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HM400 1L Cebd015301 PDF
HM400 1L Cebd015301 PDF
Shop
Manual
HM400-1L
ARTICULATED TRUCK
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recom-
mended that customers contact their distributor for information on the latest revision.
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2 1 HM400-1L
PRODUCT PUBLICATIONS INFORMATION
Various product Parts and Service Publications are available to all KOMATSU construction equipment
owners, including operation and maintenance manuals, parts books and service manuals.
Special publications, such as service tool, air conditioning and turbocharger service manuals are also
available as well as selected Operation and Service manuals in foreign languages.
The Publications listed below are available for this particular machine(s).
SHOP MANUAL
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM015300
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SEBM022209
SAFETY MANUAL
Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D48-2
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00-2-2 1 HM400-1L
FOREWORD
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HM400-1L 00-2-3 1
FOREWORD
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FOREWORD
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FOREWORD
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FOREWORD
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FOREWORD
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FOREWORD
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HM400-1L 00-2-11 1
FOREWORD SAFETY
12
SAFETY 00
SAFETY NOTICE 00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accom-
panying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first con-
sider safety, and take the necessary actions to deal with the situation.
Mistakes in operation are extremely dangerous. Read the 1. Before adding oil or making repairs, park the machine
OPERATION & MAINTENANCE MANUAL carefully on hard, level ground, and block the wheels or tracks to
BEFORE operating the machine. prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all the 2. Before starting work, lower blade, ripper, bucket or any
precautions given on the decals which are fixed to the other work equipment to the ground. If this is not possi-
machine. ble, insert the safety pin or use blocks to prevent the
work equipment from falling. In addition, be sure to
2. When carrying out any operation, always wear safety lock all the control levers and hang warning signs on
shoes and helmet. Do not wear loose work clothes, or them.
clothes with buttons missing.
● Always wear safety glasses when hitting parts with a 3. When disassembling or assembling, support the
hammer. machine with blocks, jacks or stands before starting
● Always wear safety glasses when grinding parts with a work.
grinder, etc.
4. Remove all mud and oil from the steps or other places
used to get on and off the machine. Always use the
3. If welding repairs are needed, always have a trained,
handrails, ladders or steps when getting on or off the
experienced welder carry out the work. When carrying
machine. Never jump on or off the machine. If it is
out welding work, always wear welding gloves, apron,
impossible to use the handrails, ladders or steps, use a
glasses, cap and other clothes suited for welding work.
stand to provide safe footing.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure PRECAUTIONS DURING WORK 00
before starting. Always inform your fellow workers 1. When removing the oil filler cap, drain plug or hydrau-
before starting any step of the operation. Before starting lic pressure measuring plugs, loosen them slowly to pre-
work, hang UNDER REPAIR signs on the controls in vent the oil from spurting out. Before disconnecting or
the operator's compartment. removing components of the oil, water or air circuits,
first remove the pressure completely from the circuit.
5. Keep all tools in good condition and learn the correct
way to use them. 2. The water and oil in the circuits are hot when the engine
is stopped, so be careful not to get burned. Wait for the
6. Decide a place in the repair workshop to keep tools and oil and water to cool before carrying out any work on
removed parts. Always keep the tools and parts in their the oil or water circuits.
correct places. Always keep the work area clean and
make sure that there is no dirt or oil on the floor. Smoke 3. Before starting work, remove the leads from the battery.
only in the areas provided for smoking. Never smoke ALWAYS remove the lead from the negative (-) termi-
while working. nal first.
HM400-1L 00-3
FOREWORD SAFETY
12
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.
5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in posi-
tion on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.
7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.
8. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing elec-
trical parts.
9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed cor-
rectly.
12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measure-
ments.
14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.
00-4 HM400-1L
FOREWORD GENERAL
12
GENERAL 00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate under-
standing of the product and by showing him the correct way to perform repairs and make judgements. Make sure you under-
stand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
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.
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at comple-
tion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.
HM400-1L 00-5
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP
REVISIONS
MANUAL
00
00
10-5
00-6 HM400-1L
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00
can result. Hooks have maximum strength at the middle
portion.
HOISTING 00
3. Do not sling a heavy load with one rope alone, but sling
● If a part cannot be smoothly removed from the machine with two or more ropes symmetrically wound on to the
by hoisting, the following checks should be made: load.
1. Check for removal of all bolts fastening the part to the
WARNING! Slinging with one rope may
relative parts.
cause turning of the load during
2. Check for existence of another part causing interface
hoisting, untwisting of the rope,
with the part to be removed.
or slipping of the rope from its
original winding position on the
WIRE ROPES 00
HM400-1L 00-7
FOREWORD HOISTING INSTRUCTIONS
k Before carrying out the following work, release the residual pres-
sure from the hydraulic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from hydraulic tank.
Disconnection 00
1. Release the residual pressure from the hydraulic tank. For details,
see TESTING AND ADJUSTING, Releasing residual pressure
from hydraulic tank.
2. Hold adapter (1) and push hose joint (2) into mating adapter (3).
(See Fig. 1)
★ The adapter can be pushed in about 3.5 mm.
★ Do not hold rubber cap portion (4).
3. After hose joint (2) is pushed into adapter (3), press rubber cap
portion (4) against (3) until it clicks. (See Fig. 2)
4. Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3)
★ Since some hydraulic oil flows out, prepare an oil receiving
container.
Connection 00
1. Hold hose adapter (1) or hose (5) and insert it in mating adapter
(3), aligning them with each other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
2. After inserting the hose in the mating adapter perfectly, pull it
back to check its connecting condition. (See Fig. 5)
★ When the hose is pulled back, the rubber cap portion moves
toward the hose about 3.5 mm. This does not indicate abnor-
mality, however.
00-8 HM400-1L
FOREWORD HOISTING INSTRUCTIONS
Type 2 Type 3
1. Hold the mouthpiece of the tightening portion and 1. Hold the mouthpiece of the tightening portion and
push body (2) in straight until sliding prevention push body (2) in straight until sliding prevention
ring (1) contacts contact surface a of the hexago- ring (1) contacts contact surface a of the hexago-
nal portion at the male end. nal portion at the male end.
2. Hold in the condition in Step 1, and turn lever (4) 2. Hold in the condition in Step 1, and push until
to the right (clockwise). cover (3) contacts contact surface a of the hexag-
onal portion at the male end.
Disassembly
3. Hold in the condition in Steps 1 and 2, and pull 3. Hold in the condition in Steps 1 and 2, and pull
out whole body (2) to disconnect it. out whole body (2) to disconnect it.
● Hold the mouthpiece of the tightening portion and ● Hold the mouthpiece of the tightening portion and
push body (2) in straight until sliding prevention push body (2) in straight until sliding prevention
ring (1) contacts contact surface a of the hexago- ring (1) contacts contact surface a of the hexago-
nal portion at the male end to connect it. nal portion at the male end to connect it.
Connection
HM400-1L 00-9
FOREWORD COATING MATERIALS
COATING MATERIALS 00
★ The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
● Used to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions and cork plugs from coming out
● Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene ● Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pes.) container polypropylene, tetrafluoroethylene, and
vinyl chloride), rubber, metal and non-
metal.
● Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g ● Used for anti-loosening and sealant pur-
container
poses for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive ● Used as adhesive or sealant for metal, glass
LT-3 Hardening Can
and hardening or plastic.
agent:
agent)
Adhesives
500 g
Polyethylene
LT-4 790-129-9040 250 g ● Used as sealant for machined holes.
container
Holtz ● Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
● Quick hardening type adhesive.
Three
Polyethylene ● Cure time: within 5 sec. to 3 min.
bond 179-129-9140 2g
container ● Used mainly for adhesion of metals, rub-
1735
bers, plastics and woods.
● Quick hardening type adhesive.
Aron- ● Quick cure type (max. strength after 30
Polyethylene
alpha 790-129-9130 50 g minutes).
container
201 ● Used mainly for adhesion of rubbers, plas-
tics and metals.
● Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc ● Used at joint portions subject to high tem-
648-50 container
perature.
● Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
● Features: Resistance to heat
Gasket seal- ● Used as sealant for flange surfaces and bolts
ant at high temperature locations; used to pre-
LG-3 790-129-9070 1 kg Can vent seizure.
● Used as sealant for heat resistant gasket for
at high temperature locations such as engine
pre-combustion chamber, exhaust pipe.
00-10 HM400-1L
FOREWORD COATING MATERIALS
vent squeaking).
disulphide
lubricant
HM400-1L 00-11
FOREWORD STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE 00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.
mm mm Nm kgm
6 10 13.2 ±1.4 1.35 ±0.15
8 13 31.4 ±2.9 3.20 ±0.3
10 17 65.7 ±6.8 6.70 ±0.7
12 19 112 ±9.8 11.5 ±1.0
14 22 177 ±19 18 ±2.0
16 24 279 ±29 28.5 ±3
18 27 383 ±39 39 ±4
20 30 549 ±58 56 ±6
22 32 745 ±78 76 ±8
24 36 927 ±98 94.5 ±10
27 41 1320 ±140 135 ±15
30 46 1720 ±190 175 ±20
33 50 2210 ±240 225 ±25
36 55 2750 ±290 280 ±30
39 60 3280 ±340 335 ±35
mm mm Nm kgm
6 10 7.85 ± 1.95 0.8 ± 0.2
8 13 18.6 ± 4.9 1.9 ± 0.5
10 14 40.2 ± 5.9 4.1 ± 0.6
12 27 82.35 ± 7.85 8.4 ± 0.8
00-12 HM400-1L
FOREWORD STANDARD TIGHTENING TORQUE
12
TIGHTENING TORQUE OF HOSE NUTS 00
HM400-1L 00-13
FOREWORD STANDARD TIGHTENING TORQUE
12
TIGHTENING TORQUE FOR 102 ENGINE SERIES 00
2. Eye Joints
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
3. Tapered Screws
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter Tightening torque
inch Nm kgm
1 / 16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.41
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE
SEAL TYPE) 00
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
9
02 19 34 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
00-14 HM400-1L
FOREWORD STANDARD TIGHTENING TORQUE
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Thread size Nominal thread size - Root diameter (mm)
Range Target (mm) Threads per inch, (Reference)
Thread series
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 – –
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 – –
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42 – –
HM400-1L 00-15
FOREWORD ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS 00
Copper wire
Nominal num- Cable O.D. Current rat-
Number of Dia. Of strand Cross section Applicable circuit
ber (mm) ing (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
Circuits
Priority Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Primary
Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yel- Yellow & Green &
Color — Red & Black Blue & Red
Black low Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Red & Yel- Yellow & Green & Blue & Yel-
Color — Black & Red
Blue low Green Yellow low
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
00-16 HM400-1L
FOREWORD CONVERSION TABLES
12
CONVERSION TABLES 00
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.
EXAMPLE
● Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as 1, then draw a horizontal line from 1.
B. Locate the number 5 in the row across the top, take this as 2, then draw a perpendicular line down from 2.
C. Take the point where the two lines cross as 3. This point 3 gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.
2
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
3
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
1
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
HM400-1L 00-17
FOREWORD CONVERSION TABLES
12
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-18 HM400-1L
FOREWORD CONVERSION TABLES
12
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
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
HM400-1L 00-19
FOREWORD CONVERSION TABLES
12
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-20 HM400-1L
FOREWORD CONVERSION TABLES
12
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
HM400-1L 00-21
FOREWORD CONVERSION TABLES
12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, con-
sider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column
at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
00-22 HM400-1L
01 GENERAL
HM400-1L 01-1
GENERAL SPECIFICATION DRAWING
12
SPECIFICATION DRAWING
01-2 HM400-1L
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model HM400-1L
mm IN
Type Aftercooled
01-3 HM400-1L
GENERAL SPECIFICATIONS
Main brake Front wheel Independent front and rear system brake, sealed,
Front rear wheel wet-type, multiple disc, hydraulically operated type
Rear rear wheel
Brakes
01-4 HM400-1L
GENERAL SPECIFICATIONS
12
Hoist cylinder - type 2- stage piston type (only second stage double-acting)
Cylinder
HM400-1L 01-5
GENERAL WEIGHT TABLE
12
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
kg lb
HM400-1L Serial Numbers A10001 and up 30,350 66,910
Engine 1,470 3,241
Output shaft assembly 88 194
Cooling assembly 349 769
Fuel tank (individual part) 200 441
Torque converter assembly 282 662
Transmission assembly 1,324 2,919
Drive shaft assembly 295 650
Front axle assembly 2,131 4,698
Differential 428 944
Final drive 1,060 2,337
Center axle assembly 2,423 5,342
Differential 397 875
Final drive 1,047 2,308
Rear axle assembly 2,297 5,064
Differential 265 584
Final drive 1047 2,308
Front suspension cylinder 91.2 201
Rear suspension cylinder 78.2 172
Oscillation hitch assembly 851.1 1,876
Front frame 1,585 3,494
Rear frame 2,000 4,409
Cab (including platform, interior components) 652 1,437
Operator’s seat 56.1 124
Steering cylinder (one side) 65.6 145
Hoist cylinder (one side) Rear frame 254 560
Flow amp valve 29 64
Hoist valve 63 139
Hydraulic tank 240 529
Hydraulic pump (SBL(1)21) 2.6 6
Hydraulic pump (SAR(3)80+(1)25) 19.4 43
Hydraulic pump (SAR(3)100) 13 29
Hydraulic pump (SAR(3)100+100+(1)8) 35.8 79
Hydraulic pump (SAR(3)100+(1)12+8) 23.9 53
Hydraulic pump (SBR(1)8+8) 4.7 10
Hydraulic motor 1.9 4
Body assembly 4,232 9,330
01-6 HM400-1L
GENERAL FUEL, COOLANT AND LUBRICANTS
12
FUEL, COOLANT AND LUBRICANTS
It is not our policy to approve fuel, coolant and lubricants or to guarantee performance in service. The responsibility for the
quality of the fuel, coolant and lubricant must remain with the supplier. When in doubt, consult your Komatsu distributor. The
following table shows specified fuel, coolant and lubricants recommended for this machine.
Specified Capacity: Total amount of oil including oil for components and piping.
Refill Capacity: Amount of oil needed to refill system during normal maintenance.
Other equipment may be necessary when operating the machine at temperatures below -20°C (-4°F). Consult your Komatsu
distributor for your specific needs.
HM400-1L 01-7
GENERAL FUEL, COOLANT AND LUBRICANTS
12
ENGINE OIL SPECIFICATIONS
NORMAL OPERATION
Oil performance recommendations are as follows:
The use of a quality engine lubricating oil combined with appropriate oil and filter change intervals are critical factors in
maintaining engine performance and durability.
Komatsu Engine Oil or multi-viscosity engine oil meeting American Petroleum Institute (API) performance classification
CF-4, CG-4, CF-4/SG or CG-4/SH or MIL-L-2104D or E is recommended.
NOTICE:
Classification CD, CE, CD/SF or CE/SF oils may be used in areas where CF-4, CG-4, CF-4/SG or CG-4/SH oil
is not yet available. If API classification CC or CC/CD is used, reduce the engine oil change interval by half.
A sulfated ash limit of 1.0 to 1.5 mass percent is suggested for optimum valve and piston deposit and oil consumption
control. The sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of 1.85 mass percent has been placed
on all engine lubricating oils recommended for use in the engine. Higher ash oils can cause valve and/or piston damage
and lead to excessive oil consumption.
The API service symbol displays the following information. The upper half of the symbol displays the appropriate oil cat-
egories; the lower half may contain words to describe oil energy conserving features. The center section identifies the
SAE oil viscosity grade.
The use of a multi-grade lubricating oil has been found to improve oil consumption control and improve engine cranking
in cold temperatures while maintaining lubrication at high operating temperatures.
While SAE 15W-40 multi-viscosity oil is recommended for most operating climates, refer to the previous table for oil vis-
cosity recommendations for extreme climates.
NOTICE:
Limited use of low viscosity oils, such as SAE 10W-30 may be used for easier starting and providing sufficient
oil flow at ambient temperatures below -5°C (+23°F). However, continuous use of low viscosity oils can
decrease engine life due to wear.
Special “break-in” lubricating oils are not recommended for a new or rebuilt engine. Use the same type of oil during the
“break-in” as specified for normal operation.
Additional information regarding lubricating oil availability throughout the world is available in the “E.M.A. Lubricating
Oils Data Book for Automotive and Industrial Engines.” The data book may be ordered from the Engine Manufacturers
Association, 401 North Michigan Ave., Chicago, Il U.S.A. 60611. The telephone number is (312) 644-6610.
ARCTIC OPERATION
If an engine is operated in ambient temperatures consistently below -23°C (-10°F) and there are no provisions to keep the
engine warm when it is not in operation, use a synthetic engine oil API performance classification CF-4, CG-4, CF-4/SG
or CG-4/SH with adequate low temperature properties such as SAE 5W-20 or 5W-30.
The oil supplier must be responsible for meeting the performance service specifications.
NOTICE:
The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change intervals can
decrease engine life due to factors such as corrosion, deposits and wear.
01-8 HM400-1L
GENERAL FUEL, COOLANT AND LUBRICANTS
Komatsu Engine Oil or engine oil meeting American Petroleum Institute (API) performance classification CF-4, CG-4, CF-4/
SG or CG-4/SH or MIL-L-2104D or E is recommended.
NOTICE:
Classification CD, CE, CD/SF or CE/SF oils may be used in areas where CF-4, CG-4, CF-4/SG or CG-4/SH oil is
not yet available.
Komatsu Gear Lubricant or an equivalent multi-purpose gear lubricant meeting API GL-5 or MIL-L-2105C is recommended.
For drive axle oil, use only the recommended oil as follows:
SHELL: DONAX TT or TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
MOBIL: MOBIL 424
Engine oil: SAE 30 API classification CD (May increase brake noise, but will not affect durability.)
WARNING
Never mix gasoline, gasohol and/or alcohol with diesel fuel. This practice creates an extreme fire hazard and, under
certain conditions, an explosion which could result in personal injury or death.
WARNING
Never remove the fuel tank filler cap or refill the fuel tank while the engine is running or when hot or when the
machine is indoors. Fumes are dangerous, a spark or flame could result in a fire or explosion.
NOTICE:
The precise tolerances of diesel fuel injection systems demand that the fuel be kept clean and free of contaminates
or water. Contaminates or water in the system can cause severe damage to both the injection pump and nozzles.
REMARK:
Below -12°C (+10°F) the paraffin in ASTM Grade No. 2-D diesel fuel will change to wax particles and clog the fuel
filters. For best results use Grade No. 1-D diesel fuel in cold weather.
For normal service above -10°C (+14°F), the use of ASTM Grade No. 2-D diesel fuel with a minimum Cetane number of 40 is
recommended. The use of No. 2-D diesel fuel will result in optimum engine performance under most operating conditions.
Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to prevent
misfires and excessive smoke.
At operating temperatures below -10°C (+14°F) or extended engine idling, use ASTM Grade No. 1-D diesel fuel. The use of
lighter fuels can reduce fuel economy.
HM400-1L 01-9
GENERAL FUEL, COOLANT AND LUBRICANTS
Where a winterized blend of Grade No. 2-D and No. 1-D fuels is available, it may be substituted for Grade No. 1-D fuel. How-
ever, it is the supplier's responsibility to provide the fuel for the anticipated ambient temperature.
Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expected fuel temperature. Cloud
point is the temperature at which crystals begin to form in the fuel.
The viscosity of the fuel must be kept above 1.3 cSt to provide adequate fuel system lubrication.
Optionally, the equivalent grades of recognized Federal Government specifications may be used; the latest revisions of VV-F-
800a.
COOLANT SPECIFICATIONS
GENERAL
Selection and maintenance of the engine coolant is important to long engine life. The following information provides recom-
mendations for selecting the engine coolant and maintaining the supplemental coolant additives (SCA).
Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant additives. The
coolant mixture must be drained and replaced at the specified service interval or every two years of operation, whichever
comes first.
WATER
Use water which has a low mineral content. Water used with antifreeze, coolant filters and inhibited water must meet the fol-
lowing standards:
Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scale deposits. Water
containing dissolved magnesium and calcium (the usual reason for water hardness) above the spec-
ified amount will cause scale deposits to develop in the engine.
Chlorides - Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent corrosion.
Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent corrosion.
Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon maximum) to minimize sludge deposits, scale
deposits, corrosion or a combination of these.
If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. To determine if local water
supplies meet these standards, water samples can be tested by water treatment laboratories. Softened water that is prepared
using common salt (sodium chloride) contains excessive amounts of chlorides and should not be used.
NOTICE:
Never use water alone in the cooling system because rust, scale deposits and corrosion will occur.
ANTIFREEZE
Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing point and
by raising its boiling point.
In climates where the temperature is above -34°C (-30°F), use a coolant mixture that contains 50 percent antifreeze. Do not
use more than 50 percent antifreeze in the mixture unless additional freeze protection is required. Never use more than 68 per-
cent antifreeze under any condition.
01-10 HM400-1L
GENERAL FUEL, COOLANT AND LUBRICANTS
An antifreeze concentration greater than 68% will adversely affect freeze protection and heat transfer rates. Antifreeze concen-
trations between 68 and 100% actually have a higher freezing point than a 68% antifreeze concentration and should not be
used due to reduced heat transfer rates.
Ethylene glycol, low silicate antifreeze is recommended. The antifreeze should contain no more than 0.1% anhydrous alkali
metasilicate. Low silicate antifreeze is recommended to avoid the formation of silica-gel (hydro-gel). This gel formation can
occur when the cooling system contains an over concentration of high silicate antifreeze and/or supplemental coolant additive.
DO NOT use methanol or alcohol, which has an unacceptably low boiling point.
Antifreeze may retain its freeze protection for more than one season but coolant conditioners must be added to maintain corro-
sion protection.
Antifreeze formulated with methoxy propanol, or propylene glycol, is not recommended for this system.
NOTICE:
Do not mix types of antifreeze solutions. Mixed solutions make it impossible to determine the protection against
freezing. Antifreeze containing sealer or anti-leak additives should NOT be used in this system. Sealer or anti-leak
additives will cause plugging problems in the cooling system.
WARNING
Use extreme caution when adding coolant to a hot radiator to avoid being burned. Wear gloves and gog-
gles and keep face away from the filler neck.
Check the solution periodically and at normal operating temperature, to be sure the cooling system has sufficient protection
against freezing. An antifreeze concentration greater than 68% will adversely affect antifreeze protection and heat transfer
rates. Antifreeze concentrations between 68% and 100% actually have a higher freezing points than a 68% antifreeze concen-
tration as well as reduced heat transfer rates and should not be used.
REMARK:
Do not use a 100% antifreeze solution for freezing protection. This will cause severe corrosion in the cooling system
and if not detected will cause radiator and oil cooler core damage. Use a water/antifreeze solution as described in
the following table.
The following table shows the approximate percentage of antifreeze solution required for various temperatures.
Approximate Freezing Point Percentage of Antifreeze Concentra- Specific Gravity at 16°C (60°F)
tion by Volume
HM400-1L 01-11
GENERAL FUEL, COOLANT AND LUBRICANTS
In tropical climates where antifreeze availability may be limited, use a corrosion inhibitor or supplemental coolant additive
(SCA), to protect the engine cooling system.
1. All supplemental cooling system additives, including those in antifreeze solutions, become depleted through normal oper-
ation. If the coolant additives in antifreeze are allowed to become depleted, the antifreeze becomes corrosive and attacks
and coats the metallic surfaces of the cooling system which reduces heat transfer. Cooling system conditioners which con-
tain these additives must be added to maintain corrosion protection.
2. SOLUBLE OIL IS NOT RECOMMENDED for use in this engine as its use will reduce heat transfer and allow internal
engine damage.
3. There are no miracle additives that will increase heat transfer or prevent overheating. Conditioned water is still the best
coolant.
4. A corrosion inhibitor/conditioner is recommended to inhibit corrosion in the cooling system for the following reasons:
• Improved compatibility with high silicate antifreezes to minimize hydro-gel formation if over concentration occurs.
• Provides engine protection in the following areas:
- Solder corrosion/bloom - Copper corrosion/erosion/stress cracking
- Oil fouling - Cylinder liner cavitation corrosion
- Aluminum cavitation/corrosion - Seal and gasket degradation
Keeping the engine coolant properly inhibited will keep the engine and radiator free of rust, scale deposits and corrosion.
New machines are delivered with antifreeze protection. Service at a regular scheduled interval specified in the Operation and
Maintenance Manual.
Each time the coolant is drained and replaced, the coolant must be recharged with supplemental coolant additives. New cool-
ant can be correctly charged with coolant additives by using a replacement coolant filter and/or concentrate.
If coolant is added between drain intervals, additional coolant additives may be required.
When the cooling system is maintained as recommended, the conditioner concentration should be satisfactory. The SCA con-
centration must not fall below 1.0 unit per 3.8 liters (1 gal) or exceed 2 units per 3.8 liters (1 gal) of coolant. The only accurate
method for testing chemical concentrations in coolant with mixed chemical compounds is a laboratory analysis. For this rea-
son, the coolant inhibitor should be maintained as shown in the Operation and Maintenance Manual.
NOTICE:
Inadequate concentration of the coolant additive can result in major corrosive damage to cooling system compo-
nents. Over-concentration can cause formation of gel that can cause restriction, plugging of passages and overheat-
ing.
01-12 HM400-1L
GENERAL FUEL, COOLANT AND LUBRICANTS
12
Replenishing Coolant Conditioner
Install a “precharge” coolant filter when the coolant is changed or a significant (more than 50%) coolant loss occurs.
When antifreeze is added, add coolant conditioner equal to 1.0 unit per 3.8 liters (1 US gal) of antifreeze.
NOTICE:
Mixing of DCA4 and other supplemental coolant additives is not recommended because there is currently no test
kit available to measure concentration levels with mixed chemical solutions.
Use supplemental coolant additives (corrosion inhibitors) to protect the engine cooling system from corrosion. Antifreeze
alone does not provide enough corrosion protection for a heavy duty diesel engine. Supplemental corrosion protection
must be supplied through periodic additions of supplemental coolant additives to the coolant.
To protect against corrosion, a new coolant charge must be brought up to 0.26 SCA unit per liter [one unit per U.S. gallon]
of coolant (initial charge). Maintain the correct SCA concentration by changing the service coolant filter at each engine oil
and filter change interval.
Each time the coolant is drained and replace, the coolant must be recharged with supplemental coolant additives. Use the
appropriate replacement coolant filter listed in following tables. The coolant mixture must be drained and replaced as
defined under “General.”
The amount of a replacement inhibitor is determined by the length of the service interval and the cooling system capacity.
Refer to the DCA4 Unit Guide for the selection of the correct filter to replenish the SCA.
HM400-1L 01-13
GENERAL FUEL, COOLANT AND LUBRICANTS
12 If coolant is added between drain intervals, additional SCA will be required. Check the coolant DCA concentration level
anytime make up coolant is added to the system. The SCA concentration must not fall below 0.13 units per liter or
exceed 0.5 units per liter [0.5 units per U.S. gallon or exceed 2 units per U.S. gallon].
DCA4 Liquid
DCA60L 4 (1 pt)
DCA80L 1760 (55 gal)
DCA4 Powder
DCA95 20
NOTE 1 - After draining and replacing coolant, always precharge the cooling system to maintain the SCA concentration
between 1.0 and 2.0 units per 3.8 liters (1 US gal).
NOTICE:
When performing service which requires draining the cooling system, discard the coolant. Reusing coolant can
introduce contaminants or over-concentrated chemicals and result in premature failure of cooling system compo-
nents.
01-14 HM400-1L
GENERAL FUEL, COOLANT AND LUBRICANTS
12
NOTE 2 - To precharge cooling systems larger than 114 liters (30 gal) do the following:
• Install appropriate service filter listed in the above table based on cooling system capacity.
• The answer represents the additional units required to precharge the cooling system. Four bottles of powder, part
number DCA95, will provide a sufficient amount of SCA units (80) to precharge the example cooling system.
• Install the appropriate service filter at the next and subsequent maintenance intervals.
NOTE 3 - Change the coolant filter at every engine oil and filter change interval to protect the cooling system.
Maintain a nominal SCA concentration of 1.0 unit per 3.8 liters (1 US gal) of coolant in the system. Less than 0.5 units per 3.8
liters (1 US gal) indicates an under-concentrated coolant solution. More than 2.0 units per 3.8 liters (1 US gal) indicates an
over-concentrated coolant solution.
To check the SCA concentration level, use Coolant Test Kit CC-2626. Instructions are included with the test kit.
11 - 16 Drops Marginally under-concentrated -0.45 Add SCA liquid units to maintain 1.0
to 0.8 SCA units per 3.8 liters (1 US SCA unit per 3.8 liters (1 US gal) mini-
gal) mum or change the DCA 4 coolant fil-
ter.
Over 55 Drops Extremely over-concentrated Drain 50% of the coolant and replace
with water antifreeze mixture. Retest
the system for correct SCA unit concen-
tration.
HM400-1L 01-15
GENERAL FUEL, COOLANT AND LUBRICANTS
12
COOLING SYSTEM TEST KIT
The following cooling system test kit may be purchased from your Komatsu America International Company distributor.
01-16 HM400-1L
10 STRUCTURE AND FUNCTION
HM400-1L 10-1
STRUCTURE AND FUNCTION TABLE OF CONTENTS
TORQUE CONVERTER RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52
LOCKING DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
TRAVELING IN A STRAIGHT LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
TURNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
WHEN DIFFERENTIAL LOCK IS ACTUATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
CENTER, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64
BRAKE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-67
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
UPPER PORTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
LOWER PORTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
APPLYING BRAKE WHEN UPPER VALVE FAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
APPLYING BRAKE WHEN LOWER VALVE FAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
WHEN ACTUATION IS BALANCED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
BRAKE RELEASED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
ACCUMULATOR CHARGE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-71
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-71
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-73
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-75
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-75
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-75
SLACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-79
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-79
CENTER, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
PROPORTIONAL REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
BRAKE SYSTEM TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-85
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
PARKING BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88
SPRING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-89
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-89
PARKING BRAKE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90
10-2 HM400-1L
STRUCTURE AND FUNCTION TABLE OF CONTENTS
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-93
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95
SUSPENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-97
STRUCTURE AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98
OSCILLATION HITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101
STEERING, HOIST OIL PRESSURE PIPING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102
DUMP BODY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103
HYDRAULIC TANK AND FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104
FLOW AMP VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106
STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
CONNECTION BETWEEN HAND PUMP AND SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110
FUNCTION OF CENTER SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-113
HOIST VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116
HOIST VALVE AT HOLD POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116
HOIST VALVE AT RAISE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-117
HOIST VALVE AT FLOAT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-118
HOIST VALVE AT LOWER POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-119
EPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120
PILOT CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-121
HOIST CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-122
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-123
STEERING, HOIST + PILOT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-123
TRANSMISSION + DIFFERENTIAL LOCK PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124
BRAKE COOLING + BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-125
AUXILIARY STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
DIFFERENTIAL LOCK PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-127
CAB TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-128
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-129
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-129
AIR CONDITIONER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130
RECEIVER DRYER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-131
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-133
MACHINE MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
NETWORK DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-135
MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
OPTION SETTING CONNECTOR DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-139
ADJUSTING MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-139
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
SELF-DIAGNOSTIC FUNCTION WHEN OPERATING STARTING SWITCH . . . . . . . . . . . . . . . 10-143
CHECK FUNCTION OF CENTRAL WARNING LAMP, ALARM BUZZER, MONITOR LAMPS AND
METERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
SERVICE METER DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
ODOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
HM400-1L 10-3
STRUCTURE AND FUNCTION TABLE OF CONTENTS
OUTLINE OF SERVICE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
OPERATION METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-148
AUTOMATIC SHIFT CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-149
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150
TRANSMISSION CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151
GEARSHIFT LEVER POSITION AND AUTOMATIC GEARSHIFTING RANGE . . . . . . . . . . . . . . . . 10-154
GEARSHIFTING CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-154
AUTOMATIC GEARSHIFTING GRAPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155
GEARSHIFT LEVER POSITIONS AND SHIFTING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-156
SHIFT HOLD FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157
GEARSHIFTING TIME DELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157
SAFETY FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157
SELF-DIAGNOSTIC FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158
AUTO AUXILIARY STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-159
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-159
SENSORS, SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
ACCELERATOR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
ACCELERATOR SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
IDLE VALIDATION SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
ENGINE COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
BRAKE COOLING OIL TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
STEERING OIL TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-163
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-163
TILT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-164
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-164
AIR CLEANER CLOGGING SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-165
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-165
HYDRAULIC OIL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
BODY POSITIONER SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-167
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-167
RETARDER CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-168
RETARDER CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169
RETARDER CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-173
RETARDER CONTROL SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-173
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOIST CONTROL FUNCTION 10-175
HOIST CONTROL SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-175
DIFFERENTIAL LOCK CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-177
DIFFERENTIAL LOCK CONTROL SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-177
BRAKE CONTROL SYSTEM (E-SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-179
BRAKE CONTROLLER (E-SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180
BRAKE CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-184
BRAKE CONTROL SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-184
HOIST CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-185
HOIST CONTROL SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-185
DIFFERENTIAL LOCK CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-187
DIFFERENTIAL LOCK CONTROL SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-187
10-4 HM400-1L
STRUCTURE AND FUNCTION TABLE OF CONTENTS
DUMP CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-188
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190
DUMP CONTROL LEVER OPERATED TO FLOAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190
DUMP CONTROL LEVER FLOAT CANCELED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190
DUMP CONTROL LEVER OPERATED TO LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-191
DUMP CONTROL LEVER OPERATED TO RAISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-191
DUMP CONTROL LEVER RAISE CANCELED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-191
PLM-HM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
SYSTEM STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
PRINCIPLE OF CALCULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-193
ACCURATE CALCULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
GENERAL LOCATIONS OF LOAD METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-195
LEFT FACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-196
BASIC FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-197
KEY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-205
SERVICE CHECK MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-207
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-212
ERROR CODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-214
LOCAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-217
HM400-1L 10-5
STRUCTURE AND FUNCTION RADIATOR, OIL COOLER, AFTERCOOLER
12
RADIATOR, OIL COOLER, AFTERCOOLER
1. Aftercooler SPECIFICATIONS
2. Coolant filler
3. Reservoir tank
Radiator
4. Upper tank
• Core type: CF4-5
5. Lower tank (torque converter, oil cooler)
• Total heat dissipating area: 67.93 m2
A. From thermostat Torque converter oil cooler
B. To water pump • Core type: PTO-LS
C. From rear brake • Total heat dissipating area: 4.0655 m2
D. To oil filter Steering oil cooler
E. From hoist valve • Core type: PTO-OL
F. To hydraulic tank • Total heat dissipating area: 0.896m2
G. From water pump
10-6 HM400-1L
STRUCTURE AND FUNCTION POWER TRAIN SKELETON
LOCKING DIFFERENTIAL
HM400-1L 10-7
STRUCTURE AND FUNCTION POWER TRAIN SKELETON
1. Engine
2. Output shaft
3. Front drive shaft
4. Brake cooling and brake system pump (SAR(3)80+(1)25)
5. Torque converter, transmission, front brake cooling, differential lock control pump (SAR(3)100+(1)12+8)
6. PTO
7. Torque converter
8. Steering, hoist control pump (SAR(3)100+100+(1)8)
9. Transmission
10. Oscillation hitch
11. Center drive shaft
12. Front differential
13. Front differential lock
14. Tire
15. Final drive (front)
16. Brake (front)
17. Rear drive shaft (front)
18. Center differential
19. Center differential lock
20. Tire
21. Final drive (center)
22. Brake (center)
23. Rear drive shaft (rear)
24. Rear differential
25. Rear differential lock
26. Tire
27. Final drive (rear)
28. Brake (rear)
29. Interaxle differential lock
10-8 HM400-1L
STRUCTURE AND FUNCTION OUTPUT SHAFT
OUTPUT SHAFT
HM400-1L 10-9
STRUCTURE AND FUNCTION OUTPUT SHAFT
Unit: mm
No. Check item Criteria Remedy
Wear of oil seal contact surface of Standard size Repair limit Repair or
5
coupling 95 94.7 replace
10-10 HM400-1L
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION HYDRAULIC
HM400-1L 10-11
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION HYDRAULIC
1. Engine
2. Torque converter
3. Transmission
4. Oil cooler (built into radiator)
5. Torque converter, transmission, brake cooling return filter
6. Rear brake cooling and brake system pump (SAR(3)80+25)
7. Brake system tank
8. Torque converter, transmission, front brake cooling, differential control pump (SAR(3)100+12+8) (SAR(3)100:E-SPEC)
9. Hydraulic tank
10-12 HM400-1L
STRUCTURE AND FUNCTION TORQUE CONVERTER
TORQUE CONVERTER
Lockup clutch:
• Multiple-disc clutch
• Hydraulic control (with modulation valve)
Stall torque ratio:
• 2.63
HM400-1L 10-13
STRUCTURE AND FUNCTION TORQUE CONVERTER
10-14 HM400-1L
STRUCTURE AND FUNCTION TORQUE CONVERTER
HM400-1L 10-15
STRUCTURE AND FUNCTION TORQUE CONVERTER
Unit: mm
No. Check item Criteria Remedy
10-16 HM400-1L
STRUCTURE AND FUNCTION TORQUE CONVERTER
The power generated by the engine goes from the damper through
the drive shaft, is transmitted to coupling (3), input shaft (4) and
clutch housing (5), and rotates drive case (1) and pump (6) as one
unit.
The power from pump (6) uses oil as a medium, rotates turbine (2),
and is transmitted from turbine (2) to transmission output shaft (7).
The power generated by the engine goes from the damper through
the drive shaft, is transmitted to coupling (3), input shaft (4) and
clutch housing (5), and rotates drive case (1) and pump (6) as one
unit.
In addition, drive case (1) and turbine (2) are engaged by the clutch,
so the power is transmitted directly from turbine (2) to transmission
output shaft (7) without using oil as a medium.
HM400-1L 10-17
STRUCTURE AND FUNCTION TORQUE CONVERTER
OIL FLOW
The oil passes through the main relief valve, is adjusted by the torque
converter relief valve to a pressure less than the set pressure, and enters
inlet port A. It then passes through the oil passage in stator shaft (1) and
flows from between pump (2) and stator (3) to pump (2). The oil is
given centrifugal force by pump (2), enters turbine (4), and transmits the
energy of the oil to the turbine.
The oil from turbine (4) is sent to stator (3), and enters the pump again.
However, part of the oil passes between turbine (4) and stator (3) and is
sent from outlet port B to the oil cooler to be cooled. It is then used to
lubricate the transmission.
10-18 HM400-1L
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
HM400-1L 10-19
STRUCTURE AND FUNCTION TRANSMISSION
10-20 HM400-1L
STRUCTURE AND FUNCTION TRANSMISSION
HM400-1L 10-21
STRUCTURE AND FUNCTION TRANSMISSION
Tolerance
Standard Standard Clearance
size clearance limit
1 Clearance (F) between FL, R clutch bear- Shaft Hole
ing and case
o 160 0 0 -0.040 –0.025 –
-0.025 -0.040
5 Clearance (F) between 2nd, 3rd clutch o 160 0 -0.012 -0.052 –0.013 –
bearing and case -0.025 -0.052
6 Clearance (R) between 2nd, 3rd clutch o 160 0 -0.017 -0.052 –0.008 –
bearing and cage -0.025 -0.052
10-22 HM400-1L
STRUCTURE AND FUNCTION TRANSMISSION
Unit: mm
No. Check item Criteria Remedy
HM400-1L 10-23
STRUCTURE AND FUNCTION TRANSMISSION
FL - R CLUTCH
Unit: mm
No. Check item Criteria Remedy
10-24 HM400-1L
STRUCTURE AND FUNCTION TRANSMISSION
FH - 1ST CLUTCH
Unit: mm
No. Check item Criteria Remedy
HM400-1L 10-25
STRUCTURE AND FUNCTION TRANSMISSION
Unit: mm
No. Check item Criteria Remedy
10-26 HM400-1L
STRUCTURE AND FUNCTION TRANSMISSION
DIFFERENTIAL LOCK
HM400-1L 10-27
STRUCTURE AND FUNCTION TRANSMISSION
10-28 HM400-1L
STRUCTURE AND FUNCTION TRANSMISSION
CLUTCH OPERATIONS
Clutch engaged (fixed)
● The oil sent from the transmission valve passes through the oil pas-
sage inside shaft (1), reaches the back face of piston (6) and acts on
piston (6).
● When piston (6) is actuated, separator plate (2) and friction plate (3)
are pressed together, shaft (1) and clutch gear (4) form one unit, and
the power is transmitted.
● When this happens, the oil is drained from oil drain hole (5), but the
drain amount is less than the amount of oil supplied, so there is no
influence on the actuation of the clutch.
★ Oil drain hole (5) forms part of the structure of only the 2nd, 3rd,
and differential lock clutches.
● The oil sent from the transmission valve is shut off, so the pressure
of the oil acting on the back face of piston (6) goes down.
● Piston (6) is returned to its original position by wave spring (7), and
shaft (1) and clutch gear (4) are separated.
● When the clutch is disengaged, centrifugal force is used to drain the
oil at the back face of the piston through oil drain hole (5). This acts
to prevent the clutch from being partially applied.
HM400-1L 10-29
STRUCTURE AND FUNCTION TRANSMISSION
FORWARD 1ST
OPERATION
● When FORWARD 1st, FL clutch (3) and 1st clutch (11) are engaged, the power from the torque converter is transmitted to
input shaft (1), and then transmitted to front and rear output shafts (28) and (29).
● FL clutch (3) and 1st clutch (11) hold each clutch disc in position with the oil pressure applied to the piston.
● The power from the torque converter is transmitted from input shaft (1) through FL clutch (3), goes to FL gear (5), and is
then transmitted to FH, 1st cylinder gear (8).
● 1st clutch (11) is engaged, so the power transmitted to FH, 1st cylinder gear (8) passes through 1st clutch (11), and goes
from 1st gear (12) to 2nd, 3rd cylinder gear (14). It then goes through idler gear (19) and output gear (20), and is transmit-
ted to differential lock carrier (21).
● When the differential lock switch is OFF, the front output force passes from planet gear (25) through sun gear (26), and is
transmitted to front output shaft (28). The rear output force passes from planet gear (25) through ring gear (27), and is
transmitted to rear output shaft (29).
★ If the differential lock is ON, see FORWARD 2ND.
10-30 HM400-1L
STRUCTURE AND FUNCTION TRANSMISSION
FORWARD 2ND
OPERATION
● When FORWARD 2nd, FH clutch (10) and 1st clutch (11) are engaged, the power from the torque converter is transmitted
to input shaft (1), and then transmitted to front and rear output shafts (28) and (29).
● FH clutch (10) and 1st clutch (11) hold each clutch disc in position with the oil pressure applied to the piston.
● The power from the torque converter is transmitted from input shaft (1) to idler gear (2) and goes to FH gear (9), passes
through FH clutch (10), and is then transmitted to FH, 1st cylinder gear (8).
● 1st clutch (11) is engaged, so the power transmitted to FH, 1st cylinder gear (8) passes through 1st clutch (11), and goes
from 1st gear (12) to 2nd, 3rd cylinder gear (14). It then goes through idler gear (19) and output gear (20), and is transmit-
ted to differential lock carrier (21).
● When the differential lock switch is ON, the front output force passes from housing (22) through differential lock clutch
(23) and clutch hub (24), and is transmitted to front output shaft (28). The rear output force passes from planet gear (25)
through ring gear (27), and is transmitted to rear output shaft (29).
★ If the differential lock is OFF, see FORWARD 1ST.
HM400-1L 10-31
STRUCTURE AND FUNCTION TRANSMISSION
FORWARD 3RD
OPERATION
● When FORWARD 3rd, FL clutch (3) and 2nd clutch (17) are engaged, the power from the torque converter is transmitted
to input shaft (1), and then transmitted to front and rear output shafts (28) and (29).
● FL clutch (3) and 2nd clutch (17) hold each clutch disc in position with the oil pressure applied to the piston.
● The power from the torque converter is transmitted from input shaft (1) through FL clutch (3), goes to FL gear (5), and is
then transmitted through FH, 1st cylinder gear (8) and idler gear (13), and goes to 2nd gear (15).
● 2nd clutch (17) is engaged, so the power transmitted to 2nd gear (15) passes through 2nd clutch (17), and goes to 2nd, 3rd
cylinder gear (14). It then goes through idler gear (19) and output gear (20), and is transmitted to differential lock carrier
(21).
★ The diagram above shows the situation when the differential lock is OFF.
★ For details of the actuation when the differential lock is OFF, see FORWARD 1ST; for details of the actuation when the
differential lock is ON, see FORWARD 2ND.
10-32 HM400-1L
STRUCTURE AND FUNCTION TRANSMISSION
FORWARD 4TH
OPERATION
● When FORWARD 4th, FH clutch (10) and 2nd clutch (17) are engaged, the power from the torque converter is transmit-
ted to input shaft (1), and then transmitted to front and rear output shafts (28) and (29).
● FH clutch (10) and 2nd clutch (17) hold each clutch disc in position with the oil pressure applied to the piston.
● The power from the torque converter is transmitted from input shaft (1), goes to idler gear (2) and FH gear (9), passes
through FH clutch (10), and is then transmitted through FH, 1st cylinder gear (8) and idler gear (13), and is transmitted to
2nd gear (15).
● 2nd clutch (17) is engaged, so the power transmitted to 2nd gear (15) passes through 2nd clutch (17), and goes to 2nd, 3rd
cylinder gear (14). It then goes through idler gear (19) and output gear (20), and is transmitted to differential lock carrier
(21).
★ The diagram above shows the situation when the differential lock is ON.
★ For details of the actuation when the differential lock is OFF, see FORWARD 1ST; for details of the actuation when the
differential lock is ON, see FORWARD 2ND.
HM400-1L 10-33
STRUCTURE AND FUNCTION TRANSMISSION
FORWARD 5TH
OPERATION
● When FORWARD 5th, FL clutch (3) and 3rd clutch (18) are engaged, the power from the torque converter is transmitted
to input shaft (1), and then transmitted to front and rear output shafts (28) and (29).
● FL clutch (3) and 3rd clutch (18) hold each clutch disc in position with the oil pressure applied to the piston.
● The power from the torque converter is transmitted from input shaft (1) through FL clutch (3), goes to FL gear (5), and is
then transmitted through FH, 1st cylinder gear (8) to 3rd gear (16).
● 3rd clutch (18) is engaged, so the power transmitted to 3rd gear (16) passes through 3rd clutch (18), and goes to 2nd, 3rd
cylinder gear (14). It then goes through idler gear (19) and output gear (20), and is transmitted to differential lock carrier
(21).
★ The diagram above shows the situation when the differential lock is OFF.
★ For details of the actuation when the differential lock is OFF, see FORWARD 1ST; for details of the actuation when the
differential lock is ON, see FORWARD 2ND.
10-34 HM400-1L
STRUCTURE AND FUNCTION TRANSMISSION
FORWARD 6TH
OPERATION
● When FORWARD 6th, FH clutch (10) and 3rd clutch (18) are engaged, the power from the torque converter is transmitted
to input shaft (1), and then transmitted to front and rear output shafts (28) and (29).
● FH clutch (10) and 3rd clutch (18) hold each clutch disc in position with the oil pressure applied to the piston.
● The power from the torque converter is transmitted from input shaft (1), goes to idler gear (2) and FH gear (9), passes
through FH clutch (10), and is then transmitted through FH, 1st cylinder gear (8) to 3rd gear (16).
● 3rd clutch (18) is engaged, so the power transmitted to 3rd gear (16) passes through 3rd clutch (18), and goes to 2nd, 3rd
cylinder gear (14). It then goes through idler gear (19) and output gear (20), and is transmitted to differential lock carrier
(21).
★ The diagram above shows the situation when the differential lock is ON.
★ For details of the actuation when the differential lock is OFF, see FORWARD 1ST; for details of the actuation when the
differential lock is ON, see FORWARD 2ND.
HM400-1L 10-35
STRUCTURE AND FUNCTION TRANSMISSION
REVERSE 1ST
OPERATION
● When REVERSE 1st, R clutch (4) and 1st clutch (11) are engaged, the power from the torque converter is transmitted to
input shaft (1), and then transmitted to front and rear output shafts (28) and (29).
● R clutch (4) and 1st clutch (11) hold each clutch disc in position with the oil pressure applied to the piston.
● The power from the torque converter is transmitted from input shaft (1) through R clutch (4), goes to R gear (6), is rotated
in the opposite direction by R idler gear (7), passes through idler gear (13), and is then transmitted to FH, 1st cylinder gear
(8).
● 1st clutch (11) is engaged, so the power transmitted to FH, 1st cylinder gear (8) passes through 1st clutch (11), and goes
from 1st gear (12) to 2nd, 3rd cylinder gear (14). It then goes through idler gear (19) and output gear (20), and is transmit-
ted to differential lock carrier (21).
★ The diagram above shows the situation when the differential lock is OFF.
★ For details of the actuation when the differential lock is OFF, see FORWARD 1ST; for details of the actuation when the
differential lock is ON, see FORWARD 2ND.
10-36 HM400-1L
STRUCTURE AND FUNCTION TRANSMISSION VALVE
TRANSMISSION VALVE
A. Lock-up clutch oil pressure detection port 1. ECMV (for lock-up clutch)
B. 2nd clutch oil pressure detection port 2. ECMV (for 2nd clutch)
C. 3rd clutch oil pressure detection port 3. ECMV (for 3rd clutch)
D. R clutch oil pressure detection port 4. ECMV (for R clutch)
E. FL clutch oil pressure detection port 5. ECMV (for FL clutch)
F. 1st clutch oil pressure detection port 6. ECMV (for 1st clutch)
G. FH clutch oil pressure detection port 7. ECMV (for FH clutch)
H. Differential lock clutch oil pressure detection port 8. ECMV (for differential lock clutch)
9. Seat
10. Last chance filter
HM400-1L 10-37
STRUCTURE AND FUNCTION TRANSMISSION VALVE
ECMV clutch operation table
ECMV
F1 w w
F2 w w
F3 w w
F4 w w
F5 w w
F6 w w
R1 w w
R2 w w
N
10-38 HM400-1L
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
HM400-1L 10-39
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
OPERATION
During torque converter travel
10-40 HM400-1L
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
1. When filling
When the transmission is in direct travel (lock-up), if electric cur-
rent is applied to proportional solenoid (1) by the electric signal, a
hydraulic force balancing with the force of the solenoid acts on
chamber B, and pressure control valve spool (3) moves to the left.
As a result, the circuit between pump port P and clutch port A
opens, and oil starts to fill the clutch. When the clutch is filled with
oil, fill switch (6) is turned ON.
2. Adjusting pressure
When electric current flows to proportional solenoid (1), the sole-
noid generates a propulsion force proportional to the current. The
pressure is adjusted so that the total of this propulsion force of the
solenoid, the propulsion force of the oil pressure at the clutch port,
and the reaction force of pressure control valve spring (2) is bal-
anced. To reduce the shock when shifting gear, the oil pressure of
the lock-up clutch is temporarily lowered during the gearshifting
operation. The oil pressure at this point is an oil pressure which bal-
ances the pushing force of the lock-up piston and the pressure
inside the torque converter.
HM400-1L 10-41
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
The proportional solenoid receives the flow of electricity sent from the
transmission controller, and the pressure control valve converts this into
hydraulic pressure.
Fill switch
This detects when oil has filled the clutch. It has the following func-
tions.
1. When the clutch is filled with oil, it sends a signal (fill signal) to the
controller to inform the controller that the filling is completed.
10-42 HM400-1L
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
ECMV OPERATION
The ECMV is controlled by the command current from the transmission
controller to the proportional solenoid and the fill switch output signal.
The relationship between the ECMV proportional solenoid command
current and the clutch input pressure and fill switch output signal is as
shown in the diagram below.
HM400-1L 10-43
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
2. When filling (when trigger command is input to pressure control
valve) (Ranges B and C in graph)
When there is no oil inside the clutch, if electric current is applied
to proportional solenoid (1), a hydraulic force balancing the force
of the solenoid acts on chamber B, and pressure control valve spool
(3) moves to the left. As a result, the circuit between pump port P
and clutch port A opens, and oil starts to fill the clutch. When the
clutch is filled with oil, fill switch (6) is turned ON.
10-44 HM400-1L
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
HM400-1L 10-45
STRUCTURE AND FUNCTION MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
Unit: mm
No. Check item Criteria Remedy
8 Main relief valve spring (outside) Free length Installed Installed Free length Installed
length load load
108 79.5 275 N 104.8 261 N
9 Main relief valve spring (inside) 108 79.5 326 N 104.8 309 N
10-46 HM400-1L
STRUCTURE AND FUNCTION MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
OUTLINE
TORQUE CONVERTER RELIEF VALVE
The torque converter relief valve protects the torque converter from
abnormally high pressure. It is installed in the torque converter inlet port
circuit to hold the oil pressure in the torque converter inlet port circuit
below the set pressure.
Set pressure: 0.91 MPa {9.31 kg/cm2}
(Cracking pressure)
OPERATION
Torque converter relief valve operation
● The oil relieved by the main relief valve flows from port C into the
torque converter, and at the same time, passes through orifice b of
spool (2) and enters chamber D. When the circuit leading to the
torque converter becomes filled with oil, the oil pressure starts to
rise.
● As the oil pressure going to the torque converter rises, the oil enter-
ing chamber D pushes piston (9). The reaction force compresses
valve spring (3) and moves spool (2) to the right to open the circuit
between port C and port E. When this happens, the oil at port C is
relieved to port E and drains to the oil tank. The oil pressure at port
C at this point is 0.91 MPa {9.31 kg/cm2} (cracking pressure).
● The oil from the hydraulic pump passes through the filter and enters
port A of the relief valve. It then passes through orifice a of spool
(6) and enters chamber B. When the oil from the pump fills the cir-
cuit, the oil pressure starts to rise.
HM400-1L 10-47
STRUCTURE AND FUNCTION MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
As the oil pressure in the circuit rises, the oil entering chamber B pushes
piston (4). The reaction force compresses valve spring (7) and moves
spool (6) to the left to open the circuit between port A and port C. When
this happens, the oil at port A is relieved to port C and flows from port C
to the torque converter. The oil pressure at port A at this point is 2.62
MPa {26.7 kg/cm2} (engine at rated speed).
10-48 HM400-1L
STRUCTURE AND FUNCTION DRIVE SHAFT
DRIVE SHAFT
HM400-1L 10-49
STRUCTURE AND FUNCTION AXLE
AXLE
FRONT
1. Drive shaft
2. Front differential
3. Brake
4. Final drive
10-50 HM400-1L
STRUCTURE AND FUNCTION AXLE
CENTER
1. Center differential
2. Center axle
3. Brake
4. Final drive
5. Drain plug
HM400-1L 10-51
STRUCTURE AND FUNCTION AXLE
REAR
1. Drain plug
2. Rear differential
3. Rear axle
4. Brake
5. Final drive
10-52 HM400-1L
STRUCTURE AND FUNCTION LOCKING DIFFERENTIAL
LOCKING DIFFERENTIAL
FRONT
1. Bevel gear (no. of teeth: 41) 5. Pinion gear (no. of teeth: 14)
2. Bevel pinion (no. of teeth: 12) 6. Shaft
3. Differential case 7. Plate
4. Side gear (no. of teeth: 24 8. Disc
HM400-1L 10-53
STRUCTURE AND FUNCTION LOCKING DIFFERENTIAL
Unit: mm
No. Check item Criteria Remedy
10-54 HM400-1L
STRUCTURE AND FUNCTION LOCKING DIFFERENTIAL
CENTER
1. Disc 5. Shaft
2. Plate 6. Side gear (no. of teeth: 24)
3. Pinion gear (no. of teeth: 14) 7. Bevel gear (no. of teeth: 41)
4. Differential case 8. Bevel pinion (no. of teeth: 12)
HM400-1L 10-55
STRUCTURE AND FUNCTION LOCKING DIFFERENTIAL
Unit: mm
No. Check item Criteria Remedy
10-56 HM400-1L
STRUCTURE AND FUNCTION LOCKING DIFFERENTIAL
REAR
HM400-1L 10-57
STRUCTURE AND FUNCTION LOCKING DIFFERENTIAL
Unit: mm
No. Check item Criteria Remedy
OPERATION
● The power from the engine is transmitted through the output shaft,
front drive shaft, torque converter, and transmission to each axle.
● Inside the axle, the power is transmitted from pinion gear (5) to
bevel gear (1), is converted and sent at 90°, has its speed reduced,
and is transmitted through pinion gear (6) and side gear (3) to the
axle shaft.
● The power transmitted to the axle shaft has its speed further reduced
by the planetary gear type final drive, and is transmitted to the
wheels
TURNING
● When the machine is turned, the speed that the wheels turn on the
left and right sides is different, so pinion gear (6) and side gear (3)
inside the differential rotate according to the difference in the turn-
ing speed on the left and right sides, and transmit the power of dif-
ferential case (2) to the left and right shafts.
10-58 HM400-1L
STRUCTURE AND FUNCTION LOCKING DIFFERENTIAL
HM400-1L 10-59
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
FRONT
1. Axle shaft
2. Ring gear (no. of teeth: 67)
3. Planet gear (no. of teeth: 24)
4. Planet carrier
5. Sun gear (no. of teeth: 17)
6. Drain plug
7. Brake
10-60 HM400-1L
STRUCTURE AND FUNCTION FINAL DRIVE
Unit: mm
No. Check item Criteria Remedy
HM400-1L 10-61
STRUCTURE AND FUNCTION FINAL DRIVE
CENTER, REAR
Unit: mm
No. Check item Criteria Remedy
10-62 HM400-1L
STRUCTURE AND FUNCTION FINAL DRIVE
FUNCTION
The final drive uses a planetary gear mechanism to reduce the speed in
order to give a large drive force, and transmits this drive force to the
tires.
OPERATION
The power from the differential passing through axle shaft (1) is trans-
mitted to sun gear (5) and then goes to planet gear (3).
The planet gear rotates on the inside of fixed ring gear (2) and transmits
the reduced speed to planetary carrier (4). This power is then transmitted
to the wheels that are installed to the planetary carrier.
HM400-1L 10-63
STRUCTURE AND FUNCTION STEERING COLUMN
STEERING COLUMN
1. Steering shaft
2. Steering column
3. Lock lever
4. Yoke
5. Joint shaft
6. Steering valve
10-64 HM400-1L
STRUCTURE AND FUNCTION BRAKE PIPING
BRAKE PIPING
HM400-1L 10-65
STRUCTURE AND FUNCTION BRAKE PIPING
10-66 HM400-1L
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE
HM400-1L 10-67
STRUCTURE AND FUNCTION BRAKE VALVE
OPERATION
UPPER PORTION
● When brake pedal (1) is depressed, the operating force is transmit-
ted to spool (3) through rod (2) and spring (4). When spool (3) goes
down, drain port a is closed, and the oil from the pump and accumu-
lator flows from port A to port C and actuates the center and rear
brake cylinders.
●
LOWER PORTION
● When brake pedal (1) is depressed, the operating force is transmit-
ted to spool (3) through rod (2) and spring (4). When spool (3) goes
down, spool (5) is also pushed down by plunger (6). When this hap-
pens, drain port b is closed, and the oil from the pump and accumu-
lator flows from port B to port D and actuates the front brake
cylinders.
● When oil fills the center and rear brake cylinders and the pressure
between port A and port C becomes high, the oil entering port H
from orifice e of spool (3) pushes against spring (4). It pushes up
spool (3) and shuts off the circuit between port A and port C. When
this happens, drain port a stays closed, so the oil entering the brake
cylinder is held and the brake remains applied.
10-68 HM400-1L
STRUCTURE AND FUNCTION BRAKE VALVE
Lower portion
● When spool (3) in the upper portion moves up and the circuit
between port A and port C is shut off, oil also fills the front brake
cylinder at the same time, so the pressure in the circuit between port
B and port D rises. The oil entering port J from orifice f of spool (5)
pushes up spool (5) by the same amount that spool (3) moves, and
shuts off port B and port D. Drain port b is closed, so the oil entering
the brake cylinder is held, and the brake is applied.
● The pressure in the space in the upper portion is balanced with the
operating force of the pedal, and the pressure in the space in the
lower portion is balanced with the pressure in the space in the upper
portion. When spools (3) and (5) move to the end of their stroke, the
circuits between ports A and C and between ports B and D are fully
opened, so the pressure in the space in the upper and lower portions
and the pressure in the left and right brake cylinders is the same as
the pressure from the pump. Therefore, up to the point where the
piston moves to the end of its stroke, the effect of the brake can be
adjusted by the amount that the pedal is depressed.
HM400-1L 10-69
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE RELEASED
Upper portion
When pedal (1) is released and the operating force is removed from the
top of the spool, the back pressure from the brake cylinder and the force
of the spool return spring move spool (3) up. Drain port a is opened and
the oil from the brake cylinder flows to the brake system tank return cir-
cuit to release the center and rear brakes.
Lower portion
When the pedal is released, spool (3) in the upper portion moves up. At
the same time, the back pressure from the brake cylinder and the force of
the spool return spring move spool (5) up. Drain port b is opened and the
oil from the brake cylinder flows to the brake system tank return circuit
to release the front brake.
10-70 HM400-1L
STRUCTURE AND FUNCTION ACCUMULATOR CHARGE VALVE
HM400-1L 10-71
STRUCTURE AND FUNCTION ACCUMULATOR CHARGE VALVE
10-72 HM400-1L
STRUCTURE AND FUNCTION ACCUMULATOR CHARGE VALVE
OPERATION
1. When oil is not supplied to accumulator
(cut-out condition)
● The pressure at port B is higher than the set pressure of the relief
valve (R1), so piston (8) is forcibly pushed up by the oil pressure at
port B. Poppet (6) is opened, so port C and port T are short cir-
cuited.
● The spring chamber at the right end of spool (15) is connected to
port C of the relief valve (R1), so the pressure becomes the brake oil
tank pressure. The oil from the pump enters port P, pushes spool
(15) to the right at a low pressure equivalent to the load on spring
(14). It also passes through orifices (17), (18) and (16), and flows to
the brake oil tank.
A. (cut-in condition)
● When the pressure at port B is lower than the set pressure of the
relief valve (R1), piston (8) is pushed back down by spring (5).
Valve seat (7) and poppet (6) are brought into tight contact, and
port C and port T are shut off.
● The spring chamber at the right end of spool (15) is also shut
off from port T, so the pressure rises, and the pressure at port P
also rises in the same way.
● When the pressure at port P goes above the pressure at port B
(accumulator pressure), the supply of oil to the accumulator
starts immediately. In this case, it is decided by the size (area)
of orifice (17) and the pressure difference (equivalent to the
load on spring (14)) generated on both sides of the orifice. A
fixed amount is supplied regardless of the engine speed.
HM400-1L 10-73
STRUCTURE AND FUNCTION ACCUMULATOR CHARGE VALVE
B. (When cut-out pressure is reached)
● When the pressure at port B (accumulator pressure) reaches the
set pressure of the relief valve (R1), poppet (6) separates from
valve seat (7), so an oil flow is generated and the circuit is
relieved.
● When the circuit is relieved, a pressure difference is generated
above and below piston (8), so piston (8) moves up, poppet (6)
is forcibly opened, and port C and port T are short circuited.
● The spring chamber at the right end of spool (15) is connected
to port C of the relief valve (R1), so the pressure becomes the
brake oil tank pressure.
● The pressure at port P drops in the same way to a pressure
equivalent to the load on spring (14), so the supply of oil to port
B is stopped.
10-74 HM400-1L
STRUCTURE AND FUNCTION ACCUMULATOR
ACCUMULATOR
1. Valve FUNCTION
2. Top cover
3. Cylinder
● The accumulator is installed between the accumula-
4. Piston
tor charge valve and the brake valve. It is charged
with nitrogen gas between cylinder (3) and free pis-
ton (4), and uses the compressibility of the gas to
absorb the pulse of the hydraulic pump or to main-
tain the braking force and to make it possible to
operate the machine if the engine should stop.
SPECIFICATIONS
Gas used: Nitrogen gas
Charge amount: 4,000 cc
Charging pressure: 4.4 0 0.15MPa
HM400-1L 10-75
STRUCTURE AND FUNCTION SLACK ADJUSTER
SLACK ADJUSTER
10-76 HM400-1L
STRUCTURE AND FUNCTION SLACK ADJUSTER
FUNCTION
The slack adjuster is installed in the brake oil line from the brake valve
to the brake piston. It acts to keep the clearance between the brake piston
and discs constant even when the brake discs are worn. In this way it acts
to keep a constant time lag when the brake is operated.
OPERATION
1. When brake pedal is depressed
● Before the brake is depressed, piston (4) is returned by the distance
of stoke S (full stroke). When the brake pedal is depressed, the oil
discharged from the brake valve flows from port P of the slack
adjuster and is divided to left and right cylinders (2), where it moves
piston (4) by stroke S to the left and right.
● When this is done, brake piston (7) moves by a distance of stroke S.
In this condition, the closer the clearance between the brake piston
and disc is to 0, the greater the braking force becomes.
● If the brake pedal is depressed further, and the oil pressure dis-
charged from the brake valve goes above to set pressure, check
valve (3) opens and the pressure is applied to port C to act as the
braking force. Therefore, when the brake is applied, the time lag is a
fixed value.
● If the brake pedal is depressed further, and the oil pressure dis-
charged from the brake valve goes above to set pressure, check
valve (3) opens and the pressure is applied to port C to act as the
braking force. Therefore, when the brake is applied, the time lag is
a fixed value.
HM400-1L 10-77
STRUCTURE AND FUNCTION SLACK ADJUSTER
2. When brake pedal is released
● When the brake is released, piston (4) is returned by brake return
spring (8) by an amount equivalent to the oil for the stroke S, and
the brake is released. In other words, return stroke T of brake piston
(7) is determined by the amount of oil for stroke S of the slack
adjuster. The time lag of the brake is always kept constant regard-
less of the wear of the brake disc.
10-78 HM400-1L
STRUCTURE AND FUNCTION BRAKE
BRAKE
FRONT
1. Stud pin
2. Cylinder
3. Brake piston
4. Disc
5. Plate
6. Hub gear (No. of teeth: 112)
7. Outer gear (No. of teeth: 164)
HM400-1L 10-79
STRUCTURE AND FUNCTION BRAKE
Unit: mm
No. Check item Criteria Remedy
Backlash between outer gear and Standard size Repair limit
1
plate 0.52 – 0.90 1.5
Backlash between hub gear and
2 0.52 – 0.90 1.5
plate
Standard size Repair limit
3 Thickness of plate
2.4 2.15
4 Thickness of disc 5.1 4.6
Replace
5 Thickness of damper 6.9 5.1
Standard warping Repair limit
6 Warping of disc friction surface
Max 0.45 0.7
Warping of plate and damper fric-
7 Max 0.50 0.7
tion surface
Assemble thickness of plate and Standard warping Repair limit
8
disc 56.4 51.4
9 Retainer oil seal contact surface 430 0 – -0.155 Correct or replace
CENTER, REAR
10-80 HM400-1L
STRUCTURE AND FUNCTION BRAKE
1. Stud pin
2. Cylinder
3. Brake piston
4. Disc
5. Plate
6. Hub gear (No. of teeth: 112)
7. Outer gear (No. of teeth: 164)
HM400-1L 10-81
STRUCTURE AND FUNCTION BRAKE
Unit: mm
No. Check item Criteria Remedy
Backlash between outer gear and Standard size Repair limit
1
plate 0.52 – 0.90 1.5
Backlash between hub gear and
2 0.52 – 0.90 1.5
plate
Standard size Repair limit
3 Thickness of plate
2.4 2.15
4 Thickness of disc 5.1 4.6
Replace
5 Thickness of damper 6.9 5.1
Standard warping Repair limit
6 Warping of disc friction surface
Max 0.45 0.7
Warping of plate and damper fric-
7 Max 0.50 0.7
tion surface
Assemble thickness of plate and Standard warping Repair limit
8
disc 56.4 51.4
9 Retainer oil seal contact surface 430 0 – -0.155 Correct or replace
10-82 HM400-1L
STRUCTURE AND FUNCTION BRAKE
FUNCTION
There are wet-type multiple disc brakes installed to all of the six wheels.
OPERATIONS
● When the brake pedal is depressed, pressure oil from the brake
valve moves brake piston (3) to the right in the direction of the
arrow. This presses disc (7) and plate (6) together and generates
friction between the disc and plate. The wheel is rotating together
with the disc, so this friction reduces the travel speed and stops the
machine.
● When the brake pedal is released, the pressure at the back face of
brake piston (3) is released, so the piston is moved to the left in the
direction of the arrow by the internal pressure, and this releases the
brake.
HM400-1L 10-83
STRUCTURE AND FUNCTION PROPORTIONAL REDUCING VALVE
1. Filter FUNCTION
2. Connector
3. Solenoid assembly
The proportional reducing valve is a valve used for
retarder control. It is installed between the brake valve
A. To slack adjuster
and the slack adjuster in the brake circuit.
P. To brake valve (inlet)
T. To brake system tank
It varies the discharge pressure of the pressure oil in
accordance with the turning angle of the retarder control
lever, so the retarder control can be carried out as
desired.
10-84 HM400-1L
STRUCTURE AND FUNCTION BRAKE SYSTEM TANK
1. Boss
2. Return
3. Suction tube
A. To hydraulic pump
B. From accumulator charge valve
C. Oil filler port
D. Drain port
HM400-1L 10-85
STRUCTURE AND FUNCTION PARKING BRAKE
PARKING BRAKE
10-86 HM400-1L
STRUCTURE AND FUNCTION PARKING BRAKE
Unit: mm
No. Check item Criteria Remedy
Rebuild
(Thickness of disc
Min. 20
4 Thickness of disc 25 must not be under
20 mm)
Max. 20
Thickness of pad (including thick- Replace
5 21.5 11.5
ness of plate)
Standard dimen- Standard clear- Allowable
Tolerance
sion of blade ance clearance
0
22.3
-0.3
Clearance between blade and
6 Standard dimen- Correct or replace
brake assembly Tolerance
sion of brake 1.0 0 0.4 1.5
assembly
+0.4
22.3
-0.1
HM400-1L 10-87
STRUCTURE AND FUNCTION PARKING BRAKE CALIPER
1. Adjuster OUTLINE
2. Piston
3. Piston shaft
● A piston guide is installed to caliper (5). Piston (2)
4. Pad
and piston shaft (3) are inserted, and the rotation of
5. Caliper
piston shaft (3) moves piston (2) in the axial direc-
tion to bring pad (4) into tight contact.
● The lever is joined by a spline to the spline side of
piston shaft (3). Pad (4) is inserted together with
caliper (5) into the caliper mounting plate and is
held in position.
10-88 HM400-1L
STRUCTURE AND FUNCTION SPRING CYLINDER
SPRING CYLINDER
HM400-1L 10-89
STRUCTURE AND FUNCTION PARKING BRAKE SOLENOID
10-90 HM400-1L
STRUCTURE AND FUNCTION SUSPENSION
SUSPENSION
FRONT
HM400-1L 10-91
STRUCTURE AND FUNCTION SUSPENSION
Unit: mm
No. Check item Criteria Remedy
10-92 HM400-1L
STRUCTURE AND FUNCTION SUSPENSION
REAR
HM400-1L 10-93
STRUCTURE AND FUNCTION SUSPENSION
1. Arm
2. Equalizer bar
3. Lateral rod (center)
4. Spring
5. Rear suspension
6. Lateral rod (rear)
10-94 HM400-1L
STRUCTURE AND FUNCTION SUSPENSION
Unit: mm
No. Check item Criteria Remedy
OUTLINE
● The suspension supports the weight of the machine. It also reduces
any impact caused by unevenness in the road surface and provides a
comfortable ride for the operator. By ensuring that all the tires are
always in contact with the road surface, it maintains the stability of
the machine, and also fulfills the operating performance by ensur-
ing that the machine can accelerate, brake, and turn.
● The suspension cylinders reducing the impact from the road surface
are a hydro-pneumatic type. The inside of the suspension cylinder
is charged (sealed) with oil and nitrogen gas. In this way, the com-
pression and expansion of the nitrogen gas and oil act as a spring
and shock absorber, and is used to absorb the load from the road
surface.
FUNCTION
1. Front suspension
The front suspension cylinder has the function of a shock absorber
and spring. It is joined to the arm and main frame by a spherical
bearing, and the arm oscillates according to the extension and
retraction of the front suspension cylinder.
The main frame and arm are joined by a lateral rod and receive the
lateral load.
HM400-1L 10-95
STRUCTURE AND FUNCTION SUSPENSION
2. Center, rear suspension
The center axle and rear axle are both fixed to arms. The center axle
is joined to the equalizer bar through a spring, and the rear axle is
joined through the rear suspension cylinder. The arm and equalizer
bar oscillate in accordance with the condition of the road surface to
keep the wheels in contact with the road surface.
The main frame and arm are connected by a lateral rod and receive
the lateral load.
10-96 HM400-1L
STRUCTURE AND FUNCTION SUSPENSION CYLINDER
SUSPENSION CYLINDER
HM400-1L 10-97
STRUCTURE AND FUNCTION SUSPENSION CYLINDER
Unit: mm
No. Check item Criteria Remedy
1. Retracting action
When the machine is traveling and it hits a bump or object on the
road, the wheels are pushed up, and the cylinder rod is pushed
inside the cylinder. When this happens, the nitrogen gas inside
chamber (2) is compressed, the oil in chamber (1) is sent through
both orifices (4) and (5) to cavity (3), and cavity (3) is filled more
quickly than when extending.
2. Extending action
When the machine has passed any bump or object on the road sur-
face, the cylinder rod is pushed up by the weight of the wheels and
axle and the pressure of the nitrogen inside chamber (2). As a
result, the amount of oil in cavity (3) is reduced, and pressure is
applied to the oil remaining in cavity (3).
This pressurized oil closes orifice (4) with check ball (6), and is
sent to chamber (1) only through orifice (5), so the controlled flow
of oil passing through the orifice less than during retraction. In this
way, the amount of oil returning to chamber (1) is restricted to pro-
vide a shock-absorbing effect.
1. Oil chamber
2. Nitrogen gas chamber
3. Cavity
4. Orifice
5. Orifice
6. Check ball
10-98 HM400-1L
STRUCTURE AND FUNCTION OSCILLATION HITCH
OSCILLATION HITCH
HM400-1L 10-99
STRUCTURE AND FUNCTION OSCILLATION HITCH
10-100 HM400-1L
STRUCTURE AND FUNCTION OSCILLATION HITCH
Unit: mm
No. Check item Criteria Remedy
–
2 Standard shim thickness –
Clearance between bushing and -0.036 +0.054 0.036 –
3 115 -0.090 0 0.144 –
front frame
Clearance between shaft and bush- -0.036 +0.054 0.036 –
4 ing 85 -0.066 0 0.120 –
OUTLINE
● The front frame and the rear frame are connected by the ● In addition, the output from the transmission is trans-
oscillation hitch. mitted from center drive shaft (3) to coupling (9). It is
then transmitted from coupling (11) through the rear
● Front frame (2) is connected with bearings and pins (6)
drive shaft to the rear axle.
and (12); rear frame (4) is connected with a spacer,
retainer, and bearing. This makes it possible for the
front and rear frames to articulate and oscillate.
HM400-1L 10-101
STRUCTURE AND FUNCTION STEERING, HOIST OIL PRESSURE PIPING DIAGRAM
10-102 HM400-1L
STRUCTURE AND FUNCTION DUMP BODY CONTROL
HM400-1L 10-103
STRUCTURE AND FUNCTION HYDRAULIC TANK AND FILTER
10-104 HM400-1L
STRUCTURE AND FUNCTION FLOW AMP VALVE
HM400-1L 10-105
STRUCTURE AND FUNCTION FLOW AMP VALVE
OPERATION
1. At neutral
● Port P of steering unit (7) is closed and the flow amp ● For priority valve (2) also, the oil is drained from relief
valve is closed at chamber M of pressure control valve valve (1). Before starting, priority valve (2) is pushed to
(3). the far left by the spring, so in reality, port EF of the
● Ports L, R, and T of steering unit (7) are connected to flow amp valve is almost closed.
each other, so the oil passes through port T of the flow ● At the same time the engine starts, oil flows to port HP
amp valve and is drained to the hydraulic tank. By con- of the flow amp valve and then flows to port P of steer-
necting in this way, directional valve (6) is always held ing unit (7). At the same time, the pilot pressure that is
at the neutral position by the springs on both sides. For connected to port PP suddenly rises. As a result of bal-
this reason, at the neutral position, the reaction or ancing with the spring and moving to the right, port EF
impact from the steering cylinder is not transmitted to opens and the oil flows to the hoist piping.
steering unit (7).
10-106 HM400-1L
STRUCTURE AND FUNCTION FLOW AMP VALVE
2. When turning
● When steering unit (7) is actuated, the oil sent from
port P of priority valve (2) passes through ports P and L
of steering unit (7) and enters port L of directional
● The oil at the steering cylinder head end goes out from
valve (6). At the same time, oil from priority valve (2)
suction valve (5). It then goes from port CR of direc-
also enters chamber M of pressure control valve (3).
tional valve (6) through check valve (4) and is drained
● When the oil entering directional valve (6) rises to a to the hydraulic tank from port HT of the flow amp
pressure greater than the force of the spring, it pushes valve.
the spool to the right, and enters chamber C of pressure
● If there are rocks on the road or the road surface is
control valve (3). When it rises to a pressure greater
uneven, and any abnormal external force is applied to
than the force of the spring in chamber C, it pushes the
the tires and steering cylinder, relief valves (8) and (9)
spool to the left.
of suction valve (5) open at a pressure of 23.5 Mpa
● The oil that is already in chamber M of pressure control {240 kg/cm2}, so the oil passes through directional
valve (3) enters chamber N when the spool is pushed to valve (6) and is drained to the hydraulic tank.
the left by the action of steering unit (7). It then flows
from port P, goes out from port CL of directional valve
(6), and flows from suction valve (5) to the bottom end
of the steering cylinder.
HM400-1L 10-107
STRUCTURE AND FUNCTION STEERING VALVE
STEERING VALVE
10-108 HM400-1L
STRUCTURE AND FUNCTION STEERING VALVE
OUTLINE
● The steering valve is connected directly to the shaft of the steering
wheel. It switches the flow of oil from the steering pump to the left
and right steering cylinders to determine the direction of travel of
the machine.
● The orbit-roll valve, broadly speaking, consists of the following
components: rotary type spool (9) and sleeve (8), which have the
function of selecting the direction, and the Gerotor set (a combina-
tion of rotor (5) and stator (10)), which acts as hydraulic motor dur-
ing normal steering operations, and as a hand pump (in fact, the
operating force of the steering wheel is too high, so it cannot be
operated) when the steering pump or engine have failed and the
supply of oil is stopped.
STRUCTURE
● Spool (9) is connected to the drive shaft of the steering wheel, and
is connected to sleeve (8) by center pin (7) (this is not touching the
spool when the steering wheel is at the neutral position) and center-
ing spring (2).
● Drive shaft (3) is meshed at the top with center pin (7) and forms
one unit with sleeve (8). The bottom is meshed with the spline of
rotor (5) of the Gerotor set.
● Valve body (4) has five ports. These are connected to the pump cir-
cuit, tank circuit, steering cylinder head end, bottom end, and flow
amp valve pilot end. In addition, the port at the pump end and the
port at the tank end are connected by the check valve inside the
body. If there is any failure in the pump or engine, this check valve
acts to suck in oil directly from the tank.
HM400-1L 10-109
STRUCTURE AND FUNCTION STEERING VALVE
10-110 HM400-1L
STRUCTURE AND FUNCTION STEERING VALVE
● In this way, the ports of the Gerotor acting as delivery ports are con-
nected to ports which are connected to the end of the steering valve
spool. The ports acting as suction ports are connected to the pump
circuit.
● Adjusting delivery in accordance with angle of steering wheel: for
every 1/7 turn of the steering wheel, the inner teeth of the Gerotor
gear advance one position so the oil flow from the pump is adjusted
by this movement. The oil delivered from the pump is directly pro-
portional to the amount the steering wheel is turned.
HM400-1L 10-111
STRUCTURE AND FUNCTION STEERING VALVE
The springs are assembled in spool (9) and sleeve (8) as shown in the
diagram on the right.
When the steering wheel is turned, the spring is compressed and a dif-
ference in rotation (angle variation a) arises between the spool and the
sleeve. Because of this, the ports in the spool and sleeve are connected
and oil is sent to the cylinder. When the turning of the steering wheel is
stopped, the Gerotor also stops turning, so no more oil is sent to the cyl-
inder and the oil pressure rises.
To prevent this, when the turning of the steering wheel is stopped, the
action of the centering spring only allows it to turn by an amount equal
to the difference in angle of rotation (angle variation a) of the sleeve and
spool, so the steering wheel returns to the NEUTRAL position.
10-112 HM400-1L
STRUCTURE AND FUNCTION STEERING CYLINDER
STEERING CYLINDER
Unit: mm
No. Check item Criteria Remedy
HM400-1L 10-113
STRUCTURE AND FUNCTION HOIST VALVE
HOIST VALVE
10-114 HM400-1L
STRUCTURE AND FUNCTION HOIST VALVE
AB: To hoist cylinder bottom
AH: To hoist cylinder head
P: From demand valve
PA: From EPC valve (pressurizing for LOWER, FLOAT)
PB: From EPC valve (pressurizing for RAISE)
T: To hydraulic tank
T2: To pilot check valve
1. Valve body
2. Hoist spool
3. Check valve
4. Housing
5. Relief valve
Unit: mm
No. Check item Criteria Remedy
HM400-1L 10-115
STRUCTURE AND FUNCTION HOIST VALVE
OPERATION
HOIST VALVE AT HOLD POSITION
● The oil from the demand valve enters port C. The pas- ● The ports to the hoist cylinder are blocked at both the
sage to the hoist cylinder is blocked by hoist spool (2), bottom end and head end, so the hoist cylinder is held
so the oil is drained from tank D to the tank. in position.
10-116 HM400-1L
STRUCTURE AND FUNCTION HOIST VALVE
● When the hoist lever inside the cab is operated to the ● From chamber A, the oil enters the bottom end of the
RAISE position, hoist spool (2) is moved to the left by hoist cylinder, extends the hoist cylinder, and raises the
the solenoid valve. dump body.
● As a result, the oil flows from chamber C, opens check ● At the same time, the return oil from the head end flows
valve (3), and enters chamber A. from port B to port D, and flows to the tank circuit.
HM400-1L 10-117
STRUCTURE AND FUNCTION HOIST VALVE
10-118 HM400-1L
STRUCTURE AND FUNCTION HOIST VALVE
● When the hoist lever inside the cab is operated from the
● At the same time, the return oil from the head end of
FLOAT position to the LOWER position, hoist spool
the hoist cylinder flows from chamber A to chamber H.
(2) is moved further to the right from the FLOAT posi-
tion by the solenoid valve. As a result, the oil flows ● When the dump body is lowered, the output pressure of
from chamber C, pushes open check valve (3), and the solenoid valve rises and becomes greater than the
enters chamber B. cracking pressure of the pilot check valve. As a result,
the return oil from chamber H returns to the tank
● The oil from chamber B enters the head end of the hoist
through two lines: one from chamber D to the tank, and
cylinder, retracts the cylinder, and lowers the dump
the other from chamber E to the tank.
body.
