Komatsu HM400-1 Articulated Dump Truck Shop Manual SEBM023020 – PDF DOWNLOAD

Komatsu HM400-1 Articulated Dump Truck Shop Manual SEBM023020 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HM400-1 Articulated Dump Truck Shop Manual SEBM023020 – PDF DOWNLOAD

Language : English
Pages : 1172
Downloadable : Yes
File Type : PDF
Size: 76.7 MB

TABLE OF CONTENTS:

Komatsu HM400-1 Articulated Dump Truck Shop Manual SEBM023020 – PDF DOWNLOAD

COVER 1
CONTENTS 2
SAFETY 9
SAFETY NOTICE 9
01 GENERAL 29
SPECIFICATION DRAWINGS 30
SPECIFICATIONS 31
WEIGHT TABLE 34
FUEL,COOLANT AND LUBRICANTS 35
FOREWORD 11
GENERAL 11
HOW TO READ THE SHOP MANUAL 12
HOISTING INSTRUCTIONS 13
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 14
COATING MATERIALS 16
STANDARD TIGHTENING TORQUE 18
ELECTRIC WIRE CODE 21
CONVERSION TABLE 22
UNITS 28
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 37
RADIATOR,OIL COOLER,AFTERCOOLER 38
POWER TRAIN SKELETON 40
OUTPUT SHAFT 44
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING 46
TORQUE CONVERTER 48
TRANSMISSION 54
TRANSMISSION VALVE 72
ECMV (ELECTRONIC CONTROL MODULATION VALVE) 73
MAIN RELIEF,TORQUE CONVERTER RELIEF VALVE 80
DRIVE SHAFT 82
AXLE 83
DIFFERENTIAL 86
LIMITED SLIP DIFFERENTIAL 100
FINAL DRIVE 104
STEERING COLUMN 108
BRAKE PIPING 110
BRAKE VALVE 112
ACCUMULATOR CHARGE VALVE 115
ACCUMULATOR 119
SLACK ADJUSTER 120
BRAKE 122
PROPORTIONAL REDUCING VALVE 127
BRAKE SYSTEM TANK 128
PARKING BRAKE 130
PARKING BRAKE CALIPER 132
SPRING CYLINDER 133
PARKING BRAKE SOLENOID 134
SUSPENSION 136
SUSPENSION CYLINDER 142
OSCILLATION HITCH 144
STEERING, HOIST OIL PRESSURE PIPING DIAGRAM 148
DUMP BODY CONTROL 149
HYDRAULIC TANK AND FILTER 150
FLOW AMP VALVE 151
STEERING VALVE 154
STEERING CYLINDER 158
HOIST VALVE 160
EPC VALVE 166
PILOT CHECK VALVE 167
HOIST CYLINDER 169
HYDRAULIC PUMP 170
CAB TILT 177
AIR CONDITIONER 178
MACHINE MONITOR SYSTEM 183
AUTOMATIC SHIFT CONTROL SYSTEM 197
TRANSMISSION CONTROLLER 199
AUTO EMERGENCY STEERING SYSTEM 205
SENSORS,SWITCHES 206
RETARDER CONTROL SYSTEM 214
BRAKE CONTROL SYSTEM (E-SPEC) 224
DUMP CONTROL LEVER 234
PLM-HM 239
20 TESTING AND ADJUSTING 275
STANDARD VALUE TABLE FOR ENGINE 276
STANDARD VALUE TABLE FOR CHASSIS 277
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 281
TESTING AND ADJUSTING 295
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 296
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 298
MEASURING EXHAUST TEMPERATURE 299
MEASURING EXHAUST COLOR 301
MEASURING COMPRESSION PRESSURE 302
ADJUSTING VALVE CLEARANCE 303
MEASURING BLOW-BY PRESSURE 304
MEASURING ENGINE OIL PRESSURE 305
HANDING EQUIPMENT IN FUEL CIRCUIT 306
RELEASING REMAINING PRESSURE IN FUEL SYSTEM 306
MEASURING FUEL PRESSURE 307
BLEEDING AIR FROM FUEL CIRCUIT 308
REDUCED CYLINDER MODE OPERATION 309
CHECKING FOR LEAKAGE IN FUEL CIRCUIT 310
ADJUSTING ENGINE SPEED SENSOR 311
TESTING AND ADJUSTING FAN BELT TENSION 312
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 315
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 315
ADJUSTING THE BODY MOUNT 316
TESTING TORQUE CONVERTER STALL SPEED 318
MEASURING POWER TRAIN OIL PRESSURE 319
TESTING AND ADJUSTING LEFT AND RIGHT DIFFERENTIAL LOCK OIL PRESSURE 327
ADJUSTING TRANSMISSION SPEED SENSOR 332
TESTING AND ADJUSTING BRAKE OIL PRESSURE 335
TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS 340
TESTING BRAKE PERFORMANCE 348
RELEASING REMAINING PRESSURE IN BRAKE CIRCUIT 350
BLEEDING AIR FROM BRAKE CIRCUIT 352
TESTING WEAR OF WHEEL BRAKE DISC 354
TESTING WEAR OF PARKING BRAKE PAD 355
METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE 357
TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE 358
TESTING AND ADJUSTING SUSPENSION CYLINDER 360
METHOD OF TILTING CAB UP 364
TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE 366
ADJUSTING BODY POSITIONER SENSOR 369
PROCEDURE FOR ADUSTING LENGTH OF SPRING IN BODY HEATING SPHERICAL JOINT 370
HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT 370
ADJUSTING TRANSMISSION CONTROLLER 371
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM 372
ADJUSTING MACHINE MONITOR 376
SPECIAL FUNCTIONS OF MACHINE MONITOR 380
PM-CLINIC INSPECTION SHEET 416
TROUBLESHOOTING 419
POINTS TO REMEMBER WHEN TROUBLESHOOTING 420
SEQUENCE OF EVENTS IN TROUBLESHOOTING 421
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 422
CHECKS BEFORE TROUBLESHOOTING 430
CONNECTOR TYPES AND MOUNTING LOCATIONS 431
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 447
CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS 474
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ENG MODE) 479
ENG MODE RELATED ELECTRICAL CIRCUIT DIAGRAM 481
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE 484
ENG-1 FAILURE CODE [A000N1] (ENGINE: OVERRUN N1)) 496
ENG-2 FAILURE CODE [A570NX] (ENGINE OIL FILTER: CLOGGED (NX)) 497
ENG-3 FAILURE CODE [AD00L2] (COMMON RAIL: *SEE CONTENTS (L2)) 498
ENG-4 FAILURE CODE [AD00MA] (COMMON RAIL: FUNCTION IMPOSSIBLE (MA)) 498
ENG-5 FAILURE CODE [AD10L3] (FUEL SUPPLY PUMP: *SEE CONTENTS (L3)) 499
ENG-6 FAILURE CODE [AD10MA] (FUEL SUPPLY PUMP: FUNCTION IMPOSSIBLE (MA)) 501
ENG-7 FAILURE CODE [AD10MB] (FUEL SUPPLY PUMP: DROP IN FUNCTION (MB)) 501
ENG-8 FAILURE CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID VALVE 1: DISCONNECTION (KA)) 502
ENG-9 FAILURE CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID VALVE 1: SHORT CIRCUIT (KB)) 503
ENG-10 FAILURE CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID VALVE 2: DISCONNECTION (KA)) 504
ENG-11 FAILURE CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID VALVE 2: SHORT CIRCUIT (KB)) 505
ENG-12 FAILURE CODE [ADA1KA] (NO 1 INJECTOR SOLENOID VALVE: DISCONNECTION (KA)) 506
ENG-13 FAILURE CODE [ADZKKB] (NO 1,2,3 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB)) 507
ENG-14 FAILURE CODE [ADB1KA] (NO 2 INJECTOR SOLENOID VALVE: DISCONNECTION (KA)) 511
ENG-15 FAILURE CODE [ADC1KA] (NO 3 INJECTOR SOLENOID VALVE: DISCONNECTION (KA)) 512
ENG-16 FAILURE CODE [ADD1KA] (NO 4 INJECTOR SOLENOID VALVE: DISCONNECTION (KA)) 513
ENG-17 FAILURE CODE [ADDZKB] (NO 4,5,6 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB)) 514
ENG-18 FAILURE CODE [ADE1KA] (NO 5 INJECTOR SOLENOID VALVE: DISCONNECTION (KA)) 518
ENG-19 FAILURE CODE [ADF1KA] (NO 6 INJECTOR SOLENOID VALVE: DISCONNECTION (KA)) 519
ENG-20 FAILURE CODE [B@BAZG] (ENGINE OIL: DROP IN OIL PRESSURE (ZG)) 520
ENG-21 FAILURE CODE [B@BAZK] (ENGINE OIL: DROP IN LEVEL (ZK)) 521
ENG-22 FAILURE CODE [B@BCNS] (RADIATOR WATER: OVERHEAT (NS)) 522
ENG-23 FAILURE CODE [D181KZ] (PREHEATING RELAY CONTACT: DISCONNECTION OR SHORT CIRCUIT (KZ)) 523
ENG-24 FAILURE CODE [D182KZ] (PREHEATING RELAY COIL: DISCONNECTION OR SHORT CIRCUIT (KZ)) 525
ENG-25 FAILURE CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: SHORT CIRCUIT (KB)) 526
ENG-26 FAILURE CODE [D5ZAKX] (ENGINE THROTTLE MODIFY 1 SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX)) 528
ENG-27 FAILURE CODE [DB20KT] (ENGINE CONTROLLER: ABNORMALITY INSIDE CONTROLLER (KT)) 529
ENG-28 FAILURE CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: DROP IN POWER SUPPLY VOLTAGE,INPUT (KK)) 530
ENG-29 FAILURE CODE [DB29KQ] (ENGINE CONTROLLER CONNECTION WIRING HARNESS: MODEL SELECTION SIGNAL MISMATCH (KQ)) 532
ENG-30 FAILURE CODE [DB2AMA] (ENGINE CONTROLLER FUEL INJECTION QUANTITY CONTROL SWITCH: FUNCTION IMPOSSIBLE (MA)) 533
ENG-31 FAILURE CODE [KK11KB] (STARTING SWITCH: SHORT CIRCUIT (KB)) 534
ENG-32 FAILURE CODE [DDA1L5] (ACCELERATION SWITCH: *SEE CONTENTS (L5)) 535
