Komatsu HM400-2 Articulated Dump Truck Shop Manual CEBM007901 PDF

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Komatsu HM400-2 Articulated Dump Truck Shop Manual CEBM007901 – PDF DOWNLOAD

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Komatsu HM400-2 Articulated Dump Truck Shop Manual CEBM007901 – PDF DOWNLOAD 

Language : English
Pages : 1494
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu HM400-2 Articulated Dump Truck Shop Manual CEBM007901 – PDF DOWNLOAD 

SERIAL NUMBERS HM400-2 A11001 and up
ENGINE SAA6D140E-5

How to read the shop manual 
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00.Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01.Specification
This section explains the specifications of the machine.
10.Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20.Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30.Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40.Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50.Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90.Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

Komatsu HM400-2 Articulated Dump Truck Shop Manual CEBM007901 – PDF DOWNLOAD 

SERIAL NUMBERS HM400-2 A11001 and up
ENGINE SAA6D140E-5

CEBM007900 – s/n A11001 AND UP 0
00 Index and foreword 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 17
Safety notice 18
How to read the shop manual 23
Explanation of terms for maintenance standard 25
Handling of electric equipment and hydraulic component 27
Handling of connectors newly used for engines 36
How to read electric wire code 39
Precautions when carrying out operation 42
Method of disassembling and connecting push-pull type coupler 45
Standard tightening torque table 48
Conversion table 52
01 Specification 59
Specification and technical data 59
Specification drawings 60
Specifications 61
Weight table 64
Fuel, coolant and lubricants 65
10 Structure, function and maintenance standard 69
Engine and cooling system 69
Radiator, oil cooler, aftercooler 70
Output shaft 71
Power train, Part 1 75
Power train skeleton 76
Torque converter and transmission hydraulic piping 80
Brake cooling oil control valve (BCV) 82
Power train pump 83
Torque converter 86
Transmission 92
FL, R clutch 98
FH, 1st clutch 99
2nd, 3rd clutch 100
Differential lock clutch 102
Operation of the disc clutch 104
When clutch is “engaged” (fixed) 104
Clutch “disengaged” (released) 104
Forward 1st speed 106
Forward 2nd speed 108
Forward 3rd speed 110
Forward 4th speed 112
Forward 5th speed 114
Forward 6th speed 116
Reverse 1st speed 118
Transmission control valve 120
ECMV 121
Main relief, torque converter relief valve 128
Power train, Part 2 131
Drive shaft 132
Front drive shaft 133
Left and right drive shaft 133
Center drive shaft 134
Rear drive shaft (front) 134
Rear drive shaft (rear) 135
Axle 136
Front 136
Center 137
Rear 138
Differential 140
Front 140
Center 142
Rear 144
(Machine with limited slip differential) 146
Front 146
Center 148
Rear 150
Limited slip differential 152
Final drive 156
Front 156
Center, rear 158
Steering system 161
Steering column 162
Brake system 165
Brake piping 166
Brake valve 168
Accumulator charge valve 171
Accumulator 175
Slack adjuster 176
Brake 178
Front 178
Center, rear 180
Proportional reducing valve 183
Brake system tank 184
Parking brake 186
Parking brake caliper 188
Spring cylinder 189
Parking brake solenoid valve 190
Undercarriage and frame 193
Suspension 194
Front 194
Rear 196
Suspension cylinder 199
Oscillation hitch 201
Hydraulic system 205
Steering, hoist oil pressure piping diagram 206
Dump body control 207
Hydraulic tank and filter 208
Flow amp valve 209
Steering valve 212
Steering cylinder 216
Hoist valve 218
Dump control valve (EPC valve) 224
Pilot check valve 228
Hoist cylinder 229
Hydraulic pump 230
Steering, hoist control pump 230
Emergency steering pump 231
Differential lock pump (Machine with differential lock differential) 232
Cab and its attachments 235
ROPS cab 236
Cab tilt 237
Air conditioner 238
Rear view monitor 246
Controller related 249
Electrical system, Part 1 251
Machine monitor system 252
Machine monitor 254
Electrical system, Part 2 273
Automatic shift control system 274
Transmission controller 277
Input and output signals 278