HM400-1L 10-119
STRUCTURE AND FUNCTION EPC VALVE
EPC VALVE
10-120 HM400-1L
STRUCTURE AND FUNCTION PILOT CHECK VALVE
Unit: mm
No. Check item Criteria Remedy
HM400-1L 10-121
STRUCTURE AND FUNCTION HOIST CYLINDER
HOIST CYLINDER
Unit: mm
No. Check item Criteria Remedy
2 Clearance between piston rod and 90 -0.036 +0.270 0.097 – 0.693 Replace
bushing -0.123 +0.061 0.393
Clearance between piston rod sup- +0.004
3 port pin and bearing 60 – -0.019 – 1.0
10-122 HM400-1L
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
Unit: mm
No. Check item Criteria Remedy
Model Standard clearance Clearance limit
SAR(3)-100
1 Side clearance 0.13 – 0.18 0.21
SAR(3)-100
SAR(1)-8 0.10 – 0.15 0.19
Clearance between inside diameter SAR(3)-100
0.060 – 0.149 0.20
2 of plain bearing and outside of SAR(3)-100
Replace
diameter of gear shaft SAR(1)-8 0.06 – 0.144 0.20
Model Standard size Tolerance Repair limit
SAR(3)-100 0
14
3 Depth for knocking in pin SAR(3)-100 -0.5
–
0
SAR(1)-8 10
-0.5
4 Rotating torque of spline shaft 8.7 – 20.7 Nm
Standard
Rotating Delivery Delivery
delivery
Model speed pressure amount limit
Discharge amount amount
(rpm) (MPa) (L/min) –
(L/min)
– Oil: EO10-CD
Oil temperature: 45–55°C SAR(3)-100
231.5 213.5
SAR(3)-100 2,500 20.6
SAR(1)-8 17.2 15.8
HM400-1L 10-123
STRUCTURE AND FUNCTION HYDRAULIC PUMP
Unit: mm
No. Check item Criteria Remedy
Model Standard clearance Clearance limit
SAR100 0.13 – 0.18 0.21
1 Side clearance
SAR12
0.10 – 0.15 0.19
SAR8
Clearance between inside diameter SAR100 0.06 – 0.149
Replace
2 of plain bearing and outside of SAR12 0.20
0.06 – 0.144
diameter of gear shaft SAR8
Standard size Tolerance Repair limit
3
Depth for knocking in pin 14 0
–
4 10 -0.5
5 Rotating torque of spline shaft 10.9 – 21.6 Nm
Standard
Rotating Delivery Delivery
delivery
Model speed pressure amount limit
Discharge amount amount
(rpm) (MPa) (L/min) –
– Oil: EO10-CD (L/min)
Oil temperature: 45–55°C SAR100 231.5 213.5
SAR12 2,500 20.6 26.8 24.6
SAR8 17.2 15.8
10-124 HM400-1L
STRUCTURE AND FUNCTION HYDRAULIC PUMP
Unit: mm
No. Check item Criteria Remedy
HM400-1L 10-125
STRUCTURE AND FUNCTION HYDRAULIC PUMP
Unit: mm
No. Check item Criteria Remedy
10-126 HM400-1L
STRUCTURE AND FUNCTION HYDRAULIC PUMP
Unit: mm
No. Check item Criteria Remedy
HM400-1L 10-127
STRUCTURE AND FUNCTION CAB TILT
CAB TILT
10-128 HM400-1L
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
HM400-1L 10-129
STRUCTURE AND FUNCTION AIR CONDITIONER
10-130 HM400-1L
STRUCTURE AND FUNCTION AIR CONDITIONER
RECEIVER DRYER
1. Body
2. Sight glass
3. Dryer
4. Dryer
HM400-1L 10-131
STRUCTURE AND FUNCTION AIR CONDITIONER
CONDENSER
1. Fin
2. Tube
10-132 HM400-1L
STRUCTURE AND FUNCTION AIR CONDITIONER
COMPRESSOR
1. Case
2. Clutch
HM400-1L 10-133
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
NETWORK DATA
1. From machine monitor to each controller
● Switch input data
● Option setting data
2. From each controller to machine monitor
● Display data related to each controller
● Service mode data
● Troubleshooting data
3. From transmission controller to machine monitor
● Model selection data
10-134 HM400-1L
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
OUTLINE
1. With the machine monitor system, the controllers on the network use the data from the sensors installed to all parts of the
machine to observe and control the condition of the machine and transmit that data as network data to the machine moni-
tor. The machine monitor is a system to display this data and inform the operator of the condition of the machine.
2. There are two types of display on the machine monitor: the normal mode and the service mode.
3. The items that are always displayed for the operator are the normal mode items. Their main content is as follows.
C. When the filter, oil replacement interval is reached, the item needing replacement is displayed in the character dis-
play.
D. Other functions using the character display and the machine monitor mode selector switch to operate include the fol-
lowing: Total reverse distance traveled display, filter, oil replacement interval reset, telephone number input, and lan-
guage selection.
4. To make it easier to troubleshoot controllers (including the monitor panel itself), a service mode function is provided. Its
main content is as follows.
C. Real-time monitor
● Takes input and output signal values recognized by each controller on network and displays in real time
E. ECMV compensation
This is used for the initial adjustment of the transmission.
G. Controller initialize
This function is used to set the machine monitor when the machine is shipped from the factory.
HM400-1L 10-135
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
5. The service mode has the following functions.
6. The machine monitor system consists of the monitor panel, buzzer, and switches, network, controllers on the network, and
the sensors inputting data to the monitor panel.
10-136 HM400-1L
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR
HM400-1L 10-137
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
10-138 HM400-1L
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
2. Precautions
A. When setting, follow the instructions in TESTING AND ADJUSTING, Adjusting machine monitor, and do not
change them.
B. When moving the switches, use a precision screwdriver and turn slowly.
C. Be careful not to touch anything except the switches inside the grommet.
E. After completing the setting, return the grommet securely to its original position.
HM400-1L 10-139
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
Lights up
When side lamps light
Backlight LED Amber up when ⎯ ⎯
actuated
Actuated
Service 0 - 65535.0h
when
meter engine is
Service Display * Displayed on top
⎯ ⎯
When time exceeds 65535.0h,
(normal running
meter letters: line of character stops at 65535.0h
display display
Ratio of
items) Black movement
7 LCD
Background to time 1:1
color:
Odometer Green 0 - 999999.9km
Actuated When distance exceeds
(normal Odometer
* Displayed on bottom
when ⎯ ⎯ 999999.9km, stops at
display line of character
traveling 999999.9km
items) display
10-140 HM400-1L
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
HM400-1L 10-141
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
When
actuated:
Seat belt When seat belt is not Lights up
28 LED Red ⎯ ⎯
caution fastened When not
actuated:
Goes outs
10-142 HM400-1L
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
1. When the starting switch is turned to the ON position before starting the engine, the central warning lamp, caution lamps,
and pilot lamps light up for approximately two seconds and then go out for one second to carry out a system check.
● The alarm buzzer sounds for two seconds and then stops for one second.
● The shift indicator displays 88 for two seconds and then goes out for one second.
● The indicator gauges and meters carry out the above system check for three seconds and then start normal actuation.
● KOMATSU SYSTEM CHECK is displayed for three seconds on the character display.
2. If the starting switch is turned to the START position before three seconds have passed with the starting switch at the ON
position, everything will go to the normal operating condition. However, even if everything goes to the normal operating
condition, the indicator gauges and meters will not work until three seconds have passed after the starting switch was
turned to the ON position.
3. However, even if everything goes to the normal operating condition, the indicator gauges and meters will not work until
three seconds have passed after the starting switch was turned to the ON position. Check central warning lamp, alarm
buzzer, caution lamps, pilot lamps, indicator gauges and meters. Before starting the engine, turn the starting switch to the
ON position, then press the machine monitor check switch. In addition to the instruments and gauges in the system check
when the starting switch is turned ON, the indicator gauges and meters will be actuated. When this is done, the character
display gives the model and software version of the machine monitor.
HM400-1L 10-143
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
ODOMETER
The odometer shows the total distance that the machine has traveled in units of km on the bottom part of the character display.
If dipswitch 1 (position: 1) at the rear of the machine monitor is set to ON, the display is given in units of miles. Even if the
starting switch is OFF, the service meter and odometer can be displayed while the top ( ) of machine monitor mode selector
switch 1 is kept pressed.
Note:If the starting switch is OFF, and the service meter and odometer are displayed even though the top ( ) of machine mon-
itor mode selector switch 1 is not being pressed, there is probably a failure on the machine, so carry out inspection and mainte-
nance.
10-144 HM400-1L
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
%%%%%: Displays time that has elapsed since failure first
occurred (Present service meter reading - Service
meter reading when problem first occurred = Time
elapsed)
@@@@@: Displays time that has elapsed since failure last
occurred (Present service meter reading - Service
meter reading when problem last occurred = Time
elapsed)
The failure code flashes for failures that are still occurring at
present. The number of times that the failure code for the machine
system has occurred is saved in memory.
The failure code flashes for failures that are still occurring at
present. The number of times that the failure code for the machine
system has occurred is saved in memory.
HM400-1L 10-145
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
3. Real-time monitor
This function is used when checking the input and output signals
recognized by the controllers on the network. The real-time monitor
display on the character display is as shown at the right.
10-146 HM400-1L
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
4. Reduced cylinder mode
For details of this function, see TESTING AND ADJUSTING, Engine reduced cylinder mode operation.
5. ECMV compensation
For details of this function, see TESTING AND ADJUSTING, Adjusting transmission, 2. ECMV compensation.
7. Controller initialize
This function is used only at the factory, so do not touch it.
HM400-1L 10-147
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
OPERATION METHOD
For details of the operating method of each service mode function, see TROUBLESHOOTING..
For details on setting the service meter, travel distance total, and reverse travel distance total, see TESTING AND ADJUST-
ING. REMARK: When the starting switch is turned OFF, it returns to the normal mode.
10-148 HM400-1L
STRUCTURE AND FUNCTION AUTOMATIC SHIFT CONTROL SYSTEM
HM400-1L 10-149
STRUCTURE AND FUNCTION AUTOMATIC SHIFT CONTROL SYSTEM
OUTLINE
● The transmission controller receives the shift position signal for the gearshift lever, the accelerator signal for the accelera-
tor pedal, the speed signal for the transmission, and the other signals from the switches and sensors. It then automatically
controls the transmission and shifts it to the optimum speed range.
● In addition to the shift control, the transmission controller also controls the torque converter lock-up solenoid and operates
the brake to prevent overrun. Each clutch pack of the clutch packs and torque converter lock-up clutch in the transmission
is equipped with an electronically controlled modulation valve, and each clutch pack is independently controlled. In this
way, the initial pressure, build-up ratio, and torque-off time for each clutch is controlled according to the condition of the
machine. This reduces the gearshifting shock and prevents shift hunting, this improves the durability of the clutches.
● The transmission shift controller uses the signals from the switches and sensors to drive the machine monitor displays and
caution and pilot lamps, and transmits this data to the network.
10-150 HM400-1L
STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER
TRANSMISSION CONTROLLER
HM400-1L 10-151
STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER
Battery direct power source Torque converter oil pressure Torque converter oil temperature
7 7 ECMV output Low (+) 7 7
input (24V) signal input signal input
ECMV output inter-axle Inter-axle differential lock Brake cooling oil temperature
8 GND 8 8 8
differential lock (+) command input (center wheel) signal input
10 æ 10 ECMV output lock-up (+) 10 Emergency escape switch input 10 Brake cooling oil temperature (rear
wheel) signal input
21 GND
10-152 HM400-1L
STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER
20 æ
HM400-1L 10-153
STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER
GEARSHIFTING CHARACTERISTICS
Shifting the transmission up and down is done according to the shift map saved in the controller memory.
There are three types of shift map, depending on the condition of the input signals.
The settings for each mode are as shown in the table below.
Braking mode:
The shift-down point and the shift-up point are both raised, the engine speed is maintained at a higher level, and the amount of
cooling oil for the retarder is ensured to provide greater effect when the engine is used as a brake.
Economy mode:
When the machine is being used under light load, such as when traveling unloaded or on flat ground, the shift-up point and
shift-down point are both lowered, the engine speed is maintained at a lower level, and the fuel consumption, noise, and trans-
mission shock are improved. In this mode, the engine output is limited to 90% of the maximum engine output.
10-154 HM400-1L
STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER
2. Economy mode:
● For the shift-up point, the optimum point between 1750 and 1900 min-1 is selected according to the amount the accel-
erator pedal is depressed, the acceleration of the machine, and the speed range.
● For the shift-down point also, the optimum point between 1120 and 1200 min-1 is selected according to the amount
the accelerator pedal is depressed and the speed range.
4. Lock-up
● For the lock-up ON point, the optimum point between 1050 and 1400 min-1 is selected according to the torque con-
verter input speed (engine speed) and output speed (transmission input shaft speed).
● The lock-up OFF point when the footbrake or retarder brake are operated is 950 min-1.
HM400-1L 10-155
STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER
● When the footbrake or retarder brake are not operated, it is 850 min-1.
● When the machine moves downhill with the accelerator pedal released, the lock-up is not engaged until the accelera-
tor pedal is depressed or the footbrake is applied.
i. When the gearshift lever is set at position D, the transmission is set to F2 torque converter range.
ii. When the accelerator pedal is depressed, the engine speed rises and accelerates. When the transmission input
shaft speed reaches 1050 - 1400 min-1, the lock-up clutch is engaged, so the torque converter is directly engaged
and the transmission is set to direct travel.
iii. As the engine speed rises further and reaches 1750 - 2070 min-1, the transmission shifts up to F3.
iv. While the transmission is shifting up, the engine speed is also lowered (a command is output to the engine con-
troller) in order to reduce the shock when shifting gear.
v. Immediately after shifting up, the engine speed momentarily goes down, but as the machine accelerates, it rises
again and the transmission shifts up in turn to F4 to F6 in the same way as in iii above.
i. When the load increases and the engine speed drops to 1120 - 1250 min-1, the transmission shifts down one
speed. (For example, when traveling in F6, the transmission shifts down to F5.) While the transmission is shift-
ing up, the engine speed is also raised (a command is sent to the engine controller) in order to reduce the shock
when shifting gears.
ii. As the engine speed goes down further and the transmission shifts down in turn to F2, the torque converter lock-
up clutch is disengaged and the transmission enters the torque converter drive.
★ In the above explanation, the set speed or actuation may differ according to the travel conditions. For details, see
the automatic gearshifting graph.
(Manual shift):
The safety functions related to travel in reverse are the directional inhibitor and reverse safety. If the operation is not correct,
gearshifting is restricted.
10-156 HM400-1L
STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER
SAFETY FUNCTIONS
HM400-1L 10-157
STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER
5. REVERSE safety
The machine will not travel in reverse if the dump control lever is not at FLOAT and the dump body is not completely
lowered (turnover prevention function). However, if the gearshift lever is at the R1 position and the shift hold switch is
pressed, it is possible to travel in reverse while the switch is being pressed, even if the dump body is not fully lowered.
SELF-DIAGNOSTIC FUNCTION
● The controller performs a self-diagnosis of the system and displays any failures.
● The details of the self-diagnosis are displayed as a 2-digit code with LEDs.
● If a failure is detected by the self-diagnosis function, the failure data is transmitted to the network and displayed as an
action code on the machine monitor. The transmission system caution, warning lamp, or alarm buzzer may also be actu-
ated.
10-158 HM400-1L
STRUCTURE AND FUNCTION AUTO AUXILIARY STEERING SYSTEM
HM400-1L 10-159
STRUCTURE AND FUNCTION SENSORS, SWITCHES
SENSORS, SWITCHES
1. Magnet
2. Locknut
3. Wiring harness
4. Connector
FUNCTION
The engine speed sensor is installed to the ring gear of the flywheel housing. It uses the rotation of the gear teeth to generate a
pulse voltage and transmits a signal to the transmission controller.
10-160 HM400-1L
STRUCTURE AND FUNCTION ACCELERATOR SENSOR
ACCELERATOR SENSOR
1. Connector
2. Connector
3. Pedal
OUTLINE
ACCELERATOR SIGNAL
This is installed under the operator’s cab. The accelerator pedal and
accelerator sensor are connected by a link. When the accelerator pedal is
depressed, the movement is passed through the link and rotates the shaft
of the potentiometer inside the accelerator sensor. As a result, the resis-
tance changes. A fixed voltage is impressed between the No. 1 – 3 pins
of the potentiometer. A voltage signal corresponding to the angle of the
accelerator pedal is sent from the No. 2 pin to the transmission control-
ler.
HM400-1L 10-161
STRUCTURE AND FUNCTION ACCELERATOR SENSOR
1. Thermistor
2. Plug
3. Wiring harness
4. Connector
FUNCTION
The sensors are installed to the brake cooling piping. They take the change in resistance of the thermistor as the change in the
temperature and transmit a signal to the transmission controller. The signal is sent from the transmission controller through the
network to the machine monitor panel to display the temperature level. When the display on the monitor panel reaches the
specified position, the lamp flashes and the buzzer sounds to warn of a problem.
1. Sensor
2. Terminal
3. Connector
FUNCTION
The steering oil temperature sensor is installed to the steering and hoist piping. The sensor portion detects the temperature, and
when the oil temperature goes above the specified level, the warning lamps lights up and a message is displayed on the charac-
ter display of the monitor panel.
10-162 HM400-1L
STRUCTURE AND FUNCTION ACCELERATOR SENSOR
1. Connector
2. Float
3. Arm
4. Body
5. Spring
6. Contact
7. Spacer
FUNCTION
The fuel sensor is installed to the side face of the fuel tank. The float moves up and down according to the fuel level. This
movement of the float is transmitted by the arm and actuates a variable resistance. This sends a signal to the monitor panel to
indicate the remaining fuel level. When the display of the monitor panel reaches a certain level, a warning lamp flashes.
HM400-1L 10-163
STRUCTURE AND FUNCTION ACCELERATOR SENSOR
TILT SENSOR
FUNCTION
The tilt sensor is installed to the rear of the chassis. A magnet supported by a leaf spring is installed to a case charged with
damper oil. It uses the position in relation to the magnetic resistance element to detect the tilt angle of the chassis. The magnet
is supported by the leaf spring, so it does not detect the front-to-rear tilt of the chassis.
10-164 HM400-1L
STRUCTURE AND FUNCTION ACCELERATOR SENSOR
1. Indicator
2. Spring
3. Adapter
FUNCTION
The air cleaner clogging sensor is installed to the outward port of the air cleaner. If the air cleaner becomes clogged and
reaches the set pressure (negative pressure), the maintenance warning lamp lights up to warn of the abnormality.
HM400-1L 10-165
STRUCTURE AND FUNCTION ACCELERATOR SENSOR
1. Connector
2. Float
3. Switch
FUNCTION
The hydraulic oil level sensor is installed to the side face of the hydraulic tank. When the oil goes below the specified level, the
float goes down, the switch is turned OFF, and the maintenance caution lamp lights up to warn of the abnormality.
10-166 HM400-1L
STRUCTURE AND FUNCTION ACCELERATOR SENSOR
1. Bearing
2. Rotor
3. Connector
FUNCTION
The body position sensor is installed to the rear of the chassis. When the angle of the dump body changes, the shaft receives
sliding resistance through the link installed to the dump body, and the dump body angle is detected.
HM400-1L 10-167
STRUCTURE AND FUNCTION RETARDER CONTROL SYSTEM
10-168 HM400-1L
STRUCTURE AND FUNCTION RETARDER CONTROL SYSTEM
RETARDER CONTROLLER
1. Retarder control
The electromagnetic proportional valve for the front and rear wheels is controlled according to the operating angle of the
retarder control lever and actuates the retarder brake.
3. Hoist control
This controls the hoist EPC valve (electromagnetic proportional valve) and hoist selector valve (ON/OFF valve) accord-
ing to the position of the dump control lever and actuates the dump body.
HM400-1L 10-169
STRUCTURE AND FUNCTION RETARDER CONTROL SYSTEM
4. Differential lock control
i. The differential lock command is sent to the transmission controller according to the condition of the machine
(differential lock switch, travel speed, etc.).
ii. Based on the command from the retarder controller, the transmission controller drives the ECMV and actuates
the inter-axle differential lock.
i. Depending on the setting of the left and right differential lock selector switch, if the differential lock foot switch
is ON and the speed range is low (F1, F2, F3, R1, R2), the left and right differential lock is actuated.
A. Retarder actuation, float caution, parking brake actuation, exhaust brake actuation, inter-axle differential lock actua-
tion, accumulator oil pressure drop warning, and other data are transmitted to the monitor panel.
B. The exhaust brake command, overrun prevention, retarder command when there is abuse, and other data sent from
the transmission controller are received.
C. The inter-axle differential lock actuation command, reverse inhibit, and other data are transmitted to the transmission
controller.
10-170 HM400-1L
STRUCTURE AND FUNCTION RETARDER CONTROL SYSTEM
11 Kick-out solenoid 11 æ 11 æ 11 æ
13 Brake cut relay 13 æ 13 Transmission output shaft speed 13 Body position sensor
21 GND
HM400-1L 10-171
STRUCTURE AND FUNCTION RETARDER CONTROL SYSTEM
8 FLASH SW. (ON/OFF) 8 Brake system filter switch 8 Brake wear switch ML
10 GND. (SERIAL) 10 æ 10 æ
11 RS485(-) 11 æ 11 æ
12 S-NET (+) 12 æ 12 æ
13 æ 13 æ
14 æ 14 æ
15 æ 15 æ
16 æ 16 æ
17 æ
19 æ
20 æ
10-172 HM400-1L
STRUCTURE AND FUNCTION RETARDER CONTROL SYSTEM
The operating angle of the retarder lever is detected by the potentiometer and a current corresponding to this is sent to the elec-
tromagnetic proportional valve for the front and rear wheels to actuate the retarder.
HM400-1L 10-173
STRUCTURE AND FUNCTION RETARDER CONTROL SYSTEM
Relationship between retarder lever potentiometer and output to electromagnetic proportional valve
1. To improve the initial response of the electromagnetic proportional reducing valve, the output (trigger output) is set to a
high value.
2. To make the actuation of the hydraulic pressure smooth in the low pressure range, the output is set to a high value.
3. In the range where the retarder is normally used, the output is proportional to the angle of the lever.
4. To make the opening of the hydraulic pressure smooth in the low pressure range, the output is set to a low value.
10-174 HM400-1L
STRUCTURE AND FUNCTION RETARDER CONTROL SYSTEM
HM400-1L 10-175
STRUCTURE AND FUNCTION RETARDER CONTROL SYSTEM
5. Float caution function
If the output is not FLOAT or the dump body is not fully lowered, the float caution lamp on the monitor panel lights up.
"FLOAT OUTPUT" and "SEATED" → Float caution OFF
"NO FLOAT OUTPUT" or "NOT SEATED" → Float caution ON
7. Calibration function
To absorb any inherent error in the dump body potentiometer, calibration is done to recognize the dump body seating and
the body cylinder stopper condition.
After adjusting the installation of the body potentiometer or after replacing the retarder controller, calibrate in the follow-
ing order.
Order of dump control calibration (hydraulic oil temperature: 80 - 90°C)
A. Lower the dump body completely and run the engine. Change the lever from HOLD to FLOAT and check that the
float caution lamp goes off.
B. Operate the lever to the RAISE position and raise the dump body until it contacts the stopper. Keep the lever at the
RAISE position with the cylinder at the stopper position for at least five seconds.
C. Lower the dump body completely and keep the lever at HOLD for at least five seconds.
D. Run the engine at low idle and operate RAISE → FLOAT with the dump body raised to the maximum height, then
lower the dump body completely. Repeat this operation ten times.
E. Run the engine at high idle and operate RAISE → FLOAT with the dump body raised to the maximum height, then
lower the dump body completely. Repeat this operation ten times.
10-176 HM400-1L
STRUCTURE AND FUNCTION RETARDER CONTROL SYSTEM
HM400-1L 10-177
STRUCTURE AND FUNCTION RETARDER CONTROL SYSTEM
Inter-axle differential lock output
The inter-axle differential lock command is an analog signal and is transmitted from the retarder controller to the transmission
controller. The transmission controller sends electric current to the electromagnetic proportional valve.
The retarder controller output is constant value A when starting to control the differential lock. After A is output, when the
filled signal (signal reporting the completion of filling the electromagnetic proportional valve with oil) comes ON, it provides
an output and angle θ-1 to line B and angle θ-2 to target output line C.
Left and right differential lock output
The left and right differential lock command drives the left and right differential lock solenoid (for front wheels, for rear
wheels) from the retarder controller.
Retarder control lever
The manual retarder potentiometer and lever validation switches 1 and 2 are built into the lever.
The manual retarder potentiometer output is a voltage signal matching the position of the lever and is sent to the retarder con-
troller.
The lever validation switches sends the ON/OFF data for the lever position to the retarder controller.
Dump control lever
The dump control lever potentiometer and lever kick-out solenoid are built into the dump control lever.
The dump control lever potentiometer output is a voltage signal matching the position of the lever and is sent to the retarder
controller.
The lever kick-out solenoid fixes the lever at the RAISE position when it receives the ON signal from the retarder controller
and returns the lever to the HOLD position when it receives the OFF signal.
10-178 HM400-1L
STRUCTURE AND FUNCTION BRAKE CONTROL SYSTEM (E-SPEC)
★ Since the retarder function is not used in E-SPEC, the retarder control lever potentiometer is used to bleed air from the
brake oil circuit.
HM400-1L 10-179
STRUCTURE AND FUNCTION BRAKE CONTROL SYSTEM (E-SPEC)
2. Hoist control
This controls the hoist EPC valve (electromagnetic proportional valve) and hoist selector valve (ON/OFF valve) accord-
ing to the position of the dump control lever and actuates the dump body.
Based on the command from the brake controller, the transmission controller drives the ECMV and actuates the inter-
axle differential lock.
10-180 HM400-1L
STRUCTURE AND FUNCTION BRAKE CONTROL SYSTEM (E-SPEC)
B. Left and right differential lock control (Machine with differential lock differential)
Depending on the setting of the left and right differential lock selector switch, if the differential lock foot switch is
ON and the speed range is low (F1, F2, F3, R1, R2), the left and right differential lock is actuated.
A. Brake actuation, float caution, parking brake actuation, exhaust brake actuation, inter-axle differential lock actuation,
accumulator oil pressure drop warning, and other data is transmitted to the monitor panel.
B. The exhaust brake command, overrun prevention, brake command when there is abuse, and other data sent from the
transmission controller are received.
C. The inter-axle differential lock actuation command, reverse inhibit, and other data is transmitted to the transmission
controller.
HM400-1L 10-181
STRUCTURE AND FUNCTION BRAKE CONTROL SYSTEM (E-SPEC)
11 Kick-out solenoid 11 æ 11 æ 11 æ
13 Brake cut relay 13 æ 13 Transmission output shaft speed 13 Body position sensor
21 GND
10-182 HM400-1L
STRUCTURE AND FUNCTION BRAKE CONTROL SYSTEM (E-SPEC)
8 FLASH SW. (ON/OFF) 8 Brake system filter switch 8 Brake wear switch ML
10 GND. (SERIAL) 10 æ 10 æ
11 RS485(-) 11 æ 11 æ
12 S-NET (+) 12 æ 12 æ
13 æ 13 æ
14 æ 14 æ
15 æ 15 æ
16 æ 16 æ
17 æ
19 æ
20 æ
HM400-1L 10-183
STRUCTURE AND FUNCTION BRAKE CONTROL SYSTEM (E-SPEC)
★ Since the retarder function is not used in E-SPEC, the retarder control lever potentiometer is used to bleed air from the
brake oil circuit.
The electromagnetic proportional valve for the front and rear wheels is controlled based on the command (ON/OFF command)
from the transmission controller and actuates the brake by a fixed amount.
10-184 HM400-1L
STRUCTURE AND FUNCTION BRAKE CONTROL SYSTEM (E-SPEC)
HM400-1L 10-185
STRUCTURE AND FUNCTION BRAKE CONTROL SYSTEM (E-SPEC)
5. Float caution function
If the output is not FLOAT or the dump body is not fully lowered, the float caution lamp on the monitor panel lights up.
"FLOAT OUTPUT" and "SEATED" → Float caution OFF
"NO FLOAT OUTPUT" or "NOT SEATED" → Float caution ON
7. Calibration function
To absorb any inherent error in the dump body potentiometer, calibration is done to recognize the dump body seating and
the body cylinder stopper condition.
After adjusting the installation of the body potentiometer or after replacing the brake controller, calibrate in the following
order.
Order of dump control calibration (hydraulic oil temperature: 80 - 90°C)
A. Lower the dump body completely and run the engine. Change the lever from HOLD to FLOAT and check that the
float caution lamp goes off.
B. Operate the lever to the RAISE position and raise the dump body until it contacts the stopper. Keep the lever at the
RAISE position with the cylinder at the stopper position for at least five seconds.
C. Lower the dump body completely and keep the lever at HOLD for at least five seconds.
D. Run the engine at low idle and operate RAISE → FLOAT with the dump body raised to the maximum height, then
lower the dump body completely. Repeat this operation 10 times.
E. Run the engine at high idle and operate RAISE → FLOAT with the dump body raised to the maximum height, then
lower the dump body completely. Repeat this operation ten times.
10-186 HM400-1L
STRUCTURE AND FUNCTION BRAKE CONTROL SYSTEM (E-SPEC)
If 1 or 2 are selected, the differential lock foot switch is pressed, and the speed range is low (F1, F2, F3, R1, R2), the dif-
ferential lock command is activated.
HM400-1L 10-187
STRUCTURE AND FUNCTION DUMP CONTROL LEVER
10-188 HM400-1L
STRUCTURE AND FUNCTION DUMP CONTROL LEVER
1. Lever
2. Rod
3. Spring
4. Spring
5. Retainer
6. Body
7. Body
8. Bushing
9. Solenoid
10. Nut
11. Rod
12. Detent spring
13. Retainer
14. Ball
15. Seat
16. Potentiometer
17. Lever
18. Rod
19. Rod
20. Detent spring
HM400-1L 10-189
STRUCTURE AND FUNCTION DUMP CONTROL LEVER
FUNCTION
● When lever (1) is operated, rod (18) moves up or down according to the amount the lever is operated, and rotates potenti-
ometer (16).
● The amount the control lever is operated (travels) is detected by the potentiometer, and this is sent as a signal voltage to
the controller.
● One potentiometer is installed and sends two related signal voltages as shown in the "Output voltage characteristics"
graph.
OPERATION
DUMP CONTROL LEVER OPERATED TO FLOAT
● When LOWER rod (2) is pushed by lever (1) and moves down, ball
(14) contacts protrusion a of rod (11) during the stroke (before start
of actuation of mechanical detent).
● When rods (2) and (11) are pushed in further, ball (14) is held by
detent spring (12). While pushing retainer (13) up, it escapes to the
outside, and rod (11) passes over protrusion a.
● When this happens, rod (18) on the opposite side is pushed up by
spring (4). Ball (14) is moved to the small diameter side of protru-
sion b of rod (19) by retainer (13) that is held by detent spring (20).
● Even if the lever is released, rod (18) is held in position by the
pushing force of the ball and protrusion b of rod (19), so the lever is
held at the FLOAT position.
10-190 HM400-1L
STRUCTURE AND FUNCTION DUMP CONTROL LEVER
Or, when the solenoid power source is turned OFF, the RAISE position
is canceled and the lever returns to the N position.
HM400-1L 10-191
STRUCTURE AND FUNCTION PLM-HM
PLM-HM
SYSTEM STRUCTURE
10-192 HM400-1L
STRUCTURE AND FUNCTION PLM-HM
PRINCIPLE OF CALCULATION
1. Outline
The articulate dump truck is suspended by six wheels, a pair each of front, central and rear wheels. The front and rear
wheels are suspended by hydro-pneumatic suspension cylinder. The force Fr, which the rear wheel suspends is equal as
the force Fc, which the central wheel suspends because the central and rear wheels are suspended by the equalizer bar.
The suspended force F = Ff + Fc + Fr = Ff + 2 x Fr
The force Ff = Af x Pf (Af: Suspension cylinder cross section, Pf: Suspension gas pressure)
4. Correction on slope
If the dump truck is loaded on a slope, the measured weight is different from the weight measured on a level ground. To
solve this problem, the longitudinal inclination of the dump track is measured and measured weight is corrected according
to the inclination angle (correction angle of inclination angle: ± 5°).
HM400-1L 10-193
STRUCTURE AND FUNCTION PLM-HM
ACCURATE CALCULATION
1. Suspension cylinder length
The PLM-HM calculates the payload by the signal of the suspension cylinder pressure sensors. Please maintain the length
of the suspension cylinder to be within nominal length. Please ask your Komatsu distributor for assistance.
2. Calibration run
Calibration run has to be done when:
● The dump truck is shipped to the site
● The dump body is modified (the weight of the dump truck is changed)
● The gas of the suspension cylinder is maintained
● Periodically (each season)
Calibration run needs a flat, horizontal 100m straight course. If the course is not flat, horizontal or straight, the accuracy of
the calibration run could be in error. This influences the accuracy of the payload measurement.
3. Traveling method
When the traveling method is selected to be stored,
● The accuracy of traveling method depends on the road condition. The more flat the road, the more accurate. Please
maintain the road conditions to get the higher accuracy.
● The accuracy of traveling method depends on the distance of traveling. The longer the distance, the more accurate. It
needs at least 100m for accuracy. The traveling measurement is achieved only when the dump truck speed exceeds
8km/h and the incline of the road is within ±5°. The haul road must be more than 100m which meets the condition
above for Traveling Method.
● Rapid acceleration, braking and steering could affect the accuracy of calculations.
5. Loading method
To keep the accuracy of loading method (including external display lamps)
● The better maintained the ground of loading spot, the more accurate.
● The incline of the loading spot has to be within ±5°. If the incline exceeds ±5°, the accuracy is getting worse.
● Stop the dump truck gently. Do not change the shift to neutral position until the dump truck is stopped completely.
● When the dump truck is stopped, please activate the parking brake and release the service brake or retarder brake.
Please stop the dump truck gently.
● Do not load the material before the dump truck is stopped completely.
● The controller recognizes the loading is finished when the dump truck travels more than 5m after the loading is
started.
10-194 HM400-1L
STRUCTURE AND FUNCTION PLM-HM
● The equalizer bar hits the stopper
● If the equalizer bar hits the stopper, the accuracy would become very bad.
● The PLM-HM detects this hit when the empty dump truck stops at the loading stop. When the PLM-HM detects
the equalizer bar to hit the stopper, then the error code "F-FL" is displayed in the PLM-HM load meter display,
and all the external display lamps are flashed.
● Do not load when all the external display lamps are flashed.
● If the error code "F-FL" appears, please move the dump truck forward a little bit and stop until the "F-FL" disap-
pears.
● When moving the dump truck forward, please shift the transmission to drive range. When stopping the dump
truck, please shift the transmission to neutral range after the dump truck is completely stopped.
6. Download
The PLM-HM stores the cycle data for 2,900 cycles (normally more than one month operation). If the number of cycles
exceeds 2,900, the newest data is overwritten on the oldest data. Please download the data periodically and clear all the
data before overwriting.
HM400-1L 10-195
STRUCTURE AND FUNCTION PLM-HM
LEFT FACE
★ The switches are adjusted before the machine is shipped. Do not touch any other switch.
10-196 HM400-1L
STRUCTURE AND FUNCTION PLM-HM
BASIC FUNCTIONS
1. Power ON
When the power is turned ON, all functions are checked and displayed.
HM400-1L 10-197
STRUCTURE AND FUNCTION PLM-HM
3. Normal operation display
Total payload**
When dumping N Unseated → Seated OFF
(100 ton)
When an error
--- --- --- See ERROR CODE DISPLAY
occurs
10-198 HM400-1L
STRUCTURE AND FUNCTION PLM-HM
5. Memory content
A. Cycle Data
● The period between one dumping operation and the next dumping operation is taken as one cycle and the data is
recorded.
● The cycle data is recorded when the dumping is finished.
● The maximum limit for cycle data in memory is 2,900 cycles.
● Cycle data is recorded for more than 2,600 cycle, the error message "F-11" is displayed.
HM400-1L 10-199
STRUCTURE AND FUNCTION PLM-HM
C. Error, warning data
● Each load meter error or warning that is generated or cancelled is recorded.
● The maximum limit in memory for error or warning data is 230 generated/cancelled sets.
B. Machine ID setting
C. Open ID setting
10-200 HM400-1L
STRUCTURE AND FUNCTION PLM-HM
9. Downloading saved data
It is possible to download any data recorded in PLM-HM to a PC through a cable (RS232C). For details, see the PC soft-
ware manual provided by Komatsu.
D. Forced initialization
● This forcibly deletes all the data in PLM-HM. PLM-HM becomes just same as the one when the controller is shipped
from the factory.
● Before doing this operation, check the time and date. Always perform this operation with the machine unloaded.
Do not carry out the operation unless necessary.
● If this is carried out, the calibration data is cleared. The inclinometer calibration and calibration run are necessary
to be done again.
HM400-1L 10-201
STRUCTURE AND FUNCTION PLM-HM
E. Parameter setting
● This allows to modify the parameter setting.
10-202 HM400-1L
STRUCTURE AND FUNCTION PLM-HM
If the error is almost constant according to the payload, "Payload offset" has to be modified. For example, PLM-
HM shows one ton more than the actual for 25.9 ton (70%) payload and 37.0 ton (100%) payload. "Payload gain"
has to be set at "91" ((37.0-25.9)/39.0-26.9)%) and "Payload offset" has to be set as "1.5"(37-0.91*39).
If the error is different according to the payload, "Payload offset" and "Payload gain" has to be modified. For
example, PLM-HM shows one ton more for 70% payload and two tons more for 100% payload, "Payload offset"
has to be set as "-1.5" and "Payload gain" has to be set as "91".
HM400-1L 10-203
STRUCTURE AND FUNCTION PLM-HM
xi. Stable payload threshold
The calculated payload changes dynamically when loading. PLM-HM waits for the calculation until the calcu-
lated payload becomes stable. This threshold is the one PLM-HM recognizes. This setting (two tons) is alright
for almost all conditions. This impacts the accuracy of the estimated display of the external display lamps. If the
function is strange, this setting can be modified to be less value (one ton). In this case, the time delay to display
the lamps after loading might be longer.
10-204 HM400-1L
STRUCTURE AND FUNCTION PLM-HM
KEY OPERATION
The chart below describes the key operation tree.
HM400-1L 10-205
STRUCTURE AND FUNCTION PLM-HM
10-206 HM400-1L
STRUCTURE AND FUNCTION PLM-HM
Key operation and the display includes
A. Power on procedure
B. Normal display
D. Open ID input
A through E are explained in the Operator’s Manual. The key switch operation for F is explained in this section.
HM400-1L 10-207
STRUCTURE AND FUNCTION PLM-HM
1. Service input signal check mode
10-208 HM400-1L
STRUCTURE AND FUNCTION PLM-HM
2. Service calibration data mode
HM400-1L 10-209
STRUCTURE AND FUNCTION PLM-HM
3. Service setting mode
10-210 HM400-1L
STRUCTURE AND FUNCTION PLM-HM
4. Forcibly initialization mode
● Press [CAL/CLR] switch (1), [TOTAL/SFT] switch (2) and
[LIGHT/INC] switch (3) simultaneously for more than two
seconds, then "ACLE" is flashed.
● This means the forcibly initialize mode is ready. Press [CAL/
CLR] switch (1) for more than two seconds, "ACLE" is lighted
up and the forcibly initialize mode is started.
● If you want to cancel the process when "ACLE" is flashed,
press [MODE] switch (4) then "CHEC" is flashed.
● Several seconds after the forcibly initialize mode is started,
power on process is started. It means that the forcibly initial-
ization is completed.
★ Do not carry out this forcibly initialize mode if not neces-
sary. All the data including the calibration data is cleared.
★ After the execution of this mode, all procedures for local
installation is necessary.
HM400-1L 10-211
STRUCTURE AND FUNCTION PLM-HM
SENSORS
1. Pressure sensor
● The pressure sensor is installed at the bottom end of the sus-
pension cylinder for front right/left suspension cylinders and
rear right/left suspension cylinders and acts to measure the
pressure at the cylinder bottom.
● When replacing pressure sensor (1), leave the valve (2)
installed to the suspension and remove only pressure sensor
(1).
● When removing or installing pressure sensor (1), be careful not
to let valve (2) rotate. Valve (2) includes a check valve and pre-
vents the pressure from going down.
2. Inclinometer
● To carry out compensation on slopes, the inclinometer mea-
sures the longitudinal tilt angle of the chassis. It is installed at
the real frame.
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STRUCTURE AND FUNCTION PLM-HM
3. Body sensor
● Body sensor is a proximity sensor which detects the body to be
seated or not.
● The gap between the sensor and the plate has to be maintained
within 3.5 to 6.3 mm.
HM400-1L 10-213
STRUCTURE AND FUNCTION PLM-HM
10-214 HM400-1L
STRUCTURE AND FUNCTION PLM-HM
HM400-1L 10-215
STRUCTURE AND FUNCTION PLM-HM
c. If this warning occurs, please download the data and clear the all data (see Data all clear).
*5. Equalizer bar hits the stopper
a. If the equalizer bar hits the stopper, the accuracy would become very bad. The PLM-HM detects this hit when the
empty dump truck is stopped at the loading spot.
b. If the error code "F-FLE" is displayed in the PLM-HM display panel, please move the dump truck forward a little bit
and stop the dump truck until the "F-FLE" code disappears. When moving the dump truck forward, please shift the
transmission to drive range. When stopping the dump truck, please shift the transmission to Neutral range after the
dump truck is completely stopped.
*6. Articulated too much when dumping
When the dumping mode is selected, the payload is calculated just before dumping. If the dump truck is articulated
too much, the accuracy tends to worsen. The articulated angle is more than 22.5° (half of full range), this fault code is
activated. If this fault code is activated, please straighten the dump truck.
10-216 HM400-1L
STRUCTURE AND FUNCTION PLM-HM
LOCAL INSTALLATION
1. Preparation
A. Before this procedure is carried out, check the suspension length. If the suspension length is out of the nominal range,
charge or discharge the suspension gas and check the suspension length again to be within nominal range (see
HM400-1 Shop Manual). This process is very important to keep the accuracy of PLM-HM. This process has to be
done very carefully.
B. Check the dump body to be empty. If mud is on the dump body or on the chassis, clean it. It impacts the accuracy.
C. The procedure below has to be carried out with installation checklist for articulate dump truck PLM.
D. Calibration needs about 120m straight course with flat and horizontal ground.
E. The more straight, the more accurate. The more flat and horizontal, the more accurate.
G. Set the articulate straight. Mark the dump truck position on the ground.
★ Press switch for 0.5 to one second, do not press switch for more than two seconds.
★ If a mistake is made during switch operation, the MODE switch is effective for recovering in most situations.
★ If you fail in the procedure below, turn off the key and start from the beginning.
C. Display "C0:00" (is machine model code = 0[HM400-1]) for about eight seconds. Buzzer sounds one second again
(error detection for F.ICL, and F.CAL).
HM400-1L 10-217
STRUCTURE AND FUNCTION PLM-HM
F. Display two fault codes, "F.ICL (inclinometer is not calibrated)" and "F.CAL (calibration run is not executed)" alter-
nated. "F-.FL" might be flashed, it’s no problem.
A. Press MODE switch and LIGHT switch simultaneously for more than two seconds. The display flashes "CHEC" (it
means service check mode).
B. Press TOTAL switch and LIGHT switch simultaneously for more than two seconds. The display flashes "S.SEL" (it
means service setting mode).
C. Press CAL switch 15 times. The display is changing from "1._ _5" to "f._ _ 0" ("f" means "external display lamp
check mode"). The symbol " _ " means the "space".
D. Make sure that all the external lamps have flashed (it means error "F-FL" and "F.ICL" to be detected).
E. Press LIGHT switch. The display is "f. _ _ 1". Make sure that only the green lamp has turned on.
F. Press LIGHT switch. The display is "f. _ _ 2". Make sure that only the yellow lamp has turned on.
G. Press LIGHT switch. The display is "f. _ _ 3". Make sure that only the red lamp has turned on.
H. Press LIGHT switch. The display is "f. _ _ 0". Make sure that all the lamps have flashed.
I. If the lamps do not work correctly, please check the connector around the lamps or around the relay circuit.
4. Setting
A. Press CAL switch two times. The display is "J. _ _ 0" ("J" means "payload weight unit setting mode". "0" means met-
ric ton unit). If you want to change the unit to short ton, press TOTAL switch, then the display is "J. _ _ 1" (short ton).
B. Press CAL switch. The display is "L. _ _ 0" ("L" means "area setting mode". "0" means "except Australia"). If the
area is Australia, press TOTAL switch, then the display is "L. _ _ 1" (Australia).
C. Press MODE switch. The display flashes "CHEC" (it means service check mode).
A. Start engine.
B. Press CAL switch and TOTAL switch simultaneously for more than two seconds. The display flashes "S.CHE" (it
means service input signal check mode).
C. Press CAL switch. The display is "1X.XX" ("1" is flashed). The right three digits shows the voltage of front left sus-
pension pressure sensor. Write down the value on the check sheet. If the value is out of range, check the wiring or sen-
sor install.
D. Press CAL switch. The display is "2X.XX" ("2" is flashed). The right three digits show the voltage of front right sus-
pension pressure sensor. Write down the value on the check sheet. If the value is out of range, check the wiring or sen-
sor install.
E. Press CAL switch. The display is "3X.XX" ("3" is flashed). The right three digits show the voltage of the rear left sus-
pension pressure sensor. Write down the value on the check sheet. If the value is out of range, check the wiring or sen-
sor install.
10-218 HM400-1L
STRUCTURE AND FUNCTION PLM-HM
F. Press CAL switch. The display is "4X.XX" ("4" is flashed). The right three digits show the voltage of the rear right
suspension pressure sensor. Write down the value on the check sheet. If the value is out of range, check the wiring or
sensor install.
G. Press CAL switch. The display is "5X.XX" ("5" is flashed). The right three digits show the voltage of the inclinome-
ter. If the value is out of range, check the wiring or sensor install.
H. Press CAL switch. The display is "6X.XX" ("6" is flashed). The right three digits show the voltage of the backup bat-
tery. Write down the value on the check sheet. If the value is out of range, the backup battery has to be replaced.
I. Press CAL switch. The display is "7X.XX" ("7" is flashed). The right three digits show the voltage of R terminal. The
voltage of R terminal has to be more than 24V, but the maximum value of this display is around 8.3V. If the display is
around 8.3V, it’s OK. If the value is out of range, check the wiring.
J. Press CAL switch. The display is "8X.XX" ("8" is flashed). The right three digits show the voltage of the articulated
sensor. Write down the value on the check sheet. If the value is out of range, check the wiring or sensor install.
K. Press CAL switch six times. The display is "F _ _ 1" ("F" is flashed). The far right digit shows the neutral signal (1 is
neutral, 0 is other). Move the shift lever to "D" range. The display on PLM has to be "F _ _ 0". Return the shift lever
to "N" range. The display on PLM has to be "F _ _ 1". (Check on the check sheet.) If the value is not correct, check
the wiring.
L. Press CAL switch. The display is "H _ _ 1" ("H" is flashed). The far right digit shows the body seated signal (1 is
seated, 0 is not seated). Raise the dump body and the display on the PLM has to be "H _ _ 0". Lower the dump body
and the display on PLM has to become "H _ _ 1". (Check on the check sheet.) If the value is not correct, check the
wiring or sensor install.
M. Press CAL switch. The display is "J _ _ 0" ("J" is flashed). The far right digit shows the velocity. Put the shift lever to
2nd position and move the vehicle with full throttle pedal. The display on PLM has to be around 12 Km/h. (Check on
the check sheet.) If the value is not correct, check the wiring
N. Press the MODE switch. The display flashes "CHEC". Press Mode switch again. Display two error codes, "F.ICL
(inclinometer is not calibrated)" and "F.CAL (calibration run is not executed)" alternately. "F-.FL" might be flashed,
it’s no problem.
A. Start engine.
E. Press CAL switch for more than two seconds. The display
flashes "CAL.0" (service calibration data check mode).
HM400-1L 10-219
STRUCTURE AND FUNCTION PLM-HM
F. Press CAL switch and TOTAL switch simultaneously for more than two seconds. "CAL.1" (means inclinometer cali-
bration mode) will be displayed and the calibration for inclinometer and articulate sensor are executed for three sec-
onds. "CAL.2" will be flashed after three seconds.
G. Turn the dump truck around and park in the exact same posi-
tion as above, but now facing the opposite direction.
H. Press CAL switch for more than two seconds. "CAL.2" will be
turned on and the calibration for inclinometer and articulate
sensor are calibrated for three seconds again for opposite direc-
tion. "CHEC" will be flashed after the calibration is finished.
7. Calibration run
A. The weight of the empty dump truck has to be calibrated because the weight of empty dump truck might be different
by the vessel and attachment options.
B. Park the dump truck on the flat and horizontal ground. Calibration run needs about 120m straight and flat course.
C. Press CAL switch for more than two seconds. "CAL" will be flashed.
D. If you are ready to start, press CAL switch. "CAL" will be lighted up.
F. Press throttle pedal full. After the velocity becomes over 9Km/h, the display counts up the elapsed time (seconds).
Calibration run needs 30 second runs.
H. Stop the dump truck gently, shift the transmission to neutral, turn on the parking brake and release the retarder brake
or service brake. Do not change the transmission to neutral before the dump truck is stopped.
I. Write down the current payload. The displayed payload has to be around 0 ton because the dump truck is empty.
J. Press MODE switch, then the display has to be "clock". If "F.-FL" is still flashed, please move the dump truck and
stop it gently. "F.-FL" must be distinguished. Do not change the transmission to neutral before the dump truck is
stopped.
M. This calibration run has to be done periodically by the customer. Please explain the procedure to the customer.
10-220 HM400-1L
STRUCTURE AND FUNCTION PLM-HM
8. Clock set
A. Clock is set for Japanese standard time. The date and the hour might be modified to the local time.
B. Press MODE switch for more than two seconds. The display flashes "oCHE" (it means operator check mode).
C. Press MODE switch. The display is "d000" (it means machine ID).
D. Press MODE switch, The display is "_ _ YZ" ("Z" is flashed, YZ means lower two digits of year. "YZ" for 2003 is
"03").
F. Press TOTAL switch. The display is "_ _ YZ" ("Y" is flashed, YZ means lower two digits of year. "YZ" for 2003 is
"03").
H. Press TOTAL switch. The display is "MM:dd" ("MM" is flashed, MM means month, dd means day).
J. Press TOTAL switch. The display is "MM:dd" (dd is flashed, MM means month, dd means day).
L. Press TOTAL switch. The display is "HH.mm" ("HH" is flashed, HH means hour, mm means minutes).
A. This PLM-HM has three measurement methods; dumping method, traveling method and loading method. These three
methods are carried out for corresponding stage of each cycle. But only the payload by one method is stored and can
be downloaded. Komatsu service can set which method to be recorded by switch operation in the PLM-HM control-
ler.
B. Each method has its pros and cons. The method to be recorded has to be decided by the site condition and the cus-
tomer’s request.
ii. If all the haul road is very rough or the distance of haul road is less than 200m, and the ground of the dumping
area is flat and the incline is less than ± 5°, dumping method can be selected.
iii. If all the haul road is very rough or the distance of haul is less than 200m, and the ground of the dumping area is
not flat or the incline is more than ± 5°, the dumping method cannot be selected.
HM400-1L 10-221
STRUCTURE AND FUNCTION PLM-HM
iv. If the customer wants to have the payload data at the loading spot, loading method can be selected.
D. Press MODE switch and LIGHT switch simultaneously for more than two seconds. The display flashes "CHEC" (it
means service check mode).
E. Press TOTAL switch and LIGHT switch simultaneously for more than two seconds. The display flashes "S.SEL" (it
means service setting mode).
F. Press CAL switch 11 times. The display is changing from "1._ _ 5" to "b._ _ 2" ("b" means "store mode setting", "2"
means "traveling method"). If you want to change the store mode, press LIGHT switch. Then the display is changing
to "b._ _ 3" (loading method) to "b._ _1" (dumping method) to "b._ _ 2" (traveling mode). Write down the mode you
set on the check sheet.
G. After the mode is selected, press MODE switch. The display flashes "CHEC" (it means service check mode).
A. Try one cycle including loading, traveling and dumping with almost 100% payload.
Total payload**
When dumping N Unseated → Seated OFF
(100 ton)
When an error
--- --- --- See ERROR CODE DISPLAY
occurs
D. Download the data. Check the data in the cycle data (payload, dumping time) to be correct.
A. Press MODE switch for more than two seconds. The display flashes "oCHE" (it means operator check mode).
B. Press MODE switch. The display is "d000" (it means machine ID).
10-222 HM400-1L
STRUCTURE AND FUNCTION PLM-HM
C. Press MODE switch. The display is "_ _ YZ" ("Z is flashed, YZ means lower two digits of year. "YZ" for 2003 is
"03").
E. Press CAL switch for more than two seconds. The display is "A.CLE" (A.CLE" is flashed).
F. Press CAL switch for more than two seconds. The display is "A.CLE" ("A.CLE is lighted up). All clear of the cycle
data and fault history will be started.
HM400-1L 10-223
STRUCTURE AND FUNCTION PLM-HM
10-224 HM400-1L
20 TESTING, ADJUSTING AND
TROUBLESHOOTING
HM400-1L 20-1 1
TESTING AND ADJUSTING TABLE OF CONTENTS
TESTING PARKING BRAKE BRAKING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
TESTING OVERRUN PROTECTION BRAKING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
BLEEDING AIR FROM BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-48
BLEEDING AIR FROM SLACK ADJUSTER PORTION OF WHEEL BRAKE . . . . . . . . . . . . . . . . . . . . 20-48
BLEEDING AIR FROM WHEEL BRAKE PORTION OF FOOT BRAKE CIRCUIT . . . . . . . . . . . . . . . . 20-49
BLEEDING AIR FROM PARKING BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-49
CHECKING WEAR LIMIT ON WHEEL BRAKE DISC AND PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50
CHECKING BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50
CHECKING BRAKE PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51
ADJUSTING PAD CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52
RELEASING EMERGENCY PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-53
TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-54
MEASURING STEERING RELIEF OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-54
ADJUSTING STEERING RELIEF OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55
TESTING AND ADJUSTING SUSPENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-56
CHECKING CYLINDER LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-56
RELEASING NITROGEN GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-56
ADJUSTING OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-57
CHARGING WITH NITROGEN GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-58
ADJUSTING CYLINDER LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-59
TILTING THE CAB UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60
PREPARATORY WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60
TILTING CAB UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60
USING EXTERNAL CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
HOLDING CAB IN POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
LOWERING CAB DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62
TESTING DUMP MAIN RELIEF OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62
ADJUSTING DUMP MAIN RELIEF OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62
MEASURING DUMP PILOT RELIEF OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63
ADJUSTING DUMP PILOT RELIEF OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63
ADJUSTING BODY POSITIONER SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64
CHECKING SENSOR OUTPUT/INPUT VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64
ADJUSTING LINK LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64
CALIBRATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-65
HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
ADJUSTING TRANSMISSION CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-67
SETTING ROTARY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-67
ADJUSTING TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-67
ESCAPE METHOD FOR ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-68
ADJUSTING MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72
FUNCTIONS OF MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-76
NORMAL AND THE SPECIAL FUNCTIONS OF MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . 20-76
FLOW OF MODES AND FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-77
OPERATION AND DISPLAYS FOR OPERATOR MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-79
SWITCHING TO SERVICE MODE 1 AND SCREEN DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-87
20-2 1 HM400-1L
TESTING AND ADJUSTING STANDARD VALUE TABLE
12
STANDARD VALUE TABLE
FOR ENGINE
Machine model HM400-1L
Engine SAA6D140E-3
Standard value for
Item Measurement conditions Unit Service limit value
new machine
High idling 2,200 ± 50 2,200 ± 50
Engine speed Low idling rpm 725 ± 25 725 ± 25
Rated speed 2,000 ± 50 2,000 ± 50
Air supply kPa Min. 133.32 Min. 112
At rated speed
(boost pressure) (psi) (19.3) (16.2)
Whole speed range [ambient ºC Max. 650 Max. 700
Exhaust temperature
temperature: 20ºC (68ºF)] ºF (1202) (1292)
At sudden acceleration Bosch Max. 4.0 Max. 6.0
Exhaust gas color
At high idling index Max. 1.0 Max. 2.0
Valve clearance Intake valve mm 0.35 (0.01) –
(normal temperature) Exhaust valve (in) 0.57 (0.22)) –
Oil temp. 40 – 60ºC kPa
4.12 (0.6) 2.84 (0.4)
Compression pressure (104 – 140ºF) (psi)
[200 - 250] [200 - 250]
[engine speed] [rpm]
Coolant temperature: Within
kPa 1.96 3.92
Blow-by pressure operating range
(psi)} (0.3) (0.6)
At rated output
Coolant temperature:
Within operating range
0.34 – 0.54 Min. 0.21
At high idling
(49 - 78) (30)
SAE30 or SAE15W-40 oil
MPa 0.29 – 0.49 Min. 0.18
Oil pressure SAE10W oil
(psi) (42 - 71) (26)
At low idling
0.12 (17) Min. 0.07 (10.2)
SAE30 or SAE15W-40 oil
0.10 (15) Min. 0.07 (10.2)
SAE10W oil
Whole speed range
Oil temperature ºC (ºF) 80 – 110 (176 - 230) Max. 120 (248)
(inside oil pan)
13 – 15 (1.0 - 1.2) 13 – 15 (1.0 - 1.2)
Deflection when pressed with finger When new When new
Fan belt tension force of approximately mm (in) 17 – 19 (1.2 - 1.3) 17 – 19 (1.2 - 1.3)
98 Nm (72 ft/lbs) When adjusting When adjusting
tension tension
Deflection when pressed with finger
Alternator belt tension force of approximately mm (in) 13 – 16 (1.0 - 1.2) 13 – 16 (1.0 - 1.2)
98 Nm 72 ft/lbs) (for 1 belt)
Deflection when pressed with finger
Refrigerant compressor
force of approximately mm (in) 10 (0.2)) 10 (0.2))
belt tension
58.8 Nm (43 ft/lbs)
HM400-1L 20-3 1
TESTING AND ADJUSTING STANDARD VALUE TABLE
12
FOR CHASSIS
Machine model HM400-1L
Standard value
Service limit
Cat. Item Measurement conditions Unit for new
value
machine
Starting to 17.7 ± 4.9 17.7 ± 4.9
Accelerator pedal
High idling
Gearshift lever: N (lbs) (334 ± 22) (334 ± 22)
Torque converter inlet 0.90 ± 0.10 0.90 ± 0.10
Oil pressure
20-4 1 HM400-1L
TESTING AND ADJUSTING STANDARD VALUE TABLE
clutch pressure Torque converter oil temperature: (355 ± 22) (355 ± 22)
MPa
Transmission R clutch Within operating range 2.55 ± 0.15 2.55 ± 0.15
(psi)
pressure Engine speed: High idling (370 ± 22) (370 ± 22)
Inter-axle differential 2.55 ± 0.15 2.55 ± 0.15
lock clutch pressure (370 ± 22) (370 ± 22)
Transmission
0.20 ± 0.04 0.20 ± 0.04
lubricating pressure
(29 ± 6) (29 ± 6)
(reference)
7.2 ± 5% 7.2 ± 5%
F1
Power train
4 ± 5% 4 ± 5%
11.0 ± 5% 11.0 ± 5%
F2
7 ± 5% 7 ± 5%
16.9 ± 5% 16.9 ± 5%
F3 Flat ground 11± 5% 11± 5%
Engine coolant temperature: Within
Travel speed
25.8 ± 5% 25.8 ± 5%
F4 operating range
km/h 16 ± 5% 16 ± 5%
Torque converter oil temperature:
(mph) 39.4 ± 5% 39.4 ± 5%
F5 Within operating range
24 ± 5% 24 ± 5%
Dump body: Unloaded
Travel resistance: 3.3% 58.6 ± 5% 58.6 ± 5%
F6
36 ± 5% 36 ± 5%
7.4 ± 5% 7.4 ± 5%
R1
5 ± 5% 5 ± 5%
17.5 ± 5% 17.5 ± 5%
R2
11 ± 5% 11 ± 5%
Standard tire: 29.5 - R25 MPa 0.372 0.372
Tire inflation pressure
Dump body: Unloaded (psi) (54) (54)
25 ± 2.5
25 ± 2.5
Differential lock
(3626 ± 363)
Left and right differential lock switch:
MPa
ON
(psi) 25 ± 2.5 25 ± 2.5
Center differential Left and right differential lock pedal:
(3626 ± 363) (3626 ± 363)
Depressed
25 ± 2.5 25 ± 2.5
Rear differential
(3626 ± 363) (3626 ± 363)
N Max. 294 Max. 294
Brake pedal
Operating effort
(lbs) (Max. 66) (Max. 66)
Tip of pedal
mm 40 ± 5 40 ± 5
Travel
Brakes
Operating effort
(lbs) (1.4 – 2.2) (1 – 3.3)
Point 10 mm from tip of lever
Travel mm (in) 78 (255) 78 (255)
HM400-1L 20-5 1
TESTING AND ADJUSTING STANDARD VALUE TABLE
Wheel brake actuation Drop in wheel brake actuation pressure: 4.9 ± 0.49 4.9 ± 0.49
pressure Drop in pressure 5 minutes after MPa (711 ± 71) (711 ± 71)
Drop in wheel brake specified oil pressure (psi) Max. 40.49 Max. 40.49
actuation pressure 4.9 MPa (711 psi) is applied (Max. 5873) (Max. 5873)
Parking, exhaust brake actuation
Parking brake 3.92 ± 0.25 3.92 ± 0.25
pressure: Engine at high idling
actuation pressure (569 ± 36) (569 ± 36)
Parking brake switch: ON
Exhaust brake Exhaust brake switch: ON 0.59 ± 0.10 0.59 ± 0.10
actuation pressure (86 ± 15) (86 ± 15)
Foot brake braking
1,510 1,510
performance
Brakes
20-6 1 HM400-1L
TESTING AND ADJUSTING STANDARD VALUE TABLE
Dump body
HM400-1L 20-7 1
TESTING AND ADJUSTING STANDARD VALUE TABLE
20-8 1 HM400-1L
TESTING AND ADJUSTING STANDARD VALUE TABLE
pressure sensor (male) voltage Between (1) and (3) 4.6 – 5.4 V
Between (2) and (3) 0.3 – 4.7 V ON.
HM400-1L 20-9 1
TESTING AND ADJUSTING STANDARD VALUE TABLE
it is normal OFF.
Measure
No. 5 injector solenoid CN5 (male) Between (1) and (2) 0.4 – 1.1 Ω 2) Disconnect CN5.
resistance
Between (1)(2) and ground Min. 1MΩ
20-10 1 HM400-1L
TESTING AND ADJUSTING STANDARD VALUE TABLE
HM400-1L 20-11 1
TESTING AND ADJUSTING STANDARD VALUE TABLE
it is normal OFF.
Resistance 2) Disconnect 3-SW.
3rd clutch ECMV fill 3-SW Measure Pin Clutch value
switch (male) resistance When
Between (1) disengaged Min. 1 MΩ
and ground
When engaged Max. 1 Ω
20-12 1 HM400-1L
TESTING AND ADJUSTING STANDARD VALUE TABLE
it is normal
Steering oil Resistance 2) Disconnect T04.
Steering oil Measure Pin temperature value
T04 (male)
temperature switch resistance Max. 1 Ω
Between (1) 25 ºC (77ºF)
and ground 100 ºC (212ºF) Min. 1 MΩ
HM400-1L 20-13 1
TESTING AND ADJUSTING STANDARD VALUE TABLE
20-14 1 HM400-1L
TESTING AND ADJUSTING STANDARD VALUE TABLE
Released Min. 1 MΩ
Between (5) position
and (6) Applied
position Max. 1 Ω
HM400-1L 20-15 1
TESTING AND ADJUSTING STANDARD VALUE TABLE
20-16 1 HM400-1L
TESTING AND ADJUSTING STANDARD VALUE TABLE
HM400-1L 20-17 1
TESTING AND ADJUSTING STANDARD VALUE TABLE
20-18 1 HM400-1L
TESTING AND ADJUSTING STANDARD VALUE TABLE
HM400-1L 20-19 1
TESTING AND ADJUSTING STANDARD VALUE TABLE
20-20 1 HM400-1L
TESTING AND ADJUSTING STANDARD VALUE TABLE
HIGH
WASH
WASH
HM400-1L 20-21 1
TESTING AND ADJUSTING TOOLS FOR TESTING AND ADJUSTING
12
TOOLS FOR TESTING AND ADJUSTING
-101 - -199.9kPa
Air supply pressure A 799-201-2202 Boost gauge kit
{-760 - 1,500mmHg}
Exhaust, coolant, and oil Digital temperature
B 799-101-1502 –99.9 – 1,299ºC
temperatures gauge
1 799-201-9000 Handy Smoke Checker Discoloration 0 - 70%
(with standard color)
Exhaust color C Commercially
2 Smoke meter (Discoloration % x 1/10 = Bosch
available index)
Commercially
Valve clearance D Feeler gauge Intake: 0.35 mm; exhaust: 0.57 mm
available
Blow-by pressure E 799-201-1504 Blow-by checker 0 – 4,9MPa {0 – 500 mmH2O}
20-22 1 HM400-1L
TESTING AND ADJUSTING TOOLS FOR TESTING AND ADJUSTING
Commercially
Stroke, hydraulic drift J Scale
available
Commercially
Work equipment speed K Stop watch
available
Voltage, resistance L 79A-264-0211 Tester
790-601-8000 T-adapter kit
790-601-9000 T-adapter kit For HD30, DT connector
Wiring harnesses, sensors M
799-601-9420 Adapter For engine oil pressure sensor
799-601-9430 Socket For fuel supply pump PCV
HM400-1L 20-23 1
TESTING AND ADJUSTING ENGINE COMPONENTS
ENGINE COMPONENTS
Remark
To tune, test and troubleshoot the following procedures you must refer to ENGINE SHOP MANUAL for tools and
proper procedures.
20-24 1 HM400-1L
TESTING AND ADJUSTING ENGINE COMPONENTS
12
ADJUSTING ENGINE SPEED SENSOR
★ The G and Ne speed sensor for the engine controller cannot be adjusted.
★ Adjust the engine speed sensor (EREV) for the transmission controller as follows.
2. Install sensor (1) until it contacts the tip of the toothed flywheel
ring gear (2).
• Be careful not to let the tip of the sensor be scratched or to let
any iron particles stick to the sensor tip.
3. When sensor (1) contacts gear (2), turn it back 1/2 - 2/3 turn. Adjust
clearance a between the tip of the sensor and the tip of the gear
tooth to 0.75 - 1.00 mm. (0.03 - 0.04 in)
HM400-1L 20-25 1
TESTING AND ADJUSTING ENGINE COMPONENTS
Checking Tension
• Measure the deflection when the belt is pressed with a finger at a point (marked by the arrow) at the center of the belt
between the fan pulley and crankshaft pulley.
• Check each belt individually.
• Pushing force: 98 N (22 lbs)
• Deflection: 13 - 15 mm (1 - 1.2) new part
• 17 - 19 mm (2 - 2.1) when adjusting tension
Adjusting Belt
2. Move tension pulley (3) with adjustment bolt (2) and adjust the tension of the belts.
20-26 1 HM400-1L
TESTING AND ADJUSTING ENGINE COMPONENTS
Checking Tension
• Measure the deflection when the belt is pressed with a finger at a point (marked by the arrow) midway between the
alternator pulley and drive pulley.
• Pushing force: 98 N (22 lbs)
• Deflection: 13 - 16 mm (1 - 1.2 in)
Adjusting Belt
2. Loosen locknut (3), move alternator (1) with adjustment nut (4), and adjust the tension of the belt.
HM400-1L 20-27 1
TESTING AND ADJUSTING ENGINE COMPONENTS
12
ADJUSTING REFRIGERANT COMPRESSOR BELT
Checking Tension
• Measure the deflection when the belt is pressed with a finger at a point (marked by the arrow) midway between the
compressor pulley and crankshaft pulley.
• Pushing force: 58.8 Nm (13 lbs)
• Deflection: 10 mm (0.4 in)
Adjusting Belt
1. Loosen 3 mounting bolts of compressor assembly (1) and adjustment rod (2).
2. Loosen locknut (3), move compressor assembly (1) with adjustment nut (4), and adjust the tension of the belt.
4. Tighten 3 mounting bolts of compressor assembly (1) and adjustment rod (3).
20-28 1 HM400-1L
TESTING AND ADJUSTING TESTING TORQUE CONVERTER STALL SPEED
12
TESTING TORQUE CONVERTER STALL SPEED
WARNING! Stop the machine on flat level ground, turn the parking brake switch ON, and block the
tires.
2. Start the engine and raise the temperature of the hydraulic oil and transmission oil.
• Transmission oil temperature: 60 - 80oC (140 - 176oF)
• Hydraulic oil temperature: 45 - 55oC (113 - 131oF)
3. Turn the parking brake switch ON, depress the parking brake pedal, then set the gearshift lever to the D position.
• If the gearshift lever is moved to any position other than the D position, the machine may move off even if the brake
is depressed, always measure in the D position.
4. Depress the accelerator pedal gradually, run the engine at high idling and stall the torque converter to raise the torque
converter oil temperature.
Remark
There is danger of damage to the internal parts of the transmission, so never operate the gearshift lever to any
position other than the D position during the stall operation.
5. When the torque converter oil temperature goes above 90oC (194oF), return the engine immediately to a low idle and
move the gearshift lever to the N position.
Remark
Never operate the gearshift lever with the accelerator pedal depressed. This will cause a sudden shock which may
lead to a reduction in the service life of the machine.
6. Run the engine at a mid-range speed, and when the torque converter oil temperature goes down to approximately 80oC
(176oF), run at low idling. (Keep the gearshift lever at the N position).
7. Repeat Steps 3 - 6 and equalize the oil temperature in the torque converter and transmission.
8. At the same time as repeating Steps 3 and 4, measure the stall speed when the torque converter oil temperature is 80oC
(176oF). Measure the stall speed 2 or 3 times.
• The stall speed may vary according to the following conditions, so always measure the stall speed at the time of delivery.
• Variations according to the engine serial number
• Variations in engine output due to atmospheric pressure and temperature
• Variations due to consumption torque of accessories
• Variations due to features of the torque converter
• Variations according to the method of measuring the stall
HM400-1L 20-29 1
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURES
12
MEASURING POWER TRAIN OIL PRESSURES
WARNING!
• Stop the machine on flat level ground, turn the parking brake switch ON, and block the tires.
• Wait for the oil temperature to go down fully before removing or installing the measuring tools.
• If measuring the oil pressure while traveling, make sure that there is a wide travel area and check
the safety conditions of the surrounding area.
• When tilting the cab up or down, See TILTING THE CAP UP for details
20-30 1 HM400-1L
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURES
2. Remove oil pressure test plug (1), then install nipple and hose (1).
Pull the hose out to the rear of the transmission.
5. Start the engine and raise the temperature of the torque converter oil
to the operating range.
6. Keep the gearshift lever at the N position and measure the oil
pressure at low idling and high idling.
7. After completing the test, remove the test equipment and restore to original condition.
3. Start the engine and raise the temperature of the torque converter oil
to the operating range.
4. Keep the gearshift lever at the N position and measure the oil
pressure at high idle.
5. After completing the test, remove the test equipment and restore to
original condition.
2. Remove oil pressure test plug (3), then install nipple and hose (1).
Pull the hose out to the rear of the transmission.
5. Start the engine and raise the temperature of the torque converter oil
to the operating range.
6. Keep the gearshift lever at the N position and measure the oil
pressure at high idling.
7. After completing the measurement, remove the measuring equipment and set to the original condition.
HM400-1L 20-31 1
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURES
12
MEASURING TORQUE CONVERTER “LOCK-UP” CLUTCH PRESSURE
Table Of Gearshift Lever Positions, Speed Ranges, And Clutches Actuated
Speed range
Gearshift lever Clutches
★ The mark indicates the speed ranges that are actuated for each position of the gearshift lever.
★ The mark and mark indicate the clutches that are actuated for each travel speed.
★ The mark indicates the speed range when measuring the oil pressure for each clutch.
2. Remove oil pressure test plug (4), then install nipple and hose (1)
and connect oil pressure gauge.
3. Start the engine and raise the temperature of the torque converter oil
to the operating range.
4. Turn the parking brake switch OFF, depress the parking brake
pedal, then set the gearshift lever to position 1.
5. Release the brake, travel at a high idle speed, and measure the oil
pressure when the lock-up pilot lamp lights up.
• In F1, a maximum travel speed of approximately 7 km/h
(5mph) is reached.
6. After completing the tests, remove the test equipment and return machine to the original condition.
20-32 1 HM400-1L
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURES
2. Remove oil pressure test plug (5), then install nipple and hose (1)
and connect oil pressure gauge.
3. Start the engine and raise the temperature of the torque converter oil
to the operating range.
4. Turn the parking brake switch OFF, depress the parking brake
pedal, then set the gearshift lever to position 1.
5. Release the brake and measure the oil pressure when traveling at
high idle.
• In F1, a maximum travel speed of approximately 7 km/h (5
m.p.h.).
6. After completing the tests, remove the test equipment and return machine to the original condition.
2. Remove oil pressure test plug (6), then install nipple and hose (1)
and connect oil pressure gauge.
3. Start the engine and raise the temperature of the torque converter oil
to the operating range.
4. Turn the parking brake switch OFF, depress the parking brake
pedal, then set the gearshift lever to position 2.
5. Release the brake, travel at high idling, and measure the oil
pressure when the shift indicator shows “2”.
• In F2, a maximum travel speed of approximately 11 km/h (7
mph).
6. After completing the measurement, remove the measuring equipment and set to the original condition.
2. Remove oil pressure test plug (7), then install nipple and hose (1)
and connect oil pressure gauge.
3. Start the engine and raise the temperature of the torque converter oil
to the operating range.
4. Turn the parking brake switch OFF, depress the parking brake
pedal, then set the gearshift lever to position 1.
5. Release the brake and measure the oil pressure when traveling at
high idle.
HM400-1L 20-33 1
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURES
• In F1, a maximum travel speed of approximately 7 km/h (7 mph).
6. After completing the test, remove the testing equipment and return machine to the original condition.
2. Remove oil pressure test plug (8), then install nipple and hose (1)
and connect oil pressure gauge.
3. Start the engine and raise the temperature of the torque converter oil
to the operating range.
4. Turn the parking brake switch OFF, depress the parking brake
pedal, then set the gearshift lever to position 3.
5. Release the brake, travel at high idle, and measure the oil pressure
when the shift indicator shows “3”.
• In F3, a maximum travel speed of approximately 16 km/h (10
mph).
6. After completing the test, remove the testing equipment and return machine to the original condition.
2. Remove oil pressure test plug (10), then install nipple and hose (1)
and connect oil pressure gauge.
3. Start the engine and raise the temperature of the torque converter oil
to the operating range.
4. Turn the parking brake switch OFF, depress the parking brake
pedal, then set the gearshift lever to position 5.
5. Release the brake, travel at high idle, and measure the oil pressure
when the shift indicator shows “5”.
• In F5, a maximum travel speed of approximately 38 km/h (24
mph).
6. After completing the test, remove the testing equipment and return machine to the original condition.
20-34 1 HM400-1L
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURES
2. Remove oil pressure test plug (7), then install nipple and hose (1)
and connect oil pressure gauge.
3. Start the engine and raise the temperature of the torque converter oil
to the operating range.
4. Turn the parking brake switch OFF, depress the parking brake
pedal, then set the gearshift lever to position R1.
5. Release the brake and measure the oil pressure when traveling at
high idle.
• In R1, a maximum travel speed of approximately 7 km/h (4
mph).
6. After completing the test, remove the testing equipment and return machine to the original condition.
2. Remove oil pressure test plug (11), then install nipple and hose (1)
and connect oil pressure gauge.
3. Start the engine and raise the temperature of the torque converter oil
to the operating range.
4. Keep the gearshift lever in the N position and move the inter-axle
differential lock switch to the MANUAL position.
6. After completing the test, remove the testing equipment and return
machine to the original condition.
HM400-1L 20-35 1
TESTING AND ADJUSTING “L” AND “R” DIFFERENTIAL LOCK PRESSURE
12
“L” AND “R” DIFFERENTIAL LOCK PRESSURE
(Machine With Differential Lock)
WARNING!
• Stop the machine on flat level ground, turn the parking brake switch ON, and block the tires.
• Wait for the oil temperature to go down fully before removing or installing the measuring tools.
5. Run the engine and push in manual operation button (2) of the
differential lock solenoid valve and measure the oil pressure at high
idle.
• This type of testing requires two persons. One person shall
push in the manual operation button on the solenoid valve and
the other person shall operate the accelerator pedal and
measure the oil pressure in the operator's seat.
• The differential lock oil pressure is actuated while the manual
operation button is pushed IN, if the machine is stopped.
6. After completing the test, remove the testing equipment and return
machine to the original condition.
20-36 1 HM400-1L
TESTING AND ADJUSTING “L” AND “R” DIFFERENTIAL LOCK PRESSURE
12
TESTING CENTER AXLE DIFFERENTIAL LOCK OIL PRESSURE
1. Raise the dump body to it’s full height.
5. When lowering the dump body, be careful not to let test hose
interfere with the bed.
6. Run the engine and push in manual operation button (2) of the
differential lock solenoid valve and measure the oil pressure at high
idle.
• This type of testing requires two persons. One person shall
push in the manual operation button on the solenoid valve and
the other person shall operate the accelerator pedal and
measure the oil pressure in the operator's seat.
• The differential lock oil pressure is actuated while the manual operation button is pushed IN, if the machine is
stopped
7. After completing the test, remove the testing equipment and return the machine to the original condition.
HM400-1L 20-37 1
TESTING AND ADJUSTING “L” AND “R” DIFFERENTIAL LOCK PRESSURE
3. Install nipple and hose [1].
5. When lowering the dump body, be careful not to let test hose
interfere with the bed.
6. Run the engine and push in manual operation button (2) of the
differential lock solenoid valve and measure the oil pressure at high
idle.
• This type of testing requires two persons. One person shall
push in the manual operation button on the solenoid valve and
the other person shall operate the accelerator pedal and
measure the oil pressure in the operator's seat.
• The differential lock oil pressure is actuated while the manual
operation button is pushed IN, if the machine is stopped
20-38 1 HM400-1L
TESTING AND ADJUSTING “L” AND “R” DIFFERENTIAL LOCK PRESSURE
7. After completing the adjustment, repeat the procedure for measurement to check the oil pressure again.
HM400-1L 20-39 1
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
12
ADJUSTING TRANSMISSION SPEED SENSOR
★ There are 4 speed sensors installed to the transmission. Adjust each sensor as follows.
• N1: Input shaft speed sensor
• N2: Intermediate shaft speed sensor
• N3: Output shaft R speed sensor
• FE1: Output shaft F speed sensor
• For the input shaft speed sensor, tilt the cab up before carrying out adjustment.
• For the intermediate shaft speed sensor and output F shaft speed sensor, remove the transmission and front differential
assembly before carrying out adjustment.
20-40 1 HM400-1L
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
1. Screw in until the tip of sensor (1) contacts the face or tip of the
tooth of gear (2). Before installing, check that the tip of the sensor
is not scratched and that there are no iron particles sticking to the
sensor tip.
2. Turn back sensor (3) 1/2 - 1 turn from this position. Adjust
clearance a between the tip of the sensor and the tip of the gear
tooth to approximately 1.5 mm (0.06 in)
HM400-1L 20-41 1
TESTING AND ADJUSTING TESTING AND ADJUSTING BRAKE OIL PRESSURE
WARNING! Stop the machine on flat level ground, turn the parking brake switch ON, and block the
tires.
D. Measure the oil pressure when the pressure goes up after the
cut in and the indicator of pressure gauge stops.
20-42 1 HM400-1L
TESTING AND ADJUSTING TESTING AND ADJUSTING BRAKE OIL PRESSURE
2. Install brake test kit G and bleed the air from the brake circuit.
• For details, (See BLEEDING AIR FROM BRAKE CIRCUIT).
A. Run the engine for several minutes at low idling to charge the
accumulator, then stop the engine.
B. Depress the brake pedal fully and measure the oil pressure.
A. Run the engine for several minutes at low idling to charge the accumulator, then stop the engine.
C. Pull the retarder lever fully back and measure the oil pressure.
5. Measure the drop in the pressure of the foot brake under the following conditions.
A. Check that the foot brake actuation pressure and the retarder actuation pressure are correct before starting.
B. Run the engine for several minutes at low idling to charge the accumulator, then stop the engine.
C. Depress the brake pedal fully and measure the oil pressure.
E. Measure the oil pressure after 5 minutes and calculate the drop in pressure.
6. After completing the measurement, remove the measuring equipment and set to the original condition.
• Bleed the air from the brake circuit.
• For details, See BLEEDING AIR FROM BRAKE CIRCUIT.
HM400-1L 20-43 1
TESTING AND ADJUSTING TESTING AND ADJUSTING BRAKE OIL PRESSURE
2. Install nipple [1] and hose [2], and connect oil pressure gauge.
• Use a 39.2 MPa {400 kg/cm2} (5,690 PSI) pressure gauge.
3. Start the engine and operate the parking brake switch several times
at high idling to bleed the air from the circuit.
3. Install adapter [1] and nipple and hose [2], and connect oil pressure
gauge.
• Use a 5.9 MPa {60 kg/cm2} (854 psi) oil pressure gauge.
20-44 1 HM400-1L
TESTING AND ADJUSTING TESTING AND ADJUSTING BRAKE OIL PRESSURE
4. Start the engine and set the exhaust brake switch to position (a).
6. Drive the machine forward and measure the oil pressure when the
exhaust brake pilot lamp lights up.
• If the accelerator pedal is released while the machine is
traveling with exhaust brake switch at position (a) and the
torque converter in the lock-up condition, the exhaust brake is
actuated.
8. Check to be sure the parking brake switch is ON before carrying out the operation.
6. After completing the adjustment, repeat the procedure for measurement to check the oil pressure again.
HM400-1L 20-45 1
TESTING AND ADJUSTING TESTING BRAKE PERFORMANCE
12
TESTING BRAKE PERFORMANCE
WARNING! Stop the machine on flat level ground and turn the parking brake switch ON.
2. Fully depress the brake pedal, then set the gearshift lever to the D
position.
• Testing the performance of the foot brake must be carried out
with the gearshift lever at the D position. Do not place the
gearshift lever at any other position.
4. After completing the inspection, run the engine at low idle and set the gearshift lever to the N position.
1. Start the engine and turn the parking brake switch OFF.
2. Pull the retarder lever fully back, then set the gearshift lever to the
D position.
• Testing of the performance of the retarder brake must be
carried out with the gearshift lever at the D position. Do not
place the gearshift lever at any other position.
4. After completing the inspection, run the engine at low idle and set the gearshift lever to the N position.
20-46 1 HM400-1L
TESTING AND ADJUSTING TESTING BRAKE PERFORMANCE
WARNING! If the machine moves, it can cause serious injury or death. If the machine starts moving
during performance test, lower the engine speed immediately and set the gearshift lever
to the N position and depress the foot brake pedal.
4. If the machine moves while the torque converter speed is below the specified speed, adjust the brake pad clearance,
referring to TESTING WEAR OF PARKING BRAKE PAD. Adjusting pad clearance.
5. After completing the inspection, run the engine at low idle and set the gearshift lever to the N position.
1. Start the engine and turn the parking brake switch OFF.
3. Depress the accelerator pedal gradually and check that the machine
does not move when the torque converter is stalled at the specified
speed.
HM400-1L 20-47 1
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE CIRCUIT
12
BLEEDING AIR FROM BRAKE CIRCUIT
★ If the equipment in the brake circuit has been removed and installed again, bleed the air from the brake circuit as follows.
★ When bleeding the air from the wheel brake circuit, always bleed the air from the slack adjuster first, then bleed the air
from the wheel brake.
B. Loosen air bleeder (1) approximately 1/2 turn, then drain the
air mixed with the oil.
C. When no more air comes out with the oil, tighten air bleeder
(1).
B. Loosen air bleeder (1) approximately 1/2 turn, then drain oil
mixed with oil.
C. When no more air comes out with the oil, tighten air bleeder
(1).
5. Bleed air from the overrun protection brake circuit in the following
procedure (E-SPEC).
B. Loosen air bleeder approximately 1/2 turn, then drain the air
mixed with the oil.
C. When no more air comes out with the oil, tighten air bleeder (1).
20-48 1 HM400-1L
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE CIRCUIT
6. After bleeding air, be sure to move the screwdriver inserted in hole (a) to the upper end and remove it.
B. Loosen air bleeder (1) approximately 1/2 turn, then drain the
air mixed with the oil.
4. When no more air comes out with the oil, tighten air bleeder (1).
2. Use the parking brake switch to actuate and cancel the circuit several times.
• This operation automatically bleeds the air.
HM400-1L 20-49 1
TESTING AND ADJUSTING CHECKING WEAR LIMIT ON WHEEL BRAKE DISC
12
CHECKING WEAR LIMIT ON WHEEL BRAKE DISC
WARNING! Stop the machine on flat level ground, turn the parking brake switch ON, and block the
tires.
★ Carry out the inspection when the brake oil temperature is less than 60oC (140oF).
★ When the disk comes close to the wear limit, carry out the inspection more frequently. Be sure to carry out inspection of
the retarder braking performance at the same time.
