resistance between terminals (1) and (2) is 300 to 500 z .
2) While voltage (20 to 30 VDC) is not applied between terminals (1) (+) and (2), terminals between (3)
and (4) are closed.
3) While voltage (20 to 30 VDC) is applied between terminals (1) (+) and (2), terminals between (3) and
(5) are connected.

HM400-3M0 80-43
80 Appendix
Testing relays

80-44 HM400-3M0
 80 Appendix
Troubleshooting chart 1

Troubleshooting chart 1 (PC220-3840-421-A-00-A)

Numbers in T represent the item numbers in the troubleshooting quick reference table.
1. Lowered cooling performance

2. Lowered heating performance

HM400-3M0 80-45
80 Appendix
Troubleshooting chart 2

Troubleshooting chart 2 (D65-3840-421-A-00-A)

1. During cooling, the blower fan motor does not operate or the rotation speed does not match the air flow
setting.
Probable cause Check method Remedy
Check connector for disconnection. Repair broken
Wire breakage or defective parts and connect
connection See "Parts and connectors layout". correctly
Operate the fan switch to each position and check the fan
Defective blower fan motor Replace
speed. See "Air conditioner unit".
Defective power transistor Operate the fan switches in order and check the fan
Replace
(PTR) speed.
2. During cooling, the blower fan motor is normal but the flow of air is very light.
Probable cause Check method Remedy
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Check the duct joints by referring to
Air leakage through duct joints Repair
"Testing air leakage (duct)."
Remove
Obstruction at evaporator inlet Check evaporator for stain and obstruction obstruction and
clean
Defective evaporator Evaporator is frozen.
temperature sensor, defective Sensor fixing clip inspection, sensor contaminated
contact of evaporator Inspect the air conditioner hose around the pressure Repair or replace
temperature sensor, defective switch for frost.
expansion valve* (when freezing has advanced even further)
*: The evaporator temperature sensor and expansion valve are located inside the air conditioner unit.
3. Pressure abnormality (high-pressure/low-pressure) during cooling.
Probable cause Check method Remedy
Repair leaking
part, then charge
Insufficient refrigerant with proper
Check the refrigerant volume through sight glass. quantity of
Specifically, perform checking with the gauge manifold refrigerant again
connected. Collect refrigerant,
then fill up with
Overcharge with refrigerant
proper quantity of
refrigerant again
Normal pressure range
Low-pressure: Approx. 0.13 to 0.2 MPa {1.3 to 2.0 kg/cm2 See
Judgment by pressure at } Troubleshooting
inlet/outlet of compressor High pressure: Approx. 1.5 to 1.7 MPa {15 to 17 kg/cm2 } with gauge
Temperature in operator's cab: 30 to 35 °C , Engine pressure
speed: Approx. 1,500 rpm

80-46 HM400-3M0
 80 Appendix
Troubleshooting chart 2

4. During cooling, the compressor does not operate easily or at all.

a See "Troubleshooting of compressor system (Air is not cooled)".
Troubled
Probable cause Check method Remedy
part
Compressor Deflection of belt is large. Adjust tension
Slack of belt
belt
Trouble in compressor Slip of belt Repair or replace
Compressor Insufficient compressor oil See "Handling
Heating of compressor
Seizing on compressor compressor oil".
Drop of battery voltage Slip of clutch Charge battery
Open or short circuit in coil Inspect with multimeter (10 to 20 z ) Replace
Magnet
Check the grounding and connections.
clutch Wire breakage or defective
See "Troubleshooting for compressor Repair
connection of ground wire
and refrigerant system".
Defective compressor clutch
Relay See "Testing relays" Replace
relay
See
Refrigerant Low/high pressure (Operation See "Troubleshooting with gauge "Troubleshooting
pressure of pressure switch) pressure". with gauge
pressure".
See "Troubleshooting for compressor
Pressure and refrigerant system".
Defective pressure switch Replace
switch See "Testing (dual) pressure switch for
refrigerant".
5. During heating, blower fan motor is normal but air flow alone is insufficient.
Probable cause Check method Remedy
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Air leakage through duct Check the duct joints by referring to "Testing air leakage
Repair
joints (duct)."
Clogging of heater core fins Check heater core fins for clogging Clean
6. Engine coolant temperature or volume abnormalities during heating or cooling
Probable cause Check method Remedy
Low engine coolant Warm up engine, and then check engine coolant
temperature temperature Find out cause
Low engine coolant level Check coolant level in radiator Add coolant
Insufficient circulation of Check engine coolant piping for clogging
engine coolant Bleed air and correct
(hoses, pipes, cores)
The connection of IN and
OUT heater hoses is in Check the destination of heater hoses Correct
reverse.
7. Fan speed abnormalities during cooling
Probable cause Check method Remedy
See "Testing and adjusting of Air conditioner compressor
Fan speed is low belt tension" in the "Testing and adjusting" of Chapter 30 Correct
of the shop manual.

HM400-3M0 80-47
80 Appendix
Troubleshooting chart 2

8. Other abnormalities
Probable cause Check method Remarks
Temperature cannot be Try to change the temperature setting in manual mode.
controlled
Vent (mode) changeover is Common to cooling
See "Testing vent (mode) changeover".
not possible and heating
FRESH/RECIRC air
See "Testing FRESH/RECIRC air changeover".
cannot be changed over
Excessive compressor oil See "Handling compressor oil".
Cooling only
Water leakage into the cab Clogging of drain hole

80-48 HM400-3M0
 80 Appendix
Information in troubleshooting table

Information in troubleshooting table (ALL-5170-421-A-03-A)

Information in troubleshooting table
a The following information is summarized in the troubleshooting table. Before performing troubleshooting,
understand that information fully.
Failure Failure symptom that appears on machine
Related information Information on occurred failure or troubleshooting
Cause Procedure, measuring location, criteria and remarks
[Information described]
• Procedure
• Measuring location
1
a "Between A and B" denotes measuring voltage or resistance, etc.
Probable cause of failure between A and B.
(Perform troubleshooting • Criteria to determine probable causes
according to these.) • Remarks for judgment of Good or No good
[Notes on troubleshooting]
2 (1) pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (-) tester leads
as shown below unless otherwise specified.
• Connect the plus (+) lead to a pin or harness indicated in the
front.
• Connect the minus (-) lead to a pin or harness indicated in the
rear.
3 Defective — (2) Example of troubleshooting done by testing multiple items
a Normal in 1 but abnormal in 2
At this time, "Defective component" shown at left 3 is applied.

a If a wiring harness is burnt, replace it.

[Defective wiring harness]
• Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth)
circuit or chassis accidentally.
• Hot short circuit
A harness not to be connected to the power (24V) circuit comes into contact with the power (24V) circuit
accidentally.
• Short circuit
An independent wire in the harness abnormally comes into contact with another independent wire. (poor
insulation at connector and others)

Related circuit diagram

This is the extracted circuit diagram related to failure
• Indicates connector No., and pin No.
• See "Circuit diagram and arrangement of connector pins" and "Parts and connectors layout" for
connector location
• The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr:
Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are two colors
Example: WY: Yellow line on white background
a The number before the wire color indicates the wire size.
• N.C.: Normally closed (Normally ON)
• [1], [2], ... are numbers of unlabeled connectors.
• The arrow (io) indicates their rough installation position on the machine.

HM400-3M0 80-49
80 Appendix
Failure code list related to air conditioner

Failure code list related to air conditioner (HM300-K500-441-K-00-A)

Compo-
Failure (Displayed on Action Category
Failure code nent in Remarks
screen) level of record
charge
A/C Inner Sensor Open Electrical Troubleshooting cannot be
879AKA MON –
Circuit system performed while the
controller is mounted on
A/C Inner Sensor Short Electrical the machine since the
879AKB MON –
Circuit system connector cannot be
checked.
A/C Outer Sensor Open Electrical
879BKA MON –
Circuit system
A/C Outer Sensor Short Electrical
879BKB MON –
Circuit system
Ventilating Sensor Open Electrical Troubleshooting cannot be
879CKA MON –
Circuit system performed while the
controller is mounted on
Ventilating Sensor Short Electrical the machine since the
879CKB MON –
Circuit system connector cannot be
checked.
Ventilation Dumper Electrical Troubleshooting cannot be
879EMC Abnormality MON L01 system performed while the
controller is mounted on
Air Mix Dumper Electrical the machine since the
879FMC Abnormality MON L01 system connector cannot be
checked.
Electrical
879GKX Refrigerant Abnormality MON L01 system
A/C Model Selection Electrical
DAZ9KQ MON –
Abnormality system See Chapter 40,
"Troubleshooting by failure
CAN2 Discon (Aircon Electrical
DAZQKR MON L01 code"
ECU) system

a The air conditioner inner sensor means the inside (air) temperature sensor.
a The air conditioner outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The ventilation damper means the vent (mode) changeover damper (door).
a The air mix damper means the temperature adjustment (air mix) damper (door).
a Troubleshooting for the troubles which do not display failure codes
• Troubleshooting for power supply system (Air conditioner does not operate)
• Troubleshooting for compressor and refrigerant system (Air is not cooled)
• Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
• Troubleshooting for FRESH/RECIRC air changeover

80-50 HM400-3M0
 80 Appendix
Failure code [879AKA] A/C Inner sensor Open Circuit

Failure code [879AKA] A/C Inner sensor Open Circuit (PC220_10-879AKA-400-A-00-A)

Action Air conditioner inside air temperature sensor disconnection

Failure code
level Failure
— (Machine monitor system)
879AKA
Details of • Air conditioner controller detected disconnection in inside (air) temperature sensor.
failure
• The air conditioner controller sends information about the inside (air) temperature sensor
Action of disconnection to the machine monitor via CAN communication.
controller • Stops the air conditioner if it is in automatic mode.
• The air conditioner does not operate in automatic mode because of a disconnection in the
Problem on air conditioner inside air temperature sensor.
machine (The air conditioner can be operated in manual mode)
• Method of reproducing failure code: Turn starting switch to ON position.
• Check whether this failure code is displayed in the "Electrical Systems" screen of the
Related electrical system in the service mode of the machine monitor.
information • Troubleshooting cannot be performed since the connector portion of the air conditioner
inside (air) temperature sensor cannot be checked while the controller is installed on the
machine.
No. Cause Procedure, measuring location, criteria and remarks
Defective air If no failures are found by the above checks, the air conditioner controller may be
1 conditioner defective.
controller (Since this is an internal defect, troubleshooting cannot be performed.)
If no failures are found by the above checks, the air conditioner unit may be
Defective air defective.
2
conditioner unit
(Since this is an internal defect, troubleshooting cannot be performed.)

HM400-3M0 80-51
80 Appendix
Failure code [879AKB] A/C Inner sensor Short Circuit

Failure code [879AKB] A/C Inner sensor Short Circuit (PC220_10-879AKB-400-A-00-A)

Action Air conditioner inside air temperature sensor short circuit

Failure code
level Failure
— (Machine monitor system)
879AKB
Details of • Air conditioner controller detected short circuit in inside (air) temperature sensor.
failure
• The air conditioner controller sends information about the inside (air) temperature sensor
Action of short circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner if it is in automatic mode.
• The air conditioner does not operate in automatic mode because of a short circuit in the
Problem on air conditioner inside air temperature sensor.
machine (The air conditioner can be operated in manual mode)
• Method of reproducing failure code: Turn starting switch to ON position.
• Check whether this failure code is displayed in the "Electrical Systems" screen of the
Related electrical system in the service mode of the machine monitor.
information • Troubleshooting cannot be performed since the connector portion of the air conditioner
inside (air) temperature sensor cannot be checked while the controller is installed on the
machine.
No. Cause Procedure, measuring location, criteria and remarks
Defective air If no failures are found by the above checks, the air conditioner controller may be
1 conditioner defective.
controller (Since this is an internal defect, troubleshooting cannot be performed.)
If no failures are found by the above checks, the air conditioner unit may be
Defective air defective.
2
conditioner unit
(Since this is an internal defect, troubleshooting cannot be performed.)

80-52 HM400-3M0
 80 Appendix
Failure code [879BKA] A/C Outer sensor Open Circuit

Failure code [879BKA] A/C Outer sensor Open Circuit (HM300_3-879BKA-400-A-Z0-A)

Action level Failure code Open circuit in air conditioner outside air temperature
Failure sensor
– 879BKA
(Machine monitor system)
Detail of • An open circuit is detected in the air conditioner controller outside air temperature sensor
failure
• The air conditioner controller sends information about the outside air temperature sensor
Action of open circuit to the machine monitor via CAN communication.
controller • Continues control of air conditioner in automatic mode, ignoring data of outside air
temperature sensor.
• Since there is an open circuit in the air conditioner outside temperature sensor, outside
Problem on temperature is not counted in automatic mode.
machine (does not have any effect to the air conditioner in manual mode)
• Method of reproducing failure code: Turn starting switch to ON position.
• Check whether this failure code is displayed in the "Electrical Systems" (electrical
systems abnormality record) screen in the service mode of the machine monitor.
• For connectors etc., see "Parts and connectors layout".
Related • Since connector ACECU of the air conditioner controller has small pins and does not
information have a T-adapter, perform troubleshooting by using the intermediate connector (Although
the intermediate connector does not have a T-adapter either, it does have large pins).
• To replace the air conditioner harness between air conditioner controller connector
ACECU and intermediate controller, the air conditioner unit must be replaced.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective outside air 2. Disconnect connector OTS.
1 temperature sensor Resis- Between OTS (male) (1) and (2) Approx.
25 °C
tance 1.7 kz
1. Turn starting switch to OFF position.
2. Disconnect connector AC01.
Open or short circuit in wiring
2 a Same as above, if resistance is normal.
harness
Resis- Between AC01 (female) (3) and (4) Approx.
25 °C
tance 1.7 kz
a If no failure is found by check for cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors OTS and AC01.
3 (wire breakage or defective Between AC01 (female) (3) and OTS (female)
contact of connector) Max. 1 z
Resis- (2)
tance Between AC01 (female) (4) and OTS (female)
(1) Max. 1 z
If no failures are found by the above checks, the air conditioner
Defective air conditioner controller may be defective. (Since this is an internal defect,
4
controller troubleshooting cannot be performed.)
If no failure is found by above checks, air conditioner unit may be
5 Defective air conditioner unit
defective.