ENG-33 FAILURE CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH: *SEE CONTENTS (L6)) 537
ENG-34 FAILURE CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH-TEMPERATURE): INPUT SIGNAL OUTSIDE RANGE (KX)) 539
ENG-35 FAILURE CODE [DGE3LC] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW-TEMPERATURE): *SEE CONTENTS (L6)) 540
ENG-36 FAILURE CODE [DGE4KX] (FUEL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)) 541
ENG-37 FAILURE CODE [DH30KX] (BOOST PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)) 542
ENG-38 FAILURE CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)) 544
ENG-39 FAILURE CODE [DK10KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)) 546
ENG-40 FAILURE CODE [DLE3LC] (ENGINE NE SPEED SENSOR: *SEE CONTENTS (LC)) 548
ENG-41 FAILURE CODE [DLE1LC] (ENGINE G SPEED SENSOR: *SEE CONTENTS (LC)) 549
ENG-42 FAILURE CODE (ENGINE DOES NOT START (STARTING MOTOR DOES NOT TURN) 550
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (TM MODE) 553
TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM 556
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE 562
TM-1 FAILURE CODE [1380MW] (LOCK-UP CLUTCH: SLIPPING (MW)) 588
TM-2 FAILURE CODE [1500LO] (TRANSMISSION CLUTCH: *SEE CONTENTS (LO)) 589
TM-3 FAILURE CODE [15BONX] (TRANSMISSION OIL FILTER: CLOGGED (NX)) 590
TM-4 FAILURE CODE [15GOMW] (R CLUTCH: SLIPPING (MW)) 591
TM-5 FAILURE CODE [15HOMW] (HI CLUTCH: SLIPPING (MW)) 592
TM-6 FAILURE CODE [15JOMW] (LO CLUTCH: SLIPPING (MW)) 593
TM-7 FAILURE CODE [15KOMW] (1ST CLUTCH: SLIPPING (MW)) 594
TM-8 FAILURE CODE [15LOMW] (2ND CLUTCH: SLIPPING (MW)) 595
TM-9 FAILURE CODE [15MOMW] (3RD CLUTCH: SLIPPING (MW)) 596
TM-10 FAILURE CODE [15SBL1] (ECMV FOR R CLUTCH: *SEE CONTENTS (L1)) 597
TM-11 FAILURE CODE [15SBMA] (ECMV FOR R CLUTCH: FUNCTION IMPOSSIBLE (MA)) 598
TM-12 FAILURE CODE [15SCL1] (ECMV FOR HI CLUTCH: *SEE CONTENTS (L1)) 599
TM-13 FAILURE CODE [15SCMA] (ECMV FOR HI CLUTCH: FUNCTION IMPOSSIBLE (MA)) 600
TM-14 FAILURE CODE [15SDL1] (ECMV FOR LO CLUTCH: *SEE CONTENTS (L1)) 601
TM-15 FAILURE CODE [15SDMA] (ECMV FOR LO CLUTCH: FUNCTION IMPOSSIBLE (MA)) 602
TM-16 FAILURE CODE [15SEL1] (ECMV FOR 1ST CLUTCH: *SEE CONTENTS (L1)) 603
TM-17 FAILURE CODE [15SEMA] (ECMV FOR 1ST CLUTCH: FUNCTION IMPOSSIBLE (MA)) 604
TM-18 FAILURE CODE [15SFL1] (ECMV FOR 2ND CLUTCH: *SEE CONTENTS (L1)) 605
TM-19 FAILURE CODE [15SFMA] (ECMV FOR 2ND CLUTCH: FUNCTION IMPOSSIBLE (MA)) 606
TM-20 FAILURE CODE [15SGL1] (ECMV FOR 3RD CLUTCH: *SEE CONTENTS (L1)) 607
TM-21 FAILURE CODE [15SGMA] (ECMV FOR 3RD CLUTCH: FUNCTION IMPOSSIBLE (MA)) 608
TM-22 FAILURE CODE [15SJL1] (ECMV FOR LOCK-UP CLUTCH: *SEE CONTENTS (L1)) 609
TM-23 FAILURE CODE [15SJMA] (ECMV FOR LOCK-UP CLUTCH: FUNCTION IMPOSSIBLE (MA)) 610
TM-24 FAILURE CODE [15SKL1] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: *SEE CONTENTS (L1)) 611
TM-25 FAILURE CODE [15SKMA] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: FUNCTION IMPOSSIBLE (MA)) 612
TM-26 FAILURE CODE [2B61MW] (INTER-AXLE DIFFERENTIAL LOCK CLUTCH: SLIPPING (MW)) 613
TM-27 FAILURE CODE [2F00KM] (PARKING BRAKE: MISTAKEN OPERATION OR MISTAKEN SETTING (KM)) 614
TM-28 FAILURE CODE [6014NX] (HYDRAULIC TANK FILTER: CLOGGED (NX)) 616
TM-29 FAILURE CODE [989A00] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: ACTUATED (00)) 617
TM-30 FAILURE CODE [989AKZ] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ)) 618
TM-31 FAILURE CODE [989D00] (REAR OVERTURN SIGNAL: ACTUATED (00)) 619
TM-32 FAILURE CODE [AA10NX] (AIR CLANER ELEMENT: CLOGGED (NX)) 621
TM-33 FAILURE CODE [AB00MA] (ALTERNATOR: FUNCTION IMPOSSIBLE (MA)) 622
TM-34 FAILURE CODE [B@BCZK] (RADIATOR WATER: DROP IN LEVEL (ZK)) 623
TM-35 FAILURE CODE [B@HAZK] (HYDRAULIC TANK OIL: DROP IN LEVEL (ZK)) 624