1. Check to be sure the brakes other than parking brake are not being actuated.
2. Turn the ignition switch ON and check to be sure the retarder oil pressure caution lamp is not lighted up.
• If the lamp is lighted, the oil pressure in the brake circuit has dropped, start the engine and run it at approximately
2000 rpm. When the lamp goes out, stop the engine.
5. Push in the rod (2) of the gauge until it contacts the piston and
judge the amount of wear.
• There are three lines (A, B, C) on the rod. For the HM400-1L,
use line A.
• With a new machine, adjust so that initial mark a on the rod (2)
is aligned with the end face of guide (3).
• The adjustment position will move out of alignment, so do not
loosen the locknut on guide (3) except when replacing the disc.
• Limit mark b indicates the wear limit for the disc. If limit mark
b reaches the end face of guide (3), the disc has reached the
wear limit.
20-50 1 HM400-1L
TESTING AND ADJUSTING CHECKING WEAR LIMIT ON WHEEL BRAKE DISC
12
CHECKING BRAKE PAD
WARNING! Stop the machine on flat level ground, turn the parking brake switch ON, and block the
tires. Before carrying out the inspection, start the engine and raise the dump body fully.
Then insert the lock pin and stop the engine
3. Remove left and right brackets (2), then remove 2 each of spring (3)
and (4).
6. If either the front or rear pad has reached the thickness limit,
replace both pads at the same time.
HM400-1L 20-51 1
TESTING AND ADJUSTING CHECKING WEAR LIMIT ON WHEEL BRAKE DISC
2. Install 2 each of springs (4) and (3) to left and right brackets (2), then install left and right brackets (2).
3. There are two types of springs, so check the color, and be careful not to mistake the mounting position.
• Spring (4): Yellow
• Spring (3): Black
5. Turn adjustment nut (1) clockwise until pad (5) is brought into tight contact with disc (6).
6. Measure clearances b and c between pad (5) and disc (6) and turn
adjustment nut (1) counterclockwise to loosen it until the clearance
is the specified amount.
• Standard clearance (total of b and c): 1.5 mm (0.06 in)
9. Release the parking brake and check the clearance of the pad again.
• Clearance (total of b and c): 1.5 mm (0.06 in)
• If the clearance is not correct, carry out the adjustment again
from Step 3).
10. Tighten the mounting bolts of left and right brackets (2).
• Be careful not to let the mounting position move out of
alignment.
11. Check the clearance between pad (5) and disc (6) again.
• Target clearance (b + c on one side): Min. 0.5 mm (0.02 in)
• If the clearance on one side is narrow, move the mounting position of the left and right brackets to adjust.
20-52 1 HM400-1L
TESTING AND ADJUSTING RELEASING EMERGENCY PARKING BRAKE
12
RELEASING EMERGENCY PARKING BRAKE
★ If any problem occurs in the electrical system or hydraulic system of the parking brake and the parking brake is not
releasing, it is possible to release the brake temporarily as follows.
★ If any problem occurs in the hydraulic system, there is a strong possibility that the wheel brake will not work properly,
after releasing the parking brake, always tow the machine at low speed to a safe place.
★ When carrying out the operation to release the parking brake, stop the machine on flat level ground and check the
surrounding area before starting the operation. If the parking brake must be released on a slope in an emergency or other
unavoidable situation, put blocks securely under the tires.
HM400-1L 20-53 1
TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE
12
STEERING CIRCUIT PRESSURE
WARNING! Stop the machine on flat level ground, turn the parking brake switch ON, and block the
tires
3. Start engine and operate the steering to one side (either left or
right).
4. Measure the oil pressure when the steering is relieved with the
engine at high idle.
5. After completing the test, remove the testing equipment and return
machine to the original condition.
20-54 1 HM400-1L
TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE
12
ADJUSTING STEERING RELIEF OIL PRESSURE
• If the steering relief oil pressure is not correct, adjust relief valve
(2) on the flow amp valve as follows.
HM400-1L 20-55 1
TESTING AND ADJUSTING TESTING AND ADJUSTING SUSPENSION CYLINDER
12
TESTING AND ADJUSTING SUSPENSION CYLINDER
WARNING! Stop the machine on flat ground, turn the parking brake switch ON, and block the tires.
3. Loosen oil level valve (2) slowly, and when the nitrogen gas starts
to come out, hold the valve in that position.
• If oil spurts out from the valve together with the nitrogen gas,
tighten the valve slightly until no more oil comes outs and take time to release the nitrogen gas slowly.
4. Operate the hydraulic jack to lower the frame slowly until the suspension cylinder is retracted to the specified oil volume
length.
• Use the hydraulic jack carefully to prevent the suspension cylinder from being retracted too far and suffering damage.
• Specified front oil volume length: 68 ± 3 mm (3.0 ± 0.1 in)
• Specified rear oil volume length: 81 ± 3 mm (3.2 ± 0.1 in)
20-56 1 HM400-1L
TESTING AND ADJUSTING TESTING AND ADJUSTING SUSPENSION CYLINDER
12
ADJUSTING OIL LEVEL
• Adjust the oil level after completing the release of the nitrogen gas.
4. Remove the valve body from air supply valve (3), then install joint
H6.
5. Install fitting H5 to joint H4, then connect hose H3 and pump H2.
6. Operate pump H2 to release the gas from the mounting port of oil
level valve (2).
7. Pump the oil out from the mounting port until no more bubbles
come out with the oil, then fill with oil.
• Front cylinder oil charge amount (reference): 6.0
• Rear cylinder oil charge amount (reference): 6.0 l
9. Remove suspension tools H2 - H5, then remove air supply valve (3).
HM400-1L 20-57 1
TESTING AND ADJUSTING TESTING AND ADJUSTING SUSPENSION CYLINDER
12
CHARGING WITH NITROGEN GAS
• Charge with nitrogen gas after completing the adjustment of the oil
level.
3. Open the valve of nitrogen gas cylinder (1) and check the pressure
(internal pressure of the cylinder) indicated by gauge H12.
• The indicated pressure must not be higher than the internal
pressure of the cylinder 0.98 MPa (142 psi).
• Internal pressure of cylinder (both front and rear): 4.03 MPa
(624 psi).
4. Turn the handle of regulator H11 gradually to the left and set the
indicated pressure of gauge H13.
• Never charge the cylinder with nitrogen gas at a pressure of
more than 3.9 MPa (566 psi) and extend the cylinder fully.
5. Operate the handle of joint H10 and valve H7 and the suspension
cylinder with nitrogen gas.
• Pump nitrogen gas into the left and right cylinders at the same time.
6. When the length of the left and right cylinders reaches the specified installation length, turn the handle of regulator H11 to
the left to stop charging with nitrogen gas.
• Installed length a of front cylinder: 168 ± 10 mm (6.6 ± 0.4 in)
• Installed length b of front cylinder: 111 ± 5 mm (4.4 ± 0.4 in)
7. Return the handle of joint H10 fully, loosen the air bleed plug of valve H7, and discharge the gas inside the hose.
20-58 1 HM400-1L
TESTING AND ADJUSTING TESTING AND ADJUSTING SUSPENSION CYLINDER
12
ADJUSTING CYLINDER LENGTH
• Adjust the cylinder length after completion of charging with
nitrogen gas.
• When adjusting the cylinder length, stop the machine on a
horizontal surface with the dump body unloaded.
3. If the installed length is too long, adjust by discharging nitrogen gas from oil level valve (2).
• Loosen the oil level valve slightly and discharge a small amount of gas (not enough to make the cylinder move).
• If too much gas is discharged and the cylinder moves, the installed length may become shorter than the specified
installed length.
4. After completing the adjustment, repeat Steps 1) - 2) above and check the cylinder length again.
5. Check for any leakage of gas from oil level valve (2), air supply valve (3), and the cylinder gland.
• Use soapy water to check for leakage of gas.
Checking After Changing Oil Or Gas
1. If the machine is operated after changing the oil and gas, the gas will dissolve in the oil and saturate the oil inside the
cylinder. If this happens, the volume of the gas will decrease and the length of the cylinder will go below the permissible
value.
2. For this reason, check the installed length of the cylinder again 48 hours after changing the oil and the gas, and adjust the
gas if it is below the specified dimension.
Checking Cylinder Length According To Change In Ambient Temperature
1. The gas in the suspension will expand or contract according to the change in the ambient temperature when the machine is
working, so the length of the cylinder will change.
2. For this reason, in areas where there is a big difference in temperature during the year, carry out daily inspection and
adjust so that the installed length of the cylinder is within the specified range.
HM400-1L 20-59 1
TESTING AND ADJUSTING TILTING THE CAB UP
12
TILTING THE CAB UP
★ When carrying out inspection and maintenance work around the hydraulic pump or at the top of the torque converter or
transmission, tilt the cab up to the rear of the machine as follows.
★ There are the following two methods of tilting the cab up, so select the method to match the operating conditions.
★ Method using built-in tilt-up cylinder
★ Method using external crane
★ When carrying out the operation with the built-in tilt-up cylinder, an external pump is needed, so prepare a pump.
PREPARATORY WORK
• To prevent interference between the cab and dump body, set the
steering facing directly to the front.
• Turn the parking brake switch ON and block the tires.
3. Remove 4 mounting bolts (2) each from the left and right mounts at
the front of the cab.
TILTING CAB UP
★ Using built-in cylinder
1. Move pin (1) of the rear mount of the cab from hole (2) to hole (4).
20-60 1 HM400-1L
TESTING AND ADJUSTING TILTING THE CAB UP
12
USING EXTERNAL CRANE
1. Install the lifting tool [1] to the top of the cab.
HM400-1L 20-61 1
TESTING AND ADJUSTING TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE
12
TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE
WARNING! Stop the machine on flat ground, turn the parking brake switch ON, and block the tires.
4. Start the engine and operate the dump body fully to LOWER and
RAISE.
5. Run at high idling, operate the dump lever, and measure the oil
pressure when there is RAISE relief or LOWER relief.
3. After completing the adjustment, check the oil pressure again according to the procedure for measurement.
20-62 1 HM400-1L
TESTING AND ADJUSTING TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE
3. Install a nipple and hose [1] and connect oil pressure gauge.
• Use a 5.9 MPa (856 psi) oil pressure gauge.
4. Run the engine at high idling and measure the oil pressure.
(Set the dump lever in neutral.)
1. Remove the cap and loosen locknut (2) and rotate adjustment screw
(3).
4. After completing the adjustment, check the oil pressure again according to the procedure for measurement.
HM400-1L 20-63 1
TESTING AND ADJUSTING ADJUSTING BODY POSITIONER SENSOR
12
ADJUSTING BODY POSITIONER SENSOR
★ If the body positioner rod has been disconnected and connected again or the body positioner sensor has been removed and
installed again, inspect and adjust the body positioner sensor as follows.
3. Operate the dump lever and check the monitoring voltage when the dump lever is operated fully to the LOWER position
and RAISE position.
• When operated fully to LOWER: 0.38 - 0.44 V
• When operated fully to RAISE: 4.00 - 4.70 V
8. Repeat the checking procedure above to check that the input voltage is within the normal range.
20-64 1 HM400-1L
TESTING AND ADJUSTING ADJUSTING BODY POSITIONER SENSOR
12
CALIBRATING SYSTEM
1. Start the engine and raise the hydraulic oil temperature to 80 - 90 °C.
2. Lower the dump body fully and continue the LOWER relief at this position for at least 5 seconds.
3. Check that the dump body pilot lamp is not lighted up.
4. Run the engine at low idling and operate the dump body to the RAISE and FLOAT positions 10 times.
5. Operate to the end of the stroke for both the RAISE and FLOAT operations.
6. Run the engine at high idling and operate the dump body to RAISE and LOWER 10 times.
7. Operate to the end of the stroke for both the RAISE and LOWER operations.
HM400-1L 20-65 1
TESTING AND ADJUSTING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT
12
ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT
★ The engine controller uses a high-voltage circuit (110 - 130 V) for the fuel injector drive. For this reason, the high-voltage
circuit is connected to the wiring harness and connectors from the engine controller to the fuel injector. Normally, high
voltage is output from the engine controller to the fuel injector only when the engine is running. When the engine stops,
the output also stops. If you touch the high-voltage circuit directly, there is danger of electrocution, so when carrying out
inspection, always obey the following precautions.
2. Never start the engine if a T-adapter has been inserted or connected to the connector.
3. Operate the ignition switch only to the OFF or ON positions. Never turn it to the START position.
20-66 1 HM400-1L
TESTING AND ADJUSTING ADJUSTING TRANSMISSION CONTROLLER
12
ADJUSTING TRANSMISSION CONTROLLER
2. Align the SW1 rotary switch and SW2 rotary switch with the set
position.
ADJUSTING TRANSMISSION
• After carrying out any of the following operations, adjust the transmission in order to adjust the fitting between the
transmission and the transmission controller.
D. When the power train speed sensor has been repaired or replaced
E. When the transmission oil temperature sensor has been repaired or replaced
F. When the transmission oil filter has become clogged and has been cleaned
G. When adjusting the transmission, use the service function of the machine monitor.
• For details of the method of operation, see SPECIAL FUNCTIONS OF MACHINE MONITOR.
HM400-1L 20-67 1
TESTING AND ADJUSTING ESCAPE METHOD FOR ELECTRICAL SYSTEM
12
ESCAPE METHOD FOR ELECTRICAL SYSTEM
If any problem occurs in the electrical system on the engine or transmission control system, it may become impossible to start
the engine or to move the machine to a safe place, then carry out troubleshooting.
★ When problem occurs in engine control system and engine cannot be started
• Decide the escape method according to the following flowchart.
• For details of the method of checking the service code, see SPECIAL FUNCTIONS OF MACHINE MONITOR.
20-68 1 HM400-1L
TESTING AND ADJUSTING ESCAPE METHOD FOR ELECTRICAL SYSTEM
★ When problem occurs in transmission control system and machine cannot be started
• Check the service code and determine the escape method from the following chart.
• For details of the method of checking the service code, see SPECIAL FUNCTIONS OF MACHINE MONITOR.
Condition when Lever position for speed range to move
Service code Escape method Remarks
failure occurred off after escape operation
1380MW Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1 Occurrence condition 1:
1500L0 Occurrence condition 2 Escape procedure 2 - Speed range remains fixed;
when the machine is moved
15G0MW Occurrence condition 2 Escape procedure 3 D - 1: F2 off again, speed range does
15H0MW Occurrence condition 3 Escape procedure 1 D - 1: F1, R1 - R2: R1 not shift
15J0MW Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R1 ´ When lever is returned to N,
transmission shifts to
15K0MW Occurrence condition 2 Escape procedure 3 D - 1: F3, R1 - R2: R1 neutral
15L0MW Occurrence condition 2 Escape procedure 3 D - 1: F2, R1 - R2: R1 Occurrence condition 2:
15M0MW Occurrence condition 2 Escape procedure 3 D - 1: F2, R1 - R2: R1 Transmission suddenly shifts
to neutral when the machine
15SBL1 Occurrence condition 3 Escape procedure 1 R1 - R2: R1 is traveling; after machine is
15SBMA Occurrence condition 3 Escape procedure 1 D - 1: F2 stopped, transmission stays in
15SCL1 Occurrence condition 3 Escape procedure 1 D - 1: F2 neutral even when lever is
operated, and machine does
15SCMA Occurrence condition 3 Escape procedure 1 D - 1: F1, R1 - R2: R1 not move off
15SDL1 Occurrence condition 3 Escape procedure 1 D - 1: F1 Occurrence condition 3:
15SDMA Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R1 Transmission suddenly shifts
to neutral
15SEL1 Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R1 Occurrence condition 4:
15SEMA Occurrence condition 3 Escape procedure 1 D - 1: F3, R1 - R2: R2 After engine is started,
15SFL1 Occurrence condition 3 Escape procedure 1 D - 1: F3, R1 - R2: R2 transmission stays in neutral
even when lever is operated,
15SFMA Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R1 and machine does not move
15SGL1 Occurrence condition 3 Escape procedure 1 D - 1: F5, R1 - R2: R3 or equivalent off
15SGMA Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R1 Occurrence condition 5:
Response of lever becomes
15SJL1 Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1 abnormal; lever does not work
15SJMA Occurrence condition 2 Escape procedure 1 D - 1: F2, R1 - R2: R1 as operated
Normal travel possible if display returns When lever is operated,
D1B0KZ Occurrence condition 2 Escape procedure 4 transmission shifts to neutral
to normal (Note 1)
Occurrence condition 6:
Normal travel possible if display returns Speed range remains fixed;
DAQ0KK Occurrence condition 2 Escape procedure 5
to normal (Note 1) when the machine is moved
Normal travel possible if display returns off again, speed range does
DAQ2KK Occurrence condition 2 Escape procedure 4
to normal (Note 1) not shift
Normal travel possible if display returns ´ When lever is returned to N,
DAQ3KK Occurrence condition 4 Escape procedure 6 transmission shifts to
to normal (Note 1)
neutral, but after that,
Normal travel possible if display returns transmission does not shift
DAQ9KM Occurrence condition 4 Escape procedure 7
to normal (Note 1) to any speed range
Normal travel possible if display returns Note 1:
DAQ9KQ Occurrence condition 4 Escape procedure 7
to normal (Note 1) Even when the machine
Normal travel possible if display returns condition is restored after a
DAQAKQ Occurrence condition 1 Escape procedure 7 failure, the neutral condition is
to normal (Note 1)
maintained until the lever is
DDTGKA Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1 returned to the N position.
DDTHKA Occurrence condition 1 Escape procedure 1 D - 1: F2 Note 2:
DDTJKA Occurrence condition 1 Escape procedure 1 D - 1: F1 This phenomenon applies
when there is no display on
DDTKKA Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1 the machine monitor and
DDTLKA Occurrence condition 1 Escape procedure 1 D - 1: F3, R1 - R2: R2 there is also no display in the
DDTMKA Occurrence condition 1 Escape procedure 1 D - 1: F5, R1 - R2: R3 or equivalent display window of the
transmission controller.
DDTNKA Occurrence condition 1 Escape procedure 1 R1 - R2: R1
Normal travel possible if display returns
DF10KA Occurrence condition 5 Escape procedure 8
to normal (Note 1)
Normal travel possible if display returns
DF10KB Occurrence condition 2 Escape procedure 8
to normal (Note 1)
DLE2KA Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1
DLE2LC Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1
DLF1KA Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1
DLF1LC Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1
HM400-1L 20-69 1
TESTING AND ADJUSTING ESCAPE METHOD FOR ELECTRICAL SYSTEM
★ Escape Procedure 1:
B. Operate the gearshift lever again and move the machine off.
• When operating the gearshift lever, release the accelerator pedal.
• N → D or N → R1 - R2
★ Escape Procedure 2:
★ Escape Procedure 3:
B. Connect and disconnect emergency escape connectors A1 (female) and A2 (male), and switch to the emergency
escape mode.
• Connectors A1 and A2 are installed to the front of the transmission controller.
• Connect and disconnect the connectors with the ignition switch at ON or with the engine started.
C. Operate the gearshift lever again and move the machine off.
• When operating the gearshift lever, release the accelerator pedal.
• N → D or N → R1 - R2
• The emergency escape mode is maintained until the ignition switch is turned OFF.
20-70 1 HM400-1L
TESTING AND ADJUSTING ESCAPE METHOD FOR ELECTRICAL SYSTEM
12
★ Escape Procedure 4:
★ Escape Procedure 5:
A. Check the circuit breaker and fuse, and if they are normal, replace the transmission controller.
• Circuit breaker: No. 63 (80A)
• Fuse: BT3-No. 14 (10A)
★ Escape Procedure 6:
A. Check the fuse unit and fuse, and if they are normal, replace the transmission controller.
• Fuse unit: Inside battery housing (30A)
• Fuse: BT2-No. 22 (10A)
★ Escape Procedure 7:
• Check the model selection setting, and if it is normal, replace the transmission controller.
• For details of checking the model selection setting, See ADJUSTING TRANSMISSION CONTROLLER.
★ Escape Procedure 8:
• Check the fuse, and if it is normal, replace the gearshift lever.
• Fuse: BT3-No. 10 (10A)
HM400-1L 20-71 1
TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR
12
ADJUSTING MACHINE MONITOR
Machine monitor rotary switches (SW1, SW2, SW3), dip switches (SW5, SW6), and option setting connectors (OP1 - OP7)
20-72 1 HM400-1L
TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR
• In the following cases, check the settings of the rotary switches, dip switches, and option setting connectors at the rear
face of the machine monitor, and change the settings as necessary.
• When the machine monitor has been removed and installed again
• When the tire size has been changed (travel speed compensation setting)
• When the exhaust brake has been installed or removed (exhaust brake setting)
• When the left and right differential lock has been installed or removed (left and right differential lock setting)
• When parts have been replaced with new parts (service meter, odometer, reverse travel odometer setting)
• When carrying out of these settings, it is necessary to use the special operation of the character display and mode
switch, so see SPECIAL FUNCTIONS OF MACHINE MONITOR.
• When service code [DAFOKM] is displayed
• There is probably mistaken connection of the option setting connector, so See TROUBLESHOOTING OF
MACHINE MONITOR SYSTEM (MON MODE) for details.
OFF
1 Not used (always set to 0) OP5 always released
ON
OFF
2 Not used (always set to 0) OP6 always released
ON
SW6
OFF
3 Not used (always set to 0) Not needed
ON
OFF
4 Not used (always set to 0) Not needed
ON
• The condition of each switch and connector can be checked with the special function of the machine monitor (monitoring
function).
• Connector OP7 is used for the special function of the machine monitor.
• For details, See SPECIAL FUNCTIONS OF MACHINE MONITOR.
HM400-1L 20-73 1
TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR
12
★ All setting operations are carried out with the ignition switch OFF and the monitor panel removed.
• Always set each switch and connector as instructed.
• Be careful not to touch anything inside the grommet except for the switch.
• When turning the rotary switch, use a precision cross-head screwdriver and turn slowly.
• The protruding triangular part of the rotary switch is the setting arrow.
• When changing the dip switch, use a precision flat-headed screwdriver and turn slowly.
• When setting, always avoid foreign matters or dust.
• After setting, be sure to install grommet.
• The connector in the table indicates the number of the connector to be connected or released when changing the setting.
(In the case of SW1, there is no need to connect or release the connector.)
0 +7% 8 0%
1 +6% 9 -1%
2 +5% A -2%
3 +4% B -3%
4 +3% C -4%
5 +2% D -5%
6 +1% E -6%
7 0% F -7%
A. Rotary switch SW2 is set as follows. The setting must not be changed.
• Set position of SW2: 0
• Connector OP3: Released
★ Setting Rotary Switch SW3
A. Rotary switch SW3 is set as follows. The setting must not be changed.
• Set position of SW3: 0
• Connector setting: Not needed
20-74 1 HM400-1L
TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR
★ Setting Dip switch SW5-1
• Dip switch SW5-1 is set as follows. The setting must not be changed.
• The connector in the table indicates the number of the connector to be connected or released when changing the setting.
(In the case of SW5-1, there is no need to connector or release the connector.)
★ Setting Dip switch SW5-2
• Use dip switch SW5-2 to set the exhaust brake.
• When the exhaust brake has been installed or removed, set as follows.
Installed ON Connected
Installed ON Connected
HM400-1L 20-75 1
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
12
FUNCTIONS OF MACHINE MONITOR
20-76 1 HM400-1L
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
HM400-1L 20-77 1
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
12
Operator Mode
★ No. 2 - No. 5 give an endless display according to the operation of the switch.
★ When a failure occurs, the screen changes automatically to No. 6, regardless of the display screen.
★ Regardless of the display screen, if no switch is operated for more than 30 seconds, the screen automatically changes as
follows.
• Goes to No. 1: If there is no failure
• Goes to No. 6: If there is a failure
★ From No. 7 the screen changes to No. 1 with the switch operation, and if no switch is operated for more than 10 seconds,
the screen automatically changes to No. 6.
Service Mode 1
★ No. 8 - No. 14 give an endless display according to the operation of the switch.
★ Once the ID is input and confirmed, it remains effective until the ignition switch is turned OFF.
Service Mode 2
★ No. 15 - No. 17 give an endless display according to the operation of the switch.
Character Display
The character display consists of a top line and bottom line with 16
characters each. A combination of the following characters (alphabet
and numerals) and symbols is displayed according to the content.
• Numerals: 1, 2, 3...
• Small letters: a, b, c...
• Capital letters: A, B, C...
• Symbols: @, $...
• Special characters
Control Switches
Control of the machine monitor display is all carried out with machine
monitor mode selector switches (1) and (2).
: Select, Run
: Cancel, Release, Select (YES/NO only)
>: Right, Next, Continue
<: Left, Previous, Return
20-78 1 HM400-1L
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
12
OPERATION AND DISPLAYS FOR OPERATOR MODE
1. Service Meter, Odometer Display Function
When the ignition switch is turned ON, the top line shows the
service meter and the bottom line shows the odometer (Fig. 1)
• For details, see STRUCTURE AND FUNCTION,
Machine monitor system.
HM400-1L 20-79 1
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
6. Action Code Display Function
If any abnormality occurs on the machine, the degree of the
abnormality is automatically displayed as a user code on the
machine monitor to recommend appropriate action to the
operator (Fig. 7).
• The diagram on the right shows an example of action code
[E03] and [CALL+ Telephone number] being displayed in
turn.
• When action codes [E01] and [E02] are displayed,
[CALL+ Telephone number] is not displayed.
• Correspondence between user code and recommendation
to operator
20-80 1 HM400-1L
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
C: System with problem
• For details of the displayed failure codes, see FAILURE CODE TABLE.
• With the failure code display function and trouble data display function (Service mode 1), the data that are displayed
are partially different.
• If no switch is operated on the failure code display screen for more than 30 seconds, the display automatically returns
to the action code display screen.
HM400-1L 20-81 1
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
12
20-82 1 HM400-1L
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
12
Location of failure Nature of failure
Failure code Controller Action code
(location, component with failure) (problem, nature of failure)
D5ZAKX Engine throttle correction 1 signal Input signal outside range (KX) ENG E01
D5ZBKX Inter-axle differential lock command signal Input signal outside range (KX) TM E01
D5ZCKZ Exhaust brake command signal Disconnection or short circuit (KZ) TM E01
D5ZDL4 Forced neutral demand signal * See separate table (L4) TM E01
D5ZEKX Engine load signal Input signal outside range (KX) TM E01
D5ZFKZ Neutral signal 1 Disconnection or short circuit (KZ) BK E01
D5ZGKZ Neutral signal 2 Disconnection or short circuit (KZ) BK E01
Mistaken operation or mistaken setting
(DAF0KM) Monitor panel MON E03
(KM)
Mistaken operation or mistaken setting
DAF9KM) Monitor panel MON E03
(KM)
DAFSKZ Monitor panel Non match in model selection signal (KQ) MON E03
DAQ0KK Transmission controller Drop in power source voltage, input (KK) TM E03
DAQ1KK Transmission controller main power supply line Drop in power source voltage, input (KK) TM E03
DAQ2KK Transmission controller load power supply line Drop in power source voltage, input (KK) TM E03
Transmission controller battery direct power
DAQ3KK Drop in power source voltage, input (KK) TM E03
supply line
DAQ5KP Transmission controller power supply output 1 Drop in output voltage (KP) TM E03
(DAQ9KM) Transmission controller wiring harness Mistaken operation or mistaken setting (KP) TM E03
(DAQ9KQ) Transmission controller wiring harness Non match in model selection signal (KQ) TM E03
(DAQAKQ) Transmission controller rotary switch Non match in model selection signal (KQ) TM E03
Defective transmission, abnormality in
DAQSKR Transmission controller S-NET MON E03
applicable component system (KR)
DAQSMA Transmission controller Function impossible (MA) TM E03
DB10KK Retarder controller (❄1) Drop in power source voltage, input (KK) BK E03
DB11KK Retarder controller (❄1) main power supply line Drop in power source voltage, input (KK) BK E03
DB12KK Retarder controller (❄1) load power supply line Drop in power source voltage, input (KK) BK E03
Retarder controller (❄1) battery direct power
DB13KK Drop in power source voltage, input (KK) BK E03
supply line
Mistaken operation or mistaken setting
(DB19KM) Retarder controller (❄1) wiring harness BK E03
(KM)
DB1SKQ Retarder controller (❄1) S-NET line Non match in model selection signal (KQ) BK E03
Defective transmission, abnormality in
DB1SKR Retarder controller (❄1) S-NET MON E03
applicable component system (KR)
DB20KK Engine controller Drop in power source voltage, input (KK) ENG E03
DB20KT Engine controller Abnormality inside controller (KT) ENG E03
DB22KK Engine controller load power supply line Drop in power source voltage, input (KK) ENG E03
DB29KQ Engine controller connecting wiring harness Non match in model selection signal (KQ) ENG E03
Engine controller fuel injection quantity control
DB2AMA Function impossible (MA) ENG E01
switch
Defective transmission, abnormality in
DB2SKR Engine controller S-NET MON E03
applicable component system (KR)
DD11KB Ignition switch Short circuit (KB) ENG E03
DDA1L5 Accelerator switch * See separate table (L5) ENG E01
DDE2L6 Engine oil pressure switch * See separate table (L6) ENG E01
DDTFKA Fill switch for inter-axle differential lock clutch Disconnection (KA) TM E01
DDTGKA Fill switch for lock-up clutch Disconnection (KA) TM E03
DDTHKA Fill switch for Hi clutch Disconnection (KA) TM E03
DDTJKA Fill switch for Lo clutch Disconnection (KA) TM E03
HM400-1L 20-83 1
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
20-84 1 HM400-1L
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
12
HM400-1L 20-85 1
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
12
Detailed phenomena of L Series problem codes (L*)
L0 Fill signals on 2 or more channels for clutches not forming a set are input at same time
L1 Fill signal is ON when command current to ECMV is OFF
L2 Fuel pressure is higher than maximum set pressure
L3 Corresponding component cannot be controlled
L4 ON/OFF signals for 2 systems do not match
L5 Potentiometer signal and switch signal do not match
Engine speed signal, terminal C signal, signals for oil pressure switch, coolant temperature
L6
switch, etc. do not match operating condition or stopped condition of machine
L8 Analog signals for 2 systems do not match
LC Speed signals for 2 systems do not match
LH Fill signal is OFF when command current to ECMV is ON
20-86 1 HM400-1L
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
12
SWITCHING TO SERVICE MODE 1 AND SCREEN DISPLAY
★ When using Service mode 1, carry out the following special operation to switch the screen display.
HM400-1L 20-87 1
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
6. Completion Of Mode, Function
When operating at any point in any function, it is possible to finish the mode or function by using any of the
following methods.
A. Menu Selection
• Select the display function for trouble data on the menu
screen of Service mode 1 (Fig. 1).
• The total number of trouble data items recorded in memory is displayed in the [**] portion.
20-88 1 HM400-1L
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
• [<] button: Goes back to data for last record number
F.
Deleting All Trouble Data
• Display the trouble data, then press the [>] button or [<]
button to display the ALL CLEAR menu (Fig. 5).
• Press the [ ] button once to display the ALL CLEAR
screen (Fig. 6).
• [ ] button: Run ALL CLEAR menu
• Operate the buttons according to the explanation on the
screen (Fig. 6).
• [ ] button: Run
★ The data for an existing problem (flashing display) cannot be
deleted.
A. Menu Selection
• Select the display function for trouble data on the menu
screen of Service mode 1 (Fig. 1).
• The total number of trouble data items recorded in memory is displayed in the [**] portion.
HM400-1L 20-89 1
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
3: Elapsed time 1 (time elapsed on service meter since
first occurrence)
4: Elapsed time 2 (time elapsed on service meter since
last occurrence)
★ Failure codes for problems that are still existing are shown on a
flashing display.
★ For details of the failure codes displayed, see FAILURE CODE
TABLE in the explanation for the failure code display function.
★ Note that with the trouble data display function and failure code
display function for the mechanical system, the displayed data are partially different.
★ If no trouble data are recorded, [0] is displayed on the display portion for 1, and [-] is displayed on the display portion for
A, 2, 3, and 4.
A. Menu Selection
• Select the machine data monitoring function on the menu
screen of Service mode 1 (Fig. 1).
20-90 1 HM400-1L
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
D. Setting 1st Item Individual Monitoring
ii. With the menu selected, press the [ ] button and display
the monitoring data initial screen.
• [ ] button: Runs sub menu
iii. Press the [>] button or [<] button to select the item for
monitoring (Fig. 5: example).
• [>] button: Goes on to next item
• [<] button: Goes back to last item
• Scroll the monitoring items to display in the internally set
order.
• If the button is kept pressed, the items will scroll at high speed.
★ To hold or cancel monitoring data:
If the [ ] button is pressed during monitoring, the monitor
data is held and the [ ] mark flashes. If the [ ] button is
pressed again, it becomes active again.
i. Select the 2nd item display on the sub menu screen (Fig.
6).
ii. With the menu selected, press the [ ] button and display
the monitoring code input screen (Fig. 7).
• [ ] button: Runs sub menu
iii. Operate each button and input the monitoring code for the
2nd monitoring item directly.
• [>] button: Number at cursor goes up
• [<] button: Number at cursor goes down
• [ ] button: Number at cursor is confirmed
• [ ] button: Returns to code input screen
HM400-1L 20-91 1
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
★ To hold or cancel monitoring data:
If the [ ] button is pressed during monitoring, the monitor
data is held and the [ ] mark flashes. If the [ ] button is
pressed again, it becomes active again.
★ The following monitoring items display data for 2 or 3 systems at the same time.
No. 12: Input status of connector check (displays 2 items)
No. 13: Setting status of rotary switch (displays 3 items at same time)
20-92 1 HM400-1L
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
No. 14: Setting status of dip switch (displays 2 items at same time)
No. 15: Setting status of dip switch (displays 2 items at same time)
No. 16: Setting status of dip switch (displays 2 items at same time)
No. 17: Setting status of dip switch (displays 2 items at same time)
No. 18: Setting status of option selection connector (displays 2 items at same time)
No. 19: Setting status of option selection connector (displays 2 items at same time)
No. 20: Setting status of option selection connector (displays 2 items at same time)
HM400-1L 20-93 1
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
12
MONITOR PANEL [Monitor panel system]
Monitoring
No. Monitoring item Item display display range Unit
code
40 3rd clutch fill status FILL 3 31504 0-2 Status display
41 Axle sensor input voltage THROTTLE POS 31700 0.00 - 5.10 V
42 Forced neutral command 1 status N DIRECTION 1 31800 ON/OFF Status display
43 Forced neutral command 1 status N DIRECTION 2 31801 ON/OFF Status display
44 Differential lock command voltage INT DIFF SIG 31900 0.00 - 5.10 V
45 Operation status of shift hold switch SHIFT HOLD SW 32000 ON/OFF Status display
ON/OFF, ON/
46 Actuation status of emergency steering (1 & 2) ENERG STRG 1,2 32100 Status display
OFF
47 Input status of alternator terminal R ALTERNATOR R 04301 ON/OFF Status display
48 Input status of ignition switch terminal C KEY SW C 32300 ON/OFF Status display
49 Setting status of emergency escape switch ENERG TRAVEL 32400 ON/OFF Status display
50 ECMV oil temperature ECMV OIL TEMP 32500 0 - 160 oC
51 Torque converter oil pressure T/C OIL PRESS 32600 0.00 - 5.02 MPa
OVERHEAT/
52 Steering oil temperature STRG OIL TEMP 32700 Status display
NORMAL
-0.52 - 0.00 -
53 Tilt angle ANGLE SENSOR 32900 rad
0.37
ON/OFF, ON/
54 Input status of connector check (1 & 2) CONN CHK 1,2 30701 Status display
OFF
LOW/
55 Transmission oil level OIL LEVEL 33000 Status display
NORMAL
LOW/
56 Radiator coolant level COOLANT LEVEL 33100 Status display
NORMAL
CLOGGED/
57 Clogging status of air cleaner AIR CLEANER 33200 Status display
NORMAL
CLOGGED/
58 Clogging status of transmission filter T/M FILTER 33300 Status display
NORMAL
CLOGGED/
59 Clogging status of hydraulic oil filter HYD OIL FILTER 33400 Status display
NORMAL
60 Reverse permission accepted condition REVERSE (DUMP) 33500 OK/NO Status display
61 Engine load signal value ENGINE LOAD 33600 0 - 100 %
62 Setting status of rotary switch (SW1 & SW2) ROTARY SW 1,2 30801 0 - F, 0 - F Status display
63 Input status of model selection wiring harness 1 MACHINE SEL1 02701 GND/OPEN Status display
64 Input status of model selection wiring harness 2 MACHINE SEL2 02702 GND/OPEN Status display
65 Input status of model selection wiring harness 3 MACHINE SEL3 02703 GND/OPEN Status display
Note: The following monitoring items display data for 2 systems at the same time.
No. 46: Actuation condition of emergency steering (displays 2 systems at same time)
No. 54: Input status of connector check (displays 2 systems at same time)
No. 62: Setting status of rotary switch (displays 2 items at same time)
20-94 1 HM400-1L
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
12
HM400-1L 20-95 1
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
20-96 1 HM400-1L
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
❄2. The lever is not installed in E-SPEC.
Note: The following monitoring items display data for 2 systems at the same time.
No. 6: Retarder lever input (displays 2 types at same time; does not display unit for conversion%)
No. 7: Retarder lever validation switch input status (displays 2 systems at same time)
No. 20: Connector check input status (displays 2 systems at same time)
No. 35: Exhaust brake solenoid output (displays 2 types at same time; output status displayed in ( )
A. Starting engine
• With this function, it is possible to use the engine speed in
the reduced cylinder mode to judge if there is a problem
with any cylinder, so the engine can be used during the
operation.
B. Menu selection
ii.
With the menu selected, press the [ ] button and display
the cylinder selection screen (Fig. 2: example).
• [ ] button: Runs menu
★ The cylinder No. and engine speed are display at the same
time.
HM400-1L 20-97 1
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
D. Canceling Cylinder Cut Out
• Cancel the cylinder cut out in the same way as when
setting the cut out (Fig. 4: example).
• When the transmission controller has been replaced DLF2KA Transmission intermediate
• When an abnormality has occurred in the power train speed DLF2LC shaft speed sensor
sensor and it has been repaired (for details, see the failure DLF2KA Transmission output shaft
code in the chart on the right) DLF2LC R speed sensor
• When an abnormality has occurred in the transmission oil Transmission valve oil
DLF2KA
temperature sensor and it has been repaired (for details, see temperature sensor
the failure code in the chart on the right) DLF2LC Transmission oil filter
• When the transmission oil filter has become clogged and it
has been repaired (for details, see the failure code in the chart on the right)
For the adjustment operation, operate the machine monitor and machine
itself, and carry out the following items in order (Fig. 2).
★ ( ) indicates the menu to use for the adjustment operation.
(1) Adjusting individual difference of valve (02: ECMV TUNING
AUTO)
(2) Resetting gearshift feeling stabilized learning data (01: TM TRIG-
GER)
(3) Gearshift feeling stabilized initial learning (monitoring
function)
★ The MANUAL menu of [02: ECMV TUNING] is a special
function for the factory and is not used for service.
Preparatory work:
Adjusting ECMV oil temperature
★ It is necessary to carry out the adjustment operation at the specified
oil temperature, so check that there is no abnormality on the
machine and adjust the ECMV oil temperature as follows.
20-98 1 HM400-1L
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
B. Display [ECMV oil temperature] with the machine data monitoring function. (Fig. 1).
C. TRANSMISSION No. 50
HM400-1L 20-99 1
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
• The adjustment operation has been completed correctly.
• (When the ignition switch is turned OFF, the adjusted value is
recorded in the controller.)
• If [NG 1] (Outside compensation condition) is displayed:
• Adjust the ECMV oil temperature correctly, check the set
conditions of the machine again, then repeat from Step 1).
• If [NG 2] (No fill) is displayed:
• Carry out troubleshooting for failure codes [15S[ ]MA]
[DDT[ ]KA], and if it is found to be normal, repeat from Step 1).
• If [NG 3] (Compensation value over] is displayed:
• Carry out troubleshooting for failure code [15S[ ]L1], and if it is
found to be normal, repeat from Step 1).
B. With the menu selected, press the [ ] button and display the
initial screen of the sub menu (Fig. 2).
• [ ] button: Runs initialize menu
20-100 1 HM400-1L
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
C. Run the engine at low idling, hold the gearshift lever at the N
position for 10 seconds, then operate the gearshift lever as
follows.
• Gearshift lever operation: N > R1 > N
E. Operate the gearshift lever to the D position, drive the machine, and shift up to F2 - F4.
• Shift up: F2 > F3 > F4
• Be careful not to shift up to F5. If the transmission shifts up to F5, start the procedure again and move the
machine off in F2.
A. Menu selection
• Select Filter, oil replacement time setting function on the
menu screen of Service mode 1 (Fig. 1).
iii. Press the [>] or [<] buttons to select the item to be set.
• [>] button: Goes on to next item
• [<] button: Goes back to last item
★ The set items are displayed endlessly in the internal set order (for details, see Table of filter and oil replacement time set
items).
C. If the maintenance items in the display for the filter and oil replacement time set items are selected, the following
content is displayed (Fig. 3).
1: Code (2 digits)
A: Filter and oil replacement time set items
2: Remaining time to set replacement time
HM400-1L 20-101 1
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
3: Number of times of replacement up to present
ii.
Operate the buttons to input the interval (Fig. 4).
[>] button: Number at cursor goes up
[<] button: Number at cursor goes down
[ ] button: Number at cursor is confirmed
[ ] button: Returns to item selection screen
★ The time must always be input with four digits. For
numbers of less than four digits, input 0s at the beginning.
iii. When all the interval times are confirmed, the change
confirmation screen is displayed, so operate the buttons
according to the screen display (Fig. 5).
[<] button: Select YES
[>] button: Select NO
[ ] button: Run
20-102 1 HM400-1L
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
1. Initialize Function (Initialize) (exclusive function for factory)
★ This is a special function for the factory and is not used for
service.
i. Connect the OP7 connectors behind the machine monitor, and then disconnect them. (Fig. 1)
• After operating the OP7 connectors, keep them disconnected.
ii. After operating the connectors, confirm that the new initial display of service mode 2 is displayed. (Fig. 2)
• Initial display: Service meter setting function
C. Menu Selection
• Press the [>] or [<] buttons on the opening menu screen and the
menus of Service mode 2 are scrolled in the following order.
★ The menu is displayed in the places marked with [*].
[>] button: Goes on to next menu
[<] button: Goes back to previous menu
(1) Hourglass mark: Service meter setting function
(2) ODO: Function for setting value for total distance
traveled
(3) BACKWARD ODO: Function for setting value for total distance traveled in reverse
HM400-1L 20-103 1
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
★ Note that if the [ ] button is pressed on the YES/NO screen, the function will be executed.
★ If you return to the normal screen (operator mode) or service mode by mistake, repeat the procedure from Step 1)
above (there is no need to input the ID again).
A. Menu Selection
Select the setting function for the service meter on the menu
screen of Service mode 2 (Fig. 1).
iii. When all the times are confirmed, the change confirmation
screen is displayed, so operate the buttons according to the
screen display (Fig. 3).
[<] button: Select YES
[>] button: Select NO
[ ] button: Run
A. Menu Selection
Select the setting function for the distance traveled on the
menu screen of Service mode 2 (Fig. 1).
20-104 1 HM400-1L
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
ii.
Operate each button and input the odometer values.
[>] button: Number at cursor goes up
[<] button: Number at cursor goes down
[ ] button: Number at cursor is confirmed
[ ] button: Returns to initial screen (see Note)
★ The distance must always be input with five digits before the
decimal point and 1 digit after. For places where no numeral is
needed, input an 0.
iii. When all the times are confirmed, the change confirmation screen is displayed, so operate the buttons according
to the screen display (Fig. 3).
[<] button: Select YES
[>] button: Select NO
[ ] button: Run
A. Menu Selection
Select the setting function for the distance traveled in reverse
on the menu screen of Service mode 2 (Fig. 1).
ii.
Operate each button and input the values for the distance
traveled in reverse.
[>] button: Number at cursor goes up
[<] button: Number at cursor goes down
[ ] button: Number at cursor is confirmed
[ ] button: Returns to initial screen (see Note)
★ The distance must always be input with five digits before the
decimal point and 1 digit after. For places where no numeral is
needed, input an 0.
iii. When all the times are confirmed, the change confirmation screen is displayed, so operate the buttons according
to the screen display (Fig. 3).
[<] button: Select YES
[>] button: Select NO
[ ] button: Run
HM400-1L 20-105 1
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
12
MEMORANDUM
20-106 1 HM400-1L
TROUBLESHOOTING (GENERAL)
HM400-1L 20-201 b
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING
WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and parking
brake are securely fitted.
WARNING! When carrying out the operation with two or more workers, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
WARNING! If the radiator cap is removed when the engine is hot, hot coolant may spurt out and
cause burns, so wait for the engine to cool down before starting troubleshooting.
WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
WARNING! When disconnecting wiring, always disconnect negative (-) terminal of the battery first.
WARNING! When removing the plug or cap from a location which is under pressure from oil, coolant,
or air, always release the internal pressure first. When installing measuring equipment,
be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence
of the failure.
When carrying out troubleshooting, an important point is to understand the structure and function of the machine. However,
a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the
failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled
immediately after a failure occurs:
● Parts that have no connection with the failure or other unnecessary parts will be disassembled.
● It will become impossible to find the cause of the failure.
It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of
the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in accordance with the fixed procedure.
A. Have any other problems occurred apart from the problem that has been reported?
B. Was there anything strange about the machine before the failure occurred?
C. Did the failure occur suddenly, or were there problems with the machine condition before this?
E. Had any repairs been carried out before the failure? When were these repairs carried out?
20-202 b HM400-1L
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
3. Check before troubleshooting.
B. Check for any external leakage of oil from the piping or hydraulic equipment.
E. Other maintenance items can be checked externally, so check any item that is considered to be necessary.
A. Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the
method of operation, etc.
★ When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or
measurement that may make the problem worse.
5. Troubleshooting
A. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the
troubleshooting flowchart to locate the position of the failure exactly.
A. Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again.
B. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
HM400-1L 20-203 b
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
20-204 b HM400-1L
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
HM400-1L 20-205 b
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
B. Defective compression or soldering of connectors:
The pins of the male and female connectors are in contact at
the compressed terminal or soldered portion, but there is
excessive force on the wiring, and the plating peels to cause
improper connection or breakage.
C. Disconnections in wiring:
If the wiring is held and tugged and the connectors are pulled
apart, or components are lifted with a crane with the wiring
still connected, or a heavy object hits the wiring, the crimping
compression of the connectors to the wire may be loosened, or
the soldering may be damaged, or the wiring may be broken.
20-206 b HM400-1L
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
4. Removing, Installing, And Drying Connectors And Wiring
Harnesses.
A. Disconnecting connectors:
ii. When removing the connectors from the clips, pull the
connector in a parallel direction to the clip.
★ If the connector is twisted to the left and right or up
and down, the housing may break.
HM400-1L 20-207 b
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
B. Connecting connectors:
iv. When the wiring harness clamp of the connector has been
removed, always return it to its original condition and
check that there is no looseness of the clamp.
20-208 b HM400-1L
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
D. Drying wiring harness:
If there is any oil or dirt on the wiring harness, wipe it off with
a dry cloth. Avoid washing it in water or using steam. If the
connector must be washed in water, do not use high pressure
water or steam directly on the wiring harness. If water gets
directly on the connector, do as follows:
HM400-1L 20-209 b
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
6. Do not place the control unit on oil, water, or soil, or in any hot
place, even for a short time.
★ Place it on a suitable dry stand.
20-210 b HM400-1L
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
2. Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
★ Check each individual wire on the connector suspected of the problem by performing a pull test on the wire insert.
3. Always connect any disconnected connectors before going on to the next step.
★ If power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.
4. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity or current), move the related
wiring and connectors several times and check that there is no charge in the reading of the tester.
★ If there is any charge, there is probably defective contact in that circuit.
HM400-1L 20-211 b
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
20-212 b HM400-1L
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
5. Change hydraulic oil when the temperature is high.
When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the
circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible
of the old hydraulic oil must be drained out. (Do not drain the oil from the hydraulic tank; but drain the oil from the filter
and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.
6. Flushing operations.
After disassembling and assembling the equipment, or changing the
oil, use flushing oil to remove the contaminants, sludge, and old oil
from the hydraulic circuit.Normally, flushing is carried out twice:
primary flushing is carried out with flushing oil, and secondary
flushing is carried out with the specified hydraulic oil.
7. Cleaning operations.
After repairing the hydraulic equipment (pump, control valve, etc.)
or when running the machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit.The oil cleaning
equipment is used to remove the ultra fine (about 3µ) particles that
the filter built into the hydraulic equipment cannot remove, so it is
an extremely effective device.
HM400-1L 20-213 b
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
11. Check tire inflation pressure and damage - Air charge or replace
Before Starting Checking Item
40. Check sound of actuation of battery relay (When starting switch is - Replace
turned ON, OFF)
20-214 b HM400-1L
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
B. If no failure code is displayed on the machine monitor but the failure is recorded in memory.
If it is impossible to check the failure code display on the machine monitor when a problem occurs, use the trouble-
shooting history display function in the service mode of the machine monitor to check if there is a failure code.
If a failure code is recorded, it is probable that it is the cause, so go to the applicable troubleshooting for the failure
code.
HM400-1L 20-215 b
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
• Failure.
Contents Of Trouble • Failure code displayed.
• Additional information.
Tools and Procedures
Steps Circuit Diagnostic Procedures For Service Code Specifications No. Readings
1. Sensor or Actuator
• With ignition switch in the “OFF” position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸)
• Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
• Zero meter leads for proper Ω readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)
Your
Test procedure for component only. readings 1
information
Resistance Ω
A. What you are testing
or Voltage Your
Test procedure for component only. readings 2
information
2. Diode Test
• With ignition switch in the “OFF” position. (The importance of these tests are to isolate each component for testing separately)
• When checking a diode always isolate the circuit. Check diode continuity in both directions reversing meter leads each time to confirm
electrical flow. Electrical flow should be one way only. (See section 20-111 for detail).
Your
Test procedure for harness. (connector) to (connector) readings 4
A. Open or high Resistance Ω information
resistance or Voltage
Your
Test procedure for harness. (connector) to (connector) readings 5
information
Your
B. Short to chassis Test procedure for harness. (connector) to (connector) readings 6
information
Resistance Ω
ground or within
or Voltage
harness Your
Test procedure for harness. (connector) to (connector) readings 7
information
Resistance Ω Your
A. What you are testing Test procedure for any additional components. readings 8
or Voltage information
20-216 b HM400-1L
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
Chart Use
● When using this chart in a repair shop environment where you have access to a copier it is advised to remove the
pages of the fault codes displayed on the machine monitor and copy these pages. After copping the needed pages,
return the original pages back to the Shop Manual for future use. On the copied pages in the right hand column of the
chart you can record your findings for final analysis. Do not write on the original chart in the Shop Manual and
complete all test procedures.
● When using this chart while on a road service call where a copier is not available it is advised to use a blank piece of
paper and number it from #1 through the last number listed in conjunction with the Shop Manual. Record your
readings by each number on the paper for final analysis. Do not write on the original chart in the Shop Manual and
complete all test procedures.
Chart Tips
HM400-1L 20-217 b
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
12
TROUBLESHOOTING INDIVIDUAL HYDRAULIC CIRCUITS
Like the electrical diagnostic procedures it is important to complete all steps requires in the testing procedures. This method is
broken down into three steps: Question the operator, Checks before troubleshooting and Using the cross-reference tables.
Below is a description od each step.
The questions to ask the operator are given below the failure symptom.
If the answers to the questions match the information given, follow the
arrow to reach the probable cause of the failure. Consider the contents
of the question and consult the table while proceeding to step 2 and 3 to
grasp the true cause
20-218 b HM400-1L
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
12
C. Operate the machine and check the troubleshooting items other
than in 1). Operate the machine and check the items in the
same way as in 1), and if the symptom appears, record that
item for further reference. (In the chart on the right, the symp-
tom appears again for item 5).
D. Find the appropriate chart for the cause from the cause column.
In the same way as in step 2), if the symptom appears, the ❍
marks on that line indicate the possible causes. (For items No.
5 in the table on the right, the possible causes are b or e).
HM400-1L 20-219 b
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
12
CONNECTOR TYPES AND MOUNTING LOCATIONS
Connector No. Type No. of pins Name of component 3-dimensional drawing display
1-PS DT2 2 Transmission 1st clutch solenoid 4/4
1-SW DT2 2 Transmission 1st clutch fill switch 4/4
2-PS DT2 2 Transmission 2nd clutch solenoid 4/4
2-SW DT2 2 Transmission 2nd clutch fill switch 4/4
3-PS DT2 2 Transmission 3rd clutch solenoid 4/4
3-SW DT2 2 Transmission 3rd clutch fill switch 4/4
A1 M 1 Emergency cancel connector 2/4 (Overall drawing: Right)
A2 M 1 Emergency cancel connector 2/4 (Overall drawing: Right)
AC1 1-pin connector 1 Air conditioner unit 2/4 (Overall drawing: Left)
ACBM KES 2 Air conditioner blower motor 2/4 (Overall drawing: Right)
ACM1 AMP 5 Air conditioner temperature adjustment servo motor 2/4 (Overall drawing: Right)
ACM2 AMP 5 Air conditioner vent mode selector servo motor 2/4 (Overall drawing: Left)
ACM3 AMP 5 Air conditioner FRESH/RECIRC selector servo motor 2/4 (Overall drawing: Right)
ACP1 AMP 16 Air conditioner control panel 2/4 (Overall drawing: Left)
ACP2 AMP 12 Air conditioner control panel 2/4 (Overall drawing: Left)
ACPS SUMITOMO 2 Air conditioner pressure switch 2/4 (Overall drawing: Right)
ACR1 AMP 4 Air conditioner blower main relay 2/4 (Overall drawing: Right)
ACR2 AMP 4 Air conditioner blower Hi relay 2/4 (Overall drawing: Right)
ACR3 AMP 4 Air conditioner blower M2 relay 2/4 (Overall drawing: Right)
ACR4 AMP 4 Air conditioner blower M1 relay 2/4 (Overall drawing: Right)
ACR5 AMP 4 Air conditioner compressor clutch relay 2/4 (Overall drawing: Right)
ACRD DT2 2 Air conditioner gas pressure switch 1/4 (Overall drawing: Left)
ACRE AMP 4 Air conditioner blower resistor 2/4 (Overall drawing: Right)
ACTH KES 2 Air conditioner thermistor 2/4 (Overall drawing: Right)
AISS M 6 AISS LOW switch 2/4 (Overall drawing: Left)
AS1 SWP 6 Accelerator pedal 2/4 (Overall drawing: Left)
AS2 SWP 3 Accelerator pedal 2/4 (Overall drawing: Left)
ASS DT2 2 Air suspension seat 2/4 (Overall drawing: Right)
ATC1 MIC 17 Transmission controller 2/4 (Overall drawing: Right)
ATC2 MIC 21 Transmission controller 2/4 (Overall drawing: Right)
ATC3A 040 20 Transmission controller 2/4 (Overall drawing: Right)
ATC3B 040 16 Transmission controller 2/4 (Overall drawing: Right)
ATC4 040 12 Transmission controller 2/4 (Overall drawing: Right)
ATC5A 040 20 Transmission controller 2/4 (Overall drawing: Right)
ATC5B 040 16 Transmission controller 2/4 (Overall drawing: Right)
ATC6 X 4 Software rewrite connector (transmission controller) 2/4 (Overall drawing: Right)
B1 M 1 Emergency cancel connector 2/4 (Overall drawing: Right)
B2 M 1 Emergency cancel connector 2/4 (Overall drawing: Right)
B01 DT2 2 Front brake (left) wear switch 1/4 (Overall drawing: Left)
B02 DT2 2 Center brake (left) wear switch 1/4 (Overall drawing: Right)
B03 DT2 2 Brake cooling filter clogging switch 1/4 (Overall drawing: Left)
B04 DT2 2 Brake filter clogging switch 1/4 (Overall drawing: Left)
B05 DT2 2 Rear brake (left) wear switch 1/4 (Overall drawing: Right)
B08 DT2 2 Rear brake (right) wear switch 1/4 (Overall drawing: Right)
B09 DT2 2 Intermediate connector 1/4 (Overall drawing: Left)
B14 DT2 2 Parking brake solenoid valve 1/4 (Overall drawing: Left)
B15 DT2 2 Foot brake oil pressure switch 1/4 (Overall drawing: Left)
20-220 b HM400-1L
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Connector No. Type No. of pins Name of component 3-dimensional drawing display
B16 DT2 2 Rear brake oil pressure switch 1/4 (Overall drawing: Right)
B17 DT2 2 Parking brake oil pressure switch 1/4 (Overall drawing: Left)
B18 DT2 2 Rear brake EPC valve 1/4 (Overall drawing: Left)
B19 DT2 2 Front brake EPC valve 1/4 (Overall drawing: Left)
B20 DT2 2 Rear accumulator oil pressure switch 1/4 (Overall drawing: Left)
B21 DT2 2 Front accumulator oil pressure switch 1/4 (Overall drawing: Left)
B22 DT2 2 Rear accumulator gas pressure sensor -
B23 DT2 2 Front accumulator gas pressure sensor -
B24 DT2 3 Rear accumulator oil pressure sensor 1/4 (Overall drawing: Left)
B25 DT2 3 Front accumulator oil pressure sensor 1/4 (Overall drawing: Left)
B26 DT2 2 Center brake (right) wear switch 1/4 (Overall drawing: Right)
B27 DT2 3 Steering angle sensor 1/4 (Overall drawing: Right)
B28 DT2 2 Front brake (right) wear switch 1/4 (Overall drawing: Left)
B29 DT2 2 Exhaust brake solenoid valve -
B30 DT2 2 Exhaust brake oil pressure switch -
B31 DT2 3 Dump pilot valve (selector solenoid) 1/4 (Overall drawing: Right)
B32 DT2 2 Dump pilot valve (EPC solenoid) 1/4 (Overall drawing: Right)
B34 DT2 3 Body positioner sensor 1/4 (Overall drawing: Right)
B35 DT2 2 Front differential lock solenoid valve 1/4 (Overall drawing: Left)
B36 DT2 2 Differential lock motor solenoid valve 1/4 (Overall drawing: Right)
B39 DT2 2 Front differential lock oil pressure switch 1/4 (Overall drawing: Left)
B40 DT2 2 Rear differential lock oil pressure switch 1/4 (Overall drawing: Right)
BL47 M 2 Back-up lamp 1/4 (Overall drawing: Right)
BL48 M 2 Back-up lamp 1/4 (Overall drawing: Right)
BLS M 6 Rotating lamp switch 2/4 (Detail drawing: X)
BRC1 MIC 17 Retarder controller (❄) 2/4 (Overall drawing: Right)
BRC2 MIC 21 Retarder controller (❄) 2/4 (Overall drawing: Right)
BRC3A 040 20 Retarder controller (❄) 2/4 (Overall drawing: Right)
BRC3B 040 16 Retarder controller (❄) 2/4 (Overall drawing: Right)
BRC4 040 12 Retarder controller (❄) 2/4 (Overall drawing: Right)
BRC5A 040 20 Retarder controller (❄) 2/4 (Overall drawing: Right)
BRC5B 040 16 Retarder controller (❄) 2/4 (Overall drawing: Right)
BRC6 X 4 Software rewrite connector (retarder) 2/4 (Overall drawing: Right)
BT1 - - Fuse box 2/4 (Overall drawing: Right)
BT2B - - Fuse box 2/4 (Overall drawing: Right)
BT3 - - Fuse box 2/4 (Overall drawing: Right)
BT4 - - Fuse box 2/4 (Overall drawing: Right)
BZ2 M 2 Buzzer 2/4 (Overall drawing: Left)
CAB1 DT2 8 Intermediate connector 2/4 (Overall drawing: Left)
CAB2 DT2 8 Intermediate connector 2/4 (Overall drawing: Left)
CAN1 DT2 3 Resistor 2/4 (Overall drawing: Left)
CAN2 DT2 3 Resistor 2/4 (Overall drawing: Left)
CG1 1-pin connector 1 Cigarette lighter 2/4 (Overall drawing: Left)
CG2 1-pin connector 1 Cigarette lighter 2/4 (Overall drawing: Left)
CH1 S 8 Machine monitor mode selector switch 1 2/4(Detail drawing: X)
CH2 S 8 Machine monitor mode selector switch 2 2/4 (Detail drawing: X)
CJA DT2 8 Joint connector 1/4 (Overall drawing: Left)
HM400-1L 20-221 b
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
12
Connector No. Type No. of pins Name of component 3-dimensional drawing display
CJAA DT2 8 Joint connector 1/4 (Overall drawing: Left)
CJB DT2 6 Joint connector 1/4 (Overall drawing: Left)
CJC DT2 8 Joint connector 1/4 (Overall drawing: Right)
CJD DT2 8 Joint connector 1/4 (Overall drawing: Left)
CJF DT2 8 Joint connector 1/4 (Overall drawing: Left)
CJG DT2 6 Joint connector 1/4 (Overall drawing: Left)
CJH DT2 6 Joint connector 1/4 (Overall drawing: Left)
CJJ DT2 8 Joint connector 1/4 (Overall drawing: Left)
CJK DT2 8 Joint connector 1/4 (Overall drawing: Right)
CJL DT2 8 Joint connector 1/4 (Overall drawing: Left)
CJM DT2 6 Joint connector 1/4 (Overall drawing: Left)
CJN DT2 8 Joint connector 1/4 (Overall drawing: Left)
CJP DT2 6 Joint connector 1/4 (Overall drawing: Left)
CJR DT2 8 Joint connector 1/4 (Overall drawing: Left)
CJS DT2 8 Joint connector 1/4 (Overall drawing: Left)
CJT DT2 6 Joint connector 1/4 (Overall drawing: Left)
CJU DT2 6 Joint connector 1/4 (Overall drawing: Left)
CJX DT1 6 Joint connector 1/4 (Overall drawing: Left)
CJY DT1 8 Joint connector 1/4 (Overall drawing: Left)
CJZ DT2 6 Joint connector 1/4 (Overall drawing: Right)
CK1 YAZAKI 6 Machine monitor check switch 2/4 (Detail drawing: X)
CM DT2 8 Combination switch 2/4 (Overall drawing: Left)
CM DT2 2 Intermediate connector 1/4 (Overall drawing: Left)
CN1 070 12 Engine controller 2/4 (Overall drawing: Right)
CN1 DT2 2 No. 1 cylinder injector 3/4
CN2 070 18 Engine controller 2/4 (Overall drawing: Right)
CN2 DT2 2 No. 2 cylinder injector 3/4
CN3 DT2 2 No. 3 cylinder injector 3/4
CN4 070 20 Engine controller 2/4 (Overall drawing: Right)
CN4 DT2 2 No. 4 cylinder injector 3/4
CN5 DT2 2 No. 5 cylinder injector 3/4
CN6 070 10 Engine controller 2/4 (Overall drawing: Right)
CN6 DT2 2 No. 6 cylinder injector 3/4
CN7 070 14 Engine controller 2/4 (Overall drawing: Right)
CNS1 DT2 12 Intermediate connector 2/4 (Overall drawing: Right)
CNS2 DT2 12 Intermediate connector 2/4 (Overall drawing: Right)
CNS3 DT2 12 Intermediate connector 2/4 (Overall drawing: Right)
COM 1-pin connector 1 Air conditioner unit 2/4 (Overall drawing: Left)
COMP DT2 2 Air conditioner compressor 1/4 (Overall drawing: Left)
D/L-PS DT2 2 Inter-axle differential lock clutch solenoid 4/4
D/L-SW DT2 2 Inter-axle differential lock clutch fill switch 4/4
D01 DT2 2 Diode 2/4 (Overall drawing: Right)
D02 DT2 2 Diode 2/4 (Overall drawing: Right)
D03 DT2 2 Diode 2/4 (Overall drawing: Right)
D04 DT2 2 Diode 2/4 (Overall drawing: Left)
D05 DT2 2 Diode 2/4 (Overall drawing: Right)
D06 DT2 2 Diode 2/4 (Overall drawing: Right)
20-222 b HM400-1L
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
12
Connector No. Type No. of pins Name of component 3-dimensional drawing display
D07 DT2 2 Diode 2/4 (Overall drawing: Left)
D08 DT2 2 Diode 2/4 (Overall drawing: Left)
D09 DT2 2 Diode 2/4 (Overall drawing: Left)
DEF M 6 Inter-axle differential lock switch 2/4 (Overall drawing: Left)
DEL M 6 Left and right differential lock switch 2/4 (Overall drawing: Left)
DFS DT2 3 Left and right differential lock pedal 2/4 (Overall drawing: Right)
DIO DT2 2 Diode 1/4 (Overall drawing: Left)
DL DT2 12 Intermediate connector 2/4 (Overall drawing: Right)
DPC1 070 20 Machine monitor 2/4 (Overall drawing: Left)
DPC2A 070 18 Machine monitor 2/4 (Overall drawing: Left)
DPC2B 070 12 Machine monitor 2/4 (Overall drawing: Left)
DPC3A 070 18 Machine monitor 2/4 (Overall drawing: Left)
DPC4 070 12 Machine monitor 2/4 (Overall drawing: Left)
DPC6 040 8 Machine monitor 2/4 (Overall drawing: Left)
DPC7 X 4 Software rewrite connector (machine monitor) 2/4 (Overall drawing: Left)
DSL 1-pin connector 1 Left door switch
DSR 1-pin connector 1 Right door switch 1/4 (Overall drawing: Left)
DT1 DT2 3 Intermediate connector 1/4 (Overall drawing: Left)
DT2 DT2 12 Intermediate connector 1/4 (Overall drawing: Left)
DT3 DT2 8 Intermediate connector 1/4 (Overall drawing: Left)
DT4 DT2 12 Intermediate connector 1/4 (Overall drawing: Right)
DT5 DT2 8 Intermediate connector 1/4 (Overall drawing: Left)
DT6 DT2 8 Intermediate connector 1/4 (Overall drawing: Left)
DT7 DT2 12 Intermediate connector 2/4 (Overall drawing: Right)
DT8 DT2 4 Intermediate connector 2/4 (Overall drawing: Right)
E Terminal - Ground 1/4 (Overall drawing: Left)
E02 DT2 2 Steering oil pressure switch 1/4 (Overall drawing: Left)
E1 Terminal - Emergency steering motor 1 -
E2 Terminal - Emergency steering motor 2 -
EG1 DT2 12 Intermediate connector 2/4 (Overall drawing: Left)
EG2 DT2 12 Intermediate connector 2/4 (Overall drawing: Left)
EG3 DT2 12 Intermediate connector 2/4 (Overall drawing: Left)
EG4 HD30 31 Intermediate connector 1/4 (Overall drawing: Left)
EG5 HD30 31 Intermediate connector 1/4 (Overall drawing: Left)
ER Terminal - Ground 1/4 (Overall drawing: Left)
ER Terminal - Ground 1/4 (Overall drawing: Right)
ER1 Terminal - Ground 2/4 (Overall drawing: Left)
ER1 - - Ground
ER2 Terminal - Ground 2/4 (Detail drawing: V)
ER3 Terminal - Ground
ER3 Terminal - Ground 2/4 (Overall drawing: Left)
ER4 Terminal - Ground
ER5 Terminal - Ground
ER6 Terminal - Ground
ER7 Terminal - Ground
ER8 Terminal - Ground
EREV DT2 2 Engine speed sensor 3/4
HM400-1L 20-223 b
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
12
Connector No. Type No. of pins Name of component 3-dimensional drawing display
EXH M 6 Exhaust brake switch 2/4 (Overall drawing: Left)
FE1 DT2 2 Transmission output shaft (F) speed sensor 1/4 (Overall drawing: Left)
FLB 1-pin connector - Turn signal lamp flasher 2/4 (Overall drawing: Left)
FLL 1-pin connector - Turn signal lamp flasher 2/4 (Overall drawing: Left)
FOG M 6 Fog lamp switch 2/4 (Detail drawing: X)
FS3 1-pin connector 1 Spare power source connector -
FS4 1-pin connector 1 Spare power source connector -
FS5 1-pin connector 1 Spare power source connector -
FS6 1-pin connector 1 Spare power source connector -
FS7 1-pin connector 1 Spare power source connector -
FS8 1-pin connector 1 Spare power source connector -
FWL M 2 Left front working lamp 1/4 (Overall drawing: Left)
FWM 2 Front window washer motor 1/4 (Overall drawing: Left)
FWR M 2 Right front working lamp 1/4 (Overall drawing: Left)
G DT1 2 Engine G speed sensor 3/4
G2 Terminal - Ground 1/4 (Overall drawing: Left)
G21 Terminal - Air conditioner ground 2/4 (Overall drawing: Right)
GND Terminal - Battery ground 1/4 (Overall drawing: Left)
H1 1-pin connector 1 Horn 1/4 (Overall drawing: Left)
H2 1-pin connector 1 Horn 1/4 (Overall drawing: Left)
H10 1-pin connector 1 Heater unit 2/4 (Overall drawing: Left)
H20 1-pin connector 1 Heater unit 2/4 (Overall drawing: Left)
HAZ M 6 Hazard switch 2/4 (Overall drawing: Left)
HN 1-pin connector - Horn switch 2/4 (Overall drawing: Left)
H-PS DT2 2 Transmission Hi clutch solenoid 4/4
HSL DT2 4 Dump lever (potentiometer) 2/4 (Overall drawing: Right)
H-SW DT2 2 Transmission Hi clutch fill switch 4/4
JCA DT2 8 Joint connector 2/4 (Overall drawing: Right)
JCB DT2 8 Joint connector 2/4 (Overall drawing: Right)
JCC DT2 8 Joint connector 2/4 (Overall drawing: Right)
JCD DT2 8 Joint connector 2/4 (Overall drawing: Right)
JCE DT2 8 Joint connector
JCF DT2 8 Joint connector 2/4 (Overall drawing: Right)
JCG DT2 8 Joint connector 2/4 (Overall drawing: Right)
JO1 HD30 9 Intermediate connector 1/4 (Detail drawing: Y)
JO10 HD30 23 Intermediate connector 1/4 (Detail drawing: Y)
JO11 HD30 31 Intermediate connector 1/4 (Detail drawing: Y)
JO12 DT2 12 Joint connector 1/4 (Overall drawing: Right)
JO13 DT2 12 Joint connector 1/4 (Overall drawing: Right)
JO14 HD30 31 Joint connector 1/4 (Overall drawing: Right)
JO15 HD30 31 Joint connector 1/4 (Overall drawing: Right)
JO18 HD30 14 Intermediate connector 1/4 (Overall drawing: Left)
JO19 HD30 9 Intermediate connector 1/4 (Overall drawing: Left)
JO2 HD30 23 Intermediate connector 1/4 (Detail drawing: Y)
JO4 HD30 21 Intermediate connector 1/4 (Detail drawing: Y)
JO5 HD30 31 Intermediate connector 1/4 (Detail drawing: Y)
JO6 HD30 31 Intermediate connector 1/4 (Detail drawing: Y)
20-224 b HM400-1L
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
12
Connector No. Type No. of pins Name of component 3-dimensional drawing display
JO7 HD30 23 Intermediate connector 1/4 (Detail drawing: Y)
JO8 HD30 14 Intermediate connector 1/4 (Detail drawing: Y)
JO9 HD30 31 Intermediate connector 1/4 (Detail drawing: Y)
KAI 1-pin connector 1 Rotating lamp 1/4 (Detail drawing: Z)
L/U-PS DT2 2 Torque converter lock-up clutch solenoid 4/4
L/U-SW DT2 2 Torque converter lock-up clutch fill switch 4/4
LK0 DT2 2 Dump lever (solenoid) 2/4 (Overall drawing: Right)
L-PS DT2 2 Transmission Lo clutch solenoid 4/4
LS M 3 Rheostat (resistor for dimming panel lighting) 2/4 (Detail drawing: X)
L-SW DT2 2 Transmission Lo clutch fill switch 4/4
LUB-T DT2 2 Transmission oil temperature sensor 4/4
M1 Terminal - Emergency steering motor 1 -
M2 Terminal - Emergency steering motor 2 -
MC1 M 1 Memory clear connector 2/4 (Overall drawing: Right)
MC2 M 1 Memory clear connector 2/4 (Overall drawing: Right)
MON1 1-pin connector 1 Rear view monitor 2/4 (Overall drawing: Left)
MON2 1-pin connector 1 Rear view monitor 2/4 (Overall drawing: Left)
MON3 1-pin connector 1 Rear view monitor 2/4 (Overall drawing: Left)
MS M 4 Model selection connector (engine controller) 2/4 (Overall drawing: Right)
MS11 M 1 Model selection connector (transmission controller) 2/4 (Overall drawing: Right)
MS12 M 1 Model selection connector (transmission controller) 2/4 (Overall drawing: Right)
MS21 M 1 Model selection connector (transmission controller) 2/4 (Overall drawing: Right)
MS22 M 1 Model selection connector (transmission controller) 2/4 (Overall drawing: Right)
MS31 M 1 Model selection connector (transmission controller) 2/4 (Overall drawing: Right)
MS32 M 1 Model selection connector (transmission controller) 2/4 (Overall drawing: Right)
N1 DT2 2 Transmission input shaft speed sensor 4/4
N2 DT2 2 Transmission intermediate shaft speed sensor 4/4
N3 DT2 2 Transmission output shaft (R) speed sensor 4/4
NE DT1 2 Engine Ne speed sensor 3/4
OF Terminal - Engine oil filter clogging switch 3/4
OL DT1 1 Engine oil level sensor 3/4
OP1 M 1 Machine monitor setting connector 2/4 (Detail drawing: W)
OP2 M 1 Machine monitor setting connector 2/4 (Detail drawing: W)
OP3 M 1 Machine monitor setting connector 2/4 (Detail drawing: W)
OP4 M 1 Machine monitor setting connector 2/4 (Detail drawing: W)
OP5 M 1 Machine monitor setting connector 2/4 (Detail drawing: W)
OP6 M 1 Machine monitor setting connector 2/4 (Detail drawing: W)
OP7 M 1 Machine monitor setting connector 2/4 (Detail drawing: W)
OPS DT2 2 Seat heater 2/4 (Overall drawing: Right)
P01 M 3 Left head lamp 1/4 (Overall drawing: Left)
P02 1-pin connector - Left front combination lamp 1/4 (Overall drawing: Left)
P03 1-pin connector - Left front combination lamp 1/4 (Overall drawing: Left)
P04 1-pin connector - Left front combination lamp 1/4 (Overall drawing: Left)
P05 DT2 2 Left turn signal lamp 1/4 (Overall drawing: Left)
P06 DT2 2 Right turn signal lamp 1/4 (Overall drawing: Left)
P07 X 2 Left fog lamp 1/4 (Overall drawing: Left)
P13 1-pin connector 1 Horn 1/4 (Overall drawing: Left)
HM400-1L 20-225 b
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
12
Connector No. Type No. of pins Name of component 3-dimensional drawing display
P14 1-pin connector 1 Horn 1/4 (Overall drawing: Left)
P20 M 6 Right rear combination lamp 1/4 (Overall drawing: Right)
P21 M 6 Left rear combination lamp 1/4 (Overall drawing: Right)
P22 1-pin connector - Intermediate connector 1/4 (Overall drawing: Left)
P29 1-pin connector - Right front combination lamp 1/4 (Overall drawing: Left)
P30 1-pin connector - Right front combination lamp 1/4 (Overall drawing: Left)
P31 1-pin connector - Right front combination lamp 1/4 (Overall drawing: Left)
P32 M 3 Right head lamp 1/4 (Overall drawing: Left)
P33 X 2 Right fog lamp 1/4 (Overall drawing: Left)
PCV1 DENSO 2 Fuel supply pump PCV1 3/4
PCV2 DENSO 2 Fuel supply pump PCV2 3/4
PFUEL DENSO 3 Engine common rail pressure sensor 3/4
PIM DENSO 3 Engine boost pressure sensor 3/4
PSH Terminal - Engine oil high-pressure sensor 3/4
PSL Terminal - Engine oil low-pressure sensor 3/4
PWL 1-pin connector 1 Left power window motor 1/4 (Detail drawing: Z)
PWM M 6 Power mode switch 2/4 (Overall drawing: Left)
PWR 1-pin connector 1 Right power window motor 1/4 (Detail drawing: Z)
R01 Relay 5 Engine drive relay 2/4 (Detail drawing: V)
R02 Relay 5 Transmission neutral relay 2/4 (Detail drawing: V)
R03 Relay 5 Parking brake relay 2/4 (Detail drawing: V)
R04 Relay 6 Brake lamp relay 2/4 (Detail drawing: V)
R05 Relay 6 Back-up lamp, buzzer relay 2/4 (Detail drawing: V)
R06 Relayr 6 Fog lamp relay 2/4 (Detail drawing: V)
R07 Relay 6 Front working lamp relay 2/4 (Detail drawing: V)
R08 Relay 6 Rear working lamp relay 2/4 (Detail drawing: V)
R11 Relay 5 Horn relay 2/4 (Detail drawing: V)
R14 Relay 5 Breaker cut relay 2/4 (Detail drawing: V)
R15 Relay 5 Transmission cut relay 2/4 (Detail drawing: V)
R16 Relay 6 Hazard relay 1 2/4 (Detail drawing: V)
R17 Relay 5 Hazard relay 2 2/4 (Detail drawing: V)
R19 Relay 5 Parking brake safety relay 2/4 (Detail drawing: V)
R21 Relay 6 Side lamp relay 2/4 (Detail drawing: V)
R22 Relay 5 Rotating lamp relay 2/4 (Detail drawing: V)
R25 Relay 5 Right power window down relay 2/4 (Detail drawing: V)
R26 Relay 5 Right power window up relay 2/4 (Detail drawing: V)
R27 Relay 5 Left power window down relay 2/4 (Detail drawing: V)
R28 Relay 5 Left power window up relay 2/4 (Detail drawing: V)
R29 Relay 6 Head lamp Hi relay 2/4 (Detail drawing: V)
R30 Relay 5 Head lamp Lo relay 2/4 (Detail drawing: V)
R31 S 10 Passing relay 2/4 (Overall drawing: Left)
R32 Relay 5 Dust indicator relay 2/4 (Detail drawing: V)
R33 M 6 Parking brake switch 2/4 (Overall drawing: Left)
R34 - 7 Left power window switch 2/4 (Overall drawing: Right)
R35 - 7 Right power window switch 2/4 (Overall drawing: Right)
R36 Relay 5 Engine power relay 2/4 (Detail drawing: V)
R37 Relay 5 Auto preheat relay 2/4 (Detail drawing: V)
20-226 b HM400-1L
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
12
Connector No. Type No. of pins Name of component 3-dimensional drawing display
RAD YAZAKI 9 Radio 2/4 (Overall drawing: Left)
RDC YAZAKI 9 Cassette stereo 2/4 (Overall drawing: Left)
RE1 KES 2 Resistor 2/4 (Overall drawing: Right)
RL M 1 Room lamp 1/4 (Overall drawing: Left)
RL2 1-pin connector 1 Room lamp 2 1/4 (Overall drawing: Left)
R-PS DT2 2 Transmission R clutch solenoid 4/4
R-SW DT2 2 Transmission R clutch fill switch 4/4
RTL DT2 6 Retarder lever 2/4 (Overall drawing: Left)
RWL 1-pin connector 2 Left rear working lamp 1/4 (Overall drawing: Left)
RWM 2 Rear window washer motor 1/4 (Overall drawing: Left)
RWR 1-pin connector 2 Right rear working lamp 1/4 (Overall drawing: Left)
SBS DT2 2 Seat belt switch 2/4 (Overall drawing: Right)
SDE M 6 Side lamp switch 2/4 (Detail drawing: X)
SF1 DT2 12 Gearshift lever 2/4 (Overall drawing: Left)
SF2 DT2 2 Gearshift lever 2/4 (Overall drawing: Left)
SLL M 2 Left side lamp 1/4 (Overall drawing: Right)
SLR M 2 Right side lamp 1/4 (Overall drawing: Left)
S-NET - 5 S-NET monitoring connector 2/4 (Overall drawing: Right)
SP5 1-pin connector 1 Right speaker 1/4 (Overall drawing: Left)
SP6 1-pin connector 1 Right speaker 1/4 (Overall drawing: Left)
SP7 1-pin connector 1 Left speaker 1/4 (Overall drawing: Left)
SP8 1-pin connector 1 Left speaker 1/4 (Overall drawing: Left)
T01 DT2 2 Radiator water level switch 1/4 (Overall drawing: Left)
T03 DT2 2 Transmission filter clogging switch 1/4 (Overall drawing: Left)
T04 DT2 2 Steering oil temperature switch 1/4 (Overall drawing: Right)
T05 DT2 2 Hydraulic oil filter clogging switch 1/4 (Overall drawing: Right)
T06 DT2 2 Hydraulic oil level switch 1/4 (Overall drawing: Right)
T08 DT2 2 Fuel level sensor 1/4 (Overall drawing: Left)
T10 DT2 3 Inclination sensor 1/4 (Overall drawing: Right)
T11 DT2 - Air cleaner clogging sensor 1/4 (Overall drawing: Left)
T13 DT2 2 Rear retarder oil temperature sensor 1/4 (Overall drawing: Right)
T14 DT2 2 Center retarder oil temperature sensor 1/4 (Overall drawing: Right)
T15 DT2 2 Front brake oil temperature sensor 1/4 (Overall drawing: Left)
TC-INT DT2 3 Torque converter oil pressure sensor 4/4
TC-SE DT2 2 Torque converter oil temperature sensor 4/4
TEL DT2 12 Intermediate connector 2/4 (Overall drawing: Left)
TG 1-pin connector 1 Tachograph 1/4(Detail drawing: Z)
TG2 1-pin connector 1 Tachograph 1/4(Detail drawing: Z)
THL DT1 2 Fuel temperature sensor 3/4
TMF M 1 Intermediate connector 2/4 (Overall drawing: Right)
TMO M 1 Intermediate connector 2/4 (Overall drawing: Right)
TWH DT2 2 Engine water high-temperature sensor 3/4
TWL DT2 2 Engine water low-temperature sensor 3/4
WFM M 6 Front wiper motor 2/4 (Overall drawing: Left)
WFR Relay 6 Front wiper relay 2/4 (Overall drawing: Left)
WM M 4 Intermediate connector 1/4 (Overall drawing: Left)
WPS DT2 12 Wiper switch 2/4 (Overall drawing: Left)
WRF M 6 Front working lamp switch 2/4 (Detail drawing: X)
WRM M 4 Rear wiper motor 1/4 (Overall drawing: Left)
WRR M 6 Rear working lamp switch 2/4 (Detail drawing: X)
HM400-1L 20-227 b
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
X Type Connector
Number
of Pins T-adapter Part
Male (Female housing) Female (Male housing) Number
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010
2 799-601-7020
3 799-601-7030
4 799-601-7040
20-228 b HM400-1L
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
HM400-1L 20-229 b
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
16 799-601-7320
20-230 b HM400-1L
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
M Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
HM400-1L 20-231 b
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
8 799-601-7340
20-232 b HM400-1L
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
8 799-601-7140
10 (white) 799-601-7150
12 (white) 799-601-7350
16 (white) 799-601-7330
HM400-1L 20-233 b
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
10 (blue) —
— —
12 (blue) 799-601-7160
16 (blue) 799-601-7170
20-234 b HM400-1L
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
5 799-601-2710
9 799-601-2950
13 799-601-2720
HM400-1L 20-235 b
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
17 799-601-2730
21 799-601-2740
20-236 b HM400-1L
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
8 799-601-7180
12 799-601-7190
16 799-601-7210
20 799-601-7220
HM400-1L 20-237 b
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
10 799-601-7510
12 799-601-7520
14 799-601-7530
18 799-601-7540
20-238 b HM400-1L
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
20 799-601-7550
L Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing) Number
2 —
— —
PA Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
9 —
— —
HM400-1L 20-239 b
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
10 799-601-3460
— —
20-240 b HM400-1L
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
Part number: 08027-10410 (Natural color) Part number: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
6 —
Part number: 08027-10610 (Natural color) Part number: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
HM400-1L 20-241 b
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
8 —
Part number: 08027-10810 (Natural color) Part number: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
20-242 b HM400-1L
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
5 799-601-7360
— —
6 799-601-7370
— —
4 —
— —
HM400-1L 20-243 b
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
★ The pin No. is also marked on the connector (electric wire insertion end)
799-601-9210
799-601-9210
799-601-9220
799-601-9220
20-244 b HM400-1L
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
★ The pin No. is also marked on the connector (electric wire insertion end)
799-601-9230
799-601-9230
799-601-9240
799-601-9240
HM400-1L 20-245 b
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
★ The pin No. is also marked on the connector (electric wire insertion end)
799-601-9250
799-601-9250
799-601-9260
799-601-9260
20-246 b HM400-1L
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
★ The pin No. is also marked on the connector (electric wire insertion end)
799-601-9270
799-601-9270
799-601-9280
799-601-9280
HM400-1L 20-247 b
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
★ The pin No. is also marked on the connector (electric wire insertion end)
799-601-9290
799-601-9290
20-248 b HM400-1L
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
★ The pin No. is also marked on the connector (electric wire insertion end)
DT Series connector
Number
of Pins T-adapter Part
Body (plug) Body (receptacle)
Number
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
Part number: 08192-13200 (normal type) Part number: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)
4 799-601-9040
Part number: 08192-14200 (normal type) Part number: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)
6 799-601-9050
Part number: 08192-16200 (normal type) Part number: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)
HM400-1L 20-249 b
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
★ The pin No. is also marked on the connector (electric wire insertion end)
DT Series connector
Number
of Pins T-adapter Part
Body (plug) Body (receptacle)
Number
8GR: 799-601-9060
8B: 799-601-9070
8 8G: 799-601-9080
8BR: 799-601-9080
Part number: 08192-1820 T (normal type) Part number: 08192-1810 T (normal type)
08192-2820 T (fine wire type) 08192-2810 T (fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
10 12G: 799-601-9130
12BR: 799-601-9140
Part number: 08192-1920 T (normal type) Part number: 08192-1910 T (normal type)
08192-2920 T (fine wire type) 08192-2910 T (fine wire type)
20-250 b HM400-1L
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
★ The pin No. is also marked on the connector (electric wire insertion end)
DTM Series connector
Number of
Pins T-adapter Part
Body (plug) Body (receptacle)
Number
2 799-601-9010
1 —
Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
HM400-1L 20-251 b
TROUBLESHOOTING T-ADAPTER TABLE
T-ADAPTER TABLE
★ The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring harness checker
assemblies are shown in the lines.