Transmission controller list of real-time monitoring display contents 284
Hoist control function 304
Retarder control system 306
Retarder controller 308
Input and output signals 309
Retarder controller list of real-time monitoring display contents 310
Retarder control function 314
Differential lock control function 317
Auto emergency steering system 318
Emergency steering motor 319
Battery disconnect switch 320
Dump control lever 322
Electrical system, Part 3 327
Payload meter (Card type) 328
Structure of system 328
Principle of calculation 329
Method of using accurately 330
General locations of payload meter 332
Left face 333
Basic functions 334
Key operation 342
Service check mode 344
Error code table 350
Local installation 353
Electrical system, Part 4 361
Sensors, switches 362
Accelerator sensor 362
Retarder oil temperature sensor 364
Steering oil temperature sensor 364
Fuel level sensor 365
Tilt sensor 366
Air cleaner clogging sensor 367
Hydraulic oil level sensor 368
Body positioner sensor 369
Pressure sensor (for payload meter) 370
Inclinometer (for payload meter) 370
Body sensor (for payload meter) 371
Articulate angle sensor (for payload meter) 371
KOMTRAX terminal system (if equipped) 372
KOMTRAX communication modem 373
20 Standard value table 375
Standard service value table 375
Standard value table for engine 376
Standard value table for chassis 377
30 Testing and adjusting 383
Testing and adjusting, Part 1 383
Tools for testing, adjusting, and troubleshooting 385
Measuring engine speed 389
Testing intake air pressure (boost pressure) 390
Testing exhaust temperature 391
Testing exhaust gas color 392
Adjusting valve clearance 393
Testing compression pressure 394
Testing blow-by pressure 396
Testing engine oil pressure 397
Testing EGR valve and bypass valve drive oil pressure 398
Handling of fuel system devices 399
Releasing residual pressure from fuel system 399
Testing fuel pressure 400
Testing fuel return and leakage amount 401
Bleeding air from fuel circuit 404
Testing the fuel circuit for leakage 406
Testing and adjusting fan belt tension 407
Testing and adjusting alternator belt tension 408
Testing and adjusting air conditioner compressor belt tension 409
Testing and adjusting, Part 2 411
Testing torque converter stall speed 413
Testing power train oil pressure 414
List of oil pressure testing points and gauges tobe used 414
Testing instruments for power train oil pressure 415
Overall power train 415
Torque converter related 416
Transmission related 417
Testing and adjusting of differential lock oil pressure (differential lock spec ) 422
Adjusting transmission speed sensor 427
Testing and adjusting brake oil pressure 429
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 433
Testing instrument 433
Testing of accumulator nitrogen gas pressure 433
Procedure for charging accumulator with nitrogen gas 434
Testing brake performance 437
Bleeding air from brake circuit 438
Testing wear of wheel brake disc 439
Testing the parking brake pad wear 440
Emergency release of the parking brake 441
Testing and adjusting steering circuit oil pressure 442
Testing and adjusting suspension cylinder 444
Method of tilting cab up 448
Testing and adjusting dump circuit oil pressure 450
Adjusting body position sensor 452
Adjusting length of spring in body heating spherical joint 454
Handling of voltage circuit of engine controller 454
Adjusting transmission controller 454
Method for emergency escape at electrical system failure 455
Testing and adjusting, Part 3 461
Setting and adjusting various equipment 462
Setting of model selection 463
Setting of option selection 465
OFF setting of maintenance monitor (corrosion resistor) 469
Special function of machine monitor 471
Normal function and special function of machine monitor 471
Function and flow of each mode 472
Operator mode (Outline) 474
Failure code table 478
Service mode 484
Monitoring code table 491
MONITOR PANEL [Machine monitor system] 491
TRANSMISSION [Transmission controller system] 493
ENGINE [Engine controller system] 496
BRAKE [Retarder controller system] 498
Table of filter and oil replacement time set items 512
How to start operation of KOMTRAX terminal 516
Lamp display of KOMTRAX terminal 521
Pm Clinic check sheet 524