TM-36 FAILURE CODE [B@JANS] (STEERING OIL: OVERHEAT (ZK)) 625
TM-37 FAILURE CODE [D1B0KZ] (TRANSMISSION CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ)) 626
TM-38 FAILURE CODE [D5ZBKX] (INTER-AXLE DIFFERENTIAL LOCK COMMAND SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX)) 628
TM-39 FAILURE CODE [D5ZCKZ] (EXHAUST BRAKE COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ)) 629
TM-40 FAILURE CODE [D5ZDL4] (FORCED NEUTRAL DEMAND SIGNAL: *SEE CONTENTS (L4)) 630
TM-41 FAILURE CODE [D5ZEKX] (ENGINE LOAD SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX)) 632
TM-42 FAILURE CODE [DAQ0KK] (TRANSMISSION CONTROLLER: DROP IN POWER SOURCE VOLTAGE, INPUT (KK)) 633
TM-43 FAILURE CODE [DAQ1KK] (TRANSMISSION CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK)) 634
TM-44 FAILURE CODE [DAQ2KK] (TRANSMISSION CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK)) 635
TM-45 FAILURE CODE [DAQ3KK] (TRANSMISSION CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK)) 636
TM-46 FAILURE CODE [DAQ5KP] (TRANSMISSION CONTROLLER POWER SUPPLY OUTPUT 1: DROP IN OUTPUT VOLTAGE (KP)) 637
TM-47 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KP)) 638
TM-48 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: NON MATCH IN MODEL SELECTION SIGNAL (KP)) 639
TM-49 FAILURE CODE [DAQAKQ] (TRANSMISSION CONTROLLER ROTARY SWITCH: NON MATCH IN MODEL SELECTION SIGNAL (KP)) 640
TM-50 FAILURE CODE [DAQSMA] (TRANSMISSION CONTROLLER: FUNCTION IMPOSSIBLE (MA)) 640
TM-51 FAILURE CODE [DDTFKA] (FILL SWITCH FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: DISCONNECTION (KA)) 641
TM-52 FAILURE CODE [DDTGKA] (FILL SWITCH FOR LOCK-UP CLUTCH: DISCONNECTION (KA)) 642
TM-53 FAILURE CODE [DDTHKA] (FILL SWITCH FOR HI CLUTCH: DISCONNECTION (KA)) 643
TM-54 FAILURE CODE [DDTJKA] (FILL SWITCH FOR LO CLUTCH: DISCONNECTION (KA)) 644
TM-55 FAILURE CODE [DDTKKA] (FILL SWITCH FOR 1ST CLUTCH: DISCONNECTION (KA)) 645
TM-56 FAILURE CODE [DDTLKA] (FILL SWITCH FOR 2ND CLUTCH: DISCONNECTION (KA)) 646
TM-57 FAILURE CODE [DDTMKA] (FILL SWITCH FOR 3RD CLUTCH: DISCONNECTION (KA)) 647
TM-58 FAILURE CODE [DDTNKA] (FILL SWITCH FOR R CLUTCH: DISCONNECTION (KA)) 648
TM-59 FAILURE CODE [DF10KA] (GEARSHIFT LEVER: DISCONNECTION (KA)) 649
TM-60 FAILURE CODE [DF10KB] (GEARSHIFT LEVER: SHORT CIRCUIT (KB)) 651
TM-61 FAILURE CODE [DGF1KX] (TRANSMISSION VALVE OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)) 653
TM-62 FAILURE CODE [DGR2L8] (BRAKE OIL TEMPERATURE SENSOR (REAR): *SEE CONTENTS (L8)) 654
TM-63 FAILURE CODE [DGR3L8] (BRAKE OIL TEMPERATURE SENSOR (CENTER): *SEE CONTENTS (L8)) 655
TM-64 FAILURE CODE [DGR4L8] (BRAKE OIL TEMPERATURE SENSOR (FRONT): *SEE CONTENTS (L8)) 656
TM-65 FAILURE CODE [DGT1KX] (TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)) 657
TM-66 FAILURE CODE [DHT5KX] (TORQUE CONVERTER OIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)) 658
TM-67 FAILURE CODE [DHT5L6] (TORQUE CONVERTER OIL PRESSURE SENSOR: *SEE CONTENTS (L6)) 660
TM-68 FAILURE CODE [DJF1KA] (FUEL LEVEL SENSOR: DISCONNECTION (L6)) 661
TM-69 FAILURE CODE [DK11KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)) 662
TM-70 FAILURE CODE [DLE2KA] (ENGINE SPEED SENSOR: DISCONNECTION (KA)) 664
TM-71 FAILURE CODE [DLE2LC] (ENGINE SPEED SENSOR: *SEE CONTENTS (LC)) 665
TM-72 FAILURE CODE [DLF1KA] (TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)) 666
TM-73 FAILURE CODE [DLF1LC] (TRANSMISSION INPUT SHAFT SPEED SENSOR: *SEE CONTENTS (LC)) 667
TM-74 FAILURE CODE [DLF2KA] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISCONNECTION (KA)) 668
TM-75 FAILURE CODE [DLF2LC] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: *SEE CONTENTS (LC)) 669
TM-76 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)) 670