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.
20-252 b HM400-1L
TROUBLESHOOTING T-ADAPTER TABLE
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.
HM400-1L 20-253 b
TROUBLESHOOTING T-ADAPTER TABLE
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.
20-254 b HM400-1L
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
12
CONNECTOR LAYOUT DRAWING
HM400-1L 20-255 b
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
20-256 b HM400-1L
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
12
HM400-1L 20-257 b
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
12
20-258 b HM400-1L
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
12
HM400-1L 20-259 b
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
12
20-260 b HM400-1L
TROUBLESHOOTING OF ENGINE CONTROL
SYSTEM (ENG MODE)
HM400-1L 20-301 1
TESTING AND ADJUSTING TABLE OF CONTENTS
(ENG-24) FAILURE CODE [D182KZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-360
OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL (KZ) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-360
(ENG-25) FAILURE CODE [D1D0KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-362
SHORT CIRCUIT IN VOLTAGE LOAD POWER SUPPLY (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-362
(ENG-26) FAILURE CODE [D5ZAKX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-364
ENGINE THROTTLE INPUT SIGNAL OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-364
(ENG-27) FAILURE CODE [DB20KT] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-366
CONTROLLER POWER SUPPLY (KT) VOLTAGE IS LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-366
(ENG-28) FAILURE CODE [DB22KK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-367
DROP IN VOLTAGE LOAD POWER SUPPLY (KK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-367
(ENG-29) FAILURE CODE [DB29KQ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-369
NONCONFORMANCE OF MODEL SELECTION SIGNALS IN ENGINE CONTROLLER WIRING
HARNESS (KQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-369
(ENG-30) FAILURE CODE [DB2AMA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-371
“Q” ADJUSTMENT FOR ENGINE CONTROLLER NOT SET PROPERLY (MA) . . . . . . . . . . . . . . . . 20-371
(ENG-31) FAILURE CODE [KK11KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-372
TROUBLE IN INPUT OF ignition switch C (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-372
(ENG-32) FAILURE CODE [DDA1L5] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-373
TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (L5) . . . . . . . . . . . . . . . . . . . . . . . 20-373
(ENG-33) FAILURE CODE [DDE2L6] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-375
ENGINE OIL PRESSURE DROP (L6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-375
(ENG-34) FAILURE CODE [DGE2KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-377
COOLANT TEMPERATURE (HIGH) SENSOR OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . . . . . . 20-377
(ENG-35) FAILURE CODE [DGE3LC] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-378
COOLANT TEMPERATURE (LOW) SENSOR OUT OF RANGE (L6) . . . . . . . . . . . . . . . . . . . . . . . . . 20-378
(ENG-36) FAILURE CODE [DGE4KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-379
TROUBLE IN FUEL TEMPERATURE SENSOR SYSTEM (KX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-379
(ENG-37) FAILURE CODE [DH30KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-380
TROUBLE IN BOOST PRESSURE SENSOR SYSTEM (KX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-380
(ENG-38) FAILURE CODE [DH40KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-382
TROUBLE IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM (KX) . . . . . . . . . . . . . . . . . . . 20-382
(ENG-39) FAILURE CODE [DK10KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-384
TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (KX) . . . . . . . . . . . . . . . . . . . . . . 20-384
(ENG-40) FAILURE CODE [DLE3LC] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-386
TROUBLE IN ENGINE NE SPEED SENSOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-386
(ENG-41) FAILURE CODE [DLE1LC] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-387
TROUBLE IN ENGINE G SPEED SENSOR SYSTEM (LC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-387
(ENG-42) NO FAILURE CODE DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-388
ENGINE DOES NOT CRANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-388
20-302 1 HM400-1L
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
HM400-1L 20-303 1
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
20-304 1 HM400-1L
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
HM400-1L 20-305 1
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
20-306 1 HM400-1L
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
HM400-1L 20-307 1
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
20-308 1 HM400-1L
TROUBLESHOOTING ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM
HM400-1L 20-309 1
TROUBLESHOOTING ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM
20-310 1 HM400-1L
TROUBLESHOOTING ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM
12
HM400-1L 20-311 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
CONTENT OF CODE DISPLAY
Failure
Location Of Failure Nature Of Failure Probable Cause
Code
A000N1 Engine: Over speed (N1) ENG-1 C. Engine speed went above
(ENG-1) operating range
A570NX Engine oil filter: Clogged (NX) Signal circuit of engine oil filter clog- • Clogged engine oil filter (when
(ENG-2) ging switch became open (shut off system is working normally)
from GND) while engine was running • Defective engine oil filter clogging
switch
• Open in switch signal circuit wiring
harness
• Defective engine controller
AD00L2 Common rail: * See Contents (L2) Common rail fuel pressure has risen • Viscosity of fuel is too high
(ENG-3) to high pressure (level 1) (unsuitable fuel)
• Defective overflow valve
• Clogged overflow piping
• Defective pressure limiter
• Defective common rail fuel
pressure sensor
AD00MA Common rail: Function impossible Common rail fuel pressure has risen • Same as failure code [AD00L2]
(ENG-4) (MA) to high pressure (level 2)
AD10L3 Fuel supply pump: * See Contents Non-force feed (level 1) has occurred • Defective fuel low-pressure circuit
(ENG-5) (L3) in fuel supply pump (etc.)
• Defective fuel supply pump PCV
• Defective pressure limiter
• Defective common rail fuel
pressure sensor
• Defective fuel injector
• Leakage from high-pressure fuel
piping
AD10MA Fuel supply pump: Function impossi- Abnormal pressure has occurred in • Same as failure code [AD00L2]
(ENG-6) ble (MA) common rail fuel pressure
AD10MB Fuel supply pump: Drop in function Non-force feed (level 2) has occurred • Same as failure code [AD10L3]
(ENG-7) (MB) in fuel supply pump
AD11KA Fuel supply pump solenoid valve 1: Open has occurred in PCV1 circuit of • Defective fuel supply pump PCV1
(ENG-8) Open (KA) fuel supply pump • Open in PCV1 (+) circuit wiring
harness
• Open or short circuit with chassis
ground in PCV1 (-) circuit wiring
harness
• Defective engine controller
AD11KB Fuel supply pump solenoid valve 1: Excessive current has flowed in • Defective fuel supply pump PCV1
(ENG-9) Short circuit (KB) PCV1 circuit of fuel supply pump • Short circuit with chassis ground or
short circuit with power source in
PCV1 (+) circuit wiring harness
• Short circuit with power source in
PCV1 (-) circuit wiring harness
• Defective engine controller
20-312 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
A. Sensor resistance value • Carries out operation under • If machine continues to be used as E01
of terminal normal control it is, there is danger that dirt will
• When normal: Max. 1 W circulate inside engine
• When clogged: Min. 1 MW
• Carries out operation with limited • Engine output and speed are E03
output and engine speed reduced
• Carries out operation with limited • Engine output is reduced E03
output
• Solenoid resistance value • Turns output to PCV1 OFF • No great effect on machine E03
PCV1 (male) (1) - (2): 2.3 - 5.3 W (however, if failure code [AD51KB]
occurs at the same time, the
engine stops)
HM400-1L 20-313 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Failure
Location Of Failure Nature Of Failure Probable Cause
Code
AD51KA Fuel supply pump solenoid valve 2: An open has occurred in the PCV2 • Defective fuel supply pump PCV2
(ENG-10) Open (KA) circuit of the fuel supply pump • Open in PCV2 (+) circuit wiring
harness
• Open or short circuit with chassis
ground in PCV2 (-) circuit wiring
harness
• Defective engine controller
AD51KB Fuel supply pump solenoid valve 2: Excessive current has flowed in • Defective fuel supply pump PCV2
(ENG-11) Short circuit (KB) PCV2 circuit of fuel supply pump • Short circuit with chassis ground or
short circuit with power source in
PCV2 (+) circuit wiring harness
• Short circuit with power source in
PCV1 (-) circuit wiring harness
• Defective engine controller
ADA1KA No. 1 injector solenoid valve: Open An open has occurred in No. 1 injec- • Defective No. 1 injector solenoid
(ENG-12) (KA) tor solenoid circuit • Open in solenoid (+) circuit wiring
harness
• Open in solenoid (-) circuit wiring
harness
• Defective engine controller
ADZKKB No. 1, 2, 3 injector solenoid valve: Excessive current has flowed in No. • Defective No. 1 injector solenoid
(ENG-13) Short circuit (KB) 1 injector solenoid circuit, No. 2 injec- • Defective No. 2 injector solenoid
tor solenoid circuit, or No. 3 injector • Defective No. 3 injector solenoid
solenoid circuit • Short circuit with chassis ground or
short circuit with power source in
No. 1 solenoid (+) circuit and
(-) circuit wiring harness
• Short circuit with chassis ground or
short circuit with power source in
No. 2 solenoid (+) circuit and
(-) circuit wiring harness
• Short circuit with chassis ground or
short circuit with power source in
No. 3 solenoid (+) circuit and
(-) circuit wiring harness
• Defective engine controller
ADB1KA No. 2 injector solenoid valve: Open Open has occurred in No. 2 injector • Defective No. 2 injector solenoid
(ENG-14) (KA) solenoid circuit • Open in solenoid (+) circuit wiring
harness
• Open in solenoid (-) circuit wiring
harness
• Defective engine controller
ADC1KA No. 3 injector solenoid valve: Open Open has occurred in No. 3 injector • Defective No. 3 injector solenoid
(ENG-15) (KA) solenoid circuit • Open in solenoid (+) circuit wiring
harness
• Open in solenoid (-) circuit wiring
harness
• Defective engine controller
ADD1KA No. 4 injector solenoid valve: Open Open has occurred in No. 4 injector • Defective No. 4 injector solenoid
(ENG-16) (KA) solenoid circuit • Open in solenoid (+) circuit wiring
harness
• Open in solenoid (-) circuit wiring
harness
• Defective engine controller
20-314 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
• Solenoid resistance value • Turns output to PCV2 OFF • No great effect on machine E03
PCV2 (male) (1) - (2): 2.3 - 5.3 Ω (however, if failure code [AD11KB]
occurs at the same time, the
engine stops)
• Solenoid resistance value • Turns output to No. 1 injector • Engine output is reduced E03
CN1 (male) (1) - (2): 0.4 - 1.1 Ω solenoid OFF
• Solenoid resistance value • Turns output to No. 1 injector • Engine output is greatly reduced E03
CN1 (male) (1) - (2): 0.4 - 1.1 Ω solenoid OFF
CN2 (male) (1) - (2): 0.4 - 1.1 Ω • Turns output to No. 2 injector
CN3 (male) (1) - (2): 0.4 - 1.1 Ω solenoid OFF
• Turns output to No. 3 injector
solenoid OFF
• Solenoid resistance value • Turns output to No. 2 injector • Engine output is reduced E03
CN2 (male) (1) - (2): 0.4 - 1.1 Ω solenoid OFF
• Solenoid resistance value • Turns output to No. 3 injector • Engine output is reduced E03
CN3 (male) (1) - (2): 0.4 - 1.1 Ω solenoid OFF
• Solenoid resistance value • Turns output to No. 4 injector • Engine output is reduced E03
CN4 (male) (1) - (2): 0.4 - 1.1 Ω solenoid OFF
HM400-1L 20-315 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
Failure
Location Of Failure Nature Of Failure Probable Cause
Code
ADDZKB No. 4, 5, 6 injector solenoid valve: Excessive current has flowed in No. • Defective No. 4 injector solenoid
(ENG-17) Short circuit (KB) 4 injector solenoid circuit, No. 5 injec- • Defective No. 5 injector solenoid
tor solenoid circuit, or No. 6 injector • Defective No. 6 injector solenoid
solenoid circuit • Short circuit with chassis ground or
short circuit with power source in
No. 4 solenoid (+) circuit and
(-) circuit wiring harness
• Short circuit with chassis ground or
short circuit with power source in
No. 5 solenoid (+) circuit and
(-) circuit wiring harness
• Short circuit with chassis ground or
short circuit with power source in
No. 6 solenoid (+) circuit and
(-) circuit wiring harness
• Defective engine controller
ADE1KA No. 5 injector solenoid valve: Open Open has occurred in No. 5 injector • Defective No. 5 injector solenoid
(ENG-18) (KA) solenoid circuit • Open in solenoid (+) circuit wiring
harness
• Open in solenoid (-) circuit wiring
harness
• Defective engine controller
ADF1KA No. 6 injector solenoid valve: Open Open has occurred in No. 6 injector • Defective No. 6 injector solenoid
(ENG-19) (KA) solenoid circuit • Open in solenoid (+) circuit wiring
harness
• Open in solenoid (-) circuit wiring
harness
• Defective engine controller
B@BAZG Engine oil: Drop in oil pressure (ZG) When running at low idling, signal cir- • Drop in oil pressure (when system
(ENG-20) cuit of engine oil pressure low-pres- is working normally)
sure switch became closed • Defective engine oil low-pressure
(connected to GND), or when engine switch
speed was more than 1300 rpm, sig- • Defective engine oil high-pressure
nal circuit of oil pressure high-pres-
switch
sure switch became closed
(connected to GND) • Short circuit with chassis ground in
low or high -pressure switch signal
circuit wiring harness
• Defective engine controller
B@BAZK Engine oil: Drop in level (ZK) Signal circuit of engine oil pressure • Drop in engine oil level (when
(ENG-21) switch became open (shut off from system is working normally)
GND) • Defective engine oil level switch
• Open in switch circuit wiring
harness
• Defective engine controller
B@BCNS Radiator coolant: Overheat (NS) Engine coolant temperature went • Engine coolant temperature
(ENG-22) above operating range overheats (when system is
working normally)
• Defective engine controller
D181KZ Preheating relay contact: Open or Open, short circuit with ground, or • Defective heater relay
(ENG-23) short circuit (KZ) short circuit with power source has • Defective preheater relay
occurred in signal circuit of heater • Open, short circuit with chassis
relay ground, or short circuit with power
source in relay signal circuit wiring
harness
• Defective engine controller
20-316 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
• Solenoid resistance value • Turns output to No. 5 injector • Engine output is reduced E03
CN5 (male) (1) - (2): 0.4 - 1.1 W solenoid OFF
• Solenoid resistance value • Turns output to No. 6 injector • Engine output is reduced E03
CN6 (male) (1) - (2): 0.4 - 1.1 W solenoid OFF
• Low-pressure switch resistance • Carries out operation under • If the machine continues to be E03
value PSL - ground normal control used as it is, the engine may seize
• When engine is stopped: up
Max. 1W
• When engine speed is 600 rpm or
more: Min. 1 MW
PSH - ground
• When engine is stopped:
Max. 1W
• When engine speed is 1300 rpm or
more: Min. 1 MW
• Switch resistance value • Carries out operation under • If the machine continues to be E01
OL (male) (1) - ground normal control used as it is, the engine may seize
• When oil level is normal: Max. 1 W up
• When oil level is low: Min. 1 MW
• Preheating input signal voltage • Carries out operation under • It is difficult to start the engine in E03
CN4 (3) - ground normal control low temperatures
• When preheating is stopped: Max.
1V
• When preheating is being used: 20
- 30 V
HM400-1L 20-317 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
DB22KK Engine controller load power Voltage in controller power sup- • Defective engine power source relay
(ENG-28) source relay: Drop in power ply voltage circuit dropped when • Open or short circuit with chassis ground in
source voltage (KT) ignition switch was ON relay (1) circuit wiring harness
• Open or short circuit with chassis ground in
relay (2) circuit wiring harness
• Open or short circuit with chassis ground in
relay (3) circuit wiring harness
• Open or short circuit with chassis ground in
relay (5) circuit wiring harness
• Defective engine controller
DB29KQ Engine controller connecting wir- Model selection signal does not • Defective model selection connector
(ENG-29) ing harness: Model selection sig- match setting inside controller • Open in signal 1 circuit wiring harness
nal mismatch (KQ) • Open in signal 2 circuit wiring harness
• Open in signal 3 circuit wiring harness
• Open in GND circuit wiring harness
• Defective engine controller
DB2AMA Engine controller fuel injection Fuel injection quantity control set • Defective setting of fuel injection quantity
(ENG-30) quantity control switch: Function switch inside controller is not set control setting switch
impossible (MA) at correct position • Defective engine controller
KK11KB Ignition switch: Short circuit (KB) Terminal C signal from ignition • Defective ignition switch
(ENG-31) switch came ON when engine • Short circuit with power source in signal
was running circuit wiring harness
• Defective engine controller
DDA1L5 Acceleration switch: * See Con- Idling validation switch of accel- • Defective accelerator pedal
(ENG-32) tents (L5) erator pedal does not match • Open, short circuit with chassis ground, or
throttle angle signal short circuit with power source in switch
signal 2 wiring harness
• Open, short circuit with chassis ground, or
short circuit with power source in switch
signal 3 wiring harness
• Open in switch GND circuit wiring harness
• Defective engine controller
20-318 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
• Power source voltage • Carries out operation under nor- • No great effect on machine E01
CN7 (6) (14) - (5) (13) mal control
Ignition switch is OFF: Max. 1 V
Ignition switch is ON: 20 - 30 V
• Signal voltage • Does not modify throttle • There is shock when shifting E01
CN4 (16) - ground: 6 - 15 V transmission
• Signal voltage • Uses model with default setting to • Does not give specified engine E03
CN4 (13) - ground: Max. 1 V carry out control output
CN4 (14) - ground: 20 - 30 V
CN4 (15) - ground: Max. 1 V
• Signal voltage • Carries out operation under • Operates normally 10 seconds E03
CN4 (2) - ground normal control after starting
When Ignition switch is ON:
Max. 1 V
When Ignition switch is at START:
20 - 30 V
• CN4 (11) - ground (signal 2) • Carries out operation under • No great effect on machine E01
Throttle voltage normal control
•When less than 0.446 V: Max. 1 V
• When more than 0.446 V: 15 - 30 V
• CN4 (12) - ground (signal 3)
Throttle voltage
•When less than 0.446 V: 20 - 30 V
•When more than 0.446 V: Max. 1 V
HM400-1L 20-319 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
DGE2KX Engine coolant temperature sen- Signal from engine coolant high- • Defective engine coolant high-temperature
(ENG-34) sor (for high temperature): Input temperature sensor is outside sensor
signal outside range (KX) normal range • Open or short circuit with chassis ground in
sensor signal circuit wiring harness
• Defective engine controller
DGE3LC Failure code [DGE3LC] (Engine Engine coolant temperature sen- • Defective engine coolant low-temperature
(ENG-35) coolant temperature sensor sor (for low temperature): * See sensor
(low-temperature): * See Con- Contents (L6) • Open or short circuit with chassis ground in
tents (L6))
sensor signal circuit wiring harness
• Defective engine controller
DGE4KX Fuel temperature sensor: Input Signal from fuel temperature • Defective fuel temperature sensor
(ENG-36) signal outside range (KX) sensor is outside normal range • Open or short circuit with chassis ground in
sensor signal circuit wiring harness
• Open in sensor GND circuit wiring harness
• Defective engine controller
DH30KX Boost pressure sensor: Input Signal from boost sensor is out- • Defective boost pressure sensor
(ENG-37) signal outside range (KX) side normal range • Open or short circuit with chassis ground in
sensor power source circuit wiring harness
• Open or short circuit with chassis ground in
sensor GND circuit wiring harness
• Open or short circuit with chassis ground in
sensor signal circuit wiring harness
• Defective engine controller
DH40KX Common rail pressure sensor: Signal from common rail fuel • Defective common rail fuel pressure sensor
(ENG-38) Input signal outside range (KX) pressure sensor is outside nor- • Open or short circuit with chassis ground in
mal range sensor power source circuit wiring harness
• Open or short circuit with chassis ground in
sensor signal circuit wiring harness
• Defective engine controller
DK10KX Throttle angle sensor: Input sig- Throttle angle signal from accel- • Defective accelerator pedal
(ENG-39) nal outside range (KX) erator pedal is outside normal • Open or short circuit with chassis ground in
range sensor power source circuit wiring harness
• Open or short circuit with chassis ground in
sensor signal circuit wiring harness
• Defective engine controller
20-320 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Action
Condition When Normal Action By Controller Problem That Appears On Machine
Code
• Low-pressure switch resistance • Carries out operation under • If the machine continues to be E01
value PSL - ground normal control used as it is, the engine may seize
• With engine stopped: 1 Ω up
• Engine speed is 600 rpm or
more: Min. 1 MΩ
• High-pressure switch resistance
value PSH - ground
• When engine is stopped:
Max. 1Ω
• When engine speed is 1300
rpm or more: Min. 1 MΩ
• Sensor resistance value • Carries out operation under nor- • Coolant temperature display on E01
(coolant temperature: 10 - 100°C) mal control machine monitor is not correct
• TWH (male) (1) - (2): 90 - 3.5 kΩ • Fixes coolant temperature signal
output to machine monitor to 90°C
• Sensor resistance value • Carries out operation under • Exhaust gas color in low E01
(coolant temperature: 10 - 100°C) normal control temperatures is poor
• TWL (male) (1) - (2): 9 - 0.3 kΩ • It is difficult to start the engine in
low temperatures
• Sensor resistance value (fuel • Carries out operation under • Output drops slightly in low E01
temperature: 10 - 100°C)THL normal control temperatures
(male) (1) - (2): 9 - 0.3 kΩ
• Sensor power source voltage Carries out operation under normal • No great effect on machine E03
PIM (1) - (3): 4.6 - 5.4 V control
• Sensor signal voltage
PIM (2) - (3): 0.3 - 4.7 V
• Sensor power source voltage • Limits output with open control • Engine output is reduced E03
PFUEL (1) - (3): 4.6 - 5.4 V
• Sensor signal voltage
PFUEL (2) - (3): 0.3 - 4.7 V
• Sensor power source voltage • Controls at low idling or high idling • Engine speed is fixed at low idling E03
AS1 (3) - (1): 4.6 - 5.4 V according to signal from idling or high idling, it is impossible to
• Sensor signal voltage validation switch control acceleration at medium
AS1 (2) - (1): 0.3 - 4.5 V range
HM400-1L 20-321 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Failure
Location Of Failure Nature Of Failure Probable Cause
Code
DLE3LC Engine Ne speed sensor: * See Con- Signal from engine Ne speed sensor • Defective engine Ne speed sensor
(ENG-40) tents (LC) does not match signal from engine G • Open or short circuit with chassis
speed sensor ground in sensor signal circuit
wiring harness
• Open or short circuit with chassis
ground in sensor GND circuit
wiring harness
• Defective engine controller
DLE1LC Engine G speed sensor: * See Con- Signal from engine G speed sensor • Defective engine G speed sensor
(ENG-41) tents (LC) does not match signal from engine • Open or short circuit with chassis
Ne speed sensor ground in sensor signal circuit
wiring harness
• Open or short circuit with chassis
ground in sensor GND circuit
wiring harness
• Defective engine controller
20-322 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
• Sensor resistance value • Carries out operation with limited • Engine output is reduced E03
• G (male) (1) - (2): 1.4 - 3.5 kW output
HM400-1L 20-323 1
TROUBLESHOOTING INFORMATION CONTAINED IN TESTING PROCEDURES
• Failure.
Contents Of Trouble • Failure code displayed.
• Additional information.
Tools and Procedures
Steps Circuit Diagnostic Procedures For Service Code Specifications No. Readings
1. Sensor or Actuator
• With ignition switch in the “OFF” position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸)
• Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
• Zero meter leads for proper Ω readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)
Your
Test procedure for component only. readings 1
Resistance Ω information
A. What you are testing
or Voltage
Your
Test procedure for component only. readings 2
information
2. Diode Test
• With ignition switch in the “OFF” position. (The importance of these tests are to isolate each component for testing separately)
• When checking a diode always isolate the circuit. Check diode continuity in both directions reversing meter leads each time to confirm
electrical flow. Electrical flow should be one way only. (See section 20-111 for detail).
Your
Test procedure for harness. (connector) to (connector) readings 4
information
A. Open or high Resistance Ω
resistance or Voltage
Your
Test procedure for harness. (connector) to (connector) readings 5
information
Your
Test procedure for harness. (connector) to (connector) readings 6
B. Short to chassis information
Resistance Ω
ground or within
or Voltage Your
harness
Test procedure for harness. (connector) to (connector) readings 7
information
Resistance Ω Your
A. What you are testing Test procedure for any additional components. readings 8
or Voltage information
20-324 1 HM400-1L
TROUBLESHOOTING INFORMATION CONTAINED IN TESTING PROCEDURES
Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
HM400-1L 20-325 1
TROUBLESHOOTING (ENG-1) FAILURE CODE [A000N1]
Related Informa- • Engine speed can be checked with monitoring function (Code: 01004).
tion
Causes Standard Value in Normal State and Remarks on Troubleshooting
1) Turn ignition switch ON.
2) Operate machine monitor.
1 —
Perform troubleshooting for
Another code is displayed, too.
displayed code.
Diagnostic
When machine is so used that engine Remove cause and repair damaged
procedures for 2 Overrun of engine will overrun. parts of engine.
error code
1) Start engine.
2) Operate machine monitor.
3 Defective engine controller Engine speed can be read normally. Defective engine controller.
Engine speed cannot be read Perform troubleshooting for error
normally. codes [DEL3LG] and [DEH1LC].
20-326 1 HM400-1L
TROUBLESHOOTING (ENG-2) FAILURE CODE [A570NX]
12
(ENG-2) FAILURE CODE [A570NX]
Steps Circuit Diagnostic Procedures For Error Code [A570NX] Specifications No. Readings
Engine Oil Filter — Install a new oil filter and change engine oil Failure code? 1 Yes or No
A. Sensor test Resistance Ω At sensor EG5, between (23) and chassis ground. (OL) open 2
A. Open or high
Resistance Ω Between connectors EG5, (23) and CN6, (5) 0.0 to 1.0Ω 3
resistance
B. Short to chassis
ground or within Resistance Ω At connector EG5, between (23) and chassis ground. (OL) open 4
harness
HM400-1L 20-327 1
TROUBLESHOOTING (ENG-3) FAILURE CODE [AD00L2]
• The common rail pressure can be checked with monitoring function (Code: 36400).
Related • The converted torque can be checked with monitoring function (Code: 36700).
Information
• Engine speed can be checked with monitoring function (Code: 01004).
20-328 1 HM400-1L
TROUBLESHOOTING (ENG-4 OR 5) FAILURE CODE [AD00MA] OR [AD10L3]
• The common rail pressure can be checked with monitoring function (Code: 36400).
Related • The converted torque can be checked with monitoring function (Code: 36700).
Information
• Engine speed can be checked with monitoring function (Code: 01004).
HM400-1L 20-329 1
TROUBLESHOOTING (ENG-4 OR 5) FAILURE CODE [AD00MA] OR [AD10L3]
• Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter
Disassemble and check the filter. If it is clogged, clean.
2) Upstream strainer of gauze filter
If the gauze filter is clogged, clean the upstream strainer, too.
3) Fuel filter
If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
• Check the low-pressure circuit parts for the following items.
1) Remaining fuel
2) Sticking and wear of feed pump
3) Leakage and clogging of low-pressure fuel piping
4) Defective operation of bypass valve or installation of wrong parts to bypass valve
5) Oil pan oil mixed with fuel (fuel leakage in head cover)
★ Locations of overflow valve ➀ bypass valve ➁, and fuel inlet joint (gauze filter) ➂
• Overflow valve ➀ : Spring is seen through one hole (on nut side).
• Bypass valve ➁ : Spring is seen through both holes.
• Fuel inlet joint ➂ : Gauze filter is seen through both holes.
20-330 1 HM400-1L
TROUBLESHOOTING (ENG-4 OR 5) FAILURE CODE [AD00MA] OR [AD10L3]
12
• Method Of Measuring Fuel Spill Rate
WARNING! Since the fuel is hot max. 90° C (194° F), be careful.
1) Disconnect the hose from the collection part of the return spill tube (at the rear of the engine.
2) Connect a hose to the spill tube end to receive the spilling fuel.
3) Start the engine and stall at each speed and measure the quantity of the fuel spilling in 1 minute.
HM400-1L 20-331 1
TROUBLESHOOTING (ENG-8 OR 9) FAILURE CODE [AD11KA] or [AD11KB]
Steps Circuit Diagnostic Procedures For Error Codes [AD11KA] and [AD11KB] Specifications No. Readings
A. Open or high Between connectors PCV1, (1) and CN7, (10) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors PCV1, (2) and CN7, (11) 0.0 to 1.0Ω 4
At connector PCV1, between (1) and chassis ground. (OL) open 5
B. Short to chassis
ground or within Resistance Ω At connector PCV1, between (2) and chassis ground. (OL) open 6
harness
At connector PCV1, between (1) and (2) (OL) open 7
3. Engine Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Engine Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-332 1 HM400-1L
TROUBLESHOOTING (ENG-8 OR 9) FAILURE CODE [AD11KA] or [AD11KB]
Related circuit diagram
HM400-1L 20-333 1
TROUBLESHOOTING (ENG-10 OR 11) FAILURE CODE [AD51KA] or [AD51KB]
Steps Circuit Diagnostic Procedures For Error Codes [AD51KA] and [AD51KB] Specifications No. Readings
A. Open or high Between connectors PCV2, (1) and CN7, (4) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors PCV2, (2) and CN7, (12) 0.0 to 1.0Ω 4
At connector PCV2, between (1) and chassis ground. (OL) open 5
B. Short to chassis
ground or within Resistance Ω At connector PCV2, between (2) and chassis ground. (OL) open 6
harness
At connector PCV2, between (1) and (2) (OL) open 7
3. Engine Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Engine Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-334 1 HM400-1L
TROUBLESHOOTING (ENG-12) FAILURE CODE [ADA1KA]
Steps Circuit Diagnostic Procedures For Error Code [ADA1KA] Specifications No. Readings
At No.1 injector solenoid CN1, between (1) and (2) 0.4 to 1.1Ω 1
A. Solenoid test Resistance Ω At No.1 injector solenoid CN1, between (1) or (2)
(OL) open 2
and chassis ground.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (CN1) connector from injector solenoid.
• Disconnect (CN6) connector from engine controller and install T-adapter on (CN6) wiring harness connector only.
A. Open or high Between connectors CN6, (7) and CN1, (1) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors CN6, (8) and CN1, (2) 0.0 to 1.0Ω 4
3. Engine Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Engine Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-335 1
TROUBLESHOOTING (ENG-12) FAILURE CODE [ADA1KA]
Related circuit diagram
20-336 1 HM400-1L
TROUBLESHOOTING (ENG-13) FAILURE CODE [ADZKKB]
WARNING! High voltage and amperage are applied to the electrical circuit in the fuel injector system,
be careful when troubleshooting this system, refer to TESTING AND ADJUSTING,
handling high-voltage circuits on engine controller.
Steps Circuit Diagnostic Procedures For Error Code [ADZKKB] Specifications No. Readings
At sensor CN2, between (1) or (2) and chassis ground. (OL) open 5
At sensor CN3, between (1) or (2) and chassis ground. (OL) open 6
HM400-1L 20-337 1
TROUBLESHOOTING (ENG-13) FAILURE CODE [ADZKKB]
Injector #1
Injector #2
20-338 1 HM400-1L
TROUBLESHOOTING (ENG-13) FAILURE CODE [ADZKKB]
Injector #3
HM400-1L 20-339 1
TROUBLESHOOTING (ENG-14) FAILURE CODE [ADB1KA]
Steps Circuit Diagnostic Procedures For Error Code [ADB1KA] Specifications No. Readings
At No.2 injector solenoid CN2, between (1) and (2) 0.4 to 1.1Ω 1
A. Solenoid test Resistance Ω At No.2 injector solenoid CN2, between (1) or (2)
(OL) open 2
and chassis ground.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (CN2) connector from injector solenoid.
• Disconnect (CN6) connector from engine controller and install T-adapter on (CN6) wiring harness connector only.
A. Open or high Between connectors CN6, (4) and CN2, (1) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors CN6, (10) and CN2, (2) 0.0 to 1.0Ω 4
3. Engine Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Engine Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-340 1 HM400-1L
TROUBLESHOOTING (ENG-14) FAILURE CODE [ADB1KA]
Related circuit diagram
HM400-1L 20-341 1
TROUBLESHOOTING (ENG-15) FAILURE CODE [ADC1KA]
Steps Circuit Diagnostic Procedures For Error Code [ADC1KA] Specifications No. Readings
At No.3 injector solenoid CN3, between (1) and (2) 0.4 to 1.1Ω 1
A. Solenoid test Resistance Ω At No.3 injector solenoid CN3, between (1) or (2)
(OL) open 2
and chassis ground.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (CN3) connector from injector solenoid.
• Disconnect (CN6) connector from engine controller and install T-adapter on (CN6) wiring harness connector only.
A. Open or high Between connectors CN6, (3) and CN3, (1) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors CN6, (9) and CN3, (2) 0.0 to 1.0Ω 4
3. Engine Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Engine Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-342 1 HM400-1L
TROUBLESHOOTING (ENG-15) FAILURE CODE [ADC1KA]
Related circuit diagram
HM400-1L 20-343 1
TROUBLESHOOTING (ENG-16) FAILURE CODE [ADD1KA]
Steps Circuit Diagnostic Procedures For Error Code [ADD1KA] Specifications No. Readings
At No.4 injector solenoid CN4, between (1) and (2) 0.4 to 1.1Ω 1
A. Solenoid test Resistance Ω At No.4 injector solenoid CN4, between (1) or (2)
(OL) open 2
and chassis ground.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (CN4) connector from injector solenoid.
• Disconnect (CN7) connector from engine controller and install T-adapter on (CN7) wiring harness connector only.
A. Open or high Between connectors CN7, (3) and CN4, (1) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors CN7, (9) and CN4, (2) 0.0 to 1.0Ω 4
3. Engine Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Engine Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-344 1 HM400-1L
TROUBLESHOOTING (ENG-16) FAILURE CODE [ADD1KA]
Related circuit diagram
HM400-1L 20-345 1
TROUBLESHOOTING (ENG-17) FAILURE CODE [ADDZKB]
WARNING! Since high voltage and amperage are applied to the electrical circuit in the fuel injector
system, be careful when troubleshooting this system, refer to TESTING AND
ADJUSTING, handling high-voltage circuits on engine controller.
Steps Circuit Diagnostic Procedures For Error Code [ADDZKB] Specifications No. Readings
At sensor CN5, between (1) or (2) and chassis ground. (OL) open 5
At sensor CN6, between (1) or (2) and chassis ground. (OL) open 6
20-346 1 HM400-1L
TROUBLESHOOTING (ENG-17) FAILURE CODE [ADDZKB]
Injector #4
Injector #5
HM400-1L 20-347 1
TROUBLESHOOTING (ENG-17) FAILURE CODE [ADDZKB]
Injector #6
20-348 1 HM400-1L
TROUBLESHOOTING (ENG-18) FAILURE CODE [ADE1KA]
Steps Circuit Diagnostic Procedures For Error Code [ADE1KA] Specifications No. Readings
At No.5 injector solenoid CN5, between (1) and (2) 0.4 to 1.1Ω 1
A. Solenoid test Resistance Ω At No.5 injector solenoid CN5, between (1) or (2)
(OL) open 2
and chassis ground.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (CN5) connector from injector solenoid.
• Disconnect (CN7) connector from engine controller and install T-adapter on (CN7) wiring harness connector only.
A. Open or high Between connectors CN7, (1) and CN5, (1) 0.0 to 1.0Ω 2
Resistance Ω
resistance Between connectors CN7, (7) and CN5, (2) 0.0 to 1.0Ω 3
3. Engine Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Engine Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-349 1
TROUBLESHOOTING (ENG-18) FAILURE CODE [ADE1KA]
Related circuit diagram
20-350 1 HM400-1L
TROUBLESHOOTING (ENG-19) FAILURE CODE [ADF1KA]
Steps Circuit Diagnostic Procedures For Error Code [ADF1KA] Specifications No. Readings
At No.6 injector solenoid CN6, between (1) and (2) 0.4 to 1.1Ω 1
A. Solenoid test Resistance Ω At No.6 injector solenoid CN6, between (1) or (2)
(OL) open 2
and chassis ground.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (CN1) connector from injector solenoid.
• Disconnect (CN7) connector from engine controller and install T-adapter on (CN7) wiring harness connector only.
A. Open or high Between connectors CN7, (2) and CN6, (1) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors CN7, (8) and CN6, (2) 0.0 to 1.0Ω 4
3. Engine Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Engine Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-351 1
TROUBLESHOOTING (ENG-19) FAILURE CODE [ADF1KA]
Related circuit diagram
20-352 1 HM400-1L
TROUBLESHOOTING (ENG-20) FAILURE CODE [B@BAZG]
Steps Circuit Diagnostic Procedures For Error Code [B@BAZG] Specifications No. Readings
High idle
Perform a live oil pressure test on engine.
.12 to.18 MPa High idle
(If engine oil pressure is not within listed specifications
Engine Oil Pressure — (30 to 26 psi) 1
do not continue with electrical testing.
Low idle Low idle
See ENGINE SHOP MANUAl)
.07 MPa (10 psi)
A. Open or high Between pressure switch EG5, (12) and CN4, (5) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between pressure switch EG5, (13) and CN4, (6) 0.0 to 1.0Ω 5
HM400-1L 20-353 1
TROUBLESHOOTING (ENG-20) FAILURE CODE [B@BAZG]
Related circuit diagram
20-354 1 HM400-1L
TROUBLESHOOTING (ENG-21) FAILURE CODE [B@BAZK]
Steps Circuit Diagnostic Procedures For Error Code [B@BAZK] Specifications No. Readings
Engine Oil Level — Check engine oil level Within Spec. 1 Yes or No
A. Pressure switch Resistance Ω At switch OL, between (22) and chassis ground. (OL) open 2
B. Short to
chassis ground Resistance Ω At connector OL, (1) and chassis ground. (OL) open 4
or within harness
HM400-1L 20-355 1
TROUBLESHOOTING (ENG-22) FAILURE CODE [B@BCNS]
Steps Circuit Diagnostic Procedures For Error Code [B@BCNS] Specifications No. Readings
At sensor TWH, between (1) and (2) at 10°C (50°F) Approx. 90kΩ 1
A. Sensor test Resistance Ω At sensor TWH, between (1) and (2) at 100°C (212°F) Approx. 3.5kΩ 2
At sensor TWH, between (1) or (2) and chassis ground. (OL) open 3
A. Open or high Between connectors TWH, (1) and CN2, (10) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors TWH, (2) and CN2, (4) 0.0 to 1.0Ω 5
At connector TWH, between (1) and chassis ground. (OL) open 6
B. Short to chassis
ground or within Resistance Ω At connector TWH, between (2) and chassis ground. (OL) open 7
harness
At connector TWH, between (1) and (2) (OL) open 8
3. Engine Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Engine Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-356 1 HM400-1L
TROUBLESHOOTING (ENG-22) FAILURE CODE [B@BCNS]
Related circuit diagram
HM400-1L 20-357 1
TROUBLESHOOTING (ENG-23) FAILURE CODE [D181KZ]
Steps Circuit Diagnostic Procedures For Error Code [D181KZ] Specifications No. Readings
Voltage Check for voltage at EG1, (3) (check for blown fuse) 20 to 30V 1
A. Open or high Resistance Ω Between connectors R37, (5) and EG4, (31) 0.0 to 1.0Ω 6
resistance Between connectors CN4, (3) and EG5, (11) 0.0 to 1.0Ω 7
B. Short to Between connectors R37, (2) and chassis ground. (OL) open 9
chassis ground
or within harness Between connectors R37, (5) and chassis ground. (OL) open 10
Resistance Ω
Between connectors R37, (3)/(5) and chassis ground. (OL) open 11
20-358 1 HM400-1L
TROUBLESHOOTING (ENG-23) FAILURE CODE [D181KZ]
HM400-1L 20-359 1
TROUBLESHOOTING (ENG-24) FAILURE CODE [D182KZ]
Steps Circuit Diagnostic Procedures For Error Code [D182KZ] Specifications No. Readings
Voltage Check for voltage at EG1, (3) (check for blown fuse) 20 to 30V 1
A. Open or high Resistance Ω Between connectors R37, (5) and EG4, (31) 0.0 to 1.0Ω 6
resistance Between connectors CN4, (3) and EG5, (11) 0.0 to 1.0Ω 7
B. Short to Between connectors R37, (2) and chassis ground. (OL) open 9
chassis ground
or within harness Between connectors R37, (5) and chassis ground. (OL) open 10
Resistance Ω
Between connectors R37, (3)/(5) and chassis ground. (OL) open 11
20-360 1 HM400-1L
TROUBLESHOOTING (ENG-24) FAILURE CODE [D182KZ]
HM400-1L 20-361 1
TROUBLESHOOTING (ENG-25) FAILURE CODE [D1D0KB]
Steps Circuit Diagnostic Procedures For Error Code [D1D0KB] Specifications No. Readings
1. Defective Relay
• With ignition switch in the "OFF" position.
• Replace relay (R36) with another one of the same type.
• Turn ignition switch “ON”
Relay (L115)
A. (L115) relay check — Error code [D1D0KB] is displayed. 2 Yes or No
good
Relay (L115)
— Error code [D1D0KB] is not displayed. 3 Yes or No
defective
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (R36) connector from relay and (ACC) connection from ignition switch.
• Disconnect (CN7 and CN4) connector from engine controller and install T-adapter on (CN7 and CN4) wiring harness connector only.
• ✸ For the voltage test in this step, the ignition switch must be in the "ON" position.
A. Open or high Resistance Ω Between ignition switch ACC, and CN4, (7) and (18) 0.0 to 1.0Ω 4
resistance Voltage ✸ At connector R36, (3) and chassis ground. 20 to 30V 5
20-362 1 HM400-1L
TROUBLESHOOTING (ENG-25) FAILURE CODE [D1D0KB]
Related circuit diagram
HM400-1L 20-363 1
TROUBLESHOOTING (ENG-26) FAILURE CODE [D5ZAKX]
Steps Circuit Diagnostic Procedures For Error Code [D5ZAKX] Specifications No. Readings
B. Short to
chassis ground Resistance Ω At connector CN4, (16) and chassis ground. (OL) open 9
or within harness
20-364 1 HM400-1L
TROUBLESHOOTING (ENG-26) FAILURE CODE [D5ZAKX]
Related circuit diagram
HM400-1L 20-365 1
TROUBLESHOOTING (ENG-27) FAILURE CODE [DB20KT]
Steps Circuit Diagnostic Procedures For Error Code [DB20KT] Specifications No. Readings
A. Open or high Between connector CN7 (5) and chassis ground. 0.0 to 1.0Ω 1
Resistance Ω
resistance Between connector CN7 (13) and chassis ground. 0.0 to 1.0Ω 2
2. Engine Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Engine Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-366 1 HM400-1L
TROUBLESHOOTING (ENG-28) FAILURE CODE [DB22KK]
Steps Circuit Diagnostic Procedures For Error Code [DB22KK] Specifications No. Readings
1. Defective Relay
• With ignition switch in the "OFF" position.
• Replace relay (R36) with another one of the same type.
• Turn ignition switch “ON”
Relay (L115)
A. (L115) relay check — Error code [D1D0KB] is displayed. 2
good
Relay (L115)
— Error code [D1D0KB] is not displayed. 3
defective
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (R36) connector from relay and (ACC) connection from ignition switch.
• Disconnect (CN7 and CN4) connector from engine controller and install T-adapter on (CN7 and CN4) wiring harness connector only.
• ✸ For the voltage test in this step, the ignition switch must be in the "ON" position.
A. Open or high Resistance Ω Between ignition switch ACC, and CN4, (7) and (18) 0.0 to 1.0Ω 4
resistance Voltage ✸ At connector R36, (3) and chassis ground. 20 to 30V 5
HM400-1L 20-367 1
TROUBLESHOOTING (ENG-28) FAILURE CODE [DB22KK]
Related circuit diagram
20-368 1 HM400-1L
TROUBLESHOOTING (ENG-29) FAILURE CODE [DB29KQ]
Steps Circuit Diagnostic Procedures For Error Code [DB29KQ] Specifications No. Readings
A. Open or high Between connectors MS, (3) and CN4, (14) 0.0 to 1.0Ω 6
Resistance Ω
resistance Between connectors MS, (2) and CN4, (13) 0.0 to 1.0Ω 7
HM400-1L 20-369 1
TROUBLESHOOTING (ENG-29) FAILURE CODE [DB29KQ]
Related circuit diagram
20-370 1 HM400-1L
TROUBLESHOOTING (ENG-30) FAILURE CODE [DB2AMA]
Related • Setting of Q adjustment switches (SW1, SW2) can be checked with monitoring function (Code: 36800)
Information
Causes Standard Value in Normal State and Remarks on Troubleshooting
When normal F position
Setting of SW1 (On back side of
controller) When abnormal Other position than
Diagnostic F
Defective setting of Q adjustment
procedures for 1 switches
error code When normal F position
Setting of SW2 (On back side of
controller When abnormal Other position than
F
2 Defective engine controller —
Related diagram
HM400-1L 20-371 1
TROUBLESHOOTING (ENG-31) FAILURE CODE [KK11KB]
Steps Circuit Diagnostic Procedures For Error Code [KK11KB] Specifications No. Readings
A. Ignition switch Voltage Between switch terminals (C) and chassis ground. 20 to 30V 1
A. Open or high
Resistance Ω Between ignition switch (C) and CN4, (2) 0.0 to 1.0Ω 2
resistance
B. Short to
chassis ground Resistance Ω Between connector CN4, (2) and chassis ground. (OL) open 3
or within harness
20-372 1 HM400-1L
TROUBLESHOOTING (ENG-32) FAILURE CODE [DDA1L5]
Steps Circuit Diagnostic Procedures For Error Code [DDA1L5] Specifications No. Readings
Resistance Ω At switch AS1, between (4) and chassis ground. 0.0 to 1.0Ω 5
A. Open or high Between connectors AS1, (3) and CN1, (4) 0.0 to 1.0Ω 8
Resistance Ω
resistance Between connectors AS1, (4) and CN4, (8) 0.0 to 1.0Ω 9
Between connectors AS1, (5) and CN4, (11) 0.0 to 1.0Ω 10
HM400-1L 20-373 1
TROUBLESHOOTING (ENG-32) FAILURE CODE [DDA1L5]
20-374 1 HM400-1L
TROUBLESHOOTING (ENG-33) FAILURE CODE [DDE2L6]
Steps Circuit Diagnostic Procedures For Error Code [B@BAZG] Specifications No. Readings
High idle
Perform a live oil pressure test on engine.
.12 to.18 MPa High idle
(If engine oil pressure is not within listed specifications
Engine Oil Pressure — (30 to 26 psi) 1
do not continue with electrical testing.
Low idle Low idle
See ENGINE SHOP MANUAl)
.07 MPa (10 psi)
A. Open or high Between pressure switch EG5, (12) and CN4, (5) 0.0 to 1.0Ω 8
Resistance Ω
resistance Between pressure switch EG5, (13) and CN4, (6) 0.0 to 1.0Ω 9
HM400-1L 20-375 1
TROUBLESHOOTING (ENG-33) FAILURE CODE [DDE2L6]
Related circuit diagram
20-376 1 HM400-1L
TROUBLESHOOTING (ENG-34) FAILURE CODE [DGE2KX]
Steps Circuit Diagnostic Procedures For Error Code [DGE2KX] Specifications No. Readings
At sensor TWH, between (1) and (2) at 10°C (50°F) Approx. 90kΩ 1
A. Sensor test Resistance Ω At sensor TWH, between (1) and (2) at 100°C (212°F) Approx. 0.3kΩ 2
At sensor TWH, between (1) or (2) and chassis ground. (OL) open 3
A. Open or high Between connectors TWH, (1) and CN2, (4) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors TWH, (2) and CN2, (10) 0.0 to 1.0Ω 5
At connector TWH, between (1) and chassis ground. (OL) open 6
B. Short to chassis
ground or within Resistance Ω At connector TWH, between (2) and chassis ground. (OL) open 7
harness
At connector TWH, between (1) and (2) (OL) open 8
3. Engine Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Engine Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-377 1
TROUBLESHOOTING (ENG-35) FAILURE CODE [DGE3LC]
Steps Circuit Diagnostic Procedures For Error Code [DGE3L6] Specifications No. Readings
At sensor TWL, between (1) and (2) at 10°C (50°F) Approx. 9kΩ 1
A. Sensor test Resistance Ω At sensor TWL, between (1) and (2) at 100°C (212°F) Approx. 0.3kΩ 2
At sensor TWL, between (1) or (2) and chassis ground. (OL) open 3
A. Open or high Between connectors TWL, (1) and CN2, (3) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors TWL, (2) and CN2, (10) 0.0 to 1.0Ω 5
At connector TWL, between (1) and chassis ground. (OL) open 6
B. Short to chassis
ground or within Resistance Ω At connector TWL, between (2) and chassis ground. (OL) open 7
harness
At connector TWL, between (1) and (2) (OL) open 8
3. Engine Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Engine Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-378 1 HM400-1L
TROUBLESHOOTING (ENG-36) FAILURE CODE [DGE4KX]
Steps Circuit Diagnostic Procedures For Error Code [DGE4KX] Specifications No. Readings
At sensor THL, between (1) and (2) at 10°C (50°F) Approx. 9kΩ 1
A. Sensor test Resistance Ω At sensor THL, between (1) and (2) at 100°C (212°F) Approx. 0.3kΩ 2
At sensor THL, between (1) or (2) and chassis ground. (OL) open 3
A. Open or high Between connectors THL, (1) and CN2, (11) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors THL, (2) and CN2, (10) 0.0 to 1.0Ω 5
At connector THL, between (1) and chassis ground. (OL) open 6
B. Short to chassis
ground or within Resistance Ω At connector THL, between (2) and chassis ground. (OL) open 7
harness
At connector THL, between (1) and (2) (OL) open 8
3. Engine Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Engine Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-379 1
TROUBLESHOOTING (ENG-37) FAILURE CODE [DH30KX]
Steps Circuit Diagnostic Procedures For Error Code [DH30KX] Specifications No. Readings
20-380 1 HM400-1L
TROUBLESHOOTING (ENG-37) FAILURE CODE [DH30KX]
Related circuit diagram
HM400-1L 20-381 1
TROUBLESHOOTING (ENG-38) FAILURE CODE [DH40KX]
Steps Circuit Diagnostic Procedures For Error Code [DH40KX] Specifications No. Readings
20-382 1 HM400-1L
TROUBLESHOOTING (ENG-38) FAILURE CODE [DH40KX]
Related circuit diagram
HM400-1L 20-383 1
TROUBLESHOOTING (ENG-39) FAILURE CODE [DK10KX]
Steps Circuit Diagnostic Procedures For Error Code [DK10KX] Specifications No. Readings
Resistance Ω At switch AS1, between (4) and chassis ground. 0.0 to 1.0Ω 5
A. Open or high Between connectors AS1, (3) and CN1, (4) 0.0 to 1.0Ω 8
Resistance Ω
resistance Between connectors AS1, (4) and CN4, (8) 0.0 to 1.0Ω 9
Between connectors AS1, (5) and CN4, (11) 0.0 to 1.0Ω 10
20-384 1 HM400-1L
TROUBLESHOOTING (ENG-39) FAILURE CODE [DK10KX]
HM400-1L 20-385 1
TROUBLESHOOTING (ENG-40) FAILURE CODE [DLE3LC]
Steps Circuit Diagnostic Procedures For Error Code [DLE3LC] Specifications No. Readings
A. Open or high Between connectors NE, (1) and CN1, (5) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors NE, (2) and CN1, (12) 0.0 to 1.0Ω 4
20-386 1 HM400-1L
TROUBLESHOOTING (ENG-41) FAILURE CODE [DLE1LC]
12
(ENG-41) FAILURE CODE [DLE1LC]
Steps Circuit Diagnostic Procedures For Error Code [DLH1LC] Specifications No. Readings
A. Open or high Between connectors G, (1) and CN2, (1) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors G, (2) and CN2, (9) 0.0 to 1.0Ω 4
HM400-1L 20-387 1
TROUBLESHOOTING (ENG-42) NO FAILURE CODE DISPLAYED
12
(ENG-42) NO FAILURE CODE DISPLAYED
Steps Circuit Diagnostic Procedures For Error Code [ENG-1] Specifications No. Readings
1. Defective Battery
• With ignition switch in the "OFF" position.
• Check all battery connections including engine and ground circuits.
• Check battery specific gravity and load test battery if necessary.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (CN-78) connector from starter motor and install T-adapter between (CN-78) connector.
• ✸ For this test the ignition switch must be in the “ON” position.
✸ Between battery relay terminals (R), (RW),
20 to 30V 3
(B) and battery ground.
20-388 1 HM400-1L
TROUBLESHOOTING (ENG-42) NO FAILURE CODE DISPLAYED
HM400-1L 20-389 1
TROUBLESHOOTING (ENG-42) NO FAILURE CODE DISPLAYED
Related circuit diagram
20-390 1 HM400-1L
TROUBLESHOOTING OF TRANSMISSION
CONTROLLER SYSTEM (TM MODE)
HM400-1L 20-4011
TESTING AND ADJUSTING TABLE OF CONTENTS
ECMV “LOCK-UP” CLUTCH NOT DISENGAGING (l1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-487
(TM-23) FAILURE CODE [15SJMA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-489
ECMV “LOCK-UP” CLUTCH NOT ENGAGING (MA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-489
(TM-24) FAILURE CODE [15SKL1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-491
ECMV “INTER-AXLE” CLUTCH NOT DISENGAGING (L1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-491
(TM-25) FAILURE CODE [15SKMA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-493
ECMV “INTER-AXLE” CLUTCH NOT ENGAGING (MA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-493
(TM-26) FAILURE CODE [2B61MW] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-495
ECMV “INTER-AXLE” CLUTCH SLIPPING (MW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-495
(TM-27) FAILURE CODE [2F00KM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-497
PARKING BRAKE SYSTEM INDICATING FAILURE (KM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-497
(TM-28) FAILURE CODE [6014NX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-499
HYDRAULUC TANK FILTER CLOGGED (NX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-499
(TM-29) FAILURE CODE [989A00] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-501
POSSIBLE ENGINE OVER SPEED CONDITION (00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-501
(TM-30) FAILURE CODE [989AKZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-502
OPEN OR SHORT IN ENGINE OVER SPEED COMMAND SIGNAL (KZ) . . . . . . . . . . . . . . . . . . . . .20-502
(TM-31)FAILURE CODE [989D00] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-504
REAR OVERTURN SIGNAL OUT OF RANGE (00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-504
(TM-32)FAILURE CODE [AA10NX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-506
AIR CLEANER CLOGG INDICATION (NX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-506
(TM-33) FAILURE CODE [AB00MA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-508
ALTERNATOR NOT CHARGING PROPERLY (MA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-508
(TM-34) FAILURE CODE [B@BCZK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-509
COOLANT LEVEL INDICATING A LOW LEVEL CONDITION (ZK) . . . . . . . . . . . . . . . . . . . . . . . . .20-509
(TM-35) FAILURE CODE [B@HAZK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-511
LOW HYDRAULIC TANK OIL LEVEL INDICATED (ZK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-511
(TM-36) FAILURE CODE [B@JANS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-512
STEERING OIL OVERHEAT CONDITION INDICATED (ZK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-512
(TM-37) FAILURE CODE [D1B0KZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-513
POSSIBLE SHORT OR OPEN IN TRANSMISSION CUT RELAY SYSTEM (KZ) . . . . . . . . . . . . . . . .20-513
(TM-38) FAILURE CODE [D5ZBKX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-515
DEFFERENTIAL LOCK CIRCUIT SIGNIAL INCORRECT (KX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-515
(TM-39) FAILURE CODE [D5ZCKZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-517
OPEN OR SHORT IN EXHAUST BRAKE COMMAND SIGNAL (KZ) . . . . . . . . . . . . . . . . . . . . . . . .20-517
(TM-40) FAILURE CODE [DF10KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-519
FORCED NEUTRAL DEMAND SIGNAL (L4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-519
(TM-41) FAILURE CODE [D5ZEKX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-521
ENGINE LOAD SIGNIAL OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-521
(TM-42) FAILURE CODE [DAQ0KK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-523
TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK) . . . . . . . . . . . . . . . . . . . . . . . . . .20-523
(TM-43) FAILURE CODE [DAQ1KK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-525
TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK) . . . . . . . . . . . . . . . . . . . . . . . . . .20-525
(TM-44) FAILURE CODE [DAQ2KK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-527
POSSIBLE SHORT OR OPEN IN TRANSMISSION VOLTAGE SYSTEM (KK) . . . . . . . . . . . . . . . . . .20-527
(TM-45) FAILURE CODE [DAQ3KK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-529
TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK) . . . . . . . . . . . . . . . . . . . . . . . . . .20-529
(TM-46) FAILURE CODE [DAQ5KP] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-531
TRANSMISSION CONTROLLER SIGNAL OUT OF RANGE (KP) . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-531
(TM-47) FAILURE CODE [DAQ9KM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-533
MISTAKEN OPERATION SETTING (KP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-533
(TM-48) FAILURE CODE [DAQ9KM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-534
NO MATCH IN MODEL SELECTION SIGNAL (KP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-534
(TM-49) FAILURE CODE [DAQAKQ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-535
TRANSMISSION CONTROLLER ROTARY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-535
(TM-50) FAILURE CODE [DAQSMA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-535
TRANSMISSION FUNCTION INNOPERABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-535
20-402 1 HM400-1L
TESTING AND ADJUSTING TABLE OF CONTENTS
(TM-51) FAILURE CODE [DDTFKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-536
“LOCK-UP” CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . .20-536
(TM-52) FAILURE CODE [DDTFKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-538
“LOCK-UP” CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . .20-538
(TM-53) FAILURE CODE [DDTHKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-540
“HI” CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-540
(TM-54) FAILURE CODE [DDTJKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-542
“LO” CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-542
(TM-55) FAILURE CODE [DDTKKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-544
1st CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-544
(TM-56) FAILURE CODE [DDTLKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-546
2ND CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-546
(TM-57) FAILURE CODE [DDTMKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-548
3RD CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-548
(TM-58) FAILURE CODE [DDTNKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-550
“R” CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-550
(TM-59) FAILURE CODE [DF10KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-552
POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA) . . . . . . . . . . . . . . . . . . . . . . .20-552
(TM-60) FAILURE CODE [DF10KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-554
POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA) . . . . . . . . . . . . . . . . . . . . . . .20-554
(TM-61) FAILURE CODE [DGF1KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-556
TRANSMISSION OIL TEMPERATURE SENSOR OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . . . .20-556
(TM-62) FAILURE CODE [DGR2L8] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-557
REAR BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8) . . . . . . . . . . . . . . . . . . . . . . . . .20-557
(TM-63) FAILURE CODE [DGR3L8] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-559
CENTER BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8) . . . . . . . . . . . . . . . . . . . . . . .20-559
(TM-64) FAILURE CODE [DGR4L8] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-561
FRONT BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8) . . . . . . . . . . . . . . . . . . . . . . . .20-561
(TM-65) FAILURE CODE [DGT1LX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-563
TORQUE CONVERTER TEMPERATURE SENSOR OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . .20-563
(TM-66) FAILURE CODE [DHT5KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-564
TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . . .20-564
(TM-67) FAILURE CODE [DHT5L6] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-566
TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (L6) . . . . . . . . . . . . . . . . . . . . . .20-566
(TM-68) FAILURE CODE [DJF1KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-568
FUEL LEVEL SENSOR OUT OF RANGE (L6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-568
(TM-69) FAILURE CODE [DK11KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-570
THROTTLE ANGLE SENDOR OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-570
(TM-70) FAILURE CODE [DLE2KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-572
ENGINE SPEED SENSOR OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-572
(TM-71) FAILURE CODE [DLE2LC] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-573
ENGINE SPEED SENSOR OPEN OR SHORTED (LC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-573
(TM-72) FAILURE CODE [DLF1KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-574
TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . .20-574
(TM-73) FAILURE CODE [DLF1LC] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-575
TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC) . . . . . . . . . . . . . . . . . .20-575
(TM-74) FAILURE CODE [DLF2KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-576
TRANSMISSION INTERMEDATE SHAFT SPEED SENSOR OPEN OR SHORTED (KA) . . . . . . . . .20-576
(TM-75) FAILURE CODE [DLF2LC] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-577
TRANSMISSION INTERMEDATE SHAFT SPEED SENSOR OPEN OR SHORTED (LC) . . . . . . . . . .20-577
(TM-76) FAILURE CODE [DLT3KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-578
TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . .20-578
(TM-77) FAILURE CODE [DLT3LC] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-580
TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC) . . . . . . . . . . . . . . . .20-580
(TM-78) FAILURE CODE [DXH0KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-582
INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . .20-582
(TM-79) FAILURE CODE [DXH0KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-584
HM400-1L 20-403 1
TESTING AND ADJUSTING TABLE OF CONTENTS
INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . .20-584
(TM-80) FAILURE CODE [DXH1KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-586
LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-586
(TM-81) FAILURE CODE [DXH1KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-588
LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-588
(TM-82) FAILURE CODE [DXH2KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-590
HIGH CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-590
(TM-83) FAILURE CODE [DXH2KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-592
HIGH CLUTCH SYSTEM OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-592
(TM-84) FAILURE CODE [DXH3KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-594
LOW CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-594
(TM-85) FAILURE CODE [DXH3KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-596
LOW CLUTCH SYSTEM OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-596
(TM-86) FAILURE CODE [DXH4KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-598
1st CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-598
(TM-87) FAILURE CODE [DXH4KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-600
1st CLUTCH SYSTEM OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-600
(TM-88) FAILURE CODE [DXH5KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-602
2ND. CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-602
(TM-89) FAILURE CODE [DXH5KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-604
2ND. CLUTCH SYSTEM OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-604
(TM-90) FAILURE CODE [DXH6KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-606
3RD. CLUTCH SYSTEM OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-606
(TM-91) FAILURE CODE [DXH6KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-608
3RD. CLUTCH SYSTEM OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-608
(TM-92) FAILURE CODE [DXH7KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-610
REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-610
(TM-93) FAILURE CODE [DXH7KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-612
REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-612
(TM-94) NO FAILURE CODE DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-614
BACK-UP LIGHTS AND ALARM DO NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-614
20-404 1 HM400-1L
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
HM400-1L 20-405 1
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
20-406 1 HM400-1L
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
HM400-1L 20-407 1
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
20-408 1 HM400-1L
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
HM400-1L 20-409 1
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
20-410 1 HM400-1L
TROUBLESHOOTING TM MODE CONTROL SYSTEM CIRCUIT DIAGRAM
12
TM MODE CONTROL SYSTEM CIRCUIT DIAGRAM
HM400-1L 20-411 1
TROUBLESHOOTING TM MODE CONTROL SYSTEM CIRCUIT DIAGRAM
20-412 1 HM400-1L
TROUBLESHOOTING TM MODE CONTROL SYSTEM CIRCUIT DIAGRAM
12
HM400-1L 20-413 1
TROUBLESHOOTING TM MODE CONTROL SYSTEM CIRCUIT DIAGRAM
20-414 1 HM400-1L
TROUBLESHOOTING TM MODE CONTROL SYSTEM CIRCUIT DIAGRAM
HM400-1L 20-415 1
TROUBLESHOOTING TM MODE CONTROL SYSTEM CIRCUIT DIAGRAM
20-416 1 HM400-1L
TROUBLESHOOTING TM MODE CONTROL SYSTEM CIRCUIT DIAGRAM
12
MEMORANDUM
HM400-1L 20-417 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
CONTENT OF CODE DISPLAY
Lock-up clutch: Slipping When there is output to the lock-up • Defective lock-up clutch solenoid
(MW) clutch solenoid, there is an • Excessive resistance in solenoid (+)
abnormality in the value calculated circuit wiring harness
from the signals from the engine • Excessive resistance in solenoid (-)
1380MW
speed sensor, transmission input circuit wiring harness
(TM-1)
shaft speed sensor, transmission • Defective lock-up clutch, pressure
intermediate shaft speed sensor, control valve hydraulic, mechanical
and transmission system
output shaft R speed sensor. • Defective transmission controller
Transmission clutch: * See Fill switch signals have been input • Other problem occurs at same time
Contents (LO) from 2 clutches that do not form a (failure code [15S*L1] is displayed)
1500L0
normal combination. • Defective pressure control valve
(TM-2)
hydraulic, mechanical system
• Defective transmission controller
Transmission oil filter: When the torque converter oil • Clogged transmission oil filter (when
Clogged (NX) temperature is more than 50fC, the actuating system normally)
signal circuit of the transmission • Defective transmission oil filter
filter clogging switch is open (shut clogging switch
15BONX
off from the ground). • Open in switch signal circuit wiring
(TM-3)
harness
• Open in switch GND circuit wiring
harness
• Defective transmission controller
R clutch: Slipping (MW) When there is output to the R clutch • Defective R clutch solenoid
solenoid, there is an abnormality in • Excessive resistance in solenoid (+)
the value calculated from the circuit wiring harness
15G0MW signals from the transmission input • Excessive resistance in solenoid (-)
(TM-4) shaft speed sensor, intermediate circuit wiring harness
shaft speed sensor, and output • Defective R clutch, pressure control
shaft R speed sensor. valve hydraulic, mechanical system
• Defective transmission controller
Hi clutch: Slipping (MW) When there is output to the Hi • Defective Hi clutch solenoid
clutch solenoid, there is an • Excessive resistance in solenoid (+)
abnormality in the value calculated circuit wiring harness
15H0MW from the signals from the • Excessive resistance in solenoid (-)
(TM-5) transmission input shaft speed circuit wiring harness
sensor, intermediate shaft speed • Defective Hi clutch, pressure control
sensor, and output shaft R speed valve hydraulic, mechanical system
sensor. • Defective transmission controller
Lo clutch: Slipping (MW) When there is output to the Lo • Defective Lo clutch solenoid
clutch solenoid, there is an • Excessive resistance in solenoid (+)
abnormality in the value calculated circuit wiring harness
15J0MW from the signals from the • Excessive resistance in solenoid (-)
(TM-6) transmission input shaft speed circuit wiring harness
sensor, intermediate shaft speed • Defective Lo clutch, pressure control
sensor, and output shaft R speed valve hydraulic, mechanical system
sensor. • Defective transmission controller
1st clutch: Slipping (MW) When there is output to the 1st • Defective 1st clutch solenoid
clutch solenoid, there is an • Excessive resistance in solenoid (+)
abnormality in the value calculated circuit wiring harness
15K0MW from the signals from the • Excessive resistance in solenoid (-)
(TM-7) transmission input shaft speed circuit wiring harness
sensor, intermediate shaft speed • Defective 1st clutch, pressure control
sensor, and output shaft R speed valve hydraulic, mechanical system
sensor. • Defective transmission controller
20-418 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Action
Condition When Normal Action By Controller Problem That Appears On Machine
Code
• Solenoid resistance value • Holds speed range during travel, • Lock-up is canceled and
L/U-PS (male) (1) - (2): 5 - 15 Ω turns lock-up actuation OFF. transmission cannot be shifted
• Holds at Neutral if gearshift lever is • If gearshift lever is operated to N,
operated to N. machine cannot move off again until
it is stopped E03
Solenoid resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
R-PS (male) (1) - (2): 5 - 15 Ω traveling
E03
• Solenoid resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
H-PS (male) (1) - (2): 5 - 15 Ω traveling
• Cannot move off again unless
machine is stopped
E03
• Solenoid resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
L-PS (male) (1) - (2): 5 - 15 Ω traveling
• Cannot move off again unless
machine is stopped
E03
• Solenoid resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
1-PS (male) (1) - (2): 5 - 15 Ω traveling
E03
HM400-1L 20-419 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
2nd clutch: Slipping (MW) When there is output to the 2nd • Defective 2nd clutch solenoid
clutch solenoid, there is an • Excessive resistance in solenoid (+)
abnormality in the value calculated circuit wiring harness
15L0MW from the signals from the • Excessive resistance in solenoid (-)
(TM-8) transmission input shaft speed circuit wiring harness
sensor, intermediate shaft speed • Defective 2nd clutch, pressure control
sensor, and output shaft R speed valve hydraulic, mechanical system
sensor. • Defective transmission controller
(TM-9) 3rd clutch: Slipping When there is output to the 3rd • Defective 3rd clutch solenoid
(MW) clutch solenoid, there is an • Excessive resistance in solenoid (+)
abnormality in the value calculated circuit wiring harness
15M0MW from the signals from the • Excessive resistance in solenoid (-)
(TM-9) transmission input shaft speed circuit wiring harness
sensor, intermediate shaft speed • Defective 3rd clutch, pressure control
sensor, and output shaft R speed valve hydraulic, mechanical system
sensor. • Defective transmission controller
ECMV for R clutch: * See Even when the output to the R • Defective R clutch fill switch
Contents (L1) clutch solenoid is turned OFF, the • Short circuit with chassis ground in
15SBL1 signal from the fill switch stays ON switch circuit wiring harness
(TM-10) and the clutch is not disengaged. • Defective R clutch pressure control
valve hydraulic, mechanical system
• Defective transmission controller
ECMV for R clutch: Function Even when there is output to the R • Defective R clutch solenoid
impossible (MA) clutch solenoid, the signal from the • Excessive resistance in solenoid (+)
fill switch stays OFF and the clutch circuit wiring harness
15SBMA is not engaged. • Excessive resistance in solenoid (-)
(TM-11) circuit wiring harness
• Defective R clutch or pressure control
valve hydraulic, mechanical system
• Defective transmission controller
ECMV for Hi clutch: * See Even when the output to the Hi • Defective Hi clutch fill switch
Contents (L1) clutch solenoid is turned OFF, the • Short circuit with chassis ground in
15SCL1 signal from the fill switch stays ON switch circuit wiring harness
(TM-12) and the clutch is not disengaged. • Defective Hi clutch or pressure control
valve hydraulic, mechanical system
• Defective transmission controller
ECMV for Hi clutch: Function Even when there is output to the Hi • Defective Hi clutch solenoid
impossible (MA) clutch solenoid, the signal from the • Excessive resistance in solenoid (+)
fill switch stays OFF and the clutch circuit wiring harness
15SCMA is not engaged. • Excessive resistance in solenoid (-)
(TM-13) circuit wiring harness
• Defective Hi clutch pressure control
valve hydraulic, mechanical system
• Defective transmission controller
ECMV for Lo clutch: * See Even when the output to the Lo • Defective Lo clutch fill switch
Contents (L1) clutch solenoid is turned OFF, the • Short circuit with chassis ground in
15SDL1 signal from the fill switch stays ON switch circuit wiring harness
(TM-14) and the clutch is not disengaged. • Defective Lo clutch pressure control
valve hydraulic, mechanical system
• Defective transmission controller
20-420 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Action
Condition When Normal Action By Controller Problem That Appears On Machine
Code
• Solenoid resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
2-PS (male) (1) - (2): 5 - 15 Ω traveling
E03
• Solenoid resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
3-PS (male) (1) - (2): 5 - 15 Ω traveling
E03
Switch resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
R-SW (male) (1) - ground: traveling
• When clutch is released: Min. • Cannot move off again unless
E03
1 MΩ machine is stopped
• When clutch is engaged: Max. 1
Ω
• Solenoid resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
R-PS (male) (1) - (2): 5 - 15 Ω traveling
• Cannot move off again unless
machine is stopped
E03
• Switch resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
H-SW (male) (1) - ground: traveling
• When clutch is released: Min. • Cannot move off again unless
E03
1 MΩ machine is stopped
• When clutch is engaged: Max. 1
Ω
• Solenoid resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
H-PS (male) (1) - (2): 5 - 15 Ω traveling
• Cannot move off again unless
machine is stopped
E03
• Switch resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
L-SW (male) (1) - ground: traveling
• When clutch is released: Min. 1 • Cannot move off again unless
E03
Ω machine is stopped
• When clutch is engaged: Max. 1
Ω
HM400-1L 20-421 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
ECMV for Lo clutch: Func- Even when there is output to the Lo • Defective Lo clutch solenoid
tion impossible (MA) clutch solenoid, the signal from the • Excessive resistance in solenoid (+)
fill switch stays OFF and the clutch circuit wiring harness
15SDMA is not engaged. • Excessive resistance in solenoid (-)
(TM-15) circuit wiring harness
• Defective Lo clutch or pressure control
valve hydraulic, mechanical system
• Defective transmission controller
ECMV for 1st clutch: * See Even when the output to the 1st • Defective 1st clutch fill switch
Contents (L1) clutch solenoid is turned OFF, the • Short circuit with chassis ground in
15SEL1 signal from the fill switch stays ON switch circuit wiring harness
(TM-16) and the clutch is not disengaged. • Defective 1st clutch pressure control
valve hydraulic, mechanical system
• Defective transmission controller
ECMV for 1st clutch: Func- Even when there is output to the 1st • Defective 1st clutch solenoid
tion impossible (MA) clutch solenoid, the signal from the • Excessive resistance in solenoid (+)
fill switch stays OFF and the clutch circuit wiring harness
15SEMA is not engaged. • Excessive resistance in solenoid (-)
(TM-17) circuit wiring harness
• Defective 1st clutch or pressure control
valve hydraulic, mechanical system
• Defective transmission controller
ECMV for 2nd clutch: * See Even when the output to the 2nd • Defective 2nd clutch fill switch
Contents (L1) clutch solenoid is turned OFF, the • Short circuit with chassis ground in
15SFL1 signal from the fill switch stays ON switch circuit wiring harness
(TM-18) and the clutch is not disengaged. • Defective 2nd clutch pressure control
valve hydraulic, mechanical system
• Defective transmission controller
ECMV for 2nd clutch: Func- Even when there is output to the • Defective 2nd clutch solenoid
tion impossible (MA) 2nd clutch solenoid, the signal from • Excessive resistance in solenoid (+)
the fill switch stays OFF and the circuit wiring harness
clutch is not engaged. • Excessive resistance in solenoid (-)
15SFMA
circuit wiring harness
(TM-19)
• Defective 2nd clutch or pressure
control valve hydraulic, mechanical
system
• Defective transmission controller
ECMV for 3rd clutch: * See Even when the output to the 3rd • Defective 3rd clutch fill switch
Contents (L1) clutch solenoid is turned OFF, the • Short circuit with chassis ground in
15SGL1 signal from the fill switch stays ON switch circuit wiring harness
(TM-20) and the clutch is not disengaged. • Defective 3rd clutch pressure control
valve hydraulic, mechanical system
• Defective transmission controller
ECMV for 3rd clutch: Func- Even when there is output to the 3rd • Defective 3rd clutch solenoid
tion impossible (MA) clutch solenoid, the signal from the • Excessive resistance in solenoid (+)
fill switch stays OFF and the clutch circuit wiring harness
15SGMA is not engaged. • Excessive resistance in solenoid (-)
(TM-21) circuit wiring harness
• Defective 3rd clutch or pressure control
valve hydraulic, mechanical system
• Defective transmission controller
20-422 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Action
Condition When Normal Action By Controller Problem That Appears On Machine
Code
• Solenoid resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
L-PS (male) (1) - (2): 5 - 15 Ω traveling
• Cannot move off again unless
machine is stopped
E03
• Switch resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
1-SW (male) (1) - ground: traveling
• When clutch is released: Min. • Cannot move off again unless
E03
1 MΩ machine is stopped
• When clutch is engaged: Max. 1
Ω
• Solenoid resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
1-PS (male) (1) - (2): 5 - 15 Ω traveling
• Cannot move off again unless
machine is stopped
E03
• Switch resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
2-SW (male) (1) - ground: traveling
• When clutch is released: Min. • Cannot move off again unless
E03
1 MΩ machine is stopped
• When clutch is engaged: Max. 1
Ω
• Solenoid resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
2-PS (male) (1) - (2): 5 - 15 Ω traveling
• Cannot move off again unless
machine is stopped
E03
• Switch resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
3-SW (male) (1) - ground: traveling
• When clutch is released: Min. • Cannot move off again unless
E03
1 MΩ machine is stopped
• When clutch is engaged: Max. 1
Ω
• Solenoid resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
3-PS (male) (1) - (2): 5 - 15 Ω traveling
• Cannot move off again unless
machine is stopped
E03
HM400-1L 20-423 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
ECMV for lock-up clutch: * Even when the out put to the lock- • Defective lock-up clutch fill switch
See Contents (L1) up clutch solenoid is turned OFF, • Short circuit with chassis ground in
the signal from the fill switch stays switch circuit wiring harness
15SJL1
ON and the clutch is not • Defective lock-up clutch pressure
(TM-22)
disengaged. control valve hydraulic, mechanical
system
• Defective transmission controller
ECMV for lock-up clutch: Even when there is output to the • Defective lock-up clutch solenoid
Function impossible (MA) lock-up clutch solenoid, the signal • Excessive resistance in solenoid (+)
from the fill switch stays OFF and circuit wiring harness
the clutch is not engaged. • Excessive resistance in solenoid (-)
15SJMA
circuit wiring harness
(TM-23)
• Defective lock-up clutch or pressure
control valve hydraulic, mechanical
system
• Defective transmission controller
ECMV for inter-axle differen- Even when the output to the • Defective differential lock clutch fill
tial lock clutch: * See Con- differential lock clutch solenoid is switch
tents (L1) turned OFF, the signal from the fill • Short circuit with chassis ground in
15SKL1 switch stays ON and the clutch is switch circuit wiring harness
(TM-24) not disengaged. • Defective differential lock clutch
pressure control valve hydraulic,
mechanical system
• Defective transmission controller
ECMV for inter-axle differen- Even when there is output to the • Defective differential lock clutch
tial lock clutch: Function differential lock clutch solenoid, the solenoid
impossible (MA) signal from the fill switch stays OFF • Excessive resistance in solenoid (+)
and the clutch is not engaged. circuit wiring harness
15SKMA • Excessive resistance in solenoid (-)
(TM-25) circuit wiring harness
• Defective differential lock clutch or
pressure control valve hydraulic,
mechanical system
• Defective transmission controller
Inter-axle differential lock When there is output to the differen- • Defective differential lock clutch
clutch: Slipping (MW) tial lock clutch solenoid, there is an solenoid
abnormality in the value calculated • Excessive resistance in solenoid (+)
from the signals from the transmis- circuit wiring harness
2B61MW sion output shaft F speed sensor • Excessive resistance in solenoid (-)
(TM-26) and output shaft R speed sensor circuit wiring harness
(retarder controller is responsible • Defective differential lock clutch or
for calculating value). pressure control valve hydraulic,
mechanical system
• Defective transmission controller
Parking brake: Mistaken Travel operation was carried out • Forgot to release parking brake (when
operation or mistaken setting when parking brake signal circuit system is working normally)
(KM) was closed (connected with ground) • Blown fuse
• Defective parking brake oil pressure
switch
2F00KM
• Defective parking brake relay
(TM-27)
• Open or short circuit with chassis
ground in switch power source circuit
wiring harness
• Open in relay GND circuit wiring
harness
20-424 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Action
Condition When Normal Action By Controller Problem That Appears On Machine
Code
• Switch resistance value • Holds speed range when traveling • Lock-up is canceled and it becomes
L/U-SW (male) (1) - ground: and turns lock-up actuation OFF impossible to shift gear
• When clutch is released: Min. • When gearshift lever is returned to • If gearshift lever is returned to N,
1 MΩ N, holds in Neutral machine cannot move off again until E03
• When clutch is engaged: Max. 1 it is stopped
Ω • Lock-up pilot lamp does not give
display normally
• Solenoid resistance value • Holds speed range when traveling • Lock-up is canceled and it becomes
L/U-PS (male) (1) - (2): 5 - 15 Ω and turns lock-up actuation OFF impossible to shift gear
• When gearshift lever is returned to • If gearshift lever is returned to N,
N, holds in Neutral machine cannot move off again until
it is stopped E03
• Switch resistance value • Turns inter-axle differential lock • Inter-axle differential lock does not
D/L-SW (male) (1) - ground: command OFF work
• When clutch is released: Min.
1 MΩ
E03
• When clutch is engaged: Max. 1
Ω
• Solenoid resistance value • Turns inter-axle differential lock • Inter-axle differential lock does not
D/L-PS (male) (1) - (2) : 5 - 15 Ω command OFF work
E01
• Solenoid resistance value • Turns inter-axle differential lock • Inter-axle differential lock does not
D/L-PS (male) (1) - (2) : 5 - 15 Ω command OFF work
E01
• Switch resistance value • Takes no action • If the machine is used as it is, there
B17 (male) (1) - (2) : • User code is not displayed is danger that the parking brake may
• Brake released: Min. 1 MΩ be damaged
• Brake applied: Max. 1 Ω
• Relay resistance value
R32 (male) (1) - (2) : 100 - 500 Ω None
HM400-1L 20-425 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Hydraulic tank filter: Clogged When the torque converter oil • Clogged hydraulic oil filter (when
(NX) temperature is more than 50fC, the system is working normally)
6014NX signal circuit of the transmission • Defective hydraulic oil filter clogging
(TM-28) filter clogging switch is open (shut switch
off from the ground). • Open in switch circuit wiring harness
• Defective transmission controller
Engine overrun prevention The transmission input shaft speed • Engine overrun
989A00 command signal: Actuated became more than 2450 rpm when • Defective transmission controller
(TM-29) (00) the speed range was other than
Neutral.
Engine overrun prevention Open, short circuit with ground, • Defective retarder controller
command signal: Open or short circuit with power source • Open, short circuit with chassis ground,
989AKZ
short circuit (KZ) occurred in overrun prevention or short circuit with power source in
(TM-30)
command circuit, or did not match signal circuit wiring harness
communications data (S-NET) • Defective transmission controller
Rear overturn signal: Actu- Dump body was operated to RAISE • Dump operated when machine is
ated (00) when machine was inclined more inclined (when system is working
than 15O normally)
• Defective inclination sensor
• Open or short circuit with power source
in sensor power source circuit wiring
989D00
harness
(TM-31)
• Open in sensor GND circuit wiring
harness
• Open, short circuit with chassis ground,
or short circuit with power source in
sensor signal circuit wiring harness
• Defective transmission controller
Air cleaner element: Clogged Air cleaner clogging signal circuit • Clogged air cleaner element (when
(NX) became open (shut off from system is working normally)
ground) when engine was running • Defective air cleaner clogging sensor
• Defective dust indicator relay
• Short circuit with chassis ground in
AA10NX
sensor signal circuit wiring harness
(TM-32)
• Open in relay signal circuit wiring
harness
• Open in relay GND circuit wiring
harness
• Defective transmission controller
Alternator: Function impossi- Electricity generation signal was not • Defective alternator
ble (MA) input from alternator when engine • Open or short circuit with chassis
AB00MA was running. ground in alternator signal circuit
(TM-33) • Defective transmission controller
Radiator water: Drop in level Radiator water level switch signal • Drop in radiator water level (when
(ZK) circuit became open (shut off from system is working normally)
ground) when engine was running • Defective radiator water level switch
B@BCZK • Open in switch signal circuit wiring
(TM-34) harness
• Open in switch GND circuit wiring
harness
• Defective transmission controller
20-426 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Action
Condition When Normal Action By Controller Problem That Appears On Machine
Code
• Sensor resistance value • Takes no action • If the machine is used as it is, dirt
T05 (male) (1) - (2) may circulate in the dump circuit
• When normal: Max. 1 Ω
E01
• When clogged: Min. 1 MΩ
• Sensor resistance value • Takes no action • If the machine is used as it is, the
T11 (male) (1) - (2) engine air intake capacity may drop
• When normal: Min. 1 MΩ
• When clogged: Max. 1 Ω
• Relay resistance value
R32 (male) (3) - (6): Max. 1 Ω E01
• Alternator generating voltage • Takes no action • If the machine is used as it is, the
Alternator R - E: 27.5 - 29.5 V power supply voltage will drop and it
may become impossible for the
E03
machine to travel
• Dump body cannot be controlled
(Dump body does not move).