Initial setting of payload meter 527
40 Troubleshooting 529
General information on troubleshooting 529
Points to remember when troubleshooting 530
Sequence of events in troubleshooting 531
Check before troubleshooting 532
Classification and procedures for troubleshooting 533
Classification for troubleshooting 533
Procedure for troubleshooting 533
Phenomena looking like troubles and troubleshooting Nos 534
Connection table for connector pin numbers 536
T-branch box and T-branch adapter table 572
Troubleshooting by failure code, General 577
Troubleshooting by failure code, General 578
Failure codes table 578
Before troubleshooting by failure code 586
Locations and connections of circuit breakers (30 A and 80 A) 586
Location and connection of fuse box (BT1) 587
Location and connection of fuse box (BT2) 588
Location and connection of fuse box (BT3) 589
Location and connection of fuse box (BT4) 590
Location and connection of fuse (V) 591
Fuse box (BT4) 592
Information in troubleshooting table 594
Troubleshooting by failure code, Part 1 597
Troubleshooting by failure code, Part 1 599
Failure code [1500L0] Double engagement 599
Failure code [15B0NX] Transmission oil filter: Clogged 600
Failure code [15F0KM] R o F shifting abuse 1 602
Failure code [15F0MB] R o F shifting abuse 2 602
Failure code [15F7KM] Transmission forward clutch abuse 603
Failure code [15G0MW] Trouble in reverse clutch system (Slip) 604
Failure code [15G7KM] Transmission reverse clutch abuse 606
Failure code [15H0MW] Trouble in Hi clutch system (Slip) 608
Failure code [15J0MW] Trouble in Lo clutch system (Slip) 610
Failure code [15K0MW] Trouble in 1st clutch system (Slip) 612
Failure code [15L0MW] Trouble in 2nd clutch system (Slip) 614
Failure code [15M0MW] Trouble in 3rd clutch system (Slip) 616
Failure code [15SBL1] Trouble in reverse clutch pressure control valve 618
Failure code [15SBMA] Trouble in reverse clutch pressure control valve 622
Failure code [15SCL1] Trouble in Hi clutch pressure control valve 624
Failure code [15SCMA] Trouble in Hi clutch pressure control valve 628
Failure code [15SDL1] Trouble in Lo clutch pressure control valve 630
Failure code [15SDMA] Trouble in Lo clutch pressure control valve 632
Troubleshooting by failure code, Part 2 637
Failure code [15SEL1] Trouble in 1st clutch pressure control valve 639
Failure code [15SEMA] Trouble in 1st clutch pressure control valve 642
Failure code [15SFL1] Trouble in 2nd clutch pressure control valve 644
Failure code [15SFMA] Trouble in 2nd clutch pressure control valve 648
Failure code [15SGL1] Trouble in 3rd clutch pressure control valve 650
Failure code [15SGMA] Trouble in 3rd clutch pressure control valve 654
Failure code [15SJMA] Trouble in lockup clutch pressure control valve 656
Failure code [15SKMA] Trouble in interaxle differential lock clutch pressure control valve 658
Failure code [2A62L1] Trouble in front wheel differential lock pressure control valve 2 660
Failure code [2A62LH] Trouble in front wheel differential lock pressure control valve 1 662
Failure code [2B62L1] Trouble in rear wheel differential lock pressure control valve 2 664
Failure code [2B62LH] Trouble in rear wheel differential lock pressure control valve 1 666
Failure code [2C4MNX] Clogging of retarder cooling oil filter 668
Failure code [2F00KM] Dragging of parking brake 670
Failure code [2G42ZG] Lowering of accumulator oil pressure (front) 672
Failure code [2G43ZG] Lowering of accumulator oil pressure (rear) 672
Failure code [989A00] Operation of engine overrun prevention system 673
Failure code [989D00] Rear section tipping over alarm (Raising operation on slope) 673
Failure code [A570NX] Clogging of engine oil filter 674
Failure code [AA10NX] Clogging of air cleaner 676
Failure code [AB00MA] Trouble in battery charge circuit 678
Failure code [B@BAZG] Lowering of engine oil pressure 679
Failure code [B@BAZK] Lowering of engine oil level 680
Failure code [B@BCNS] Overheating of engine 681
Failure code [B@BCZK] Lowering of coolant level 682
Failure code [B@BFZK] Lowering of fuel level 684
Failure code [B@C6NS] Overheating of brake cooling oil (front) 685
Failure code [B@C7NS] Overheating of brake cooling oil (rear) 685
Failure code [B@C8NS] Overheating of brake cooling oil (center) 686