HM400-3M0 80-53
80 Appendix
Failure code [879BKA] A/C Outer sensor Open Circuit

Circuit diagram related to air conditioner outside air temperature sensor

80-54 HM400-3M0
 80 Appendix
Failure code [879BKB] A/C Outer sensor Short Circuit

Failure code [879BKB] A/C Outer sensor Short Circuit (HM300_3-879BKB-400-A-Z0-A)

Action level Failure code Short circuit in air conditioner outside air temperature
Failure sensor
– 879BKB
(Machine monitor system)
Detail of • Air conditioner controller detected short circuit in outside air temperature sensor.
failure
• The air conditioner controller sends information about the outside air temperature sensor
Action of short circuit to the machine monitor via CAN communication.
controller • Continues control of air conditioner in automatic mode, ignoring data of outside air
temperature sensor.
• Since there is a short circuit in the air conditioner outside air temperature sensor, outside
Problem on temperature is not counted in automatic mode.
machine (does not have any effect to the air conditioner in manual mode)
• Method of reproducing failure code: Turn starting switch to ON position.
• Check whether this failure code is displayed in the "Electrical Systems" (electrical
systems abnormality record) screen in the service mode of the machine monitor.
• For connectors etc., see "Parts and connectors layout".
Related • Since connector ACECU of the air conditioner controller has small pins and does not
information have a T-adapter, perform troubleshooting by using the intermediate connector (Although
the intermediate connector does not have a T-adapter either, it does have large pins).
• To replace the air conditioner harness between air conditioner controller connector
ACECU and intermediate controller, the air conditioner unit must be replaced.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective outside air 2. Disconnect connector OTS.
1 temperature sensor Resis- Between OTE (male) (1) and (2) Approx.
25 °C
tance 1.7 kz
1. Turn starting switch to OFF position.
2. Disconnect connector AC01.
Open or short circuit in wiring
2 a Same as above, if resistance is normal.
harness
Resis- Between AC01 (female) (3) and (4) Approx.
25 °C
tance 1.7 kz
a If no failure is found by check for cause 2, this check is not required.
1. Turn starting switch to OFF position.
3 Short circuit in wiring harness 2. Disconnect connectors OTS and AC01.
Resis- Between AC01 (female) (3) and (4), or between
OTS (female) (1) and (2) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors OTS and AC01.
4
(contact with ground circuit) Resis- Between ground and AC01 (female) (3) or OTS
(female) (2) Min. 1 Mz
tance
If no failures are found by the above checks, the air conditioner
Defective air conditioner controller may be defective. (Since this is an internal defect,
5
controller troubleshooting cannot be performed.)
If no failure is found by above checks, air conditioner unit may be
6 Defective air conditioner unit
defective.

HM400-3M0 80-55
80 Appendix
Failure code [879BKB] A/C Outer sensor Short Circuit

Circuit diagram related to air conditioner outside air temperature sensor

80-56 HM400-3M0
 80 Appendix
Failure code [879CKA] Ventilating sensor Open Circuit

Failure code [879CKA] Ventilating sensor Open Circuit (PC220_10-879CKA-400-A-00-A)

Action Evaporator temperature (frost) sensor disconnection

Failure code
level Failure
— (Machine monitor system)
879CKA
Details of • Air conditioner controller detected disconnection in evaporator temperature (frost) sensor.
failure
• Th air conditioner controller sends information about the evaporator temperature (frost)
Action of sensor disconnection to the machine monitor via CAN communication.
controller • Stops the air conditioner.
Problem on • The air conditioner does not operate due to a disconnection in the evaporator
machine temperature (frost) sensor.
• Method of reproducing failure code: Turn starting switch to ON position.
• Check whether this failure code is displayed in the "Electrical Systems" screen of the
Related electrical system in the service mode of the machine monitor.
information • Troubleshooting cannot be performed since the connector portion of the evaporator
temperature (frost) sensor cannot be checked while the air conditioner unit is installed on
the machine.
No. Cause Procedure, measuring location, criteria and remarks
Defective air If no failures are found by the above checks, the air conditioner controller may be
1 conditioner defective.
controller (Since this is an internal defect, troubleshooting cannot be performed.)
If no failures are found by the above checks, the air conditioner unit may be
Defective air defective.
2
conditioner unit
(Since this is an internal defect, troubleshooting cannot be performed.)

HM400-3M0 80-57
80 Appendix
Failure code [879CKB] Ventilating sensor Short Circuit

Failure code [879CKB] Ventilating sensor Short Circuit (PC220_10-879CKB-400-A-00-A)

Action Evaporator temperature (frost) sensor short circuit

Failure code
level Failure
— (Machine monitor system)
879CKB
Details of • Air conditioner controller detected short circuit in evaporator temperature (frost) sensor.
failure
• The air conditioner controller sends information about the evaporator temperature (frost)
Action of sensor short circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner.
Problem on • The air conditioner does not operate due to a short circuit in the evaporator temperature
machine (frost) sensor.
• Method of reproducing failure code: Turn starting switch to ON position.
• Check whether this failure code is displayed in the "Electrical Systems" screen of the
Related electrical system in the service mode of the machine monitor.
information • Troubleshooting cannot be performed since the connector portion of the evaporator
temperature (frost) sensor cannot be checked while the air conditioner unit is installed on
the machine.
No. Cause Procedure, measuring location, criteria and remarks
Defective air If no failures are found by the above checks, the air conditioner controller may be
1 conditioner defective.
controller (Since this is an internal defect, troubleshooting cannot be performed.)
If no failures are found by the above checks, the air conditioner unit may be
Defective air defective.
2
conditioner unit
(Since this is an internal defect, troubleshooting cannot be performed.)

80-58 HM400-3M0
 80 Appendix
Failure code [879EMC] Ventilating Damper Abnormality

Failure code [879EMC] Ventilating Damper Abnormality (PC220_10-879EMC-400-A-00-A)

Action Abnormality in vent (mode) changeover damper servomotor

Failure code
level Failure
(Machine monitor system)
L01 879EMC
Details of • Air conditioner controller judged from potentiometer voltage of servomotor that vent
failure (mode) changeover damper servomotor is not operating.
Action of • The air conditioner controller sends information about the abnormality in vent (mode)
controller changeover damper to the machine monitor via CAN communication.
Problem on • Vent (mode) cannot be changed but air conditioner can be operated.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
• Check whether this failure code is displayed in the "Electrical Systems" screen of the
Related electrical system in the service mode of the machine monitor.
information • Troubleshooting cannot be performed since the connector portion of vent (mode)
changeover damper servomotor cannot be checked while the air conditioner unit is
installed on the machine.
No. Cause Procedure, measuring location, criteria and remarks
Defective air If no failures are found by the above checks, the air conditioner controller may be
1 conditioner defective.
controller (Since this is an internal defect, troubleshooting cannot be performed.)
If no failures are found by the above checks, the air conditioner unit may be
Defective air defective.
2
conditioner unit
(Since this is an internal defect, troubleshooting cannot be performed.)

HM400-3M0 80-59
80 Appendix
Failure code [879FMC] Air Mix Damper Abnormality

Failure code [879FMC] Air Mix Damper Abnormality (PC220_10-879FMC-400-A-00-A)

Action Abnormality in air mix (temperature regulation) damper

Failure code
level Failure servomotor
L01 879FMC (Machine monitor power train control system)
Details of • The air conditioner controller judged from the potentiometer voltage of the servomotor
failure that the air mix (temperature regulation) damper servomotor is not operating.
Action of • The air conditioner controller sends information about the air mix damper abnormality to
controller the machine monitor via CAN communication.
Problem on • The air conditioner does not operate since temperature cannot be regulated.
machine
• Method of reproducing failure code: Turn starting switch ON position.
• Check whether this failure code is displayed in the "Electrical Systems" screen of the
Related
electrical system in the service mode of the machine monitor.
information
• Troubleshooting cannot be performed since the connector part of the air mix damper
servomotor cannot be checked while the air conditioner unit is installed on the machine.
No. Cause Procedure, measuring location, criteria and remarks
Defective air If no failures are found by the above checks, the air conditioner controller may be
1 conditioner defective.
controller (Since this is an internal defect, troubleshooting cannot be performed.)
If no failures are found by the above checks, the air conditioner unit may be
Defective air defective.
2
conditioner unit
(Since this is an internal defect, troubleshooting cannot be performed.)

80-60 HM400-3M0
 80 Appendix
Failure code [879GKX] Refrigerant Abnormality

Failure code [879GKX] Refrigerant Abnormality (HM300_3-879GKX-400-A-Z0-A)

Action level Failure code Refrigerant (dual) pressure switch abnormality

Failure
L01 879GKX (Machine monitor system)
Detail of • Air conditioner controller detected that dual pressure switch was OFF (abnormal).
failure
• The air conditioner controller sends information about the refrigerant pressure abnormality
to the machine monitor via CAN communication.
Action of • The air conditioner controller turns OFF compressor clutch relay, since refrigerant
controller pressure is abnormal.
(air conditioner compressor stops)
Problem on • Air conditioner (cooling) does not work
machine
• Method of reproducing failure code: Turn starting switch to ON position.
• Check whether this failure code is displayed in the "Electrical Systems" (electrical
systems abnormality record) screen in the service mode of the machine monitor.
• For connectors etc., see "Parts and connectors layout".
Related • Since connector ACECU of the air conditioner controller has small pins and does not
information have a T-adapter, perform troubleshooting by using the intermediate connector (Although
the intermediate connector does not have a T-adapter either, it does have large pins).
• To replace the air conditioner harness between air conditioner controller connector
ACECU and intermediate controller, the air conditioner unit must be replaced.
No. Cause Procedure, measuring location, criteria and remarks
1. See "Testing (dual) pressure switch for refrigerant".
Defective refrigerant (dual)
1 pressure switch k When replacing the dual pressure switch, be sure to collect
refrigerant in advance. See "Caution for refrigerant"
1. Turn starting switch to OFF position.
2. Disconnect connectors AC01 and HLS.
Open circuit in wiring harness Between HLS (female) (1) and AC01 (female)
(5) Max. 1 z
2 (wire breakage or defective
contact of connector) Resis- Between HLS (female) (2) and ground
tance
a Check ground terminal ER2 for looseness Max. 1 z
and rust.
If no failures are found by the above checks, the air conditioner
Defective air conditioner controller may be defective. (Since this is an internal defect,
3
controller troubleshooting cannot be performed.)
If no failure is found by above checks, air conditioner unit may be
4 Defective air conditioner unit
defective.

HM400-3M0 80-61
80 Appendix
Failure code [879GKX] Refrigerant Abnormality

Circuit diagram related to refrigerant (dual) pressure switch

80-62 HM400-3M0
 80 Appendix
A-1 Troubleshooting for power supply system (Air
conditioner does not operate)

A-1 Troubleshooting for power supply system (Air conditioner does not
operate) (HM300_3-FJ0-400-A-Z0-A)
Failure Air conditioner does not operate due to power supply system failure.
Problem on • [DAZQKR] is displayed on the operation screen of machine monitor.
machine • No air blows out (Blower motor does not rotate).
• If failure code [DAZQKR] is displayed on the machine monitor, carry out this
troubleshooting first.
a The machine monitor (meter unit), engine controller, monitor controller, transmission
controller, retarder hoist controller, KOMTRAX terminal and air conditioner controller are
connected via CAN communication.
• [DAZQKR] is displayed on the operation screen of machine monitor in the following
cases. In this section, 1. and 2. of the following are explained.
1. The air conditioner controller is receiving no power.
2. The air conditioner controller is malfunctioning.
3. No communication is possible between the air conditioner controller and the machine
monitor.
a See failure code [DAZQKR] for item 3.
Related • Turn the starting switch to the ON position and check whether if failure code [DAZQKR] is
information displayed on the machine monitor and whether CAN communication is abnormal. This
type of abnormal status indicates that CAN communication cannot be performed between
the air conditioner controller above the air conditioner unit and the machine monitor.
• Referring to "Parts and connectors layout", check fuse No. 18 (5 A) in fuse box BT4 for
breakage.
• Ground cable of air conditioner is connected in machine wiring harness together with
electrical equipment of machine.
• For each connector, see "Parts and connectors layout".
• In cases where fuses are blown when the A/C switch is pressed, see "Troubleshooting for
compressor and refrigerant system."
• Since connector ACECU of the air conditioner controller has small pins and does not have
a T-adapter, perform troubleshooting by using the intermediate connector (Although the
intermediate connector does not have a T-adapter either, it does have large pins).
• To replace the air conditioner harness between air conditioner controller connector
ACECU and intermediate controller, the air conditioner unit must be replaced.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective wiring 2. Turn battery disconnect switch to OFF position.
1 harness (ground) 3. Disconnect connector AC02.
Between (1) (black) on the harness side of
Resistance connector AC02 and chassis ground Max. 1 z