• Sensor resistance value • Takes no action • If the machine is used as it is, the
T01 (male) (1) - (2): engine may overheat
• When normal: Max. 1 Ω
• When clogged: Min. 1 MΩ
E01
HM400-1L 20-427 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Hydraulic tank oil: Drop in When the engine was stopped, the • Drop in hydraulic tank oil level (when
level (ZK) signal circuit of the hydraulic tank system is working normally)
B@HAZK
level switch became open (shut off • Defective hydraulic tank level switch
(TM-35)
from GND) • Open in switch circuit wiring harness
• Defective transmission controller
Steering oil: Overheat (ZK) The signal circuit of the steering oil • Steering oil temperature overheating
temperature switch became open (when system is working normally)
B@JANS (shut off from GND) • Defective steering oil temperature
(TM-36) switch
• Open in switch circuit wiring harness
• Defective transmission controller
Transmission cut relay: Open Abnormal voltage was generated in • Defective transmission cut relay
or short circuit (KZ) the transmission cut relay circuit • Open or short circuit with chassis
When relay is actuated: 10 V or ground in relay power source circuit
more wiring harness
D180KZ
When relay is stopped: Less than 4 • Open or short circuit with chassis
(TM-37)
V ground, or short circuit with power
source in relay output circuit wiring
harness
• Defective transmission controller
Inter-axle differential lock The voltage in the differential lock • Defective retarder controller
command signal: Input signal signal circuit became less than 0.5 • Open, short circuit with chassis ground,
D5ZBKX
outside range (KX) V or more than 4.5 V or short circuit with power source in
(TM-38)
signal circuit wiring harness
• Defective transmission controller
Exhaust brake command sig- Open or Openshort circuit with • Defective retarder controller
nal: Open or short circuit ground, or short circuit with power • Open or short circuit with chassis
D5ZCKZ (KZ) source was generated in the ground, or short circuit with power
(TM-39) exhaust brake command circuit, or source in signal circuit wiring harness
there was a mismatch with the • Defective transmission controller
communication (S-NET) data
Forced neutral demand sig- There was a mismatch between • Defective retarder controller
nal: * See Contents (L4) forced neutral demand signal 1 and • Open or short circuit with chassis
signal 2 ground, or short circuit with power
D5ZDL4 source in signal 1 circuit wiring harness
(TM-40) • Open or short circuit with chassis
ground, or short circuit with power
source in signal 2 circuit wiring harness
• Defective transmission controller
Engine load signal: Input sig- The engine load signal circuit was • Defective engine controller
nal outside range (KX) outside the correct range • Open or short circuit with chassis
D5ZEKX
ground, or short circuit with power
(TM-41)
source in signal circuit wiring harness
• Defective transmission controller
Transmission controller: When the engine was running, both • Another problem is occurring at the
Drop in power source volt- the main power supply voltage same time (failure code displayed)
DAQ0KK
age, input (KK) circuit and the direct power supply • Battery tends to lose power
(TM-42)
voltage circuit became less than 18 • Open or short circuit in wiring harness
V • Defective transmission controller
20-428 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Action
Condition When Normal Action By Controller Problem That Appears On Machine
Code
• Sensor resistance value • Takes no action • If the machine is used as it is, it may
T06 (male) (1) - ground: become impossible to carry out
• When oil level is normal: 1 Ω dump operations E01
• When oil level has dropped:
Min. 1 MΩ
• Sensor resistance value • Takes no action • If the machine is used as it is, oil
T04 (male) (1) - ground: leakage may occur
• When oil temperature is 25OC:
E02
Max 1 Ω
• When oil temperature is
123OC: Min. 1 MΩ
• Controller inlet voltage • Turns transmission cut relay OFF. • Suddenly shifts to Neutral when
ATC1 (15) - (8)(16): • Sets transmission to Neutral. traveling and machine cannot move
• When relay actuated: Max. 1 off again
V
• When relay stopped: 20 - 30 V E03
• Signal voltage • Turns inter-axle differential lock • Inter-axle differential lock does not
ATC3A (8) - (18): 0.47 - 4.3 V command OFF work
E01
E01
• Signal voltage • Carries out control with load taken • Gearshift feeling may change
ATC3A (4) - (16): 0 - 15 V as heavy load slightly
E01
• Main power source voltage • Sets transmission to Neutral. • Suddenly shifts to Neutral when
ATC (9)(17) - (8)(16): 20 - 30 V traveling and machine cannot move
• Direct power source voltage off again E03
ATC1 (7) - (8)(16): 20 - 30 V
HM400-1L 20-429 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Transmission controller main The voltage difference between the • Open or short circuit with chassis
DAQ1KK power supply line: Drop in main power supply voltage circuit ground in main power source circuit
(TM-43) power source voltage, input and the direct power supply voltage wiring harness
(KK) circuit became more than 5 V • Defective transmission controller
Transmission controller load When the controller power supply • Defective transmission cut relay
power supply line: Drop in voltage circuit was normal, the • Open or short circuit with chassis
power source voltage, input solenoid power supply voltage ground in relay power source circuit
DAQ2KK (KK) circuit became less than 18 V wiring harness
(TM-44) • Open or short circuit with chassis
ground in relay output circuit wiring
harness
• Defective transmission controller
Transmission controller bat- The voltage in the direct power • Open or short circuit with chassis
DAQ3KK tery direct power supply line: supply voltage circuit became less ground in direct power source circuit
(TM-45) Drop in power source volt- than 5 V wiring harness
age, input (KK) • Defective transmission controller
Transmission controller The voltage in the 12V power • Defective inclination sensor
power supply output 1: Drop supply circuit for the sensor became • Short circuit with chassis ground in
DAQ5KP
in output voltage (KP) less than 6 V sensor power source circuit wiring
(TM-46)
harness
• Defective transmission controller
Transmission controller wir- When the ignition switch is ON, the • Mistaken connection of connector
ing harness: Mistaken opera- input connector check signal does ATC3 (A, B) and connector ATC5 (A, B)
DAQ9KM
tion or mistaken setting (KP) not match the setting inside the (when system is working normally)
(TM-47)
controller • Open in signal 1 circuit wiring harness
• Defective transmission controller
Transmission controller wir- When the ignition switch is ON, the • Open in model selection signal circuit
DAQ9KQ ing harness: Non match in input model selection signal is wiring harness
(TM-48) model selection signal (KP) different from the setting of the • Defective transmission controller
controller
Transmission controller The model setting of the rotary • Defective setting of rotary switch
DAQAKQ
rotary switch: Non match in switch does not match the setting • Defective transmission controller
(TM-49)
model selection signal (KP) inside the controller
Transmission controller: The communication (S-NET) with • Another problem is occurring at the
Function impossible (MA) the machine monitor is defective same time (failure code DAQSKR is
DAQSMA
and the option setting cannot be displayed)
(TM-50)
made • Defective machine monitor
• Defective transmission controller
Fill switch for inter-axle differ- When the output is made to the • Defective differential clutch fill switch
ential lock clutch: Open (KA) differential lock clutch solenoid, the • Open or short circuit with power source
DDTFKA
clutch engages, but the signal from in switch circuit wiring harness
(TM-51)
the fill switch does not come ON • Defective transmission controller
20-430 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Action
Condition When Normal Action By Controller Problem That Appears On Machine
Code
• Main power source voltage • Does not allow updating of input • Condition before problem occurred
ATC1 (9)(17) - (8)(16): 20 - 30 V related data is maintained
E03
• Solenoid power source voltage • Turns transmission cut relay OFF. • Suddenly shifts to Neutral when
ATC2 (1)(12) - ATC1 (8)(16): 20 • Sets transmission to Neutral. traveling and machine cannot move
- 30 V off again
E03
• Direct power source voltage • Sets transmission to Neutral. • Suddenly shifts to Neutral when
ATC1 (7) - (8)(16): 20 - 30 V traveling and machine cannot move
E03
off again
• Controller output voltage • Shuts off output of sensor 12V • Does not judge rear overturn alarm
ATC2 (14) - ATC3A (16): 11 - 13 power supply
V E03
• Wiring harness resistance value • Turns transmission cut relay OFF. • Machine does not move off even
ATC5A (female) (1) - ground: • Holds transmission in Neutral. when operation is carried out to
Max. 1 Ω • Does not record in trouble data. move machine off E03
• Wiring harness resistance value • Turns transmission cut relay OFF. • Machine does not move off even
ATC5B (female) (14)(15)(16) - • Holds transmission in Neutral. when operation is carried out to
E03
ground: Max. 1 Ω • Does not record in trouble data. move machine off
• Rotary switch setting position • Turns transmission cut relay OFF. • Machine does not move off even
See TESTING AND • Holds transmission in Neutral. when operation is carried out to E03
ADJUSTING. • Does not record in trouble data. move machine off
• Sets transmission to Neutral. • Machine does not move off even
when operation is carried out to
move machine off E03
HM400-1L 20-431 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Fill switch for lock-up clutch: When the output is made to the • Defective lock-up clutch fill switch
Open (KA) lock-up clutch solenoid, the clutch • Open or short circuit with power source
DDTGKA
engages, but the signal from the fill in switch circuit wiring harness
(TM-52)
switch does not come ON • Defective transmission controller
Fill switch for Hi clutch: When the output is made to the Hi • Defective Hi clutch fill switch
Open (KA) clutch solenoid, the clutch engages, • Open or short circuit with power source
DDTHKA
but the signal from the fill switch in switch circuit wiring harness
(TM-53)
does not come ON • Defective transmission controller
Fill switch for Lo clutch: When the output is made to the Lo • Defective Lo clutch fill switch
Open (KA) clutch solenoid, the clutch engages, • Open or short circuit with power source
DDTJKA
but the signal from the fill switch in switch circuit wiring harness
(TM-54)
does not come ON • Defective transmission controller
•
Fill switch for 1st clutch: When the output is made to the 1st • Defective 1st clutch fill switch
Open (KA) clutch solenoid, the clutch engages, • Open or short circuit with power source
DDTKKA
but the signal from the fill switch in switch circuit wiring harness
(TM-55)
does not come ON • Defective transmission controller
•
Fill switch for 2nd clutch: When the output is made to the 2nd • Defective 2nd clutch fill switch
Open (KA) clutch solenoid, the clutch engages, • Open or short circuit with power source
DDTLKA
but the signal from the fill switch in switch circuit wiring harness
(TM-56)
does not come ON • Defective transmission controller
•
Fill switch for 3rd clutch: When the output is made to the 3rd • Defective 3rd clutch fill switch
Open (KA) clutch solenoid, the clutch engages, • Open or short circuit with power source
but the signal from the fill switch in switch circuit wiring harness
does not come ON • Defective transmission controller
DDTMKA
(TM-57)
Fill switch for R clutch: When the output is made to the R • Defective R clutch fill switch
Open (KA) clutch solenoid, the clutch engages, • Open or short circuit with power source
but the signal from the fill switch in switch circuit wiring harness
DDTNKA does not come ON • Defective transmission controller
(TM-58)
Gearshift lever: Open (KA) Nothing is input for the gearshift • Defective gearshift lever
lever signal • Open or short circuit with chassis
ground in lever power source circuit
wiring harness
DF10KA • Open in lever GND circuit wiring
(TM-59) harness
• Open or short circuit with chassis
ground in lever signal circuit wiring
harness
• Defective transmission controller
20-432 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Action
Condition When Normal Action By Controller Problem That Appears On Machine
Code
• Fill switch resistance value • Holds speed range during travel • Cannot shift gear
ATC5A (male) (11) - ground: • When gearshift lever is returned to • If gearshift lever is returned to N,
• When clutch is released: N, holds in Neutral machine cannot move off again until E03
Min. 1 MΩ it is stopped
• When clutch is engaged: 1 Ω • Lock-up pilot lamp does not light up
• Fill switch resistance value • Holds speed range during travel • Cannot shift gear
ATC5A (male) (12) - ground: • When gearshift lever is returned to • If gearshift lever is returned to N,
• When clutch is released: N, holds in Neutral machine cannot move off again until E03
Min. 1 MΩ it is stopped
• When clutch is engaged: 1 Ω
• Fill switch resistance value • Holds speed range during travel • Cannot shift gear
ATC5A (male) (11) - ground: • When gearshift lever is returned to • If gearshift lever is returned to N,
• When clutch is released: N, holds in Neutral machine cannot move off again until E03
Min. 1 MΩ it is stopped
• When clutch is engaged: 1 Ω
• Fill switch resistance value • Holds speed range during travel • Cannot shift gear
ATC5A (male) (13) - ground: • When gearshift lever is returned to • If gearshift lever is returned to N,
• When clutch is released: N, holds in Neutral machine cannot move off again until E03
Min. 1 MΩ it is stopped
• When clutch is engaged: 1 Ω
• Fill switch resistance value • Holds speed range during travel • Cannot shift gear
ATC5A (male) (14) - ground: • When gearshift lever is returned to • If gearshift lever is returned to N,
• When clutch is released: N, holds in Neutral machine cannot move off again until E03
Min. 1 MΩ it is stopped
• When clutch is engaged: 1 Ω
• Fill switch resistance value • Holds speed range during travel • Cannot shift gear
ATC5A (male) (15) - ground: • When gearshift lever is returned to • If gearshift lever is returned to N,
• When clutch is released: N, holds in Neutral machine cannot move off again until
Min. 1 MΩ it is stopped
• When clutch is engaged: Max. 1
E03
Ω
• Fill switch resistance value • Holds speed range during travel • Cannot shift gear
ATC5A (male) (16) - ground: • When gearshift lever is returned to • If gearshift lever is returned to N,
• When clutch is released: N, holds in Neutral machine cannot move off again until
Min. 1 MΩ it is stopped E03
• When clutch is engaged: Max. 1
Ω
• Gearshift lever power source • Condition before abnormality • Shifts to higher speed range than
voltage occurred is maintained speed range set by gearshift lever
SF1 (1) - (2): 20 - 24 V • Stays in Neutral and machine cannot
• Gearshift lever signal voltage move off
• SF1 • Impossible to change direction of
E03
(3)(4)(5)(6)(7)(8)(9)(10)(11) - travel between FORWARD and
(2): REVERSE
• Selected circuit: 20 - 24 V • All gearshift lever position lamps go
• Not selected circuit: Max. 1 V out
HM400-1L 20-433 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Gearshift lever: Short circuit The gearshift lever signal was input • Defective shift lever
(KB) at the same time from 2 or more • Short circuit with power source in lever
systems signal circuit wiring harness
DF10KB
• Defective transmission controller
(TM-60)
Transmission valve oil tem- The voltage of the signal circuit for • Defective transmission valve oil
perature sensor: Input signal the transmission valve oil temperature sensor
outside range (KX) temperature sensor became less • Open or short circuit with chassis
than 0.97 V, or there was a big ground, or short circuit with power
DGF1KX
difference from the torque converter source in sensor signal circuit wiring
(TM-61)
oil temperature harness
• Open in sensor GND circuit wiring
harness
• Defective transmission controller
Brake oil temperature sensor When the front brake oil • Defective rear brake oil temperature
(rear): * See Contents (L8) temperature sensor signal and sensor
center brake oil temperature sensor • Open or short circuit with power source
DGR2L8
signal were more than 60oC, the in sensor signal circuit wiring harness
(TM-62)
rear brake oil temperature sensor • Open in sensor GND circuit wiring
was less than 10OC harness
• Defective transmission controller
Brake oil temperature sensor When the front brake oil • Defective center brake oil temperature
(center): * See Contents (L8) temperature sensor signal and rear sensor
brake oil temperature sensor signal • Open or short circuit with power source
DGR3L8
were more than 60oC, the center in sensor signal circuit wiring harness
(TM-63)
brake oil temperature sensor was • Open in sensor GND circuit wiring
OC harness
less than 10
• Defective transmission controller
Brake oil temperature sensor When the center brake oil • Defective front brake oil temperature
(front): * See Contents (L8) temperature sensor signal and rear sensor
brake oil temperature sensor signal • Open or short circuit with power source
DGR4L8
were more than 60oC, the front in sensor signal circuit wiring harness
(TM-64)
brake oil temperature sensor was • Open in sensor GND circuit wiring
oC harness
less than 10
• Defective transmission controller
Torque converter oil temper- The voltage of the signal circuit for • Defective torque converter oil
ature sensor: Input signal the torque converter oil temperature temperature sensor
outside range (KX) sensor became less than 0.97 V, or • Open or short circuit with chassis
DGT1KX there was a big difference from the ground, or short circuit with power
(TM-65) transmission valve oil temperature source in sensor signal circuit wiring
sensor signal harness
• Open in sensor GND circuit
• Defective transmission controller
Torque converter oil pressure The voltage in the signal circuit of • Defective torque converter oil pressure
sensor: Input signal outside the torque converter oil pressure sensor
range (KX) sensor became less than 0.5 V or • Open or short circuit with chassis
more than 4.5 V ground in sensor power source circuit
DHT5KX wiring harness
(TM-66) • Open or short circuit with chassis
ground, or short circuit with power
source in sensor signal circuit wiring
harness
• Defective transmission controller
20-434 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Action
Condition When Normal Action By Controller Problem That Appears On Machine
Code
• Gearshift lever power source • Controls using signal in order of • Shifts to higher speed range than
voltage high priority speed range set by gearshift lever
SF1 (1) - (2): 20 - 24V • (1): N > D > 5 > 4 > 3 > 2 > 1 • Stays in Neutral and machine cannot
• Gearshift lever signal voltage• (2): N > R2 > R1 move off E03
• SF1(3)(4)(5)(6)(7)(8)(9)(10)(11)
• If the signal for both system (1) and • Gearshift lever position lamps are
• Selected circuit: 20 - 24 V system (2) are input at the same different from position of lever
• Not selected circuit: Max. 1 V time, shifts transmission to Neutral
• Sensor resistance value • Controls clutch oil pressure with • Transmission shock becomes
LUB-T (male) (1) - (2): clutch oil temperature before excessive
• When oil temperature is 25oC: abnormality occurred
37 - 50 kΩ
• When oil temperature is E03
100oC: 3.5 - 4.0 kΩ
• Sensor power source voltage • Fixes torque converter oil pressure • Excessive shock when lock-up is
TC-INT (2) - (1): 20 - 30 V to oil pressure set inside controller actuated
• Sensor signal voltage and carries out control
TC-INT (3) - (1): 0.8 - 2.0 V
E01
HM400-1L 20-435 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Torque converter oil pressure When the engine is stopped, the • Defective torque converter oil pressure
sensor: * See Contents (L6) torque converter oil pressure circuit (when actuating system
sensor signal circuit inputs the oil normally)
DHT5L6 pressure • Defective torque converter oil pressure
(TM-67) sensor
• Short circuit with power source in
sensor signal circuit wiring harness
• Defective transmission controller
Fuel level sensor: Open (L6) The voltage of the signal circuit of • Defective fuel level sensor
the fuel level sensor became more • Open or short circuit with power source
DJF1KA than 4.0 V in sensor signal circuit wiring harness
(TM-68) • Open in sensor GND circuit wiring
harness
• Defective transmission controller
Throttle angle sensor: Input The voltage in the signal circuit of • Defective accelerator sensor or
signal outside range (KX) the acceleration sensor became defective accelerator pedal
less than 0.6 V or more than 4.7 V • Open or short circuit with chassis
ground, or short circuit with power
source in sensor power source circuit
wiring harness
DK11KX
• Open in sensor GND circuit wiring
(TM-69)
harness
• Open or short circuit with chassis
ground, or short circuit with power
source in sensor signal circuit wiring
harness
• Defective transmission controller
Engine speed sensor: Open There is an open in the signal circuit • Defective engine speed sensor or
(KA) of the engine speed sensor and the defective adjustment
signal is not input • Open in sensor signal circuit wiring
DLE2KA
harness
(TM-70)
• Open in sensor GND circuit wiring
harness
• Defective transmission controller
Engine speed sensor: * See When the signal of the engine • Defective engine speed sensor
Contents (LC) speed sensor is less than 350 rpm, • Short circuit with chassis ground or
DLE2LC
the signal of the transmission input short circuit with power source in
(TM-71)
shaft speed sensor inputs more sensor signal circuit wiring harness
than 500 rpm • Defective transmission controller
Transmission input shaft There is an open in the signal circuit • Defective transmission input shaft
speed sensor: Open (KA) of the transmission input shaft speed sensor or defective adjustment
speed sensor and the signal is not • Open in sensor signal circuit wiring
DLF1KA
input harness
(TM-72)
• Open in sensor GND circuit wiring
harness
• Defective transmission controller
Transmission input shaft There is an abnormality in the • Defective transmission input shaft
speed sensor: * See Con- speed calculated from the engine speed sensor
tents (LC) speed sensor signal, transmission • Short circuit with chassis ground or
DLF1LC intermediate shaft speed sensor short circuit with power source in
(TM-73) signal, and output shaft R speed sensor signal circuit wiring harness
sensor signal, and the speed of the • Defective transmission controller
transmission input shaft sensor
signal
20-436 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Action
Condition When Normal Action By Controller Problem That Appears On Machine
Code
• Sensor power source voltage • Fixes torque converter oil pressure • Excessive shock when lock-up is
TC-INT (2) - (1): 20 - 30 V to oil pressure set inside controller actuated
• Sensor signal voltage and carries out control
TC-INT (3) - (1): 0.8 - 2.0 V
E01
• Sensor resistance value • Takes no action • Fuel gauge does not give correct
T08 (male) (1) - (2): display
• When full: Max. 12 Ω
E01
• When empty: 74 - 100 Ω
• Sensor power source voltage • Carries out automatic shifting in • Transmission shock becomes
AS2 (1) - (3): 4.6 - 5.4 V normal mode (but controls with excessive
• Sensor signal voltage clutch oil pressure taken as engine • Immediately shifts up when traveling
• AS3 (2) - (3): at full throttle) downhill
• Lo position: 1.0 - 1.4 V
• Hi position: 3.6 - 4.0 V
E03
• Sensor resistance value • Holds speed range during travel • Cannot shift gear
EREV (male) (1) - (2): 500 - 1000 • When gearshift lever is returned to • If gearshift lever is returned to N,
Ω N, holds in Neutral machine cannot move off again until
it is stopped E03
• Tachometer does not work (displays
0 rpm)
• Sensor resistance value • Holds speed range during travel • Cannot shift gear
EREV (male) (1) - (2): 500 - 1000 • When gearshift lever is returned to • If gearshift lever is returned to N,
Ω N, holds in Neutral machine cannot move off again until E03
it is stopped
• Tach. does not go above 350 rpm
• Sensor resistance value • Holds speed range during travel • Lock-up is canceled and
N1 (male) (1) - (2): 500 - 1000 Ω and turns actuation of lock-up OFF transmission cannot be shifted
• When gearshift lever is returned to • If gearshift lever is returned to N,
N, holds in Neutral machine cannot move off again until E03
it is stopped
• Sensor resistance value • Holds speed range during travel • Lock-up is canceled and
N1 (male) (1) - (2): 500 - 1000 Ω and turns actuation of lock-up OFF transmission cannot be shifted
• When gearshift lever is returned to • If gearshift lever is returned to N,
N, holds in Neutral machine cannot move off again until
E03
it is stopped
HM400-1L 20-437 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Transmission intermediate There is an open in the signal circuit • Defective transmission intermediate
shaft speed sensor: Open of the transmission intermediate shaft speed sensor or defective
(KA) shaft speed sensor and the signal is adjustment
DLF2KA not input • Open in sensor signal circuit wiring
(TM-74) harness
• Open in sensor GND circuit wiring
harness
• Defective transmission controller
Transmission intermediate There is an abnormality in the • Defective transmission intermediate
shaft speed sensor: * See speed calculated from the engine shaft speed sensor
Contents (LC) speed sensor signal, transmission • Short circuit with chassis ground or
DLF2LC
input shaft speed sensor signal, and short circuit with power source in
(TM-75)
output shaft R speed sensor signal, sensor signal circuit wiring harness
and the speed of the transmission • Defective transmission controller
intermediate shaft sensor signal
Transmission output shaft There is an open in the signal circuit • Defective transmission output shaft R
speed sensor: Open (KA) of the transmission output shaft R speed sensor or defective adjustment
speed sensor and the signal is not • Open in sensor signal circuit wiring
DLT3KA
input harness
(TM-76)
• Open in sensor GND circuit wiring
harness
• Defective transmission controller
Transmission output shaft There is an abnormality in the • Defective transmission output shaft R
speed sensor: * See Con- speed calculated from the engine speed sensor or defective adjustment
tents (LC) speed sensor signal, transmission • Short circuit with chassis ground or
DLT3LC input shaft speed sensor signal, and short circuit with power source in
(TM-77) intermediate shaft speed sensor sensor signal circuit wiring harness
signal, and the speed of the • Defective transmission controller
transmission output shaft R sensor • efective retarder controller
signal
Solenoid for inter-axle differ- No electric current flows when there • Defective differential lock clutch
ential lock: Open (KA) is output to the differential lock solenoid
clutch solenoid • Open in solenoid (+) circuit wiring
DXH0KA
harness
(TM-78)
• Open in solenoid (-) circuit wiring
harness
• Defective transmission controller
Solenoid for inter-axle differ- An extremely large electric current • Defective differential lock clutch
ential lock: Short circuit (KB) flows when there is output to the solenoid
differential lock clutch solenoid or • Short circuit, short circuit with chassis
DXH0KB
electric current flows when it is OFF ground, or short circuit with power
(TM-79)
source in solenoid (+) circuit wiring
harness
• Defective transmission controller
Solenoid for lock-up clutch: No electric current flows when there • Defective lock-up clutch solenoid
DXH1KA Open (KA) is output to the lock-up clutch • Open in solenoid (+) circuit
(TM-80) solenoid • Open in solenoid (-) circuit
• Defective transmission controller
Solenoid for lock-up clutch: An extremely large electric current • Defective lock-up clutch solenoid
Short circuit (KB) flows when there is output to the • Short circuit, with chassis ground, or
lock-up clutch solenoid or electric short circuit with power source in
DXH1KB current flows when it is OFF solenoid (+) circuit wiring harness
(TM-81) • Defective transmission controller
20-438 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Action
Condition When Normal Action By Controller Problem That Appears On Machine
Code
• Sensor resistance value • Holds speed range during travel • Cannot shift gear
N2 (male) (1) - (2): 500 - 1000 Ω • When gearshift lever is returned to • If gearshift lever is returned to N,
N, holds in Neutral machine cannot move off again until
it is stopped
E03
• Sensor resistance value • Holds speed range during travel • Cannot shift gear
N2 (male) (1) - (2): 500 - 1000 Ω • When gearshift lever is returned to • If gearshift lever is returned to N,
N, holds in Neutral machine cannot move off again until
it is stopped E03
• Sensor resistance value • Holds speed range during travel • Speedometer displays 0 km/h
N3 (male) (1) - (2): 500 - 1000 Ω • When gearshift lever is returned to • Cannot shift gear
N, holds in Neutral • If gearshift lever is returned to N,
machine cannot move off again until E03
it is stopped
• Sensor resistance value • Holds speed range during travel • Cannot shift gear
N3 (male) (1) - (2): 500 - 1000 Ω • When gearshift lever is returned to • If gearshift lever is returned to N,
N, holds in Neutral machine cannot move off again until
it is stopped
E03
• Speedometer displays abnormal
speed
• Solenoid resistance value • Continues output as it is • Inter-axle differential lock does not
D/L-PS (male) (1) - (2): 5 - 15 Ω work
E01
• Solenoid resistance value • Turns inter-axle differential lock • Inter-axle differential lock does not
D/L-PS (male) (1) - (2): 5 - 15 Ω command OFF work or is not canceled
E01
• Solenoid resistance value • Turns lock-up actuation OFF • Lock-up is not actuated
L/U-PS (male) (1) - (2): 5 - 15 Ω
E03
• Solenoid resistance value • Holds speed range during travel • Lock-up is always canceled or
L/U-PS (male) (1) - (2): 5 - 15 Ω and turns actuation of lock-up OFF always actuated and transmission
• When gearshift lever is returned to cannot be shifted
N, holds in Neutral • If gearshift lever is operated to N,
E03
machine cannot move off again until
it is stopped (depending on condition
of failure, machine may not be able
to move off again)
HM400-1L 20-439 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Solenoid for Hi clutch: Open No electric current flows when there • Defective Hi clutch solenoid
(KA) is output to the Hi clutch solenoid • Open in solenoid (+) circuit
DXH2KA
• Open in solenoid (-) circuit
(TM-82)
• Defective transmission controller
Solenoid for Hi clutch: Short An extremely large electric current • Defective Hi clutch solenoid
circuit (KB) flows when there is output to the Hi • Short circuit, short circuit with chassis
clutch solenoid or electric current ground, or short circuit with power
DXH2KB flows when it is OFF source in solenoid (+) circuit wiring
(TM-83) harness
• Short circuit with power source in
solenoid (-) circuit wiring harness
• Defective transmission controller
Solenoid for Lo clutch: Open No electric current flows when there • Defective Lo clutch solenoid
DXH3KA (KA) is output to the Lo clutch solenoid • Open in solenoid (+) circuit
(TM-84) • Open in solenoid (-) circuit
• Defective transmission controller
Solenoid for Lo clutch: Short An extremely large electric current • Defective Lo clutch solenoid
circuit (KB) flows when there is output to the Lo • Short circuit, short circuit with chassis
clutch solenoid or electric current ground, or short circuit with power
DXH3KB flows when it is OFF source in solenoid (+) circuit wiring
(TM-85) harness
• Short circuit with power source in
solenoid (-) circuit wiring harness
• Defective transmission controller
Solenoid for 1st clutch: Open No electric current flows when there • Defective 1st clutch solenoid
DXH4KA (KA) is output to the 1st clutch solenoid • Open in solenoid (+) circuit
(TM-86) • Open in solenoid (-) circuit
• Defective transmission controller
Solenoid for 1st clutch: Short An extremely large electric current • Defective 1st clutch solenoid
circuit (KB) flows when there is output to the 1st • Short circuit, short circuit with chassis
clutch solenoid or electric current ground, or short circuit with power
DXH4KB flows when it is OFF source in solenoid (+) circuit wiring
(TM-87) harness
• Short circuit with power source in
solenoid (-) circuit wiring harness
• Defective transmission controller
Solenoid for 2nd clutch: No electric current flows when there • Defective 2nd clutch solenoid
DXH5KA Open (KA) is output to the 2nd clutch solenoid • Open in solenoid (+) circuit
(TM-88) • Open in solenoid (-) circuit
• Defective transmission controller
Solenoid for 2nd clutch: An extremely large electric current • Defective 2nd clutch solenoid
Short circuit (KB) flows when there is output to the • Short circuit, short circuit with chassis
2nd clutch solenoid or electric ground, or short circuit with power
DXH5KB current flows when it is OFF source in solenoid (+) circuit wiring
(TM-89) harness
• Short circuit with power source in
solenoid (-) circuit wiring harness
• Defective transmission controller
20-440 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Action
Condition When Normal Action By Controller Problem That Appears On Machine
Code
• Solenoid resistance value • Shifts to Neutral during travel
H-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine
cannot move off again E03
• Solenoid resistance value • Sets transmission to Neutral. • Shifts to Neutral during travel
H-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine
cannot move off again (depending
on condition of failure, machine may
E03
not be able to move off again)
• Solenoid resistance value • Sets transmission to Neutral. • Shifts to Neutral during travel
L-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine
E03
cannot move off again
• Solenoid resistance value • Sets transmission to Neutral. • Shifts to Neutral during travel
L-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine
cannot move off again (depending
on condition of failure, machine may
E03
not be able to move off again)
• Solenoid resistance value • Sets transmission to Neutral. • Shifts to Neutral during travel
1-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine
E03
cannot move off again
• Solenoid resistance value • Sets transmission to Neutral. Shifts to Neutral during travel
1-PS (male) (1) - (2): 5 - 15 Ω If travel is not stopped, machine
cannot move off again (depending
on condition of failure, machine may
E03
not be able to move off again)
• Solenoid resistance value • Sets transmission to Neutral. • Shifts to Neutral during travel
2-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine
E03
cannot move off again
• Solenoid resistance value • Sets transmission to Neutral. • Shifts to Neutral during travel
2-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine
cannot move off again (depending
on condition of failure, machine may
E03
not be able to move off again)
HM400-1L 20-441 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Solenoid for 3rd clutch: Open No electric current flows when there • Defective 3rd clutch solenoid
(KA) is output to the 3rd clutch solenoid • Open in solenoid (+) circuit
DXH6KA
• Open in solenoid (-) circuit
(TM-90)
• Defective transmission controller
Solenoid for 3rd clutch: Short An extremely large electric current • Defective 3rd clutch solenoid
circuit (KB) flows when there is output to the 3rd • Short circuit, short circuit with chassis
clutch solenoid or electric current ground, or short circuit with power
flows when it is OFF source in solenoid (+) circuit wiring
DXH6KB
harness
(TM-91)
• Short circuit with power source in
solenoid (-) circuit wiring harness
• Defective transmission controller
Solenoid for R clutch: Open No electric current flows when there • Defective R clutch solenoid
DXH7KA (KA) is output to the R clutch solenoid • Open in solenoid (+) circuit
(TM-92) • Open in solenoid (-) circuit
• Defective transmission controller
Solenoid for R clutch: Short An extremely large electric current • Defective R clutch solenoid
circuit (KB) flows when there is output to the R • Short circuit, short circuit with chassis
clutch solenoid or electric current ground, or short circuit with power
DXH7KB flows when it is OFF source in solenoid (+) circuit wiring
(TM-93) harness
• Short circuit with power source in
solenoid (-) circuit wiring harness
• Defective transmission controller
20-442 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12)
Action
Condition When Normal Action By Controller Problem That Appears On Machine
Code
Solenoid resistance value • Sets transmission to Neutral. • Shifts to Neutral during travel
3-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine
cannot move off again E03
Solenoid resistance value • Sets transmission to Neutral. • Shifts to Neutral during travel
3-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine
cannot move off again (depending
on condition of failure, machine may
not be able to move off again) E03
Solenoid resistance value • Sets transmission to Neutral. • Shifts to Neutral during travel
R-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine
E03
cannot move off again
Solenoid resistance value • Sets transmission to Neutral. • Shifts to Neutral during travel
R-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine
cannot move off again (depending
on condition of failure, machine may
E03
not be able to move off again)
HM400-1L 20-443 1
TROUBLESHOOTING INFORMATION CONTAINED IN TESTING PROCEDURES
12
INFORMATION CONTAINED IN TESTING PROCEDURES
★ The testing table and the related circuit diagrams contain the following information. Read all information and each step
carefully, if necessary, repeat each step in a test procedure to confirm the fault. The idea behind these procedures is to
isolate each part of the circuit.
• Failure.
Contents Of Trouble • Failure code displayed.
• Additional information.
Tools and Procedures
Steps Circuit Diagnostic Procedures For Service Code Specifications No. Readings
1. Sensor or Actuator
• With ignition switch in the “OFF” position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸)
• Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
• Zero meter leads for proper Ω readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)
Your
Test procedure for component only. readings 1
Resistance Ω information
A. What you are testing
or Voltage Your
Test procedure for component only. readings 2
information
2. Diode Test
• With ignition switch in the “OFF” position. (The importance of these tests are to isolate each component for testing separately)
• When checking a diode always isolate the circuit. Check diode continuity in both directions reversing meter leads each time to confirm
electrical flow. Electrical flow should be one way only. (See section 20-111 for detail).
At a diode, between point (x) and (x) Continuity one
A. Diode test Resistance Ω 3 Yes or No
reverse meter lead polarity each time to check diode. way only?
3. Wiring Harness Assembly Test
• With ignition switch in the “OFF” position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸)
• Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
• Zero meter leads for proper Ω readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)
Your
Test procedure for harness. (connector) to (connector) readings 4
A. Open or high Resistance Ω information
resistance or Voltage Your
Test procedure for harness. (connector) to (connector) readings 5
information
Your
B. Short to chassis Test procedure for harness. (connector) to (connector) readings 6
Resistance Ω information
ground or within
or Voltage Your
harness Test procedure for harness. (connector) to (connector) readings 7
information
4. Additional Components To Be Tested
• With ignition switch in the “OFF” position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸)
• Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
• Zero meter leads for proper Ω readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)
Resistance Ω Your
A. What you are testing Test procedure for any additional components. readings 8
or Voltage information
20-444 1 HM400-1L
TROUBLESHOOTING INFORMATION CONTAINED IN TESTING PROCEDURES
Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
HM400-1L 20-445 1
TROUBLESHOOTING (TM-1) FAILURE CODE [1380MW]
12
(TM-1) FAILURE CODE [1380MW]
Steps Circuit Diagnostic Procedures For Failure Code [1380MW] Specifications No. Readings
1. L/U Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (L/U-PS) connector from solenoid and isolate solenoid.
• Disconnect (L/U-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid L/U-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch L/U-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch L/U-SW, between (1) and (2) engine running
0.0 to 1.0Ω 3
and system operating
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (L/U-PS and L/U-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors L/U-PS, (1) and ATC2, (10) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors L/U-PS, (2) and ATC2, (20) 0.0 to 1.0Ω 5
resistance
Between connectors L/U-SW, (1) and ATC5A, (11) 0.0 to 1.0Ω 6
At connector L/U-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector L/U-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector L/U-PS, between (1) and (2) (OL) open 9
At connector L/U-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-446 1 HM400-1L
TROUBLESHOOTING (TM-1) FAILURE CODE [1380MW]
Related circuit diagram
HM400-1L 20-447 1
TROUBLESHOOTING (TM-2) FAILURE CODE [1500LO]
12
(TM-2) FAILURE CODE [1500LO]
Cause Remedy
NO
YES
Defective transmission controller Replace
20-448 1 HM400-1L
TROUBLESHOOTING (TM-3) FAILURE CODE [15BONX]
Steps Circuit Diagnostic Procedures For Failure Code [15BONX] Specifications No. Readings
Transmission Filter ⎯ Replace transmission filter and fluid System OK? 1 Yes or No
1. Clog Switch Unit
• With ignition switch in the "OFF" position.
• Disconnect (T03) connector from clog switch and isolate switch.
• Zero meter leads for proper Ω readings.
At switch TO3, between (1) and (2) (OL) open 2
A. Switch test Resistance Ω
At switch TO3, between (1) or (2) and chassis ground. (OL) open 3
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (TO3) connector from switch and isolate connector.
• Disconnect (ATC5A) connector from transmission controller and install T-adapter on (ATC5A) wiring harness connector only.
A. Open or high Between connectors ATC5A, (6) and TO3, (1) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors TO3, (2) and chassis ground. 0.0 to 1.0Ω 5
B. Short to chassis At connector TO3, between (1) and chassis ground. (OL) open 6
ground or within Resistance Ω
harness At connector TO3, between (1) and (2) (OL) open 7
HM400-1L 20-449 1
TROUBLESHOOTING (TM-3) FAILURE CODE [15BONX]
Related circuit diagram
20-450 1 HM400-1L
TROUBLESHOOTING (TM-4) FAILURE CODE [15GOMW]
Steps Circuit Diagnostic Procedures For Failure Code [15GOMW] Specifications No. Readings
1. “R” Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (R-PS) connector from solenoid and isolate solenoid.
• Disconnect (R-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid R-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch R-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch R-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (R-PS and R-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors R-PS, (1) and ATC2, (5) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors R-PS, (2) and ATC2, (15) 0.0 to 1.0Ω 5
resistance
Between connectors R-SW, (1) and ATC5A, (16) 0.0 to 1.0Ω 6
At connector R-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector R-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector R-PS, between (1) and (2) (OL) open 9
At connector R-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-451 1
TROUBLESHOOTING (TM-4) FAILURE CODE [15GOMW]
Related circuit diagram
20-452 1 HM400-1L
TROUBLESHOOTING (TM-5) FAILURE CODE [15HOMW]
Steps Circuit Diagnostic Procedures For Failure Code [15HOMW] Specifications No. Readings
1. “HI” Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (H-PS) connector from solenoid and isolate solenoid.
• Disconnect (H-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid H-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch H-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch H-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (H-PS and H-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors H-PS, (1) and ATC2, (4) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors H-PS, (2) and ATC2, (15) 0.0 to 1.0Ω 5
resistance
Between connectors H-SW, (1) and ATC5A, (12) 0.0 to 1.0Ω 6
At connector H-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector H-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector H-PS, between (1) and (2) (OL) open 9
At connector H-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-453 1
TROUBLESHOOTING (TM-5) FAILURE CODE [15HOMW]
Related circuit diagram
20-454 1 HM400-1L
TROUBLESHOOTING (TM-6) FAILURE CODE [15JOMW]
Steps Circuit Diagnostic Procedures For Failure Code [15JOMW] Specifications No. Readings
1. “Lo” Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (L-PS) connector from solenoid and isolate solenoid.
• Disconnect (L-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid L-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch L-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch L-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (L-PS and L-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors L-PS, (1) and ATC2, (7) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors L-PS, (2) and ATC2, (17) 0.0 to 1.0Ω 5
resistance
Between connectors L-SW, (1) and ATC5A, (10) 0.0 to 1.0Ω 6
At connector L-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector L-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector L-PS, between (1) and (2) (OL) open 9
At connector L-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-455 1
TROUBLESHOOTING (TM-6) FAILURE CODE [15JOMW]
Related circuit diagram
20-456 1 HM400-1L
TROUBLESHOOTING (TM-7) FAILURE CODE [15KOMW]
Steps Circuit Diagnostic Procedures For Failure Code [15KOMW] Specifications No. Readings
1. 1st Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (1-PS) connector from solenoid and isolate solenoid.
• Disconnect (1-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid 1-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch 1-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch 1-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (1-PS and 1-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors 1-PS, (1) and ATC2, (2) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors 1-PS, (2) and ATC2, (13) 0.0 to 1.0Ω 5
resistance
Between connectors 1-SW, (1) and ATC5A, (13) 0.0 to 1.0Ω 6
At connector 1-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector 1-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector 1-PS, between (1) and (2) (OL) open 9
At connector 1-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-457 1
TROUBLESHOOTING (TM-7) FAILURE CODE [15KOMW]
Related circuit diagram
20-458 1 HM400-1L
TROUBLESHOOTING (TM-8) FAILURE CODE [15LOMW]
Steps Circuit Diagnostic Procedures For Failure Code [15LOMW] Specifications No. Readings
1. 2nd Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (2-PS) connector from solenoid and isolate solenoid.
• Disconnect (2-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid 2-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch 2-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch 2-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (2-PS and 2-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors 2-PS, (1) and ATC2, (9) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors 2-PS, (2) and ATC2, (19) 0.0 to 1.0Ω 5
resistance
Between connectors 2-SW, (1) and ATC5A, (14) 0.0 to 1.0Ω 6
At connector 2-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector 2-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector 2-PS, between (1) and (2) (OL) open 9
At connector 2-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-459 1
TROUBLESHOOTING (TM-8) FAILURE CODE [15LOMW]
Related circuit diagram
20-460 1 HM400-1L
TROUBLESHOOTING (TM-9) FAILURE CODE [15MOMW]
Steps Circuit Diagnostic Procedures For Failure Code [15MOMW] Specifications No. Readings
1. 3rd Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (3-PS) connector from solenoid and isolate solenoid.
• Disconnect (3-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid 3-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch 3-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch 3-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (3-PS and 3-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors 3-PS, (1) and ATC2, (3) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors 3-PS, (2) and ATC2, (13) 0.0 to 1.0Ω 5
resistance
Between connectors 3-SW, (1) and ATC5A, (15) 0.0 to 1.0Ω 6
At connector 3-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector 3-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector 3-PS, between (1) and (2) (OL) open 8
At connector 3-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-461 1
TROUBLESHOOTING (TM-9) FAILURE CODE [15MOMW]
Related circuit diagram
20-462 1 HM400-1L
TROUBLESHOOTING (TM-10) FAILURE CODE [15SBL1]
Steps Circuit Diagnostic Procedures For Failure Code [15SBL1] Specifications No. Readings
1. R Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (R-PS) connector from solenoid and isolate solenoid.
• Disconnect (R-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid R-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch R-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch R-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (R-PS and R-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors R-PS, (1) and ATC2, (5) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors R-PS, (2) and ATC2, (15) 0.0 to 1.0Ω 5
resistance
Between connectors R-SW, (1) and ATC5A, (16) 0.0 to 1.0Ω 6
At connector R-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector R-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector R-PS, between (1) and (2) (OL) open 9
At connector R-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-463 1
TROUBLESHOOTING (TM-10) FAILURE CODE [15SBL1]
Related circuit diagram
20-464 1 HM400-1L
TROUBLESHOOTING (TM-11) FAILURE CODE [15SBMA]
Steps Circuit Diagnostic Procedures For Failure Code [15SBMA] Specifications No. Readings
1. R Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (R-PS) connector from solenoid and isolate solenoid.
• Disconnect (R-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid R-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch R-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch R-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (R-PS and R-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors R-PS, (1) and ATC2, (5) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors R-PS, (2) and ATC2, (15) 0.0 to 1.0Ω 5
resistance
Between connectors R-SW, (1) and ATC5A, (16) 0.0 to 1.0Ω 6
At connector R-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector R-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector R-PS, between (1) and (2) (OL) open 9
At connector R-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-465 1
TROUBLESHOOTING (TM-11) FAILURE CODE [15SBMA]
Related circuit diagram
20-466 1 HM400-1L
TROUBLESHOOTING (TM-12) FAILURE CODE [15SCL1]
Steps Circuit Diagnostic Procedures For Failure Code [15SCL1] Specifications No. Readings
1. Hi Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (H-PS) connector from solenoid and isolate solenoid.
• Disconnect (H-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid H-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch H-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch H-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (H-PS and H-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors H-PS, (1) and ATC2, (4) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors H-PS, (2) and ATC2, (15) 0.0 to 1.0Ω 5
resistance
Between connectors H-SW, (1) and ATC5A, (12) 0.0 to 1.0Ω 6
At connector H-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector H-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector H-PS, between (1) and (2) (OL) open 9
At connector H-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-467 1
TROUBLESHOOTING (TM-12) FAILURE CODE [15SCL1]
Related circuit diagram
20-468 1 HM400-1L
TROUBLESHOOTING (TM-13) FAILURE CODE [15SCMA]
Steps Circuit Diagnostic Procedures For Failure Code [15SCMA] Specifications No. Readings
1. HI Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (H-PS) connector from solenoid and isolate solenoid.
• Disconnect (H-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid H-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch H-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch H-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (H-PS and H-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors H-PS, (1) and ATC2, (4) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors H-PS, (2) and ATC2, (15) 0.0 to 1.0Ω 5
resistance
Between connectors H-SW, (1) and ATC5A, (12) 0.0 to 1.0Ω 6
At connector H-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector H-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector H-PS, between (1) and (2) (OL) open 9
At connector H-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-469 1
TROUBLESHOOTING (TM-13) FAILURE CODE [15SCMA]
Related circuit diagram
20-470 1 HM400-1L
TROUBLESHOOTING (TM-14) FAILURE CODE [15SDL1]
Steps Circuit Diagnostic Procedures For Failure Code [15SDL1] Specifications No. Readings
1. Lo Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (L-PS) connector from solenoid and isolate solenoid.
• Disconnect (L-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid L-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch L-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch L-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (L-PS and L-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors L-PS, (1) and ATC2, (7) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors L-PS, (2) and ATC2, (17) 0.0 to 1.0Ω 5
resistance
Between connectors L-SW, (1) and ATC5A, (10) 0.0 to 1.0Ω 6
At connector L-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector L-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector L-PS, between (1) and (2) (OL) open 9
At connector L-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-471 1
TROUBLESHOOTING (TM-14) FAILURE CODE [15SDL1]
Related circuit diagram
20-472 1 HM400-1L
TROUBLESHOOTING (TM-15) FAILURE CODE [15SDMA]
Steps Circuit Diagnostic Procedures For Failure Code [15SDMA] Specifications No. Readings
1. R Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (L-PS) connector from solenoid and isolate solenoid.
• Disconnect (L-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid L-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch L-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch L-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (L-PS and L-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors L-PS, (1) and ATC2, (7) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors L-PS, (2) and ATC2, (17) 0.0 to 1.0Ω 5
resistance
Between connectors L-SW, (1) and ATC5A, (10) 0.0 to 1.0Ω 6
At connector L-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector L-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector L-PS, between (1) and (2) (OL) open 9
At connector L-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-473 1
TROUBLESHOOTING (TM-15) FAILURE CODE [15SDMA]
Related circuit diagram
20-474 1 HM400-1L
TROUBLESHOOTING (TM-16) FAILURE CODE [15SEL1]
Steps Circuit Diagnostic Procedures For Failure Code [15SEL1] Specifications No. Readings
1. R Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (1-PS) connector from solenoid and isolate solenoid.
• Disconnect (1-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid 1-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch 1-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch 1-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (1-PS and 1-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors1 -PS, (1) and ATC2, (2) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors 1-PS, (2) and ATC2, (13) 0.0 to 1.0Ω 5
resistance
Between connectors 1-SW, (1) and ATC5A, (13) 0.0 to 1.0Ω 6
At connector 1-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector 1-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector 1-PS, between (1) and (2) (OL) open 9
At connector 1-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-475 1
TROUBLESHOOTING (TM-16) FAILURE CODE [15SEL1]
Related circuit diagram
20-476 1 HM400-1L
TROUBLESHOOTING (TM-17) FAILURE CODE [15SEMA]
Steps Circuit Diagnostic Procedures For Failure Code [15SEMA] Specifications No. Readings
1. 1st Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (1-PS) connector from solenoid and isolate solenoid.
• Disconnect (1-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid 1-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch 1-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch 1-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (1-PS and 1-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors 1-PS, (1) and ATC2, (2) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors 1-PS, (2) and ATC2, (13) 0.0 to 1.0Ω 5
resistance
Between connectors 1-SW, (1) and ATC5A, (13) 0.0 to 1.0Ω 6
At connector 1-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector 1-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector 1-PS, between (1) and (2) (OL) open 9
At connector 1-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-477 1
TROUBLESHOOTING (TM-17) FAILURE CODE [15SEMA]
Related circuit diagram
20-478 1 HM400-1L
TROUBLESHOOTING (TM-18) FAILURE CODE [15SFL1]
Steps Circuit Diagnostic Procedures For Failure Code [15SFL1] Specifications No. Readings
1. 2nd Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (2-PS) connector from solenoid and isolate solenoid.
• Disconnect (2-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid 2-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch 2-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch 2-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (R-PS and R-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors 2-PS, (1) and ATC2, (9) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors 2-PS, (2) and ATC2, (19) 0.0 to 1.0Ω 5
resistance
Between connectors 2-SW, (1) and ATC5A, (14) 0.0 to 1.0Ω 6
At connector 2-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector 2-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector 2-PS, between (1) and (2) (OL) open 9
At connector 2-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-479 1
TROUBLESHOOTING (TM-18) FAILURE CODE [15SFL1]
Related circuit diagram
20-480 1 HM400-1L
TROUBLESHOOTING (TM-19) FAILURE CODE [15SFMA]
Steps Circuit Diagnostic Procedures For Failure Code [15SFMA] Specifications No. Readings
1. 2nd Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (2-PS) connector from solenoid and isolate solenoid.
• Disconnect (2-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid 2-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch 2-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch 2-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (2-PS and 2-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors 2-PS, (1) and ATC2, (9) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors 2-PS, (2) and ATC2, (19) 0.0 to 1.0Ω 5
resistance
Between connectors 2-SW, (1) and ATC5A, (14) 0.0 to 1.0Ω 6
At connector 2-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector 2-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector 2-PS, between (1) and (2) (OL) open 9
At connector 2-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-481 1
TROUBLESHOOTING (TM-19) FAILURE CODE [15SFMA]
Related circuit diagram
20-482 1 HM400-1L
TROUBLESHOOTING (TM-20) FAILURE CODE [15SGL1]
Steps Circuit Diagnostic Procedures For Failure Code [15SGL1] Specifications No. Readings
1. 3rd Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (-PS) connector from solenoid and isolate solenoid.
• Disconnect (-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid 3-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch 3-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch 3-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (3-PS and 3-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors 3-PS, (1) and ATC2, (3) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors 3-PS, (2) and ATC2, (13) 0.0 to 1.0Ω 5
resistance
Between connectors 3-SW, (1) and ATC5A, (15) 0.0 to 1.0Ω 6
At connector 3-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector 3-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector 3-PS, between (1) and (2) (OL) open 9
At connector 3-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-483 1
TROUBLESHOOTING (TM-20) FAILURE CODE [15SGL1]
Related circuit diagram
20-484 1 HM400-1L
TROUBLESHOOTING (TM-21) FAILURE CODE [15SGMA]
Steps Circuit Diagnostic Procedures For Failure Code [15SGMA] Specifications No. Readings
1. 3rd Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (3-PS) connector from solenoid and isolate solenoid.
• Disconnect (3-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid 3-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch 3-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch 3-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (3-PS and 3-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors 3-PS, (1) and ATC2, (3) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors 3-PS, (2) and ATC2, (13) 0.0 to 1.0Ω 5
resistance
Between connectors 3-SW, (1) and ATC5A, (15) 0.0 to 1.0Ω 6
At connector 3-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector 3-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector 3-PS, between (1) and (2) (OL) open 9
At connector 3-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-485 1
TROUBLESHOOTING (TM-21) FAILURE CODE [15SGMA]
Related circuit diagram
20-486 1 HM400-1L
TROUBLESHOOTING (TM-22) FAILURE CODE [15SJL1]
Steps Circuit Diagnostic Procedures For Failure Code [15SJL1] Specifications No. Readings
1. Lock-up Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (L/U-PS) connector from solenoid and isolate solenoid.
• Disconnect (L-U-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid L/U-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch L/U-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch L/U-SW, between (1) and (2) engine running
0.0 to 1.0Ω 3
and system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (L/U-PS and L/U-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors L/U-PS, (1) and ATC2, (10) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors L/U -PS, (2) and ATC2, (20) 0.0 to 1.0Ω 5
resistance
Between connectors L/U-SW, (1) and ATC5A, (11) 0.0 to 1.0Ω 6
At connector L/U-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector L/U-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector L/U-PS, between (1) and (2) (OL) open 9
At connector L/U-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-487 1
TROUBLESHOOTING (TM-22) FAILURE CODE [15SJL1]
Related circuit diagram
20-488 1 HM400-1L
TROUBLESHOOTING (TM-23) FAILURE CODE [15SJMA]
Steps Circuit Diagnostic Procedures For Failure Code [15SJMA] Specifications No. Readings
1. Lock-up Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (L/U-PS) connector from solenoid and isolate solenoid.
• Disconnect (L/U-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid L/U-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch L/U-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch L/U-SW, between (1) and (2) engine running
0.0 to 1.0Ω 3
and system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (L/U-PS and L/U-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors L/U-PS, (1) and ATC2, (10) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors L/U-PS, (2) and ATC2, (20) 0.0 to 1.0Ω 5
resistance
Between connectors L/U-SW, (1) and ATC5A, (11) 0.0 to 1.0Ω 6
At connector L/U-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector L/U-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector L/U-PS, between (1) and (2) (OL) open 9
At connector L/U-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-489 1
TROUBLESHOOTING (TM-23) FAILURE CODE [15SJMA]
Related circuit diagram
20-490 1 HM400-1L
TROUBLESHOOTING (TM-24) FAILURE CODE [15SKL1]
Steps Circuit Diagnostic Procedures For Failure Code [15SKL1] Specifications No. Readings
1. Inter-axle Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (D/L-PS) connector from solenoid and isolate solenoid.
• Disconnect (D/L-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid D/L-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch D/L-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch D/L-SW, between (1) and (2) engine running
0.0 to 1.0Ω 3
and system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (D/L-PS and D/L-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors D/L-PS, (1) and ATC2, (8) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors D/L-PS, (2) and ATC2, (18) 0.0 to 1.0Ω 5
resistance
Between connectors D/L-SW, (1) and ATC5A, (17) 0.0 to 1.0Ω 6
At connector D/L-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector D/L-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector D/L-PS, between (1) and (2) (OL) open 9
At connector D/L-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-491 1
TROUBLESHOOTING (TM-24) FAILURE CODE [15SKL1]
Related circuit diagram
20-492 1 HM400-1L
TROUBLESHOOTING (TM-25) FAILURE CODE [15SKMA]
Steps Circuit Diagnostic Procedures For Failure Code [15SKMA] Specifications No. Readings
1. Inter-axle Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (D/L-PS) connector from solenoid and isolate solenoid.
• Disconnect (D/L-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid D/L-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch D/L-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch D/L-SW, between (1) and (2) engine running
0.0 to 1.0Ω 3
and system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (R-PS and R-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors D/L-PS, (1) and ATC2, (8) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors D/L-PS, (2) and ATC2, (18) 0.0 to 1.0Ω 5
resistance
Between connectors D/L-SW, (1) and ATC5A, (17) 0.0 to 1.0Ω 6
At connector D/L-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector D/L-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector D/L-PS, between (1) and (2) (OL) open 9
At connector D/L-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-493 1
TROUBLESHOOTING (TM-25) FAILURE CODE [15SKMA]
Related circuit diagram
20-494 1 HM400-1L
TROUBLESHOOTING (TM-26) FAILURE CODE [2B61MW]
Steps Circuit Diagnostic Procedures For Failure Code [2B61MW] Specifications No. Readings
1. Inter-axle Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (D/L-PS) connector from solenoid and isolate solenoid.
• Disconnect (D/L-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid D/L-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch D/L-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch D/L-SW, between (1) and (2) engine running
0.0 to 1.0Ω 3
and system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (D/L-PS and D/L-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors D/L-PS, (1) and ATC2, (8) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors D/L-PS, (2) and ATC2, (18) 0.0 to 1.0Ω 5
resistance
Between connectors D/L-SW, (1) and ATC5A, (17) 0.0 to 1.0Ω 6
At connector D/L-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector D/L-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector D/L-PS, between (1) and (2) (OL) open 9
At connector D/L-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-495 1
TROUBLESHOOTING (TM-26) FAILURE CODE [2B61MW]
Related circuit diagram
20-496 1 HM400-1L
TROUBLESHOOTING (TM-27) FAILURE CODE [2F00KM]
Steps Circuit Diagnostic Procedures For Failure Code [2F00KM] Specifications No. Readings
Fuse Check ⎯ Check to see if fuse (BT3-16) is blown ⎯ 1 Yes or No
1. Parking Brake Switch
• With ignition switch in the “OFF” position.
• Disconnect (B17) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At switch B17, between (1) and (2)
(OL) open 2
parking brake “OFF” position.
A. Switch test Resistance Ω
At switch B17, between (1) and (2)
0.0 to 1.0Ω 3
parking brake “ON” position.
2. Parking Brake Relay
• With ignition switch in the “OFF” position.
• Replace relay (R03) with known good relay.
• Turn ignition switch to the “ON” position.
A. Relay check ⎯ Is failure code [2F00KM] gone? ⎯ 4 Yes or No
3. Wiring Harness Assembly Test
• With ignition switch in the “OFF” position.
• Disconnect (B17) connector from switch and isolate connector.
• Disconnect (R03) relay and isolate connector.
• Disconnect (BRC5A) connector from the transmission controller and install T-adapter on (BRC5A) wiring harness connector only.
• ✸ Turn ignition switch to the “ON” position and start the engine for this test.
Between connection B17, (1) and chassis ground, fuse
(OL) open 5
A. Short to removed.
chassis ground Resistance Ω
Between connection B17, (2) and chassis ground. (OL) open 6
or within harness
At connection B17, between (1) and (2) (OL) open 7
Voltage ✸ Between connection B17, (1) and chassis ground. 20 to 30V 8
B. Open or high Between connection B17, (2) and R03, (1) 0.0 to 1.0Ω 9
resistance Resistance Ω At connection R03, (2) and (6) and chassis ground. 0.0 to 1.0Ω 10
Between connection R03, (3) and BRC5A, (5) 0.0 to 1.0Ω 11
4. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-497 1
TROUBLESHOOTING (TM-27) FAILURE CODE [2F00KM]
Related circuit diagram
20-498 1 HM400-1L
TROUBLESHOOTING (TM-28) FAILURE CODE [6014NX]
Steps Circuit Diagnostic Procedures For Failure Code [6014NX] Specifications No. Readings
Hydraulic Tank Filter ⎯ Check or replace hydraulic tank filter System OK? 1 Yes or No
1. Hydraulic Tank Filter Switch
• With ignition switch in the “OFF” position.
• Disconnect (T05) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
A. Switch test Resistance Ω At switch T05, between (1) and (2) 0.0 to 1.0Ω 2
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (T05) connector from switch and isolate connector.
• Disconnect (ATC5A) connector from transmission controller and install T-adapter on (ATC5A) wiring harness connector only.
A. Short to Between connector T05, (1) and chassis ground. (OL) open 3
chassis ground Resistance Ω
or within harness At connector T05, between (1) and (2) (OL) open 4
B. Open or high Between connectors T05, (1) and ATC5A, (9) 0.0 to 1.0Ω 5
resistance Resistance Ω
Between connector T05, (2) and chassis ground. 0.0 to 1.0Ω 6
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-499 1
TROUBLESHOOTING (TM-28) FAILURE CODE [6014NX]
Related circuit diagram
20-500 1 HM400-1L
TROUBLESHOOTING (TM-29) FAILURE CODE [989A00]
12
(TM-29) FAILURE CODE [989A00]
HM400-1L 20-501 1
TROUBLESHOOTING (TM-30) FAILURE CODE [989AKZ]
Steps Circuit Diagnostic Procedures For Failure Code [989AKZ] Specifications No. Readings
1. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (BRC1, BRC2, BRC5B) connector from retarder controller and install T-adapter between (BRC1, BRC2, BRC5B) wiring harness
connector and controller.
• Disconnect (ATC1) connector from transmission controller and install T-adapter between (ATC1) wiring harness connector and controller.
• ✸ Turn ignition switch to the “ON” position for this test.
✸ At connector ATC1, (13) and chassis ground. 0.7 to 5.0V 1
✸ At connector ATC1, (7) and chassis ground. 20 to 30V 2
✸ At connector ATC1, (9), (17) and chassis ground, igni-
Voltage 20 to 30V 3
tion key in the ON position.
20-502 1 HM400-1L
TROUBLESHOOTING (TM-30) FAILURE CODE [989AKZ]
Related circuit diagram
HM400-1L 20-503 1
TROUBLESHOOTING (TM-31)FAILURE CODE [989D00]
Steps Circuit Diagnostic Procedures For Failure Code [989D00] Specifications No. Readings
Was dump operations carried out on slope of more than
Inclination Of Machine ⎯ 15o max. 1 Yes or No
15o
1. Inclination Sensor
• With ignition switch in the "OFF" position.
• Disconnect (T10) connector from inoculation sensor and isolate sensor.
• Zero meter leads for proper Ω readings.
• Park machine on a level surface.
At sensor T10, between (1) and (3) 2
A. Switch test Resistance Ω At sensor T10, between (2) and (3) 3
At sensor T10, between (2) and (1) 4
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (T10) connector from sensor and isolate connector.
• Disconnect (ATC2, ATC3A and ATC3B) connector from transmission controller and install T-adapter on (ATC2, ATC3A and ATC3B) wiring
harness connector only
• ✸ For this test the ignition key must be in the “ON” position.
✸ At controller ATC2, between (1) and chassis
Voltage 12V 5
ground.
At controller ATC3A, between (16) and chassis
0.0 to 1.0Ω 6
A. Open or high ground.
resistance
Resistance Ω Between connections T10, (1) and ATC2, (14) 0.0 to 1.0Ω 7
Between connections T10, (2) and ATC3A, (16) 0.0 to 1.0Ω 8
Between connections T10, (3) and ATC3B, (16) 0.0 to 1.0Ω 9
At connector T10, between (1) and chassis ground. (OL) open 10
At connector T10, between (2) and chassis ground. (OL) open 11
B. Short to At connector T10, between (3) and chassis ground. (OL) open 12
chassis ground Resistance Ω
or within harness At connector T10, between (1) and (2) (OL) open 13
At connector T10, between (1) and (3) (OL) open 14
At connector T10, between (2) and (3) (OL) open 15
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-504 1 HM400-1L
TROUBLESHOOTING (TM-31)FAILURE CODE [989D00]
Related circuit diagram
HM400-1L 20-505 1
TROUBLESHOOTING (TM-32)FAILURE CODE [AA10NX]
Steps Circuit Diagnostic Procedures For Failure Code [AA10NX] Specifications No. Readings
Air Cleaner ⎯ Check condition of air cleaner Air cleaner OK? 1 Yes or No
Fuse Check ⎯ Check condition of fuse (BT3-14) Fuse OK? 2 Yes or No
1. Air Cleaner Switch
• With ignition switch in the "OFF" position.
• Disconnect (T11) connector from air cleaner and isolate air cleaner switch.
• Zero meter leads for proper Ω readings.
At switch T11, between (1) and (2) 0.0 to 1.0Ω 3
A. Switch test Resistance Ω
At switch T11, between (1) or (2) and chassis ground. (OL) open 4
2. Dust Indicator Relay
• With ignition switch in the “OFF” position.
• Replace relay (R32) with known good relay.
• Turn ignition switch to the “ON” position.
A. Relay check ⎯ Is failure code [AA10NX] gone? ⎯ 5 Yes or No
3. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (T11) connector from air cleaner switch.
• Disconnect (ATC3A) connector from transmission controller and install T-adapter on (ATC3A) wiring harness connector only
• ✸ For this test the ignition key must be in the “ON” position.
Voltage ✸ At connector R32, between (1) and chassis ground. 20 to 30V 6
Between connectors T11, (1) and R32, (2) 0.0 to 1.0Ω 7
A. Open or high
Between connectors T11, (2) and chassis ground. 0.0 to 1.0Ω 8
resistance Resistance Ω
Between connectors R32, (3) and ATC3A, (19)l 0.0 to 1.0Ω 9
Between connectors R32, (6) and ATC3A, (16)l 0.0 to 1.0Ω 10
At connector T11, between (1) and chassis ground. (OL) open 11
At connector T11, between (1) and (2) (OL) open 12
B. Short to At connector ATC3A, between (16) and chassis
(OL) open 13
chassis ground Resistance Ω ground.
or within harness
At connector ATC3A, between (19) and chassis
(OL) open 14
ground.
At connector ATC3A, between (16) and (19) (OL) open 15
20-506 1 HM400-1L
TROUBLESHOOTING (TM-32)FAILURE CODE [AA10NX]
Related circuit diagram
HM400-1L 20-507 1
TROUBLESHOOTING (TM-33) FAILURE CODE [AB00MA]
Steps Circuit Diagnostic Procedures For Failure Code [AB00MA] Specifications No. Readings
1. Alternator Check
• With ignition switch in the "OFF" position.
• Disconnect (DT1) connector from alternator and insert T-adaptor between (DT1) and alternator connector.
• Start the engine and run at mid speed.
At connector DT1, between (3) and chassis ground. 20 to 30V 1
Between alternator terminals (B) and (E) 20 to 30V 2
A. Alternator test Voltage
With engine OFF, and ignition switch in the “ON”
position between alternator terminal (B) and 20 to 30V 3
chassis ground.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (DT1) connector from alternator.
• Disconnect (ATC3B) connector from transmission controller and install T-adapter on (ATC3B) wiring harness connector only
A. Short to
chassis ground Resistance Ω At connector DT1, between (3) and chassis ground. (OL) open 4
or within harness
B. Open or high
Resistance Ω Between connectors DT1, (3) and ATC3B, (1) 0.0 to 1.0Ω 5
resistance
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-508 1 HM400-1L
TROUBLESHOOTING (TM-34) FAILURE CODE [B@BCZK]
Steps Circuit Diagnostic Procedures For Failure Code [B@BCZK] Specifications Readings
Code
Check condition of coolant level first.
Coolant Level ⎯ [B@BCZK] 1 Yes or No
Add if necessary
gone?
1. Coolant Level Switch
• With ignition switch in the "OFF" position.
• Disconnect (T01) from level switch.
• Zero meter leads for proper Ω readings.
At switch T01, between (1) and (2) coolant full 0.0 to 1.0Ω 2
A. Switch test Resistance Ω
At switch T01, between (1) or (2) and chassis ground. (OL) open 3
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (T01) connector from level switch.
• Disconnect (ATC5A) connector from transmission controller and install T-adapter on (ATC5A) wiring harness connector only
A. Open or high Between connectors T01, (2) and chassis ground. 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors T01, (1) and ATC5A, (3) 0.0 to 1.0Ω 5
B. Short to At connector T01, between (1) and chassis ground. (OL) open 6
chassis ground Resistance Ω
or within harness At connector T01, between (1) and (2) (OL) open 7
HM400-1L 20-509 1
TROUBLESHOOTING (TM-34) FAILURE CODE [B@BCZK]
Related circuit diagram
20-510 1 HM400-1L
TROUBLESHOOTING (TM-35) FAILURE CODE [B@HAZK]
Steps Circuit Diagnostic Procedures For Failure Code [B@HAZK] Specifications No. Readings
1. Level Indicator Switch
• With ignition switch in the "OFF" position.
• Disconnect (T06) from level switch.
• Zero meter leads for proper Ω readings.
A. Switch test Resistance Ω At switch T06, between (1) and chassis ground. 0.0 to 1.0Ω 1
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (T06) connector from level switch.
• Disconnect (ATC5A) connector from transmission controller and install T-adapter on (ATC5A) wiring harness connector only
A. Short to
chassis ground Resistance Ω Between connector T06, (1) and chassis ground. (OL) open 2
or within harness
B. Open or high
Resistance Ω Between connectors T06, (1) and ATC5A, (2) 0.0 to 1.0Ω 3
resistance
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-511 1
TROUBLESHOOTING (TM-36) FAILURE CODE [B@JANS]
Steps Circuit Diagnostic Procedures For Failure Code [B@JANS] Specifications No. Readings
Oil Temperature Check ⎯ Is the steering oil temperature over 123oC (253oF) ⎯ 1 Yes or No
1. Temperature Indicator Switch
• With ignition switch in the "OFF" position.
• Disconnect (T04) from temperature switch.
• Zero meter leads for proper Ω readings.
A. Switch test Resistance Ω At switch T04, between (1) and chassis ground. 0.0 to 1.0Ω 2
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (T04) connector from temperature switch.
• Disconnect (ATC3A) connector from transmission controller and install T-adapter on (ATC3A) wiring harness connector only
A. Short to
chassis ground Resistance Ω Between connector T01, (1) and chassis ground. (OL) open 3
or within harness
B. Open or high
Resistance Ω Between connectors T01, (1) and ATC3A, (11) 0.0 to 1.0Ω 4
resistance
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-512 1 HM400-1L
TROUBLESHOOTING (TM-37) FAILURE CODE [D1B0KZ]
Steps Circuit Diagnostic Procedures For Failure Code [D1B0KZ] Specifications No. Readings
Fuse Check ⎯ Check condition of fuse (BT3-14) Fuse OK? 1 Yes or No
1. Relay Check
• With ignition switch in the "OFF" position.
• Disconnect (R15) relay and install a known good relay.
Did code [D1B0KZ] disappear and is system working
A. Relay test ⎯ ⎯ 2 Yes or No
normal?
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (R15) connector from relay.
• Disconnect (ATC1 and ATC2) connector from transmission controller and install T-adapter on (ATC1 and ATC2) wiring harness connector only
• ✸ Turn ignition switch to the “ON” position for this test.
✸ Between connector R15, (3) and chassis ground. 20 to 30V 3
✸ Between connector R15, (2) and chassis ground. 20 to 30V 4
Voltage
✸ Between connector ATC1, (17) and chassis ground. 20 to 30V 5
A. Open or high ✸ Between connector ATC1, (9) and chassis ground. 20 to 30V 6
resistance Between connectors R15, (1) and ATC1, (15) 0.0 to 1.0Ω 7
Between connectors R15, (5) and ATC2, (12) 0.0 to 1.0Ω 8
Resistance Ω
Between connector ATC1, (16) and chassis ground. 0.0 to 1.0Ω 9
Between connector ATC1, (8) and chassis ground. 0.0 to 1.0Ω 10
B. Short to Between connector ATC2, (12) and chassis ground. (OL) open 11
chassis ground Resistance Ω
or within harness Between connector ATC1, (15) and chassis ground. (OL) open 12
HM400-1L 20-513 1
TROUBLESHOOTING (TM-37) FAILURE CODE [D1B0KZ]
Related circuit diagram
20-514 1 HM400-1L
TROUBLESHOOTING (TM-38) FAILURE CODE [D5ZBKX]
Steps Circuit Diagnostic Procedures For Failure Code [D5ZBKX] Specifications No. Readings
1. Retarder Controller
• With ignition switch in the "OFF" position.
• Disconnect (ATC3A) connector from transmission controller and install T-adapter between (ATC3A) connector and transmission controller.
• Turn ignition switch to the “ON” position.
A. Controller test Voltage At connection ATC3A, between (3) and (18) 0.5 to 5.0V 1
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (BRC1, BRC2) connector from retarder controller and install T-adapter between (BRC1, BRC2) wiring harness connector
and controller.
• Disconnect (ATC1, ATC2, ATC3A) connector from transmission controller and install T-adapter between (ATC1, ATC2, ATC3A) wiring
harness connector and controller.
• ✸ Turn ignition switch to the “ON” position for this test.
✸ At connector ATC3A, between (8) and (18) 0.7 to 5.0V 2
✸ Between connector ATC3A, (8) and chassis ground. 0.7 to 5.0V 3
✸ Between connector ATC1, (7) and chassis ground. 20 to 30V 4
✸ Between connector ATC1, (9), (17) and chassis
20 to 30V 5
ground, ignition switch ON
HM400-1L 20-515 1
TROUBLESHOOTING (TM-38) FAILURE CODE [D5ZBKX]
Related circuit diagram
20-516 1 HM400-1L
TROUBLESHOOTING (TM-39) FAILURE CODE [D5ZCKZ]
Steps Circuit Diagnostic Procedures For Failure Code [D5ZCKZ] Specifications No. Readings
1. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (BRC1, BRC2, BRC5B) connector from retarder controller and install T-adapter between (BRC1, BRC2, BRC5B) wiring harness
connector and controller.
• Disconnect (ATC1, ATC2) connector from transmission controller and install T-adapter between (ATC1, ATC2) wiring harness connector and
controller.
• ✸ Turn ignition switch to the “ON” position for this test.
✸ At connector ATC1, (14) and chassis ground. less than 1V 1
✸ At connector ATC1, (7) and chassis ground. 20 to 30V 2
✸ At connector BRC1, (7) and chassis ground. 20 to 30V 3
✸ At connector ATC1, (9), (17) and chassis ground, igni-
20 to 30V 4
tion switch ON
Voltage
✸ At connector ATC2, (1), (12) and chassis ground, igni-
20 to 30V 5
tion switch ON
A. Open or high ✸ At connector BRC1, (9), (17) and chassis ground, igni-
20 to 30V 6
resistance tion switch ON
✸ At connector ATC1, (1), (12) and chassis ground, igni-
20 to 30V 7
tion switch ON
Between connector ATC1, (8), (16) and chassis ground. 0.0 to 1.0Ω 8
Between connector ATC2, (21) and chassis ground. 0.0 to 1.0Ω 9
Resistance Ω Between connector BRC1, (8), (16) and chassis ground. 0.0 to 1.0Ω 10
Between connector BRC2, (21) and chassis ground. 0.0 to 1.0Ω 11
Between connections BRC5B, (4) and ATC1, (14) 0.0 to 1.0Ω 12
B. Short to With controllers (BRC5B and ATC1) disconnected from
chassis ground Resistance Ω wiring harness between connections BRC5B, (4) and (OL) open 13
or within harness chassis ground.
2. Transmission Or Retarder Controller Units
• No testing procedure for the controllers.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission or Retarder
Controller Unit. Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-517 1
TROUBLESHOOTING (TM-39) FAILURE CODE [D5ZCKZ]
Related circuit diagram
20-518 1 HM400-1L
TROUBLESHOOTING (TM-40) FAILURE CODE [DF10KA]
Steps Circuit Diagnostic Procedures For Failure Code [DF10KA] Specifications No. Readings
1. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (BRC1, BRC2) connector from retarder controller and install T-adapter on (BRC1, BRC2) wiring harness connector only.
• Disconnect (ATC1, ATC2, ATC5A) connector from transmission controller and install T-adapter on (ATC1, ATC2, ATC5A) wiring harness
connector only
• ✸ Turn ignition switch to the “ON” position for this test
✸ Between ATC5A, (7) and chassis ground. less than 1V 1
✸ Between ATC5A, (8) and chassis ground. less than 1V 2
✸ Between connector ATC1, (7) and chassis ground. 20 to 30V 3
✸ Between connector ATC1, (9), (17) and chassis
20 to 30V 4
ground.and chassis ground.
HM400-1L 20-519 1
TROUBLESHOOTING (TM-40) FAILURE CODE [DF10KA]
Related circuit diagram
20-520 1 HM400-1L
TROUBLESHOOTING (TM-41) FAILURE CODE [D5ZEKX]
Steps Circuit Diagnostic Procedures For Failure Code [D5ZEKX] Specifications No. Readings
1. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (CN2, CN4) connector from engine controller and install T-adapter on (CN2, CN4) wiring harness connector only.
• Disconnect (ATC1, ATC2, ATC3A) connector from transmission controller and install T-adapter on (ATC1, ATC2, ATC3A) wiring harness
connector only
• ✸ Turn ignition switch to the “ON” position for this test
Between connector CN4, (9), (18), (20) and chassis
20 to 30V 1
ground, ignition key in the ON position.
Between connector ATC1, (7) and chassis ground. 20 to 30V 2
Voltage Between connector ATC1, (9), (17) and chassis ground,
20 to 30V 3
ignition key in the ON position.
A. Open or high Between connector ATC2, (1), (12) and chassis ground,
resistance 20 to 30V 4
ignition key in the ON position.
Between connectors CN2, (14) and ATC3A, (4) 0.0 to 1.0Ω 5
Between connectors CN4, (8), (19) and chassis ground. 0.0 to 1.0Ω 6
Resistance Ω
Between connectors ATC1, (8), (16) and chassis ground. 0.0 to 1.0Ω 7
Between connectors ATC2, (21) and chassis ground. 0.0 to 1.0Ω 8
B. Short to
chassis ground Resistance Ω Between connector CN2, (14) and chassis ground. (OL) open 9
or within harness
2. Transmission Or Retarder Controller Units
• No testing procedure for the controllers.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission or Retarder
Controller Unit. Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-521 1
TROUBLESHOOTING (TM-41) FAILURE CODE [D5ZEKX]
Related circuit diagram
20-522 1 HM400-1L
TROUBLESHOOTING (TM-42) FAILURE CODE [DAQ0KK]
Steps Circuit Diagnostic Procedures For Failure Code [DAQ0KK] Specifications No. Readings
Fuse Check ⎯ Check fuses (BT2-22 and BT3-14) condition Fuses OK? 1 Yes or No
Circuit Breaker Breaker and
⎯ Check (circuit breaker) and fuse link (FU) 2 Yes or No
And Fuse Link Fuse Link OK?
1. Wiring Harness Assembly Test
• With ignition switch in the “OFF” position.
• Disconnect (ATC1) connector from transmission controller and install T-adapter on (ATC1) wiring harness connector only.
• ✸ Turn ignition switch to the “ON” position for this test.
Between connector ATC1, (7) and chassis ground. 20 to 30V 3
Voltage ✸ Between connector ATC1, (17) and chassis ground. 20 to 30V 4
A. Open or high
✸ Between connector ATC1, (9) and chassis ground. 20 to 30V 5
resistance
Between connectors ATC1, (8) and chassis ground. 0.0 to 1.0Ω 6
Resistance Ω
Between connectors ATC1, (16) and chassis ground. 0.0 to 1.0Ω 7
Between connectors ATC1, (9) and chassis ground. (OL) open 8
B. Short to
Between connectors ATC1, (17) and chassis ground. (OL) open 9
chassis ground Resistance Ω
or within harness Between connectors ATC1, (7) and chassis ground
(OL) open 10
battery disconnected.
2. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-523 1
TROUBLESHOOTING (TM-42) FAILURE CODE [DAQ0KK]
Related circuit diagram
20-524 1 HM400-1L
TROUBLESHOOTING (TM-43) FAILURE CODE [DAQ1KK]
Steps Circuit Diagnostic Procedures For Failure Code [DAQ1KK] Specifications No. Readings
Fuse Check ⎯ Check fuses (BT2-22 and BT3-14) condition Fuses OK? 1 Yes or No
Circuit Breaker Breaker and
⎯ Check (circuit breaker) and fuse link (FU) 2 Yes or No
And Fuse Link Fuse Link OK?
1. Wiring Harness Assembly Test
• With ignition switch in the “OFF” position.
• Disconnect (ATC1) connector from transmission controller and install T-adapter on (ATC1) wiring harness connector only.
• ✸ Turn ignition switch to the “ON” position for this test.
Between connector ATC1, (7) and chassis ground. 20 to 30V 3
Voltage ✸ Between connector ATC1, (17) and chassis ground. 20 to 30V 4
A. Open or high
✸ Between connector ATC1, (9) and chassis ground. 20 to 30V 5
resistance
Between connectors ATC1, (8) and chassis ground. 0.0 to 1.0Ω 6
Resistance Ω
Between connectors ATC1, (16) and chassis ground. 0.0 to 1.0Ω 7
Between connectors ATC1, (9) and chassis ground. (OL) open 8
B. Short to
Between connectors ATC1, (17) and chassis ground. (OL) open 9
chassis ground Resistance Ω
or within harness Between connectors ATC1, (7) and chassis ground
(OL) open 10
battery disconnected.
2. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-525 1
TROUBLESHOOTING (TM-43) FAILURE CODE [DAQ1KK]
Related circuit diagram
20-526 1 HM400-1L
TROUBLESHOOTING (TM-44) FAILURE CODE [DAQ2KK]
Steps Circuit Diagnostic Procedures For Failure Code [DAQ2KK] Specifications No. Readings
Fuse Check ⎯ Check condition of fuse (BT3-14) Fuse OK? 1 Yes or No
1. Relay Check
• With ignition switch in the "OFF" position.
• Disconnect (R15) relay and install a known good relay.
Did code [DAQ2KK] disappear and is system working
A. Relay test ⎯ ⎯ 2 Yes or No
normal?
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (R15) connector from relay.
• Disconnect (ATC1 and ATC2) connector from transmission controller and install T-adapter on (ATC1 and ATC2) wiring harness connector only
• ✸ Turn ignition switch to the “ON” position for this test.
✸ Between connector R15, (3) and chassis ground. 20 to 30V 3
✸ Between connector R15, (2) and chassis ground. 20 to 30V 4
Voltage
✸ Between connector ATC1, (17) and chassis ground. 20 to 30V 5
A. Open or high ✸ Between connector ATC1, (9) and chassis ground. 20 to 30V 6
resistance Between connectors R15, (1) and ATC1, (15) 0.0 to 1.0Ω 7
Between connectors R15, (5) and ATC2, (12) 0.0 to 1.0Ω 8
Resistance Ω
Between connector ATC1, (16) and chassis ground. 0.0 to 1.0Ω 9
Between connector ATC1, (8) and chassis ground. 0.0 to 1.0Ω 10
B. Short to Between connector ATC2, (12) and chassis ground. (OL) open 11
chassis ground Resistance Ω
or within harness Between connector ATC1, (15) and chassis ground. (OL) open 12
HM400-1L 20-527 1
TROUBLESHOOTING (TM-44) FAILURE CODE [DAQ2KK]
Related circuit diagram
20-528 1 HM400-1L
TROUBLESHOOTING (TM-45) FAILURE CODE [DAQ3KK]
Steps Circuit Diagnostic Procedures For Failure Code [DAQ3KK] Specifications No. Readings
Fuse Check ⎯ Check fuses (BT2-22 and BT3-14) condition Fuses OK? 1 Yes or No
Circuit Breaker Breaker and
⎯ Check (circuit breaker) and fuse link (FU) 2 Yes or No
And Fuse Link Fuse Link OK?
1. Wiring Harness Assembly Test
• With ignition switch in the “OFF” position.
• Disconnect (ATC1) connector from transmission controller and install T-adapter on (ATC1) wiring harness connector only.
• ✸ Turn ignition switch to the “ON” position for this test.
Between connector ATC1, (7) and chassis ground. 20 to 30V 3
Voltage ✸ Between connector ATC1, (17) and chassis ground. 20 to 30V 4
A. Open or high
✸ Between connector ATC1, (9) and chassis ground. 20 to 30V 5
resistance
Between connectors ATC1, (8) and chassis ground. 0.0 to 1.0Ω 6
Resistance Ω
Between connectors ATC1, (16) and chassis ground. 0.0 to 1.0Ω 7
Between connectors ATC1, (9) and chassis ground. (OL) open 8
B. Short to
Between connectors ATC1, (17) and chassis ground. (OL) open 9
chassis ground Resistance Ω
or within harness Between connectors ATC1, (7) and chassis ground
(OL) open 10
battery disconnected.
2. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-529 1
TROUBLESHOOTING (TM-45) FAILURE CODE [DAQ3KK]
Related circuit diagram
20-530 1 HM400-1L
TROUBLESHOOTING (TM-46) FAILURE CODE [DAQ5KP]
Steps Circuit Diagnostic Procedures For Failure Code [DAQ5KP] Specifications No. Readings
Was dump operations carried out on slope of more than
Inclination Of Machine ⎯ 15o max. 1 Yes or No
15o
1. Inclination Sensor
• With ignition switch in the "OFF" position.
• Disconnect (T10) connector from inoculation sensor and isolate sensor.
• Zero meter leads for proper Ω readings.
At sensor T10, between (1) and (3) 2
A. Switch test Resistance Ω At sensor T10, between (2) and (3) 3
At sensor T10, between (2) and (1) 4
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (T10) connector from sensor and isolate connector.
• Disconnect (ATC2, ATC3A and ATC3B) connector from transmission controller and install T-adapter on (ATC2, ATC3A and ATC3B) wiring
harness connector only
• ✸ For this test the ignition key must be in the “ON” position.
✸ At controller ATC2, between (1) and chassis
Voltage 12V 5
ground.
At controller ATC3A, between (16) and chassis
0.0 to 1.0Ω 6
A. Open or high ground.
resistance
Resistance Ω Between connections T10, (1) and ATC2, (14) 0.0 to 1.0Ω 7
Between connections T10, (2) and ATC3A, (16) 0.0 to 1.0Ω 8
Between connections T10, (3) and ATC3B, (16) 0.0 to 1.0Ω 9
At connector T10, between (1) and chassis ground. (OL) open 10
At connector T10, between (2) and chassis ground. (OL) open 11
B. Short to At connector T10, between (3) and chassis ground. (OL) open 12
chassis ground Resistance Ω
or within harness At connector T10, between (1) and (2) (OL) open 13
At connector T10, between (1) and (3) (OL) open 14
At connector T10, between (2) and (3) (OL) open 15
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-531 1
TROUBLESHOOTING (TM-46) FAILURE CODE [DAQ5KP]
Related circuit diagram
20-532 1 HM400-1L
TROUBLESHOOTING (TM-47) FAILURE CODE [DAQ9KM]
Steps Circuit Diagnostic Procedures For Failure Code [DAQ9KM] Specifications No. Readings
1. Wiring Harness Assembly Test
• With ignition switch in the “OFF” position.
• Disconnect (ATC5A) connector from transmission controller and install T-adapter on (ATC5A) wiring harness connector only
A. Open or high
Resistance Ω Between connector ATC5A, (1) and chassis ground. 0.0 to 1.0Ω 1
resistance
2. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-533 1
TROUBLESHOOTING (TM-48) FAILURE CODE [DAQ9KM]
Steps Circuit Diagnostic Procedures For Failure Code [DAQ9KM] Specifications No. Readings
1. Wiring Harness Assembly Test
• With ignition switch in the “OFF” position.
• Disconnect (ATC1 and ATC5B) connector from transmission controller and install T-adapter on (ATC1 and ATC5B) wiring harness connector
only
Between connector ATC1, (8) and chassis ground. 0.0 to 1.0Ω 1
Between connector ATC1, (16) and chassis ground. 0.0 to 1.0Ω 2
A. Open or high
Resistance Ω Between connector ATC5B, (14) and chassis ground. 0.0 to 1.0Ω 3
resistance
Between connector ATC5B, (15) and chassis ground. 0.0 to 1.0Ω 4
Between connector ATC5B, (16) and chassis ground. 0.0 to 1.0Ω 5
2. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-534 1 HM400-1L
TROUBLESHOOTING (TM-49) FAILURE CODE [DAQAKQ]
12
(TM-49) FAILURE CODE [DAQAKQ]
Replace
Defective transmission controller
Cause Remedy
NO
YES
Replace
Defective transmission controller
HM400-1L 20-535 1
TROUBLESHOOTING (TM-51) FAILURE CODE [DDTFKA]
Steps Circuit Diagnostic Procedures For Failure Code [DDTFKA] Specifications No. Readings
1. Lock-up Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (D/L-PS) connector from solenoid and isolate solenoid.
• Disconnect (D/L-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid D/L-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch D/L-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch D/L-SW, between (1) and (2) engine running
0.0 to 1.0Ω 3
and system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (D/L-PS and D/L-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors D/L-PS, (1) and ATC2, (8) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors D/L-PS, (2) and ATC2, (18) 0.0 to 1.0Ω 5
resistance
Between connectors D/L-SW, (1) and ATC5A, (17) 0.0 to 1.0Ω 6
At connector D/L-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector D/L-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector D/L-PS, between (1) and (2) (OL) open 9
At connector D/L-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-536 1 HM400-1L
TROUBLESHOOTING (TM-51) FAILURE CODE [DDTFKA]
Related circuit diagram
HM400-1L 20-537 1
TROUBLESHOOTING (TM-52) FAILURE CODE [DDTFKA]
Steps Circuit Diagnostic Procedures For Failure Code [DDTFKA] Specifications No. Readings
1. Lock-up Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (L/U-PS) connector from solenoid and isolate solenoid.
• Disconnect (L/U-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid L/U-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch L/U-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch L/U-SW, between (1) and (2) engine running
0.0 to 1.0Ω 3
and system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (L/U-PS and L/U-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors L/U-PS, (1) and ATC2, (10) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors L/U-PS, (2) and ATC2, (20) 0.0 to 1.0Ω 5
resistance
Between connectors L/U-SW, (1) and ATC5A, (11) 0.0 to 1.0Ω 6
At connector L/U-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector L/U-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector L/U-PS, between (1) and (2) (OL) open 9
At connector L/U-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-538 1 HM400-1L
TROUBLESHOOTING (TM-52) FAILURE CODE [DDTFKA]
Related circuit diagram
HM400-1L 20-539 1
TROUBLESHOOTING (TM-53) FAILURE CODE [DDTHKA]
Steps Circuit Diagnostic Procedures For Failure Code [DDTHKA] Specifications No. Readings
1. HI Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (H-PS) connector from solenoid and isolate solenoid.
• Disconnect (H-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid H-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch H-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch H-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (H-PS and H-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors H-PS, (1) and ATC2, (4) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors H-PS, (2) and ATC2, (15) 0.0 to 1.0Ω 5
resistance
Between connectors H-SW, (1) and ATC5A, (12) 0.0 to 1.0Ω 6
At connector H-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector H-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector H-PS, between (1) and (2) (OL) open 9
At connector H-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-540 1 HM400-1L
TROUBLESHOOTING (TM-53) FAILURE CODE [DDTHKA]
Related circuit diagram
HM400-1L 20-541 1
TROUBLESHOOTING (TM-54) FAILURE CODE [DDTJKA]
Steps Circuit Diagnostic Procedures For Failure Code [DDTJKA] Specifications No. Readings
1. Lo Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (L-PS) connector from solenoid and isolate solenoid.
• Disconnect (L-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid L-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch L-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch L-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (L-PS and L-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors L-PS, (1) and ATC2, (7) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors L-PS, (2) and ATC2, (17) 0.0 to 1.0Ω 5
resistance
Between connectors L-SW, (1) and ATC5A, (10) 0.0 to 1.0Ω 6
At connector L-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector L-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector L-PS, between (1) and (2) (OL) open 9
At connector L-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-542 1 HM400-1L
TROUBLESHOOTING (TM-54) FAILURE CODE [DDTJKA]
Related circuit diagram
HM400-1L 20-543 1
TROUBLESHOOTING (TM-55) FAILURE CODE [DDTKKA]
Steps Circuit Diagnostic Procedures For Failure Code [DDTKKA] Specifications No. Readings
1. 1st Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (1-PS) connector from solenoid and isolate solenoid.
• Disconnect (1-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid 1-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch 1-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch 1-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (1-PS and 1-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors 1-PS, (1) and ATC2, (2) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors 1-PS, (2) and ATC2, (13) 0.0 to 1.0Ω 5
resistance
Between connectors 1-SW, (1) and ATC5A, (13) 0.0 to 1.0Ω 6
At connector 1-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector 1-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector 1-PS, between (1) and (2) (OL) open 9
At connector 1-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-544 1 HM400-1L
TROUBLESHOOTING (TM-55) FAILURE CODE [DDTKKA]
Related circuit diagram
HM400-1L 20-545 1
TROUBLESHOOTING (TM-56) FAILURE CODE [DDTLKA]
Steps Circuit Diagnostic Procedures For Failure Code [DDTLKA] Specifications No. Readings
1. 2nd Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (2-PS) connector from solenoid and isolate solenoid.
• Disconnect (2-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid 2-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch 2-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch 2-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (2-PS and 2-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors 2-PS, (1) and ATC2, (9) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors 2-PS, (2) and ATC2, (19) 0.0 to 1.0Ω 5
resistance
Between connectors 2-SW, (1) and ATC5A, (14) 0.0 to 1.0Ω 6
At connector 2-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector 2-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector 2-PS, between (1) and (2) (OL) open 9
At connector 2-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-546 1 HM400-1L
TROUBLESHOOTING (TM-56) FAILURE CODE [DDTLKA]
Related circuit diagram
HM400-1L 20-547 1
TROUBLESHOOTING (TM-57) FAILURE CODE [DDTMKA]
Steps Circuit Diagnostic Procedures For Failure Code [DDTMKA] Specifications No. Readings
1. 3rd Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (3-PS) connector from solenoid and isolate solenoid.
• Disconnect (3-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid 3-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch 3-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch 3-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (3-PS and 3-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors 3-PS, (1) and ATC2, (3) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors 3-PS, (2) and ATC2, (13) 0.0 to 1.0Ω 5
resistance
Between connectors 3-SW, (1) and ATC5A, (15) 0.0 to 1.0Ω 6
At connector 3-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector 3-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector 3-PS, between (1) and (2) (OL) open 9
At connector 3-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-548 1 HM400-1L
TROUBLESHOOTING (TM-57) FAILURE CODE [DDTMKA]
Related circuit diagram
HM400-1L 20-549 1
TROUBLESHOOTING (TM-58) FAILURE CODE [DDTNKA]
Steps Circuit Diagnostic Procedures For Failure Code [DDTNKA] Specifications No. Readings
1. R Clutch ECMV Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (R-PS) connector from solenoid and isolate solenoid.
• Disconnect (R-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid R-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch R-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch R-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (R-PS and R-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors R-PS, (1) and ATC2, (5) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors R-PS, (2) and ATC2, (15) 0.0 to 1.0Ω 5
resistance
Between connectors R-SW, (1) and ATC5A, (16) 0.0 to 1.0Ω 6
At connector R-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector R-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector R-PS, between (1) and (2) (OL) open 9
At connector R-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-550 1 HM400-1L
TROUBLESHOOTING (TM-58) FAILURE CODE [DDTNKA]
Related circuit diagram
HM400-1L 20-551 1
TROUBLESHOOTING (TM-59) FAILURE CODE [DF10KA]
12
(TM-59) FAILURE CODE [DF10KA]
Steps Circuit Diagnostic Procedures For Error Code [DF10KA] Specifications No. Readings
Fuse Check ⎯ Check fuses (BT3-10) condition Fuses OK? 1 Yes or No
1. Gear Shift Lever
• With ignition switch in the "OFF" position.
• Disconnect (SF1) connector from gear shift lever and install T-adapter between (SF1) connector and controller.
• Turn ignition switch to the “ON” position.
At connector SF1, between (1) and (2) 20 to 30V 2
A. Voltage supply test Voltage
Between connector SF1, (1) and chassis ground. 20 to 30V 3
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (SF1) connector from shift lever and isolate connector.
• Disconnect (ATC5B and ATC3A) connector from transmission controller and install T-adapter on (ATC5B and ATC3A) wiring harness
connector only.
• ✸ For this test the ignition key must be in the “ON” position.
20-552 1 HM400-1L
TROUBLESHOOTING (TM-59) FAILURE CODE [DF10KA]
Related circuit diagram
ATC5B (2) - ATC3A (14) R1 ATC5B (2) - SF1 (4) (2) and ground
ATC5B (3) - ATC3A (14) R2 ATC5B (3) - SF1 (3) (3) and ground
ATC5B (4) - ATC3A (14) N ATC5B (4) - SF1 (5) (4) and ground
20 to 30 V
ATC5B (5) - ATC3A (14) D ATC5B (5) - SF1 (6) (5) and ground
0.0 to 1.0Ω
(OL) open
ATC5B (6) - ATC3A (14) 1 ATC5B (6) - SF1 (11) (6) and ground
ATC5B (7) - ATC3A (14) 2 ATC5B (7) - SF1 (10) (7) and ground
ATC5B (8) - ATC3A (14) 3 ATC5B (8) - SF1 (9) (8) and ground
ATC5B (9) - ATC3A (14) 4 ATC5B (9) - SF1 (8) (9) and ground
ATC5B (10) - ATC3A (14) 5 ATC5B (10) - SF1 (7) (10) and ground
HM400-1L 20-553 1
TROUBLESHOOTING (TM-60) FAILURE CODE [DF10KB]
Steps Circuit Diagnostic Procedures For Error Code [DF10KA] Specifications No. Readings
Fuse Check ⎯ Check fuses (BT3-10) condition Fuses OK? 1 Yes or No
1. Gear Shift Lever
• With ignition switch in the "OFF" position.
• Disconnect (SF1) connector from gear shift lever and install T-adapter between (SF1) connector and controller.
• Turn ignition switch to the “ON” position.
At connector SF1, between (1) and (2) 20 to 30V 2
A. Voltage supply test Voltage
Between connector SF1, (1) and chassis ground. 20 to 30V 3
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (SF1) connector from shift lever and isolate connector.
• Disconnect (ATC5B and ATC3A) connector from transmission controller and install T-adapter on (ATC5B and ATC3A) wiring harness
connector only.
• ✸ For this test the ignition key must be in the “ON” position.
20-554 1 HM400-1L
TROUBLESHOOTING (TM-60) FAILURE CODE [DF10KB]
Related circuit diagram
ATC5B (2) - ATC3A (14) R1 ATC5B (2) - SF1 (4) (2) and ground
ATC5B (3) - ATC3A (14) R2 ATC5B (3) - SF1 (3) (3) and ground
ATC5B (4) - ATC3A (14) N ATC5B (4) - SF1 (5) (4) and ground
20 to 30 V
ATC5B (5) - ATC3A (14) D ATC5B (5) - SF1 (6) (5) and ground
0.0 to 1.0Ω
(OL) open
ATC5B (6) - ATC3A (14) 1 ATC5B (6) - SF1 (11) (6) and ground
ATC5B (7) - ATC3A (14) 2 ATC5B (7) - SF1 (10) (7) and ground
ATC5B (8) - ATC3A (14) 3 ATC5B (8) - SF1 (9) (8) and ground
ATC5B (9) - ATC3A (14) 4 ATC5B (9) - SF1 (8) (9) and ground
ATC5B (10) - ATC3A (14) 5 ATC5B (10) - SF1 (7) (10) and ground
HM400-1L 20-555 1
TROUBLESHOOTING (TM-61) FAILURE CODE [DGF1KX]
12
(TM-61) FAILURE CODE [DGF1KX]
Steps Circuit Diagnostic Procedures For Failure Code [DGF1KX] Specifications No. Readings
1. Temperature Sensor
• With ignition switch in the "OFF" position.
• Disconnect (LUB-T) connector from sensor and isolate temperature sensor unit.
• Zero meter leads for proper Ω readings.
At sensor LUB-T, between (1) and (2) temperature of oil
37 to 50kΩ 1
around 25oC (77oF)
A. Sensor test Resistance Ω
At sensor LUB-T, between (1) and (2) temperature of oil
3.5 to 4.0kΩ 2
around 100oC (212oF)
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (LUB-T) connector from sensor.
• Disconnect (ATC3A and ATC3B) connector from transmission controller and install T-adapter on (ATC3A and ATC3B) wiring harness
connector only
Between connector LUB-T, (1) and chassis ground. (OL) open 3
A. Short to
chassis ground Resistance Ω Between connector LUB-T, (2) and chassis ground. (OL) open 4
or within harness
At connector LUB-T, between (1) and (2) (OL) open 5
B. Open or high Between connectors LUB-T, (1) and ATC3B, (9) 0.0 to 1.0Ω 6
Resistance Ω
resistance Between connectors LUB-T, (2) and ATC3A, (16) 0.0 to 1.0Ω 7
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-556 1 HM400-1L
TROUBLESHOOTING (TM-62) FAILURE CODE [DGR2L8]
12
(TM-62) FAILURE CODE [DGR2L8]
Steps Circuit Diagnostic Procedures For Failure Code [DGR2L8] Specifications No. Readings
1. Temperature Sensor
• With ignition switch in the "OFF" position.
• Disconnect (T13) connector from sensor and isolate temperature sensor unit.
• Zero meter leads for proper Ω readings.
At sensor T13, between (1) and (2) temperature of oil
37 to 50kΩ 1
around 25oC (77oF)
A. Sensor test Resistance Ω
At sensor T13, between (1) and (2) temperature of oil
3.5 to 4.0kΩ 2
around 100oC (212oF)
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (T13) connector from sensor.
• Disconnect (ATC3A and ATC3B) connector from transmission controller and install T-adapter on (ATC3A and ATC3B) wiring harness
connector only
Between connector T13, (1) and chassis ground. (OL) open 3
A. Short to
chassis ground Resistance Ω Between connector T13, (2) and chassis ground. (OL) open 4
or within harness
At connector T13, between (1) and (2) (OL) open 5
B. Open or high Between connectors T13, (1) and ATC3B, (10) 0.0 to 1.0Ω 6
Resistance Ω
resistance Between connectors T13, (2) and ATC3A, (16) 0.0 to 1.0Ω 7
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-557 1
TROUBLESHOOTING (TM-62) FAILURE CODE [DGR2L8]
Related circuit diagram
20-558 1 HM400-1L
TROUBLESHOOTING (TM-63) FAILURE CODE [DGR3L8]
12
(TM-63) FAILURE CODE [DGR3L8]
Steps Circuit Diagnostic Procedures For Failure Code [DGR3L8] Specifications No. Readings
1. Temperature Sensor
• With ignition switch in the "OFF" position.
• Disconnect (T14) connector from sensor and isolate temperature sensor unit.
• Zero meter leads for proper Ω readings.
At sensor T14, between (1) and (2) temperature of oil
37 to 50kΩ 1
around 25oC (77oF)
A. Sensor test Resistance Ω
At sensor T14, between (1) and (2) temperature of oil
3.5 to 4.0kΩ 2
around 100oC (212oF)
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (T14) connector from sensor.
• Disconnect (ATC3A and ATC3B) connector from transmission controller and install T-adapter on (ATC3A and ATC3B) wiring harness
connector only
Between connector T13, (1) and chassis ground. (OL) open 3
A. Short to
chassis ground Resistance Ω Between connector T13, (2) and chassis ground. (OL) open 4
or within harness
At connector T13, between (1) and (2) (OL) open 5
B. Open or high Between connectors T13, (1) and ATC3B, (8) 0.0 to 1.0Ω 6
Resistance Ω
resistance Between connectors T13, (2) and ATC3A, (16) 0.0 to 1.0Ω 7
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-559 1
TROUBLESHOOTING (TM-63) FAILURE CODE [DGR3L8]
Related circuit diagram
20-560 1 HM400-1L
TROUBLESHOOTING (TM-64) FAILURE CODE [DGR4L8]
Steps Circuit Diagnostic Procedures For Failure Code [DGR4L8] Specifications No. Readings
1. Temperature Sensor
• With ignition switch in the "OFF" position.
• Disconnect (T15) connector from sensor and isolate temperature sensor unit.
• Zero meter leads for proper Ω readings.
At sensor T15, between (1) and (2) temperature of oil
37 to 50kΩ 1
around 25oC (77oF)
A. Sensor test Resistance Ω
At sensor T15, between (1) and (2) temperature of oil
3.5 to 4.0kΩ 2
around 100oC (212oF)
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (T15) connector from sensor.
• Disconnect (ATC3A and ATC3B) connector from transmission controller and install T-adapter on (ATC3A and ATC3B) wiring harness
connector only
Between connector T15, (1) and chassis ground. (OL) open 3
A. Short to
chassis ground Resistance Ω Between connector T15, (2) and chassis ground. (OL) open 4
or within harness
At connector T15, between (1) and (2) (OL) open 5
B. Open or high Between connectors T15, (1) and ATC3B, (3) 0.0 to 1.0Ω 6
Resistance Ω
resistance Between connectors T15, (2) and ATC3A, (16) 0.0 to 1.0Ω 7
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-561 1
TROUBLESHOOTING (TM-64) FAILURE CODE [DGR4L8]
Related circuit diagram
20-562 1 HM400-1L
TROUBLESHOOTING (TM-65) FAILURE CODE [DGT1LX]
12
(TM-65) FAILURE CODE [DGT1LX]
Steps Circuit Diagnostic Procedures For Failure Code [DGT1LX] Specifications No. Readings
1. Temperature Sensor
• With ignition switch in the "OFF" position.
• Disconnect (T13) connector from sensor and isolate temperature sensor unit.
• Zero meter leads for proper Ω readings.
At sensor TC-SE, between (1) and (2) temperature of oil
37 to 50kΩ 1
around 25oC (77oF)
A. Sensor test Resistance Ω
At sensor TC-SE, between (1) and (2) temperature of oil
3.5 to 4.0kΩ 2
around 100oC (212oF)
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (TC-SE) connector from sensor.
• Disconnect (ATC3A and ATC3B) connector from transmission controller and install T-adapter on (ATC3A and ATC3B) wiring harness
connector only
Between connector TC-SE, (1) and chassis ground. (OL) open 3
A. Short to
chassis ground Resistance Ω Between connector TC-SE, (2) and chassis ground. (OL) open 4
or within harness
At connector TC-SE, between (1) and (2) (OL) open 5
B. Open or high Between connectors TC-SE, (1) and ATC3B, (7) 0.0 to 1.0Ω 6
Resistance Ω
resistance Between connectors TC-SE, (2) and ATC3A, (16) 0.0 to 1.0Ω 7
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-563 1
TROUBLESHOOTING (TM-66) FAILURE CODE [DHT5KX]
Steps Circuit Diagnostic Procedures For Failure Code [DHT5KX] Specifications No. Readings
1. Oil Pressure Sensor
• With ignition switch in the "OFF" position.
• Disconnect (TC-INT) connector from pressure sensor and isolate sensor.
• Zero meter leads for proper Ω readings.
At sensor TC-INT, between (1) and (2) 1
A. Switch test Resistance Ω At sensor TC-INT, between (2) and (3) 2
At sensor TC-INT, between (1) and (3) 3
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (TC-INT) connector from sensor and isolate connector.
• Disconnect (ATC3A and ATC1) connector from transmission controller and install T-adapter on (ATC3A and ATC1) wiring harness connector
only
• ✸ For this test the ignition key must be in the “ON” position.
✸ At controller ATC1, between (3) and chassis
Voltage 24V 4
ground.
Between connections TC-INT, (1) and ATC3A, (17) 0.0 to 1.0Ω 5
A. Open or high
resistance Between connections TC-INT, (1) and ATC3A, (16) 0.0 to 1.0Ω 6
Resistance Ω
Between connections TC-INT, (2) and ATC1, (3) 0.0 to 1.0Ω 7
Between connections TC-INT, (3) and ATC3A, (7) 0.0 to 1.0Ω 8
At connector TC-INT, between (1) and chassis ground. (OL) open 9
At connector TC-INT, between (2) and chassis ground. (OL) open 10
B. Short to At connector TC-INT, between (3) and chassis ground. (OL) open 11
chassis ground Resistance Ω
or within harness At connector TC-INT, between (1) and (2) (OL) open 12
At connector TC-INT, between (1) and (3) (OL) open 13
At connector TC-INT, between (2) and (3) (OL) open 14
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-564 1 HM400-1L
TROUBLESHOOTING (TM-66) FAILURE CODE [DHT5KX]
Related circuit diagram
HM400-1L 20-565 1
TROUBLESHOOTING (TM-67) FAILURE CODE [DHT5L6]
Steps Circuit Diagnostic Procedures For Failure Code [DHT5L6] Specifications No. Readings
1. Oil Pressure Sensor
• With ignition switch in the "OFF" position.
• Disconnect (TC-INT) connector from pressure sensor and isolate sensor.
• Zero meter leads for proper Ω readings.
At sensor TC-INT, between (1) and (2) 1
A. Switch test Resistance Ω At sensor TC-INT, between (2) and (3) 2
At sensor TC-INT, between (1) and (3) 3
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (TC-INT) connector from sensor and isolate connector.
• Disconnect (ATC3A and ATC1) connector from transmission controller and install T-adapter on (ATC3A and ATC1) wiring harness connector
only
• ✸ For this test the ignition key must be in the “ON” position.
✸ At controller ATC1, between (3) and chassis
Voltage 24V 4
ground.
Between connections TC-INT, (1) and ATC3A, (17) 0.0 to 1.0Ω 5
A. Open or high
resistance Between connections TC-INT, (1) and ATC3A, (16) 0.0 to 1.0Ω 6
Resistance Ω
Between connections TC-INT, (2) and ATC1, (3) 0.0 to 1.0Ω 7
Between connections TC-INT, (3) and ATC3A, (7) 0.0 to 1.0Ω 8
At connector TC-INT, between (1) and chassis ground. (OL) open 9
At connector TC-INT, between (2) and chassis ground. (OL) open 10
B. Short to At connector TC-INT, between (3) and chassis ground. (OL) open 11
chassis ground Resistance Ω
or within harness At connector TC-INT, between (1) and (2) (OL) open 12
At connector TC-INT, between (1) and (3) (OL) open 13
At connector TC-INT, between (2) and (3) (OL) open 14
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-566 1 HM400-1L
TROUBLESHOOTING (TM-67) FAILURE CODE [DHT5L6]
Related circuit diagram
HM400-1L 20-567 1
TROUBLESHOOTING (TM-68) FAILURE CODE [DJF1KA]
Steps Circuit Diagnostic Procedures For Failure Code [DJF1KA] Specifications No. Readings
1. Fuel Level Sensor
• With ignition switch in the "OFF" position.
• Disconnect (T08) connector from sensor and isolate sensor.
• Zero meter leads for proper Ω readings.
At sensor T08, between (1) and (2) tank full. 1
A. Sensor test Resistance Ω At sensor T08, between (1) and (2) tank half full. 2
At sensor T08, between (1) and (2) tank empty. 3
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (T08) connector from fuel level sensor.
• Disconnect (ATC3A and ATC3B) connector from transmission controller and install T-adapter on (ATC3A and ATC3B) wiring harness
connector only
A. Open or high Between connectors T08, (1) and ATC3B, (4) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors T08, (2) and ATC3A, (16) 0.0 to 1.0Ω 5
B. Short to Between connector T08, (1) and chassis ground. (OL) open 6
chassis ground Resistance Ω Between connector T08, (2) and chassis ground. (OL) open 7
or within harness At connector T08, between (1) and (2) (OL) open 8
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-568 1 HM400-1L
TROUBLESHOOTING (TM-68) FAILURE CODE [DJF1KA]
Related circuit diagram
HM400-1L 20-569 1
TROUBLESHOOTING (TM-69) FAILURE CODE [DK11KX]
12
(TM-69) FAILURE CODE [DK11KX]
Steps Circuit Diagnostic Procedures For Failure Code [DK11KX] Specifications No. Readings
1. Throttle Angle Sensor
• With ignition switch in the "OFF" position.
• Disconnect (AS2) connector from angle sensor.
• Zero meter leads for proper Ω readings.
At sensor AS2, between (1) and (3) 1
Ohms
At sensor AS2, between (2) and (1) slowly depressing increases or
2 Yes or No
pedal (from idle position to full throttle position) decrease
A. Sensor test Resistance Ω steadily?
Ohms
At sensor AS2, between (2) and (3) slowly depressing increases or
3 Yes or No
pedal (from idle position to full throttle position) decrease
steadily?
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (F.PS) connector from solenoid.
• Disconnect (L63) connector from transmission controller and install T-adapter on (L63) wiring harness connector only
Between connector AS2, (1) and chassis ground. (OL) open 4
Between connector AS2, (2) and chassis ground. (OL) open 5
A. Short to Between connector AS2, (3) and chassis ground. (OL) open 6
chassis ground Resistance Ω
or within harness At connector AS2, between (1) and (2) (OL) open 7
At connector AS2, between (1) and (3) (OL) open 8
At connector AS2, between (3) and (2) (OL) open 9
Between connectors AS2, (1) and ATC3A, (6) 0.0 to 1.0Ω 10
B. Open or high
Resistance Ω Between connectors AS2, (2) and ATC3B, (11) 0.0 to 1.0Ω 11
resistance
Between connectors AS2, (3) and ATC3A, (16) 0.0 to 1.0Ω 12
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-570 1 HM400-1L
TROUBLESHOOTING (TM-69) FAILURE CODE [DK11KX]
Related circuit diagram
HM400-1L 20-571 1
TROUBLESHOOTING (TM-70) FAILURE CODE [DLE2KA]
Steps Circuit Diagnostic Procedures For Failure Code [DLE2KA] Specifications No. Readings
1. Engine Speed Sensor
• With ignition switch in the "OFF" position.
• Disconnect (EREV) connector from sensor and isolate sensor.
• Zero meter leads for proper Ω readings.
At sensor EREV, between (1) and (2) 500 to 1000Ω 1
A. Solenoid test Resistance Ω At sensor EREV, between (1) or (2)
(OL) open 2
and chassis ground.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (EREV) connector from sensor.
• Disconnect (ATC3A) connector from transmission controller and install T-adapter on (ATC3A) wiring harness connector only
A. Open or high Between connectors EREV, (1) and ATC3A, (13) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors EREV, (2) and ATC3A, (14) 0.0 to 1.0Ω 4
Between connector EREV, (1) and chassis ground. (OL) open 5
B. Short to
chassis ground Resistance Ω Between connector EREV, (2) and chassis ground. (OL) open 6
or within harness
At connector EREV, between (1) and (2) (OL) open 7
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-572 1 HM400-1L
TROUBLESHOOTING (TM-71) FAILURE CODE [DLE2LC]
Steps Circuit Diagnostic Procedures For Failure Code [DLE2LC] Specifications No. Readings
1. Engine Speed Sensor
• With ignition switch in the "OFF" position.
• Disconnect (EREV) connector from sensor and isolate sensor.
• Zero meter leads for proper Ω readings.
At sensor EREV, between (1) and (2) 500 to 1000Ω 1
A. Solenoid test Resistance Ω At sensor EREV, between (1) or (2)
(OL) open 2
and chassis ground.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (EREV) connector from sensor.
• Disconnect (ATC3A) connector from transmission controller and install T-adapter on (ATC3A) wiring harness connector only
A. Open or high Between connectors EREV, (1) and ATC3A, (13) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors EREV, (2) and ATC3A, (14) 0.0 to 1.0Ω 4
Between connector EREV, (1) and chassis ground. (OL) open 5
B. Short to
chassis ground Resistance Ω Between connector EREV, (2) and chassis ground. (OL) open 6
or within harness
At connector EREV, between (1) and (2) (OL) open 7
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-573 1
TROUBLESHOOTING (TM-72) FAILURE CODE [DLF1KA]
Steps Circuit Diagnostic Procedures For Failure Code [DLF1KA] Specifications No. Readings
1. Transmission Speed Sensor
• With ignition switch in the "OFF" position.
• Disconnect (N1) connector from sensor and isolate sensor.
• Zero meter leads for proper Ω readings.
At sensor N1, between (1) and (2) 500 to 1000Ω 1
A. Solenoid test Resistance Ω At sensor N1, between (1) or (2)
(OL) open 2
and chassis ground.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (N1) connector from sensor.
• Disconnect (ATC3A) connector from transmission controller and install T-adapter on (ATC3A) wiring harness connector only
A. Open or high Between connectors N1, (1) and ATC3A, (2) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors N1, (2) and ATC3A, (14) 0.0 to 1.0Ω 4
Between connector N1, (1) and chassis ground. (OL) open 5
B. Short to
chassis ground Resistance Ω Between connector N1, (2) and chassis ground. (OL) open 6
or within harness
At connector N1, between (1) and (2) (OL) open 7
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-574 1 HM400-1L
TROUBLESHOOTING (TM-73) FAILURE CODE [DLF1LC]
Steps Circuit Diagnostic Procedures For Failure Code [DLF1LC] Specifications No. Readings
1. Transmission Speed Sensor
• With ignition switch in the "OFF" position.
• Disconnect (N1) connector from sensor and isolate sensor.
• Zero meter leads for proper Ω readings.
At sensor N1, between (1) and (2) 500 to 1000Ω 1
A. Solenoid test Resistance Ω At sensor N1, between (1) or (2)
(OL) open 2
and chassis ground.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (N1) connector from sensor.
• Disconnect (ATC3A) connector from transmission controller and install T-adapter on (ATC3A) wiring harness connector only
A. Open or high Between connectors N1, (1) and ATC3A, (2) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors N1, (2) and ATC3A, (14) 0.0 to 1.0Ω 4
Between connector N1, (1) and chassis ground. (OL) open 5
B. Short to
chassis ground Resistance Ω Between connector N1, (2) and chassis ground. (OL) open 6
or within harness
At connector N1, between (1) and (2) (OL) open 7
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-575 1
TROUBLESHOOTING (TM-74) FAILURE CODE [DLF2KA]
Steps Circuit Diagnostic Procedures For Failure Code [DLF2KA] Specifications No. Readings
1. Transmission Speed Sensor
• With ignition switch in the "OFF" position.
• Disconnect (N2) connector from sensor and isolate sensor.
• Zero meter leads for proper Ω readings.
At sensor N2, between (1) and (2) 500 to 1000Ω 1
A. Solenoid test Resistance Ω At sensor N2, between (1) or (2)
(OL) open 2
and chassis ground.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (N2) connector from sensor.
• Disconnect (ATC3A) connector from transmission controller and install T-adapter on (ATC3A) wiring harness connector only
A. Open or high Between connectors N2, (1) and ATC3A, (12) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors N2, (2) and ATC3A, (14) 0.0 to 1.0Ω 4
B. Short to Between connector N2, (1) and chassis ground. (OL) open 5
chassis ground Resistance Ω Between connector N2, (2) and chassis ground. (OL) open 6
or within harness At connector N2, between (1) and (2) (OL) open 7
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-576 1 HM400-1L
TROUBLESHOOTING (TM-75) FAILURE CODE [DLF2LC]
Steps Circuit Diagnostic Procedures For Failure Code [DLF2LC] Specifications No. Readings
1. Transmission Speed Sensor
• With ignition switch in the "OFF" position.
• Disconnect (N2) connector from sensor and isolate sensor.
• Zero meter leads for proper Ω readings.
At sensor N2, between (1) and (2) 500 to 1000Ω 1
A. Solenoid test Resistance Ω At sensor N2, between (1) or (2)
(OL) open 2
and chassis ground.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (N2) connector from sensor.
• Disconnect (ATC3A) connector from transmission controller and install T-adapter on (ATC3A) wiring harness connector only
A. Open or high Between connectors N2, (1) and ATC3A, (12) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors N2, (2) and ATC3A, (14) 0.0 to 1.0Ω 4
B. Short to Between connector N2, (1) and chassis ground. (OL) open 5
chassis ground Resistance Ω Between connector N2, (2) and chassis ground. (OL) open 6
or within harness At connector N2, between (1) and (2) (OL) open 7
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-577 1
TROUBLESHOOTING (TM-76) FAILURE CODE [DLT3KA]
Steps Circuit Diagnostic Procedures For Failure Code [DLT3KA] Specifications No. Readings
1. Transmission Speed Sensor
• With ignition switch in the "OFF" position.
• Disconnect (N3) connector from sensor and isolate sensor.
• Zero meter leads for proper Ω readings.
At sensor N3, between (1) and (2) 500 to 1000Ω 1
A. Solenoid test Resistance Ω At sensor N3, between (1) or (2)
(OL) open 2
and chassis ground.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (N3) connector from sensor.
• Disconnect (ATC3A and BRC3A) connector from transmission controller and install T-adapter on (ATC3A and BRC3A) wiring harness
connector only
Between connectors N3, (1) and ATC3A, (3) 0.0 to 1.0Ω 3
A. Open or high
Resistance Ω Between connectors N3, (1) and BRC3A, (13) 0.0 to 1.0Ω 4
resistance
Between connectors N3, (2) and ATC3A, (14) 0.0 to 1.0Ω 5
B. Short to Between connector N3, (1) and chassis ground. (OL) open 6
chassis ground Resistance Ω Between connector N3, (2) and chassis ground. (OL) open 7
or within harness At connector N3, between (1) and (2) (OL) open 8
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-578 1 HM400-1L
TROUBLESHOOTING (TM-76) FAILURE CODE [DLT3KA]
Related circuit diagram
HM400-1L 20-579 1
TROUBLESHOOTING (TM-77) FAILURE CODE [DLT3LC]
Steps Circuit Diagnostic Procedures For Failure Code [DLT3LC] Specifications No. Readings
1. Transmission Speed Sensor
• With ignition switch in the "OFF" position.
• Disconnect (N3) connector from sensor and isolate sensor.
• Zero meter leads for proper Ω readings.
At sensor N3, between (1) and (2) 500 to 1000Ω 1
A. Solenoid test Resistance Ω At sensor N3, between (1) or (2)
(OL) open 2
and chassis ground.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (N3) connector from sensor.
• Disconnect (ATC3A and BRC3A) connector from transmission controller and install T-adapter on (ATC3A and BRC3A) wiring harness
connector only
Between connectors N3, (1) and ATC3A, (3) 0.0 to 1.0Ω 3
A. Open or high
Resistance Ω Between connectors N3, (1) and BRC3A, (13) 0.0 to 1.0Ω 4
resistance
Between connectors N3, (2) and ATC3A, (14) 0.0 to 1.0Ω 5
Between connector N3, (1) and chassis ground. (OL) open 6
B. Short to
chassis ground Resistance Ω Between connector N3, (2) and chassis ground. (OL) open 7
or within harness
At connector N3, between (1) and (2) (OL) open 8
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-580 1 HM400-1L
TROUBLESHOOTING (TM-77) FAILURE CODE [DLT3LC]
Related circuit diagram
HM400-1L 20-581 1
TROUBLESHOOTING (TM-78) FAILURE CODE [DXH0KA]
Steps Circuit Diagnostic Procedures For Failure Code [DXH0KA] Specifications No. Readings
1. Differential Lock Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (D/L-PS) connector from solenoid and isolate solenoid.
• Disconnect (D/L-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid D/L-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch D/L-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch D/L-SW, between (1) and (2) engine running
0.0 to 1.0Ω 3
and system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (D/L-PS and D/L-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors D/L-PS, (1) and ATC2, (8) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors D/L-PS, (2) and ATC2, (18) 0.0 to 1.0Ω 5
resistance
Between connectors D/L-SW, (1) and ATC5A, (17) 0.0 to 1.0Ω 6
At connector D/L-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector D/L-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector D/L-PS, between (1) and (2) (OL) open 9
At connector D/L-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-582 1 HM400-1L
TROUBLESHOOTING (TM-78) FAILURE CODE [DXH0KA]
Related circuit diagram
HM400-1L 20-583 1
TROUBLESHOOTING (TM-79) FAILURE CODE [DXH0KB]
Steps Circuit Diagnostic Procedures For Failure Code [DXH0KB] Specifications No. Readings
1. Differential Lock Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (D/L-PS) connector from solenoid and isolate solenoid.
• Disconnect (D/L-SW) cincture from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid D/L-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch D/L-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch D/L-SW, between (1) and (2) engine running
0.0 to 1.0Ω 3
and system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (D/L-PS and D/L-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors D/L-PS, (1) and ATC2, (8) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors D/L-PS, (2) and ATC2, (18) 0.0 to 1.0Ω 5
resistance
Between connectors D/L-SW, (1) and ATC5A, (17) 0.0 to 1.0Ω 6
At connector D/L-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector D/L-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector D/L-PS, between (1) and (2) (OL) open 9
At connector D/L-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-584 1 HM400-1L
TROUBLESHOOTING (TM-79) FAILURE CODE [DXH0KB]
Related circuit diagram
HM400-1L 20-585 1
TROUBLESHOOTING (TM-80) FAILURE CODE [DXH1KA]
Steps Circuit Diagnostic Procedures For Failure Code [DXH1KA] Specifications No. Readings
1. Lock-up Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (L/U-PS) connector from solenoid and isolate solenoid.
• Disconnect (L/U-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid L/U-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch L/U-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch L/U-SW, between (1) and (2) engine running
0.0 to 1.0Ω 3
and system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (L/U-PS and L/U-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors L/U-PS, (1) and ATC2, (10) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors L/U-PS, (2) and ATC2, (20) 0.0 to 1.0Ω 5
resistance
Between connectors L/U-SW, (1) and ATC5A, (11) 0.0 to 1.0Ω 6
At connector L/U-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector L/U-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector L/U-PS, between (1) and (2) (OL) open 9
At connector L/U-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-586 1 HM400-1L
TROUBLESHOOTING (TM-80) FAILURE CODE [DXH1KA]
Related circuit diagram
HM400-1L 20-587 1
TROUBLESHOOTING (TM-81) FAILURE CODE [DXH1KB]
Steps Circuit Diagnostic Procedures For Failure Code [DXH1KB] Specifications No. Readings
1. Lock-up Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (L/U-PS) connector from solenoid and isolate solenoid.
• Disconnect (L/U-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid L/U-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch L/U-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch L/U-SW, between (1) and (2) engine running
0.0 to 1.0Ω 3
and system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (L/U-PS and L/U-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors L/U-PS, (1) and ATC2, (10) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors L/U-PS, (2) and ATC2, (20) 0.0 to 1.0Ω 5
resistance
Between connectors L/U-SW, (1) and ATC5A, (11) 0.0 to 1.0Ω 6
At connector L/U-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector L/U-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector L/U-PS, between (1) and (2) (OL) open 9
At connector L/U-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-588 1 HM400-1L
TROUBLESHOOTING (TM-81) FAILURE CODE [DXH1KB]
Related circuit diagram
HM400-1L 20-589 1
TROUBLESHOOTING (TM-82) FAILURE CODE [DXH2KA]
Steps Circuit Diagnostic Procedures For Failure Code [DXH2KA] Specifications No. Readings
1. High Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (H-PS) connector from solenoid and isolate solenoid.
• Disconnect (H-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid H-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch H-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch H-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (H-PS and H-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors H-PS, (1) and ATC2, (4) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors H-PS, (2) and ATC2, (15) 0.0 to 1.0Ω 5
resistance
Between connectors H-SW, (1) and ATC5A, (12) 0.0 to 1.0Ω 6
At connector H-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector H-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector H-PS, between (1) and (2) (OL) open 9
At connector H-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-590 1 HM400-1L
TROUBLESHOOTING (TM-82) FAILURE CODE [DXH2KA]
Related circuit diagram
HM400-1L 20-591 1
TROUBLESHOOTING (TM-83) FAILURE CODE [DXH2KB]
Steps Circuit Diagnostic Procedures For Failure Code [DXH2KB] Specifications No. Readings
1. High Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (H-PS) connector from solenoid and isolate solenoid.
• Disconnect (H-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid H-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch H-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch H-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (H-PS and H-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors H-PS, (1) and ATC2, (4) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors H-PS, (2) and ATC2, (15) 0.0 to 1.0Ω 5
resistance
Between connectors H-SW, (1) and ATC5A, (12) 0.0 to 1.0Ω 6
At connector H-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector H-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector H-PS, between (1) and (2) (OL) open 9
At connector H-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-592 1 HM400-1L
TROUBLESHOOTING (TM-83) FAILURE CODE [DXH2KB]
Related circuit diagram
HM400-1L 20-593 1
TROUBLESHOOTING (TM-84) FAILURE CODE [DXH3KA]
Steps Circuit Diagnostic Procedures For Failure Code [DXH3KA] Specifications No. Readings
1. Low Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (L-PS) connector from solenoid and isolate solenoid.
• Disconnect (L-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid L-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch L-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch L-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (L-PS and L-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors L-PS, (1) and ATC2, (7) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors L-PS, (2) and ATC2, (17) 0.0 to 1.0Ω 5
resistance
Between connectors L-SW, (1) and ATC5A, (10) 0.0 to 1.0Ω 6
At connector L-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector L-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector L-PS, between (1) and (2) (OL) open 9
At connector L-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-594 1 HM400-1L
TROUBLESHOOTING (TM-84) FAILURE CODE [DXH3KA]
Related circuit diagram
HM400-1L 20-595 1
TROUBLESHOOTING (TM-85) FAILURE CODE [DXH3KB]
Steps Circuit Diagnostic Procedures For Failure Code [DXH3KB] Specifications No. Readings
1. Low Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (L-PS) connector from solenoid and isolate solenoid.
• Disconnect (L-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid L-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch L-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch L-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (L-PS and L-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors L-PS, (1) and ATC2, (7) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors L-PS, (2) and ATC2, (17) 0.0 to 1.0Ω 5
resistance
Between connectors L-SW, (1) and ATC5A, (10) 0.0 to 1.0Ω 6
At connector L-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector L-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector L-PS, between (1) and (2) (OL) open 9
At connector L-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-596 1 HM400-1L
TROUBLESHOOTING (TM-85) FAILURE CODE [DXH3KB]
Related circuit diagram
HM400-1L 20-597 1
TROUBLESHOOTING (TM-86) FAILURE CODE [DXH4KA]
Steps Circuit Diagnostic Procedures For Failure Code [DXH4KA] Specifications No. Readings
1. 1st Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (1-PS) connector from solenoid and isolate solenoid.
• Disconnect (1-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid 1-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch 1-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch 1-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (1-PS and 1-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors 1-PS, (1) and ATC2, (2) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors 1-PS, (2) and ATC2, (13) 0.0 to 1.0Ω 5
resistance
Between connectors 1-SW, (1) and ATC5A, (13) 0.0 to 1.0Ω 6
At connector 1-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector 1-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector 1-PS, between (1) and (2) (OL) open 9
At connector 1-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-598 1 HM400-1L
TROUBLESHOOTING (TM-86) FAILURE CODE [DXH4KA]
Related circuit diagram
HM400-1L 20-599 1
TROUBLESHOOTING (TM-87) FAILURE CODE [DXH4KB]
Steps Circuit Diagnostic Procedures For Failure Code [DXH4KB] Specifications No. Readings
1. 1st Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (1-PS) connector from solenoid and isolate solenoid.
• Disconnect (1-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid 1-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch 1-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch 1-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (1-PS and 1-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors 1-PS, (1) and ATC2, (2) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors 1-PS, (2) and ATC2, (13) 0.0 to 1.0Ω 5
resistance
Between connectors 1-SW, (1) and ATC5A, (13) 0.0 to 1.0Ω 6
At connector 1-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector 1-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector 1-PS, between (1) and (2) (OL) open 9
At connector 1-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-600 1 HM400-1L
TROUBLESHOOTING (TM-87) FAILURE CODE [DXH4KB]
Related circuit diagram
HM400-1L 20-601 1
TROUBLESHOOTING (TM-88) FAILURE CODE [DXH5KA]
Steps Circuit Diagnostic Procedures For Failure Code [DXH5KA] Specifications No. Readings
1. 2nd Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (2-PS) connector from solenoid and isolate solenoid.
• Disconnect (2-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid 2-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch 2-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch 2-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (2-PS and 2-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors 2-PS, (1) and ATC2, (9) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors 2-PS, (2) and ATC2, (19) 0.0 to 1.0Ω 5
resistance
Between connectors 2-SW, (1) and ATC5A, (14) 0.0 to 1.0Ω 6
At connector 2-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector 2-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector 2-PS, between (1) and (2) (OL) open 9
At connector 2-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-602 1 HM400-1L
TROUBLESHOOTING (TM-88) FAILURE CODE [DXH5KA]
Related circuit diagram
HM400-1L 20-603 1
TROUBLESHOOTING (TM-89) FAILURE CODE [DXH5KB]
Steps Circuit Diagnostic Procedures For Failure Code [DXH5KB] Specifications No. Readings
1. 1st. Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (2-PS) connector from solenoid and isolate solenoid.
• Disconnect (2-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid 2-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch 2-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch 2-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (2-PS and 2-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors 2-PS, (1) and ATC2, (9) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors 2-PS, (2) and ATC2, (19) 0.0 to 1.0Ω 5
resistance
Between connectors 2-SW, (1) and ATC5A, (14) 0.0 to 1.0Ω 6
At connector 2-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector 2-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector 2-PS, between (1) and (2) (OL) open 9
At connector 2-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-604 1 HM400-1L
TROUBLESHOOTING (TM-89) FAILURE CODE [DXH5KB]
Related circuit diagram
HM400-1L 20-605 1
TROUBLESHOOTING (TM-90) FAILURE CODE [DXH6KA]
Steps Circuit Diagnostic Procedures For Failure Code [DXH6KA] Specifications No. Readings
1. 3rd. Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (3-PS) connector from solenoid and isolate solenoid.
• Disconnect (3-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid 3-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch 3-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch 3-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (3-PS and 3-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors 3-PS, (1) and ATC2, (3) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors 3-PS, (2) and ATC2, (13) 0.0 to 1.0Ω 5
resistance
Between connectors 3-SW, (1) and ATC5A, (15) 0.0 to 1.0Ω 6
At connector 3-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector 3-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector 3-PS, between (1) and (2) (OL) open 9
At connector 3-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-606 1 HM400-1L
TROUBLESHOOTING (TM-90) FAILURE CODE [DXH6KA]
Related circuit diagram
HM400-1L 20-607 1
TROUBLESHOOTING (TM-91) FAILURE CODE [DXH6KB]
Steps Circuit Diagnostic Procedures For Failure Code [DXH6KB] Specifications No. Readings
1. 3rd. Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (3-PS) connector from solenoid and isolate solenoid.
• Disconnect (3-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid 3-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch 3-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch 3-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (3-PS and 3-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors 3-PS, (1) and ATC2, (3) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors 3-PS, (2) and ATC2, (13) 0.0 to 1.0Ω 5
resistance
Between connectors 3-SW, (1) and ATC5A, (15) 0.0 to 1.0Ω 6
At connector 3-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector 3-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector 3-PS, between (1) and (2) (OL) open 9
At connector 3-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-608 1 HM400-1L
TROUBLESHOOTING (TM-91) FAILURE CODE [DXH6KB]
Related circuit diagram
HM400-1L 20-609 1
TROUBLESHOOTING (TM-92) FAILURE CODE [DXH7KA]
Steps Circuit Diagnostic Procedures For Failure Code [DXH7KA] Specifications No. Readings
1. Reverse Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (R-PS) connector from solenoid and isolate solenoid.
• Disconnect (R-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid R-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch R-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch R-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (R-PS and R-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors R-PS, (1) and ATC2, (5) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors R-PS, (2) and ATC2, (15) 0.0 to 1.0Ω 5
resistance
Between connectors R-SW, (1) and ATC5A, (16) 0.0 to 1.0Ω 6
At connector R-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector R-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector R-PS, between (1) and (2) (OL) open 9
At connector R-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-610 1 HM400-1L
TROUBLESHOOTING (TM-92) FAILURE CODE [DXH7KA]
Related circuit diagram
HM400-1L 20-611 1
TROUBLESHOOTING (TM-93) FAILURE CODE [DXH7KB]
Steps Circuit Diagnostic Procedures For Failure Code [DXH7KB] Specifications No. Readings
1. Reverse Solenoid And Switch
• With ignition switch in the "OFF" position.
• Disconnect (R-PS) connector from solenoid and isolate solenoid.
• Disconnect (R-SW) connector from switch and isolate switch.
• Zero meter leads for proper Ω readings.
At solenoid R-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch R-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch R-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (R-PS and R-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors R-PS, (1) and ATC2, (5) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors R-PS, (2) and ATC2, (15) 0.0 to 1.0Ω 5
resistance
Between connectors R-SW, (1) and ATC5A, (16) 0.0 to 1.0Ω 6
At connector R-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector R-PS, between (2) and chassis ground. (OL) open 8
ground or within Resistance Ω
harness At connector R-PS, between (1) and (2) (OL) open 9
At connector R-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-612 1 HM400-1L
TROUBLESHOOTING (TM-93) FAILURE CODE [DXH7KB]
Related circuit diagram
HM400-1L 20-613 1
TROUBLESHOOTING (TM-94) NO FAILURE CODE DISPLAYED
Steps Circuit Diagnostic Procedures For Failure Code [NONE] Specifications No. Readings
Fuse Check ⎯ Check fuses (BT1-16) condition Fuses OK? 1 Yes or No
1. Defective Diodes Or Relay
• Turn ignition switch to the “OFF” position.
• Disconnect diodes (D05 and D06) and isolate diodes.
At diode D05, between (1) and (2) reversing meter leads Continuity one
2 Yes or No
to check. way only?
A. Diodes Resistance Ω
At diode D06, between (1) and (2) reversing meter leads Continuity one
3 Yes or No
to check. way only?
B. Relay test — Replace R05 relay with known good relay. System OK? 4 Yes or No
2. Wiring Harness Assembly and Relay Test
• With ignition switch in the "OFF" position.
• Disconnect (BL47 and BL48), (Back-up Buzzer) connectors and remove relay (R05).
• Disconnect (ATC5B) connector and install T-adapter on (ATC5B) connector only.
• ✸ For this test the ignition key must be in the “ON” position with the relay (R05) and diodes (D05 and D06) installed.
✸ With shift lever set in R1 or R2, at connector BL48,
20 to 30V 5
between (1) and (2)
✸ With shift lever set in R1 or R2, at connector BL47,
Voltage 20 to 30V 6
between (1) and (2)
✸ With shift lever set in R1 or R2, at connector of
20 to 30V 7
back-up buzzer, between (1) and (2)
Between connector BL48, (2) and chassis ground. 0.0 to 1.0Ω 8
Between connector BL47, (2) and chassis ground. 0.0 to 1.0Ω 9
A. Open or high Between connector for alarm, (2) and chassis ground. 0.0 to 1.0Ω 10
resistance ✸ Between connector R05, (2), (4) and chassis ground. 20 to 30V 11
Between connectors BL48, (1) and R05, (3) 0.0 to 1.0Ω 12
Resistance Ω Between connectors BL47, (1) and R05, (1) 0.0 to 1.0Ω 13
Between connectors back-up alarm, (1) and R05, (3) 0.0 to 1.0Ω 14
Between connectors SF1, (3) and R05, (5) 0.0 to 1.0Ω 15
Between connectors SF1, (4) and R05, (5) 0.0 to 1.0Ω 16
Between connectors SF1, (3) and ATC5B, (2) 0.0 to 1.0Ω 17
Between connectors SF1, (4) and ATC5B, (1) 0.0 to 1.0Ω 18
20-614 1 HM400-1L
TROUBLESHOOTING (TM-94) NO FAILURE CODE DISPLAYED
12
Between connector BL48, (1) and chassis ground. (OL) open 19
Between connector BL47, (1) and chassis ground. (OL) open 20
B. Short to
chassis ground Resistance Ω Between connector alarm, (1) and chassis ground. (OL) open 21
or within harness
Between connector SF1, (3) and chassis ground. (OL) open 22
Between connector FS1, (4) and chassis ground. (OL) open 23
3. Transmission Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-615 1
TESTING AND ADJUSTING (TM-94) NO FAILURE CODE DISPLAYED
12
MEMORANDUM
20-616 HM400-1L
TROUBLESHOOTING OF RETARDER
CONTROLLER SYSTEM (BK MODE)
HM400-1L 20-701 1
TESTING AND ADJUSTING TABLE OF CONTENTS
RETARDER CONTROL S-NET LINE MISMATCHED (KQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-765
(BK-23) FAILURE CODE [DHU2KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-766
ACCUMULATOR OIL PRESSURE FRONT SENSOR OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . 20-766
(BK-24) FAILURE CODE [DHU3KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-768
ACCUMULATOR OIL PRESSURE rear SENSOR OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . . . . 20-768
(BK-25) FAILURE CODE [DK51L5] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-770
TROUBLE IN RETARDER LEVER POTENTIOMETER SYSTEM (KB) . . . . . . . . . . . . . . . . . . . . . . . . 20-770
(BK-26) FAILURE CODE [DK52KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-772
DUMP LEVER INPUT SIGNAL OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-772
(BK-27) FAILURE CODE [DK53L8] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-774
DUMP LEVER INPUT SIGNAL OUT OF RANGE (L8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-774
(BK-28) FAILURE CODE [DK54KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-776
BODY POSITION SENSOR SIGNAL OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-776
(BK-29) FAILURE CODE [DLF4KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-778
TRANSMISSION OUTPUT SHAFT “F” SPEED SENSOR OUT OF RANGE (KA) . . . . . . . . . . . . . . . 20-778
(BK-30) FAILURE CODE [DLT3KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-779
TRANSMISSION OUTPUT SHAFT “R” SPEED SENSOR OUT OF RANGE (KA) . . . . . . . . . . . . . . . 20-779
(BK-31) FAILURE CODE [DW71KZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-781
EXHAUST BRAKE SOLENOID OPEN OR SHORTED (KZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-781
(BK-32) FAILURE CODE [DK72KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-782
DUMP LEVER INPUT SIGNAL OUT OF RANGE (KZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-782
(BK-33) FAILURE CODE [DW73KZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-784
DUMP SELECTOR VALVE OPEN OR SHORTED (KZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-784
(BK-34) FAILURE CODE [DX11KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-786
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . 20-786
(BK-35) FAILURE CODE [DX11KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-787
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . 20-787
(BK-36) FAILURE CODE [DX11KY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-788
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KY) . . . . . . . . . . . . . . . 20-788
(BK-37) FAILURE CODE [DX12KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-789
FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KA) . . . . . . . . . . . . . . 20-789
(BK-38) FAILURE CODE [DX12KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-790
FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB) . . . . . . . . . . . . . . 20-790
(BK-39) FAILURE CODE [DX13KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-791
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-791
(BK-40) FAILURE CODE [DX13KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-793
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-793
(BK-41) FAILURE CODE [DX13KY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-795
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-795
(BK-42) FAILURE CODE [DX14KZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-797
REAR DIFFERENTIAL LOCK SOLENOID OPEN OR SHORTED (KZ) . . . . . . . . . . . . . . . . . . . . . . . 20-797
(BK-43) FAILURE CODE [DX15KZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-798
FRONT DIFFERENTIAL LOCK SOLENOID OPEN OR SHORTED (KZ) . . . . . . . . . . . . . . . . . . . . . . 20-798
(BK-44) NO FAILURE CODE DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-800
PARKING BRAKE SYSTEM FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-800
20-702 1 HM400-1L
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
HM400-1L 20-703 1
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
20-704 1 HM400-1L
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
HM400-1L 20-705 1
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
20-706 1 HM400-1L
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
HM400-1L 20-707 1
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
20-708 1 HM400-1L
TROUBLESHOOTING BK CONTROL SYSTEM CIRCUIT DIAGRAM
HM400-1L 20-709 1
TROUBLESHOOTING BK CONTROL SYSTEM CIRCUIT DIAGRAM
20-710 1 HM400-1L
TROUBLESHOOTING BK CONTROL SYSTEM CIRCUIT DIAGRAM
12
HM400-1L 20-711 1
TROUBLESHOOTING BK CONTROL SYSTEM CIRCUIT DIAGRAM
20-712 1 HM400-1L
TROUBLESHOOTING BK CONTROL SYSTEM CIRCUIT DIAGRAM
HM400-1L 20-713 1
TROUBLESHOOTING BK CONTROL SYSTEM CIRCUIT DIAGRAM
20-714 1 HM400-1L
TROUBLESHOOTING BK CONTROL SYSTEM CIRCUIT DIAGRAM
12
MEMORANDUM
HM400-1L 20-715 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
2A62LH Front differential lock control valve: *When at least 30 seconds have • Defective front differential lock oil
(BK-2) See Contents (LH) passed after starting engine, even if pressure switch
(Machine with differential lock differ- output is sent to front differential lock • Open in switch signal circuit wiring
ential) solenoid circuit when engine is run- harness
ning, signal from front differential lock • Open in switch GND circuit wiring
oil pressure switch remains OFF
harness
• Defective retarder controller (❋)
2B62L1 Rear differential lock control valve: * Even when output to rear differential • Defective rear differential lock oil
(BK-3) See Contents (L1) lock solenoid circuit is turned OFF, pressure switch
(Machine with differential lock differ- signal from rear differential lock oil • Short circuit with chassis ground in
ential) pressure switch remains ON switch signal circuit wiring harness
• Defective retarder controller (❋)
2B62LH Rear differential lock control valve: * When at least 30 seconds have • Defective rear differential lock oil
(BK-4) See Contents (LH) passed after starting engine, even if pressure switch
(Machine with differential lock differ- output is sent to rear differential lock • Open in switch signal circuit wiring
ential) solenoid circuit when engine is run- harness
ning, signal from rear differential lock • Open in switch GND circuit wiring
oil pressure switch remains OFF
harness
• Defective retarder controller (❋)
2C4MNX Brake cooling filter: Clogged (NX) When brake cooling oil temperature • Clogged brake cooling filter (when
(BK-5) went above 50°C when engine was system is working normally)
running, signal circuit of brake cool- • Defective brake cooling filter
ing filter clogging switch became clogging switch
open (shut off from GND) • Open in switch signal circuit wiring
harness
• Open in switch GND circuit wiring
harness
• Defective retarder controller (❋)
2D01CA Front brake (right): Wear (CA) When gearshift lever was at N posi- • Worn front brake (right) (when
(BK-6) tion, signal circuit of front brake system is working normally)
(right) wear switch became open • Defective front brake (right) wear
switch
• Open or short circuit with chassis
ground in sensor power source
circuit wiring harness
• Open or short circuit with chassis
ground in sensor signal circuit
wiring harness
• Defective retarder controller (❋)
20-716 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
• Switch resistance value • Takes no action • If the machine is used as it is, there E01
B28 (male) (1) - (2): is danger that the brake will lose
• When normal: Max. 1Ω its effect
• When worn: Min. 1Ω
HM400-1L 20-717 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
2D02CA Front brake (left): Wear (CA) When gearshift lever was at N • Worn front brake (left) (when system is
(BK-7) position, signal circuit of front working normally)
brake (left) wear switch became • Defective front brake (left) wear switch
open
• Open or short circuit with chassis ground
in sensor power source circuit wiring
harness
• Defective retarder controller (❋)
2D03CA Center brake (right): Wear (CA) When gearshift lever was at N • Worn center brake (right) (when system is
(BK-8) position, signal circuit of center working normally)
brake (right) wear switch became • Defective center brake (right) wear switch
open
• Open or short circuit with chassis ground
in sensor power source circuit wiring
harness
• Defective retarder controller (❋)
2D04CA Center brake (left): Wear (CA) When gearshift lever was at N • Worn center brake (left) (when system is
(BK-9) position, signal circuit of center working normally)
brake (left) wear switch became • Defective center brake (left) wear switch
open
• Open or short circuit with chassis ground
in sensor power source
• circuit wiring harness
• Defective retarder controller (❋)
2D05CA Rear brake (right): Wear (CA) When gearshift lever was at N • Worn rear brake (right) (when system is
(BK-10) position, signal circuit of rear brake working normally)
(right) wear switch became open • Defective rear brake (right) wear switch
• Open or short circuit with chassis ground
in sensor power source
• circuit wiring harness
• Defective retarder controller (❋)
2D06CA Rear brake (left): Wear (CA) When gearshift lever was at N • Worn rear brake (left) (when system is
(BK-11) position, signal circuit of rear brake working normally)
(left) wear switch became open • Defective rear brake (left) wear switch
• Open or short circuit with chassis ground
in sensor power source
• circuit wiring harness
• Defective retarder controller (❋)
2G42ZG Accumulator (front): Drop in oil With engine running (continuously • Defective hydraulic, mechanical system of
(BK-12) pressure (ZG) for at least 30 seconds), oil pres- front accumulator
sure of less than 6.86 MPa {70 kg/
2
cm } was input for front accumula-
tor oil pres-sure sensor signal
2G43ZG Accumulator (rear): Drop in oil With engine running (continuously • Defective hydraulic, mechanical system of
(BK-13) pressure (ZG) for at least 30 seconds), oil pres- rear accumulator
sure of less than 6.86 MPa {70 kg/
2} was input for rear accumula-
cm
tor oil pressure sensor signal
20-718 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
• Switch resistance value • Takes no action • If the machine is used as it is, there E01
B26 (male) (1) - (2): is danger that the brake will lose
• When normal: Max. 1Ω its effect
• When worn: Min. 1Ω
• Switch resistance value • Takes no action • If the machine is used as it is, there E01
B02 (male) (1) - (2): is danger that the brake will lose
• When normal: Max. 1Ω its effect
• When worn: Min. 1Ω
• Switch resistance value • Takes no action • If the machine is used as it is, there E01
B08 (male) (1) - (2): is danger that the brake will lose
• When normal: Max. 1Ω its effect
• When worn: Min. 1Ω
• Switch resistance value • Takes no action • If the machine is used as it is, there E01
B05 (male) (1) - (2): is danger that the brake will lose
• When normal: Max. 1Ω its effect
• When worn: Min. 1Ω
HM400-1L 20-719 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
Failure
Location Of Failure Nature Of Failure Probable Cause
Code
D1C0KZ Brake cut relay: Open or short circuit When output is sent to brake cut • Defective brake cut relay
(BK-14) (KZ) relay circuit, excessive electric cur- • Open or short circuit with chassis
rent flows; when there is output, no ground, or short circuit with power
electric current flows; when output is source in relay signal circuit wiring
OFF, electric current flows harness
• Open in relay GND circuit wiring
harness
• Defective retarder controller (❋)
D5ZFKZ Neutral signal 1: Open or short circuit When output is sent to neutral signal • Defective transmission controller
(BK-15) (KZ) 1 circuit, excessive electric current • Open or short circuit with chassis
flows; when there is output, no elec- ground in signal 1 circuit wiring
tric current flows harness
• Defective retarder controller (❋)
D5ZGKZ Neutral signal 2: Open or short circuit When output is sent to neutral signal • Defective transmission controller
(BK-16) (KZ) 2 circuit, excessive electric current • Open or short circuit with chassis
flows; when there is output, no elec- ground in signal 2 circuit wiring
tric current flows harness
• Defective retarder controller (❋)
DB10KK Retarder controller (q1): Drop in Both main power source voltage cir- • Other problem occurs at same
(BK-17) power source voltage, input (KK) cuit and direct power source voltage time (failure code AB00MA is
circuit went below 17 V displayed)
• Battery tends to lose power
• Open or short circuit with chassis
ground in power source circuit
• wiring harness
• Open in GND circuit wiring
harness
• Defective retarder controller (❋)
DB11KK Retarder controller (q1) main power Voltage difference between main • Open or short circuit with chassis
(BK-18) supply line: Drop in power supply power source voltage circuit and ground in main power source
voltage, input (KK) direct power source voltage went circuit wiring harness
below 5 V (main power source < • Defective retarder controller (❋)
direct power source)
DB12KK Retarder controller (q1) load power When controller power source volt- • Defective brake cut relay
(BK-19) supply line: Drop in power supply age circuit was normal, solenoid • Open or short circuit with chassis
voltage, input (KK) power source voltage circuit went ground in relay power source
below 17 V circuit wiring harness
• Open or short circuit with chassis
ground in relay output circuit wiring
harness
• Defective retarder controller (❋)
DB13KK Retarder controller (q1) battery direct Voltage of direct power source volt- • Open or short circuit with chassis
(BK-20) power supply line: Drop in power age circuit went below 5 V ground in direct power source
supply voltage, input (KK) circuit wiring harness
• Defective retarder controller (❋)
DB19KM Retarder controller (q1) wiring har- When ignition switch is ON, input • Mistaken connection of connector
(BK-21) ness: Mistaken operation or mistaken connector check signal does not BRC3 (A, B) and connector BRC5
setting (KM) match setting inside controller (A, B) (when system is working
normally)
• Open in signal 2 circuit wiring
harness
• Defective retarder controller (❋)
20-720 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
• Turns neutral signal 1 and signal 2 • Even when transmission output E01
OFF shaft F speed goes above 4200
rpm, the transmission does not
shift to N
• Main power source voltage • Takes no action (moves as long as • No great effect on machine E03
BRC1 (9)(17) - (8)(16): 20 - 30 V it is possible to actuate)
• Direct power source voltage
BRC1 (7) - (8)(16): 20 - 30 V
•
• Main power source voltage • Takes no action • No great effect on machine E03
BRC1 (9)(17) - (8)(16): 20 - 30 V
• Solenoid power source voltage • Turns all output circuits OFF • The whole system of the retarder E03
BRC2 (1)(12) - BRC1 (8)(16): • Turns 24V power supply of sensor controller (q1) stops working
20 - 30 V OFF (retarder, inter-axle differential lock,
left and right differential lock, dump,
exhaust brake, neutral signal)
• Failure codes (DHU2KX, DHU3KX)
are displayed at same time
• Direct power source voltage • Takes no action • No great effect on machine E03
BRC1 (7) - (8)(16): 20 - 30 V
• Wiring harness resistance value • Turns all outputs OFF • The whole system of the retarder E03
BRC5A (female) (1) - ground: Max. • Does not record in trouble data controller (q1) stops working
1Ω (retarder, inter-axle differential lock,
left and right differential lock, dump,
exhaust brake, neutral signal)
• Failure codes (DB12KK, DHU2KX,
DHU3KX) are displayed at same
time
HM400-1L 20-721 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
20-722 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
• Sensor power source voltage • Takes no action • No great effect on machine E01
B25 (2) - (1): 20 - 30 V
• Sensor signal voltage
B25 (3) - (1): 000 - 000 V
• Sensor power source voltage • Takes no action • No great effect on machine E01
B24 (2) - (1): 20 - 30 V
• Sensor signal voltage
B24 (3) - (1): 1.8 - 3.5 V
• Potentiometer power source voltage Depending on condition of occur- Depending on nature of action E01
RTL (1) - (3): 4.1 - 4.8 V rence of failure • No great effect on machine
• Potentiometer signal voltage • Carries out control with • Fine control of retarder is
RTL (2) - (3): 0.3 - 4.7 V potentiometer signal impossible (which is not used in E-
• Switch resistance value • Limits output to solenoid to 70% SPEC)
(lever at RELEASED position) • Turns output to solenoid OFF • Retarder does not work (foot brake
• RTL (male) (4) - (6): Max. 1Ω works) (which is not used in E-
• RTL (male) (5) - (6): Min. 1 MΩ SPEC)
• Switch resistance value (lever at
APPLIED position)
• RTL (male) (4) - (6): Min. 1 MΩ
• RTL (male) (5) - (6): Max. 1Ω
• Potentiometer power source Recognizes dump lever position as • Dump body does not move E03
voltage HOLD
HSL (4) - (1): 4.6 - 5.4 V
• Potentiometer signal voltage
HSL (3) - (1) (signal 1): 0.3 - 4.7 V
HSL (2) - (1) (signal 2): 0.3 - 4.7 V
HM400-1L 20-723 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
DLT3KA Transmission output shaft R Open has occurred in signal cir- • Defective transmission output shaft R
(BK-30) speed sensor: Open (KA) cuit of transmission output shaft speed sensor or defective adjustment
R speed sensor and signal is not • Open in sensor signal wiring harness
input
• Open in sensor GND circuit wiring harness
• Defective retarder controller (❋)
DW71KZ Exhaust brake solenoid: Open or When output is sent to exhaust • Defective exhaust brake solenoid
(BK-31) short circuit (KZ) brake solenoid circuit, exces- • Open or short circuit with chassis ground, or
(Machine with exhaust brake) sive electric current flows; when short circuit with
there is output, no electric cur-
rent flows; when output is OFF, • power source in solenoid signal circuit
electric current flows wiring harness
• Open in solenoid GND circuit wiring
harness
• Defective retarder controller (❋)
DW72KZ Dump lever kick-out solenoid: When output is sent to dump • Defective dump lever (kick-out solenoid)
(BK-32) Open or short circuit (KZ) lever kick-out solenoid circuit, • Open or short circuit with chassis ground, or
excessive electric current flows; short circuit with power source in solenoid
when there is output, no electric
current flows; when output is signal circuit wiring harness
OFF, electric current flows • Open in solenoid GND circuit wiring
harness
• Defective retarder controller (❋)
DW73KZ Dump selector valve solenoid: When output is sent to dump • Defective dump pilot valve (selector
(BK-33) Open or short circuit (KZ) selector valve solenoid circuit, solenoid)
excessive electric current flows; • Open or short circuit with chassis ground, or
when there is output, no electric
current flows; when output is short circuit with power source in solenoid
OFF, electric current flows signal circuit wiring harness
• Open in solenoid GND circuit wiring
harness
• Defective retarder controller (❋)
20-724 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
• Sensor power source voltage • Carries out dump control accord- • here is a big shock when dump E03
B34 (3) - (1): 4.6 - 5.4 V ing to signal from dump lever body is seated
• Sensor signal voltage • Recognizes that dump body is not • Dump lever positioner function
B34 (2) - (1) seated when carrying out control does not work
When seated: 0.30 - 0.46 V • Maximum travel speed range is
When fully raised: 4.00 - 4.70 V limited
• Machine cannot travel in reverse if
dump lever is not at FLOAT
• Sensor resistance value • Cancels inter-axle differential lock • Inter-axle differential lock does not E01
FE1 (male) (1) - (2): 500 - 1000Ω command work
• Does not output neutral signal • Even when transmission output
shaft F speed goes above 4200
rpm, the transmission does not
shift to N
• Sensor resistance value • Cancels inter-axle differential lock • Inter-axle differential lock does not E01
FE1 (male) (1) - (2): 500 - 1000Ω command work
• Solenoid resistance value Turns output to exhaust brake sole- • Exhaust brake does not work E01
B29 (male) (1) - (2): 20 - 60Ω noid OFF
• Solenoid resistance value • Turns output to dump lever kick- • Dump lever is not locked in detent E01
LKO (male) (1) - (2): 39Ω ± 5% out solenoid OFF
• Solenoid resistance value • Turns output to dump selector • Dump body does not move E03
B31 (male) (1) - (2): Approx. 30Ω valve solenoid OFF
• Turns output to dump EPC valve
solenoid OFF
HM400-1L 20-725 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
DX11KB Rear brake pressure reducing valve When output is sent to rear brake • Defective rear brake pressure
(BK-35) solenoid: Short circuit (KB) pressure reducing valve solenoid cir- reducing valve solenoid
cuit, excessive electric current flows • Short circuit or short circuit with
chassis ground in solenoid (+)
circuit wiring harness
• Defective retarder controller (❋)
DX11KY Rear brake pressure reducing valve When output to rear brake pressure • Short circuit with power source in
(BK-36) solenoid: Short circuit in power reducing valve solenoid circuit is solenoid (+) circuit wiring harness
source line (KY) OFF, electric current flows • Short circuit with power source in
solenoid (–) circuit wiring harness
• Defective retarder controller (❋)
DX12KA Front brake pressure reducing valve When output is sent to front brake • Defective front brake pressure
(BK-37) solenoid: Open (KA) pressure reducing valve solenoid cir- reducing valve solenoid
cuit, no electric current flows • Open in solenoid (+) circuit wiring
harness
• Open in solenoid (-) circuit wiring
harness
• Defective retarder controller (❋)
DX12KB Front brake pressure reducing valve When output is sent to front brake • Defective front brake pressure
(BK-38) solenoid: Short circuit (KB) pressure reducing valve solenoid cir- reducing valve solenoid
cuit, excessive electric current flows • Short circuit or short circuit with
chassis ground in solenoid (+)
circuit wiring harness
• Defective retarder controller (❋)
DX12KY Front brake pressure reducing valve When output to front brake pressure • Short circuit with power source in
(BK-39) solenoid: Short circuit in power reducing valve solenoid circuit is solenoid (+) circuit wiring harness
source line (KY) OFF, electric current flows • Short circuit with power source in
solenoid (-) circuit wiring harness
• Defective retarder controller (❋)
DX13KA Dump EPC valve solenoid: Open When output is sent to dump EPC • Defective dump pilot valve (EPC
(BK-40) (KA) valve solenoid circuit, no electric cur- solenoid)
rent flows • Open in solenoid (+) circuit wiring
harness
• Open in solenoid (-) circuit wiring
harness
• Defective retarder controller (❋)
20-726 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
• Solenoid resistance value • Turns output to rear brake • Rear brake (center brake, rear E03
B18 (male) (1) - (2): 10~30Ω pressure reducing valve solenoid brake) does not work
OFF
• Turns output to rear brake • The whole system of the retarder E03
pressure reducing valve solenoid controller (❋ ) stops working
OFF (retarder, inter-axle differential lock,
• Turns output to brake cut relay left and right differential lock, dump,
OFF exhaust brake, neutral signal)
• Failure codes (DB12KK, DHU2KX,
DHU3KX) are displayed at same
time
• Solenoid resistance value • Turns output to front brake • Front brake does not work E03
B19 (male) (1) - (2): 10~30Ω pressure reducing valve solenoid
OFF
• Solenoid resistance value • Turns output to front brake • Front brake does not work E03
B19 (male) (1) - (2): 10~30Ω pressure reducing valve solenoid
OFF
• • Turns output to front brake • The whole system of the retarder E03
pressure reducing valve solenoid controller (❋ ) stops working
OFF (retarder, inter-axle differential lock,
• Turns output to brake cut relay left and right differential lock, dump,
OFF exhaust brake, neutral signal)
• Failure codes (DB12KK, DHU2KX,
DHU3KX) are displayed at same
time
• Solenoid resistance value • Turns output to dump selector • Dump body does not work E03
B32 (male) (1) - (2): Approx. valve solenoid OFF
5~20Ω • Turns output to dump EPC valve
solenoid OFF
HM400-1L 20-727 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
DX13KY Dump EPC valve solenoid: Short cir- When output to dump EPC valve • Short circuit with power source in
(BK-42) cuit in power source line (KY) solenoid circuit is OFF, electric cur- solenoid (+) circuit wiring harness
rent flows • Short circuit with power source in
solenoid (-) circuit wiring harness
• Defective retarder controller (❋)
DX14KZ Rear differential lock solenoid: Open When output is sent to rear differen- • Defective rear differential lock
(BK-43) or short circuit (KZ) tial lock solenoid circuit, excessive solenoid
(Machine with differential lock differ- electric current flows; when there is • Open or short circuit with chassis
ential) output, no electric current flows;
when output is OFF, electric current ground, or short circuit with power
flows source in solenoid signal circuit
wiring harness
• Open in solenoid GND circuit
wiring harness
• Defective retarder controller (❋)
DX15KZ Front differential lock solenoid: Open When output is sent to front differen- • efective front differential lock
(BK-44) or short circuit (KZ) tial lock solenoid circuit, excessive solenoid
(Machine with differential lock differ- electric current flows; when there is • Open or short circuit with chassis
ential) output, no electric current flows;
when output is OFF, electric current ground, or short circuit with power
flows source in solenoid signal circuit
wiring harness
• Open in coolant in solenoid GND
circuit wiring harness
• Defective retarder controller (❋)
20-728 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
• Turns output to dump selector • Dump body does not work E03
valve solenoid OFF
• Turns output to dump EPC valve
solenoid OFF
• Solenoid resistance value • Turns output to rear differential • Rear differential lock (center E03
B36 (male) (1) - (2): 15~30Ω lock solenoid OFF differential, rear differential) does
not work
• Solenoid resistance value • Turns output to front differential • Front differential lock does not E03
B35 (male) (1) - (2): 15~30Ω lock solenoid OFF work
HM400-1L 20-729 1
TROUBLESHOOTING INFORMATION CONTAINED IN TESTING PROCEDURES
• Failure.
Contents Of Trouble • Failure code displayed.
• Additional information.
Tools and Procedures
Steps Circuit Diagnostic Procedures For Service Code Specifications No. Readings
1. Sensor or Actuator
• With ignition switch in the “OFF” position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸)
• Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
• Zero meter leads for proper Ω readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)
Your
Test procedure for component only. readings 1
Resistance Ω information
A. What you are testing
or Voltage
Your
Test procedure for component only. readings 2
information
2. Diode Test
• With ignition switch in the “OFF” position. (The importance of these tests are to isolate each component for testing separately)
• When checking a diode always isolate the circuit. Check diode continuity in both directions reversing meter leads each time to confirm
electrical flow. Electrical flow should be one way only. (See section 20-111 for detail).
Your
Test procedure for harness. (connector) to (connector) readings 4
information
A. Open or high Resistance Ω
resistance or Voltage
Your
Test procedure for harness. (connector) to (connector) readings 5
information
Your
Test procedure for harness. (connector) to (connector) readings 6
B. Short to chassis information
Resistance Ω
ground or within
or Voltage Your
harness
Test procedure for harness. (connector) to (connector) readings 7
information
Resistance Ω Your
A. What you are testing Test procedure for any additional components. readings 8
or Voltage information
20-730 1 HM400-1L
TROUBLESHOOTING INFORMATION CONTAINED IN TESTING PROCEDURES
Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
HM400-1L 20-731 1
TROUBLESHOOTING (BK-1) FAILURE CODE [2A62L1]
Steps Circuit Diagnostic Procedures For Failure Code [2A62L1] Specifications No. Readings
A. Open or high Between connectors B39, (1) and BRC5A, (11) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors B39, (2) and chassis ground. 0.0 to 1.0Ω 5
B. Short to chassis At connector B39, between (1) and chassis ground. (OL) open 6
ground or within Resistance Ω
harness At connector B39, between (1) and (2) (OL) open 7
20-732 1 HM400-1L
TROUBLESHOOTING (BK-1) FAILURE CODE [2A62L1]
Related circuit diagram
HM400-1L 20-733 1
TROUBLESHOOTING (BK-2) FAILURE CODE [2A62LH]
Steps Circuit Diagnostic Procedures For Failure Code [2A62LH] Specifications No. Readings
A. Open or high Between connectors B39, (1) and BRC5A, (11) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors B39, (2) and chassis ground. 0.0 to 1.0Ω 5
B. Short to chassis At connector B39, between (1) and chassis ground. (OL) open 6
ground or within Resistance Ω
harness At connector B39, between (1) and (2) (OL) open 7
20-734 1 HM400-1L
TROUBLESHOOTING (BK-2) FAILURE CODE [2A62LH]
Related circuit diagram
HM400-1L 20-735 1
TROUBLESHOOTING (BK-3) FAILURE CODE [2B62L1]
Steps Circuit Diagnostic Procedures For Failure Code [2B62L1] Specifications No. Readings
At switch B41, between (1) or (2) and chassis ground. (OL) open 5
20-736 1 HM400-1L
TROUBLESHOOTING (BK-3) FAILURE CODE [2B62L1]
Related circuit diagram
HM400-1L 20-737 1
TROUBLESHOOTING (BK-4) FAILURE CODE [2B62LH]
Steps Circuit Diagnostic Procedures For Failure Code [2B62LH] Specifications No. Readings
At switch B41, between (1) or (2) and chassis ground. (OL) open 5
20-738 1 HM400-1L
TROUBLESHOOTING (BK-4) FAILURE CODE [2B62LH]
Related circuit diagram
HM400-1L 20-739 1
TROUBLESHOOTING (BK-5) FAILURE CODE [2C4MNX]
• When the brake cooling oil temperature went above 50oC (122oF) when the engine was running, the signal circuit of
Contents Of Trouble
the brake cooling filter clogging switch became open (shut off from GND).
Tools and Procedures
Steps Circuit Diagnostic Procedures For Failure Code [2C4MNX] Specifications No. Readings
Brake Cooling Filter ⎯ Check condition of brake filter Filter good? 1 Yes or No
A. Open or high Between connectors B03, (1) and BRC5A, (9) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connector B03, (2) and chassis ground. 0.0 to 1.0Ω 5
B. Short to chassis At connector B03, between (1) and chassis ground. (OL) open 6
ground or within Resistance Ω
harness At connector B03, between (1) and (2) (OL) open 7
20-740 1 HM400-1L
TROUBLESHOOTING (BK-5) FAILURE CODE [2C4MNX]
Related circuit diagram
HM400-1L 20-741 1
TROUBLESHOOTING (BK-6) FAILURE CODE [2D02CA]
Steps Circuit Diagnostic Procedures For Failure Code [2D02CA] Specifications No. Readings
Lining worn
Left Front Brake ⎯ Check condition of left front brake lining 1 Yes or No
out?
A. Open or high Between connectors DT2-2, (1) and BRC1, (1) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors DT2-2, (2) and BRC5B, (2) 0.0 to 1.0Ω 5
20-742 1 HM400-1L
TROUBLESHOOTING (BK-7) FAILURE CODE [2D01CA]
Steps Circuit Diagnostic Procedures For Failure Code [2D01CA] Specifications No. Readings
Lining worn
Right Front Brake ⎯ Check condition of right front brake lining 1 Yes or No
out?
A. Open or high Between connectors DT2-2, (1) and BRC1, (1) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors DT2-2, (2) and BRC5B, (3) 0.0 to 1.0Ω 5
HM400-1L 20-743 1
TROUBLESHOOTING (BK-8) FAILURE CODE [2D03CA]
Steps Circuit Diagnostic Procedures For Failure Code [2D03CA] Specifications No. Readings
Lining worn
Right Center Brake ⎯ Check condition of right center brake lining 1 Yes or No
out?
A. Open or high Between connectors DT2-2, (1) and BRC1, (1) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors DT2-2, (2) and BRC5B, (9) 0.0 to 1.0Ω 5
20-744 1 HM400-1L
TROUBLESHOOTING (BK-9) FAILURE CODE [2D04CA]
Steps Circuit Diagnostic Procedures For Failure Code [2D04CA] Specifications No. Readings
Lining worn
Left Center Brake ⎯ Check condition of left center brake lining 1 Yes or No
out?
A. Open or high Between connectors DT2-2, (1) and BRC1, (1) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors DT2-2, (2) and BRC5B, (8) 0.0 to 1.0Ω 5
HM400-1L 20-745 1
TROUBLESHOOTING (BK-10) FAILURE CODE [2D05CA]
Steps Circuit Diagnostic Procedures For Failure Code [2D05CA] Specifications No. Readings
Lining worn
Right Rear Brake ⎯ Check condition of right rear brake lining 1 Yes or No
out?
A. Open or high Between connectors DT2-2, (1) and BRC1, (1) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors DT2-2, (2) and BRC5B, (7) 0.0 to 1.0Ω 5
20-746 1 HM400-1L
TROUBLESHOOTING (BK-11) FAILURE CODE [2D06CA]
Steps Circuit Diagnostic Procedures For Failure Code [2D06CA] Specifications No. Readings
Lining worn
Left Rear Brake ⎯ Check condition of left rear brake lining 1 Yes or No
out?
A. Open or high Between connectors DT2-2, (1) and BRC1, (1) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors DT2-2, (2) and BRC5B, (6) 0.0 to 1.0Ω 5
HM400-1L 20-747 1
TROUBLESHOOTING (BK-12) FAILURE CODE [2G42ZG]
Cause Remedy
NO
Defective retarder controller Repair
20-748 1 HM400-1L
TROUBLESHOOTING (BK-13) FAILURE CODE [2G43ZG]
12
(BK-13) FAILURE CODE [2G43ZG]
Cause Remedy
NO
Defective retarder controller Repair
HM400-1L 20-749 1
TROUBLESHOOTING (BK-14) FAILURE CODE [D1C0KZ]
Steps Circuit Diagnostic Procedures For Failure Code [D1C0KZ] Specifications No. Readings
20-750 1 HM400-1L
TROUBLESHOOTING (BK-14) FAILURE CODE [D1C0KZ]
Related circuit diagram
HM400-1L 20-751 1
TROUBLESHOOTING (BK-15) FAILURE CODE [D5ZFKZ]
Steps Circuit Diagnostic Procedures For Error Code [D5ZFKZ] Specifications No. Readings
Between connector ATC1, (8), (16) and chassis ground. 0.0 to 1.0Ω 6
20-752 1 HM400-1L
TROUBLESHOOTING (BK-15) FAILURE CODE [D5ZFKZ]
Related circuit diagram
HM400-1L 20-753 1
TROUBLESHOOTING (BK-16) FAILURE CODE [D5ZGKZ]
Steps Circuit Diagnostic Procedures For Error Code [D5ZGKZ] Specifications No. Readings
Between connector ATC1, (8), (16) and chassis ground. 0.0 to 1.0Ω 6
20-754 1 HM400-1L
TROUBLESHOOTING (BK-16) FAILURE CODE [D5ZGKZ]
Related circuit diagram
HM400-1L 20-755 1
TROUBLESHOOTING (BK-17) FAILURE CODE [DB10KK]
Steps Circuit Diagnostic Procedures For Failure Code [DB10KK] Specifications No. Readings
Fuses Check ⎯ Check condition of fuses (BT2-22) and (BT3-12) Fuses good? 1 Yes or No
Fuse Link ⎯ Check condition of fuse link (FU) Link good? 3 Yes or No
A. Open or high ✸ Between connectors BRC1, (7) and chassis ground 20 to 30V 5
resistance Voltage ✸ Between connectors BRC1, (17) and chassis ground 20 to 30V 6
20-756 1 HM400-1L
TROUBLESHOOTING (BK-17) FAILURE CODE [DB10KK]
Related circuit diagram
HM400-1L 20-757 1
TROUBLESHOOTING (BK-18) FAILURE CODE [DB11KK]
Steps Circuit Diagnostic Procedures For Failure Code [DB11KK] Specifications No. Readings
Fuses Check ⎯ Check condition of fuses (BT2-22) and (BT3-12) Fuses good? 1 Yes or No
Fuse Link ⎯ Check condition of fuse link (FU) Link good? 3 Yes or No
A. Open or high ✸ Between connectors BRC1, (7) and chassis ground 20 to 30V 5
resistance Voltage ✸ Between connectors BRC1, (17) and chassis ground 20 to 30V 6
20-758 1 HM400-1L
TROUBLESHOOTING (BK-18) FAILURE CODE [DB11KK]
Related circuit diagram
HM400-1L 20-759 1
TROUBLESHOOTING (BK-19) FAILURE CODE [DB12KK]
Steps Circuit Diagnostic Procedures For Failure Code [DB12KK] Specifications No. Readings
Fuse Check ⎯ Check to see if fuse (BT3-12) is blown ⎯ 1 Yes or No
20-760 1 HM400-1L
TROUBLESHOOTING (BK-19) FAILURE CODE [DB12KK]
Related circuit diagram
HM400-1L 20-761 1
TROUBLESHOOTING (BK-20) FAILURE CODE [DB13KK]
Steps Circuit Diagnostic Procedures For Failure Code [DB13KK] Specifications No. Readings
Fuses Check ⎯ Check condition of fuses (BT2-22) and (BT3-12) Fuses good? 1 Yes or No
Fuse Link ⎯ Check condition of fuse link (FU) Link good? 3 Yes or No
A. Open or high ✸ Between connectors BRC1, (7) and chassis ground 20 to 30V 5
resistance Voltage ✸ Between connectors BRC1, (17) and chassis ground 20 to 30V 6
20-762 1 HM400-1L
TROUBLESHOOTING (BK-20) FAILURE CODE [DB13KK]
Related circuit diagram
HM400-1L 20-763 1
TROUBLESHOOTING (BK-21) FAILURE CODE [DB19KM]
Steps Circuit Diagnostic Procedures For Error Code [DB19KM] Specifications No. Readings
20-764 1 HM400-1L
TROUBLESHOOTING (BK-22) FAILURE CODE [DB1SKQ]
Cause Remedy
NO
YES
Defective retarder controller Replace
HM400-1L 20-765 1
TROUBLESHOOTING (BK-23) FAILURE CODE [DHU2KX]
Steps Circuit Diagnostic Procedures For Failure Code [DHU2KX] Specifications No. Readings
1. Pressure Sensor
• With ignition switch in the "OFF" position.
• Disconnect (B25) connector from sensor and install T-adapter between (B25) connector and sensor.
• Zero meter leads for proper Ω readings.
• ✸ Turn ignition switch to the “ON” position for this test.
Resistance Ω At sensor B25, between (1) and chassis ground. 0.0 to 1.0Ω 3
A. Open or high Between connectors B25, (1) and BRC3A, (16) 0.0 to 1.0Ω 5
resistance Resistance Ω Between connectors B25, (2) and BRC1, (1) 0.0 to 1.0Ω 6
20-766 1 HM400-1L
TROUBLESHOOTING (BK-23) FAILURE CODE [DHU2KX]
Related circuit diagram
HM400-1L 20-767 1
TROUBLESHOOTING (BK-24) FAILURE CODE [DHU3KX]
Steps Circuit Diagnostic Procedures For Failure Code [DHU3KX] Specifications No. Readings
1. Pressure Sensor
• With ignition switch in the "OFF" position.
• Disconnect (B24) connector from sensor and install T-adapter between (B25) connected and sensor.
• Zero meter leads for proper Ω readings.
• ✸ Turn ignition switch to the “ON” position for this test.
Resistance Ω At sensor B24, between (1) and chassis ground. 0.0 to 1.0Ω 3
A. Open or high Between connectors B24, (1) and BRC3A, (16) 0.0 to 1.0Ω 5
resistance Resistance Ω Between connectors B24, (2) and BRC1, (1) 0.0 to 1.0Ω 6
20-768 1 HM400-1L
TROUBLESHOOTING (BK-24) FAILURE CODE [DHU3KX]
Related circuit diagram
HM400-1L 20-769 1
TROUBLESHOOTING (BK-25) FAILURE CODE [DK51L5]
Steps Circuit Diagnostic Procedures For Error Code [DK51L5] Specifications No. Readings
A. Open or high Between connectors RTL, (3) and BRC3A, (16) 0.0 to 1.0Ω 8
Resistance Ω
resistance Between connectors RTL, (4) and BRC5A, (6) 0.0 to 1.0Ω 9
Between connectors RTL, (5) and BRC5A, (7) 0.0 to 1.0Ω 10
20-770 1 HM400-1L
TROUBLESHOOTING (BK-25) FAILURE CODE [DK51L5]
HM400-1L 20-771 1
TROUBLESHOOTING (BK-26) FAILURE CODE [DK52KX]
Steps Circuit Diagnostic Procedures For Failure Code [DK52KX] Specifications No. Readings
At resistor LKO, between (1) or (2) and chassis ground. (OL) open 5
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (HSL and LKO) connectors from dump lever and isolate connectors.
• Disconnect (BRC1, BRC3A and BRC3B) connector from the retarder controller and install T-adapter on (BRC1, BRC3A and BRC3B)
wiring harness connector only.
A. Open or high Between connectors HSL, (3) and BRC3B, (12) 0.0 to 1.0Ω 8
Resistance Ω
resistance Between connectors HSL, (4) and BRC3A, (6) 0.0 to 1.0Ω 9
At connector HSL, between (1) and (2), (3), (4) (OL) open 17
20-772 1 HM400-1L
TROUBLESHOOTING (BK-26) FAILURE CODE [DK52KX]
Related circuit diagram
HM400-1L 20-773 1
TROUBLESHOOTING (BK-27) FAILURE CODE [DK53L8]
Steps Circuit Diagnostic Procedures For Failure Code [DK52KX] Specifications No. Readings
At resistor LKO, between (1) or (2) and chassis ground. (OL) open 5
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (HSL and LKO) connectors from dump lever and isolate connectors.
• Disconnect (BRC1, BRC3A and BRC3B) connector from the retarder controller and install T-adapter on (BRC1, BRC3A and BRC3B)
wiring harness connector only.
A. Open or high Between connectors HSL, (3) and BRC3B, (12) 0.0 to 1.0Ω 8
Resistance Ω
resistance Between connectors HSL, (4) and BRC3A, (6) 0.0 to 1.0Ω 9
At connector HSL, between (1) and (2), (3), (4) (OL) open 17
20-774 1 HM400-1L
TROUBLESHOOTING (BK-27) FAILURE CODE [DK53L8]
Related circuit diagram
HM400-1L 20-775 1
TROUBLESHOOTING (BK-28) FAILURE CODE [DK54KX]
Steps Circuit Diagnostic Procedures For Failure Code [DK54KX] Specifications No. Readings
20-776 1 HM400-1L
TROUBLESHOOTING (BK-28) FAILURE CODE [DK54KX]
Related circuit diagram
HM400-1L 20-777 1
TROUBLESHOOTING (BK-29) FAILURE CODE [DLF4KA]
Steps Circuit Diagnostic Procedures For Failure Code [DLF4KA] Specifications No. Readings
A. Solenoid and switch At sensor DT2-2, between (1) and (2) 500 to 1000Ω 1
Resistance Ω
test At sensor DT2-2, between (1) or (2) and chassis ground. (OL) open 2
A. Open or high Between connectors DT2-2, (1) and BRC3A, (12) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors DT2-2, (2) and BRC3A, (14) 0.0 to 1.0Ω 4
At connector DT2-2, between (1) and chassis ground. (OL) open 5
B. Short to chassis
ground or within Resistance Ω At connector DT2-2, between (2) and chassis ground. (OL) open 6
harness
At connector DT2-2, between (1) and (2) (OL) open 7
20-778 1 HM400-1L
TROUBLESHOOTING (BK-30) FAILURE CODE [DLT3KA]
Steps Circuit Diagnostic Procedures For Failure Code [DLT3KA] Specifications No. Readings
1. Output Shaft Speed Sensor
• With ignition switch in the "OFF" position.
• Disconnect (N3) connector from sensor and isolate sensor.
• Zero meter leads for proper Ω readings.
A. Solenoid and switch At sensor N3, between (1) and (2) 500 to 1000Ω 1
Resistance Ω
test At sensor N3, between (1) or (2) and chassis ground. (OL) open 2
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (N3) connectors from sensor and isolate connector.
• Disconnect (BRC3A and ATC3A) connector from the retarder controller and install T-adapter on (BRC3A and ATC3A) wiring harness
connector only.
Between connectors N3, (1) and ATC3A, (3) 0.0 to 1.0Ω 3
A. Open or high
Resistance Ω Between connectors N3, (2) and ATC3A, (14) 0.0 to 1.0Ω 4
resistance
Between connectors N3, (1) and BRC3A, (13) 0.0 to 1.0Ω 5
At connector N3, between (1) and chassis ground. (OL) open 6
B. Short to chassis
ground or within Resistance Ω At connector N3, between (2) and chassis ground. (OL) open 7
harness
At connector N3, between (1) and (2) (OL) open 8
3. Retarder Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Retarder Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-779 1
TROUBLESHOOTING (BK-30) FAILURE CODE [DLT3KA]
Related circuit diagram
20-780 1 HM400-1L
TROUBLESHOOTING (BK-31) FAILURE CODE [DW71KZ]
Steps Circuit Diagnostic Procedures For Failure Code [DW71KZ] Specifications No. Readings
A. Short to Between connector B29, (1) and chassis ground. (OL) open 3
chassis ground Resistance Ω
or within harness At connector B29, between (1) and (2) (OL) open 4
B. Open or high Between connectors B29, (1) and BRC1, (3) 0.0 to 1.0Ω 5
resistance Resistance Ω
Between connector B29, (2) and chassis ground. 0.0 to 1.0Ω 6
HM400-1L 20-781 1
TROUBLESHOOTING (BK-32) FAILURE CODE [DK72KX]
Steps Circuit Diagnostic Procedures For Failure Code [DK72KX] Specifications No. Readings
1. Dump Lever Switch
• With ignition switch in the "OFF" position.
• Disconnect (HSL) connector from dump lever and isolate dump lever.
• Disconnect (LKO) connector from resistor and isolate resistor.
• Zero meter leads for proper Ω readings.
At switch HSL, between (1) and (4) 1
At switch HSL, between (1) and (2) 2
A. Open or high Between connectors HSL, (3) and BRC3B, (12) 0.0 to 1.0Ω 8
Resistance Ω
resistance Between connectors HSL, (4) and BRC3A, (6) 0.0 to 1.0Ω 9
Between connectors LKO, (1) and BRC1, (11) 0.0 to 1.0Ω 10
Between connectors LKO, (2) and chassis ground. 0.0 to 1.0Ω 11
At connector HSL, between (1) and chassis ground. (OL) open 12
At connector HSL, between (2) and chassis ground. (OL) open 13
At connector HSL, between (3) and chassis ground. (OL) open 14
B. Short to chassis At connector HSL, between (4) and chassis ground. (OL) open 15
ground or within Resistance Ω
harness At connector LKO, between (1) and (2) (OL) open 16
At connector HSL, between (1) and (2), (3), (4) (OL) open 17
At connector HSL, between (2) and (3), (4) (OL) open 18
At connector HSL, between (3) and (4) (OL) open 19
3. Retarder Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Retarder Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-782 1 HM400-1L
TROUBLESHOOTING (BK-32) FAILURE CODE [DK72KX]
Related circuit diagram
HM400-1L 20-783 1
TROUBLESHOOTING (BK-33) FAILURE CODE [DW73KZ]
Steps Circuit Diagnostic Procedures For Failure Code [DW73KZ] Specifications No. Readings
A. Dump pilot valve At switch B32, between (1) and (2) 5 to 20Ω 2
Resistance Ω
test At resistor B31, between (1) or (2) and chassis ground. (OL) open 3
At resistor B32, between (1) or (2) and chassis ground. (OL) open 4
A. Open or high Between connectors B31, (2) and chassis ground. 0.0 to 1.0Ω 6
Resistance Ω
resistance Between connectors B32, (1) and BRC2, (10) 0.0 to 1.0Ω 7
20-784 1 HM400-1L
TROUBLESHOOTING (BK-33) FAILURE CODE [DW73KZ]
Related circuit diagram
HM400-1L 20-785 1
TROUBLESHOOTING (BK-34) FAILURE CODE [DX11KA]
Steps Circuit Diagnostic Procedures For Failure Code [DX11KA] Specifications No. Readings
A. Short to Between connector B18, (1) and chassis ground. (OL) open 3
chassis ground Resistance Ω
or within harness At connector B18, between (1) and (2) (OL) open 4
B. Open or high Between connectors B18, (1) and BRC2, (9) 0.0 to 1.0Ω 5
resistance Resistance Ω
Between connectors B18, (2) and BRC2, (19) 0.0 to 1.0Ω 6
3. Retarder Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Retarder Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-786 1 HM400-1L
TROUBLESHOOTING (BK-35) FAILURE CODE [DX11KB]
Steps Circuit Diagnostic Procedures For Failure Code [DX11KB] Specifications No. Readings
A. Short to Between connector B18, (1) and chassis ground. (OL) open 3
chassis ground Resistance Ω
or within harness At connector B18, between (1) and (2) (OL) open 4
B. Open or high Between connectors B18, (1) and BRC2, (9) 0.0 to 1.0Ω 5
resistance Resistance Ω
Between connectors B18, (2) and BRC2, (19) 0.0 to 1.0Ω 6
3. Retarder Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Retarder Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-787 1
TROUBLESHOOTING (BK-36) FAILURE CODE [DX11KY]
Steps Circuit Diagnostic Procedures For Failure Code [DX11KY] Specifications No. Readings
A. Short to Between connector B18, (1) and chassis ground. (OL) open 3
chassis ground Resistance Ω
or within harness At connector B18, between (1) and (2) (OL) open 4
B. Open or high Between connectors B18, (1) and BRC2, (9) 0.0 to 1.0Ω 5
resistance Resistance Ω
Between connectors B18, (2) and BRC2, (19) 0.0 to 1.0Ω 6
3. Retarder Controller Unit
• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Retarder Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
20-788 1 HM400-1L
TROUBLESHOOTING (BK-37) FAILURE CODE [DX12KA]
Steps Circuit Diagnostic Procedures For Failure Code [DX12KA] Specifications No. Readings
B. Open or high Between connectors B19, (1) and BRC2, (8) 0.0 to 1.0Ω 5
resistance Resistance Ω
Between connectors B19, (2) and BRC2, (18) 0.0 to 1.0Ω 6
HM400-1L 20-789 1
TROUBLESHOOTING (BK-38) FAILURE CODE [DX12KB]
Steps Circuit Diagnostic Procedures For Failure Code [DX12KB] Specifications No. Readings
B. Open or high Between connectors B19, (1) and BRC2, (8) 0.0 to 1.0Ω 5
resistance Resistance Ω
Between connectors B19, (2) and BRC2, (18) 0.0 to 1.0Ω 6
20-790 1 HM400-1L
TROUBLESHOOTING (BK-39) FAILURE CODE [DX13KA]
Steps Circuit Diagnostic Procedures For Failure Code [DX13KA] Specifications No. Readings
1. Dump Pilot Valve
• With ignition switch in the “OFF” position.
• Disconnect (B31) connector from dump pilot valve and isolate dump pilot valve.
• Disconnect (B32) connector from dump pilot valve and isolate dump pilot valve.
• Zero meter leads for proper Ω readings.
At valve B31, between (1) and (2) 15 to 35Ω 1
A. Dump pilot valve At switch B32, between (1) and (2) 5 to 20Ω 2
Resistance Ω
test At resistor B31, between (1) or (2) and chassis ground. (OL) open 3
At resistor B32, between (1) or (2) and chassis ground. (OL) open 4
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (B31 and B32) connectors from dump pilot valves and isolate connectors.
• Disconnect (BRC1 and BRC2) connector from the retarder controller and install T-adapter on (BRC1 and BRC2) wiring harness connector only.
Between connectors B31, (1) and BRC1, (12) 0.0 to 1.0Ω 5
A. Open or high Between connectors B31, (2) and chassis ground. 0.0 to 1.0Ω 6
Resistance Ω
resistance Between connectors B32, (1) and BRC2, (10) 0.0 to 1.0Ω 7
Between connectors B32, (2) and BRC2, (20) 0.0 to 1.0Ω 8
At connector B31, between (1) and chassis ground. (OL) open 9
At connector B32, between (1) and chassis ground. (OL) open 10
B. Short to
chassis ground Resistance Ω At connector B32, between (2) and chassis ground. (OL) open 11
or within harness
At connector B31, between (1) and (2) (OL) open 12
At connector B32, between (1) and (2) (OL) open 13
3. Retarder And Retarder Controller Units
• No testing procedure for the controllers.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Retarder or Retarder
Controller Unit. Be sure all steps are completed correctly before faulting the controller unit.
HM400-1L 20-791 1
TROUBLESHOOTING (BK-39) FAILURE CODE [DX13KA]
Related circuit diagram
20-792 1 HM400-1L
TROUBLESHOOTING (BK-40) FAILURE CODE [DX13KB]
Steps Circuit Diagnostic Procedures For Failure Code [DX13KB] Specifications No. Readings
A. Dump pilot valve At switch B32, between (1) and (2) 5 to 20Ω 2
Resistance Ω
test At resistor B31, between (1) or (2) and chassis ground. (OL) open 3
At resistor B32, between (1) or (2) and chassis ground. (OL) open 4
A. Open or high Between connectors B31, (2) and chassis ground. 0.0 to 1.0Ω 6
Resistance Ω
resistance Between connectors B32, (1) and BRC2, (10) 0.0 to 1.0Ω 7
HM400-1L 20-793 1
TROUBLESHOOTING (BK-40) FAILURE CODE [DX13KB]
Related circuit diagram
20-794 1 HM400-1L
TROUBLESHOOTING (BK-41) FAILURE CODE [DX13KY]
Steps Circuit Diagnostic Procedures For Failure Code [DX13KY] Specifications No. Readings
A. Dump pilot valve At switch B32, between (1) and (2) 5 to 20Ω 2
Resistance Ω
test At resistor B31, between (1) or (2) and chassis ground. (OL) open 3
At resistor B32, between (1) or (2) and chassis ground. (OL) open 4
A. Open or high Between connectors B31, (2) and chassis ground. 0.0 to 1.0Ω 6
Resistance Ω
resistance Between connectors B32, (1) and BRC2, (10) 0.0 to 1.0Ω 7
HM400-1L 20-795 1
TROUBLESHOOTING (BK-41) FAILURE CODE [DX13KY]
Related circuit diagram
20-796 1 HM400-1L
TROUBLESHOOTING (BK-42) FAILURE CODE [DX14KZ]
Steps Circuit Diagnostic Procedures For Failure Code [DX14KZ] Specifications No. Readings
A. Short to Between connector B36, (1) and chassis ground. (OL) open 3
chassis ground Resistance Ω
or within harness At connector B36, between (1) and (2) (OL) open 4
B. Open or high Between connectors B36, (1) and BRC1, (2) 0.0 to 1.0Ω 5
resistance Resistance Ω
Between connector B36, (2) and chassis ground. 0.0 to 1.0Ω 6
HM400-1L 20-797 1
TROUBLESHOOTING (BK-43) FAILURE CODE [DX15KZ]
Steps Circuit Diagnostic Procedures For Failure Code [DX15KZ] Specifications No. Readings
A. Short to Between connector B35, (1) and chassis ground. (OL) open 3
chassis ground Resistance Ω
or within harness At connector B35, between (1) and (2) (OL) open 4
B. Open or high Between connectors B35, (1) and BRC1, (2) 0.0 to 1.0Ω 5
resistance Resistance Ω
Between connector B35, (2) and chassis ground. 0.0 to 1.0Ω 6
20-798 1 HM400-1L
TROUBLESHOOTING (BK-43) FAILURE CODE [DX15KZ]
Related circuit diagram
HM400-1L 20-799 1
TROUBLESHOOTING (BK-44) NO FAILURE CODE DISPLAYED
Steps Circuit Diagnostic Procedures For Failure Code [NONE] Specifications No. Readings
At switch B20, between (1) or (2) and chassis ground. (OL) open 6
A. Switch test Resistance Ω
At switch B21, between (1) and (2) (OL) open 7
At switch B21, between (1) or (2) and chassis ground. (OL) open 8
A. Short to Between connection B20, (1) and chassis ground. (OL) open 11
chassis ground Resistance Ω Between connection B20, (2) and chassis ground. (OL) open 12
or within harness
Between connection R33, (1) and chassis ground. (OL) open 13
20-800 1 HM400-1L
TROUBLESHOOTING (BK-44) NO FAILURE CODE DISPLAYED
Between connection R33, (1) and R19, (1), (3) 0.0 to 1.0Ω 17
B. Open or high Between connection R33, (2) and B21, (1) 0.0 to 1.0Ω 18
resistance Between connection R19, (2) and chassis ground. 0.0 to 1.0Ω 19
Resistance Ω
Between connection B14, (2) and chassis ground. 0.0 to 1.0Ω 20
HM400-1L 20-801 1
TESTING AND ADJUSTING (BK-44) NO FAILURE CODE DISPLAYED
20-802 HM400-1L
TROUBLESHOOTING MACHINE MONITOR
PANEL SYSTEM (MON MODE)
HM400-1L 20-901 1
TESTING AND ADJUSTING TABLE OF CONTENTS
INNER AXLE DIFFERENTIAL LOCK SYSTEM DOES NOT WORK PROPERLY . . . . . . . . . . . . . . . 20-953
(MON-22) NO FAILURE CODE DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-955
EXHAUST BRAKE DOES NOT WORK PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-955
(MON-23) NO FAILURE CODE DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-957
SEAT BELT CAUTION LAMP DOES NOT WORK PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-957
(MON-24) NO FAILURE CODE DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-959
SIGNAL OR HAZARD LAMPS DO NOT WORK PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-959
(MON-25) NO FAILURE CODE DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-962
HEAD AND TAIL LAMPS DO NOT WORK PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-962
20-902 1 HM400-1L
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
HM400-1L 20-903 1
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
20-904 1 HM400-1L
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
HM400-1L 20-905 1
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
20-906 1 HM400-1L
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
HM400-1L 20-907 1
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
20-908 1 HM400-1L
TROUBLESHOOTING MON CONTROL SYSTEM CIRCUIT DIAGRAM
HM400-1L 20-909 1
TROUBLESHOOTING MON CONTROL SYSTEM CIRCUIT DIAGRAM
20-910 1 HM400-1L
TROUBLESHOOTING MON CONTROL SYSTEM CIRCUIT DIAGRAM
12
HM400-1L 20-911 1
TROUBLESHOOTING MON CONTROL SYSTEM CIRCUIT DIAGRAM
20-912 1 HM400-1L
TROUBLESHOOTING MON CONTROL SYSTEM CIRCUIT DIAGRAM
HM400-1L 20-913 1
TROUBLESHOOTING MON CONTROL SYSTEM CIRCUIT DIAGRAM
20-914 1 HM400-1L
TROUBLESHOOTING MON CONTROL SYSTEM CIRCUIT DIAGRAM
12
MEMORANDUM
HM400-1L 20-915 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
Front brake oil: Overheat Front brake cooling oil is over- • Front brake cooling oil is overheated
B@C6NS
(NS) heated (when system is working normally)
(MON-1)
• Defective machine monitor
Rear brake oil: Overheat Rear brake cooling oil is overheated • Rear brake cooling oil is overheated
B@C7NS
(NS) (when system is working normally)
(MON-2)
• Defective machine monitor
Center brake oil: Overheat Centre brake cooling oil is over- • Centre brake cooling oil is overheated
B@C8NS
(NS) heated (when system is working normally)
(MON-3)
• Defective machine monitor
Torque converter: Overheat Torque converter is overheated • Torque converter oil is overheated
B@CENS
(NS) (when system is working normally)
(MON-4)
• Defective machine monitor
Monitor panel: Mistaken Option setting of rotary switch at • Defective setting of rotary switch, dip
operation or mistaken setting rear of machine monitor and dip switch, or option connector (when sys-
DAFOKM (KM)) switches does not match signal tem is working normally)
(MON-5) from option setting connector • Open or short circuit in r circuit wiring
harness
• Defective machine monitor
Monitor panel: Mistaken Check signal of connector does not • Mistaken connection of connector
operation or mistaken setting match internal setting of machine DPC2 (A, B) and connector DPC3 (A,
DAF9KM (KM)) monitor B) (when system is working normally)
(MON-6) • Open or short circuit with chassis
ground in signal 1 circuit wiring harness
• Defective machine monitor
Monitor panel: Monitor panel: Communication (S-NET) with trans- • Open or short circuit with chassis
Non match in model selec- mission controller is defective and ground, or short circuit with power
DAFSKQ tion signal (KQ) model selector information cannot source in S-NET circuit wiring harness
(MON-7) be received, or setting of transmis- • Defective transmission controller
sion controller rotary switch is not • Defective machine monitor
correct
Transmission controller S- S-NET data cannot be received • Open or short circuit with chassis
NET: Defective communica- from transmission controller ground, or short circuit with power
DAQSKR tion, abnormality in corre- source in S-NET (+) circuit wiring har-
(MON-8) sponding component system ness
(KR) • Defective transmission controller
• Defective machine monitor
Retarder controller (q1) S- S-NET data cannot be received • Open or short, short circuit with chassis
NET: Defective communica- from retarder controller ground, or short circuit with power
DB1SKR tion, abnormality in corre- source in S-NET (+) circuit wiring har-
(MON-9) sponding component system ness
(KR) • Defective retarder controller (❋)
• Defective machine monitor
Engine controller S-NET: Unable to receive S-NET informa- • Wiring harness in S-NET (+) circuit dis-
Defective communication, tion from engine controller connected or connected defectively or
DB2SKR abnormality in corresponding short-circuit
(MON-10) component system (KR) • Engine controller faulty
• Machine monitor faulty
Alarm buzzer: Short-circuit Alarm buzzer output circuit short- • Alarm buzzer faulty
DV00KB (KB) circuit • Wiring harness in alarm buzzer output
(MON-11) circuit short-circuit
• Machine monitor faulty
❋ The code (MON-**) given below the failure code is the troubleshooting number
20-916 1 HM400-1L
TROUBLESHOOTING CONTENT OF CODE DISPLAY
Action
Condition When Normal Action By Controller Problem That Appears On Machine
Code
• Takes no action • If machine continues to be used as it
is, there is danger that front brake E02
will break
• Takes no action • If machine continues to be used as it
is, there is danger that rear brake will E02
break
• Takes no action • If machine continues to be used as it
is, there is danger that centre brake E02
will break
• Takes no action • If machine continues to be used as it
is, there is danger that torque con- E02
verter will break
• Wiring harness resistance value • Holds abnormal condition until igni- • Some functions (options) do not
DPC3A (female) tion switch is turned OFF work
(4)(6)(7)(13)(14)(15) - ground • Does not recognize functions (op-
• When connector is connected: tions) where setting does not match E03
Max. 1 W • Does not record as trouble data
• When connector is discon-
nected: Min. 1 MW
• Signal voltage • Holds abnormal condition until igni-
DPC2A (female) (5) - ground: tion switch is turned OFF
20 - 30 V • Does not record as trouble data
E03
• S-NET voltage • Holds condition existing when prob- • Meters, gauges, cautions, special
Between DPC4 (1)(2) and (4)(5): lem occurred function receiving data from trans-
6-9V mission controller do not work or E03
Between ATC4 (6)(12) and (10): give any display
6-9V
• S-NET voltage • Holds condition existing when prob- • Cautions, special function receiving
Between DPC4 (1)(2) and (4)(5): lem occurred data from retarder controller (q1) do
6-9V not work or give any display E03
Between ATC4 (6)(12) and (10):
6-9V
• S-NET voltage • Holds condition existing when prob- • Cautions, special function receiving
• Between DPC4 (1)(2) and (4)(5): lem occurred data from engine controller do not
6-9V work or give any display E03
• Between CN2 (8)(18) and (6):
6-9V
• Output circuit voltage • Holds abnormal condition until igni- • Alarm buzzer does not sound
DPC1 (13) - (9)(10): When tion switch is turned OFF
buzzer is stopped: 20 - 30 V. • Turns buzzer output circuit OFF E01
When buzzer is sounding: 1 V
HM400-1L 20-917 1
TROUBLESHOOTING INFORMATION CONTAINED IN TESTING PROCEDURES
● Failure.
Contents Of Trouble ● Failure code displayed.
● Additional information.
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
Steps Circuit Diagnostic Procedures For Service Code Specifications No. Readings
1. Sensor or Actuator
• With ignition switch in the “OFF” position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸)
• Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
• Zero meter leads for proper Ω readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)
Your
Test procedure for component only. readings 1
Resistance Ω information
A. What you are testing
or Voltage Your
Test procedure for component only. readings 2
information
2. Diode Test
• With ignition switch in the “OFF” position. (The importance of these tests are to isolate each component for testing separately)
• When checking a diode always isolate the circuit. Check diode continuity in both directions reversing meter leads each time to confirm
electrical flow. Electrical flow should be one way only. (See section 20-111 for detail).
At a diode, between point (x) and (x) Continuity one
A. Diode test Resistance Ω 3 Yes or No
reverse meter lead polarity each time to check diode. way only?
3. Wiring Harness Assembly Test
• With ignition switch in the “OFF” position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸)
• Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
• Zero meter leads for proper Ω readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)
Your
Test procedure for harness. (connector) to (connector) readings 4
A. Open or high Resistance Ω information
resistance or Voltage Your
Test procedure for harness. (connector) to (connector) readings 5
information
Your
B. Short to chassis Test procedure for harness. (connector) to (connector) readings 6
Resistance Ω information
ground or within
or Voltage Your
harness Test procedure for harness. (connector) to (connector) readings 7
information
4. Additional Components To Be Tested
• With ignition switch in the “OFF” position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸)
• Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
• Zero meter leads for proper Ω readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)
Resistance Ω Your
A. What you are testing Test procedure for any additional components. readings 8
or Voltage information
20-918 1 HM400-1L
TROUBLESHOOTING INFORMATION CONTAINED IN TESTING PROCEDURES
Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
HM400-1L 20-919 1
TROUBLESHOOTING (MON-1) FAILURE CODE [B@C6NS]
12
(MON-1) FAILURE CODE [B@C6NS]
Cause Remedy
NO
Defective machine monitor Repair
Cause Remedy
NO
Defective machine monitor Repair
20-920 1 HM400-1L
TROUBLESHOOTING (MON-3) FAILURE CODE [B@C8NS]
Cause Remedy
NO
Defective machine monitor Repair
Cause Remedy
NO
Defective machine monitor Repair
HM400-1L 20-921 1
TROUBLESHOOTING (MON-5) FAILURE CODE [DAF0KM]
Contents Of Trouble
● The option setting of the rotary switch at the rear of the machine monitor and dip switches does
not match the signal from the option setting connector
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
Steps Circuit Diagnostic Procedures For Action Code [E03] Specifications No. Readings
Dip Switches ⎯ Check setting on dip switches first Setting correct? 1 Yes or No
A. Open or high Between connector DPC3A, (7) and chassis ground. 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connector DPC3A, (13) and chassis ground. 0.0 to 1.0Ω 5
20-922 1 HM400-1L
TROUBLESHOOTING (MON-5) FAILURE CODE [DAF0KM]
Related circuit diagram
HM400-1L 20-923 1
TROUBLESHOOTING (MON-6) FAILURE CODE [DAF9KM]
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
Steps Circuit Diagnostic Procedures For Action Code [E03] Specifications No. Readings
A. Open or high
Voltage At connector DPC2A, (5) and chassis ground. 20 to 30V 2
resistance
20-924 1 HM400-1L
TROUBLESHOOTING (MON-7) FAILURE CODE [DAFSKQ]
12
(MON-7) FAILURE CODE [DAFSKQ]
★ Communication (S-NET) with the transmission controller is defective and the model selector information cannot be
received, or the setting of the transmission controller rotary switch is not correct
Cause Remedy
YES
YES
Defective machine controller Replace
HM400-1L 20-925 1
TROUBLESHOOTING (MON-8) FAILURE CODE [DAQSKR]
● The S-NET data cannot be received from the transmission controller. Check that the continuity
Contents Of Trouble of the junction
connectors (JCB, JCC, JCD, JCE, JCF, JCG) is normal.
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
Steps Circuit Diagnostic Procedures For Action Code [E03] Specifications No. Readings
1. Wiring Harness Assembly Test
• With ignition switch in the “OFF” position.
• Disconnect transmission controller (ATC4) and install T-adapter on wiring harness only.
• Disconnect retarder controller (BRC4) and install T-adapter on wiring harness only.
• Disconnect engine controller (CN2) and install T-adapter on wiring harness only.
• Disconnect monitor controller (DPC4) and install T-adapter on wiring harness only.
A. Open or high Between connector DPC4, (2) and CN2, (8) 0.0 to 1.0Ω 6
Resistance Ω
resistance Between connector DPC4, (4) and BRC4, (10) 0.0 to 1.0Ω 7
20-926 1 HM400-1L
TROUBLESHOOTING (MON-8) FAILURE CODE [DAQSKR]
Related circuit diagram
HM400-1L 20-927 1
TROUBLESHOOTING (MON-9) FAILURE CODE [DA1SKR]
● The S-NET data cannot be received from the transmission controller. Check that the continuity
Contents Of Trouble of the junction
connectors (JCB, JCC, JCD, JCE, JCF, JCG) is normal.
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
Steps Circuit Diagnostic Procedures For Action Code [E03] Specifications No. Readings
1. Wiring Harness Assembly Test
• With ignition switch in the “OFF” position.
• Disconnect transmission controller (ATC4) and install T-adapter on wiring harness only.
• Disconnect retarder controller (BRC4) and install T-adapter on wiring harness only.
• Disconnect engine controller (CN2) and install T-adapter on wiring harness only.
• Disconnect monitor controller (DPC4) and install T-adapter on wiring harness only.
A. Open or high Between connector DPC4, (2) and CN2, (8) 0.0 to 1.0Ω 6
Resistance Ω
resistance Between connector DPC4, (4) and BRC4, (10) 0.0 to 1.0Ω 7
20-928 1 HM400-1L
TROUBLESHOOTING (MON-9) FAILURE CODE [DA1SKR]
Related circuit diagram
HM400-1L 20-929 1
TROUBLESHOOTING (MON-10) FAILURE CODE [DA2SKR]
● The S-NET data cannot be received from the transmission controller. Check that the continuity
Contents Of Trouble of the junction
connectors (JCB, JCC, JCD, JCE, JCF, JCG) is normal.
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
Steps Circuit Diagnostic Procedures For Action Code [E03] Specifications No. Readings
1. Wiring Harness Assembly Test
• With ignition switch in the “OFF” position.
• Disconnect transmission controller (ATC4) and install T-adapter on wiring harness only.
• Disconnect retarder controller (BRC4) and install T-adapter on wiring harness only.
• Disconnect engine controller (CN2) and install T-adapter on wiring harness only.
• Disconnect monitor controller (DPC4) and install T-adapter on wiring harness only.
A. Open or high Between connector DPC4, (2) and CN2, (8) 0.0 to 1.0Ω 6
Resistance Ω
resistance Between connector DPC4, (4) and BRC4, (10) 0.0 to 1.0Ω 7
20-930 1 HM400-1L
TROUBLESHOOTING (MON-10) FAILURE CODE [DA2SKR]
Related circuit diagram
HM400-1L 20-931 1
TROUBLESHOOTING (MON-11) FAILURE CODE [DV00KB]
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
Steps Circuit Diagnostic Procedures For Action Code [E01] Specifications No. Readings
B. Short to chassis
ground or within Resistance Ω At connector DPC1, between (13) and chassis ground. (OL) open 7
harness
20-932 1 HM400-1L
TROUBLESHOOTING (MON-11) FAILURE CODE [DV00KB]
Related circuit diagram
HM400-1L 20-933 1
TROUBLESHOOTING (MON-12) NO FAILURE CODE DISPLAYED
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
Fuse Check ⎯ Check fuses (BT2-2, BT2-20 and BT2-22) condition Fuses OK? 1 Yes or No
20-934 1 HM400-1L
TROUBLESHOOTING (MON-12) NO FAILURE CODE DISPLAYED
Related circuit diagram
HM400-1L 20-935 1
TROUBLESHOOTING (MON-13) NO FAILURE CODE DISPLAYED
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
Fuse Check ⎯ Check fuses (BT2-2, BT2-20 and BT2-22) condition Fuses OK? 1 Yes or No
20-936 1 HM400-1L
TROUBLESHOOTING (MON-13) NO FAILURE CODE DISPLAYED
Related circuit diagram
HM400-1L 20-937 1
TROUBLESHOOTING (MON-14) NO FAILURE CODE DISPLAYED
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
1. Caution Buzzer
• With ignition switch in the "OFF" position.
• Disconnect (BZ2) connector from buzzer and isolate buzzer.
• Zero meter leads for proper Ω readings.
B. Short to chassis
ground or within Resistance Ω At connector DPC1, between (13) and chassis ground. (OL) open 7
harness
20-938 1 HM400-1L
TROUBLESHOOTING (MON-14) NO FAILURE CODE DISPLAYED
Related circuit diagram
HM400-1L 20-939 1
TROUBLESHOOTING (MON-15) NO FAILURE CODE DISPLAYED
12
(MON-15) NO FAILURE CODE DISPLAYED
Cause Remedy
YES
YES
Replace
Defective machine monitor
Cause Remedy
YES
YES
Replace
Defective machine monitor
YES
Replace
Defective machine monitor
20-940 1 HM400-1L
TROUBLESHOOTING (MON-16) NO FAILURE CODE DISPLAYED
Contents Of Trouble ● Even when the machine monitor check switch is pressed, no lamps or gauges work, or
even when the machine monitor check switch is released, all the lamps stay ON.
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
At switch CK1, between (3) and (6), switch released. (OL) open 2
A. Check switch Resistance Ω At switch CK1, between (3) and (6), switch pressed. 0.0 to 1.0Ω 3
At switch CK1, between (3) or (6) and chassis ground. (OL) open 4
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (CK1) connector from monitor check switch and isolate connectors.
• Disconnect (DPC2A) connector from the monitor controller and install T-adapter on (DPC2A) wiring harness connector only.
• ✸ Turn ignition switch to the “ON” position for this test.
A. Open or high Voltage ✸ Between connector CK1, (3) and chassis ground. 20 to 30V 5
resistance Resistance Ω Between connectors CK1, (6) and DPC2A, (10) 0.0 to 1.0Ω 6
B. Short to chassis At connector CK1, between (6) and chassis ground. (OL) open 7
ground or within Resistance Ω
harness At connector CK1, between (3) and (6) (OL) open 8
HM400-1L 20-941 1
TROUBLESHOOTING (MON-16) NO FAILURE CODE DISPLAYED
Related circuit diagram
20-942 1 HM400-1L
TROUBLESHOOTING (MON-17) NO FAILURE CODE DISPLAYED
Contents Of Trouble ● Even when the machine monitor switches 1 or 2 are operated nothing happens.
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
Fuse Check ⎯ Check fuse (BT2-2 and BT2-22) Fuse good? 1 Yes or No
At switch CH1, between (2) and (3), switch in [U] 0.0 to 1.0Ω 2
At switch CH1, between (2) and (3), switch in neutral. (OL) open 3
At switch CH1, between (1) and (3), switch in neutral. (OL) open 4
At switch CH1, between (1) and (3), switch in [u] 0.0 to 1.0Ω 5
A. Mode switches Resistance Ω
At switch CH2, between (2) and (3), switch in [>] 0.0 to 1.0Ω 6
At switch CH2, between (2) and (3), switch in neutral. (OL) open 7
At switch CH2, between (1) and (3), switch in neutral. (OL) open 8
At switch CH2, between (1) and (3), switch in [<] 0.0 to 1.0Ω 9
A. Open or high Between connectors CH1, (1) and DPC2A, (14) 0.0 to 1.0Ω 12
resistance Between connectors CH1, (2) and DPC2A, (8) 0.0 to 1.0Ω 13
Resistance Ω
Between connectors CH2, (2) and DPC2A, (6) 0.0 to 1.0Ω 14
Between connectors CH2, (1) and DPC2A, (15) 0.0 to 1.0Ω 15
HM400-1L 20-943 1
TROUBLESHOOTING (MON-17) NO FAILURE CODE DISPLAYED
Fuse Check ⎯ Check fuse (BT2-2 and BT2-22) Fuse good? 1 Yes or No
20-944 1 HM400-1L
TROUBLESHOOTING (MON-18) NO FAILURE CODE DISPLAYED
● Even when the power mode selection switch is operated, the power mode switching function
Contents Of Trouble does not work normally, or the power mode pilot lamp does not light up and go out normally
(no failure code is displayed).
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
At switch PWM, between (1) and (3), switch UP. (OL) open 2
A. Mode switch Resistance Ω At switch PWM, between (1) and (3), switch DOWN. 0.0 to 1.0Ω 3
At switch PWM, between (1) or (3) and chassis ground. (OL) open 4
A. Open or high Voltage ✸ Between connector PWM, (1) and chassis ground. 20 to 30V 5
resistance Resistance Ω Between connectors PWM, (3) and DPC2A, (13) 0.0 to 1.0Ω 6
B. Short to chassis At connector PWM, between (3) and chassis ground. (OL) open 7
ground or within Resistance Ω
harness At connector PWM, between (1) and (3) (OL) open 8
HM400-1L 20-945 1
TROUBLESHOOTING (MON-18) NO FAILURE CODE DISPLAYED
Related circuit diagram
20-946 1 HM400-1L
TROUBLESHOOTING (MON-19) NO FAILURE CODE DISPLAYED
Contents Of Trouble ● Even when the AISS switch is operated, the AISS function does not work normally.
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
At switch AISS, between (1) and (3), switch UP. (OL) open 2
A. AISS switch Resistance Ω At switch AISS, between (1) and (3), switch DOWN. 0.0 to 1.0Ω 3
At switch AISS, between (1) or (3) and chassis ground. (OL) open 4
A. Open or high Voltage ✸ Between connector AISS, (1) and chassis ground. 20 to 30V 5
resistance Resistance Ω Between connectors AISS, (3) and DPC2A, (2) 0.0 to 1.0Ω 6
B. Short to chassis At connector AISS, between (3) and chassis ground. (OL) open 7
ground or within Resistance Ω
harness At connector AISS, between (1) and (3) (OL) open 8
HM400-1L 20-947 1
TROUBLESHOOTING (MON-19) NO FAILURE CODE DISPLAYED
Related circuit diagram
20-948 1 HM400-1L
TROUBLESHOOTING (MON-20) NO FAILURE CODE DISPLAYED
RIGHT AND LEFT DIFFERENTIAL LOCK SWITCH DOES NOT WORK PROP-
ERLY
Contents Of Trouble ● Even when the differential switch is operated, the differential function does not work normally.
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
At switch DFL, between (1) and (3), switch UP. 0.0 to 1.0Ω 2
A. Lock switches Resistance Ω At switch DFL, between (1) and (3), switch in neutral. (OL) open 3
At switch DFL, between (1) and (3), switch DOWN. 0.0 to 1.0Ω 4
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (DFL) connector from differential lock switch and isolate connectors.
• Disconnect (DPC3A) connector from the monitor controller and install T-adapter on (DPC3A) wiring harness connector only.
• ✸ Turn ignition switch to the “ON” position for this test.
Voltage ✸ Between connector DFL, (1) and chassis ground. 20 to 30V 5
A. Open or high
Between connectors DFL, (2) and DPC3A, (2) 0.0 to 1.0Ω 6
resistance Resistance Ω
Between connectors DFL, (3) and DPC3A, (3) 0.0 to 1.0Ω 7
At connector DFL, between (2) and chassis ground. (OL) open 8
B. Short to chassis At connector DFL, between (3) and chassis ground. (OL) open 9
ground or within Resistance Ω
harness At connector DFL, between (1) and (2) (OL) open 10
At connector DFL, between (1) and (2), (3) (OL) open 11
HM400-1L 20-949 1
TROUBLESHOOTING (MON-20) NO FAILURE CODE DISPLAYED
Related circuit diagram
20-950 1 HM400-1L
TROUBLESHOOTING (MON-20) NO FAILURE CODE DISPLAYED
LEFT AND RIGHT DIFFERENTIAL PEDAL LOCK SYSTEM DOES NOT WORK
PROPERLY
Contents Of Trouble ● Differential pedal lock system does not work properly.
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
At switch DFS, between (A) and (B), switch released. (OL) open 2
A. Pedal switch Resistance Ω At switch DFS, between (A) and (B), switch depressed. 0.0 to 1.0Ω 3
At switch DFS, between (A) or (B) and chassis ground. (OL) open 4
2. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (DFS) connector from lock switch and isolate connectors.
• Disconnect (DPC3A) connector from the monitor controller and install T-adapter on (DPC3A) wiring harness connector only.
• ✸ Turn ignition switch to the “ON” position for this test.
A. Open or high Voltage ✸ Between connector DFS, (A) and chassis ground. 20 to 30V 5
resistance Resistance Ω Between connectors DFS, (B) and DPC3A, (1) 0.0 to 1.0Ω 6
B. Short to chassis
ground or within Resistance Ω At connector DFS, between (B) and chassis ground. (OL) open 7
harness
HM400-1L 20-951 1
TROUBLESHOOTING (MON-20) NO FAILURE CODE DISPLAYED
Related circuit diagram
20-952 1 HM400-1L
TROUBLESHOOTING (MON-21) NO FAILURE CODE DISPLAYED
Contents Of Trouble ● Inner axle lock system does not work properly.
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
At switch DEF, between (1) and (3), switch UP. (OL) open 2
A. Lock switch Resistance Ω At switch DEF, between (1) and (3), switch DOWN. 0.0 to 1.0Ω 3
At switch DEF, between (1) or (3) and chassis ground. (OL) open 4
A. Open or high Voltage ✸ Between connector DEF, (1) and chassis ground. 20 to 30V 5
resistance Resistance Ω Between connectors DEF, (3) and DPC2A, (12) 0.0 to 1.0Ω 6
B. Short to chassis
ground or within Resistance Ω At connector DEF, between (3) and chassis ground. (OL) open 7
harness
HM400-1L 20-953 1
TROUBLESHOOTING (MON-21) NO FAILURE CODE DISPLAYED
Related circuit diagram
20-954 1 HM400-1L
TROUBLESHOOTING (MON-22) NO FAILURE CODE DISPLAYED
● Even when the exhaust brake switch is operated, the exhaust brake does not work normally, or
Contents Of Trouble the exhaust brake pilot lamp does not light up and go out normally (no failure code is dis-
played).
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
At switch EXH, between (1) and (2), switch UP. 0.0 to 1.0Ω 2
At switch EXH, between (1) and (2), switch in neutral. (OL) open 3
A. Brake switches Resistance Ω
At switch EXH, between (1) and (3), switch in neutral. (OL) open 4
At switch EXH, between (1) and (3), switch DOWN. 0.0 to 1.0Ω 5
HM400-1L 20-955 1
TROUBLESHOOTING (MON-22) NO FAILURE CODE DISPLAYED
Related circuit diagram
20-956 1 HM400-1L
TROUBLESHOOTING (MON-23) NO FAILURE CODE DISPLAYED
Contents Of Trouble ● Seat belt warning system does not work properly.
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
At switch SBS, between (1) and (2), belt connected. (OL) open 2
A. Belt switch Resistance Ω
At switch SBS, between (1) and (2), belt disconnected. 0.0 to 1.0Ω 3
A. Open or high Voltage ✸ Between connector SBS, (1) and chassis ground. 20 to 30V 4
resistance Resistance Ω Between connectors SBS, (2) and DPC2B, (11) 0.0 to 1.0Ω 5
B. Short to chassis
ground or within Resistance Ω At connector SBS, between (2) and chassis ground. (OL) open 6
harness
HM400-1L 20-957 1
TROUBLESHOOTING (MON-23) NO FAILURE CODE DISPLAYED
Related circuit diagram
20-958 1 HM400-1L
TROUBLESHOOTING (MON-24) NO FAILURE CODE DISPLAYED
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
Fuse Check ⎯ Check condition of fuse (BT2-24 and BT1-4) Fuse good? 1 Yes or No
1. Relay Check
• With ignition switch in the "OFF" position.
• Disconnect listed relays and install a known good relays.
A. Relay test ⎯ Does system work normal when (R17) is replaced? ⎯ 2 Yes or No
B. Relay test ⎯ Does system work normal when (R16) is replaced? ⎯ 3 Yes or No
C. Flasher test ⎯ Does system work normal when flasher is replaced? ⎯ 4 Yes or No
At switch CM, between (6) and (7) switch in turn R. 0.0 to 1.0Ω 5
A. Switch test Resistance Ω
At switch CM, between (6) and (8) switch in turn L. 0.0 to 1.0Ω 6
HM400-1L 20-959 1
TROUBLESHOOTING (MON-24) NO FAILURE CODE DISPLAYED
Fuse Check ⎯ Check condition of fuse (BT2-24 and BT1-4) Fuse good? 1 Yes or No
1. Relay Check
• With ignition switch in the "OFF" position.
• Disconnect listed relays and install a known good relays.
B. Open or high At connector R16, between (1) and (3) 0.0 to 1.0Ω 22
Resistance Ω
resistance Between connectors R16, (2) and JO13, (4) 0.0 to 1.0Ω 23
At connector (P30) to chassis ground. 0.0 to 1.0Ω 24
20-960 1 HM400-1L
TROUBLESHOOTING (MON-24) NO FAILURE CODE DISPLAYED
Related circuit diagram
HM400-1L 20-961 1
TROUBLESHOOTING (MON-25) NO FAILURE CODE DISPLAYED
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
Fuse Check ⎯ Check condition of fuses BT1, (6), (8), (10), (12) Fuses good? 1 Yes or No
1. Relay Check
• With ignition switch in the "OFF" position.
• Disconnect listed relays and install a known good relays.
A. Relay test ⎯ Does system work normal when (R30) is replaced? ⎯ 2 Yes or No
B. Relay test ⎯ Does system work normal when (R29) is replaced? ⎯ 3 Yes or No
Does system work normal when passing relay is
C. Passing relay test ⎯ ⎯ 4 Yes or No
replaced?
At switch CM, between (3) and (1) switch ON. 0.0 to 1.0Ω 5
At switch CM, between (3) and (1) switch OFF. (OL) open 6
At switch CM, between (3) and (2) switch ON. 0.0 to 1.0Ω 7
Resistance Ω
At switch CM, between (3) and (2) switch OFF. (OL) open 8
A. Switch test
At switch CM, between (4) and (5) in HI beam. 0.0 to 1.0Ω 9
✸ At switch LS, between (2) and (3) turn switch left. 6 to 10V 11
Voltage
✸ At switch LS, between (2) and (3) turn switch right. 18 to 27V 12
20-962 1 HM400-1L
TROUBLESHOOTING (MON-25) NO FAILURE CODE DISPLAYED
Between connectors R29, (2), (4) and P01, (3), P32, (3) 0.0 to 1.0Ω 13
Between connectors R29, (2), (4) and DPC2A, (1) 0.0 to 1.0Ω 14
Between connectors R29, (2), (4) and R31, (8), (6) 0.0 to 1.0Ω 15
Between connectors R29, (1), (3) and CM, (1), (4) 0.0 to 1.0Ω 16
Between connectors R30, (6) and P01, (1), P32, (1) 0.0 to 1.0Ω 21
A. Open or high Between connectors R30, (3) and R31, (5), (7) 0.0 to 1.0Ω 22
Resistance Ω
resistance Between connectors R30, (2) and chassis ground. 0.0 to 1.0Ω 23
Between connectors LS, (1) and JO13, (3), (6) 0.0 to 1.0Ω 31
HM400-1L 20-963 1
TROUBLESHOOTING (MON-25) NO FAILURE CODE DISPLAYED
Related circuit diagram
20-964 1 HM400-1L
TROUBLESHOOTING FOR HYDRAULIC AND
MECHANICAL SYSTEM (H MODE)
(H-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1002
THE MACHINE DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1002
(H-2) AND (H-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1003
MACHINE DOES NOT TRAVEL SMOOTHLY (MOVEMENT IS JERKEY) . . . . . . . . . . . . . . . . . . . 20-1003
LOCK-UP CANNOT BE DISENGAGED (ENGINE STALLS WHEN STOPPING) . . . . . . . . . . . . . . . 20-1003
(H-4) AND (H-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1004
EXCESSIVE SHOCK WHEN STARTING TO MOVE OR SHIFTING GEARS . . . . . . . . . . . . . . . . . . 20-1004
TRANSMISSION WILL NOT UP SHIFT GEAR RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1004
(H-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1005
MACHINE LACKS POWER OR SPEED WHEN TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1005
(H-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1006
ABNORMAL OPERATION AT SOME SPEED RANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1006
(H-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1007
TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1007
(H-7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1008
TIME LAG EXCESSIVE DURING MOVEMENT OR SPEED RANGE CHANGES . . . . . . . . . . . . . . 20-1008
(H-8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1009
TORQUE CONVERTER OIL TEMPERATURE IS OUT OF RANGE (HIGH) . . . . . . . . . . . . . . . . . . . 20-1009
(H-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1010
TORQUE CONVERTER OIL PRESSURE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1010
(H-10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1011
FRONT BRAKE IS INEFFECTIVE OR INNEFECTIVE ON ONE SIDE ONLY . . . . . . . . . . . . . . . . . 20-1011
(H-11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1012
CENTER BRAKING SYSTEM IS INEFFECTIVE OR EFFECTIVE ON ONE SIDE . . . . . . . . . . . . . . 20-1012
(H-12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1013
REAR BRAKE IS INEFFECTIVE OR EFFECTIVE ON ONE SIDE ONLY . . . . . . . . . . . . . . . . . . . . . 20-1013
(H-13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1014
STEERING EFFERT SEAMS HEAVY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1014
(H-14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1015
STEERING SYSTEM DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1015
(H-15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1016
STEERING WHEEL VIBRATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1016
(H-16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1017
DUMP BODY LIFTING SPEED IS SLOW OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1017
(H-17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1018
DUMP OPERATIONS DO NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1018
(H-18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1019
EXCESSIVE HYDRAULIC DRIFT IN DUMP BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1019
HM400-1L 20-1001 1
TROUBLESHOOTING (H-1)
12
(H-1)
Clogging of strainer
Remedy ∆ ∆
No. X C ∆ X X X X X X X X X
Diagnosis X X
1 Abnormal noise between power train pump and filter
2 The machine does not move in any specific gear range
3 The machine moves normal in certain speed ranges.
4 When trans. oil temp. rises, machine still does not move
5 Slow in every speed range
Slow at certain speed
6 Measure power train main
relief pressure. ranges
Pressure gauge readings
7 unstable
Clutch Used
F1 ● ●
F2 ● ●
F3 ● ●
F4 ● ●
F5 ● ●
F6 ● ●
20-1002 1 HM400-1L
TROUBLESHOOTING (H-2) AND (H-3)
12
(H-2) AND (H-3)
Remedy C ∆
No. Diagnosis X X X
1 When lock-up clutch pressure is measured it does not go down to 0
2 When lock-up clutch pressure is measured it is at 0, but lock-up clutch is not disengaged
3 Operation of lock-up ECMV valve is normal
4 Operation of lock-up ECMV solenoid is normal
HM400-1L 20-1003 1
TROUBLESHOOTING (H-4) AND (H-5)
Remedy C C
No. Diagnosis X X X
1 Excessive shock when starting movement or shifting gears
Clutch used
Defective operation of speed clutch ECMV
Hi Lo 1st. 2nd. 3rd. R
Slipping or damaged lock-up clutch
F1 ● ●
F2 ● ●
F3 ● ●
F4 ● ●
F5 ● ●
F6 ● ●
No. Diagnosis ∆ ∆ X ∆X
Remedy X X C
1 Shifts up when traveling down hill
2 Does not shift up, regardless of road surface
20-1004 1 HM400-1L
TROUBLESHOOTING (H-6)
12
(H-6)
Torque converter lock-up does not engage (carry out troubleshooting for H-6b)
• Are any of the brakes dragging
Excessive oil leakage inside torque converter (defective seal, loose plug)
• Is the retarder lever in the RELEASE position
• Are any failure codes displayed on monitor
HM400-1L 20-1005 1
TROUBLESHOOTING (H-6)
(H-6)
R2 ● ●
R1 ● ●
N
Speed Range
F1 ● ●
F2 ● ●
F3 ● ●
F4 ● ●
F5 ● ●
F6 ● ●
No. Diagnosis X X X X X X X X X X X X
Remedy
1 F2, F4, and F6 are abnormal, but other speed ranges are normal
Same as item 1, but condition returns to normal when ECMV for HI clutch is replaced
2 with ECMV for R clutch.
3 F1, F3, and F4 are abnormal, but other speed ranges are normal
Same as item 3, but condition returns to normal when ECMV for Lo clutch is replaced
4
with ECMV for R clutch.
5 F1, F2, and R1 are abnormal, but other speed ranges are normal
6 Same as item 5, but condition returns to normal when ECMV for 1st. clutch is
replaced with ECMV for R clutch.
7 F3, F4, and R2 are abnormal, but other speed ranges are normal
Same as item 7, but condition returns to normal when ECMV for 2nd. clutch is
8 replaced with ECMV for R clutch.
9 F5 and F6 are abnormal, but other speed ranges are normal.
Same as item 11, but condition returns to normal when ECMV for 3rd. clutch is
10
replaced with ECMV for R clutch.
11 R1 and R2 are abnormal, but other speed ranges are normal
12 Same as item 11, but condition returns to normal when ECMV for R. clutch is replaced
with ECMV for Hi clutch.
20-1006 1 HM400-1L
TROUBLESHOOTING (H-6)
12
(H-6)
HM400-1L 20-1007 1
TROUBLESHOOTING (H-7)
(H-7)
R2 ● ●
R1 ● ●
N
Speed Range
F1 ● ●
F2 ● ●
F3 ● ●
F4 ● ●
F5 ● ●
F6 ● ●
No. Diagnosis C ∆
∆
∆ X ∆ X X X X X X X X X X X X
Remedy X X
1 Abnormal noise comes from around power train pump
2 There is a time lag in any speed range
3 There is a time lag when shifting to F2, F4, F6
4 There is a time lag when shifting to F1, F3, F4
5 There is a time lag when shifting to F1, F1, R1
6 There is a time lag when shifting to F3, F4, R2
7 There is a time lag when shifting to F5, F6,
8 There is a time lag when shifting to R1, R2
9 Clutch pressure is low when placed in any speed range
10 Torque converter oil temperature goes above operating range
20-1008 1 HM400-1L
TROUBLESHOOTING (H-8)
(H-8)
★ If the results of all troubleshooting items are normal, this is the probable cause.
HM400-1L 20-1009 1
TROUBLESHOOTING (H-9)
(H-9)
Air is being sucked into the inlet side of the power train pump
20-1010 1 HM400-1L
TROUBLESHOOTING (H-10)
12
(H-10)
Air is being sucked into the suction side of the PPC pump
HM400-1L 20-1011 1
TROUBLESHOOTING (H-11)
(H-11)
Air is being sucked into the suction side of the PPC pump
20-1012 1 HM400-1L
TROUBLESHOOTING (H-12)
12
(H-12)
Air is being sucked into the suction side of the PPC pump
HM400-1L 20-1013 1
TROUBLESHOOTING (H-13)
12
(H-13)
Air is being sucked in at the suction end of the hydraulic steering pump
• Is the differential lock systems off when turning the machine?
20-1014 1 HM400-1L
TROUBLESHOOTING (H-14)
12
(H-14)
Air is being sucked in at the suction end of the hydraulic steering pump
• Is the brake (service or retarder) operating?
HM400-1L 20-1015 1
TROUBLESHOOTING (H-15)
12
(H-15)
20-1016 1 HM400-1L
TROUBLESHOOTING (H-16)
12
(H-16)
Drip in set pressure of dump valve relief valve or incorrect or contaminated oil
Air is being sucked in at the suction side of the hydraulic and steering pump
• Is the single valve of dump lever within normal range
• Are there any failure codes relating to this system displayed?
HM400-1L 20-1017 1
TROUBLESHOOTING (H-17)
12
(H-17)
Drop in set pressure of flow amplifier valve, relief valve or incorrect or contaminated oil
• Is signal valve on dump body within normal range?
Drop in set pressure of dump valve relief valve or incorrect or contaminated oil
• Are any failure codes displayed relating to this system
• Is the battery charge circuit caution lamp lit-up
Air is being sucked in at the suction end if the hydraulic steering pump
(If the alternator signal R is not within range the dump controller will not operate)
1 When pressure pick-up port plug is removed and engine is cranked, no oil comes out of
port
2 Steering also does not work normal
3 Steering works normal
4 Item 2 is abnormal, steering relief pressure and dump relief is low
5 Item 4 is abnormal, abnormal noises are heard from around the relief valve
6 Dump relief pressure is low
7 Item 6 is abnormal, abnormal noises are heard from around the relief valve
8 Dump relief pressure is low at engine high idle
9 Normal when engine is at low idle
10 Hydraulic and steering pump discharge amount is low
When dump body is raised, and hose at LOWER end of dump cylinder id removed, a
11
massive amount of oil flows out.
20-1018 1 HM400-1L
TROUBLESHOOTING (H-18)
12
(H-18)
HM400-1L 20-1019 1
TROUBLESHOOTING (H-18)
12
MEMORANDUM
20-1020 HM400-1L
30 DISASSEMBLY AND ASSEMBLY
HM400-1L 30-1
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
REMOVAL OF CENTER AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-272
INSTALLATION OF CENTER AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-275
REMOVAL OF REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-277
INSTALLATION OF REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-280
REMOVAL OF FRONT SUSPENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-281
INSTALLATION OF FRONT SUSPENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-282
REMOVAL OF REAR SUSPENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-283
REMOVAL OF EQUALIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-285
INSTALLATION OF EQUALIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-287
REMOVAL OF FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-288
INSTALLATION OF FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-288
REMOVAL AND INSTALLATION OF REAR WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-289
REMOVAL OF HITCH FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-291
INSTALLATION OF HITCH FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-297
DISASSEMBLY OF HITCH FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-299
ASSEMBLY OF HITCH FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-301
STANDARD INTEGRAL ORBIT-ROLL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-304
DISASSEMBLY OF STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-306
ASSEMBLY OF STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-310
REMOVAL OF FLOW AMPLIFIER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-316
INSTALLATION OF FLOW AMPLIFIER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-317
REMOVAL OF HOIST VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-318
INSTALLATION OF HOIST VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-319
DISASSEMBLY OF HOIST VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-320
ASSEMBLY OF HOIST VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-321
DISASSEMBLY OF STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-323
ASSEMBLY OF STEERING CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-325
DISASSEMBLY OF HOIST CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-328
ASSEMBLY OF HOIST CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-330
REMOVAL OF BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-334
INSTALLATION OF BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-336
DISASSEMBLY AND ASSEMBLY OF OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-337
30-2 HM400-1L
DISASSEMBLY AND ASSEMBLY HOW TO USE MANUAL
12
HOW TO USE MANUAL
1. When removing or installing unit assemblies
A. When removing or installing a unit assembly, the order of work and techniques used are given for the removal opera-
tion; the order of work for the installation operation is not given.
B. Any special techniques applying only to the installation procedure are marked , and the same mark is placed
after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to.
Example Explanation
(Component/assembly) Specification
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as
PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the
operation.
HM400-1L 30-3
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
12
PRECAUTIONS WHEN CARRYING OUT OPERATION
When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given
below when carrying out the operation.
30-4 HM400-1L
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
D. If the part is not under hydraulic pressure, the following corks
can be used.
Nominal Dimensions (mm)
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
HM400-1L 30-5
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Neces- New/
Component Symbol Part No. Part Name Q’ty Sketch Nature of work, remarks
sity remodel
01643-31032 Washer 2
30-6 HM400-1L
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
HM400-1L 30-7
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
30-8 HM400-1L
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
HM400-1L 30-9
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
30-10 HM400-1L
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
HM400-1L 30-11
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
C1 Plate
C6 Push tool
30-12 HM400-1L
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
C7 Push tool
C8 Push tool
HM400-1L 30-13
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
D3 Push tool
D5 Block
30-14 HM400-1L
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
H3, H5 Push tool
H4 Push tool
HM400-1L 30-15
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
H4 Push tool
H8 Push tool
30-16 HM400-1L
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
H9 Plate
HM400-1L 30-17
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
H4 Push tool
J1 Fixture
30-18 HM400-1L
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
J1 Fixture
J2 Push tool
HM400-1L 30-19
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
J3 Push tool
J4 Push tool
30-20 HM400-1L
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
Q1 Push tool
Q1 Push tool
HM400-1L 30-21
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
Q1 Push tool
Q3 Push tool
30-22 HM400-1L
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
Q3 Push tool
HM400-1L 30-23
DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP REMOVAL
3. Remove plugs (4) (2 places, at the upper and lower part), then
check that the stamp line is aligned with the fuel supply pump drive
gear and forcing tap hole.
4. Remove cover (5). Remove gear mounting nut and washer (6) and
(7) with care not to drop them in the engine.
6. Remove fuel hose (9), then remove fuel tube (10), fuel supply tube
(11), oil tube (12), and overflow tube (13).
★ Mask the joints and joint portions of piping to keep dust and
debris out.
30-24 HM400-1L
DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP INSTALLATION
8. Loosen bolts (16) and nuts (17) of the bracket and fuel supply
mounting bolts (18) (4 places on the front and rear sides).
9. Clockwise rotate tool bolt (center bolt) A3 to pull out the fuel sup-
ply pump drive gear.
★ Key (19) is inside, be careful not to drop it.
10. Remove bolts (16) and nuts (17) loosened at step 9, then remove
fuel supply pump (20).
● Air clamp
Mounting bolt upper side: 4.9 ± 1.0 N•m
HM400-1L 30-25
DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY REMOVAL
3. Engine undercover
Remove the engine undercover.
C. Loosen the clamp of air cleaner tube (11) and shift it to the
right of the vehicle body.
30-26 HM400-1L
DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY REMOVAL
7. Fan guard
Remove fan guard (12).
8. Fan
Remove fan (13).
★ Bring the fan down toward the radiator.
HM400-1L 30-27
DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY REMOVAL
12. Exhaust pipe
Remove exhaust pipe (18).
14. Alternator wiring harnesses, heater hoses, fuel spill tubes, and
exhaust brake linkage
Disconnect alternator wiring harnesses (22) (three places, four
pieces), heater hoses (23) and (24), fuel spill tube (25) (two pieces),
and exhaust brake linkage (34). Remove radiator lower tube and
hose (35).
30-28 HM400-1L
DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY REMOVAL
15. Engine centralized connector and heater relay connector
Remove cover (26) and disconnect engine centralized connector
(27) (CN-EG4, EG5) and heater relay connector (28).
16. Hydraulic hoses and drive shaft between engine and transmission
B. Remove guard bracket (30) from the output shaft cover and
disconnect drive shaft (31) between the engine and transmis-
sion from the engine.
HM400-1L 30-29
DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY REMOVAL
18. Engine assembly
Lift off engine assembly (33).
30-30 HM400-1L
DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY INSTALLATION
• When installing the drive shaft, check that the key way of the spider cap is matched to that of the mating yoke and tighten
the bolts.
★ When dismantling the engine assembly, transmission and torque converter assembly or drive shafts, center the engine
and transmission in the left and right direction in the following manner, using tool A4.
A. Install tool A4 to the coupling on the engine side and the coupling on the torque converter side.
B. Put scale [1] to the left and right sides of tool A4.
C. Measure the clearance between scale [1] and tool A4 on the left
side "a" and on the right side "b".
★ Check that the maximum clearance remains below 3 mm
both on the left and right sides. (If both clearances are not
in parallel, check that the clearance remains less than 3
mm even at the widest point)
★ If the clearance exceeds 3 mm, make adjustment by shift-
ing the position of torque converter and transmission
assembly mount.
★ When installing the drive shaft, check that the keyway of
spider cap fully engage with that of the corresponding
yoke, and then tighten the mounting bolt.
HM400-1L 30-31
DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY INSTALLATION
★ When measuring dimension "a" between the flywheel housing and the coupling tip, while drive shaft (43)
between the engine and transmission is in place, and if this dimension "a" falls out of the value shown below,
make adjustment by shifting the position of engine assembly mount or transmission and front differential assem-
bly mount so that the dimension falls within the specified value.
Dimension "a" between flywheel housing and coupling tip: 210.2 -30 mm
Refilling with coolant
Add coolant to the coolant filler of the radiator. Run the engine to circulate the coolant through the system. Then, check the
coolant level in the reservoir tank again.
Refilling with oil
30-32 HM400-1L
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY REMOVAL
1. Tilt up operator's cab (1) and support it with the safety bar.
2. Remove engine top cover (2) and coolant reservoir tank (3).
★ Disconnect the radiator coolant level connector (CN-B01), too.
HM400-1L 30-33
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY REMOVAL
4. Turbocharger and exhaust manifold assembly
A. Remove corrosion resistor (11), fuel filter (12), and oil filter
(13).
★ Make match marks on the hoses and refer to them when connecting
the hose again
30-34 HM400-1L
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY REMOVAL
B. Remove the wiring harness clamp, each fuel injector connec-
tor, and fuel supply pump connector (14), then move wiring
harness (15).
F. Seeing air intake connector (20) from the front side of the
engine, remove the mounting bolt at the left lower part.
HM400-1L 30-35
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY REMOVAL
G. Sling exhaust manifold assembly (21) temporarily and remove
the mounting bolt, then remove the assembly.
6. Ribbon heater
Remove ribbon heater wiring harness (22) to remove each ribbon heater
(23).
9. Head cover
Remove head cover (31).
30-36 HM400-1L
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY REMOVAL
10. Rocker arm
A. Remove two nuts (37) of the upper solenoid valve of fuel injec-
tor (36) and pull out spring clamp (38).
HM400-1L 30-37
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY REMOVAL
12. Push rod
Remove push rod (46).
30-38 HM400-1L
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD INSTALLATION
1. Fit the gaskets to both sides of ribbon heater (23) and install them to
air intake manifold assembly.
2. Install wiring harness (22) to ribbon heater (23) and assemble them
with the air intake manifold
HM400-1L 30-39
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD INSTALLATION
A. Tighten all the bolts of the five high-pressure pipe clamps by
hand, then tighten them permanently. Then, secure the clamp
stays permanently.
B. Tighten all the bolts of the stays and upper and lower clamps of
high-pressure pipe clamps (25), (52), (53) by hand.
E. Install gate frame (26) temporarily. Secure clamp (on the back
side of the gate frame) permanently first, then secure gate
frame (26) permanently with special bolts (4).
★ There are 16 rubber caps. All of them have respective slits, the
directions of which are important.
F. Caps at common rail outlet (50) with their slits toward the cyl-
inder block.
30-40 HM400-1L
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD INSTALLATION
G. Fit the six rubber caps at fuel injector inlet sleeve (51) with
their slits down.
★ Secure the rubber caps with metal clips
● Screw sleeve nut (54) by two turns with the hand into the
threads of the fuel injector, then tighten it with a spanner.
Note1)If sleeve nut (54) does not catch the threads, press its
end with another small spanner, etc. and turn its hexagonal part
with the proper spanner.
★ Make sure that the inside of the injector sleeve is free from dirt.
H. Fit the gasket and O-ring to the fuel injector and apply engine
oil SAE No. 30 to them.
I. Insert holder (41) in fuel injector (36), then insert them simul-
taneously with the injector connection directed to the hole for
the fuel high-pressure pipe.
J. Fit the ball washer and holder (41) to bolt (42), then tighten
them temporarily. Insert high-pressure pipe sleeve (55) in the
hole for the fuel high-pressure pipe and secure it temporarily,
matching it to injection (56). Secure holder (41) with bolt (42)
permanently.
★ Apply engine oil to the spherical surface of the ball washer
(to fit the ball washer).
30-42 HM400-1L
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD INSTALLATION
★ It is difficult to insert the connector from inside with the O-ring
fitted to it.
HM400-1L 30-43
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD INSTALLATION
N. Holding the top of the cross head (47) lightly, tighten the
adjustment screw.
4. Check that the cylinder head mounting face and inside of the cylin-
der are free of foreign matter, then set cylinder head gasket.
★ When fitting the gasket, check that the grommets are fitted cor-
rectly.
5. Before tightening the cylinder head mounting bolts, check the fol-
lowing item.
★ If a bolt is longer than the following using limit or has been
tightened five times (having five punch marks denoting the
number of tightening times) or more, replace it.
A. Measure stem length "a" of every bolt and make sure that it is
less than the using limit.
30-44 HM400-1L
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD INSTALLATION
6. Install cylinder head assembly and tighten mounting bolts.
Mounting bolt:
1st time: 137 - 157 N•m
2nd time: 284 - 294 N•m
3rd time: When using tool A1 (the angle tightening
wrench), tighten the bolts by 90° in the order of (1) -
(6).
★ After tightening bolts (1) - (6), tighten bolt (7) to 66.6 ±7.4
Nm.
● When not using tool A1, make marks on the bolts and
head with paint, then tighten the bolts by 90° +3 in the
order of (1) - (6).
★ After tightening bolts (1) - (6), tighten bolt (7) to 66.6 ±7.4
Nm.
HM400-1L 30-45
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF NOZZLE TIP
REMOVAL
30-46 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF NOZZLE TIP
4. Remove rerating nut (4) from injector assembly (3).
INSTALLATION
HM400-1L 30-47
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF NOZZLE TIP
4. Mount new nozzle assembly (3) so that the assembly fits the knock
pin of tip guide (4).
★ Be careful not to drop the tip.
5. Mount nozzle assembly (3) and manually tighten retaining nut (2).
6. Set 19-mm deep socket C in the torque wrench, then tighten the
retaining nut by following the steps below.
★ Apply rust prevention oil on the nozzle body.
30-48 HM400-1L
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY REMOVAL
2. Radiator undercover
Remove the radiator undercover.
C. Loosen the clamp of air cleaner tube (11) and shift it to the
right of the vehicle body.
HM400-1L 30-49
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY REMOVAL
B. Disconnect power train and brake circuit cooling hoses (16)
and (17) and steering and hoist circuit cooling hoses (18) and
(19).
6. Fan guard
Remove fan guard (12).
7. Fan
Remove fan (13).
★ Bring the fan down toward the radiator.
30-50 HM400-1L
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY REMOVAL
8. Air conditioner condenser and front covers
9. Stays
Remove stays (22) from both sides.
HM400-1L 30-51
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY INSTALLATION
B. Lift off radiator assembly (23) (including the fan).
Add coolant to the coolant filler of the radiator. Run the engine to circu-
late the coolant through the system. Then, check the coolant level in the
reservoir tank again.
30-52 HM400-1L
DISASSEMBLY AND ASSEMBLY OUTPUT SHAFT REMOVAL
2. Vertical member
Remove vertical member (2).
A. Disconnect suction pipes (3) and (4) and hoses (5), (6), and (7).
HM400-1L 30-53
DISASSEMBLY AND ASSEMBLY OUTPUT SHAFT REMOVAL
4. Brake cooling and differential lock (machine with differential lock
differential) pump
A. Disconnect suction pipe and hose (10) and (11) and discharge
hoses (12) and (13).
A. Remove guard bracket (15) from the output shaft cover and
disconnect drive shaft (16) between the engine and transmis-
sion.
30-54 HM400-1L
DISASSEMBLY AND ASSEMBLY OUTPUT SHAFT REMOVAL
6. Coupling and oil seal cage
Remove coupling (17) and oil seal cage (18).
8. Output shaft
Using forcing screw B and guide bolt C remove output shaft (21).
9. Bearing
Remove bearing (22).
HM400-1L 30-55
DISASSEMBLY AND ASSEMBLY OUTPUT SHAFT INSTALLATION
● When installing the drive shaft, check that the key way of the spider
cap is matched to that of the mating yoke and tighten the bolts.
★ Using tool C2, align the engine and torque converter with each
other.
Raise the cover and set to the output shaft, use tool B1 to press fit the
inner bearing, then install cover (20).
Bearing: Coat whole surface of bearing inside diameter and shaft out-
side diameter with ENS grease.
30-56 HM400-1L
DISASSEMBLY AND ASSEMBLY OUTPUT SHAFT DISASSEMBLY DIAGRAM
2. Cover assembly
Remove bearing (3) from cover (4).
A. To keep the balance when reassembling, mark the set positions of flange (6), body assembly (7), and outer body (9)
before disassembling.
B. Remove body assembly (7) and rubber (8) from outer body (9).
HM400-1L 30-57
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF OUTPUT SHAFT
A. Coat mating surface of outer body (9) and one side of flange
(6) with adhesive, then assemble.
★ Align the marking position of the outer body, inner body, and
flange, then assemble.
30-58 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF OUTPUT SHAFT
3. Install damper assembly (5) to flywheel.
HM400-1L 30-59
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF OUTPUT SHAFT
a: 60% pack (30g) g: Fill between grease lip and dust lip
b: Coat all surfaces of bearing inner dia. and shaft outer h: 50% pack (30g)
dia. i: Full pack (20g)
c: Fill three points in 20 mm width on circumference at j: Coat all spline.
labyrinth. k: Full pack (25g)
d: 60% pack (30g) l: Full pack (30g)
e: B-B m: 90% pack (25g)
f: Full pack (35g)
30-60 HM400-1L
DISASSEMBLY AND ASSEMBLYTRANSMISSION AND FRONT DIFFERENTIAL REMOVAL
8. Steering hoses
Disconnect steering hoses (5) (five pieces).
★ Before disconnecting, make match marks.
9. Heater hoses
Disconnect heater hoses (4) (five pieces).
★ Before disconnecting, make match marks.
HM400-1L 30-61
DISASSEMBLY AND ASSEMBLYTRANSMISSION AND FRONT DIFFERENTIAL REMOVAL
10. Operator's cab lift cylinder
Remove the connecting pin on the cab side and disconnect opera-
tor's cab lift cylinder (62)
A. Disconnect right rear brake hoses (8) (Upper side: four pieces,
Lower side: two pieces)
30-62 HM400-1L
DISASSEMBLY AND ASSEMBLYTRANSMISSION AND FRONT DIFFERENTIAL REMOVAL
B. Disconnect right rear brake hoses (9) and (10).
HM400-1L 30-63
DISASSEMBLY AND ASSEMBLYTRANSMISSION AND FRONT DIFFERENTIAL REMOVAL
15. Centralized connectors between vehicle body and engine
Remove top cover (15) and disconnect centralized connectors (16)
and (17) between the vehicle body and engine.
30-64 HM400-1L
DISASSEMBLY AND ASSEMBLYTRANSMISSION AND FRONT DIFFERENTIAL REMOVAL
B. Disconnect torque converter oil pressure sensor connector (28),
exhaust brake hoses (29) (two pieces), and brake oil drain hose
(30).
A. Disconnect suction pipes (31) and (32) and hoses (33), (34),
and (35).
20. Brake cooling and differential lock (machine with differential lock
differential) pump
A. Disconnect suction pipe and hose (38) and (39) and discharge
hoses (40) and (41).
HM400-1L 30-65
DISASSEMBLY AND ASSEMBLYTRANSMISSION AND FRONT DIFFERENTIAL REMOVAL
B. Lift off brake cooling and differential lock pump assembly
(42).
A. Remove guard bracket (43) from the output shaft cover and
disconnect drive shaft (44) between the engine and transmis-
sion.
30-66 HM400-1L
DISASSEMBLY AND ASSEMBLYTRANSMISSION AND FRONT DIFFERENTIAL REMOVAL
(Section under front of transmission)
HM400-1L 30-67
DISASSEMBLY AND ASSEMBLYTRANSMISSION AND FRONT DIFFERENTIAL REMOVAL
24. Transmission rear mount grease tube
Disconnect rear mount grease tube (56) from the rear mount.
26. Drive shafts on both sides (between front differential and front final
drive)
Disconnect drive shafts (58) on both sides (between front differen-
tial and front final drive) from the front differential.
30-68 HM400-1L
DISASSEMBLY AND ASSEMBLYTRANSMISSION AND FRONT DIFFERENTIAL REMOVAL
27. Transmission and front differential assembly
Remove mounting bolts (59) (Front side: four pieces) and (60)
(Rear side: eight pieces) and lift off transmission and front differen-
tial assembly (61).
HM400-1L 30-69
DISASSEMBLY AND ASSEMBLY TRANSMISSION AND FRONT DIFFERENTIAL INSTAL-
● Standard clearance "a" for operator's cab mounting pin: 0.2 mm (on
each side)
● When installing the drive shaft, check that the key way of the spider
cap is matched to that of the mating yoke and tighten the bolts.
★ Using tool C2, align the engine and torque converter with each
other.
● When installing the drive shaft, check that the key way of the spider
cap is matched to that of the mating yoke and tighten the bolts.
30-70 HM400-1L
DISASSEMBLY AND ASSEMBLY TRANSMISSION AND FRONT DIFFERENTIAL INSTAL-
● When installing the drive shaft, check that the key way of the spider
cap is matched to that of the mating yoke and tighten the bolts.
HM400-1L 30-71
DISASSEMBLY AND ASSEMBLY DISCONNECTION OF FRONT DIFFERENTIAL AND
30-72 HM400-1L
DISASSEMBLY AND ASSEMBLYCOUPLING OF FRONT DIFFERENTIAL AND TRANSMIS-
4. Front differential assembly
Lift off front differential assembly (5).
Adjust the speed sensor. For details, see TESTING AND ADJUSTING.
HM400-1L 30-73
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TORQUE CONVERTER
A. Loosen all mounting bolts (2) and remove all but three of them.
30-74 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TORQUE CONVERTER
B. Remove mounting bolts (5) on the pump side.
4. Stator assembly
Lift up and remove stator assembly (7).
★ For further disassembly, see "Disassembly of stator assembly."
5. Pump assembly
HM400-1L 30-75
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TORQUE CONVERTER
B. Using puller G, remove inner race (9) and pump assembly (10)
6. Stator shaft
A. Remove the plug. Using a bar, remove inner race (15) from sta-
tor shaft (14).
★ When installing the plug again, do not apply adhesive (LT-2).
30-76 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TORQUE CONVERTER
7. Disassembly of turbine and clutch assembly
E. Remove the mounting bolts and lift off housing assembly (23).
F. Remove piston (24) and seal ring (25) from the housing assem-
bly.
HM400-1L 30-77
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TORQUE CONVERTER
G. Using push tool 1!, remove bearing (26) from the housing.
C. Remove race (35) and free wheel (36) from race (32).
30-78 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TORQUE CONVERTER
HM400-1L 30-79
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TORQUE CONVERTER
B. Install disc (30).
★ Apply engine oil EO30-CD or EO10-CD to the sliding
surfaces.
D. Install the seal rings (27) and (25) to piston (24) and housing
(23).
★ When installing the piston take care that the seal rings will
not be caught.
30-80 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TORQUE CONVERTER
H. Install plate (21) and snap ring (20).
I. Using the push tool, press fit bearing (19) to input shaft (18).
3. Stator shaft
● The following is the assembly procedure for the torque con-
verter.
HM400-1L 30-81
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TORQUE CONVERTER
4. Pump assembly
A. Using push tool 1$, press fit bearing (13) to guide (12).
B. Set guide (12) and retainer (11) and tighten the mounting bolts.
30-82 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TORQUE CONVERTER
E. Using tool C3, tighten nut (8).
5. Stator assembly
Install stator assembly (7).
● For further assembly, see "Assembly of stator."
HM400-1L 30-83
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TORQUE CONVERTER
8. P.T.O. assembly
Fit the O-ring and install P.T.O. assembly (1), using eyebolt B.
30-84 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
DISASSEMBLY OF TRANSMISSION
1. Piping
Remove hoses and piping (1).
7. Strainer
Remove strainer (9).
10. Transmission control valve, main relief valve, valve seat and tube
Remove transmission control valve assembly (12), main relief
valve assembly (13), and valve seat (14) and tube (225).
HM400-1L 30-85
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
11. Coupling
30-86 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
13. Covers
Remove covers (18) (on the 1st clutch side) and (19) (on the 2nd
clutch side).
★ Check the thickness and quantity of the shims on the cover (19)
side.
B. Remove bearing outer race (38o), dust seal (67), and oil seal
(68) from bearing cage (66).
★ For bearing inner race, see "Disassembly of differential lock
clutch."
HM400-1L 30-87
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
★ If the transmission is disassembled with the torque converter
side up, its inside will be broken. Therefore, be sure to disas-
semble the transmission with the torque converter side down.
★ For further disassembly of the transmission case, see "step 27."
16. Shroud
Remove shroud (90).
18. FH and 1st clutch assembly and 2nd and 3rd clutch assembly
Lift off FH and 1st clutch assembly (23) and 2nd and 3rd clutch
assembly (24) simultaneously.
★ For further disassembly of the 2nd and 3rd clutch assembly, see
"step 24." For further disassembly of the FH and 1st clutch
assembly, see "step 25."
30-88 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
19. R and FL clutch assembly
Remove R and FL clutch assembly (25).
★ For further disassembly of the R and FL clutch assembly, see
"step 26."
HM400-1L 30-89
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
ii. Remove snap ring (203) from bearing and spacer and snap
ring assembly (202), then remove bearing (205) from
spacer (204).
30-90 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
23. Disassembly of differential lock clutch assembly
A. Using forcing screw D, remove gear and shaft and ring gear
assembly (30).
B. Disassemble the gear and shaft and ring gear assembly accord-
ing to the following procedure.
i. Using push tool 1%, remove shaft and ring gear assembly
(31).
ii.
Remove shaft and snap ring assembly (32), ring gear
assembly (33), and bearing (34) (Inner races: 34-1i, 34-2i,
Spacer: 34-3).
★ Bearing (34) (Inner races: 34-1, 34-2, 34-3) is the assem-
bly number.
★ For bearing outer race (34-1o, 2o), see step iv below.
HM400-1L 30-91
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
iii. Remove snap rings (36) and (68) from shaft (35).
★ Snap ring (68) is for the oil sump.
iv. Remove gear (37), bearing (34) (Outer races: 34-1o, 34-
2o), and bearing inner race (38).
30-92 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
E. Remove the mounting bolts (12 pieces) and carrier assembly
(42).
ii. Drive out shaft (44) toward ball (45) and remove shaft
(44), gear (46), ball (45), bearing (47) (two pieces), and
thrust washers (48) (two pieces).
HM400-1L 30-93
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
H. Disassemble front shaft and hub assembly (49) according to
the following procedure.
i. Remove snap ring (50), then remove hub (52) and bearing
inner race (64i) from shaft (51).
I. Remove end plate (55), discs (56) (seven pieces), plate (57)
(seven pieces), and wave springs (58) (seven pieces) from the
differential clutch.
30-94 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
J. Using the hanging tap, remove piston assembly (59).
HM400-1L 30-95
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
24. Disassembly of 2nd and 3rd clutch assembly
(2nd clutch side)
B. Using puller [4], remove spacer (226) and bearing inner race
(73i) together. After removing spacer (227) (two-piece type),
remove gear (72).
30-96 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
E. Remove needle roller bearing (78) from gear (77).
G. Remove end plate (80), plates (81) (14 pieces), discs (82) (13
pieces), and wave springs (83) (13 pieces) from the 2nd clutch.
HM400-1L 30-97
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
H. Using the hanging tap, remove thrust washers (84) and piston
assembly (86).
30-98 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
K. Remove snap ring (102) and thrust washer (103).
HM400-1L 30-99
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
O. Remove end plate (108), plates (109) (eight pieces), discs (110)
(seven pieces), and wave springs (111) (seven pieces) from the
3rd clutch.
30-100 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
P. Remove thrust washer (112) and piston assembly (113).
HM400-1L 30-101
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
C. Remove snap ring (124) and thrust washer (125).
30-102 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
G. Remove end plate (130), plates (131) (13 pieces), discs (132)
(12 pieces), and wave spring (133) (12 pieces) from the 1st
clutch.
HM400-1L 30-103
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
H. Using the hanging tap, remove thrust washers (134) and piston
assembly (136).
30-104 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
(FH clutch side)
HM400-1L 30-105
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
M. Remove end plate (147), plates (148) (ten pieces), discs (149)
(nine pieces), and wave springs (150) (nine pieces) from the
FH clutch.
30-106 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
N. Using the hanging tap, remove thrust washer (151) and piston
assembly (152).
B. Using push puller 1), remove gear and needle roller bearing
assembly (162), bearing inner race (163i), spacer (164), and
thrust washer (165) together.
★ For bearing outer race (163o), see "Disassembly of trans-
mission case assembly on opposite side of torque con-
verter," (step 27).
HM400-1L 30-107
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
C. Remove needle roller bearing (167) from gear (166).
D. Using C-clamp 1!, etc., compress the clutch spring and remove
snap ring (168).
★ The clutch spring may be compressed by holding the end
plate without using the C-clamp similarly to the 2nd
clutch. (For example, put a bar to the screw hole of the
shaft and press down the end plate with the spacer.)
30-108 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
E. Remove end plate (169), plates (170) (12 pieces), discs (171)
(11 pieces), and wave springs (172) (11 pieces) from the R
clutch.
HM400-1L 30-109
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
(FL clutch side)
H. Using push puller E, remove gear (178) and bearing inner race
(179i) together.
30-110 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
K. Using C-clamp 1!, etc., compress the clutch spring and remove
snap ring (185).
★ The clutch spring may be compressed by holding the end
plate without using the C-clamp similarly to the 2nd
clutch. (For example, put a bar to the screw hole of the
shaft and press down the end plate with the spacer.).
L. Remove end plate (186), plates (187) (12 pieces), discs (188)
(11 pieces), and wave springs (189) (11 pieces) from the FL
clutch.
HM400-1L 30-111
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
M. Remove thrust washer (190) and piston assembly (191).
30-112 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
28. Disassembly of transmission case assembly (on torque converter
side)
Remove bearing outer races (64o), (100o), and (141o) from the
case.
A. Remove nut (219) and P.T.O. gear and bearing inner race
assembly (220).
B. Remove bearing inner race (222ir) from P.T.O. gear and bear-
ing inner race assembly (221).
HM400-1L 30-113
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
ASSEMBLY OF TRANSMISSION
● Precautions for assembly
★ Clean all the parts and check them for dirt or damage before
installing.
★ Coat the sliding surfaces of the all parts with engine oil before
installing.
★ Dip the discs in clean engine oil (EO-30CD) for at least two
minutes before installing.
★ Install seal ring (a) for the piston with the pressure receiving
side (side "b") directed to housing (c) as shown in the figure.
B. Set bearing inner race (222il) in position and install P.T.O. gear
(221) and press fit it by tightening nut (219).
30-114 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
3. Assembly of transmission case assembly (on opposite side of
torque converter)
B. Fit collar (218) and install bearings (215) and (216) to gear
(214) by expansion fit.
★ Follow the installation directions carefully.
HM400-1L 30-115
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
C. Install plates (187) (12 pieces), discs (188) (11 pieces), wave
springs (189) (11 pieces), and end plate (186) to the FL clutch.
★ Dip the discs in clean engine oil (EO-30CD) for at least two
minutes before installing.
30-116 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
F. Remove the gear and needle roller bearing assembly (182).
G. Using C-clamp 1!, etc., compress the clutch spring and install
snap ring (185).
★ The clutch spring may be compressed by holding the end
plate without using the C-clamp similarly to the 2nd
clutch. (For example, put a bar to the screw hole of the
shaft and press down the end plate with the spacer.)
HM400-1L 30-117
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
(R clutch side)
30-118 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
L. Install plates (170) (12 pieces), discs (171) (11 pieces), wave
springs (172) (11 pieces), and end plate (169) to the R clutch.
★ Dip the discs in clean engine oil (EO-30CD) for at least
two minutes before installing.
HM400-1L 30-119
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
O. Remove the gear and needle roller bearing assembly (162).
P. Using C-clamp, jig 1!, etc., compress the clutch spring and
install snap ring (168).
★ The clutch spring may be compressed by holding the end
plate without using the C-clamp similarly to the 2nd
clutch. (For example, put a bar to the screw hole of the
shaft and press down the end plate with the spacer.)
Q. Install gear and needle roller bearing assembly (162), thrust washer
(165), and spacer (164).
★ If gear and needle roller bearing assembly (162) is difficult to
install, repeat the procedure from step N.
30-120 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
S. Install seal rings (161) (three pieces).
HM400-1L 30-121
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
C. Install plates (148) (ten pieces), discs (149) (nine pieces), wave
springs (150) (nine pieces), and end plate (147) to the FH
clutch.
★ Dip the discs in clean engine oil (EO-30CD) for at least two
minutes before installing.
30-122 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
F. Remove the gear and needle roller bearing assembly (140).
HM400-1L 30-123
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
(1st clutch side)
30-124 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
L. Install plates (131) (12 pieces), discs (132) (11 pieces), wave
springs (133) (11 pieces), and end plate (130) to the 1st clutch.
★ Dip the discs in clean engine oil (EO-30CD) for at least
two minutes before installing.
HM400-1L 30-125
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
O. Remove the gear and needle roller bearing assembly (126).
30-126 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
S. Install gear (127).
HM400-1L 30-127
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
C. Install plates (109) (eight pieces), discs (110) (seven pieces),
wave springs (111) (seven pieces), and end plate (108) to the
3rd clutch.
★ Dip the discs in clean engine oil (EO-30CD) for at least
two minutes before installing.
30-128 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
HM400-1L 30-129
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
(2nd clutch side)
30-130 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
M. Install plates (81) (14 pieces), discs (82) (13 pieces), wave
springs (83) (13 pieces), and end plate (80) to the 2nd clutch.
★ Dip the discs in clean engine oil (EO-30CD) for at least
two minutes before installing.
HM400-1L 30-131
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
P. Remove the gear and needle roller bearing assembly (76).
S. Install gear (73), spacer (227) (two-piece type), and spacer (226)
(having a spline).
30-132 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
T. Install bearing inner race (73i) by shrink fit.
★ Shrink fit temperature: Approximately 120°C for 30 min-
utes.
i.Using push tool 1@, press fit bearing inner race (65i) to
housing (62).
★ For bearing outer race (65o), see "Disassembly of trans-
mission case assembly on torque converter side," (step
28).
ii. Using push tool 1#, press fit bearing outer race (64o) to
housing (62).
HM400-1L 30-133
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
iii. Install seal ring (63).
★ Install the seal ring with the pressure receiving side
directed to the housing.
i. Using push tool 1$, press fit bearing inner race (64i) to
shaft (51).
30-134 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
ii. Install hub (52) to shaft (51), then install snap ring (50).
HM400-1L 30-135
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
F. Install plates (57) (seven pieces), discs (56) (seven pieces),
wave springs (58) (seven pieces), and end plate (55) to the dif-
ferential clutch.
★ Dip the discs in clean engine oil (EO-30CD) for at least
two minutes before installing.
i.Set gear (46), bearings (47) (two pieces) and thrust wash-
ers (48) (two pieces) in position and drive in shaft (44)
halfway and put in ball (45), then drive shaft (44) to the
end.
★ First, adjust the position (direction) of the hole to put the
ball in.
30-136 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
H. Install carrier assembly (42).
K. Assemble the gear and shaft and ring gear assembly according
to the following procedure.
HM400-1L 30-137
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
ii. Press fit bearing inner race (38i) to gear (37).
★ For bearing outer race (38o), see the section of bearing
cage.
iii. Using push tool 1^, press fit bearing outer race (34-2o) to
gear (37).
★ Bearing (34) (Inner races: 34-1, 34-2, 34-3) is the assem-
bly number.
iv. Install shaft and snap ring assembly (32) to ring gear (33).
v. Set the snap ring side of shaft and snap ring assembly (32)
as the receiver and press fit (install) ring gear (33) and
bearing inner race (34-2i) together, using push tool 1&.
30-138 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
vi. Install spacer (34-3) to shaft and ring gear assembly (69).
vii. Set the snap ring side of shaft and snap ring assembly (32)
as the receiver and press fit (install) gear assembly (70)
and bearing inner race (34-1i) together, using push tool
1*.
viii. Install gear and shaft and ring gear assembly (30).
HM400-1L 30-139
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
9. P.T.O. assembly
Install the O-ring and P.T.O. assembly (28).
30-140 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
ii. Using push tool 1(, press fit bearing (205) to spacer (204)
and install snap ring (203).
iii. Install bearing and spacer and snap ring assembly (202),
then install snap ring (201).
HM400-1L 30-141
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
B. Install cage assembly (26).
★ Check that the cuts of the seal rings (three places) are not
opened.
12. 1st and FH clutch assembly and 2nd and 3rd clutch assembly
Sling and install 1st and FH clutch assembly (23) and 2nd and 3rd
clutch assembly (24) simultaneously.
★ For assembly of the 1st and FH clutch assembly, see step 5. For
assembly of the 2nd and 3rd clutch assembly, see step 6.
★ Check that the cuts of the seal rings (six places) are not opened.
30-142 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
14. Shroud
Install shroud (90).
★ Press the shroud lightly against the housing, then separate it
from the housing by 1 mm and install it.
★ For assembly of the transmission case (on the opposite side of the
torque converter), see step 3.
HM400-1L 30-143
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
C. Using push tool 2), press fit oil seal (67) to bearing cage (66).
★ Adjust distance "g" from the cage end to 13.5 ± 0.2 mm.
D. Check that the tightening torque of the mounting bolt has not
changed. If it has changed, repeat steps A and B.
30-144 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
G. Subtract the following value from the average of clearance "a" obtained earlier in step F above. Insert shims of the
thickness equivalent to the result of this calculation.
★ Reduction of thickness: 0.10 - 0.15 mm
★ Allowable range of shim thickness (Reference): 1.7 - 3.0
mm
I. Measure the rotating torque of the output shaft and check that
its increase from the value obtained in step E is in the follow-
ing range: 2.94 - 9.81 Nm.
J. Measure clearance "a" between bearing cage (20) and the rear
transmission case at three places (equally spaced on the periph-
ery) and obtain the average.
★ If the dispersion of the measured values at the three places
exceeds 0.15 mm, check the bearing and other parts for
abnormality. Correct any abnormal part and measure
clearance "a" again.
L. Rotating the output shaft, tighten the mounting bolts of bearing cage
(20) to the following torque.
M. Measure the rotating torque of the output shaft and check that
its increase from the value obtained in step I is in the following
range.
★ Increase of rotating torque: 2.94 - 9.81 Nm
HM400-1L 30-145
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
N. Install cover (18) (1st clutch side).
19. Coupling
30-146 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
B. Install input coupling (27).
20. Transmission control valve, torque converter valve, valve seat and
tube
B. Install the O-ring, valve seat (14), transmission control valve assem-
bly (12), and main relief valve assembly (13).
23. Strainer
Install strainer (9).
HM400-1L 30-147
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
25. Torque converter oil temperature sensors
Install torque converter oil temperature sensors (6) and (7).
30-148 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
29. Piping
Install piping (1).
HM400-1L 30-149
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT DIFFERENTIAL
30-150 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT DIFFERENTIAL
B. Disassemble pinion and case assembly (9) according to the fol-
lowing procedure.
iii. Remove seals (14) and (15), bearing (16), and bearing
outer race (13o) from case (11).
HM400-1L 30-151
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT DIFFERENTIAL
4. Input shaft coupling and holder
Remove holder (5) and coupling and gear assembly (6).
A. Sling the differential gear case with wires and remove side car-
rier and shaft assembly (19) on the bevel gear side by using
forcing screw B.
★ Check the thickness and quantity of the shims.
30-152 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT DIFFERENTIAL
B. Under the above condition, remove side carrier and shaft
assembly (20) on the opposite side by using forcing screw
C.
★ Check the thickness and quantity of the shims and the
position of the side carrier.
★ For disassembly of side carrier and shaft assembly, see 8.
HM400-1L 30-153
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT DIFFERENTIAL
B. Disassemble the differential gear and differential lock assem-
bly according to the following procedure.
30-154 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT DIFFERENTIAL
ii. Remove seal ring (25).
HM400-1L 30-155
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT DIFFERENTIAL
vi. Remove seal ring (30) and thrust washer (68) from case
(27).
30-156 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT DIFFERENTIAL
HM400-1L 30-157
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT DIFFERENTIAL
x. Remove pinion gear assembly (43) and cross shaft (44) in
one unit.
30-158 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT DIFFERENTIAL
8. Disassembly of side carrier and shaft assembly
iii. Remove bearing (53) and bearing outer races (38o) and
(51o) from case (52).
★ Bearing (53) is divided into the inner race and outer race
when the shaft is removed (pulled out).
HM400-1L 30-159
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT DIFFERENTIAL
B. Disassemble the side carrier and shaft assembly on the oppo-
site side of the bevel gear according to the following proce-
dure.
iii. Remove bearing (58) and bearing outer races (24o) and
(56o) from case (57).
★ Bearing (58) is divided into the inner race and outer race
when the shaft is removed (pulled out).
30-160 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT DIFFERENTIAL
A. Assemble the side carrier and shaft assembly on the bevel gear
side according to the following procedure.
HM400-1L 30-161
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT DIFFERENTIAL
● Adjust the shims for the bearing according to the follow-
ing procedure.
a) Measure the starting tangential force in the tangen-
tial direction of the bolt hole (φ234) of the case.
★ Standard tangential force: Max. 21.5 N
b) If the starting tangential force is too large, increase
the shims. If the former is too little, decrease the
latter. Then, measure the starting tangential force
again.
★ If the starting tangential force is too large, disassemble
shaft and bearing inner race assembly (50) and case
assembly (61) and increase the shims, then execute the
bullet statement before this one.
30-162 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT DIFFERENTIAL
ii. Shaft and bearing inner race assembly
● Using tool H4, press fit bearing inner race (56i) to shaft
(63).
HM400-1L 30-163
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT DIFFERENTIAL
★ The procedure for installing both side carrier and shaft assemblies
to the body is explained in step 3 (Side carrier and shaft assembly)
below.
ii. Install bushing (sleeve) (47), pinion gear (46), and washer
(45).
iii. Install pinion gear assembly (43) and cross shaft (44) in
one unit.
30-164 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT DIFFERENTIAL
iv. Install differential side gear (42) and washer (41).
HM400-1L 30-165
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT DIFFERENTIAL
vi. Install pin (33), plate (31), and disc (32).
★ Apply engine oil (EO-30) to the surfaces of the disc and
plate.
vii. Install seal ring (30) and thrust washer (68) to piston case
(27).
★ When installing the seal ring, take care of its direction.
30-166 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT DIFFERENTIAL
x. Install case and piston assembly (26).
xii. Using push tool J, press fit bearing inner race (24i) and
retainer (23) in one unit.
HM400-1L 30-167
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT DIFFERENTIAL
B. Sling differential gear and differential lock assembly (22) and
install it to differential gear case (67) and tighten the retainer
mounting bolts (21) (three pieces).
A. Sling the differential gear case and set the standard shims (hav-
ing the thickness and quantity checked when disassembled)
and install side carrier and shaft assembly (19) on the bevel
gear side.
B. Under the above condition, set the standard shim (having the
thickness and quantity checked when disassembled) and install
side carrier and shaft assembly (20) on the opposite side.
30-168 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT DIFFERENTIAL
C. Adjusting preload on side bearing
ii.
If the rotating force is larger than the standard level,
increase the thickness/quantity of the shims. If the former
is in the standard range, it is normal.
★ After adjusting the tooth contact and backlash, the shims
on both sides may be exchanged with each other. Do not
change the total quantity and thickness of the shims on
both sides, however.
i. Using push tool 1), install bearing outer race (13o) to case
(11).
ii. Using push tool 1!, install bearing outer race (16o) to case
(11).
HM400-1L 30-169
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT DIFFERENTIAL
iii. Using tool H1, press fit bearing inner race (13i) to pinion
(10).
B. Using tool H1, press fit case assembly (11) to pinion (10).
★ Never push the case assembly with a press.
★ Press fit bearing inner race (16i) with tool H1.
★ Press fitting force: 0 - 8134 N
★ Press fit case assembly (11), turning it.
i. Using push tool 1@, press fit seal (15) to case (11).
ii. Using tool H2, press fit seal (14) to case (11).
30-170 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT DIFFERENTIAL
A. Using push tool 1#, press fit speed detection gear (8) to cou-
pling (7).
★ Press fit the gear until it is flush with the coupling.
HM400-1L 30-171
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT DIFFERENTIAL
7. Adjusting tooth contact and backlash
Adjust the backlash and tooth contact simultaneously.
i. Move the bevel gear with the shims (69) and (70) of both
carrier assemblies. At this time, do not change the total
quantity and thickness of the shims on both sides so that
the preload on the bearing will not change
30-172 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT DIFFERENTIAL
Testing
A. Apply red lead thinly to the tooth surfaces of the bevel pinion
and turn the bevel gear in the forward and reverse directions,
then check the tooth contact pattern on the bevel gear.
HM400-1L 30-173
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT DIFFERENTIAL
Adjusting
If the tooth contact pattern is not proper, adjust it according to the fol-
lowing procedure.
1. If the bevel pinion is too far from the center line of the bevel gear,
the contact is at the small end of the bevel gear tooth surfaces
curved outward and at the large end of the bevel gear tooth surfaces
curved inward.
● In this case, adjust the tooth contact according to the following
procedure. Adjust the thickness of the shims on the bevel pin-
ion side to move the bevel pinion in direction A. Adjust the
thickness of the shims of both carrier assemblies to move the
bevel gear in direction B, then check the tooth contact pattern
and backlash again.
2. If the bevel pinion is too close to the center line of the bevel gear,
contact is at the large end of the bevel gear tooth faces curved out-
ward and the small end of the bevel gear tooth faces curved inward.
● In this case, adjust the tooth contact similarly to step 1 above.
Reverse directions A and B, however.
● If the shim on either side is reduced to adjust the projection of
the bevel gear, increase the shim on the opposite side by the
same quantity so that the preload on the bearing will not
change.
● After adjusting the tooth contact, refer to the sections of the
mounting bolts of both bevel gear side carriers, both output
shaft couplings, pinion and case assembly, and input shaft and
observe the application of adhesive and tightening torque.
30-174 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF CENTER DIFFERENTIAL
1. Draining oil
Drain oil from the center differential case and center final drive
case.
★ Make match marks so that the spline will not shift in the cir-
cumferential direction.
HM400-1L 30-175
DISASSEMBLY AND ASSEMBLY REMOVAL OF CENTER DIFFERENTIAL
5. Coupling on rear differential side
Remove the holder, coupling (4) on the rear differential side, and
cover (5).
30-176 HM400-1L
DISASSEMBLY AND ASSEMBLY INSTALLATION OF CENTER DIFFERENTIAL
● When installing the drive shaft, check that the key way of the spider
cap is matched to that of the mating yoke and tighten the bolts.
★ When installing the drive shaft, check that the key way of the spider
cap is matched to that of the mating yoke and tighten the bolts.
HM400-1L 30-177
DISASSEMBLY AND ASSEMBLY INSTALLATION OF CENTER DIFFERENTIAL
● Pour the specified oil in the center differential case and final drive
case to the specified level.
● Check the oil level in the transmission case and add the specified
oil to the specified level if necessary.
● Check the oil level in the hydraulic tank and add the specified oil to
the specified level if necessary.
30-178 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CENTER DIFFERENTIAL
2. Cover
Remove cover (1).
4. Cage
HM400-1L 30-179
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CENTER DIFFERENTIAL
B. Remove side seal (5), oil seal (6), and bearing outer race (7o)
from cage (12).
30-180 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CENTER DIFFERENTIAL
B. Remove holder (14) and key (15).
7. Transfer case
B. Remove bearing outer race (10o) and bearing (18) from trans-
fer case (17).
HM400-1L 30-181
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CENTER DIFFERENTIAL
8. Input gear and spacer
Remove spacer (19) and input gear (20).
★ Check the identification mark (A - J) of the spacer.
9. Cage assembly
30-182 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CENTER DIFFERENTIAL
B. Disassemble pinion assembly (24) according to the following
procedure. Remove bearing inner race (21i) from pinion (25).
B. Using tool H6, loosen adjustment nuts (28) and (29) to the
degree that you can turn them with fingers.
HM400-1L 30-183
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CENTER DIFFERENTIAL
E. Disassemble the differential gear case assembly according to
the following procedure.
i. Gear case
a. Set the gear case to a block (Height: Approximately
200 mm).
b. Remove mounting bolts (33) (20 pieces).
c. Lift off case (34) with wires.
d. Remove seal rings (35) and (36) from case (34).
30-184 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CENTER DIFFERENTIAL
b. Using puller E, remove bearing inner race (50i) from
bevel gear and case assembly (49).
c. Remove case (51) from bevel gear (52).
HM400-1L 30-185
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CENTER DIFFERENTIAL
x. Remove pinion gear assembly (55) and cross shaft (56) in
one unit.
30-186 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER DIFFERENTIAL
ii. Install bushing (sleeve) (59), pinion gear (58), and washer
(57).
HM400-1L 30-187
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER DIFFERENTIAL
iii. Install pinion gear assembly (55) and cross shaft (56) in
one unit.
30-188 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER DIFFERENTIAL
b. Install bearing inner race (50i) to bevel gear and case
assembly (49) by shrink fit.
★ Shrink fit temperature: 120° C for 30 minutes
vi. Turn over the case and install pin (45), disc (44), and plate
(43).
★ Apply engine oil (EO-30) to the surfaces of the disc and
plate.
HM400-1L 30-189
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER DIFFERENTIAL
vii. Install seal ring (40) to piston (39).
★ Take care of the direction of the seal ring.
xiii. Install sleeve (42), taking care not to damage seal ring
(36).
2. Differential assembly
ii. Sling gear case (62) and install the outer race to the bear-
ing, then install them to differential case (61).
3. Caps
A. Install caps (31) and (32) and tighten bolt (30) temporarily.
30-190 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER DIFFERENTIAL
4. Bearing
A. Rotate the adjustment rings (28) and (29) with bar H6 until the
ring gear reaches the pinion gear and the backlash is elimi-
nated.
★ Rotate the bearing sufficiently so that it will come in con-
tact with the other contact surfaces and hit the ring gear
with a copper hammer, etc.
★ Apply sufficient amount of oil to the bearing.
★ If you loosened either adjustment ring by one turn, tighten
the other one by one turn.
B. Install a spring balance to the ring gear and measure the free
rotating force at this time.
Starting tangential force: 10.1 - 19.4 N
HM400-1L 30-191
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER DIFFERENTIAL
A. Install input shaft and gear assembly (8) to transfer case (17)
without inserting any shim. Install cage assembly (4) and
tighten mounting bolts (64) (eight pieces) to 113.0 Nm.
★ At this time, tighten mounting bolts (64) repeatedly, rotat-
ing the bearing, until rotation is stabilized.
B. Sling the coupling with a crane and measure the end play after
adjustment with dial gauge 1!. Determine the thickness of the
shims so that end play will be 0 - 0.05 mm.
30-192 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER DIFFERENTIAL
9. Assembly of bevel pinion assembly
Assemble bevel pinion assembly (8) according to the following
procedure.
● Using push tool 1@, press fit bearing inner race (21i) to pinion
(25).
B. Cage assembly
HM400-1L 30-193
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER DIFFERENTIAL
C. Input gear and spacer
Install input gear (20) and spacer (19).
★ Install the spacer checked when disassembled.
MD shim Part No. Letter stamped on
Spacer width
thickness range of spacer spacer
0.013 - 0.113 56B-23-16910 A 25.887±0.025
0.114 - 0.213 56B-23-169120 B 25.787±0.025
0.214 - 0.313 56B-23-16930 C 25.687±0.025
0.314 - 0.413 56B-23-16940 D 25.587±0.025
0.414 - 0.513 56B-23-16950 E 25.487±0.025
0.514 - 0.613 56B-23-16960 F 25.387±0.025
0.614 - 0.713 56B-23-16970 G 25.287±0.025
0.714 - 0.813 56B-23-16980 H 25.187±0.025
0.814 - 0.913 56B-23-16990 J 25.087±0.025
D. Transfer case
Install transfer case assembly (16).
H Check that the bearing of the pinion is fitted accurately.
30-194 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER DIFFERENTIAL
F. Input shaft holder
ii. Set the standard shim (having the thickness and quantity
checked when disassembled) and install holder (13).
i. Move the bevel gear with the adjustment nuts (28) and
(29). At this time, rotate the nuts on both sides by the same
turns in the same direction so that the preload on the bear-
ing will not change.
HM400-1L 30-195
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER DIFFERENTIAL
Testing
ii.
The center of the tooth contact must be at the middle of the
tooth height and about 33% (b) of tooth depth from the
small end. The width of the tooth contact must be 30 -
60% (a) of the tooth depth. Check that there is not a strong
contact at the tips or bottoms of the teeth of both small end
and large end.
★ If the bevel gear and bevel pinion are adjusted in this way,
their teeth come in contact with each other correctly when
they are loaded.
30-196 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER DIFFERENTIAL
Adjusting
If the tooth contact pattern is not proper, adjust it according to the
following procedure.
iii. If the bevel pinion is too far from the center line of the
bevel gear, the contact is at the small end of the bevel gear
tooth surfaces curved outward and at the large end of the
bevel gear tooth surfaces curved inward.
● In this case, adjust the tooth contact according to the fol-
lowing procedure.
Adjust the thickness of the shims on the bevel pinion side
to move the bevel pinion in direction A. Adjust the thick-
ness of the shims of both carrier assemblies to move the
bevel gear in direction B, then check the tooth contact pat-
tern and backlash again.
iv. If the bevel pinion is too close to the center line of the
bevel gear, contact is at the large end of the bevel gear
tooth faces curved outward and the small end of the bevel
gear tooth faces curved inward.
● In this case, adjust the tooth contact similarly to iii above.
Reverse directions A and B, however.
★ If the shim on either side is reduced to adjust the projec-
tion of the bevel gear, increase the shim on the opposite
side by the same quantity so that the preload on the bear-
ing will not change.
13. Cage
A. Install bearing outer race (7o) to cage (10). Using tool H11,
press fit oil seal (6).
★ Press fit oil seal (6) so that clearance "c" between the
periphery of oil seal (6) and cage (10) will be 10 ± 0.5
mm.
HM400-1L 30-197
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER DIFFERENTIAL
B. Using tool H5, press fit side seal (5) to cage (10).
★ If the side seal is press fitted with this tool until it is flush
with the cage, it is positioned accurately.
30-198 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER DIFFERENTIAL
15. Cover
Install cover (1).
HM400-1L 30-199
DISASSEMBLY AND ASSEMBLY REAR DIFFERENTIAL REMOVAL
1. Draining oil
Drain oil from the rear differential case and rear final drive case.
30-200 HM400-1L
DISASSEMBLY AND ASSEMBLY REAR DIFFERENTIAL INSTALLATION
5. Rear differential assembly
Sling rear differential (10) temporarily. Using forcing screws (M14
x 2), pull out the rear differential. After pulling out the differential
halfway, change the slinging position (increase the number of
slings) and remove the differential.
★ Support the rear differential from its underside, too, with trans-
mission jack B, etc.
★ Since the rear side of the rear differential is a little low, it does
not come out easily. Accordingly, use guide bolt C, etc. to pull
out the rear differential forward carefully.
★ When installing the drive shaft, check that the key way of the spider
cap is matched to that of the mating yoke and tighten the bolts.
HM400-1L 30-201
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF REAR DIFFERENTIAL
B. Remove side seal (6) and oil seal (7) from pinion and cage
assembly (5).
30-202 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF REAR DIFFERENTIAL
C. Remove pinion assembly (8) from cage assembly (9).
HM400-1L 30-203
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF REAR DIFFERENTIAL
4. Differential gear and differential lock assembly
★ Sling the differential case in advance.
B. Using tool H6, loosen adjustment nuts (28) and (29) to the
degree that you can turn them with fingers.
i. Gear case
a. Set the gear case to a block (Height: Approximately
200 mm).
b. Remove mounting bolts (33) (20 pieces).
c. Lift off case (34) with wires.
d. Remove seal rings (35) and (36) from case (34).
30-204 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF REAR DIFFERENTIAL
vi. Remove plate (43) and disc (44).
HM400-1L 30-205
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF REAR DIFFERENTIAL
ix. Remove washer (53) and differential side gear (54).
30-206 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF REAR DIFFERENTIAL
xii. Remove side gear (60).
HM400-1L 30-207
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF REAR DIFFERENTIAL
ii. Install bushing (sleeve) (59), pinion gear (58), and washer
(57).
iii. Install pinion gear assembly (55) and cross shaft (56) in
one unit.
30-208 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF REAR DIFFERENTIAL
iv. Install differential side gear (54) and washer (53).
HM400-1L 30-209
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF REAR DIFFERENTIAL
vi. Turn over the case and install pin (45), disc (44), and plate
(43).
★ Apply engine oil (EO-30) to the surfaces of the disc and
plate.
xiii. Install sleeve (42), taking care not to damage seal ring
(36).
2. Assembly of differential
ii. Sling gear case (62) and install the outer race to the bear-
ing, then install them to differential case (63).
30-210 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF REAR DIFFERENTIAL
3. Caps
A. Install caps (31) and (32) and tighten bolt (30) temporarily.
4. Bearing
A. Rotate the adjustment rings (28) and (29) with bar H6 until the
ring gear reaches the pinion gear and the backlash is elimi-
nated.
★ Rotate the bearing sufficiently so that it will come in con-
tact with the other contact surfaces and hit the ring gear
with a copper hammer, etc.
★ Apply sufficient amount of oil to the bearing.
★ If you loosened either adjustment ring by one turn, tighten
the other one by one turn.
B. Install a spring balance to the ring gear and measure the free
rotating force at this time.
Starting tangential force: 10.1 - 19.4 N
HM400-1L 30-211
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF REAR DIFFERENTIAL
B. Disassembly of pinion assembly
Install bearing inner race (12i) to pinion (10).
★ Install bearing inner race (12i) by shrink fit or by using
push tool H.
C. Erect pinion assembly (8) and insert spacer (11) and install
cage assembly (9).
30-212 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF REAR DIFFERENTIAL
D. Using push tool I and turning cage assembly (9), install bear-
ing inner race (14i).
★ Never push bearing inner race (14i) with a press.
★ Apply oil to bearing inner race (14i).
HM400-1L 30-213
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF REAR DIFFERENTIAL
6. Pinion and cage assembly
Set the standard shim (having the thickness and quantity checked
when disassembled) and install pinion and cage assembly (3).
★ Execute Step 8 "Measurement of tooth contact and backlash,"
then determine the quantity and thickness of the shims.
i. Move the bevel gear with the adjustment nuts (28) and
(29). At this time, rotate the nuts on both sides by the same
turns in the same direction so that the preload on the bear-
ing will not change.
30-214 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF REAR DIFFERENTIAL
Testing
ii.
The center of the tooth contact must be at the middle of the
tooth height and about 33% (b) of tooth depth from the
small end. The width of the tooth contact must be 30 -
60% (a) of the tooth depth. Check that there is not a strong
contact at the tips or bottoms of the teeth of both small end
and large end.
★ If the bevel gear and bevel pinion are adjusted in this way,
their teeth come in contact with each other correctly when
they are loaded.
HM400-1L 30-215
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF REAR DIFFERENTIAL
Adjusting
If the tooth contact pattern is not proper, adjust it according to the fol-
lowing procedure.
iii. If the bevel pinion is too far from the center line of the
bevel gear, the contact is at the small end of the bevel gear
tooth surfaces curved outward and at the large end of the
bevel gear tooth surfaces curved inward.
● In this case, adjust the tooth contact according to the fol-
lowing procedure. Adjust the thickness of the shims on the
bevel pinion side to move the bevel pinion in direction A.
Adjust the thickness of the shims of both carrier assem-
blies to move the bevel gear in direction B, then check the
tooth contact pattern and backlash again.
iv. If the bevel pinion is too close to the center line of the
bevel gear, contact is at the large end of the bevel gear
tooth faces curved outward and the small end of the bevel
gear tooth faces curved inward.
● In this case, adjust the tooth contact similarly to iii above.
Reverse directions A and B, however.
★ If the shim on the either side is reduced to adjust the pro-
jection of the bevel gear, increase the shim on the opposite
side by the same quantity so that the preload on the bear-
ing will not change.
30-216 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF FRONT FINAL DRIVE AND BRAKE
2. Jacking up
3. Left fender
Lift of left fender (1).
4. Front wheels
Sling the front wheels (2) temporarily, then remove the mounting
HM400-1L 30-217
DISASSEMBLY AND ASSEMBLY REMOVAL OF FRONT FINAL DRIVE AND BRAKE
6. Brake cooling tubes and brake drive hose
Disconnect brake cooing tubes (4) (two pieces) and brake drive
hose (5).
7. Front final drive and brake and side drive shaft assembly
Lift off front final drive and brake and side drive shaft assembly
(6).
★ When removing, take extreme care that the spline at the
center of the side drive shaft will not come out.
30-218 HM400-1L
DISASSEMBLY AND ASSEMBLY INSTALLATION OF FRONT FINAL DRIVE AND BRAKE
● When installing the drive shaft, check that the key way of the spider
cap is matched to that of the mating yoke and tighten the bolts.
HM400-1L 30-219
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
30-220 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
3. Place the assembly with the brake side down.
4. Sun gear
Remove sun gear (5).
5. Carrier assembly
HM400-1L 30-221
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
6. Thrust washer
Remove thrust washer (11).
7. Plate
Using forcing screw B, remove plate (12).
9. Ring gear
30-222 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
B. Disassemble the ring gear according to the following proce-
dure.
HM400-1L 30-223
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
11. Place the assembly with the brake side up.
30-224 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
b. Remove seal rings (28) and (29) from cylinder (26) and
piston (27).
C. Remove damper (end plate) (30), plate (31), and disc (32).
★ Check the cut of the plate.
HM400-1L 30-225
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
13. Hub (inner gear) and outer gear
B. Remove floating seal and cage assembly (36) and floating seal
(22b) from hub (inner gear) (35).Check the cut of the plate.
C. Remove floating seal (37a) from floating seal and cage assem-
bly (36).
30-226 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
D. Remove cover (39) from outer gear (38), then remove seal
(40).
HM400-1L 30-227
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
A. Using tool J5, install floating seal (37o) to outer gear (38).
30-228 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
C. Install cover (39) to outer gear (38).
E. Using tool J5, install floating seal (22b) to hub (inner gear)
(35).
HM400-1L 30-229
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
G. Install outer gear (34) to hub (inner gear) (33).
★ Take extreme care that the floating seal will not be dam-
aged or rolled up.
3. Brake assembly
A. Install disc (31), plate (30), and damper (end plate) (29).
★ When installing the plate, match the six cuts on its periph-
ery.
30-230 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
B. Assemble the brake assembly according to the following pro-
cedure.
HM400-1L 30-231
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
iii. Install tools J1.
30-232 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
B. Install floating seal cage (21) {including a half part of floating
seal (22a)}.
6. Ring gear
i. Using tool J3, press fit bearing inner race (46) to inner hub
(20).
HM400-1L 30-233
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
B. Install ring gear (16).
ii. Remove tools J1 (from three places) and tighten the bolts.
30-234 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
B. Set a shim of proper thickness and retainer (15) and tighten the
mounting bolts.
★ Rotating inner gear (13), tighten the mounting bolt evenly
until the tightening torque becomes constant.
★ After tightening the mounting bolts, turn inner gear (13) and
check that it rotates normally.
8. Shaft
Install shaft (4).
9. Plate
Install plate (12).
HM400-1L 30-235
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
10. Thrust washer
Install thrust washer (11).
30-236 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
12. Sun gear
Install sun gear (5) and snap ring (3).
★ If the inside diameter of removed snap ring (3) is larger than
51.4 mm or its level difference measured on a level place is
larger than 0.3 mm, do not use it again.
13. Cover
Install cover (2).
HM400-1L 30-237
DISASSEMBLY AND ASSEMBLY REMOVAL OF CENTER FINAL DRIVE AND BRAKE
30-238 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF CENTER FINAL DRIVE AND BRAKE
5. Sun gear and drive shaft
Remove the center final drive cover and sun gear and drive shaft
(4).
HM400-1L 30-239
DISASSEMBLY AND ASSEMBLY INSTALLATION OF CENTER FINAL DRIVE AND BRAKE
30-240 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CENTER FINAL DRIVE AND PLATE
2. Carrier assembly
HM400-1L 30-241
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CENTER FINAL DRIVE AND PLATE
4. Ring gear
Remove ring gear (9).
30-242 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CENTER FINAL DRIVE AND PLATE
5. Floating seal cage and floating seal
Remove floating seal cage (14) [including a half part of floating
seal (15a)].
★ Use a forcing screw of M10 (long size) to remove the floating
seal cage.
7. Brake assembly
HM400-1L 30-243
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CENTER FINAL DRIVE AND PLATE
B. Disassemble the brake assembly according to the following
procedure.
30-244 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CENTER FINAL DRIVE AND PLATE
b. Remove seal rings (21) and (22) from cylinder (19) and
piston (20).
C. Remove damper (end plate) (23), plate (24), and disc (25).
★ Check the cut of the plate.
HM400-1L 30-245
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CENTER FINAL DRIVE AND PLATE
8. Hub (inner gear) and outer gear
B. Remove floating seal and cage assembly (29) and floating seal
(15b) from hub (inner gear) (28).
C. Remove floating seal (30a) from floating seal and cage assem-
bly (29).
30-246 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CENTER FINAL DRIVE AND PLATE
D. Remove cover (32) from outer gear (31), then remove seal
(33).
HM400-1L 30-247
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE
A. Using tool J5, install floating seal (30b) to outer gear (31).
30-248 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE
D. Using tool J5, install floating seal (30a) to cage (36).
★ Measure height A of the seal above the gear, hub, and
ratainer (at four places on the periphery) and check that its
dispersion is less than 1 mm.
E. Using tool J5, install floating seal (15b) to hub (inner gear)
(28).
HM400-1L 30-249
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE
3. Brake assembly
A. Install disc (25), plate (24), and damper (end plate) (23).
★ When installing the plate, match the six cuts on its periph-
ery.
30-250 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE
b. Install piston (20) to cylinder (19).
HM400-1L 30-251
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE
4. Place the assembly with the brake side down.
30-252 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE
6. Ring gear
i. Using tool J3, press fit bearing inner race (39) to inner hub
(13).
HM400-1L 30-253
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE
7. Retainer and shim
ii. Remove tools J1 (from three places) and tighten the bolts.
30-254 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE
B. Set a shim of proper thickness and retainer (8) and tighten the
mounting bolts.
★ Rotating inner gear (6), tighten the mounting bolt evenly
until the tightening torque becomes constant.
8. Carrier assembly
HM400-1L 30-255
DISASSEMBLY AND ASSEMBLY REMOVAL OF REAR FINAL DRIVE AND BRAKE
4. Rear wheel
Sling the rear wheels (1) temporarily and remove the mounting
bolts to remove rear wheels (1).
30-256 HM400-1L
DISASSEMBLY AND ASSEMBLY INSTALLATION OF REAR FINAL DRIVE AND BRAKE
6. Sun gear and drive shaft
Remove the rear final drive cover and sun gear and drive shaft (4).
HM400-1L 30-257
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF REAR FINAL DRIVE AND BRAKE
2. Carrier assembly
30-258 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF REAR FINAL DRIVE AND BRAKE
4. Ring gear
HM400-1L 30-259
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF REAR FINAL DRIVE AND BRAKE
5. Floating seal cage and floating seal
Remove floating seal cage (14) [including a half part of floating
seal (15a)].
★ Use a forcing screw of M10 (long size) to remove the floating
seal cage.
7. Brake assembly
30-260 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF REAR FINAL DRIVE AND BRAKE
B. Disassemble the brake assembly according to the following
procedure.
HM400-1L 30-261
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF REAR FINAL DRIVE AND BRAKE
b. Remove seal rings (21) and (22) from cylinder (19) and
piston (20).
C. Remove damper (end plate) (23), plate (24), and disc (25).
★ Check the cut of the plate.
30-262 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF REAR FINAL DRIVE AND BRAKE
8. Hub (inner gear) and outer gear
B. Remove floating seal and cage assembly (29) and floating seal
(15b) from hub (inner gear) (28).
C. Remove floating seal (30a) from floating seal and cage assem-
bly (29).
HM400-1L 30-263
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF REAR FINAL DRIVE AND BRAKE
D. Remove cover (32) from outer gear (31), then remove seal
(33).
30-264 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF REAR FINAL DRIVE AND BRAKE
A. Using tool J5, install floating seal (30b) to outer gear (31).
HM400-1L 30-265
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF REAR FINAL DRIVE AND BRAKE
D. Using tool J5, install floating seal (30a) to cage (36).
★ Measure height A of the seal above the gear, hub, and
ratainer (at four places on the periphery) and check that its
dispersion is less than 1 mm.
E. Using tool J5, install floating seal (15b) to hub (inner gear)
(28).
30-266 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF REAR FINAL DRIVE AND BRAKE
3. Brake assembly
A. Install disc (25), plate (24), and damper (end plate) (23).
★ When installing the plate, match the six cuts on its periph-
ery.
HM400-1L 30-267
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF REAR FINAL DRIVE AND BRAKE
ii. Install cylinder assembly (18).
30-268 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF REAR FINAL DRIVE AND BRAKE
B. Install floating seal cage (14) {including a half part of floating
seal (15a)}.
★ Measure height A of the seal above the gear, hub, and
ratainer (at four places on the periphery) and check that its
dispersion is less than 1 mm.
6. Ring gear
i. Using tool J3, press fit bearing inner race (39) to inner hub
(13).
HM400-1L 30-269
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF REAR FINAL DRIVE AND BRAKE
ii. Install holder (11) and tighten mounting bolts (10).
ii. Remove tools J1 (from three places) and tighten the bolts.
30-270 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF REAR FINAL DRIVE AND BRAKE
B. Set a shim of proper thickness and retainer (8) and tighten the
mounting bolts.
★ Rotating inner gear (6), tighten the mounting bolt evenly
until the tightening torque becomes constant.
8. Carrier assembly
HM400-1L 30-271
DISASSEMBLY AND ASSEMBLY REMOVAL OF CENTER AXLE
2. Jacking up frame
B. Jack up the center axle and rear axle with jacks C and D.
3. Center wheels
Sling both center wheels temporarily, then remove the mounting
bolts and center wheels (1).
30-272 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF CENTER AXLE
5. Drive shaft between center differential and rear differential
Remove the guard and sling off drive shaft (8) between the center
differential and rear differential.
7. Lateral rod
Remove lateral rod (10).
HM400-1L 30-273
DISASSEMBLY AND ASSEMBLY REMOVAL OF CENTER AXLE
B. Remove holder plate (13) of the center axle arm support, then
remove center axle and arm assembly (12) down.
30-274 HM400-1L
DISASSEMBLY AND ASSEMBLY INSTALLATION OF CENTER AXLE
★ When installing the drive shaft, check that the key way of the spider
cap is matched to that of the mating yoke and tighten the bolts.
Mounting bolt of drive shaft between center differential and
rear differential: Adhesive (LT-2)
★ When installing the lateral rod, match tap hole (a) to the center line
of bearing (15) as shown in Fig. 1.
HM400-1L 30-275
DISASSEMBLY AND ASSEMBLY INSTALLATION OF CENTER AXLE
★ Install the center axle and arm assembly so that distance (y)
between the rear frame top and equalizer bar spring top will be 201
mm when distance (x) between the rear suspension cylinder pins is
574 mm (Clearance "z" between the rear axle top and rear frame
bottom is 130 mm at this time).
30-276 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF REAR AXLE
2. Jacking up frame
B. Jack up the center axle and rear axle with jacks C and D.
3. Rear wheels
Sling both rear wheels temporarily, then remove the mounting bolts
and rear wheels (1).
HM400-1L 30-277
DISASSEMBLY AND ASSEMBLY REMOVAL OF REAR AXLE
5. Drive shaft between center differential and rear differential
Remove the guard and sling off drive shaft (8) between the center
differential and rear differential.
6. Lateral rod
Remove lateral rod (9).
7. Bracket (left)
Remove bracket (left) (10).
30-278 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF REAR AXLE
B. Remove holder plate (12) of the rear axle arm support pin.
C. Pull out lower pin (14) of rear suspension cylinder (13) and
remove rear axle and arm assembly (11) down.
HM400-1L 30-279
DISASSEMBLY AND ASSEMBLY INSTALLATION OF REAR AXLE
● When installing the drive shaft, check that the key way of the spider
cap is matched to that of the mating yoke and tighten the bolts.
★ When installing the lateral rod, match tap hole (a) to the center line
of bearing (15) as shown in Fig. 1.
★ Install the rear axle and arm assembly so that distance (y) between
the rear frame top and equalizer bar spring top will be 201 mm
when distance (x) between the rear suspension cylinder pins is 574
mm (Clearance "z" between the rear axle top and rear frame bottom
is 130 mm at this time).
30-280 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF FRONT SUSPENSION CYLINDER
1. Jacking up
2. Left fender
Lift left fender (1).
3. Front wheels
Sling the front wheels (2) temporarily, then remove the mounting
bolts and front wheels (2).
HM400-1L 30-281
DISASSEMBLY AND ASSEMBLY INSTALLATION OF FRONT SUSPENSION CYLINDER
4. Front suspension cylinder
B. Remove upper and lower pins (4) and (5) and front suspension
cylinder assembly (6).
30-282 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF REAR SUSPENSION CYLINDER
A. Jack up the rear frame and rear axle with jacks B and C.
2. Bracket
Remove bracket (2).
HM400-1L 30-283
DISASSEMBLY AND ASSEMBLY REMOVAL OF REAR SUSPENSION CYLINDER
★ When installing the lateral rod, match tap hole (a) to the center line
of bearing (15) as shown in Fig. 1.
30-284 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF EQUALIZER BAR
4. Remove the rear wheels (front and rear) on the side from which the
equalizer bar will be removed. For details, see Removal of rear
wheel assembly.
5. Remove bottom pin (5) of the rear suspension cylinder and bring
cylinder (6) down toward the rear of the vehicle body.
HM400-1L 30-285
DISASSEMBLY AND ASSEMBLY REMOVAL OF EQUALIZER BAR
6. Remove four mounting bolts (8) of the equalizer bar above cushion
(7).
8. Remove mounting bolts (10) of plate (9) at the center of the equal-
izer bar.
30-286 HM400-1L
DISASSEMBLY AND ASSEMBLY INSTALLATION OF EQUALIZER BAR
Refill the rear suspension cylinder with nitrogen gas. For details, see
Testing and adjusting suspension cylinder.
★ When installing the plate, measure the distance between the vehicle
body and equalizer bar and adjust the difference between distances
"a" and "b" and between "c" and "d" will be 2 mm respectively.
★ Install the rear axle and arm assembly so that distance (y) between
the rear frame top and equalizer bar spring top will be 201 mm
when distance (x) between the rear suspension cylinder pins is 574
mm (clearance "z" between the rear axle top and rear frame bottom
is 130 mm at this time).
HM400-1L 30-287
DISASSEMBLY AND ASSEMBLY REMOVAL OF FRONT WHEEL
2. Left fender
Lift of left fender (1).
3. Front wheels
Sling the front wheels (2) temporarily, then remove the mounting
bolts and front wheels (2).
30-288 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF REAR WHEEL AS-
HM400-1L 30-289
DISASSEMBLY AND ASSEMBLY REMOVAL OF HITCH FRAME
A. Disconnect hoist cylinder hoses (1) and (2), brake hoses (3) -
(6), brake cooling hoses (7) and (8), and parking brake hose
(9).
C. Remove the mounting bolts of plate (13) and parking brake and
cylinder assembly (14).
30-290 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF HITCH FRAME
3. Drive shaft between hitch frame and center differential
Remove the guard and drive shaft (15) between the hitch frame and
center differential.
HM400-1L 30-291
DISASSEMBLY AND ASSEMBLY REMOVAL OF HITCH FRAME
7. Steering cylinder
Remove head pin (19) and disconnect steering cylinders (20) (on
both sides).
ii. Support the front frame with a jack, etc. for safety.
9. Hinge pins
A. Move the rear frame of the front operator’s cab section and the
front frame of the rear dump body section up and down with
jacks D and E to center the hinge pins.
30-292 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF HITCH FRAME
B. Remove plate (21) and pull down out upper hinge pin (22).
HM400-1L 30-293
DISASSEMBLY AND ASSEMBLY REMOVAL OF HITCH FRAME
10. Disconnection of front and rear sections
Hold the front part of the front operator’s cab section with a forklift
and a crane and move it forward to disconnect from the rear dump
body section.
30-294 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF HITCH FRAME
C. Pulling out hitch frame assembly (26) forward, lift it off.
★ When pulling out the hitch frame assembly forward, hold
bearing inner race (26i) so that it will not fall.
★ Push out the side end of hitch frame (25) forward with a
thin and small puller, and the hitch frame is pulled out
(removed) easily.
★ After pulling out the hitch frame halfway, increase the
number of slings (change the slinging position) so that the
hitch frame will be balanced when lifted off.
HM400-1L 30-295
DISASSEMBLY AND ASSEMBLY INSTALLATION OF HITCH FRAME
★ Bleed air from the brake circuit. For details, see TESTING
AND ADJUSTING, Bleeding air from brake circuit.
★ Test the wear of the brake pad and adjust the brake pad clear-
ance. For details, see TESTING AND ADJUSTING, Testing
wear of parking brake pad.
★ When installing the drive shaft, check that the key way of the
spider cap is matched to that of the mating yoke and tighten the
bolts.
● When installing the drive shaft, check that the key way of the spider
cap is matched to that of the mating yoke and tighten the bolts.
30-296 HM400-1L
DISASSEMBLY AND ASSEMBLY INSTALLATION OF HITCH FRAME
★ When installing rear seal (27) to rear retainer (28), use push tool
G matched to the diameter of the seal.
D. Rotate hitch frame (31) by five to six turns, then repeat steps B
and C above.
★ Repeat steps B through D above until dimension "d" is sta-
bilized.
HM400-1L 30-297
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF HITCH FRAME
2. Rear retainer
B. Remove ring (5) and dust seal (6) from rear retainer (4).
3. Center shaft
30-298 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF HITCH FRAME
B. Remove rear bearing (10) and front bearing inner race (11i)
from center shaft (9).
HM400-1L 30-299
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF HITCH FRAME
1. Center shaft
Using the push tool, press fit rear bearing (10) and bearing inner
race (11i) to center shaft (9).
Fill the inside space of ring (15) with grease [Part A: 60%
pack (76g), Part: 60% pack (88g)].
Fill the inside space of front bearing outer race (11o) with
grease [Part 1: 40% pack (27g)].
Fill the inside space of rear bearing (10) with grease [Part J:
40% pack (23g)].
30-300 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF HITCH FRAME
3. Installation of center shaft and bearing assembly
Install the center shaft and bearing assembly (8) to hitch frame (7)
carefully from rear.
★ At this time, press fit rear bearing (10) to hitch frame (7), too.
Fill the inside space of rear bearing (10) with grease [Part J:
40% pack (23g)].
★ Select grease for the above parts from Table 1. (For part J, see
2 above.)
Table 1
B. Install dust seal (18) and O-ring to front cage (17), then install
front cage (13) to hitch frame (12).
Fill the inside space of dust seal (18) with grease [Part K: Full
pack (25g), Part C: 60% pack (74g)].
HM400-1L 30-301
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF HITCH FRAME
5. Coupling
Install coupling (2) and coupling holder (1).
6. Rear retainer
A. Install ring (5), dust seal (6), and O-ring to rear retainer (4).
30-302 HM400-1L
DISASSEMBLY AND ASSEMBLY STANDARD INTEGRAL ORBIT-ROLL
HM400-1L 30-303
DISASSEMBLY AND ASSEMBLY STANDARD INTEGRAL ORBIT-ROLL
30-304 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF STEERING VALVE
1. Put end cap (3) at the top, fit side face of housing between copper
sheets in vice I, and be careful not to over-tighten vice.
2. Remove six screws (1) and one retainer screw (2), then remove end
cap (3). Remove O-ring (22) from end cap (3).
HM400-1L 30-305
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF STEERING VALVE
4. Remove drive (8), then remove spacer plate (7). Remove O-ring
(23) from housing.
6. Set housing upside down, remove two springs (31), two retainer
lugs (30), and two balls (32).
★ Be careful not to drop or lose the parts.
30-306 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF STEERING VALVE
8. Set housing on clean cloth with axial line of valve horizontal. Turn
spool and sleeve assembly to set sleeve pin in horizontal position,
then push out spool and sleeve assembly slightly, and remove seal
gland bushing (21) from housing.
Remove oil seal and dust seal from gland bushing.
★ When removing the seal, be careful not to damage the seal
gland bushing.
10. Push spline portion inside spool with thumb and remove spool and
sleeve assembly from opposite side of housing flange. When doing
this, be careful not to let outside diameter of sleeve get caught in
inside diameter of housing.
★ Depending on the assembly of sleeve and spool, it may not
work properly if it is assembled 180° from the proper direction,
so make marks to show the position of spool and sleeve (43).
Remove pin (12).
11. Push out spool inside sleeve slightly, and remove centering spring
(13) carefully by hand from spool.
HM400-1L 30-307
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF STEERING VALVE
12. Rotate spool slowly and pull out spool (11) from sleeve (10).
Remove O-ring from housing.
30-308 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF STEERING VALVE
1. Turn spool (11) and insert slowly into sleeve (10). Grip spline por-
tion of spool and check that spool rotates smoothly inside sleeve.
Align mark made when disassembling.
2. Align two spring grooves at 180° in spool and sleeve, then stand on
a horizontal plate. Insert spring insertion tool (Part No.: 60057) in
spring groove, then fit centering spring to insertion tool so that
notched portions at both ends are at bottom. When doing this, it is
easier to insert if spool is lifted up slightly from sleeve. Hold cen-
tering spring at opposite end with a finger and compress it to push it
into spool sleeve groove. When doing this, slide insertion tool at
same speed as pushing in spring. After inserting, align end of spring
with outside diameter of sleeve. Insert sleeve pin into hole in
sleeve, and align both ends of pin with outside diameter of sleeve.
HM400-1L 30-309
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF STEERING VALVE
3. Set housing on clean cloth with axial line of valve horizontal. Insert
spool and sleeve assembly from opposite end of housing to flange
end. In this condition, check that spool and sleeve assembly rotates
smoothly inside housing.
★ When inserting spool and sleeve assembly, be careful not to
insert it at an angle and get it caught. Keep the pin at near the
horizontal position, and rotate slightly to left and right to insert.
★ Insert so that the end face of the spool and sleeve assembly is
level with the end face of the housing. If it is inserted further,
the pin will fall inside the housing, so stop inserting when the
end face is level.
★ There are two types of seal: Teflon seal and standard seal.
5. Assemble dust seal (19) to seal gland bushing (21). Assemble dust
seal so that flat surface is at seal gland bushing end. Assemble oil
seal (18) to seal gland bushing.
★ Assemble the oil seal carefully so that there is no twisting or
deformation.
★ The diagram below is the Teflon seal specification drawing;
(44) is the distinguishing groove.
30-310 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF STEERING VALVE
6. After assembling seals, rotate seal gland bushing (21) and insert to
spool. Tap with plastic hammer to insert to specified position.
Assemble retaining ring (20) to housing.
★ Push open with a flat-headed screwdriver so that the whole cir-
cumference of the retaining ring fits securely in the groove in
the housing.
● Assemble O-ring (38) to plug (37). Fit grease to ball holder (35)
and install ball (34). Using tweezers, assemble ball holder (35) and
spring (36) to housing. Using hexagonal wrench (width across flats:
3/16 inch), assemble plug (37) to housing.
★ The size of the overload valve ball and the anti-cavitation
check valve ball is different, so be careful not to mix them.
HM400-1L 30-311
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF STEERING VALVE
ASSEMBLY OF ANTI-CAVITATION CHECK VALVE
● Grip the port surface and side surface of the housing lightly in a
vice. Fit copper sheets in the vice, and be careful not to tighten the
vice too strongly.
Of the seven bolt holes in the end face of the housing, insert one
each of spring (31), retainer plug (30), and ball (32) in the two holes
shown in the drawing.
★ Be careful not to drop or lose the ball. Be careful of the assem-
bly direction of the retainer plug.
● Grip the port surface and side surface of the housing lightly in a
vice. (45): 25 mm. Fit copper sheets in the vice, and be careful not
to overtighten the vice.
● Of the seven bolt holes in the end face of the housing, insert ball
(40) in the holes shown in the drawing. Assemble adapter screw
(39) in holes in same drawing.
30-312 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF STEERING VALVE
● Turn spool and sleeve assembly and set pin (12) and port surface
(46) of housing in parallel. Insert drive (8) into portion (47), then
mate drive yoke and pin (12). To carry out positioning exactly, use a
felt pen to draw line on end face of drive (8) parallel to pin.
● Set O-ring at end face of Gerotor (4) at spacer plate (7) side, align
concave portions (48) of Gerotor star teeth with pin (12), align with
mark drawn on end face of drive (8), and assemble.
When doing this, check carefully that lines A, B, C, and D are par-
allel as shown in diagram below.
★ Turn Gerotor ring to align bolt holes. Do not remove mating of
drive and Gerotor star.
★ The above procedure is important for aligning the valve tim-
ing.
HM400-1L 30-313
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF STEERING VALVE
● Order for tightening end cap mounting screws is as shown in dia-
gram below.
Discharge
Discharge Spacer thickness
capacity
capacity symbol (mm)
(cc/rev)
A 51
B 69
C 96 3.6
D 120 6.1
E 159 12.2
G 184 12.2
3.6
K 230 22.0
M 277 24.4
P 369 41.1
S 461 53.7
T 553 66.4
U 737 91.8
30-314 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF FLOW AMPLIFIER VALVE
2. Steering valve
A. Remove left side cover (2) of the operator’s cab and steering
valve side cover.
HM400-1L 30-315
DISASSEMBLY AND ASSEMBLY INSTALLATION OF FLOW AMPLIFIER VALVE
D. Disconnect pump circuit (HP) hose (8) and remove tank circuit
(HT) piping (9).
30-316 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF HOIST VALVE
2. Left fender
Lift off left fender (1).
3. Steering valve
Remove the steering valve assembly. For details, see Removal of
steering valve assembly.
A. Remove the tube of port P of the loosened hoist valve and dis-
connect tank circuit hoses (2), (3), (4).
C. Remove the throttle between tube (6) and hoist valve, too.
D. Disconnect hoses (7) and (8) of pilot ports (PA) and (PB).
F. Disconnect tube (10) and (11) of hoist cylinder ports (A) and
(B).
★ Loosen the rear tube clamp and move the tubes toward the
hydraulic tank.
HM400-1L 30-317
DISASSEMBLY AND ASSEMBLY INSTALLATION OF HOIST VALVE
5. Hoist valve
Remove hoist valve assembly (12).
30-318 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF HOIST VALVE
HM400-1L 30-319
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF HOIST VALVE
● Clean the all parts carefully and remove burrs. 3. Housing assembly
● Apply engine oil to the sliding parts before installing. A. Install retainer (14), valve (13), and spring
(12) to housing (2) and tighten sleeve (11).
1. Body assembly B. Install seat (10) and holder (9) and tighten
A. Install valve (31), spring (30), and seat (29) to body (1). nut (3).
B. Install plug (28) and spool (27) to body (1). C. Install poppet (8), spring (7), and retainer
(6) and tighten nut (5) and screw (4).
2. Spring case assembly D. Install body (1) to housing (2).
A. Install spring (26), retainer (25), and springs (24) and (23) to
spring case (19), then install flange (22).
B. Install plug (21).
C. Install retainer (20) to body (1), then install spring case (19).
D. Install retainer (18) and springs (17) and (16) to body (1), then
install spring case (15).
30-320 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF HOIST VALVE
HM400-1L 30-321
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF STEERING CYLINDER
2. Raise lock of cylinder head nut, and using tool U2, remove cylinder
head assembly (2).
3. Pull out cylinder head and piston rod assembly (3) from cylinder
(4) and remove.
★ When the piston rod assembly is pulled out from the cylinder,
oil will come out, so catch it in a container.
30-322 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF STEERING CYLINDER
6. Disassembly of piston assembly
HM400-1L 30-323
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF STEERING CYLINDER ASSEMBLY
A. Using tool U5, press fit bushing (15) to cylinder head (16).
★ Take care not to deform bushing (15) when press fitting it.
D. Using tool U6, install dust seal (13) to cylinder head (16).
30-324 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF STEERING CYLINDER ASSEMBLY
2. Assembly piston assembly
HM400-1L 30-325
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF STEERING CYLINDER ASSEMBLY
B. Using tool U4, tighten nuts (5).
5. Assemble cylinder head and piston rod assembly (3) in cylinder (4).
30-326 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF HOIST CYLINDER ASSEMBLY
4. Remove bolt (3), then lift off rod (5) from cylinder II (4).
HM400-1L 30-327
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF HOIST CYLINDER ASSEMBLY
7. Disassembly of cylinder head assembly.
A. Remove O-ring, then remove dust seal (9) and rod packing
(10).
8. Remove snap ring (12) from cylinder II (4), then remove piston
assembly (13).
10. Remove snap ring (16) from cylinder II (4), then remove dust seal
(17), rod packing (18), and bushing (19).
30-328 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF HOIST CYLINDER
3. Using tool U6 fit dust seal (17) and install snap ring (16).
HM400-1L 30-329
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF HOIST CYLINDER
4. Assembly of piston assembly
A. Using tool U4, expand piston ring (14), and assemble to piston
(13).
★ Set the piston ring on tool, and turn the handle eight to ten
times to expand the ring.
30-330 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF HOIST CYLINDER
7. Assembly of cylinder head assembly.
HM400-1L 30-331
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF HOIST CYLINDER
9. Sling rod (5) and assemble to cylinder II (4).
★ Align the stud bolt at the tip of the rod with the bolt hole in the
piston assembly.
★ Remove all oil and grease from the assembly portion of the
nuts and blots.
12. Using tool U2 install crown (1) to cylinder I (2), and fit grease nip-
ple.
30-332 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF BODY ASSEMBLY
2. Loosening lever block B, lower the crane to place the bottom of the
hoist cylinder on the tire.
B. Install lever block B between the vehicle body and hoist cylin-
der and tense it to prevent the hoist cylinder from falling down.
HM400-1L 30-333
DISASSEMBLY AND ASSEMBLY REMOVAL OF BODY ASSEMBLY
30-334 HM400-1L
DISASSEMBLY AND ASSEMBLY INSTALLATION OF BODY ASSEMBLY
● When installing the body hinge pin, check the thickness and quan-
tity of the shims.
A. Install spacer (5) 58 mm high to the end of body (4) (one place
on each side).
E. Lower the body and check that all of the six parts of the bottom
mount are in contact with the frame top.
HM400-1L 30-335
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF OPERATOR’S
DISASSEMBLY
1. Headrest
A. Referring to the figure, check the positions of the two clips (2)
of headrest stay (1) on both sides.
30-336 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF OPERATOR’S
B. Apply force b to part a of each clip (2) in the direction of the
arrow to turn the clip. Release headrest stay (1) from part d of
the clip and pull out up headrest (3).
2. Seatback
A. Disconnect three air hoses (5) from the rear left of seatback (4).
★ Before disconnecting the air hoses, check their types.
HM400-1L 30-337
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF OPERATOR’S
B. Remove seatback hinge mounting bolt (6) (M8 bolt).
E. Applying the force to seatback (4), pull its right side up.
30-338 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF OPERATOR’S
3. Seat cushion
A. Push cushion adjuster lever (7) inward and slide seat cushion
(8) to the front end.
B. Push cushion stopper wire (9) down with screwdriver [1], etc.
4. Armrest
● The procedure for disassembling right-hand armrest (10) is
shown below.
(Disassemble left-hand armrest (11) similarly.)
HM400-1L 30-339
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF OPERATOR’S
A. Remove plastic cap (12) from the armrest hinge.
★ Use a flat-head screwdriver, etc. to remove the cap.
C. Remove plastic cap (14), and then remove lower mounting bolt
(15A) (M8 bolt) of right-hand armrest (10).
30-340 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF OPERATOR’S
5. Suspension cover
B. Remove plastic plate (18) from the rear with screwdriver [1],
etc.
★ Take care not to damage the plastic plate by prying it off
forcibly with a screwdriver, etc.
HM400-1L 30-341
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF OPERATOR’S
E. Remove three metallic suspension cover clips (24).
F. Remove six plastic suspension cover clips (small) (25) and two
plastic suspension cover clips (large) (26).
★ Clips (small) (25):
Front upper part; two places
Each side; one place
Rear lower part; two places
Clips (large) (26):
Front lower part; two places
6. Rails
A. Turn over the seat assembly to set rails (28) on the upside.
C. Remove one hexagon socket head bolt (29) and one lock
washer (30) from the front part of each rail.
30-342 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF OPERATOR’S
D. Slide rails (28) to the front end.
E. Remove one hexagon socket head bolt (29) and one lock
washer (30) from the rear part of each rail, and then remove
rails (28).
ASSEMBLY
1. Rails
A. Put height adjustment washers (31) between rails (28) and sus-
pension, and then set rails (28) in position.
B. Set rails (28) to the front end and install one lock washer (30)
and one hexagon socket head bolt (29) to each rail.
HM400-1L 30-343
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF OPERATOR’S
C. Set rails (28) to the rear end and install one lock washer (30)
and one hexagon socket head bolt (29) to each rail.
2. Suspension cover
A. Set suspension cover (27) in position and install six plastic sus-
pension cover clips (small) (25) and two plastic suspension
cover clips (large) (26).
★ Clips (small) (25):
Front upper part; two places
Each side; one place
Rear lower part; two places
Clips (large) (26):
Front lower part; two places
C. Set four bushings (23) and two cushion rails (22), and then
install cushion rear fixing plate (21), and four mounting bolts
(20).
30-344 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF OPERATOR’S
D. Install four suspension cover fixing rings (19).
3. Armrest
● The procedure for assembling right-hand armrest (10) is shown
below.
(Assemble left-hand armrest (11) similarly.)
A. Install two position adjustment washers (16) for each bolt and
set right-hand armrest (10) in position.
HM400-1L 30-345
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF OPERATOR’S
B. Tighten lower mounting bolt (15A) lightly and turn armrest
(10) by 180°.
4. Seat cushion
A. Slide in the seat cushion from the front of the fitting position.
★ If seat cushion (8) is slid to the rear, it is locked by cushion
stopper wire (9).
30-346 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF OPERATOR’S
5. Seatback
A. Insert the left side of seatback (4), and then lower and set the
right side.
C. Connect three air hoses (5) to the rear left of the seatback (4).
HM400-1L 30-347
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF OPERATOR’S
6. Headrest
30-348 HM400-1L
90 OTHERS
HM400-1L 90-1
OTHERS POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
12
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
90-2 HM400-1L
OTHERS STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM
HM400-1L 90-3
OTHERS DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM
90-4 HM400-1L
OTHERS BRAKE HYDRAULIC CIRCUIT DIAGRAM
12
BRAKE HYDRAULIC CIRCUIT DIAGRAM
90-5 HM400-1L
OTHERS BRAKE HYDRAULIC CIRCUIT DIAGRAM
HM400-1L 90-6
OTHERS AIR CONDITIONER
AIR CONDITIONER
90-7 HM400-1L
OTHERS AIR CONDITIONER
HM400-1L 90-8
OTHERS TO ENGINE CONTROLLER (1/2)
90-9 HM400-1L
OTHERS TO ENGINE CONTROLLER (1/2)
HM400-1L 90-10
OTHERS TO ENGINE CONTROLLER (2/2)
12
TO ENGINE CONTROLLER (2/2)
90-11 HM400-1L
OTHERS TO ENGINE CONTROLLER (2/2)
12
HM400-1L 90-12
OTHERS TO MAIN HARNESS INSIDE OF CAB (1/10)
12
TO MAIN HARNESS INSIDE OF CAB (1/10)
90-13 HM400-1L
OTHERS TO MAIN HARNESS INSIDE OF CAB (1/10)
12
HM400-1L 90-14
OTHERS TO MAIN HARNESS INSIDE OF CAB (2/10)
12
TO MAIN HARNESS INSIDE OF CAB (2/10)
90-15 HM400-1L
OTHERS TO MAIN HARNESS INSIDE OF CAB (2/10)
12
HM400-1L 90-16
OTHERS TO MAIN HARNESS INSIDE OF CAB (3/10)
12
TO MAIN HARNESS INSIDE OF CAB (3/10)
90-17 HM400-1L
OTHERS TO MAIN HARNESS INSIDE OF CAB (3/10)
12
HM400-1L 90-18
OTHERS TO MAIN HARNESS INSIDE OF CAB (4/10)
12
TO MAIN HARNESS INSIDE OF CAB (4/10)
90-19 HM400-1L
OTHERS TO MAIN HARNESS INSIDE OF CAB (4/10)
12
HM400-1L 90-20
OTHERS TO MAIN HARNESS INSIDE OF CAB (5/10)
12
TO MAIN HARNESS INSIDE OF CAB (5/10)
90-21 HM400-1L
OTHERS TO MAIN HARNESS INSIDE OF CAB (5/10)
12
HM400-1L 90-22
OTHERS TO MAIN HARNESS INSIDE OF CAB (6/10)
12
TO MAIN HARNESS INSIDE OF CAB (6/10)
90-23 HM400-1L
OTHERS TO MAIN HARNESS INSIDE OF CAB (6/10)
12
HM400-1L 90-24
OTHERS TO MAIN HARNESS INSIDE OF CAB (7/10)
12
TO MAIN HARNESS INSIDE OF CAB (7/10)
90-25 HM400-1L
OTHERS TO MAIN HARNESS INSIDE OF CAB (7/10)
12
HM400-1L 90-26
OTHERS TO MAIN HARNESS INSIDE OF CAB (8/10)
12
TO MAIN HARNESS INSIDE OF CAB (8/10)
90-27 HM400-1L
OTHERS TO MAIN HARNESS INSIDE OF CAB (8/10)
12
HM400-1L 90-28
OTHERS TO MAIN HARNESS INSIDE OF CAB (9/10)
12
TO MAIN HARNESS INSIDE OF CAB (9/10)
90-29 HM400-1L
OTHERS TO MAIN HARNESS INSIDE OF CAB (9/10)
12
HM400-1L 90-30
OTHERS TO MAIN HARNESS INSIDE OF CAB (10/10)
12
TO MAIN HARNESS INSIDE OF CAB (10/10)
90-31 HM400-1L
OTHERS TO MAIN HARNESS INSIDE OF CAB (10/10)
12
HM400-1L 90-32
OTHERS SWITCH PANEL (1/3)
12
SWITCH PANEL (1/3)
90-33 HM400-1L
OTHERS SWITCH PANEL (1/3)
12
HM400-1L 90-34
OTHERS SWITCH PANEL (2/3)
12
SWITCH PANEL (2/3)
90-35 HM400-1L
OTHERS SWITCH PANEL (2/3)
12
HM400-1L 90-36
OTHERS SWITCH PANEL (3/3)
12
SWITCH PANEL (3/3)
90-37 HM400-1L
OTHERS SWITCH PANEL (3/3)
12
HM400-1L 90-38
OTHERS DISPLAY PANEL (1/2)
12
DISPLAY PANEL (1/2)
90-39 HM400-1L
OTHERS DISPLAY PANEL (1/2)
12
HM400-1L 90-40
OTHERS DISPLAY PANEL (2/2)
12
DISPLAY PANEL (2/2)
90-41 HM400-1L
OTHERS DISPLAY PANEL (2/2)
12
HM400-1L 90-42
OTHERS RETARD CONTROLLER (1/2)
12
RETARD CONTROLLER (1/2)
90-43 HM400-1L
OTHERS RETARD CONTROLLER (1/2)
12
HM400-1L 90-44
OTHERS RETARD CONTROLLER (2/2)
12
RETARD CONTROLLER (2/2)
90-45 HM400-1L
OTHERS RETARD CONTROLLER (2/2)
12
HM400-1L 90-46
OTHERS TO TRANSMISSION CONTROLLER (1/2)
12
TO TRANSMISSION CONTROLLER (1/2)
90-47 HM400-1L
OTHERS TO TRANSMISSION CONTROLLER (1/2)
12
HM400-1L 90-48
OTHERS TO TRANSMISSION CONTROLLER (2/2)
12
TO TRANSMISSION CONTROLLER (2/2)
90-49 HM400-1L
OTHERS TO TRANSMISSION CONTROLLER (2/2)
12
HM400-1L 90-50
OTHERS TO HARNESS OUTSIDE OF CAB (1/2)
12
TO HARNESS OUTSIDE OF CAB (1/2)
90-51 HM400-1L
OTHERS TO HARNESS OUTSIDE OF CAB (1/2)
12
HM400-1L 90-52
OTHERS TO HARNESS OUTSIDE OF CAB (2/2)
12
TO HARNESS OUTSIDE OF CAB (2/2)
90-53 HM400-1L
OTHERS TO HARNESS OUTSIDE OF CAB (2/2)
12
HM400-1L 90-54
OTHERS FUSE BLOCK
12
FUSE BLOCK
90-55 HM400-1L
OTHERS FUSE BLOCK
12
HM400-1L 90-56
OTHERS LOAD METER (1/2)
12
LOAD METER (1/2)
90-57 HM400-1L
OTHERS LOAD METER (1/2)
12
HM400-1L 90-58
OTHERS LOAD METER (2/2)
12
LOAD METER (2/2)
90-59 HM400-1L
OTHERS LOAD METER (2/2)
12
HM400-1L 90-60
Komatsu America Corp.
DataKom Publications & Training PROPOSAL FOR MANUAL OR CSS REVISION
440 North Fairway Drive
Vernon Hills, IL. 60061-8112 U.S.A.
Attn: Service Publications
Fax No. (847)-970-4186
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MACHINE MODEL & S/N:
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PROPFREV.FM 100903