Failure code [B@CENS] Overheating of torque converter oil 686
Failure code [B@JANS] Overheating of steering oil 687
Troubleshooting by failure code, Part 3 689
Failure code [CA111] Trouble in engine controller 692
Failure code [CA115] Trouble in engine Ne and Bkup speed sensors 694
Failure code [CA122] Abnormally high charge pressure 696
Failure code [CA123] Abnormally low charge pressure 698
Failure code [CA131] Abnormally high throttle sensor signal 700
Failure code [CA132] Abnormally low throttle sensor signal 702
Failure code [CA135] Abnormally high engine oil pressure 704
Failure code [CA141] Abnormally low engine oil pressure 706
Failure code [CA144] Abnormally high coolant temperature 708
Failure code [CA145] Abnormally low coolant temperature 710
Failure code [CA153] Abnormally high charge temperature 712
Failure code [CA154] Abnormally low charge temperature 714
Failure code [CA187] Abnormally low voltage in sensor power supply 2 715
Failure code [CA221] Abnormally high ambient pressure 716
Failure code [CA222] Abnormally low ambient pressure 718
Failure code [CA227] Abnormally high voltage in sensor power supply 2 720
Failure code [CA234] Engine overspeed 722
Failure code [CA238] Trouble in Ne speed sensor power supply 724
Failure code [CA263] Abnormally high fuel temperature 726
Failure code [CA265] Abnormally low fuel temperature 728
Failure code [CA271] Short circuit in PCV1 729
Failure code [CA272] Disconnection in PCV1 730
Failure code [CA273] Short circuit in PCV2 731
Failure code [CA274] Disconnection in PCV2 732
Failure code [CA322] Disconnection or short circuit in injector #1 (L #1) 734
Failure code [CA323] Disconnection or short circuit in injector #5 (L #5) 736
Failure code [CA324] Disconnection or short circuit in injector #3 (L #3) 738
Failure code [CA325] Disconnection or short circuit in injector #6 (L #6) 740
Failure code [CA331] Disconnection or short circuit in injector #2 (L #2) 742
Failure code [CA332] Disconnection or short circuit in injector #4 (L #4) 744
Failure code [CA342] Matching error in engine controller data 746
Failure code [CA351] Trouble in injector drive circuit 748
Failure code [CA352] Abnormally low voltage in sensor power supply 1 750
Failure code [CA386] Abnormally high voltage in sensor power supply 1 752
Troubleshooting by failure code, Part 4 755
Failure code [CA431] Trouble in idle validation switch 758
Failure code [CA432] Trouble in idle validation process 761
Failure code [CA441] Abnormally low voltage in power supply 761
Failure code [CA442] Abnormally high voltage in power supply 762
Failure code [CA449] Abnormally high common rail pressure 2 762
Failure code [CA451] Abnormally high common rail pressure 764
Failure code [CA452] Abnormally low common rail pressure 766
Failure code [CA553] Abnormally high common rail pressure 1 766
Failure code [CA554] In-range error in common rail pressure sensor 767
Failure code [CA559] Supply pump low pressure 1 769
Failure code [CA689] Trouble in engine Ne speed sensor 772
Failure code [CA731] Phase error in engine Bkup speed sensor 774
Failure code [CA757] Loss of all data in engine controller 774
Failure code [CA778] Trouble in engine Bkup speed sensor 776
Failure code [CA1228] Trouble in EGR valve servo 1 778
Failure code [CA1625] Trouble in EGR valve servo 2 779
Failure code [CA1626] Short circuit in bypass valve solenoid drive circuit 780
Failure code [CA1627] Disconnection in bypass valve solenoid drive circuit 782
Failure code [CA1628] Trouble in bypass valve servo 1 783
Failure code [CA1629] Trouble in bypass valve servo 2 784
Failure code [CA1631] Abnormally high signal in bypass valve lift sensor 786
Failure code [CA1632] Abnormally low signal in bypass valve lift sensor 788
Failure code [CA1633] Trouble in KOMNET 790
Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor 792
Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor 794
Failure code [CA2185] Abnormally high voltage in throttle sensor power supply 796
Failure code [CA2186] Abnormally low voltage in throttle sensor power supply 798
Failure code [CA2249] Low pressure in supply pump 2 798
Failure code [CA2271] Abnormally high signal voltage in EGR valve lift sensor 800