TM-77 FAILURE CODE [DLT3LC] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: *SEE CONTENTS (LC)) 671
TM-78 FAILURE CODE [DXH0KA] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: DISCONNECTION (KA)) 672
TM-79 FAILURE CODE [DXH0KB] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: SHORT CIRCUIT (KB)) 673
TM-80 FAILURE CODE [DXH1KA] (SOLENOID FOR LOCK-UP CLUTCH: DISCONNECTION (KA)) 674
TM-81 FAILURE CODE [DXH1KB] (SOLENOID FOR LOCK-UP CLUTCH: SHORT CIRCUIT (KB)) 675
TM-82 FAILURE CODE [DXH2KA] (SOLENOID FOR HI CLUTCH: DISCONNECTION (KA)) 676
TM-83 FAILURE CODE [DXH2KB] (SOLENOID FOR HI CLUTCH: SHORT CIRCUIT (KB)) 677
TM-84 FAILURE CODE [DXH3KA] (SOLENOID FOR LO CLUTCH: DISCONNECTION (KA)) 678
TM-85 FAILURE CODE [DXH3KB] (SOLENOID FOR LO CLUTCH: SHORT CIRCUIT (KB)) 679
TM-86 FAILURE CODE [DXH4KA] (SOLENOID FOR 1ST CLUTCH: DISCONNECTION (KA)) 680
TM-87 FAILURE CODE [DXH4KB] (SOLENOID FOR 1ST CLUTCH: SHORT CIRCUIT (KB)) 681
TM-88 FAILURE CODE [DXH5KA] (SOLENOID FOR 2ND CLUTCH: DISCONNECTION (KA)) 682
TM-89 FAILURE CODE [DXH5KB] (SOLENOID FOR 2ND CLUTCH: SHORT CIRCUIT (KB)) 683
TM-90 FAILURE CODE [DXH6KA] (SOLENOID FOR 3RD CLUTCH: DISCONNECTION (KA)) 684
TM-91 FAILURE CODE [DXH6KB] (SOLENOID FOR 3RD CLUTCH: SHORT CIRCUIT (KB)) 685
TM-92 FAILURE CODE [DXH7KA] (SOLENOID FOR R CLUTCH: DISCONNECTION (KA)) 686
TM-93 FAILURE CODE [DXH7KB] (SOLENOID FOR R CLUTCH: SHORT CIRCUIT (KB)) 687
TM-94 BACKUP LAMP, BACKUP BUZZER DO NOT WORK PROPERLY 688
TROUBLESHOOTING OF RETARDER CONTROLLER (※1) SYSTEM (BK MODE) 691
BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM 694
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE 700
BK-1 FAILURE CODE [2A62L1] (FRONT DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (L1)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL) 714
BK-2 FAILURE CODE [2A62LH] (FRONT DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (LH)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL) 715
BK-3 FAILURE CODE [2B62L1] (REAR DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (L1)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL) 716
BK-4 FAILURE CODE [2B62LH] (REAR DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (LH)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL) 717
BK-5 FAILURE CODE [2C4MNX] (RETARDER COOLING FILTER: CLOGGED (NX)) 718
BK-6 FAILURE CODE [2D01CA] (FRONT BRAKE (RIGHT): WEAR (CA)) 719
BK-7 FAILURE CODE [2D02CA] (FRONT BRAKE (LEFT): WEAR (CA)) 720
BK-8 FAILURE CODE [2D03CA] (CENTER BRAKE (RIGHT): WEAR (CA)) 721
BK-9 FAILURE CODE [2D04CA] (CENTER BRAKE (LEFT): WEAR (CA)) 722
BK-10 FAILURE CODE [2D05CA] (REAR BRAKE (RIGHT): WEAR (CA)) 723
BK-11 FAILURE CODE [2D06CA] (REAR BRAKE (LEFT): WEAR (CA)) 724
BK-12 FAILURE CODE [2G42ZG] (ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG)) 725
BK-13 FAILURE CODE [2G43ZG] (ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG)) 725
BK-14 FAILURE CODE [D1C0KZ] (BRAKE CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ)) 726
BK-15 FAILURE CODE [D5ZFKZ] (NEUTRAL SIGNAL 1: DISCONNECTION OR SHORT CIRCUIT (KZ)) 727
BK-16 FAILURE CODE [D5ZGKZ] (NEUTRAL SIGNAL 2: DISCONNECTION OR SHORT CIRCUIT (KZ)) 728
BK-17 FAILURE CODE [DB10KK] (RETARDER CONTROLLER: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK) 729
BK-18 FAILURE CODE [DB11KK] (RETARDER CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK) 730
BK-19 FAILURE CODE [DB12KK] (RETARDER CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK) 731
BK-20 FAILURE CODE [DB13KK] (RETARDER CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK) 732
BK-21 FAILURE CODE [DB19KM] (RETARDER CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KM)) 733
BK-22 FAILURE CODE [DB1SKQ] (RETARDER CONTROLLER S-NET LINE: MODEL SELECTION SIGNAL MISMATCH (KQ)) 734