1. Turn starting switch to OFF position.

2 Blown fuse 2. Referring to "Parts and connectors layout", check fuse No. 18 (5 A) in fuse
box BT4.
a If fuse described in related information is blown, replace it.
1. Turn starting switch to OFF position.
Defective wiring 2. Turn battery disconnect switch to OFF position.
3 3. Disconnect connector AC02.
harness
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Voltage Between AC02 (female) (blue) and (1) (black) 20 to 30 V
a If fuse is blown again in the above test, perform the following procedure.
Ground fault in wiring 1.Turn starting switch to OFF position.
harness 2.Turn battery disconnect switch to OFF position.
4 3.Disconnect connector AC02.
(contact with ground
circuit) 4.Remove fuse No. 18 in fuse box BT4.
Min. 1 Mz
Resistance Between ground and AC02 (4) (blue) or BT4-18

HM400-3M0 80-63
80 Appendix
A-1 Troubleshooting for power supply system (Air
conditioner does not operate)

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Turn battery disconnect switch to OFF position.
Open circuit in wiring
5 3. Disconnect connector AC02.
harness
4. Remove fuse No. 18 in fuse box BT4.
Resistance Between AC02 (female) (4) (blue) and BT4-18 Min. 1 Mz
Defective air conditioner Replace the air conditioner controller as a trial.
6
controller
Defective air conditioner If no failure is found by above checks, air conditioner unit may be defective.
7
unit
Defective machine If no failure is found by above checks, machine monitor is defective.
8
monitor

Electrical diagram related to power supply

80-64 HM400-3M0
 80 Appendix
A-2 Troubleshooting for compressor and refrigerant
system (Air is not cooled)

A-2 Troubleshooting for compressor and refrigerant system (Air is not

cooled) (HM300_3-FKE-400-A-Z0-A)
Failure Air is not cooled due to compressor or refrigerant system failure.
• When engine is started and A/C switch is pressed on air conditioner screen of machine
Problem on monitor, air is not cooled as displayed on screen.
machine • Air conditioner compressor does not operate.
• Referring to "Testing with self-diagnosis function", display "Electrical Systems" (electrical
systems abnormality record) screen in service mode of the machine monitor and check to
see if the refrigerant pressure is abnormal, by checking whether failure code [879GKX] is
displayed. If the refrigerant pressure is abnormal, the compressor will not be turned ON
and air will not subsequently be cooled.
a Abnormal refrigerant pressure indicates that "Signal ((21) of connector ACECU) from the
dual pressure switch is not grounded".
Related • In certain cases, the air conditioner will not turn on at 3 °C or lower (normal).
information • If air does not come out, see "Troubleshooting of blower motor system".
• For each connector and fuse, see "Parts and connectors layout".
a T-adapter is not available for connectors other than connector CM.
• Since connector ACECU of the air conditioner controller has small pins and does not have
a T-adapter, perform troubleshooting by using the intermediate connector (Although the
intermediate connector does not have a T-adapter either, it does have large pins).
• To replace the air conditioner harness between air conditioner controller connector
ACECU and intermediate controller, the air conditioner unit must be replaced.
No. Cause Procedure, measuring location, criteria and remarks
a If failure code [879GKX] is displayed on the electrical system abnormality
record screen of the machine monitor, perform following procedure.
See failure code [879GKX].
Defective dual pressure a In certain cases, the dual pressure switch may be operating normally and
1 switch system set to OFF, therefore, if abnormality is indicated (i.e., switch OFF), attach a
pressure gauge to the air conditioner compressor and check the
refrigerant pressure. (See "Troubleshooting with gauge pressure.")
k Before replacing pressure switch, collect refrigerant.
1. Turn starting switch to OFF position.
2. Disconnect connector CM from air conditioner compressor and connect T-
adapters to male side.
Defective air conditioner a Ensure connection of air conditioner compressor ground cable (E).
2 compressor (See "Parts and connectors layout".)
Between connector CM (male) (1) and chassis Approx. 15
Resistance ground (to measure resistance of air conditioner z
compressor coil)

HM400-3M0 80-65
80 Appendix
A-2 Troubleshooting for compressor and refrigerant
system (Air is not cooled)

No. Cause Procedure, measuring location, criteria and remarks

• Referring to "Testing relays", check sound when compressor clutch relay
is turned ON.
Click is heard. ... A
a When A above is abnormal and B below is abnormal and C is normal (if
the relay is normal), go to cause 4.
1. Turn starting switch to OFF position.
Defective compressor 2. Disconnect connector CCR.
3 clutch relay (does not 3. Use a wire to short (3) (yellow) to (5) (blue) of connector CCR (wiring
turn ON) harness side) (to start compressor forcibly without using the relay).
4. Turn starting switch to ON position.
Air is cooled. ... B
1. Turn starting switch to OFF position.
2. Disconnect connector CCR and perform troubleshooting in that condition.
Between CCR (male) (1) and (2) (to 300 to
Resistance measure coil resistance) C
500 z
1. Turn starting switch to OFF position.
2. Disconnect connector CCR and perform troubleshooting with starting
switch at OFF position.
a Ensure that test result for cause 2 is normal (air conditioner compressor is
normal).
Open circuit in wiring Between CCR (female) (5) and BT1-16
4 Max. 1 z
harness (Pressure switch is turned ON)
Between CCR (female) (3) and chassis ground Approx. 15
Resistance (Air conditioner compressor coil resistance) z
Between BT4-18 and AC01 (female) (7) 300 to 500
a Relay coil resistance z

Ground fault in wiring a If the fuse is not blown, skip troubleshooting.

harness 1. Turn starting switch to OFF position.
5 2. Disconnect connectors CM and CCR, and connect T-adapters to female
(contact with ground
circuit) side of connector CM.
Resistance Between CM (female) (1) and chassis ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors AC01, AC02, and CCR.
Short circuit in wiring
6 a Ensure that test result for cause 2 is normal.
harness
Between CCR (harness side) (2) and each of AC02
Resistance (female) (2), (3), and (4) Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connector CCR.
Defective air conditioner 3. Turn starting switch to ON position.
7
controller 4. Display the air conditioner operation screen on the machine monitor and
press the A/C switch.
Voltage Between CCR (female) (2) and chassis ground Max. 1 V
Defective machine 1. Turn starting switch to ON position.
8 monitor 2. Display the air conditioner operation screen on the machine monitor.
(defective switch) Press A/C switch. "A/C ON" is displayed
Defective air conditioner If no failure is found by above checks, air conditioner unit may be defective.
9
unit

80-66 HM400-3M0
 80 Appendix
A-2 Troubleshooting for compressor and refrigerant
system (Air is not cooled)

Circuit diagram related to compressor and refrigerant system

HM400-3M0 80-67
80 Appendix
A-3 Troubleshooting for blower motor system (No air
comes out or air flow is abnormal)

A-3 Troubleshooting for blower motor system (No air comes out or air
flow is abnormal) (HM300_3-FK3-400-A-Z0-A)
Failure No air comes out or air flow is abnormal due to blower motor system failure.
• LCD of machine monitor on air conditioner operation screen lights up normally but air
Problem on does not come out.
machine • Air flow does not match setting made by using fan switch on air conditioner operation
screen.
• This failure is not checked with self-diagnosis function.
• In cooling operation, if blown-air volume becomes unusual after certain period of time,
evaporator may freeze.
This may be due to the followings.
1. Defective compressor clutch relay (i.e., stuck in ON position) (see item 3 A of
"Troubleshooting for compressor and refrigerant system")
2. Detachment of the evaporator temperature sensor's mounting holder (Replace air
conditioner unit)
3. Incorrect adjustment of the expansion valve (Replace air conditioner unit)
• If air comes out, fuse and relay are normal and wiring harness is seldom abnormal.
Related • For each connector and power transistor, see "Parts and connectors layout".
information a The power transistor is on the rear side of the air conditioner unit.
• In heating operation, if warm air blows out but air flow rate is unusual, power transistor
may be defective. Note that power transistor cannot be replaced with air conditioner unit
installed on machine. (If warm air does not blow out, power transistor may be defective.)
a Blower motor cannot be replaced unless air conditioner unit is once removed.
• Since connector ACECU of the air conditioner controller has small pins and does not
have a T-adapter, perform troubleshooting by using the intermediate connector (Although
the intermediate connector does not have a T-adapter either, it does have large pins).
• To replace the air conditioner harness between air conditioner controller connector
ACECU and intermediate controller, the air conditioner unit must be replaced.
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse No. 10 in fuse If fuse is blown, circuit probably has ground fault.
1
box F01
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connector AC02.
2 (wire breakage or defective 3. Remove fuse-14 in fuse box BT1.
contact of connector) Resis- Between AC02 (female) (2) and BT1-14
Max. 1 z
tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connector AC02.
3 3. Remove fuse-14 in fuse box BT1.
(contact with ground circuit)
Resis- Between ground and AC02 (female) (2) or BT1-
Max. 1 z
tance 14
If no failures are found by the above checks, the air conditioner
Defective air conditioner controller may be defective. (Since this is an internal defect,
4
controller troubleshooting cannot be performed.)
If no failure is found by above checks, air conditioner unit may be
5 Defective air conditioner unit
defective.

80-68 HM400-3M0
 80 Appendix
A-3 Troubleshooting for blower motor system (No air
comes out or air flow is abnormal)

Circuit diagram related to blower motor system

HM400-3M0 80-69
80 Appendix
A-4 Troubleshooting for FRESH/RECIRC air changeover

A-4 Troubleshooting for FRESH/RECIRC air changeover (HM300_3-FKF-400-A-Z0-A)

Failure FRESH/RECIRC air cannot be changed over

• When FRESH/RECIRC air selector switch of machine monitor is operated, recirculated or
Problem on fresh air does not change over.
machine (FRESH/RECIRC air changeover door (damper) does not rotate)
• FRESH/RECIRC air changeover is not checked with self-diagnosis function.
• Referring to "Testing FRESH/RECIRC air changeover", operate the FRESH/RECIRC air
selector switch and confirm the operation of the FRESH/RECIRC air changeover door
(damper).
• For each connector, see "Parts and connectors layout".
a The T-adapter is not prepared for the connector.
Related • Since connector ACECU of the air conditioner controller has small pins and does not
information have a T-adapter, perform troubleshooting by using the intermediate connector (Although
the intermediate connector does not have a T-adapter either, it does have large pins).
• To replace the air conditioner harness between air conditioner controller connector
ACECU and intermediate controller, the air conditioner unit must be replaced.
• Method of reproducing failure code: Turn starting switch to ON position.
• Troubleshooting cannot be performed since the connector portion of the servomotor
cannot be checked while it is installed on machine.
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse 2 in fuse box If fuse is blown, circuit probably has ground fault.
1
BT2
a Connector [5] installed on machine cannot be disconnected since it
is on the rear side of the air conditioner unit.
Open circuit in wiring harness
1. Turn starting switch to OFF position.
2 (wire breakage or defective 2. Disconnect connector AC02.
contact of connector) 3. Remove fuse-2 in BT2.
Resis- Between BT2-2 and AC02 (female) (3)
Max. 1 z
tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connector AC02.
3 (contact with ground circuit) 3. Remove fuse-2 in BT2.
Resis- Between ground and BT2-2 or AC02 (female)
(3) Max. 1 z
tance
If no failures are found by the above checks, the air conditioner
Defective air conditioner controller may be defective. (Since this is an internal defect,
4
controller troubleshooting cannot be performed.)
If no failures are found by the above checks, the air conditioner unit may
5 Defective air conditioner unit be defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
1. Turn starting switch to ON position.
Defective machine monitor 2. Display the air conditioner operation screen on the machine monitor.
6
(defective switch) Display of Recirc/Fresh
Press FRESH/RECIRC air selector switch. changes.

80-70 HM400-3M0
 80 Appendix
A-4 Troubleshooting for FRESH/RECIRC air changeover

Circuit diagram related to FRESH/RECIRC air changeover

HM400-3M0 80-71
80 Appendix
Troubleshooting with gauge pressure

Troubleshooting with gauge pressure (PC220-3840-362-A-00-A)

Perform troubleshooting according to the high and low gauge pressures of the cooling cycle. For details, see
"Connection of service tool".
a The gauge pressure varies largely with the weather condition and operating condition of the machine.
Check the gauge pressure under the pressure measurement conditions.
• Pressure of high-pressure line is too high: Min. approx. 2.5 MPa {25 kg/cm 2}
• Pressure of high-pressure line is too low: Max. approx. 1 MPa {10 kg/cm 2}
• Pressure of low-pressure line is too high: Min. approx. 0.3 MPa {3 kg/cm 2}
• Pressure of low-pressure line is too low: Max. approx. 0.05 MPa {0.5 kg/cm 2}
a Dual pressure switch turns "OFF" to protect the air conditioner circuit if the pressure of the high-pressure
or low-pressure line is abnormal.
[Measurement condition for pressure]
Item Condition value
Ambient temperature 25 to 50 °C
Engine speed 1,500 rpm
Air conditioner switch ON
Fan switch HI
Set temperature Cool-Max
• Dual pressure switch
a The switch is normally "ON", and becomes "OFF" when it detects abnormal pressure for compressor
operation.

LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}

80-72 HM400-3M0
 80 Appendix
Troubleshooting with gauge pressure

Indicated gauge pressure Cause Check method Remedy

Air conditioner cycle is operating normally.
If any problem (poor cooling) is recognized, the cause
is in other system.
Pressure is normal Pressure of high-pressure line: Approx. 1.5 to -1.7 ―
MPa {15 to 17 kg/cm2}
Pressure of low-pressure line: Approx. 0.13 to 0.2
MPa {1.3 to 2.0 kg/cm2}
Collect refrigerant, then fill
Bubbles can be seen
Insufficient refrigerant up with proper quantity of
through sight glass. *1, *3
refrigerant again. *2
Temperature difference is
recognized between inlet
Clogging of receiver drier and outlet pipes of Replace *2
receiver drier.
Tank is frosty.
Clogging of expansion Expansion valve is frosty. Clean or replace *2
valve
Gas leakage at
<Pressure of both high- Low-pressure line gauge Replace *2
thermoprobe of expansion
pressure and low- reads vacuum.
valve
pressure lines are too
Evaporator is frozen.
low>
Flow rate of refrigerant is Repair or replace
Low-pressure line gauge Defective evaporator
reduced due to freezing.
reads vacuum temperature sensor or Replace receiver drier.
defective contact of (If air conditioner is set to
Collect refrigerant, then fill
sensor (coming off of Cool Max. and HI fan
up with proper quantity of
mounting clip) speed modes, later its
refrigerant again. *2
cooling performance
lowers.)
Piping between receiver
drier and compressor is
clogged or crushed.
Clogged or crushed piping Clean or replace *2
If clogged completely, low-
pressure line gauge reads
vacuum
Collect refrigerant, then fill
Filling of too much
Connect gauge manifold. up with proper quantity of
refrigerant
refrigerant again. *2
Check condenser for dirt, Clean condenser, repair
Defective cooling of fins for clogging or fins, or repair or replace
condenser crushing, and cooling fan cooling fan *2
<Pressure of both high- for defective rotation.
pressure and low- Defective adjustment of
pressure lines are too expansion valve Bubbles can be seen
high> Replace *2
(Valve is excessively through sight glass. *3
opened.)
Evacuate air from air
Air sucked in cooling Bubbles can be seen conditioner and then fill up
cycle parts through sight glass. *3 with proper quantity of
refrigerant again. *2

HM400-3M0 80-73
80 Appendix
Troubleshooting with gauge pressure

Indicated gauge pressure Cause Check method Remedy

<Pressure of high- Piping between Remarkable temperature Clean inside of cooling
pressure line is too high compressor and difference is recognized cycle parts or replace
and that of low-pressure condenser is Clogged or across clogged part. them.*2
line is too low> crushed.
Pressures of high-
pressure and low-
<Pressure of high- pressure lines are almost
Defective compressor
pressure line is too low the same while
(compression trouble of Replace *2
and that of low-pressure compressor is running.
compressor)
line is too high>
Compressor has seized
and is extremely hot.
*1: If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check
mainly on pipe joints and dirty parts with oil.
*2:
k When replacing cooling cycle parts, be sure to collect refrigerant. For details, see "Precautions for
refrigerant". After replacing parts, fill the air conditioner circuit with refrigerant.

*3: Sight glass is on the air conditioner hose near the condenser.

80-74 HM400-3M0
 80 Appendix
Connection of service tool

Connection of service tool (HM400-S100-730-P-00-A)

k Park the machine on a level ground, set the parking switch to "PARK", and then chock the wheels.

k Turn the battery disconnect switch to the "OFF" position and pull out the key.

a The service tool kit shown below is for R134a.

Symbol Part number Part name
X 799 - 703 - 1200 Service tool kit
Service tool kit X
(1): Gauge manifold
(2): High-pressure charging hose (red)
(3): Low pressure charging hose (blue)
(4): Quick joint for HI side (large diameter)
(5): Quick joint for LO side (small diameter)
(a): As the thread is coarse, care should be taken with regard to loosening.

Connect the gauge manifold, hoses and other service tools according to the following procedure.
1. Close high-pressure valve (6) and low-pressure valve (7) of gauge manifold (1).
2. Connect the red high-pressure charging hose (2) to the HI side of the gauge manifold and the blue low-
pressure charging hose (3) to the LO side.
3. Connect quick joints (4) and (5) to each hose.
4. Connect quick joints (4) and (5) to service valves (8) and (9) of high- and low-pressure piping respectively.

HM400-3M0 80-75
80 Appendix
Connection of service tool

A: From Cab
B: To Condenser

80-76 HM400-3M0
 80 Appendix
Precautions for disconnecting and connecting air
conditioner piping

Precautions for disconnecting and connecting air conditioner

piping (HM300-K5B0-924-K-00-A)
Precautions for disconnecting
k Collect the refrigerant (Air conditioner gas: R134a) from air conditioner circuit before
disconnecting air conditioner hose to replace air conditioner unit, air conditioner compressor or
receiver drier and so on.

a Ask a qualified person for collecting, adding and filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the atmosphere.
k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skin,
you may suffer from frostbite. Accordingly, put on protective eyeglasses, gloves and working cloth
with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the
refrigerant.

• When loosening the air conditioner hose nuts after collecting the refrigerant, be sure to use 2 wrenches.
Use one wrench to fix and use the other one to loosen the nuts.
• When disconnecting the air conditioner hoses, treat so that dust, dirt or water does not enter the hose.

Precautions for connecting

• When connecting piping, apply compressor oil (ND-OIL8) for R134a to its O-rings. (See item 4 of
"Handling compressor oil")
Do not apply oil to the threads of a bolt, nut or union, however.
a O-ring is installed in the connection of all the air conditioner hoses.
• Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it. When removing it,
use a soft tool (such as a toothpick) so that the piping will not be damaged.
• Push in each pipe to the stopper and tighten the bolt or nut fully with your fingers.
• Be sure to use two wrenches to tighten each nut. Use one wrench to fix and tighten the nut with the other
wrench to the specified torque (Use a torque wrench for tightening).
a An example of O-ring installation.

Table of tightening torque for refrigerant pipe joint.

Thread size Tightening torque Nm {kgm}
3.9 to 6.9 {0.4 to 0.7} (Receiver drier)
M6 x 1.0 8 to 12 {0.8 to 1.2} (air conditioner unit, compressor, and
condenser)
M16 x 1.5 12 to 15(1.2 to 1.5)
M24 x 1.5 30 to 35 {3.1 to 3.6}

HM400-3M0 80-77
80 Appendix
Precautions for disconnecting and connecting air
conditioner piping

1. Engine
2. Compressor
3. Condenser
4. Receiver drier
5. Air conditioner unit

80-78 HM400-3M0
 80 Appendix
Handling of compressor oil

Handling of compressor oil (HM300-K594-212-K-00-A)

1. Compressor oil management (DENSO: ND-OIL8 for R134a)

Although compressor oil differs from engine oil in that it does not need regular checking or filling, the
following types of problem can occur if the amount in the system is too high or too low.
Condition Content
Insufficiency of oil Lubrication trouble and seizure of compressor
Cooling trouble
Excess of oil
(Excessive oil stick to parts and lower heat exchange performance)
Accordingly, compressor oil must be filled to the specified level, similarly to refrigerant.
2. Filling compressor oil

k Refrigerant is potentially hazardous to health and to the environment. Before disconnecting air
conditioner hoses, therefore, refrigerant should be collected in accordance with "Precautions
for connecting air conditioner piping."
a If oil for CFC-12 (R-12) is used, lubrication trouble will occur and the compressor may be broken or
seized.
Be sure to use an oil suitable for R134a (DENSO: ND-OIL8).
a Oil for use with R134a is extremely hygroscopic, and therefore, the cap must be immediately closed
after use to limit contact with air.
Store the oil can in a dry and ventilated place.
a Precautions for using oil
Do not allow oil for use with R134a to come into contact with acrylic plastic or polystyrene surfaces
(except a baked finish) as it may dissolve these plastics.
Check compressor oil in the following cases, and then add new oil if necessary.
• When much refrigerant is discharged because of leakage.
• When the compressor is troubled and replaced.
(See 3 below)
• When a cycle parts such as condenser, receiver drier, evaporator unit, etc. is replaced.
• Quantity of oil to be added when cycle part is replaced
Air conditioner part Quantity to be added (cc)
Air conditioner unit, evaporator Approx. 40
Condenser Approx. 40
Receiver drier Approx. 20
Tube (between cab and joint M24) Approximately 15
Hose (between Joint M24 and compressor) Approx. 30
Hose (Compressor – Condenser) Approx. 20
Hose (between condenser and receiver drier) Approx. 30
Each hose (between cab through joint M16 to receiver drier) Approx. 10

3. Replacement of compressor

HM400-3M0 80-79
80 Appendix
Handling of compressor oil

• In case of compressor seizure or breakage.

Metal chips will circulate through the air conditioner circuit and contaminate the compressor oil
extremely.
In this case, flush the air conditioner circuit and replace the compressor and receiver drier.
The compressor oil is removed from the air conditioner circuit by flushing. Accordingly, install a new
compressor with the oil of the specified quantity (180 cc) filled in it.
• Other cases
a New compressor contains compressor oil of 180 cc in it.
1)
1] Prepare an oil container and drain oil from the old compressor.
2] Measure the quantity of the drained oil with a measuring cylinder, and note the quantity or mark the
level.

3] Drain below-mentioned quantity of oil from the new compressor.

Quantity to be drained= 180 cc - "Noted quantity"
Example: If 30 cc was drained from the removed compressor, the quantity to be drained from the
new compressor would be 150 cc (i.e., 180 - 30 cc).
4. Applying compressor oil to O-rings
Whenever connecting piping or hoses, the compressor oil (ND-OIL8) must be applied to O-rings in order
to prevent the leakage of refrigerant.

80-80 HM400-3M0
SHOP MANUAL

ARTICULATED DUMP TRUCK

HM400-3M0
Model Serial Number

HM400-3M0 5001 and up

90 Diagrams and drawings

10 90 Diagrams and drawings

HM400-3M0 90-1
90 Diagrams and drawings
Table of contents

Table of contents (ALL-0310-002-A-00-A)

90 Diagrams and drawings................................................................................................................. 90-1
Table of contents ........................................................................................................................ 90-2
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Power train hydraulic circuit diagram...................................................................................... 90-7
Hydraulic circuit diagram....................................................................................................... 90-9
Electric circuit diagram .............................................................................................................. 90-13
Symbols in electric circuit diagram ....................................................................................... 90-13
Inside cab electrical circuit diagram ..................................................................................... 90-17
Outside cab electrical circuit diagram ................................................................................... 90-33
Electrical circuit diagram of engine....................................................................................... 90-57

90-2 HM400-3M0
 90 Diagrams and drawings
Symbols in hydraulic circuit diagram

Hydraulic circuit diagram (ALL-C000-001-K-90-A)

Symbols in hydraulic circuit diagram (PC220-0000-007-K-00-A)

(Rev. 2013/09)
Symbols Substances

Main piping line

Pilot or drain line

Flexible pipe (hose etc.)

Lines intersecting without jointing

Lines jointing (junction with a black dot)

Direction of flow

Throttle in passage

Variable

Electricity

Spring

Take-off port

Take-off port and pressure gauge

HM400-3M0 90-3
90 Diagrams and drawings
Symbols in hydraulic circuit diagram

Symbols Substances

Check valve

Suction (with strainer)

Tank and return pipe

Filter

Oil cooler

Stop valve

Drive shaft (unidirectional)

Drive shaft (bidirectional)

Hydraulic pump
Note: Black triangle shows outlet port

Variable capacity hydraulic pump

Hydraulic motor
Note: Two black triangles in the figure show direction of oil entering
hydraulic motor depending on the oil entry port, the direction of rotation is
reversed.

Servo piston

PPC valve

90-4 HM400-3M0
 90 Diagrams and drawings
Symbols in hydraulic circuit diagram

Symbols Substances

Control valve

Single-acting solenoid valve

Single-acting proportional solenoid valve

Hydraulic pilot valve

Hydraulic two-stage pilot valve

Lock valve

Drain valve

Pressure regulator valve, Safety valve, Abnormal pressure prevention

valve

Pressure regulator valve, Safety valve, Abnormal pressure prevention

valve
(when the figure shows air pressure, being released to atmosphere)

Bypass valve

Accumulator

HM400-3M0 90-5
90 Diagrams and drawings
Symbols in hydraulic circuit diagram

Symbols Substances

Cylinder

Component group

90-6 HM400-3M0
Power train hydraulic circuit diagram
HM400-3M0

HM400-3M0 90-7
Hydraulic circuit diagram (1/2) Hydraulic circuit diagram (1/2)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-9
Hydraulic circuit diagram (2/2) Hydraulic circuit diagram (2/2)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-11
 90 Diagrams and drawings
Symbols in electric circuit diagram

Electric circuit diagram (ALL-0000-001-K-90-A)

Symbols in electric circuit diagram (PC220-0000-008-K-00-A)

(Rev. 2013/09)
Symbols Substances

Electric wire

Electric wire (wires intersecting without connecting)

Electric wire (wires intersecting and connecting (junction) with a black

dot)

Electric wire (bundled drawing style)

Terminal

Chassis ground

Chassis ground using terminal

Contact, Switch

Push-button type switch (N.O. type)

N.O.: Normally Open

Push-button type switch (N.C. type)

N.C.: Normally Close

Pull-button type switch (N.O. type)

N.O.: Normally Open

Pull-button type switch (N.C. type)

N.C.: Normally Close

HM400-3M0 90-13
90 Diagrams and drawings
Symbols in electric circuit diagram

Symbols Substances

Variable

Resistor

Variable resistor

Diode

Light emitting diode (LED)

Photo diode

Constant voltage diode (zener diode)

Transistor (PNP type)

Transistor (NPN type)

Coil

Battery

Fuse

Connector
Note:
• Concave side of connecting portion (left in figure): female
• Convex side of connecting portion (right in figure): male
a Figure shows a line disconnection status

90-14 HM400-3M0
 90 Diagrams and drawings
Symbols in electric circuit diagram

Symbols Substances

Plug and receptacle type connector (left: male, right: female)

a Figure shows a line connection status

Solenoid

Motor

Lamp

Pressure switch (N.O. type)

N.O.: Normally Open

Pressure switch (N.C. type)

N.C.: Normally Close

Potentiometer, Fuel control dial

Temperature sensor

Starting switch

Back up alarm

Horn

Buzzer

Antenna

HM400-3M0 90-15
90 Diagrams and drawings
Symbols in electric circuit diagram

90-16 HM400-3M0
Inside cab electric circuit diagram (1/8) Inside cab electric circuit diagram (1/8)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-17
Inside cab electric circuit diagram (2/8) Inside cab electric circuit diagram (2/8)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-19
Inside cab electric circuit diagram (3/8) Inside cab electric circuit diagram (3/8)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-21
Inside cab electric circuit diagram (4/8) Inside cab electric circuit diagram (4/8)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-23
Inside cab electric circuit diagram (5/8) Inside cab electric circuit diagram (5/8)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-25
Inside cab electric circuit diagram (6/8) Inside cab electric circuit diagram (6/8)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-27
Inside cab electric circuit diagram (7/8) Inside cab electric circuit diagram (7/8)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-29
Inside cab electric circuit diagram (8/8) Inside cab electric circuit diagram (8/8)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-31
Outside cab electric circuit diagram (1/6) Outside cab electric circuit diagram (1/6)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-33
Outside cab electric circuit diagram (2/6) Outside cab electric circuit diagram (2/6)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-35
Outside cab electric circuit diagram (3/6) Outside cab electric circuit diagram (3/6)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-37
Outside cab electric circuit diagram (4/6) Outside cab electric circuit diagram (4/6)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-39
Outside cab electric circuit diagram (5/6) Outside cab electric circuit diagram (5/6)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-41
Outside cab electric circuit diagram (6/6) Outside cab electric circuit diagram (6/6)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-43
Outside cab electric circuit diagram (1/6) (For -40°C specification) Outside cab electric circuit diagram (1/6)
(For -40°C specification)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-45
Outside cab electric circuit diagram (2/6) (For -40°C specification) Outside cab electric circuit diagram (2/6)
(For -40°C specification)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-47
Outside cab electric circuit diagram (3/6) (For -40°C specification) Outside cab electric circuit diagram (3/6)
(For -40°C specification)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-49
Outside cab electric circuit diagram (4/6) (For -40°C specification) Outside cab electric circuit diagram (4/6)
(For -40°C specification)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-51
Outside cab electric circuit diagram (5/6) (For -40°C specification) Outside cab electric circuit diagram (5/6)
(For -40°C specification)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-53
Outside cab electric circuit diagram (6/6) (For -40°C specification) Outside cab electric circuit diagram (6/6)
(For -40°C specification)
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-55
Electrical circuit diagram of engine Electrical circuit diagram of engine
HM400-3M0
HM400-3M0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HM400-3M0 90-57
 INDEX

INDEX

A Cooling system............................................. 10-20

A-1 Troubleshooting for power supply system
(Air conditioner does not operate) ................. 80-63
A-2 Troubleshooting for compressor and
refrigerant system (Air is not cooled) ............. 80-65
A-3 Troubleshooting for blower motor system
(No air comes out or air flow is abnormal) ...... 80-68
A-4 Troubleshooting for FRESH/RECIRC air
changeover ................................................ 80-70
Accelerator pedal position sensor................. 10-292
Accumulator ............................................... 10-142
Adjusting dump body positioner sensor........... 30-82
Adjusting transmission controller.................... 30-51
Adjusting transmission speed sensor.............. 30-48
Adjusting valve clearance .............................. 30-16
Aftercooler fan motor.............................10-30, 60-8
Air conditioner component ............................... 80-4
Air conditioner controller ................................ 80-16
Air conditioner unit ........................................ 80-10
Automatic emergency steering system ......... 10-226
Axle................................................. 10-110, 60-33
B assembly.................................................. 50-209
Bleeding air from brake circuit ........................ 30-69
Bleeding air from fuel system ......................... 30-29
Brake............................................... 10-155, 60-45
Brake charge pump....................................... 60-64
Brake system tank ...................................... 10-158
Brake valve ................................................ 10-144
Bypass valve................................................ 10-13
C assembly.................................................. 50-149
Cab tilt ....................................................... 10-206
Cab tilt up procedure..................................... 30-83
Center brake cooling pump............................ 60-63
Center brake cooling relief valve .................. 10-204
Center brake cooling remote motor..... 10-194, 60-66
Center brake cooling remote pump................. 60-65
Check before troubleshooting ........................ 40-14
Circuit diagram and arrangement of connector
pins ........................................................... 80-23
Classification and procedures for
troubleshooting ........................................... 40-31
Coating materials list....................................... 50-6
Compressor ................................................. 80-17
Condenser ................................................... 80-18
Configuration and function of refrigeration
cycle ............................................................ 80-7
Connection of service tool ............................. 80-75
Connector contact identification ..................... 40-56
Connector list and layout ............................... 40-40
Conversion table .......................................... 00-62
D
Differential........................................ 10-113, 60-30
Differential lock clutch ECMV ............. 10-100, 60-27
Disassembly and assembly of center
differential assembly.................................. 50-193
Disassembly and assembly of center final drive
and brake assembly .................................. 50-235
Disassembly and assembly of front differential
assembly.................................................. 50-127
Disassembly and assembly of front final drive
and brake assembly .................................. 50-221
Disassembly and assembly of hitch frame
assembly.................................................. 50-285
Disassembly and assembly of hoist cylinder
assembly.................................................. 50-301
Disassembly and assembly of hoist valve
assembly.................................................. 50-297
Disassembly and assembly of output shaft
assembly.................................................... 50-99
Disassembly and assembly of rear differential
Disassembly and assembly of rear final drive
assembly.................................................. 50-246
Disassembly and assembly of steering cylinder
assembly.................................................. 50-258
Disassembly and assembly of suspension
cylinder assembly ..................................... 50-268
Disassembly and assembly of torque converter
assembly.................................................. 50-142
Disassembly and assembly of transmission
Disconnection and connection of front
differential assembly and transmission
assembly.................................................. 50-125
Drive shaft.......................................... 10-53, 60-10
Dual pressure switch..................................... 80-15
Dump body control...................................... 10-172
Dump EPC valve ........................................ 10-192
E
E-1 Engine does not start (Engine does not
crank) ...................................................... 40-701
E-2 Manual preheating system does not work .....40-
706
E-3 Automatic preheating system does not
work......................................................... 40-709
E-4 While preheating is working, preheating
monitor does not light up............................ 40-711
E-5 All of LCD unit, LED unit and meter unit on
machine monitor display nothing ................ 40-713

HM400-3M0 1
INDEX
E-6 LCD unit on machine monitor displays
nothing..................................................... 40-716
E-7 Backlight of LCD unit on machine monitor
is abnormal (Backlight goes out or flickers).. 40-718
E-8 LCD on machine monitor does not display
properly.................................................... 40-720
E-9 Meter unit display on machine monitor is
abnormal.................................................. 40-722
E-10 Night lighting lamp of meter unit on
machine monitor is abnormal ..................... 40-725
E-11 LED unit lamp on machine monitor is
abnormal.................................................. 40-728
E-12 Night lighting lamp of switch panel on
machine monitor is abnormal or switches
does not operate properly .......................... 40-730
E-13 2 switches operation of switch panel on
machine monitor does not function ............. 40-732
E-14 Switch panel buzzer of machine monitor
is abnormal............................................... 40-734
E-15 Rear view monitor does not light up or
backlight flickers ....................................... 40-736
E-16 Rear view monitor images are not
displayed clearly ....................................... 40-738
E-17 Rear view monitor brightness cannot be
adjusted ................................................... 40-741
E-18 Night lighting lamp of rear view monitor is
abnormal.................................................. 40-744
E-19 Rearview monitor does not display
images while reverse linked display function
is enabled................................................. 40-746
E-20 Guide line on rear view monitor is not
displayed while guide line is set.................. 40-749
E-21 Some items of gauges and caution lamps
on machine monitor are not displayed
properly.................................................... 40-751
E-22 Fuel level gauge does not indicate correct
level......................................................... 40-752
E-23 Seat belt caution lamp indication is
abnormal.................................................. 40-754
E-24 Machine monitor cannot be operated
when starting switch is in OFF position........ 40-755
E-25 Alarm buzzer does not sound............... 40-756
E-26 Alarm buzzer does not stop sounding ... 40-758
E-27 Engine mode selector function does not
operate properly........................................ 40-760
E-28 AISS function does not operate properly .....40-
761
E-29 Hoist lever does not operate properly.... 40-762
E-30 Turn signal lamp and winker lamp
(hazard lamp) do not operate properly......... 40-764
E-31 None of headlamp, clearance lamp, and
tail lamp lights ........................................... 40-768
E-32 Clearance lamp does not light up ......... 40-770
E-33 Tail lamp does not light up.................... 40-772
E-34 Low beam of headlamp does not light up ....40-
774
E-35 High beam of headlamp does not light up....40-
776
2 HM400-3M0
E-36 Neither Low beam nor High beam of
headlamp lights up .................................... 40-778
E-37 High beams do not light up while passing
switch is operated ..................................... 40-780
E-38 KOMTRAX does not operate properly... 40-782
EGR cooler .................................................. 10-17
EGR system circuit diagram ............................ 10-9
EGR system layout drawing............................. 10-8
EGR valve ................................................... 10-11
Electrical circuit diagram of engine ................. 90-57
Electrical control system.............................. 10-207
Emergency steering motor........................... 10-133
Emergency steering pump................. 10-132, 60-42
Engine mount ................................................. 60-3
Engine related parts ........................................ 10-4
Explanation of terms for maintenance standard ...00-
25
F
Failure code [1500L0] Double Engagement of
T/M Clutches ............................................ 40-121
Failure code [15B0NX] Transmission Oil Filter
Clogging................................................... 40-122
Failure code [15F0KM] Abuse 1 of Gear
Shifting from R to F ................................... 40-123
Failure code [15F0KM] Abuse 2 of Gear
Shifting from R to F ................................... 40-124
Failure code [15F7KM] Abuse of TM Forward
Clutch Disk ............................................... 40-125
Failure code [15G0MW] Failure of Clutch
(Reverse) ................................................. 40-126
Failure code [15G7KM] Abuse of TM Reverse
Clutch Disk ............................................... 40-129
Failure code [15H0MW] Failure of Clutch
(High)....................................................... 40-130
Failure code [15J0MW] Failure of Clutch (Low)....40-
133
Failure code [15K0MW] Failure of Clutch (1st).....40-
136
Failure code [15L0MW] Failure of Clutch (2nd) ....40-
139
Failure code [15M0MW] Failure of Clutch (3rd) ....40-
142
Failure code [15SBL1] Release Trouble of
ECMV (Reverse)....................................... 40-145
Failure code [15SBMA] Malfunction of ECMV
(Reverse) ................................................. 40-148
Failure code [15SCL1] Release Trouble of
ECMV (High) ............................................ 40-149
Failure code [15SCMA] Malfunction of ECMV
(High)....................................................... 40-152
Failure code [15SDL1] Release Trouble of
ECMV (Low) ............................................. 40-153
Failure code [15SDMA] Malfunction of ECMV
(Low) ....................................................... 40-156
Failure code [15SEL1] Release Trouble of
ECMV (1st)............................................... 40-157

Failure code [15SEMA] Malfunction of ECMV
(1st) ......................................................... 40-160
Failure code [15SFL1] Release Trouble of
ECMV (2nd) ............................................. 40-161
Failure code [15SFMA] Malfunction of ECMV
(2nd) ........................................................ 40-164
Failure code [15SGL1] Release Trouble of
ECMV (3rd) .............................................. 40-165
Failure code [15SGMA] Malfunction of ECMV
(3rd)......................................................... 40-168
Failure code [15SJMA] Malfunction of ECMV
(Lockup)................................................... 40-169
Failure code [15SKMA] Malfunction of ECMV
(Inter-Axle Diff.)......................................... 40-171
Failure code [2F00KM] Dragging of Parking
Brake ....................................................... 40-173
Failure code [2G42ZG] Accumulator Oil
Pressure Low (Front)................................. 40-175
Failure code [2G43ZG] Accumulator Oil
Pressure Low (Rear) ................................. 40-176
Failure code [879AKA] A/C Inner sensor Open
Circuit ........................................................ 80-51
Failure code [879AKA] A/C Inner Sensor Open
Circuit ...................................................... 40-177
Failure code [879AKB] A/C Inner sensor Short
Circuit ........................................................ 80-52
Failure code [879AKB] A/C Inner Sensor Short
Circuit ...................................................... 40-178
Failure code [879BKA] A/C Outer sensor Open
Circuit ........................................................ 80-53
Failure code [879BKA] A/C Outer Sensor
Open Circuit ............................................. 40-179
Failure code [879BKB] A/C Outer sensor Short
Circuit ........................................................ 80-55
Failure code [879BKB] A/C Outer Sensor Short
Circuit ...................................................... 40-180
Failure code [879CKA] Ventilating sensor
Open Circuit ............................................... 80-57
Failure code [879CKA] Ventilating Sensor
Open Circuit ............................................. 40-181
Failure code [879CKB] Ventilating sensor
Short Circuit ............................................... 80-58
Failure code [879CKB] Ventilating Sensor
Short Circuit ............................................. 40-182
Failure code [879EMC] Ventilating Damper
Abnormality ................................................ 80-59
Failure code [879EMC] Ventilation Damper
Abnormality .............................................. 40-183
Failure code [879FMC] Air Mix Damper
Abnormality .................................... 40-184, 80-60
Failure code [879GKX] Refrigerant
Abnormality .................................... 40-185, 80-61
Failure code [989D00] Tilt Caution................ 40-186
Failure code [989L00] Engine Controller Lock
Caution1 .................................................. 40-187
Failure code [989M00] Engine Controller Lock
Caution2 .................................................. 40-188
Failure code [989N00] Engine Controller Lock
Caution3 .................................................. 40-189
HM400-3M0
INDEX
Failure code [AA10NX] Air Cleaner Clogging. 40-190
Failure code [AB00KE] Charge Voltage Low . 40-192
Failure code [AB00KY] Hot Short of Alternator
R Terminal ................................................ 40-193
Failure code [B@BAZG]Eng Oil Press Low ... 40-194
Failure code [B@BAZK] Engine Oil Level Low ....40-
195
Failure code [B@BCNS] Eng Water Overheat .....40-
196
Failure code [B@BCZK] Eng Water Level Low ....40-
197
Failure code [B@C6NS] Retarder Oil Overheat
(Front)...................................................... 40-199
Failure code [B@C8NS] Retarder Oil Overheat
(Center).................................................... 40-200
Failure code [B@CENS] T/C Oil Temp.
Overheat .................................................. 40-201
Failure code [B@JANS] Steering Oil Overheat ....40-
202
Failure code [CA111] ECM Critical Internal
Failure ..................................................... 40-203
Failure code [CA115] Eng Ne and Bkup Speed
Sens Error ................................................ 40-204
Failure code [CA122] Chg Air Press Sensor
High Error................................................. 40-205
Failure code [CA1228] EGR Valve Servo Error
1.............................................................. 40-285
Failure code [CA123] Chg Air Press Sensor
Low Error ................................................. 40-207
Failure code [CA131] Throttle Sensor High
Error ........................................................ 40-209
Failure code [CA132] Throttle Sensor Low
Error ........................................................ 40-211
Failure code [CA153] Chg Air Temp Sensor
High Error................................................. 40-221
Failure code [CA154] Chg Air Temp Sensor
Low Error ................................................. 40-223
Failure code [CA1625] EGR Valve Servo Error
2.............................................................. 40-286
Failure code [CA1626] Bypass Valve Solenoid
Current High Error..................................... 40-287
Failure code [CA1627] Bypass Valve Solenoid
Current Low Error...................................... 40-289
Failure code [CA1628] Bypass Valve Servo
Error 1...................................................... 40-291
Failure code [CA1629] Bypass Valve Servo
Error 2...................................................... 40-292
Failure code [CA1631] BP valve Lift Position
Sensor High Error ..................................... 40-293
Failure code [CA1632] BP valve Lift Position
Sensor Low Error ...................................... 40-295
Failure code [CA187] Sensor 2 Supply Volt
Low Error ................................................. 40-225
Failure code [CA2185] Throt Sensor Sup Volt
High Error................................................. 40-297
Failure code [CA2186] Throt Sensor Sup Volt
Low Error ................................................. 40-299
Failure code [CA221] Ambient Press Sensor
High Error................................................. 40-227
3
INDEX
Failure code [CA222] Ambient Press Sens Low
Error ........................................................ 40-229
Failure code [CA2249] Rail Press Very Low
Error 2...................................................... 40-301
Failure code [CA227] Sensor 2 Supply Volt
High Error................................................. 40-231
Failure code [CA2271] EGR Valve Pos Sens
High Error................................................. 40-302
Failure code [CA2272] EGR Valve Pos Sens
Low Error ................................................. 40-304
Failure code [CA234] Eng Overspeed........... 40-232
Failure code [CA2351] EGR Valve Solenoid
Short Error................................................ 40-306
Failure code [CA2352] EGR Valve Solenoid
Open Error ............................................... 40-308
Failure code [CA238] Ne Speed Sensor
Supply Volt Error ....................................... 40-233
Failure code [CA2555] Grid Htr Relay Volt Low
Error ........................................................ 40-310
Failure code [CA2556] Grid Htr Relay Volt High
Error ........................................................ 40-312
Failure code [CA263] Fuel Temp Sensor High
Error ........................................................ 40-234
Failure code [CA265] Fuel Temp Sensor Low
Error ........................................................ 40-236
Failure code [CA271] IMV/PCV1 Short Error . 40-238
Failure code [CA272] IMV/PCV1 Open Error . 40-239
Failure code [CA273] PCV2 Short Error ........ 40-240
Failure code [CA274] PCV2 Open Error........ 40-241
Failure code [CA342] Calibration Code
Incompatibility........................................... 40-254
Failure code [CA351] Injectors Drive Circuit
Error ........................................................ 40-255
Failure code [CA386] Sensor 1 Supply Volt
High Error................................................. 40-258
Failure code [CA431] Idle Validation Sw Error .....40-
259
Failure code [CA432] Idle Validation Process
Error ........................................................ 40-262
Failure code [CA441] Battery Voltage Low
Error ........................................................ 40-265
Failure code [CA442] Battery Voltage High
Error ........................................................ 40-267
Failure code [CA449] Rail Press Very High
Error ........................................................ 40-268
Failure code [CA553] Rail Press High Error 1 40-273
Failure code [CA554] Rail Press Sensor In
Range Error.............................................. 40-274
Failure code [CA559] Rail Press Low Error ... 40-275
Failure code [CA689] Eng Ne Speed Sensor
Error ........................................................ 40-279
Failure code [CA731] Eng Bkup Speed Sens
Phase Error .............................................. 40-281
Failure code [CA757] All Continuous Data Lost
Error ........................................................ 40-282
Failure code [D150KB] Ground Fault of Emerg.
Steering Relay .......................................... 40-314
Failure code [D150KZ] Failure of Emerg.
Steering Relay .......................................... 40-315
4 HM400-3M0
Failure code [D151KB] Ground Fault of Emerg.
Steering Relay 2 ....................................... 40-316
Failure code [D151KZ] Failure of Emerg.
Steering Relay 2 ....................................... 40-317
Failure code [D164KY] Hot Short of Head Light
High Selector............................................ 40-318
Failure code [D19HKZ] Failure of Stop Lamp
(R&L) ....................................................... 40-319
Failure code [D19JKZ] Personal Code Relay
Abnormality .............................................. 40-321
Failure code [D1EHKA] Disconnection of
Engine Start Relay .................................... 40-322
Failure code [D1EHKB] Ground Fault of
Engine Start Relay .................................... 40-323
Failure code [D1EHKY] Hot Short of Engine
Start Relay ............................................... 40-324
Failure code [D1EMKA] Disconnection of
Parking Interlock Relay.............................. 40-325
Failure code [D1EMKB] Ground Fault of
Parking Interlock Relay.............................. 40-326
Failure code [D1EMKY] Hot Short of Parking
Interlock Relay.......................................... 40-327
Failure code [D1FBKB] Ground Fault of Sol.
Self-Holding Relay .................................... 40-328
Failure code [D5ZHL6] Disconnection of Key
SW C ....................................................... 40-329
Failure code [D811MC] KOMTRAX Error ...... 40-331
Failure code [D862KA] GPS Antenna Open
Circuit ...................................................... 40-332
Failure code [D8ALKA] Operating Lamp Open
Circuit (KOMTRAX) ................................... 40-333
Failure code [D8ALKB] Operating Lamp Short
Circuit (KOMTRAX) ................................... 40-335
Failure code [D8AQK4] CAN2 Discon
(KOMTRAX) 2 .......................................... 40-337
Failure code [D8AQKR] CAN2 Discon
(KOMTRAX) ............................................. 40-338
Failure code [DAF0KT] Abnormality of Non-
volatile Memory (MON) .............................. 40-339
Failure code [DAF0MB] Monitor ROM
Abnormality .............................................. 40-340
Failure code [DAF0MC] Monitor Error ........... 40-341
Failure code [DAF3KK] Controller Power
Source Low (MON) ................................... 40-342
Failure code [DAF8KB] Camera Power Supply
Short Circuit ............................................. 40-344
Failure code [DAFDKB] Monitor 12V Power
Output Short Circuit................................... 40-345
Failure code [DAFGMC] GPS Module Error .. 40-347
Failure code [DAFLKA] Operating Lamp Open
Circuit (MON)................................ 40-348, 40-362
Failure code [DAFLKB] Operating Lamp Short
Circuit (MON)............................................ 40-350
Failure code [DAFQKR] CAN2 Discon
(Monitor) .................................................. 40-352
Failure code [DAQ0KK] Controller Power
Source Low (T/M) ..................................... 40-353
Failure code [DAQ0KT] Abnormality of Non-
volatile Memory (T/M) ................................ 40-355

Failure code [DAQ0MC] T/M Con Error......... 40-356
Failure code [DAQ1KA] Disconnection of Key
SW ACC (T/M).......................................... 40-357
Failure code [DAQ2KK] Solenoid Power
Source Low (T/M) ..................................... 40-359
Failure code [DAQ9KQ] Inconsistency of
Model Selection (T/M) ............................... 40-361
Failure code [DAQLKB] Operating Lamp Short
Circuit (T/M).............................................. 40-364
Failure code [DAQQKR] CAN2 Discon
(Transmission Con) ................................... 40-366
Failure code [DAQRKR] CAN1 Discon
(Transmission Con) ................................... 40-367
Failure code [DAQRMA] Inconsistency of
Option Selection (T/M)............................... 40-371
Failure code [DAQV00] Neutral Coast Caution ....40-
372
Failure code [DAQW00] Neutral Over Speed
Caution .................................................... 40-373
Failure code [DAZ9KQ] A/C Model Selection
Abnormality .............................................. 40-374
Failure code [DAZQKR] CAN2 Discon (Aircon
ECU) ....................................................... 40-375
Failure code [DB10KT] Abnormality of Non-
volatile Memory (RHC) .............................. 40-376
Failure code [DB10MC] RHC Error ............... 40-377
Failure code [DB11KA] Disconnection of Key
SW ACC (RHC) ........................................ 40-378
Failure code [DB12KK] Solenoid Power
Source Low (RHC) .................................... 40-380
Failure code [DB13KK] Controller Power
Source Low (RHC) .................................... 40-382
Failure code [DB19KQ] Inconsistency of Model
Selection (RHC)........................................ 40-384
Failure code [DB1LKA] Disconnection of
System Ope. Lamp (RHC) ......................... 40-385
Failure code [DB1LKB] Short Circuit of System
Ope. Lamp (RHC) ..................................... 40-387
Failure code [DB1QKR] CAN2 Discon
(Retarder Hoist Con) ................................. 40-389
Failure code [DB1QMA] Inconsistency of
Option Selection (RHC) ............................. 40-390
Failure code [DB1RKR] CAN1 Discon
(Retarder Hoist Con) ................................. 40-391
Failure code [DB2QKR] CAN2 Discon (Engine
Con) ........................................................ 40-392
Failure code [DBSQKQ] Inconsistency of
Model Selection (PLM) .............................. 40-401
Failure code [DBSQKR] CAN2 Discon (PLM) 40-397
Failure code [DD1ML4] Failure of ARAC SW. 40-402
Failure code [DDAAL6] Discon of Engine
Shutdown Secondary Switch...................... 40-404
Failure code [DDTHKA] Disconnection of Fill
Switch (High) ............................................ 40-406
Failure code [DDTJKA] Disconnection of Fill
Switch (Low)............................................. 40-408
Failure code [DDTKKA] Disconnection of Fill
Switch (1st) .............................................. 40-410
HM400-3M0
INDEX
Failure code [DDTLKA] Disconnection of Fill
Switch (2nd) ............................................. 40-412
Failure code [DDTMKA] Disconnection of Fill
Switch (3rd) .............................................. 40-414
Failure code [DDTNKA] Disconnection of Fill
Switch (Reverse) ...................................... 40-416
Failure code [DF10KA] Disconnection of Shift
Lever Input ............................................... 40-418
Failure code [DF10KB] Ground Fault of Shift
Lever Input ............................................... 40-421
Failure code [DGF1KX] Out of Range of T/M
Oil Temp. Sensor ...................................... 40-425
Failure code [DGR3KB] Ground Fault of
Retarder Oil Temp. S.(C)............................ 40-427
Failure code [DGR3L8] Failure of Retarder Oil
Temp. Sensor (C) ...................................... 40-428
Failure code [DGR4KB] Ground Fault of
Retarder Oil Temp. S.(F) ............................ 40-429
Failure code [DGR4L8] Failure of Retarder Oil
Temp. Sensor (F) ...................................... 40-430
Failure code [DGR6KB] Ground Fault of
Steering Oil Temp. S.................................. 40-432
Failure code [DGR6L8] Failure of Steering Oil
Temp. Sensor ........................................... 40-433
Failure code [DGR7KX] Out of Range of Piston
Pump Oil Temp. S. .................................... 40-435
Failure code [DGR8KX] Out of Range of CAC
Output Temp. S. ........................................ 40-437
Failure code [DGT1KX] Out of Range of T/C
Oil Temp. Sensor ...................................... 40-439
Failure code [DHP4KY] Hot Short of
Suspension Press. S. (FR)......................... 40-441
Failure code [DHP4KZ] Failure of Suspension
Press. S. (FR)........................................... 40-443
Failure code [DHP5KY] Hot Short of
Suspension Press. S. (FL) ......................... 40-445
Failure code [DHP5KZ] Failure of Suspension
Press. S. (FL) ........................................... 40-447
Failure code [DHP6KY] Hot Short of
Suspension Press. S. (RR) ........................ 40-449
Failure code [DHP6KZ] Failure of Suspension
Press. S. (RR) .......................................... 40-451
Failure code [DHP7KY] Hot Short of
Suspension Press. S. (RL)......................... 40-453
Failure code [DHP7KZ] Failure of Suspension
Press. S. (RL) ........................................... 40-455
Failure code [DHT5KX] Out of Range of T/C
Input Pressure Sensor ............................... 40-459
Failure code [DHT5L6] Failure of T/C Oil Press
Sensor ..................................................... 40-461
Failure code [DHT8KX] Out of Range of
Steering Oil Press. S. ................................ 40-463
Failure code [DHT8ZG] Steering Oil Pressure
Low ......................................................... 40-465
Failure code [DHU2KX] Out of Range of Acc.
Oil Press. S. (F) ........................................ 40-466
Failure code [DHU3KX] Out of Range of Acc.
Oil Press. S. (R) ........................................ 40-468
5
INDEX
Failure code [DHUAKX] Out of Range of
Retarder Press. S. (CR)............................. 40-470
Failure code [DHUBKX] Out of Range of
Retarder Press. S. (FR) ............................. 40-472
Failure code [DHUCKX] Out of Range of
Parking Brake Press. S.............................. 40-474
Failure code [DHUDKX] Out of Range of
Emerg. Steering Press. S.1........................ 40-476
Failure code [DHQ2KX] Out of Range of Main
Flow Sel. Valve S. ..................................... 40-457
Failure code [DHUEKX] Out of Range of
Emerg. Steering Press. S.2........................ 40-478
Failure code [DHUQKX] Out of Range of
Retarder Press. S. (FL).............................. 40-480
Failure code [DHURKX] Out of Range of
Retarder Press. S. (CL) ............................. 40-482
Failure code [DJF1KA] Disconnection of Fuel
Level Sensor ............................................ 40-484
Failure code [DK30KX] Out of Range of
Steering Angle Pot. ................................... 40-486
Failure code [DK51L5] Failure of Retarder
Lever Pot. and RVS................................... 40-488
Failure code [DK52KX] Out of Range of Hoist
Lever Potentio. ......................................... 40-491
Failure code [DK53L8] Failure of Hoist Lever
Potentio.................................................... 40-493
Failure code [DK54KX] Out of Range of Body
Potentio.................................................... 40-494
Failure code [DK60KX] Out of Range of
Acceleration Sensor .................................. 40-496
Failure code [DKH0KX] Out of Range of
Inclination Angle Sensor ............................ 40-498
Failure code [DKH1KX] Out of Range of Long.
Inclination Angle S. ................................... 40-500
Failure code [DLF1KA] Disconnection of T/M
Input Speed Sensor .................................. 40-502
Failure code [DLF1LC] Failure of T/M Input
Speed Sensor........................................... 40-504
Failure code [DLF2KA] Disconnection of T/M
Inter. Speed Sensor................................... 40-506
Failure code [DLF2LC] Failure of T/M
Intermediate Speed Sensor ....................... 40-508
Failure code [DLF400] T/M Diff. Overrun
Prevention Activated ................................. 40-510
Failure code [DLF4KA] Disconnection of T/M
Diff. Speed Sensor .................................... 40-511
Failure code [DLF4LC] Failure of T/M Diff.
Speed Sensor........................................... 40-513
Failure code [DLF6LC] Failure of Wheel Speed
Sensor (FR).............................................. 40-515
Failure code [DLF7LC] Failure of Wheel Speed
Sensor (FL) .............................................. 40-517
Failure code [DLFDLC] Failure of Wheel
Speed Sensor (CR) ................................... 40-519
Failure code [DLFELC] Failure of Wheel
Speed Sensor (CL) ................................... 40-521
Failure code [DLFFLC] Failure of Wheel Speed
Sensor (Front) .......................................... 40-523
6 HM400-3M0
Failure code [DLFGLC] Failure of Wheel
Speed Sensor (Center).............................. 40-524
Failure code [DLM3KA] Disconnection of
Radiator Fan Speed Sensor....................... 40-525
Failure code [DLM3LC] Failure of Radiator Fan
Speed Sensor........................................... 40-527
Failure code [DLM3MB] Radiator Fan Control
Mismatch ................................................. 40-529
Failure code [DLM4KA] Disconnection of CAC
Fan Speed Sensor .................................... 40-530
Failure code [DLM4LC] Failure of CAC Fan
Speed Sensor........................................... 40-532
Failure code [DLM4MB] CAC Fan Control
Mismatch ................................................. 40-534
Failure code [DLT3KA] Disconnection of
Output Speed Sens. (Main)........................ 40-535
Failure code [DLT3LC] Failure of Output Speed
Sensor (Main) ........................................... 40-537
Failure code [DPQ1KR] LIN Discon (Switch
Panel) ...................................................... 40-539
Failure code [DPQ2KR] LIN Discon (LED Unit)....40-
542
Failure code [DPQ3KR] LIN Discon (Rear View
Monitor).................................................... 40-545
Failure code [DSJ0KR] CAN2 Discon (Meter
Unit)......................................................... 40-548
Failure code [DV00KB] Ground Fault of Buzzer
Output...................................................... 40-549
Failure code [DW2BKA] Disconnection of Main
Flow Selector Sol. ..................................... 40-551
Failure code [DW2BKB] Ground Fault of Main
Flow Selector Sol. ..................................... 40-552
Failure code [DW2BKY] Hot Short of Main
Flow Selector Sol. ..................................... 40-553
Failure code [DW2BL1] Release Trouble of
Main Flow Sel. Valve ................................. 40-554
Failure code [DW2BLH] Malfunction of Main
Flow Selector Valve................................... 40-555
Failure code [DW4BK4] Release Trouble of
Parking Brake Valve .................................. 40-556
Failure code [DW4BMA] Malfunction of
Parking Brake Valve .................................. 40-558
Failure code [DW72KZ] Failure of Kick out
Solenoid................................................... 40-559
Failure code [DW73KA] Disconnection of Hoist
Selector Sol. ............................................. 40-561
Failure code [DW73KB] Ground Fault of Hoist
Selector Sol. ............................................. 40-563
Failure code [DW73KY] Hot Short of Hoist
Selector Sol. ............................................. 40-565
Failure code [DW7BKB] Ground Fault of
Radiator Fan Rev. Sol................................ 40-567
Failure code [DW7BKY] Hot Short of Radiator
Fan Rev. Sol. ............................................ 40-569
Failure code [DW7BKZ] Failure of Radiator
Fan Rev. Sol. ............................................ 40-570
Failure code [DW7LKB] Ground Fault of CAC
Fan Rev. Sol. ............................................ 40-572

Failure code [DW7LKY] Hot Short of CAC Fan
Rev. Sol. .................................................. 40-573
Failure code [DW7LKZ] Failure of CAC Fan
Rev. Sol. .................................................. 40-574
Failure code [DW7NKZ] Failure of Steering
Pump Selector Sol. ................................... 40-575
Failure code [DWNJKZ] Failure of TCS Shut
off Sol. (Front)........................................... 40-577
Failure code [DWNKKZ] Failure of TCS Shut
off Sol. (Center)......................................... 40-579
Failure code [DX13KA] Disconnection of Hoist
EPC Solenoid ........................................... 40-581
Failure code [DX13KB] Ground Fault of Hoist
EPC Solenoid ........................................... 40-583
Failure code [DX13KY] Hot Short of Hoist EPC
Solenoid................................................... 40-585
Failure code [DX16KA] Disconnection of Rad.
Fan Pump EPC Sol. .................................. 40-587
Failure code [DX16KB] Ground Fault of Rad.
Fan Pump EPC Sol. .................................. 40-588
Failure code [DX16KY] Hot Short of Radiator
Fan Pump EPC Sol. .................................. 40-590
Failure code [DX29KA] Disconnection of CAC
Fan Pump EPC Sol. .................................. 40-591
Failure code [DX29KB] Ground Fault of CAC
Fan Pump EPC Sol. .................................. 40-592
Failure code [DX29KY] Hot Short of CAC Fan
Pump EPC Sol.......................................... 40-593
Failure code [DX30K4] Release Trouble of
Retarder EPC Valve(FL) ............................ 40-594
Failure code [DX30KA] Disconnection of
Retarder EPC Sol. (FL).............................. 40-596
Failure code [DX30KB] Ground Fault of
Retarder EPC Sol. (FL).............................. 40-598
Failure code [DX30KY] Hot Short of Retarder
EPC Sol. (FL) ........................................... 40-600
Failure code [DX30MA] Malfunction of
Retarder EPC Valve (FL) ........................... 40-602
Failure code [DX31K4] Release Trouble of
Retarder EPC Valve(CR) ........................... 40-604
Failure code [DX31KA] Disconnection of
Retarder EPC Sol. (CR)............................. 40-606
Failure code [DX31KB] Ground Fault of
Retarder EPC Sol. (CR)............................. 40-608
Failure code [DX31KY] Hot Short of Retarder
EPC Sol. (CR) .......................................... 40-610
Failure code [DX31MA] Malfunction of
Retarder Valve (CR) .................................. 40-612
Failure code [DX32K4] Release Trouble of
Retarder EPC Valve(CL)............................ 40-614
Failure code [DX32KA] Disconnection of
Retarder EPC Sol. (CL) ............................. 40-616
Failure code [DX32KB] Ground Fault of
Retarder EPC Sol. (CL) ............................. 40-618
Failure code [DX32KY] Hot Short of Retarder
EPC Sol. (CL) ........................................... 40-620
Failure code [DX32MA] Malfunction of
Retarder EPC Valve (CL) ........................... 40-622
HM400-3M0
INDEX
Failure code [DX33K4] Release Trouble of
Retarder EPC Valve (FR)........................... 40-624
Failure code [DX33KA] Disconnection of
Retarder EPC Sol. (FR) ............................. 40-626
Failure code [DX33KB] Ground Fault of
Retarder EPC Sol. (FR) ............................. 40-628
Failure code [DX33KY] Hot Short of Retarder
EPC Sol. (FR)........................................... 40-630
Failure code [DX33MA] Malfunction of
Retarder EPC Valve (FR)........................... 40-632
Failure code [DX34KA] Disconnection of
Remote Cooling EPC Sol........................... 40-634
Failure code [DX34KB] Ground Fault of
Remote Cooling EPC Sol........................... 40-635
Failure code [DX34KY] Hot Short of Remote
Cooling EPC Sol. ...................................... 40-637
Failure code [DXH0KA] Disconnection of
ECMV (Inter-Axle Diff.) .............................. 40-638
Failure code [DXH0KB] Ground Fault of ECMV
(Inter-Axle Diff.)......................................... 40-640
Failure code [DXH0KY] Hot Short of ECMV
(Inter-Axle Diff.)......................................... 40-642
Failure code [DXH1KA] Disconnection of
ECMV Solenoid (Lockup)........................... 40-644
Failure code [DXH1KB] Ground Fault of ECMV
Solenoid (Lockup) ..................................... 40-646
Failure code [DXH1KY] Hot Short of ECMV
Solenoid (Lockup) ..................................... 40-648
Failure code [DXH2KA] Disconnection of
ECMV Solenoid (High) .............................. 40-650
Failure code [DXH2KB] Ground Fault of ECMV
Solenoid (High) ......................................... 40-652
Failure code [DXH2KY] Hot Short of ECMV
Solenoid (High) ......................................... 40-654
Failure code [DXH3KA] Disconnection of
ECMV Solenoid (Low) ............................... 40-655
Failure code [DXH3KB] Ground Fault of ECMV
Solenoid (Low).......................................... 40-657
Failure code [DXH3KY] Hot Short of ECMV
Solenoid (Low).......................................... 40-659
Failure code [DXH4KA] Disconnection of
ECMV Solenoid (1st) ................................. 40-662
Failure code [DXH4KB] Ground Fault of ECMV
Solenoid (1st) ........................................... 40-664
Failure code [DXH4KY] Hot Short of ECMV
Solenoid (1st) ........................................... 40-666
Failure code [DXH5KA] Disconnection of
ECMV Solenoid (2nd)................................ 40-669
Failure code [DXH5KB] Ground Fault of ECMV
Solenoid (2nd) .......................................... 40-671
Failure code [DXH5KY] Hot Short of ECMV
Solenoid (2nd) .......................................... 40-673
Failure code [DXH6KA] Disconnection of
ECMV Solenoid (3rd) ................................ 40-676
Failure code [DXH6KB] Ground Fault of ECMV
Solenoid (3rd) ........................................... 40-678
Failure code [DXH6KY] Hot Short of ECMV
Solenoid (3rd) ........................................... 40-680
7
INDEX
Failure code [DXH7KA] Disconnection of
ECMV Solenoid (Reverse) ......................... 40-683
Failure code [DXH7KB] Ground Fault of ECMV
Solenoid (Reverse) ................................... 40-685
Failure code [DXH7KY] Hot Short of ECMV
Solenoid (Reverse) ................................... 40-687
Failure code [DY30MA] Malfunction 1 of
Emerg. Steering Motor............................... 40-690
Failure code [DY30MC] Malfunction 2 of
Emerg. Steering Motor............................... 40-693
Failure code [DY30ME] Emerg. Steering Long-
Time Activated .......................................... 40-696
Failure code [DY32MC] Malfunction 2 of
Emerg. Steering Motor 2 ............................ 40-698
Failure code list related to air conditioner ........ 80-50
Failure codes table ..................................... 40-108
Failure mode and cause table ...................... 40-786
Final drive ........................................ 10-117, 60-35
Flow amplifier valve .................................... 10-122
Forward and reverse clutch ECMV and gear
speed clutch ECMV........................... 10-89, 60-25
Front brake cooling relief valve..................... 10-203
Fuse location table........................................ 40-97
H
H-1 Machine does not start .......................... 40-790
H-2 Machine does not travel smoothly (engine
hunts) ...................................................... 40-792
H-3 Lockup clutch is not disengaged ............ 40-793
H-4 Abnormally large shocks result from
starting of machine and gear shifting........... 40-794
H-5 Machine does not upshift....................... 40-795
H-6 Machine lacks travel speed or power
during travel in lockup drive mode through all
gear speeds ............................................. 40-797
H-7 Machine lacks travel speed or power
during travel in torque converter drive mode 40-798
H-8 Machine lacks travel speed or power
during travel in specific gear speed ............. 40-799
H-9 Machine starts or gear speed shifts with
long time lag ............................................. 40-800
H-10 Torque converter oil temperature is high .....40-
802
H-11 Torque converter oil pressure is low ...... 40-803
H-12 Front brake does not work sufficiently ... 40-804
H-13 Center brake does not work sufficiently. 40-805
H-14 Steering wheel is heavy to turn ............ 40-806
H-15 Steering wheel does not move ............. 40-807
H-16 Steering wheel swings ........................ 40-808
H-17 Dump body raise speed or power is slow ....40-
809
H-18 Dump body does not move .................. 40-811
H-19 Hydraulic drift of dump body is large ..... 40-812
H-20 Radiator fan speed is abnormal (high,
low, or (high, low, or stationary)................... 40-813
H-21 Aftercooler fan speed is abnormal (high,
low, or stationary) ...................................... 40-814
8 HM400-3M0
H-22 Unusual noise is heard from around
radiator fan ............................................... 40-815
H-23 Unusual noise is heard from around
aftercooler fan........................................... 40-816
Handling battery disconnect switch .............. 30-174
Handling cylinder cutout mode operation ........ 30-25
Handling equipment of fuel system devices..... 00-27
Handling no‐injection cranking operation ........ 30-26
Handling of compressor oil ............................ 80-79
Handling of electrical equipment .................... 00-34
Handling of hydraulic equipment .................... 00-29
Handling of intake system parts ..................... 00-28
Handling voltage circuit of engine controller .. 30-173
Hoist cylinder ............................................... 60-70
Hoist valve ....................................... 10-185, 60-68
How to open the electrical system abnormality
record screen in service mode of the machine
monitor....................................................... 80-37
How to read electric wire code ....................... 00-42
How to read the shop manual ........................ 00-23
How to read this manual .................................. 50-4
Hydraulic circuit diagram ................................. 90-9
Hydraulic component layout......................... 10-170
Hydraulic tank ............................................ 10-173
I
Important safety notice .................................. 00-16
Information described in troubleshooting table
(H-mode).................................................. 40-783
Information in troubleshooting table ...... 40-36, 80-49
Information mentioned in troubleshooting table
(S mode) .................................................. 40-817
Input and output signals of the air conditioner
controller .................................................... 80-26
Inside cab electrical circuit diagram ................ 90-17
Inspection procedure before troubleshooting... 40-16
K
KOMTRAX system ..................................... 10-263
KOMTRAX terminal start-up procedure......... 30-169
L
Layout of brake parts .................................. 10-134
Layout of steering devices ........................... 10-120
List of abbreviation........................................ 00-57
Lockup clutch ECMV........................... 10-96, 60-26
M
Machine monitor system.............................. 10-236
Main relief valve, torque converter relief valve,
and main flow selector valve ............ 10-104, 60-28
Method of disconnecting and connecting of
push-pull type coupler ................................. 00-31
Muffler ......................................................... 10-19
 INDEX

O Removal and installation of center differential

assembly.................................................. 50-189
Oil cooler bypass valve ................................. 10-50
Removal and installation of center final drive
Oscillation hitch ................................ 10-169, 60-56
and brake assembly .................................. 50-233
Outer temperature sensor.............................. 80-20
Removal and installation of cooling fan and fan
Outline of refrigeration cycle ............................ 80-8
motor assembly for radiator.......................... 50-67
Output shaft ...........................................10-5, 60-4
Removal and installation of cylinder head
Outside cab electrical circuit diagram.............. 90-33
assembly.................................................... 50-48
Removal and installation of dump body
P assembly.................................................. 50-307
Removal and installation of EGR (Exhaust Gas
Parking brake ................................... 10-159, 60-48
Recirculation) cooler assembly................... 50-106
Parking brake emergency releasing procedure....30-
Removal and installation of EGR (Exhaust Gas
71
Recirculation) valve assembly .................... 50-104
Parking brake solenoid and accumulator
Removal and installation of engine assembly .. 50-75
charge valve ............................................. 10-136
Removal and installation of engine controller
Parts and connectors layout .......................... 80-28
assembly.................................................. 50-326
Pm Clinic service ........................................ 30-175
Removal and installation of engine front oil
Power train hydraulic circuit diagram ................ 90-7
seal ........................................................... 50-84
Power train system ....................................... 10-51
Removal and installation of engine rear oil seal ...50-
Practical use of KOMTRAX............................ 00-50
88
Precautions for disconnecting and connecting
Removal and installation of equalizer bar
air conditioner piping ................................... 80-77
assembly.................................................. 50-270
Precautions for refrigerant ............................... 80-3
Removal and installation of exhaust pipe fire
Precautions on troubleshooting of machine
prevention cover ....................................... 50-109
monitor..................................................... 40-101
Removal and installation of flow amplifier valve
Precautions when performing operation.......... 00-45
assembly.................................................. 50-290
Preparation for troubleshooting of electrical
Removal and installation of front final drive and
system ....................................................... 40-25
brake assembly ........................................ 50-219
Procedure for testing and troubleshooting ....... 80-21
Removal and installation of front suspension
Procedure for troubleshooting wiring harness
cylinder assembly ..................................... 50-264
of pressure sensor system for open circuit..... 40-38
Removal and installation of front wheel
Processing procedure of harness checker for
assembly.................................................. 50-272
troubleshooting of machine monitor LCD unit.....40-
Removal and installation of hitch frame
103
assembly.................................................. 50-278
Proportional pressure reducing valve............ 10-149
Removal and installation of hoist valve
Pump for driving torque converter,
assembly.................................................. 50-293
transmission, aftercooler fan, and center
Removal and installation of injector assembly . 50-41
brake cooling motors ................................... 60-61
Removal and installation of KOMTRAX
terminal assembly ..................................... 50-330
R Removal and installation of machine monitor
assembly.................................................. 50-324
Radiator fan motor ................................10-41, 60-7
Removal and installation of operator's cab
Radiator fan pump ................................10-22, 60-5
assembly.................................................. 50-310
Rear view monitor system ........................... 10-259
Removal and installation of operator's cab
Receiver drier............................................... 80-19
glass (adhered glass) ................................ 50-315
Removal and installation of aftercooler
Removal and installation of operator's seat
assembly.................................................... 50-69
assembly.................................................. 50-321
Removal and installation of air cleaner
Removal and installation of output shaft
assembly.................................................. 50-102
assembly.................................................... 50-94
Removal and installation of air conditioner
Removal and installation of radiator assembly . 50-60
compressor assembly ............................... 50-336
Removal and installation of rear (back side)
Removal and installation of air conditioner
wheel assembly ........................................ 50-277
condenser assembly ................................. 50-338
Removal and installation of rear (front side)
Removal and installation of air conditioner unit
wheel assembly ........................................ 50-276
assembly.................................................. 50-331
Removal and installation of rear axle assembly ...50-
Removal and installation of center axle
255
assembly.................................................. 50-251
Removal and installation of rear differential
assembly.................................................. 50-207

HM400-3M0 9
INDEX
Removal and installation of rear final drive
assembly.................................................. 50-245
Removal and installation of rear suspension
cylinder assembly ..................................... 50-266
Removal and installation of retarder and hoist
controller assembly ................................... 50-328
Removal and installation of seat belt............. 50-323
Removal and installation of supply pump
assembly.................................................... 50-37
Removal and installation of transmission and
front differential assembly .......................... 50-113
Removal and installation of transmission
controller assembly ................................... 50-329
Retrieval of disabled machine due to traction
control system (KTCS) failure....................... 30-56
Retrieval of disabled machine that resulted
from a trouble in electrical system................. 30-52
ROPS cab.................................................. 10-205
S Table of fuel, coolant, and lubricants ............... 01-12
S-1 When starting switch is turned to START
position, engine is not cranked ................... 40-818
S-2 The engine cranks but exhaust smoke
does not come out..................................... 40-819
S-3 Fuel is injected but engine does not start
(incomplete combustion, engine seems to
start but does not) ..................................... 40-820
S-4 Engine startability is poor....................... 40-821
S-5 Engine does not pick up smoothly .......... 40-823
S-6 Engine stops during operation................ 40-825
S-7 Engine runs rough or is unstable ............ 40-827
S-8 Engine lacks power............................... 40-828
S-9 Exhaust smoke is black ......................... 40-830
S-10 Engine oil consumption is excessive..... 40-832
S-11 Oil becomes contaminated quickly........ 40-833
S-12 Fuel consumption is excessive............. 40-834
S-13 Oil is in coolant (or coolant spurts or
coolant level goes down) ........................... 40-835
S-14 Oil pressure drops............................... 40-836
S-15 Fuel mixes into engine oil .................... 40-837
S-16 Water mixes into engine oil (milky)........ 40-838
S-17 Coolant temperature rises too high
(overheating) ............................................ 40-839
S-18 Unusual noise is heard ........................ 40-840
S-19 Vibration is excessive.......................... 40-841
S-20 Air cannot be bled from fuel circuit ........ 40-842
Sensor....................................................... 10-292
Sequence of events in troubleshooting ........... 40-12
Setting and adjusting each equipment ............ 30-87
Shut off solenoid valve ................................ 10-143
Sketch of tools for testing and adjusting ............ 30-8
Sketches of special tools ............................... 50-19
Slack adjuster................................... 10-151, 60-43
Special functions of machine monitor.............. 30-98
Special tools list............................................ 50-10
Specification drawing ...................................... 01-3
Specifications .........................................01-3, 01-5
Standard tightening torque table .................... 00-51
10
Standard value table for engine........................ 20-3
Standard value table for machine ..................... 20-5
Steering and hoist pump.................... 10-174, 60-58
Steering column ............................... 10-121, 60-40
Steering cylinder........................................... 60-41
Steering pump selector solenoid valve.......... 10-191
Steering valve ............................................ 10-126
Suspension ...................................... 10-162, 60-50
Suspension cylinder.......................... 10-166, 60-54
Symbols in electric circuit diagram.................. 90-13
Symbols in hydraulic circuit diagram................. 90-3
Symptom and troubleshooting numbers.......... 40-34
System chart of hydraulic and mechanical
systems ................................................... 40-784
System component parts............................. 10-266
System diagram ........................................... 80-25
T
T-boxes and T-adapters list............................ 40-92
Testing (dual) pressure switch for refrigerant ... 80-41
Testing accumulator nitrogen gas pressure and
charging procedure for accumulator nitrogen
gas ............................................................ 30-64
Testing air leakage (duct)............................... 80-33
Testing and adjusting air conditioner
compressor belt tension............................... 30-34
Testing and adjusting alternator belt tension .... 30-33
Testing and adjusting brake oil pressure ......... 30-60
Testing and adjusting dump circuit oil pressure ....30-
79
Testing and adjusting steering circuit oil
pressure..................................................... 30-58
Testing and adjusting suspension cylinder ...... 30-74
Testing blowby pressure ................................ 30-20
Testing boost pressure .................................. 30-10
Testing braking performance.......................... 30-68
Testing compression pressure ....................... 30-18
Testing drive pressure of EGR valve and
bypass valve .............................................. 30-23
Testing engine oil pressure ............................ 30-21
Testing engine speed ...................................... 30-9
Testing exhaust gas color .............................. 30-14
Testing exhaust gas temperature ................... 30-12
Testing FRESH/RECIRC air changeover ........ 80-40
Testing fuel circuit for leakage ........................ 30-31
Testing fuel pressure ..................................... 30-24
Testing fuel return rate and leakage ................ 30-27
Testing power train oil pressure ...................... 30-37
Testing radiator fan and aftercooler fan speed . 30-32
Testing relays ............................................... 80-43
Testing torque converter stall speed ............... 30-35
Testing vent (mode) changeover .................... 80-39
Testing wear of parking brake pad and
adjusting clearance ..................................... 30-72
Testing wear of wheel brake disc.................... 30-70
Testing with self-diagnosis function................. 80-36
Tools for testing and adjusting.......................... 30-3
HM400-3M0
 INDEX

Torque converter................................. 10-55, 60-13

Torque converter and transmission hydraulic
piping......................................................... 10-54
Torque converter and transmission mount....... 60-12
Transmission...................................... 10-61, 60-16
Transmission control system........................ 10-207
Transmission control valve .................. 10-86, 60-24
Troubleshooting chart 1................................. 80-45
Troubleshooting chart 2................................. 80-46
Troubleshooting points .................................. 40-10
Troubleshooting with gauge pressure ............. 80-72
Turbocharger.................................................. 10-6

W
Weight table ................................................. 01-11

HM400-3M0 11
HM400-3M0 ARTICULATED DUMP TRUCK
Form No. SEN06284-06

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Printed in Japan 05–16