Failure code [CA2272] Abnormally low signal voltage in EGR valve lift sensor 802
Failure code [CA2351] Short circuit in EGR valve solenoid drive circuit 804
Failure code [CA2352] Disconnection in EGR valve solenoid drive circuit 806
Failure code [CA2555] Disconnection in intake air heater relay 806
Failure code [CA2556] Short circuit in intake air heater relay 808
Troubleshooting by failure code, Part 5 811
Failure code [DAF9KM] Wrong connection of connector 813
Failure code [DAFRKR] Trouble in CAN communication (machine monitor) 814
Failure code [DAQ0KK] Lowering of source voltage 816
Failure code [DAQ0KT] Trouble in non-volatile memory 818
Failure code [DAQ2KK] Trouble in solenoid power supply system 820
Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller) 822
Failure code [DAQRKR] Trouble in CAN communication (Transmission controller) 824
Failure code [DAQRMA] Disagreement of option setting (Transmission controller) 826
Failure code [DB10KT] Trouble in non-volatile memory 826
Failure code [DB12KK] Trouble in solenoid power supply system 828
Failure code [DB13KK] Lowering of battery direct voltage 830
Failure code [DB19KQ] Disagreement of model selection (Retarder controller) 832
Failure code [DB1QMA] Disagreement of option setting (Retarder controller) 832
Failure code [DB1RKR] Trouble in CAN communication (Retarder controller) 834
Failure code [DB2RKR] Trouble in CAN communication (Engine controller) 836
Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal 838
Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve 840
Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve 841
Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve 842
Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve 843
Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve 844
Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve 845
Failure code [DF10KA] Input of no lever signals 846
Failure code [DF10KB] Input of multiple lever signals 850
Failure code [DGF1KX] Transmission oil temperature out of range 854
Failure code [DGR2KZ] Ground fault in brake oil temperature sensor (rear) 856
Failure code [DGR2L8] Disconnection in brake oil temperature sensor (rear) 858
Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center) 860
Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center) 862
Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front) 864
Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front) 866
Failure code [DGR6KX] Steering oil temperature out of range 868
Troubleshooting by failure code, Part 6 871
Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system 874
Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil pressure sensor system 876
Failure code [DHT5L6] Trouble in torque converter oil pressure sensor 878
Failure code [DHU2KX] Trouble in accumulator oil pressure sensor (front) system 880
Failure code [DHU3KX] Trouble in accumulator oil pressure sensor (rear) system 882
Failure code [DJF1KA] Disconnection in fuel level sensor system 884
Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS 886
Failure code [DK52KX] Trouble in dump lever potentiometer 1 888
Failure code [DK53L8] Trouble in dump lever potentiometer 2 890
Failure code [DK54KX] Trouble in dump positioner sensor 892
Failure code [DKH0KX] Pitch angle sensor signal out of range 894
Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system 896
Failure code [DLF1LC] Trouble in transmission input shaft speed sensor 897
Failure code [DLF2KA] Disconnection in transmission intermediate shaft speed sensor system 898
Failure code [DLF2LC] Disconnection in transmission intermediate shaft speed sensor system 899
Failure code [DLF4KA] Disconnection in transmission differential speed sensor system 900
Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system 901
Failure code [DV00KB] Short circuit in buzzer output circuit 902
Failure code [DW72KZ] Trouble (Disconnection or ground fault) in kick-out solenoid output system 904
Failure code [DW73KZ] Trouble in dump selector valve output system 906
Failure code [DW78KZ] Trouble in rear wheel BCV command output system 908
Failure code [DW79KZ] Trouble in front wheel BCV command output system 910
Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1 912
Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid pressure reducing valve 914
Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid pressure reducing valve 916
Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid pressure reducing valve 918
Failure code [DX11MA] Trouble in rear wheel proportional solenoid pressure reducing valve 2 920
Failure code [DX12K4] Trouble in front wheel proportional solenoid pressure reducing valve 1 922
Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid pressure reducing valve 924
Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid pressure reducing valve 926
Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid pressure reducing valve 928
Failure code [DX12MA] Trouble in front wheel proportional solenoid pressure reducing valve 2 930
Troubleshooting by failure code, Part 7 933
Troubleshooting by failure code, Part 7 936
Failure code [DX13KA] Disconnection in output circuit of dump EPC valve 936
Failure code [DX13KB] Ground fault in output circuit of dump EPC valve 938
Failure code [DX13KY] Hot short in output circuit of dump EPC valve 940
Failure code [DX14KZ] Trouble in rear wheel differential lock command output system 942
Failure code [DX15KZ] Trouble in front wheel differential lock command output system 944
Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch solenoid 946
Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch solenoid 948
Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid 950
Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid 951
Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid 952
Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid 954
Failure code [DXH2KA] Disconnection in output circuit of Hi clutch solenoid 956
Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid valve 958
Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid valve 960
Failure code [DXH3KA] Disconnection in output circuit of Lo clutch solenoid 964
Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid valve 966
Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid valve 968
Failure code [DXH4KA] Disconnection in output circuit of 1st clutch solenoid 972
Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid valve 974
Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid valve 976
Troubleshooting by failure code, Part 8 981
Troubleshooting by failure code, Part 8 982
Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch solenoid 982
Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid valve 984
Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid valve 986
Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch solenoid 990
Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid valve 992
Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid valve 994
Failure code [DXH7KA] Disconnection in output circuit of reverse clutch solenoid 998
Failure code [DXH7KB] Ground fault in output circuit of reverse clutch ECMV solenoid valve 1000
Failure code [DXH7KY] Hot short in output circuit of reverse clutch ECMV solenoid valve 1002
Troubleshooting for electrical system (E-mode) 1007
Before troubleshooting for electrical system 1009
Locations and connections of circuit breakers (30 A and 80 A) 1009
Location and connection of fuse box (BT1) 1010
Location and connection of fuse box (BT2) 1011
Location and connection of fuse box (BT3) 1012
Location and connection of fuse box (BT4) 1013
Location and connection of fuse (V) 1014
Information in troubleshooting table 1015
E-1 Engine does not start (Starting motor does not turn) 1016
E-2 Auto preheater does not operate 1020
E-3 When starting switch is turned ON, machine monitor displays nothing 1024
E-4 When starting switch is turned OFF, machine monitor cannot be operated 1026
E-5 Alarm buzzer does not stop sounding 1028
E-6 Machine monitor does not normally display gauges, caution lamps, and character display section 1029
E-7 Display of character display section cannot be changed 1030
E-8 Power mode selection function does not operate normally 1034
E-9 AISS function does not operate normally 1036
E-10 Right and left differential lock function does not operate normally (Differential lock-up specification) 1038
E-11 Interaxle differential lock-up function does not operate normally 1042
E-12 Display of seat belt caution lamp is abnormal 1044
E-13 Turn signal lamps and pilot lamps do not operate normally 1046
E-14 Night lighting is abnormal 1051
E-15 Backup lamp and backup buzzer operate abnormally 1057
E-16 Emergency steering system does not operate 1061
Troubleshooting of hydraulic and mechanical system (H-mode) 1067
Troubleshooting of hydraulic and mechanical system (H-mode) 1069
Information in troubleshooting table 1069
H-1 Machine does not start 1070
H-2 Travel is not smooth (Machine hunts) 1072
H-3 Lockup is not reset 1072
H-4 Start shock and gear shift shock are abnormally large 1073
H-5 Gear is not shifted up 1074
H-6 Travel speed or power is low 1076
H-7 Start and gearshift time lag is large 1080
H-8 Torque converter oil temperature is high 1082
H-9 Torque converter oil temperature is low 1083
H-10 Front brake does not work fully 1084
H-11 Center brake does not work fully 1085
H-12 Rear brake does not work fully 1086
H-13 Steering wheel is heavy 1087
H-14 Steering wheel does not move 1088
H-15 Steering wheel waggle 1089
H-16 Dump body raising speed is low 1090
H-17 Dump body does not move 1091
H-18 Hydraulic drift of dump body is large 1092
Troubleshooting of engine (S-mode) 1095
Method of using troubleshooting chart 1098
S-1 Starting performance of engine is poor 1102
S-2 Engine does not start 1104
S-3 Engine does not pick up smoothly 1108
S-4 Engine stops during operation 1109
S-5 Engine does not rotate smoothly 1110
S-6 Engine lack output (or lacks power) 1111
S-7 Exhaust gas is black (incomplete combustion) 1112
S-8 Oil consumption is excessive (or exhaust gas is blue) 1114
S-9 Oil becomes dirty quickly 1115
S-10 Fuel consumption is excessive 1116
S-11 Oil is in coolant (or coolant sprays back or coolant level goes down) 1117
S-12 Oil pressure drops 1118
S-13 Oil level rises (Entry of coolant or fuel) 1120
S-14 Coolant temperature becomes too high (Overheating) 1122
S-15 Abnormal noise is made 1123
S-16 Vibration is excessive 1124
50 Disassembly and assembly 1127
General information on disassembly and assembly 1127
How to read this manual 1128
List of adhesives 1130
Special tool list 1133
Sketches of special tools 1139
Engine and cooling system 1153
Removal and installation of fuel supply pump 1154
Special tools 1154
Removal 1154
Installation 1156
Removal and installation of engine assembly 1157
Special tools 1157
Removal 1157
Installation 1163
Removal and installation of cylinder head assembly 1165
Special tools 1165
Removal 1165
Installation 1173
Removal and installation of fuel injector assembly 1178
Special tools 1178
Removal 1178
Installation 1181
Removal and installation of radiator assembly 1184
Special tools 1184
Removal 1184
Installation 1187
Removal and installation of cooling assembly 1188
Removal 1188
Installation 1191
Removal and installation of aftercooler 1192
Special tools 1192
Removal 1192
Installation 1194
Removal and installation of engine front seal 1195
Special tools 1195
Removal 1195
Installation 1195
Removal and installation of engine rear seal 1197
Special tools 1197
Removal 1197
Installation 1198
Power train, Part 1 1203
Removal and installation of output shaft assembly 1204
Special tools 1204
Removal 1204
Installation 1207
Disassembly and assembly of output shaft assembly 1208
Disassembly 1208
Assembly 1209
Removal and installation of transmission and front differential assembly 1211
Special tools 1211
Removal 1211
Installation 1217
Disconnection and coupling of front differential and transmission 1219
Disconnection 1219
Coupling 1219
Disassembly and assembly of torque converter assembly 1220
Special tools 1220
Disassembly 1220
Assembly 1223
Disassembly and assembly of transmission assembly 1228
Disassembly 1228
Assembly 1247
Power train, Part 2 1275
Disassembly and assembly of front differential assembly 1276
Special tools 1276
Disassembly 1276
Assembly 1283
Removal and installation of center differential assembly 1293
Removal 1293
Installation 1294
Disassembly and assembly of center differential assembly 1296
Special tools 1296
Disassembly 1296
Assembly 1301
Removal and installation of rear differential assembly 1311
Removal 1311
Installation 1312
Disassembly and assembly of rear differential assembly 1313
Special tools 1313
Disassembly 1313
Assembly 1317
Power train, Part 3 1327
Removal and installation of front final drive and brake assembly 1328
Removal 1328
Installation 1329
Disassembly and assembly of front final drive and brake assembly 1330
Special tools 1330
Disassembly 1330
Assembly 1335
Removal and installation of center final drive and brake assembly 1343
Removal 1343
Installation 1344
Disassembly and assembly of center final drive and plate assembly 1345
Special tools 1345
Disassembly 1345
Assembly 1349
Removal and installation of rear final drive and brake assembly 1354
Removal 1354
Installation 1355
Disassembly and assembly of rear final drive and brake assembly 1356
Special tools 1356
Disassembly 1356
Assembly 1360
Removal and installation of center axle assembly 1366
Removal 1366
Installation 1367
Removal and installation of rear axle assembly 1369
Removal 1369
Installation 1371
Undercarriage and frame 1373
Removal and installation of front suspension cylinder assembly 1374
Removal 1374
Installation 1375
Removal and installation of rear suspension cylinder assembly 1376
Removal 1376
Installation 1376
Removal and installation of equalizer bar assembly 1377
Removal 1377
Installation 1378
Removal and installation of front wheel assembly 1379
Removal 1379
Installation 1379
Removal and installation of rear front wheel assembly 1380
Removal 1380
Installation 1380
Removal and installation of rear rear wheel assembly 1380
Removal 1380
Installation 1380
Removal and installation of hitch frame assembly 1381
Removal 1381
Installation 1385
Disassembly and assembly of hitch frame 1387
Disassembly 1387
Assembly 1388
Removal and installation of body assembly 1390
Removal 1390
Installation 1391
Hydraulic system 1393
Disassembly and assembly of steering valve 1394
Component parts 1394
Disassembly 1396
Assembly 1399
Removal and installation of flow amplifier valve assembly 1404
Special tools 1404
Removal 1404
Installation 1405
Removal and installation of hoist valve assembly 1406
Special tools 1406
Removal 1406
Installation 1407
Disassembly and assembly of hoist valve assembly 1408
Disassembly 1408
Assembly 1409
Disassembly and assembly of steering cylinder assembly 1410
Special tools 1410
Disassembly 1410
Assembly 1412
Disassembly and assembly of hoist cylinder assembly 1416
Special tools 1416
Disassembly 1416
Assembly 1418
Cab and its attachments 1425
Removal and installation of operator’s cab 1426
Special tools 1426
Removal 1426
Installation 1430
Removal and installation of operator’s cab glass (Stuck glass) 1431
Special tools 1432
Removal 1432
Installation 1433
Disassembly and assembly of operator’s seat assembly 1437
Disassembly 1437
Assembly 1442
Removal and installation of air conditioner unit assembly 1447
Special tools 1447
Removal 1447
Installation 1451
Electrical system 1453
Removal and installation of retarder controller assembly 1454
Removal 1454
Installation 1455
Removal and installation of transmission controller assembly 1456
Removal 1456
Installation 1457
Removal and installation of engine controller assembly 1458
Special tools 1458
Removal 1458
Installation 1459
90 Diagrams and drawings 1461
Hydraulic diagrams and drawings 1461
Steering and hoist hydraulic circuit diagram (Serial No : Previous Design) 1463
Steering and hoist hydraulic circuit diagram (Serial No : New Design) 1464
Brake hydraulic circuit diagram 1465
Brake cooling hydraulic circuit diagram 1466
Differential lock hydraulic circuit diagram 1467
Power train hydraulic circuit diagram 1469
Electrical diagrams and drawings 1472
Electrical circuit diagram for inside cab (2/4) Serial No : Previous Design 1476
Electrical circuit diagram for inside cab (1/4) 1474
Electrical circuit diagram for inside cab (2/4) Serial No : New Design 1478
Electrical circuit diagram for inside cab (3/4) Serial No : Previous Design 1480
Electrical circuit diagram for inside cab (3/4) Serial No : New Design 1482
Electrical circuit diagram for inside cab (4/4) 1484
Electrical circuit diagram for outside cab (1/3) 1486
Electrical circuit diagram for outside cab (2/3) 1488
Electrical circuit diagram for outside cab (3/3) 1490
Electrical circuit diagram for payload meter 1492
Connectors table and arrangement drawing HM400-2 1494

S.V 15/12/24