BK-23 FAILURE CODE [DHU2KX] (ACCUMULATOR OIL PRESSURE SENSOR (FRONT): INPUT SIGNAL OUTSIDE RANGE (KX)) 735
BK-24 FAILURE CODE [DHU3KX] (ACCUMULATOR OIL PRESSURE SENSOR (REAR): INPUT SIGNAL OUTSIDE RANGE (KX)) 737
BK-25 FAILURE CODE [DK51L5] (RETARDER LEVER POTENTIOMETER: *SEE SEPARATE TABLE (BK)) 739
BK-26 FAILURE CODE [DK52KX] (DUMP LEVER POTENTIOMETER 1: INPUT SIGNAL OUTSIDE RANGE (KX)) 742
BK-27 FAILURE CODE [DK53L8] (DUMP LEVER POTENTIOMETER 2: *SEE CONTENTS (L8)) 744
BK-28 FAILURE CODE [DK54KX] (BODY POSITIONER SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)) 745
BK-29 FAILURE CODE [DLF4KA] (TRANSMISSION OUTPUT SHAFT F SPEED SENSOR: DISCONNECTION (KA)) 747
BK-30 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION (KA)) 748
BK-31 FAILURE CODE [DW71KZ] (EXHAUST BRAKE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) (MACHINE WITH EXHAUST BRAKE) 749
BK-32 FAILURE CODE [DW72KZ] (DUMP LEVER KICK-OUT SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) 750
BK-33 FAILURE CODE [DW73KZ] (DUMP SELECTOR VAVLE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) 751
BK-34 FAILURE CODE [DX11KA] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA)) 752
BK-35 FAILURE CODE [DX11KB] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB)) 753
BK-36 FAILURE CODE [DX11KY] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY)) 754
BK-37 FAILURE CODE [DX12KA] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA)) 755
BK-38 FAILURE CODE [DX12KB] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB)) 756
BK-39 FAILURE CODE [DX12KY] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY)) 757
BK-40 FAILURE CODE [DX13KA] (DUMP EPC VALVE SOLENOID: DISCONNECTION (KA)) 758
BK-41 FAILURE CODE [DX13KB] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT (KB)) 759
BK-42 FAILURE CODE [DX13KY] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY)) 760
BK-43 FAILURE CODE [DX14KZ] (REAR DIFFERENTIAL LOCK SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL) 761
BK-44 FAILURE CODE [DX15KZ] (FRONT DIFFERENTIAL LOCK SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL) 762
BK-45 PARKING BRAKE DOES NOT WORK PROPERLY 764
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (MON MODE) 767
MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM 768
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE 772
MON-1 FAILURE CODE [B@C6NS] (FRONT BRAKE OIL: OVERHEAT (NS)) 774
MON-2 FAILURE CODE [B@C7NS] (REAR BRAKE OIL: OVERHEAT (NS)) 774
MON-3 FAILURE CODE [B@C8NS] (CENTER BRAKE OIL: OVERHEAT (NS)) 775
MON-4 FAILURE CODE [B@CENS] (TORQUE CONVERTER: OVERHEAT (NS)) 775
MON-5 FAILURE CODE [DAF0KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM)) 776
MON-6 FAILURE CODE [DAF9KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM)) 777
MON-7 FAILURE CODE [DAFSKQ] (MONITOR PANEL: NON MATCH IN MODEL SELECTION SIGNAL (KQ)) 778
MON-8 FAILURE CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR)) 779
MON-9 FAILURE CODE [DB1SKR] (RETARDER CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR)) 781
MON-10 FAILURE CODE [DB2SKR] (ENGINE CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR)) 783
MON-11 FAILURE CODE [DV00KB] (ALARM BUZZER: SHORT CIRCUIT (KB)) 785
MON-12 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR GIVES NO DISPLAY 786
MON-13 WHEN STARTING SWITCH IS OFF, MACHINE MONITOR CANNOT BE OPERATED 787
MON-14 ALARM BUZZER DOES NOT SOUND 788
MON-15 GAUGES, CAUTION LAMPS, CHARACTER DISPLAY ON MACHINE MONITOR DO NOT GIVE CORRECT DISPLAY 789
MON-16 ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED PROPERLY 791
MON-17 CHARACTER DISPLAY CANNOT BE SWITCHED PROPERLY 792
MON-18 POWER MODE SELECTOR FUNCTION DOES NOT WORK PROPERLY 795
MON-19 AISS FUNCTION DOES NOT WORK PROPERLY 796
MON-20 LEFT AND RIGHT DIFFERENTIAL LOCK DOES NOT WORK PROPERLY 797
MON-21 INTER-AXLE DIFFERENTIAL LOCK DOES NOT WORK PROPERLY 800
MON-22 EXHAUST BRAKE DOES NOT WORK PROPERLY (MACHINES EQUIPPED WITH EXHAUST BRAKE) 801
MON-23 SEAT BELT CAUTION LAMP DISPLAY IS NOT SHOWN PROPERLY 803
MON-24 TURN SIGNAL LAMP, HAZARD LAMP DO NOT WORK PROPERLY 804
MON-25 NIGHT LIGHTING IS NOT NORMAL 809
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 815
H-1 MACHINE DOES NOT START 816
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS) 817
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS) 817
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING 818
H-5 TRANSMISSION DOES NOT SHIFT UP 818
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING 819
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR 822
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 823
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW 824
H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE 825
H-11 CENTER BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE 826
H-12 REAR BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE 827
H-13 STEERING WHEEL IS HEAVY 828
H-14 STEERING WHEEL DOES NOT WORK 829
H-15 STEEIRNG WHEEL VIBRATES 830
H-16 DUMP BODY LIFTING SPEED IS SLOW, OR LACKS POWER 831
H-17 DUMP DOES NOT WORK 832
H-18 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY 833
TROUBLESHOOTING OF THE ENGINE BODY (S MODE) 835
POINTS TO REMEMBER WHEN TROUBLESHOOTING 836
METHOD OF USING TROUBLESHOOTING CHARTS 837
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 841
S-2 ENGINE DOES NOT START 842
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 845
S-4 ENGINE STOPS DURING OPERATIONS 846
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 847
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 848
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 849
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 850
S-9 OIL BECOMES CONTAMINATED QUICKLY 851
S-10 FUEL CONSUMPTION IS EXCESSIVE 852
S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN) 853
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 854
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) 855
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 856
S-15 ABNORMAL NOISE IS MADE 857
S-16 VIBRATION IS EXCESSIVE 858
30 DISASSEMBLY AND ASSEMBLY 859
HOW TO READ THIS MANUAL 861
REMOVAL AND INSTALLATION OF ASSEMBLIES 861
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES 862
PRECAUTIONS WHEN CARRYING OUT OPERATION 864
SPECIAL TOOL LIST 866
SKETCHES OF SPECIAL TOOLS 873
REMOVAL OF FUEL SUPPLY PUMP 889
INSTALLATION OF FUEL SUPPLY PUMP 890
REMOVAL OF ENGINE ASSEMBLY 891
INSTALLATION OF ENGINE ASSEMBLY 896
REMOVAL OF CYLINDER HEAD ASSEMBLY 897
INSTALLATION OF CYLINDER HEAD 901
REMOVAL AND INSTALLATION OF NOZZLE TIP 906
REMOVAL 906
INSTALLATION 907
REMOVAL OF RADIATOR ASSEMBLY 908
INSTALLATION OF RADIATOR ASSEMBLY 910
REMOVAL OF OUTPUT SHAFT ASSEMBLY 911
INSTALLATION OF OUTPUT SHAFT ASSEMBLY 914
DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY 915
ASSEMBLY OF OUTPUT SHAFT ASSEMBLY 916
REMOVAL OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY 918
INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY 924
DISCONNECTION OF FRONT DIFFERENTIAL AND TRANSMISSION 926
COUPLING OF FRONT DIFFERENTIAL AND TRANSMISSION 926
DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY 927
ASSEMBLY OF TORQUE CONVERTER ASSEMBLY 931
DISASSEMBLY OF TRANSMISSION ASSEMBLY 935
ASSEMBLY OF TRANSMISSION ASSEMBLY 954
DISASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY 980
ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY 987
REMOVAL OF CENTER DIFFERENTIAL ASSEMBLY 998
INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY 1000
DISASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY 1001
ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY 1007
REMOVAL OF REAR DIFFERENTIAL ASSEMBLY 1017
INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY 1018
DISASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY 1019
ASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY 1023
REMOVAL OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY 1031
INSTALLATION OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY 1032
DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY 1033
ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY 1040
REMOVAL OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY 1049
INSTALLATION OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY 1050
DISASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY 1051
ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY 1056
REMOVAL OF REAR FINAL DRIVE AND BRAKE ASSEMBLY 1064
INSTALLATION OF REAR FINAL DRIVE AND BRAKE ASSEMBLY 1065
DISASSEMBLY OF REAR FINAL DRIVE AND BRAKE ASSEMBLY 1065
ASSEMBLY OF REAR FINAL DRIVE AND BRAKE ASSEMBLY 1071
REMOVAL OF CENTER AXLE ASSEMBLY 1079
INSTALLATION OF CENTER AXLE ASSEMBLY 1081
REMOVAL OF REAR AXLE ASSEMBLY 1082
INSTALLATION OF REAR AXLE ASSEMBLY 1084
REMOVAL OF FRONT SUSPENSION CYLINDER ASSEMBLY 1085
INSTALLATION OF FRONT SUSPENSION CYLINDER ASSEMBLY 1086
REMOVAL OF REAR SUSPENSION CYLINDER ASSEMBLY 1086
INSTALLATION OF REAR SUSPENSION CYLINDER ASSEMBLY 1087
DISSEMBLY AND ASSEMBLYOF FRONT AND REAR SUSPENSIONCYLINDER ASSEMBLY 1088
REMOVAL OF EQUALIZER BAR ASSEMBLY 1090
INSTALLATION OF EQUALIZER BAR ASSEMBLY 1091
REMOVAL OF FRONT WHEEL ASSEMBLY 1092
INSTALLATION OF FRONT WHEEL ASSEMBLY 1092
REMOVAL, INSTALLATION OF REAR WHEEL ASSEMBLY 1093
REMOVAL OF HITCH FRAME ASSEMBLY 1094
INSTALLATION OF HITCH FRAME ASSEMBLY 1099
DISASSEMBLY OF HITCH FRAME 1104
ASSEMBLY OF HITCH FRAME ASSEMBLY 1107
STANDARD INTEGRAL ORBIT-ROLL 1112
DISASSEMBLY OF STEERING VALVE 1114
ASSEMBLY OF STEERING VALVE 1116
REMOVAL OF FLOW AMPLIFIER VALVE ASSEMBLY 1121
INSTALLATION OF FLOW AMPLIFIER VALVE ASSEMBLY 1122
REMOVAL OF HOIST VALVE ASSEMBLY 1123
INSTALLATION OF HOIST VALVE ASSEMBLY 1124
DISASSEMBLY OF HOIST VALVE ASSEMBLY 1125
ASSEMBLY OF HOIST VALVE ASSEMBLY 1126
DISASSEMBLY OF STEERING CYLINDER ASSEMBLY 1127
ASSEMBLY OF STEERING CYLINDER ASSEMBLY 1128
DISASSEMBLY OF HOIST CYLINDER ASSEMBLY 1130
ASSEMBLY OF HOIST CYLINDER ASSEMBLY 1132
REMOVAL OF BODY ASSEMBLY 1135
INSTALLATION OF BODY ASSEMBLY 1136
DISASSEMBLY AND ASSEMBLY OF OPERATOR’S SEAT ASSEMBLY 1137
90 OTHERS 1147
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 1148
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM 1149
DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM 1150
BRAKE HYDRAULIC CIRCUIT DIAGRAM 1151
BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM 1153
DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER 1155
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/4) 1157
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (2/4) 1159
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (3/4) 1161
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (4/4) 1163
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/3) 1165
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (2/3) 1167
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (3/3) 1169
PAYLOAD METER ELECTRICAL CIRCUIT 1171

DESCRIPTION:

Komatsu HM400-1 Articulated Dump Truck Shop Manual SEBM023020 – PDF DOWNLOAD

Machine model    Serial number
HM400-1              1001 and up

FOREWORD:
GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further
divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

IMAGES PREVIEW OF THE MANUAL: