HM400-1 2nd Edition SEBM023012

SEBM023012
Machine model Serial number
HM400-1 1001 and up
• This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
• HM400-1 mount the SAA6D140E-3 engine.

For details of the engine, see the 140-3 Series Engine Shop Manual.
© 2005
All Rights Reserved 00-1
Printed in Japan 06-05 (03) (12)
SAFETY
CONTENTS
No. of page
01 GENERAL ..........................................................................................01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD .......10-1
20 TESTING AND ADJUSTMENT..........................................................20-1
30 DISASSEMBLY AND ASSEMBLY ....................................................30-1
90 OTHERS.............................................................................................90-1
00-2 HM400-1
2
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions must be taken to these pages according to c Page to be newly added Add
the list below.
z Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are not revised at this time.
LIST OF REVISED PAGES
Revision Revision Revision Revision Revision

Mark Pages Mark Pages Mark Pages Mark Pages Mark Pages
number number number number number
z 00- 1 (12) 10- 9 (6) 10-52 10- 89 10-133 (7)

00- 2 (2) 10-10 10-53 10- 90 10-134
z 00- 2-1 (12) 10-11 (7) 10-54 10- 92 10-135
z 00- 2-2 (12) 10-12 (3) 10-54-2 (6) 10- 93 10-136
z 00- 2-3 (12) 10-13 10-54-3 (6) 10- 94 (7) 10-137
z 00- 2-4 (12) 10-14 10-54-4 (6) 10- 95 (7) 10-138 (7)
z 00- 3 10-15 10-54-5 (6) 10- 96 10-139 (6)
z 00- 4 10-16 (7) 10-54-6 (6) 10- 98 10-140 (7)
z 00- 5 10-17 (7) 10-54-7 (6) 10- 99 10-151
z 00- 6 10-18 (7) 10-54-8 (6) 10-100 (6) 10-152
z 00- 7 10-19 (7) 10-55 (6) 10-101 (6) 10-153 (11)
z 00- 8 10-20 (7) 10-55-1 (6) 10-102 (6) 10-154 (11)
z 00- 9 10-21 (7) 10-55-2 (6) 10-103 10-155 (6)
z 00-10 10-22 (7) 10-56 10-104 10-156
z 00-11 10-23 (7) 10-57 10-105 10-157 (6)
z 00-12 10-24 (3) 10-58 10-106 10-158 (6)
z 00-13 10-25 (7) 10-59 10-107 10-159 (7)
z 00-14 10-26 (3) 10-60 10-108 10-160 (7)
z 00-15 10-27 (3) 10-62 10-109 (6) 10-161 (6)
z 00-16 10-28 (3) 10-63 (6) 10- 110 (6) 10-162
z 00-17 10-29 (3) 10-64 10- 112 10-163 (6)
z 00-18 10-30 (3) 10-65 10- 113 10-164
z 00-19 10-31 (3) 10-66 10- 114 10-165
z 00-20 10-32 (3) 10-67 (6) 10- 115 10-166 (6)
z 00-21 10-33 (3) 10-68 10- 116 10-167
z 00-22 10-34 10-69 10- 117 10-168
01- 1 10-35 (3) 10-70 10- 118 (6) 10-169
01- 2 10-36 10-71 10-118-1 (6) 10-170 (6)
01- 3 (6) 10-37 10-72 10- 119 (6) 10-171
01- 4 (6) 10-38 10-73 10-120 10-172 (6)
01- 5 (6) 10-39 10-74 10-121 (6) 10-173 (6)
01- 6 (6) 10-40 10-75 10-122 10-174
01- 7 (7) 10-41 10-76 10-123 10-175 (6)
01- 8 (6) 10-42 10-77 10-124 (6) 10-176 (6)
10- 1 (10) 10-43 (3) 10-78 10-124-1 (8) 10-177
10- 2 10-44 10-79 (6) 10-125 (6) 10-178
10- 4 (6) 10-45 10-80 (6) 10-126 (6) 10-179 (5)
10- 5 (6) 10-46 10-82 10-127 10-180
10- 5-1 (6) 10-47 10-83 10-128 10-181
10- 5-2 (6) 10-48 (6) 10-84 10-129 10-181-1 (6)
10- 6 (6) 10-49 10- 85 10-130 10-181-2 (6)
10- 7 10-50 10- 86 (6) 10-131 (6) 10-181-3 (6)
10- 8 10-51 10- 88 10-132 10-181-4 (6)
HM400-1 00-2-1
(12)
10-181-5 (6) 20- 12 (1) 20-150 (1) (20-207) 20-401 (9)

10-181-6 (6) 20- 13 (6) 20-151 (1) (20-208) 20-402 (1)
10-181-7 (6) 20- 14 (6) 20-152 (1) 20-301 (7) 20-403 (4)
10-181-8 (6) 20- 15 (6) 20-153 (1) 20-302 (1) 20-404 (4)
10-181-9 (6) 20- 16 (6) 20-154 (11) 20-303 (1) 20-405 (4)
10-181-10 (6) 20- 17 (1) 20-155 (6) 20-304 (1) 20-406 (1)
10-182 20- 18 (1) 20-156 (6) 20-305 (1) 20-407 (1)
10-183 20- 19 (1) 20-156-1 (6) 20-306 (1) 20-408 (1)
10-184 20- 20 (1) 20-156-2 (6) 20-307 (6) 20-409 (1)
10-185 z 20-101 (12) 20-157 (6) 20-308 (1) 20-410 (1)
10-186 z 20-102 (12) z 20-158 (12) 20-309 (1) 20- 411 (1)
10-186 20-103 (11) 20-159 (1) 20-310 (1) 20-412 (1)
10-187 (10) 20-104 (1) 20-160 (1) 20- 311 (1) 20-413 (1)
10-188 (10) 20-105 (1) 20-161 (1) 20-312 (1) 20-414 (1)
10-189 (10) 20-106 (1) 20-162 (1) 20-313 (6) 20-415 (1)
10-190 (10) 20-107 (1) 20-163 (1) 20-314 (6) 20-416 (1)
10-191 (10) 20-108 (1) 20-164 (1) 20-315 (4) 20-417 (1)
10-192 (10) 20-109 (1) 20-165 (1) 20-316 (4) 20-418 (1)
10-193 (10) 20- 110 (1) 20-166 (1) 20-317 (4) 20-419 (1)
10-194 (10) 20- 111 (1) 20-167 (1) 20-318 (4) 20-420 (1)
10-195 (10) 20- 112 (1) 20-168 (11) 20-319 (4) 20-421 (11)
10-196 (10) 20- 113 (11) 20-169 (11) 20-320 (4) 20-422 (11)
10-197 (10) 20- 114 (1) 20-170 (11) 20-322 (4) 20-423 (1)
10-198 (10) 20- 115 (1) 20-171 (11) 20-323 (4) 20-424 (1)
10-199 (10) 20- 116 (1) 20-172 (11) 20-324 (4) 20-425 (1)
10-200 (10) 20- 117 (1) 20-173 (11) 20-324-1 (4) 20-426 (1)
10-201 (10) 20- 118 (1) 20-174 (6) 20-325 (1) 20-427 (1)
10-202 (10) 20- 119 (1) 20-175 (1) 20-326 (1) 20-428 (1)
10-203 (10) 20-120 (1) 20-176 (6) 20-327 (1) 20-429 (1)
10-204 (10) 20-121 (1) 20-177 (1) 20-328 (1) 20-430 (1)
10-205 (10) 20-122 (1) 20-178 (1) 20-329 (1) 20-431 (1)
10-206 (10) 20-123 (1) 20-179 (6) 20-330 (7) 20-432 (1)
10-207 (10) 20-124 (1) 20-180 (11) 20-331 (1) 20-433 (1)
10-208 (10) 20-125 (1) 20-181 (11) 20-332 (1) 20-434 (1)
10-209 (10) 20-126 (1) 20-182 (11) 20-333 (1) 20-435 (1)
10-210 (10) 20-127 (1) 20-183 (1) 20-334 (1) 20-436 (1)
10- 211 (10) 20-128 (1) 20-184 (11) 20-335 (1) 20-437 (1)
10-212 (10) 20-129 (6) 20-185 (1) 20-336 (1) 20-438 (1)
10-213 (10) 20-130 (6) 20-186 (11) 20-337 (1) 20-439 (1)
10-214 (10) 20-131 (6) 20-187 (1) 20-338 (1) 20-440 (1)
10-215 (10) 20-132 (6) 20-188 (1) 20-339 (1) 20-441 (1)
10-216 (10) 20-133 (6) 20-189 (1) 20-340 (1) 20-442 (1)
10-217 (10) 20-134 (11) 20-190 (1) 20-341 (7) 20-443 (1)
10-218 (10) 20-134-1 (11) 20-191 (1) 20-341-1 (6) 20-444 (1)
10-219 (10) 20-135 (6) 20-192 (1) 20-341-2 (6) 20-445 (4)
10-220 (10) 20-136 (1) 20-193 (6) 20-341-3 (6) 20-446 (4)
10-221 (10) 20-137 (7) 20-194 (1) 20-341-4 (9) 20-447 (4)
10-222 (10) 20-138 (6) 20-195 (11) 20-341-5 (6) 20-448 (9)
20- 1 (1) 20-139 (1) 20-196 (1) 20-341-6 (6) 20-449 (9)
20- 2 (1) 20-140 (6) 20-197 (7) 20-341-7 (7) 20-450 (1)
20- 3 (6) 20-141 (6) 20-198 (1) 20-341-8 (9) 20-451 (1)
20- 4 (7) 20-142 (6) 20-199 (1) 20-341-9 (11) 20-452 (1)
20- 5 (6) 20-143 (6) 20-200 (1) 20-341-10(11) 20-453 (9)
20- 6 (6) 20-144 (1) 20-201 (11) 20-341-11(11) 20-454 (1)
20- 7 (1) 20-145 (1) 20-202 (1) 20-341-12(11) 20-455 (1)
20- 8 (1) 20-146 (1) 20-203 (1) 20-342 (7) 20-456 (1)
20- 9 (1) 20-147 (1) (20-204) 20-343 (1) 20-457 (1)
20- 10 (1) 20-148 (6) (20-205) 20-344 (1) 20-458 (1)
20- 11 (1) 20-149 (6) (20-206) 20-345 (1) 20-459 (1)
00-2-2 HM400-1
(12)
20-460 (1) 20-545 (1) 20-604 (1) 20-726 (6) 20-812 (1)
20-461 (1) 20-546 (1) 20-605 (1) 20-727 (6) 20-813 (1)
20-462 (1) 20-547 (1) 20-606 (1) 20-728 (7) 20-814 (1)
20-463 (1) 20-548 (1) 20-607 (1) 20-729 (6) 20-815 (1)
20-464 (1) 20-549 (1) 20-608 (1) 20-730 (6) 20-816 (1)
20-465 (1) 20-550 (1) 20-609 (1) 20-731 (6) 20-817 (6)
20-466 (1) 20-551 (1) 20-610 (1) 20-732 (6) 20-818 (1)
20-467 (1) 20-552 (1) 20- 611 (1) 20-733 (6) 20-819 (1)
20-468 (1) 20-553 (1) 20-612 (1) 20-734 (6) 20-820 (1)
20-469 (1) 20-554 (1) 20-613 (1) 20-735 (6) 20-821 (1)
20-470 (1) 20-555 (1) 20-614 (1) 20-736 (6) 20-822 (1)
20-471 (1) 20-556 (1) 20-615 (1) 20-737 (6) 20-823 (1)
20-472 (1) 20-557 (1) 20-616 (1) 20-738 (6) 20-824 (1)
20-473 (1) 20-558 (1) 20-617 (1) 20-739 (6) 20-825 (1)
20-474 (1) 20-559 (1) 20-618 (1) 20-740 (6) 20-826 (1)
20-501 (1) 20-560 (1) 20-619 (1) 20-741 (6) 20-827 (1)
20-502 (1) 20-561 (1) 20-620 (1) 20-742 (6) 20-828 (1)
20-503 (1) 20-562 (1) 20-621 (1) 20-743 (6) 20-829 (1)
20-504 (4) 20-563 (4) 20-622 (1) 20-744 (6) 20-830 (1)
20-505 (4) 20-564 (1) 20-623 (1) 20-745 (6) 20-831 (1)
20-506 (4) 20-565 (1) 20-624 (1) 20-746 (1) 20-832 (1)
20-507 (4) 20-566 (1) 20-625 (1) 20-747 (6) 20-833 (6)
20-508 (4) 20-567 (1) 20-626 (1) 20-748 (1) 20-834 (6)
20-509 (4) 20-568 (1) 20-627 (1) 20-749 (6) 20-835 (6)
20-510 (1) 20-569 (1) 20-628 (1) 20-750 (6) 20-836 (6)
20- 511 (1) 20-570 (7) 20-629 (1) 20-751 (1) 20-837 (6)
20-512 (1) 20-571 (1) 20-630 (1) 20-752 (6) 20-838 (1)
20-513 (1) 20-572 (1) 20-631 (1) 20-753 (6) 20-839 (1)
20-514 (1) 20-573 (1) 20-632 (1) 20-754 (1) 20-840 (1)
20-515 (1) 20-574 (1) 20-633 (1) 20-755 (6) 20-841 (1)
20-516 (1) 20-575 (1) 20-634 (1) 20-756 (1) 20-842 (1)
20-517 (1) 20-576 (1) 20-635 (1) 20-757 (6) 20-843 (1)
20-518 (1) 20-577 (1) 20-636 (1) 20-758 (6) 20-844 (1)
20-519 (7) 20-578 (1) 20-637 (1) 20-759 (6) 20-845 (1)
20-520 (1) 20-579 (1) 20-638 (1) 20-760 (6) 20-846 (1)
20-521 (1) 20-580 (1) 20-701 (6) 20-761 (6) 20-847 (1)
20-522 (1) 20-581 (1) 20-702 (6) 20-762 (6) 20-848 (1)
20-523 (1) 20-582 (1) 20-704 (4) 20-763 (6) 20-849 (1)
20-524 (1) 20-583 (1) 20-705 (4) 20-764 (6) 20-850 (1)
20-525 (1) 20-584 (1) 20-706 (4) 20-765 (6) 20-901 (1)
20-526 (1) 20-585 (1) 20-707 (4) 20-766 (6) 20-902 (6)
20-527 (1) 20-586 (1) 20-708 (4) 20-767 (6) 20-903 (1)
20-528 (1) 20-587 (4) 20-709 (4) 20-768 (6) 20-904 (1)
20-529 (1) 20-588 (1) 20-710 (6) 20-769 (6) 20-905 (6)
20-530 (1) 20-589 (1) 20- 711 (6) 20-770 (6) 20-906 (6)
20-531 (1) 20-590 (1) 20-712 (6) 20-771 (6) 20-907 (1)
20-532 (1) 20-591 (1) 20-713 (1) 20-772 (6) 20-908 (1)
20-533 (1) 20-592 (1) 20-714 (6) 20-774 (1) 20-909 (1)
20-534 (1) 20-593 (1) 20-715 (6) 20-775 (1) 20-910 (1)
20-535 (1) 20-594 (1) 20-716 (6) 20-776 (1) 20- 911 (6)
20-536 (1) 20-595 (1) 20-717 (6) 20-801 (6) 20-912 (6)
20-537 (1) 20-596 (1) 20-718 (6) 20-802 (4) 20-913 (1)
20-538 (1) 20-597 (1) 20-719 (1) 20-803 (4) 20-914 (6)
20-539 (1) 20-598 (1) 20-720 (6) 20-804 (4) 20-915 (6)
20-540 (1) 20-599 (1) 20-721 (6) 20-805 (4) 20-916 (1)
20-541 (1) 20-600 (1) 20-722 (6) 20-806 (6) 20-917 (6)
20-542 (1) 20-601 (1) 20-723 (1) 20-807 (6) 20-918 (6)
20-543 (1) 20-602 (1) 20-724 (6) 20-810 (1) 20-919 (1)
20-544 (1) 20-603 (1) 20-725 (6) 20- 811 (1) 20-1001 (7)
HM400-1 00-2-3
(12)
20-1002 (7) 30- 34 (9) 30- 91 (7) 30-150 (2) 30-209 (2)
20-1003 (7) 30- 35 (9) 30- 92 (7) 30-151 (2) 30-210 (2)
20-1004 (7) 30- 35-1 (9) 30- 93 (7) 30-152 (2) 30- 211 (2)
20-1005 (7) 30- 35-2 (9) 30- 94 (7) 30-153 (2) 30-212 (2)
20-1007 (7) 30- 36 (2) 30- 95 (7) 30-154 (2) 30-213 (2)
20-1008 (7) 30- 37 (2) 30- 96 (2) 30-155 (2) 30-214 (2)
20-1009 (7) 30- 38 (2) 30- 97 (2) 30-156 (2) 30-215 (2)
20-1010 (7) 30- 39 (7) 30- 98 (7) 30-157 (2) 30-216 (11)
20-1011 (7) 30- 40 (7) 30- 99 (2) 30-158 (2) 30-217 (2)
20-1012 (7) 30- 41 (6) 30-100 (2) 30-159 (2) 30-218 (11)
20-1013 (7) 30- 42 (2) 30-101 (2) 30-160 (2) 30-220 (2)
20-1014 (7) 30- 43 (11) 30-102 (7) 30-161 (2) 30-221 (2)
20-1015 (7) 30- 44 (11) 30-103 (7) 30-162 (2) 30-222 (2)
20-1016 (7) 30- 45 (2) 30-104 (7) 30-163 (2) 30-223 (2)
20-1017 (7) 30- 46 (6) 30-105 (7) 30-164 (2) 30-224 (2)
20-1018 (7) 30- 47 (6) 30-106 (7) 30-165 (2) 30-225 (2)
20-1019 (7) 30- 48 (6) 30-107 (7) 30-166 (2) 30-226 (2)
20-1020 (7) 30- 49 (7) 30-108 (2) 30-167 (2) 30-227 (2)
20-1021 (7) 30- 50 (6) 30-109 (2) 30-168 (11) 30-228 (2)
20-1022 (7) 30- 51 (6) 30- 110 (2) 30-169 (2) 30-229 (2)
20-1023 (7) 30- 52 (6) 30- 111 (2) 30-170 (2) 30-230 (2)
20-1024 (7) 30- 53 (2) 30- 112 (2) 30-171 (2) 30-231 (2)
z 30- 1 (12) 30- 54 (7) 30- 113 (2) 30-172 (2) 30-232 (2)
c 30- 2 (12) 30- 55 (11) 30- 114 (2) 30-173 (2) 30-233 (2)
z 30- 3 (12) 30- 56 (2) 30- 115 (2) 30-174 (2) 30-234 (2)
c 30- 3-1 (12) 30- 57 (2) 30- 116 (2) 30-175 (2) 30-235 (2)
30- 4 (6) 30- 58 (2) 30- 117 (2) 30-176 (2) 30-236 (6)
30- 5 (6) 30- 59 (2) 30- 118 (2) 30-177 (2) 30-237 (2)
30- 6 (9) 30- 60 (2) 30- 119 (2) 30-178 (2) 30-238 (2)
30- 7 (8) 30- 61 (11) 30-120 (11) 30-179 (2) 30-239 (2)
30- 8 (2) 30- 62 (11) 30-121 (2) 30-180 (2) 30-240 (6)
30- 9 (2) 30- 63 (7) 30-122 (11) 30-181 (2) 30-241 (2)
z 30- 10 (12) 30- 64 (2) 30-123 (2) 30-182 (2) 30-242 (2)
30- 11 (9) 30- 65 (7) 30-124 (2) 30-183 (2) 30-243 (7)
30- 11-1 (9) 30- 66 (2) 30-125 (2) 30-184 (2) 30-244 (7)
30- 12 (2) 30- 67 (2) 30-126 (2) 30-185 (2) 30-245 (7)
30- 13 (2) 30- 68 (2) 30-127 (2) 30-186 (2) 30-246 (7)
30- 14 (2) 30- 69 (2) 30-128 (2) 30-187 (2) 30-247 (7)
30- 15 (2) 30- 70 (7) 30-129 (2) 30-188 (2) 30-248 (7)
30- 16 (2) 30- 71 (7) 30-130 (2) 30-189 (2) 30-249 (7)
30- 17 (2) 30- 72 (7) 30-131 (2) 30-190 (2) 30-250 (7)
30- 18 (2) 30- 73 (2) 30-132 (2) 30-191 (2) 30-251 (7)
30- 19 (2) 30- 74 (7) 30-133 (2) 30-192 (2) 30-252 (7)
30- 20 (2) 30- 75 (7) 30-134 (2) 30-193 (2) 90- 1 (10)
30- 21 (2) 30- 76 (7) 30-135 (2) 30-194 (2) 90- 2 (4)
30- 22 (2) 30- 77 (7) 30-136 (11) 30-195 (2) 90- 3
30- 22-1 (9) 30- 78 (7) 30-137 (11) 30-196 (2) 90- 4
30- 22-2 (9) 30- 79 (7) 30-138 (2) 30-197 (2) 90- 5
30- 23 (2) 30- 80 (2) 30-139 (2) 30-198 (2) 90- 6
30- 24 (2) 30- 81 (2) 30-140 (2) 30-199 (2) 90- 7 (7)
30- 25 (9) 30- 82 (11) 30-141 (2) 30-200 (2) 90- 9 (7)
30- 26 (9) 30- 83 (7) 30-142 (2) 30-201 (2) 90- 11 (7)
30- 27 (9) 30- 84 (7) 30-143 (2) 30-202 (2) 90- 13 (7)
30- 28 (9) 30- 85 (2) 30-144 (2) 30-203 (2) 90- 15 (4)
30- 29 (9) 30- 86 (7) 30-145 (2) 30-204 (2) 90- 17 (4)
30- 30 (9) 30- 87 (7) 30-146 (2) 30-205 (2) 90- 19 (4)
30- 31 (9) 30- 88 (2) 30-147 (2) 30-206 (2) 90- 21 (10)
30- 32 (9) 30- 89 (7) 30-148 (2) 30-207 (2)
30- 33 (9) 30- 90 (7) 30-149 (2) 30-208 (2)
00-2-4 HM400-1
(12)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic 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
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 abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used to prevent rubber gaskets, rubber

LT-1A 790-129-9030 150 g Tube
cushions, and cock plug 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 pcs.) container polyprophylene, tetrafluoroethlene and
vinyl chloride), rubber, metal and non-
metal.
• Features:
Polyethylene Resistance to heat and chemicals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for metal,
790-129-9060
1 kg glass and plastic.
(Set of adhesive
LT-3 Hardening Can
and hardening
agent:
agent)
Adhesives 500 g
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz • Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 repairing engine.
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type
Aron-alpha Polyethylene
790-129-9130 2g (max. strength after 30 minutes)
201 container
• Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container
temperatures.
• Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
• Used as sealant for various threads, pipe
joints, flanges.
LG-5 790-129-9080 1 kg Can
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance to
heat, cold
LG-6 790-129-9020 200 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive
Gasket case, etc.
sealant • Features: Silicon based, quick hardening
type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat
housing, etc.
Three bond • Used as heat-resisting sealant for
790-129-9090 100 g Tube
1211 repairing engine.
• Features: Silicone type, heat resistant,
Three bond vibration resistant, and impact resistant
419-15-18131 100 g Tube
1207B sealing material
• Used as sealing material for transfer case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used as lubricant for sliding portion (to

LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR • Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
• Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR • Used as primer for sash (Alumite).
Adhesive for cab glass
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.20
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ 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.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 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 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
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 – –
00-14
FOREWORD ELECTRIC WIRE CODE
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: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands (mm2) (mm2)
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
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
(B)
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
(C)
(A) 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
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 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 1934 1949 1963 1977
140 1991 2005 2020 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
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column 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.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–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
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
GENERAL
01 GENERAL
Specification drawings................................................................................................................................... 01-2

Specifications ................................................................................................................................................ 01-3
Weight table................................................................................................................................................... 01-6
Fuel, coolant and lubricants ........................................................................................................................... 01-7
HM400-1 01-1
GENERAL SPECIFICATION DRAWINGS
SPECIFICATION DRAWINGS
01-2 HM400-1
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model HM400-1 HM400-1 E-SPEC
Serial Numbers 1001 and up 1001 and up
Unloaded kg 3,0350
Max. payload kg 3,7000
Overall weight kg 6,7350
Unloaded (front wheel) kg 55.4

(front rear wheel) kg 22.3
(rear rear wheel) kg 22.3
Weight
Fully loaded (front wheel) kg 28.4
(front rear wheel) kg 35.8
(rear rear wheel) kg 35.8
Struck m3 16.5
Dump body capacity
Heaped (2:1) m 3 22.5
Max. travel speed km/h 58.6

Gradeability (tan 0 θ) 0.51
Min. turning radius mm 8,710
Dumping angle (angle to ground) (deg) o 70
Overall length mm 11,025

Overall width mm 3,450
Overall height mm 3,700
Wheelbase (front wheel - front rear wheel) mm 4,350
Wheelbase (front rear wheel - rear rear wheel) mm 1,970
Front tires mm 2,690

Tread Rear tires mm 2,690
Front rear wheel mm 2,690
Rear rear wheel mm 600
Engine Komatsu SAA6D140E-3
Model 4-cycle, water-cooled, in-line 6 cylinder, direct

injection, with turbocharger and air-cooled
Type after-cooler
No. of cylinders - Bore x stroke mm
l {cc}
6-140 x 165
Piston displacement 15.24{15,240}
Flywheel horsepower kW/rpm{HP/rpm} 331/2,000 {444/2,000}
Max. torque Nm/rpm{kgm/rpm} 2,045/1,400 {208.5/1,400}
Fuel consumption (rated) g/kWh{g/HPh} 204 {152}
Starting motor 11kw
Alternator 24V 60A
Battery 12V 170Ah x 2
HM400-1 01-3
6
3-element, 1-stage, 2-phase

Type
Torque converter 39. Hydraulically-actuated, wet-type, single-disc
Lock-up clutch
clutch
TORQFLOW multiple-axle transmission, fully

Type automatic, electrically-hydraulically actuated,
Transmission force-feed type pump lubrication type
No. of speeds
F6, R2
Type Straight bevel gear, splash lubrication

Reduction gear Reduction ratio 3.417
Differential type Straight bevel gear, splash lubrication
Type Planetary gear, splash lubrication

Final drive
Reduction ratio 4.941
Type Fully hydraulic
Front axle Independent suspension (MacPherson type)

Axle type Front rear axle Independent suspension (MacPherson type)
Rear rear axle Independent suspension (MacPherson type)
Front axle Hydropneumatic type

Suspension method
Rear rear axle Hydropneumatic type
Front tire 29.5 R25 x 2

Size and no. Front rear tire 29.5 R25 x 2
Rear rear tire 29.5 R25 x 2
kPa
Tire inflation pressure 0.372 {3.8}
{kg/cm2}
Independent front and rear system brake, sealed,

wet- type, multiple disc, hydraulically operated type
Front wheel
Main brake Front rear wheel
Rear rear wheel
Parking brake Spring-boosted, caliper disc type
Independent front and

rear system brake,
Retarder sealed, wet- type, multi- ———
ple disc, hydraulically
operated type
01-4 HM400-1
6
For steering
Type Gear pump
Discharge amount (l /min) 218
(when engine is at rated speed of 2000 rpm)
For hoist
Type Gear pump
Discharge amount (l /min) 18.5
For transmission, brake cooling
Type Gear pump
For brake cooling
Type Gear pump
For brake
Type Gear pump
For differential lock front
Type Gear pump
when engine is at rated speed of 2000 rpm)
For differential lock motor
Type Gear pump
For differential lock center, rear
Type Gear pump
Hoist cylinder
Type 2-stage piston type
(only 2nd stage double-acting)
No. - bore (1st-2nd) x stroke 2-(160mm-120mm) x 3,232mm

Steering cylinder
Type Piston type, double acting
No. - bore x stroke 2-120mm x 525mm
HM400-1 01-5
6
GENERAL WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
Engine assembly 1,470 1,470

Output shaft assembly 88 88
Cooling assembly 349 349
Fuel tank (individual part) 200 200
Torque converter assembly 282 282
Transmission assembly 1,324 1,324
Drive shaft assembly 295 295
Front axle assembly 2,131 2,131
Differential 428 428
Final drive 1,060 1,060
Center axle assembly 2,423 2,423
Rear axle assembly 2,297 2,297
Front suspension cylinder 91.2 91.2
Rear suspension cylinder 78.2 78.2
Oscillation hitch assembly 851.1 851.1
Front frame 1,585 1,585
Rear frame 2,000 2,000
Cab (including platform, interior components) 652 652
Operator’s seat 56.1 56.1
Steering cylinder (one side) 65.6 65.6
Hoist cylinder (one side) 254 254
Flow amp valve 29 29
Hoist valve 63 63
Hydraulic tank 240 240
Hydraulic pump (SBL(1)21) 2.6 2.6
Hydraulic pump (SAR(3)80+(1)25) 19.4 19.4
Hydraulic pump (SAR(3)100) 13 13
Hydraulic pump (SAR(3)100+100+(1)8) 35.8 35.8
Hydraulic pump (SAR(3)100+(1)12+8) 23.9 23.9
Hydraulic pump (SBR(1)8+8) 4.7 4.7
Hydraulic motor 1.9 1.9
Body assembly 4,232 4,232
01-6 HM400-1
6
GENERAL FUEL, COOLANT AND LUBRICANTS
FUEL, COOLANT AND LUBRICANTS
AMBIENT TEMPERATURE CAPACITY (¬)

KIND OF
RESERVOIR –22 –4 14 32 50 68 86 104 122°F
FLUID
–30 –20 –10 0 10 20 30 40 50°C Specified Refill
SAE 30
SAE 10W
Engine oil pan 56 52
SAE 10W-30
SAE 15W-40
Engine oil
Transmission case
SAE 10W 270 115
(Incl. brake oil tank)
Hydraulic tank 267 180
Left and right,

Front suspension SAE 10W 6 each
—
Left and right,

Rear suspension 4.2 each
—
Front differential case 26.0 26.0

With limited slip differential
Center differential case 45.0 44.5
Rear differential case 40.0 40.0

Axle oil AXO80 (q 2)
Left and right, Left and right,
Front final drive case 6.5 each 6.0 each

Center final drive case 6.5 each 5.5 each

Rear final drive case 6.5 each 5.5 each
Front differential case 22.5 22.5

With differential lock differential
Center differential case 39.5 39.0

Engine oil SAE 30W
Rear differential case 35.0 35.0

Front final drive case 6.5 each 6.0 each
Axle oil AXO80 (q 3)
Center final drive case 5.5 each 4.5 each

Rear final drive case 5.5 each 4.5 each
ASTM D975 No. 2

Diesel fuel
Fuel tank 500 —
(q 1) ASTM D975
No. 1
Cooling system Coolant Add antifreeze 89 —
HM400-1 01-7
(7)
GENERAL FUEL, COOLANT AND LUBRICANTS
q1: Use only diesel fuel.

q2: Since the front axle, center axle, and rear axle are equipped with limited slip differentials, use oil for limited
slip differential.
Maker Brand Remarks

SHELL DONAX TD 5W-30 North American manufactured DONAX TD 20W-40
must not be used
ESSO TORQUE FLUID 56 North American manufactured must not be used
MOBIL MOBIL FLUID 424
FUCHS RENOGEAR HYDRA ZF 20W-40
q3: Use the oil in the table below.
Maker Brand
SHELL DONAX TD
MOBIL MOBIL FLUID 424
01-8 HM400-1
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PLM-HM
10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD
Radiator, oil cooler, aftercooler............................................................................................................... 10- 2
Power train skeleton ............................................................................................................................... 10- 4
Output shaft ............................................................................................................................................ 10- 6
Torque converter and transmission hydraulic piping .............................................................................. 10- 8
Torque converter .................................................................................................................................... 10- 10
Transmission .......................................................................................................................................... 10- 16
Transmission valve................................................................................................................................. 10- 34
ECMV (electronic control modulation valve)........................................................................................... 10- 35
Main relief, torque converter relief valve................................................................................................. 10- 42
Drive shaft .............................................................................................................................................. 10- 44
Axle......................................................................................................................................................... 10- 45
Differential .............................................................................................................................................. 10- 48
Limited slip differential ............................................................................................................................ 10- 54-8
Final drive ............................................................................................................................................... 10- 56
Steering column...................................................................................................................................... 10- 60
Brake piping............................................................................................................................................ 10- 62
Brake valve............................................................................................................................................. 10- 64
Accumulator charge valve ...................................................................................................................... 10- 67
Accumulator............................................................................................................................................ 10- 71
Slack adjuster ......................................................................................................................................... 10- 72
Brake ...................................................................................................................................................... 10- 74
Proportional reducing valve .................................................................................................................... 10- 79
Brake system tank .................................................................................................................................. 10- 80
Parking brake ......................................................................................................................................... 10- 82
Parking brake caliper.............................................................................................................................. 10- 84
Spring cylinder........................................................................................................................................ 10- 85
Parking brake solenoid ........................................................................................................................... 10- 86
Suspension............................................................................................................................................. 10- 88
Suspension cylinder ............................................................................................................................... 10- 94
Oscillation hitch ...................................................................................................................................... 10- 96
Steering, hoist oil pressure piping diagram ............................................................................................ 10-100
Dump body control ................................................................................................................................. 10-101
Hydraulic tank and filter .......................................................................................................................... 10-102
Flow amp valve....................................................................................................................................... 10-103
Steering valve......................................................................................................................................... 10-106
Steering cylinder..................................................................................................................................... 10-110
Hoist valve .............................................................................................................................................. 10-112
EPC valve............................................................................................................................................... 10-118
Pilot check valve..................................................................................................................................... 10-118-1
Hoist cylinder .......................................................................................................................................... 10-119
Hydraulic pump....................................................................................................................................... 10-120
Cab tilt .................................................................................................................................................... 10-125
Air conditioner......................................................................................................................................... 10-126
Machine monitor system......................................................................................................................... 10-131
Automatic shift control system................................................................................................................ 10-155
Transmission controller .......................................................................................................................... 10-157
Auto emergency steering system ........................................................................................................... 10-163
Sensors, switches................................................................................................................................... 10-164
Retarder control system ......................................................................................................................... 10-172
Brake control system (e-spec)................................................................................................................ 10-181-1
Dump control lever ................................................................................................................................. 10-182
PLM-HM ................................................................................................................................................. 10-187
HM400-1 10-1
(10)
RADIATOR, OIL COOLER,
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AFTERCOOLER
RADIATOR, OIL COOLER, AFTERCOOLER
1. Aftercooler Specifications
2. Water filler Radiator
3. Reservoir tank • Core type: CF4-5
4. Upper tank • Total heat dissipation area: 67.93m2
5. Lower tank (torque converter, oil cooler) Torque converter oil cooler
A. From thermostat • Core type: PTO-LS
B. To water pump • Total heat dissipation area: 4.0655m2
C. From rear brake Steering oil cooler
C. From rear brake • Core type: PTO-OL
D. To oil filter • Total heat dissipation area: 0.896m2
E. From hoist valve
F. To hydraulic tank
G. From water pump
10-2 HM400-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN SKELETON
POWER TRAIN SKELETON

(Machine with differential lock differential)
10-4 HM400-1
6
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
HM400-1 10-5
6
(Machine with limited slip differential)
10-5-1 HM400-1
6
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 pump (SAR(3)100)
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
13. Front limited slip differential
14. Tire
15. Final drive (front)
16. Brake (front)
17. Rear drive shaft (front)
19. Center limited slip differential
20. Tire
21. Final drive (center)
22. Brake (center)
23. Rear drive shaft (rear)
25. Rear limited slip differential
26. Tire
27. Final drive (rear)
28. Brake (rear)
29. Interaxle differential lock
HM400-1 10-5-2
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD OUTPUT SHAFT
OUTPUT SHAFT
1. Rubber cushion FUNCTION

2. Outer body The output shaft is installed to the engine fly-
3. Flange wheel,and absorbs the twisting vibration caused by
4. Shaft changes in the engine torque.
5. Coupling
6. Inner body
7. Cover
10-6 HM400-1
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD OUTPUT SHAFT
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance

Clearance between size Shaft Hole clearance limit
1
flywheel and bearing
0 0 0.013 –
80 0.02
-0.013 -0.030 0.030
Clearance between shaft -0.009 0 -0.003 – Replace
2 40 0.10
and bearing -0.025 -0.012 0.025
Clearance between bearing 0 -0.006 0.009 –
3 120 –
and cover -0.015 -0.028 0.028
Clearance between bearing 0.012 0 -0.007 –
4 65 0.025
and shaft -0.007 -0.015 0.027
Weaar of oil seal contact sur- Standard size Repair limit Repair or
5
face of coupling 95 94.7 replace
Standard backlash Backlash limit

6 Backlash at spline
0.099 – 0.202 0.4
Standard backlash (Dimen-
Deformastion of Original dimension : Lo Replace
sion at smallest width : L)
7 rubber cushion
75 67
External Without cranks
HM400-1 10-7
TORQUE CONVERTER AND TRANSMISSION
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PIPING
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC

PIPING
10-8 HM400-1
TORQUE CONVERTER AND TRANSMISSION
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PIPING
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
HM400-1 10-9
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
A: Torque converter oil outlet port SPECIFICATIONS

B: Torque converter oil inlet port Type: 3 element, 1-stage, 2-phase
C: To lockup clutch with modulation and lockup
1. PTO gear (No. of teeth: 9) clutch
Lockup clutch: Multiple-disc clutch
Hydraulic control
(with modulation valve)
Stall torque ratio: 2.63
10-10 HM400-1
1. Coupling 8. Starter shaft

2. Input shaft 9. One way clutch
(No. of teeth: 108) 10. Starter
3. Housing 11. Disc
4. Drive case 12. Piston
5. Turbine 13. Clutch housing
6. Race 14. Retainer
7. Pump
HM400-1 10-11
(7)
10-12 HM400-1
3
Unit: mm
Standard size Tolerance Repair limit

Outside diameter of coupling
1 0
and oil seal sliding portion 4 95 -0.087
4 94.8
Inside diameter of seal ring
+0.025
2 sliding portion of input shaft 4 35 0
4 35.5
sliding portion
Inside diameter of seal ring +0.097
3
sliding portion of clutch housing
4 420 0
4 420.5
4
sliding portion of clutch piston
4 295 0
4 295.1
5
sliding portion of pump housing
4 135 0
4 135.5
6
sliding portion of input shaft
4 70 0
4 70.5
-0.01
Wear of clutch Width 5 4.5
7 -0.04
housing seal ring
Thickness 7 0.15 6.85 Replace
0
Wear of stator shaft Width 3.95
-0.1
3.55
8
seal ring
Thickness 5.5 0.1 4.95
Inside diameter of outer race
9 one-way clutch transmission 4 127.844 0.013 4 127.874
surface
Outside diameter of inner race
10 one-way clutch transmission 4 108.883 0.013 4 108.853
surface
Inside diameter of sliding por- +0.015
11
tion of bushing
4 109 0
4 109.08
Thickness of sliding portion 0
12 5 4.5
bushing -0.1
13 Thickness of clutch disc 5.4 0.1 4.8
Backlash between input shaft
14 0.17 – 0.45
and PTO gear
HM400-1 10-13
PATH FOR TRANSMISSION OF POWER 2. When lock-up clutch is engaged

When the lock-up clutch is engaged, drive case
1. When lock-up clutch is disengaged (1) and turbine (2) are engaged and form one
When the lock-up clutch is disengaged, drive unit. Stator (8) is rotated by the rotation of pump
case (1) and turbine (2) are separated, and the (6) and turbine (2).
torque converter functions as normal. The power generated by the engine goes from
The power generated by the engine goes from the damper through the drive shaft, is transmit-
the damper through the drive shaft, is transmitted to coupling (3), input shaft (4) and clutch
ted to coupling (3), input shaft (4) and clutch housing (5), and rotates drive case (1) and pump
housing (5), and rotates drive case (1) and pump (6) as one unit.
(6) as one unit. In addition, drive case (1) and turbine (2) are en-
The power from pump (6) uses oil as a medium, gaged by the clutch, so the power is transmitted
rotates turbine (2), and is transmitted from tur- directly from turbine (2) to transmission output
bine (2) to transmission output shaft (7). shaft (7) without using oil as a medium.
10-14 HM400-1
FLOW OF OIL
The oil passes through the main relief valve, is ad-

justed by the torque converter relief valve to a pres-
sure 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 centrifu-
gal force by pump (2), enters turbine (4), and trans-
mits the energy of the oil to the turbine.
The oil from turbine (4) is sent to stator (3), and en-
ters 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.
HM400-1 10-15
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
1. Transmission case (front)

2. Transmission case (rear)
3. Oil filler pipe mount
4. Transmission control valve
5. Main relief, torque converter relief valve
10-16 HM400-1
(7)
1. R clutch 8. Lower shaft

2. 1st clutch 9. 3rd clutch
3. 2nd clutch 10. Upper shaft
4. Differential lock clutch 11. FH clutch
5. Rear output shaft 12. Input shaft
6. Rear coupling 13. FL clutch
7. Front output shaft 14. Torque converter
HM400-1 10-17
(7)
10-18 HM400-1
(7)
Tolerance
Standard Standard Clearance
size clearance limit
1 Clearance (F) between FL, R clutch Shaft Hole
bearing and case
o 160 0
-0.025
0
-0.040
-0.040 –
0.025 –
2 Clearance (R) between FL, R clutch

bearing and case o 160 0
-0.025
0
-0.040
-0.040 –
0.025 –
3 Clearance (F) between FH, 1st clutch

-0.025
0
-0.040
-0.040 –
0.025 –
4 Clearance (R) between FH, 1st clutch

-0.025
0
-0.040
-0.040 –
0.025 –
5 Clearance (F) between 2nd, 3rd

clutch bearing and case o 160 0
-0.025
-0.012
-0.052
-0.052 –
0.013 –
6 Clearance (R) between 2nd, 3rd

clutch bearing and cage o 160 0
-0.025
-0.017
-0.052
-0.052 –
0.008 –
7 Clearance (F) between differential

lock clutch bearing and case o 230 0
-0.030
-0.014
-0.060
-0.060 –
0.016 –
8 Clearance (R) between differential

lock clutch bearing and case o 230 0
-0.030
-0.014
-0.060
-0.060 –
0.016 –
9 Clearance between front output bear-

ing and cage o 140 0
-0.018
+0.018
-0.007
-0.007 –
0.036 –
10 Clearance between front output bear-

ing and spacer o 90 +0.035
+0.013
0
-0.020
-0.055 –
-0.013 –

Width of input shaft seal ring groove
2.5 +0.18 2.7
+0.10
0 0.05
11
Width 2.4 2.2
Wear of input shaft
seal ring 0
Thickness 1.7 -0.10 1.5
Replace
Width of input shaft seal ring groove 3.2 +0.076 3.5
0
12 Width 3.1 0 0.05 2.8
Wear of input shaft
0 0.10
seal ring
Thickness 2.2 2.0
Inside diameter of seal ring sliding

portion of each shaft (rear) o 50 +0.050
0 o 50.1
Width of seal ring groove of each 3.2 +0.076 3.5

shaft (rear) 0
13
Width 3.1 0 2.8
Wear of seal ring of -0.05
0 0.10
each shaft (rear)
Thickness 2.05 1.8

portion of sleeve o 140 +0.40
0 o 140.1
Width of seal ring groove of sleeve 4.5 +0.05 5.0

+0.10
14
Width 4.5 -0.08 4.1
0 0.15
sleeve
Thickness 4.0 3.6

portion of front output shaft o 85 +0.035
0 o 85.1
Width of seal ring groove of front out- 3.0 +0.15 3.3

put shaft +0.10
15
Width 3.0 0 2.7
0 0.10
front output shaft
Thickness 3.5 3.35
16 Outside diameter of rear coupling oil

seal sliding portion o 120 0
-0.087 o 119.8
HM400-1 10-19
(7)
1. Ridler gear (No. of teeth : 35)

2. Strainer
Unit: mm

Clearance between R idler gear size Shaft Hole clearance limit
3
bearing and case
o 125
0 -0.025 -0.050 – Replace
–
-0.018 -0.050 -0.007
o 70
Clearance between R idler gear +0.032 -0.036 -0.061 –
4 –
bearing and R idler gear +0.002 -0.061 -0.018
Outline Clutch combination and reduction ratio

• The transmission is installed to the rear of the
torque converter. The power from the torque Speed range Clutch used Reduction ratio
converter passes through the transmission input
shaft and enters the transmission. F1 FL x 1st 6.061
• The transmission uses combinations of the FL,
F2 FH x 1st 3.957
FH, and R clutches and the three speed clutches
to shift the power from the input shaft and F3 FL x 2nd 2.574
selects a speed range from FORWARD 1st - 6th
or REVERSE 1st - 2nd. This is then transmitted F4 FH x 2nd 1.680
to the output shaft. F5 FL x 3rd 1.094
• Gearshifting is carried out automatically by the
automatic transmission according to the F6 FH x 3rd 0.714
changes in the engine speed.
R1 R x 1st 5.851
R2 R x 2nd 2.484
10-20 HM400-1
(7)
FL - R CLUTCH
A: R clutch oil port C: Lubricating oil port

B: FL clutch oil port D: Lock-up clutch oil port
1. Input shaft 5. FL, R cylinder

2. Idler gear (No. of teeth: 43) 6. R clutch
3. FL gear (No. of teeth: 33) 7. R gear (No. of teeth: 25)
4. FL clutch
Unit: mm

Clearance (F) between FL, R size Shaft Hole clearance limit
8
shaft and bearing (F)
o 75
+0.071 0 -0.086 –
–
+0.061 -0.015 -0.061
o 75
Clearance (R) between FL, R +0.071 0 -0.086 –
9 –
shaft and bearing (R) +0.061 -0.015 -0.061
10 Thickness 2.0 0 0.05 1.8
Separator plate
Distortion – 0.05 0.15
Thickness 3.2 0 0.08 2.75 Replace
11 Friction plate
Load of wave spring (height: 1274 N 114.7 N 1088 N
12
3.8 mm) {130 kg} {11.7 kg} {111 kg}
0 0.2
Thickness of FL clutch thrust
13 4 3.6
washer
0 0.2
Thickness of R clutch thrust
14 4 3.6
washer
15 End play of FL gear 0.14 – 0.86
16 End play of R gear 0.17 – 0.83
HM400-1 10-21
(7)
FH - 1ST CLUTCH
A: 1st clutch oil port C: Lubricating oil port

B: FL clutch oil port
1. FH gear (No. of teeth: 57) 4. 1st clutch

2. FH clutch 5. 1st gear (No. of teeth: 30)
3. FH, 1st cylinder, idler gear (No. of teeth: 67) 6. Idler gear (No. of teeth: 49)
7. Upper shaft
Unit: mm

Clearance (F) between FH, 1st size Shaft Hole clearance limit
8
shaft and bearing
o 75
+0.071 0 -0.086 –
–
+0.051 -0.015 -0.051
o 75
Clearance (R) between FH, 1st +0.071 0 -0.086 –
9 –
shaft and bearing +0.051 -0.015 -0.051
10 Thickness 2.0 0 0.05 1.8
Separator plate
11 Friction plate
12
3.8 mm) {130 kg} {11.7 kg} {111 kg}
0 0.2
Thickness of FH clutch thrust
13 4 3.6
washer
0 0.2
Thickness of 1st clutch thrust
14 4 3.6
washer
15 End play of FH gear 0.17 – 0.83
16 End play of 1st gear 0.15 – 0.85
10-22 HM400-1
(7)
2ND - 3RD CLUTCH
A: 2nd clutch oil port C: Lubricating oil port

B: 3rd clutch oil port
1. 3rd gear (No. of teeth: 25) 5. 2nd gear (No. of teeth: 43)
2. 3rd clutch 6. Idler gear (No. of teeth: 54)
3. 2nd, 3rd cylinder, idler gear (No. of teeth: 62) 7. Lower shaft
4. 2nd clutch
Unit: mm

Clearance (F) between 2nd, size Shaft Hole clearance limit
8
3rd shaft and bearing
o 75
+0.071 0 -0.086 –
–
+0.051 -0.015 -0.051
o 75
Clearance (R) between 2nd, +0.071 0 -0.086 –
9 –
3rd shaft and bearing +0.051 -0.015 -0.051
10 Thickness 2.0 0 0.05 1.8
Separator plate
11 Friction plate
12
3.8 mm) {130 kg} {11.7 kg} {111 kg}
0 0.2
Thickness of 3rd clutch thrust
13 4 3.6
washer
0 0.2
Thickness of 2nd clutch thrust
14 4 3.6
washer
15 End play of 3rd gear 0.15 – 0.85
16 End play of 2nd gear 0.15 – 0.85
HM400-1 10-23
(7)
DIFFERENTIAL LOCK
A: Lubricating oil port
1. Front output shaft 6. Planet gear (No. of teeth: 20)

2. Clutch hub 7. Ring gear (No. of teeth: 80)
3. Housing 8. Carrier
4. Differential lock clutch 9. Output gear (No. of teeth: 78)
5. Sun gear (No. of teeth: 40) 10. Rear output shaft
10-24 HM400-1
3
Unit: mm

Clearance between housing size Shaft Hole clearance limit
11
and bearing
o 170
+0.040 0 -0.065 –
–
+0.015 -0.025 -0.015
o 170
Clearance between output gear +0.065 0 -0.090 –
12 –
and bearing +0.040 -0.025 -0.040
o 130
Clearance between housing 0 -0.012 -0.052 –
13 –
and bearing -0.018 -0.052 -0.006
o 75
Clearance between front output +0.012 0 -0.027 –
14 –
shaft and bearing -0.007 -0.015 -0.007
o 150
Clearance (F) between output 0 -0.050 -0.090 –
15 –
gear and bearing -0.020 -0.090 -0.030
o 150
Clearance (R) between output 0 -0.028 -0.068 –
16 –
gear and bearing -0.020 -0.068 -0.008
o 100
Clearance between front output +0.028 0 -0.048 –
17 –
shaft and bearing +0.013 -0.020 -0.013 Replace
18 Thickness 2.0 0 0.05 1.8
Separator plate
Thickness 3.2 0 0.10 2.75
19 Friction plate
Load of wave spring (height: 1480 N 440 N 1255 N
20
3.2 mm) {151 kg} {45 kg} {128 kg}
o 70
70.1
sliding portion of carrier 0
0 0.05
Width of seal ring groove of
2.1 2.3
21 front output shaft
Wear of seal ring 0

Width 1.95 1.76
of front output -0.1
shaft Thickness 1.85 0 0.1 1.67
HM400-1 10-25
(7)
OPERATION OF CLUTCHES
Clutch engaged (fixed) Clutch disengaged (free)

• The oil sent from the transmission valve passes • The oil sent from the transmission valve is shut
through the oil passage inside shaft (1), reaches off, so the pressure of the oil acting on the back
the back face of piston (6) and acts on piston (6). face of piston (6) goes down.
• When piston (6) is actuated, separator plate (2) • Piston (6) is returned to its original position by
and friction plate (3) are pressed together, shaft wave spring (7), and shaft (1) and clutch gear (4)
(1) and clutch gear (4) form one unit, and the are separated.
power is transmitted. • When the clutch is disengaged, centrifugal force
When this happens, the oil is drained from oil is used to drain the oil at the back face of the pis-
drain hole (5), but the drain amount is less than ton through oil drain hole (5). This acts to pre-
the amount of oil supplied, so there is no influ- vent the clutch from being partially applied.
ence on the actuation of the clutch.
★ Oil drain hole (5) forms part of the structure

of only the 2nd, 3rd, and differential lock
clutches.
10-26 HM400-1
3
FORWARD 1ST
Operation
• In the case of FORWARD 1st, FL clutch (3) and • 1st clutch (11) is engaged, so the power trans-
1st clutch (11) are engaged. The power from the mitted to FH, 1st cylinder gear (8) passes
torque converter is transmitted to input shaft (1), through 1st clutch (11), and goes from 1st gear
and then transmitted to front and rear output (12) to 2nd, 3rd cylinder gear (14). It then goes
shafts (28) and (29). through idler gear (19) and output gear (20),
• FL clutch (3) and 1st clutch (11) hold each clutch and is transmitted to differential lock carrier
disc in position with the oil pressure applied to (21).
the piston. • When the differential lock switch is OFF, the
• The power from the torque converter is transmit- front output force passes from planet gear (25)
ted from input shaft (1) through FL clutch (3), through sun gear (26), and is transmitted to front
goes to FL gear (5), and is then transmitted to output shaft (28). The rear output force passes
FH, 1st cylinder gear (8). 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.
HM400-1 10-27
3
FORWARD 2ND
Operation
• In the case of FORWARD 2nd, FH clutch (10) • 1st clutch (11) is engaged, so the power trans-
and 1st clutch (11) are engaged. The power mitted to FH, 1st cylinder gear (8) passes
from the torque converter is transmitted to input through 1st clutch (11), and goes from 1st gear
shaft (1), and then transmitted to front and rear (12) to 2nd, 3rd cylinder gear (14). It then goes
output shafts (28) and (29). through idler gear (19) and output gear (20),
• FH clutch (10) and 1st clutch (11) hold each and is transmitted to differential lock carrier
clutch disc in position with the oil pressure ap- (21).
plied to the piston. • When the differential lock switch is ON, the
• The power from the torque converter is transmit- front output force passes from housing (22)
ted from input shaft (1) to idler gear (2) and goes through differential lock clutch (23) and clutch
to FH gear (9), passes through FH clutch (10), hub (24), and is transmitted to front output shaft
and is then transmitted to FH, 1st cylinder gear (28). The rear output force passes from planet
(8). gear (25) through ring gear (27), and is transmit-
ted to rear output shaft (29).
★ If the differential lock is OFF, see FORWARD
1ST.
10-28 HM400-1
3
FORWARD 3RD
Operation
• In the case of FORWARD 3rd, FL clutch (3) and • 2nd clutch (17) is engaged, so the power trans-
2nd clutch (17) are engaged. The power from mitted to 2nd gear (15) passes through 2nd
the torque converter is transmitted to input shaft clutch (17), and goes to 2nd, 3rd cylinder gear
(1), and then transmitted to front and rear output (14). It then goes through idler gear (19) and
shafts (28) and (29). output gear (20), and is transmitted to differen-
• FL clutch (3) and 2nd clutch (17) hold each tial lock carrier (21).
clutch disc in position with the oil pressure ap- ★ The diagram above shows the situation when
plied to the piston. the differential lock is OFF.
• The power from the torque converter is transmit- ★ For details of the actuation when the differential
ted from input shaft (1) through FL clutch (3), lock is OFF, see FORWARD 1ST; for details of
goes to FL gear (5), and is then transmitted the actuation when the differential lock is ON,
through FH, 1st cylinder gear (8) and idler gear see FORWARD 2ND.
(13), and goes to 2nd gear (15).
HM400-1 10-29
3
FORWARD 4TH
Operation
• In the case of FORWARD 4th, FH clutch (10) • 2nd clutch (17) is engaged, so the power trans-
and 2nd clutch (17) are engaged. The power mitted to 2nd gear (15) passes through 2nd
from the torque converter is transmitted to input clutch (17), and goes to 2nd, 3rd cylinder gear
shaft (1), and then transmitted to front and rear (14). It then goes through idler gear (19) and
output shafts (28) and (29). output gear (20), and is transmitted to differen-
• FH clutch (10) and 2nd clutch (17) hold each tial lock carrier (21).
plied to the piston. the differential lock is ON.
ted from input shaft (1), goes to idler gear (2) lock is OFF, see FORWARD 1ST; for details of
and FH gear (9), passes through FH clutch (10), the actuation when the differential lock is ON,
and is then transmitted through FH, 1st cylinder see FORWARD 2ND.
gear (8) and idler gear (13), and is transmitted
to 2nd gear (15).
10-30 HM400-1
3
FORWARD 5TH
Operation
• In the case of FORWARD 5th, FL clutch (3) and • 3rd clutch (18) is engaged, so the power trans-
3rd clutch (18) are engaged. The power from mitted to 3rd gear (16) passes through 3rd clutch
the torque converter is transmitted to input shaft (18), and goes to 2nd, 3rd cylinder gear (14). It
(1), and then transmitted to front and rear output then goes through idler gear (19) and output
shafts (28) and (29). gear (20), and is transmitted to differential lock
• FL clutch (3) and 3rd clutch (18) hold each clutch carrier (21).
disc in position with the oil pressure applied to ★ The diagram above shows the situation when
the piston. the differential lock is OFF.
ted from input shaft (1) through FL clutch (3), lock is OFF, see FORWARD 1ST; for details of
goes to FL gear (5), and is then transmitted the actuation when the differential lock is ON,
through FH, 1st cylinder gear (8) to 3rd gear see FORWARD 2ND.
(16).
HM400-1 10-31
3
FORWARD 6TH
Operation
• In the case of FORWARD 6th, FH clutch (10) • 3rd clutch (18) is engaged, so the power trans-
and 3rd clutch (18) are engaged. The power mitted to 3rd gear (16) passes through 3rd clutch
from the torque converter is transmitted to input (18), and goes to 2nd, 3rd cylinder gear (14). It
shaft (1), and then transmitted to front and rear then goes through idler gear (19) and output
output shafts (28) and (29). gear (20), and is transmitted to differential lock
• FH clutch (10) and 3rd clutch (18) hold each carrier (21).
plied to the piston. the differential lock is ON.
ted from input shaft (1), goes to idler gear (2) lock is OFF, see FORWARD 1ST; for details of
and FH gear (9), passes through FH clutch (10), the actuation when the differential lock is ON,
and is then transmitted through FH, 1st cylinder see FORWARD 2ND.
gear (8) to 3rd gear (16).
10-32 HM400-1
3
REVERSE 1ST
Operation
• In the case of REVERSE 1st, R clutch (4) and • 1st clutch (11) is engaged, so the power trans-
1st clutch (11) are engaged. The power from the mitted to FH, 1st cylinder gear (8) passes
torque converter is transmitted to input shaft (1), through 1st clutch (11), and goes from 1st gear
and then transmitted to front and rear output (12) to 2nd, 3rd cylinder gear (14). It then goes
shafts (28) and (29). through idler gear (19) and output gear (20),
• R clutch (4) and 1st clutch (11) hold each clutch and is transmitted to differential lock carrier
disc in position with the oil pressure applied to (21).
the piston. ★ The diagram above shows the situation when
• The power from the torque converter is trans- the differential lock is OFF.
mitted from input shaft (1) through R clutch (4), ★ For details of the actuation when the differential
goes to R gear (6), is rotated in the opposite di- lock is OFF, see FORWARD 1ST; for details of
rection by R idler gear (7), passes through idler the actuation when the differential lock is ON,
gear (13), and is then transmitted to FH, 1st see FORWARD 2ND.
cylinder gear (8).
HM400-1 10-33
3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION VALVE
TRANSMISSION VALVE
A. Lock-up clutch oil pressure detection port ECMV clutch operation table
B. 2nd clutch oil pressure detection port ECMV
C. 3rd clutch oil pressure detection port
FL FH R 1st 2nd 3rd
D. R clutch oil pressure detection port
w w
Speed range
E. FL clutch oil pressure detection port
F. 1st clutch oil pressure detection port F1
w w
G. FH clutch oil pressure detection port
H. Differential lock clutch oil pressure detection port F2
1. ECMV (for lock-up clutch) F3 w w

w w
2. ECMV (for 2nd clutch)
F4
w w
3. ECMV (for 3rd clutch)
4. ECMV (for R clutch)
F5
w w
5. ECMV (for FL clutch)
6. ECMV (for 1st clutch)
F6
w w
7. ECMV (for FH clutch)
8. ECMV (for differential lock clutch)
R1
w w
9. Seat
10. Last chance filter
R2
10-34 HM400-1
ECMV (Electronic Control
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD Modulation Valve)
ECMV (Electronic Control Modulation Valve)
A: To clutch 1. Connector for fill switch

P: From pump 2. Connector for proportional solenoid
T: Drain 3. Oil pressure detection valve
Dr: Drain 4. Fill switch
P1: Clutch oil pressure detection port 5. Proportional solenoid
P2: Pilot oil pressure detection port 6. Pressure control valve
HM400-1 10-35
3
ECMV FOR LOCK-UP CLUTCH
Outline Operation
• This valve acts to set the lock-up clutch oil pres- During torque converter travel
sure to the set pressure, and also to switch the • When the transmission is in torque converter
lock-up clutch. travel, no current flows to proportional solenoid
It forms a modulation wave pattern, so the lock- (1).
up clutch is engaged smoothly to reduce the Pressure control valve (3) drains the oil at clutch
shock when shifting gear. In addition, it prevents port A through drain port Dr and cancels the
generation of peak torque in the power train. As lock-up clutch.
a result, it provides a comfortable ride for the op- When this happens, there is no oil pressure act-
erator and ing on oil pressure detection valve (4), so fill
greatly increases the durability of the power switch (6) is OFF.
train.
10-36 HM400-1
DURING DIRECT TRAVEL

(torque converter travel ➔ direct travel)
1. When filling 2. Adjusting pressure

When the transmission is in direct travel (lock- When electric current flows to proportional sole-
up), if electric current is applied to proportional noid (1), the solenoid generates a propulsion
solenoid (1) by the electric signal, a hydraulic force proportional to the current. The pressure
force balancing with the force of the solenoid is adjusted so that the total of this propulsion
acts on chamber B, and pressure control valve force of the solenoid, the propulsion force of the
spool (3) oil pressure
moves to the left. As a result, the circuit at the clutch port, and the reaction force of pres-
between pump port P and clutch port A opens, sure control valve spring (2) is balanced.
and oil starts to fill the clutch. When the clutch To reduce the shock when shifting gear, the oil
is filled with oil, fill switch (6) is turned ON. pressure of the lock-up clutch is temporarily
lowered during the gearshifting operation.
The oil pressure at this point is an oil pressure
which balances the pushing force of the lock-up
piston and the pressure inside the torque con-
verter.
HM400-1 10-37
ECMV FOR SPEED CLUTCH ECMV and proportional solenoid

• There is one proportional solenoid installed to
Outline of ECMV each ECMV.
• The ECMV (Electronic Control Modulation It generates propulsion as shown in the dia-
Valve) consists of two components: the pressure gram below according to the command current
control valve and the fill switch. from the controller.
Pressure control valve The propulsion generated by the proportional
• The proportional solenoid receives the flow of solenoid acts on the pressure control valve
electricity sent from the transmission controller, spool and generates oil pressure as shown in
and the pressure control valve converts this into the diagram below. In this way, the command
hydraulic pressure. current is controlled and the propulsion force
Fill switch varies to actuate the pres-
• This detects when oil has filled the clutch. It has sure control valve and control the oil flow and oil
the following functions. pressure.
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.
2) While oil pressure is applied to the clutch, it
outputs a signal (fill signal) to the controller
to inform the controller of the existence of
the oil pressure.
A range: Before gear shifting (drained)
B range: Filling starts (trigger issued)
C range: Filling completed
D range: Regulation
E range: Filling
ECMV and fill switch

• There is one fill switch installed to each ECMV.
When the filling of the clutch is completed, the fill
switch is turned on by the clutch pressure. With
this signal, the oil pressure starts to build up.
10-38 HM400-1
OPERATION OF ECMV
• The ECMV is controlled by the command current 1. When gear shifting (during draining)
from the transmission controller to the propor- (Range A in graph)
tional solenoid and the fill switch output signal. When no current is flowing to proportional sole-
The relationship between the ECMV propor- noid (1), pressure control valve spool (3) drains
tional solenoid command current and the clutch the oil at clutch port A through drain port Dr.
input pressure and fill switch output signal is as When this happens, there is no hydraulic force
shown in the diagram below. acting on pressure detection valve (4), so fill
switch (6) is turned OFF.
A range: Before gear shifting (drained)
B range: Filling starts (trigger issued)
C range: Filling completed
D range: Regulation
E range: Filling
HM400-1 10-39
2. When filling (when trigger command is input 3. Adjusting pressure (Range D in graph)
to pressure control valve) When electric current flows to proportional sole-
(Ranges B and C in graph) noid (1), the solenoid generates a propulsion
When there is no oil inside the clutch, if elec- force proportional to the current. The pressure
tric current is applied to proportional solenoid is adjusted so that the total of this propulsion
(1), a hydraulic force balancing the force of the force of the solenoid, the propulsion force of the
solenoid acts on chamber B, and pressure con- oil pressure
trol valve spool (3) moves to the left. As a at the clutch port, and the reaction force of pres-
result, the sure control valve spring (2) is balanced.
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.
10-40 HM400-1
ECMV FOR DIFFERENTIAL LOCK
Operation
1. When differential lock switch is turned ON ➔ 2. When differential lock switch is turned OFF
OFF ➔ ON
When the differential lock switch is turned OFF, When the differential lock switch is turned ON, and
there is no electric current flowing from the con- electric signal is sent from the controller to propor-
troller to proportional solenoid (1) of the ECMV, tional solenoid (1) of the ECMV, and oil starts to fill
so the oil at clutch port A passes through drain clutch port A. As a result, piston (2) is actuated,
port Dr and is drained. As a result, the force of presses separator plate (3) and friction
the oil plate (4) together, so carrier (6) and front output
pressure at clutch port A goes down and piston shaft (7) form one unit and transmit the power.
(2) is returned to its original position by wave
spring (5). Carrier (6) and front output shaft (7)
are separated, and the power is transmitted by
the planetary gear.
The proportion of the torque at this point is as The proportion of the torque at this point is as fol-
follows: lows:
Front 1: Rear 2 Front 1: Rear 1
HM400-1 10-41
MAIN RELIEF, TORQUE CONVERTER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RELIEF VALVE
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
A: Drain (torque converter relief) 1. Body

B: Drain 2. Piston
C: From pump 3. Torque converter relief valve
D: Drain 4. Piston
E: To torque converter 5. Main relief valve
P1: Main relief oil pressure detection port
P2: Torque converter relief oil pressure detection
port
Unit: mm

Clearance between main relief size Shaft Hole clearance limit
6 valve and valve body
4 28 -0.035
-0.045
+0.013
0
0.035 –
0.058
0.078
C le aran c e b e tw ee n to rq ue c on -
7 v erte r relief va lv e a n d v al ve 4 22 -0.035
-0.045
+0.013
0
0.035 –
0.058 0.078
b od y
Standard size Repair limit
Replace
Main relief valve spring (out- Free Installed Installed Free Installed
8 length length load length load
side)
108 79.5 275 N 104.8 261 N
{28.0 kg} {26.6 kg}
326 N 309 N
9 Main relief valve spring (inside) 108 79.5 104.8
{33.2 kg} {31.5 kg}
Torque converter relief valve 173 N 164 kN
10 50 41 48.5
spring {17.6 kg} {16.7 kg}
10-42 HM400-1
MAIN RELIEF, TORQUE CONVERTER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RELIEF VALVE
OUTLINE Operation of main relief valve

• The oil from the hydraulic pump passes through
Torque converter relief valve the filter and enters port A of the relief valve. It
The torque converter relief valve protects the torque then passes through orifice a of spool (6) and
converter from abnormally high pressure. It is in- enters chamber B.
stalled in the torque converter inlet port circuit to hold When the oil from the pump fills the circuit, the
the oil pressure in the torque converter inlet port cir- oil pressure starts to rise.
cuit below the set pressure.
Set pressure: 0.91 MPa {9.31 kg/cm2}
(Cracking pressure)
Main relief valve

The main relief valve holds the oil pressure in the
transmission and brake at the set pressure.
Set pressure: 2.62 MPa {26.7 kg/cm2}
(Engine at rated speed)
Operation
Operation of torque converter relief valve As the oil pressure in the circuit rises, the oil entering
• The oil relieved by the main relief valve flows chamber B pushes piston (4). The reaction force
from port C into the torque converter, and at the compresses valve spring (7) and moves spool (6) to
same time, passes through orifice b of spool (2) the left to open the circuit between port A and port C.
and enters chamber D. When this happens, the oil at port A is relieved to
When the circuit leading to the torque converter port C and flows from port C to the torque converter.
becomes filled with oil, the oil pressure starts to The oil pressure at port A at this point is 2.62 MPa
rise. {26.7 kg/cm2} (engine at rated speed).
• As the oil pressure going to the torque converter

rises, the oil entering 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).
HM400-1 10-43
3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
1. Drive shaft (right) Outline

2. Front drive shaft • The power from the engine goes from the output
3. Drive shaft (left) shaft through front drive shaft (2), the transmis-
4. Center drive shaft sion, and the front axle, and is transmitted by left
5. Rear drive shaft (front) and right drive shafts (1) and (3).
6. Rear drive shaft (rear) The rest of the power passes through center
drive shaft (4) and the oscillation hitch, and is
transmitted by rear drive shafts (5) and (6) to
the rear axles.
• The drive shaft does not simply act to transmit
the power. It also has the following purposes.
When articulating, or when there is impact from
the road surface during travel operations or
impact during operations, the position of the
engine, transmission, and axles changes.
To enable the power to be transmitted without
causing damage to any components by the
impact or change in position, the drive shaft has
a universal joint and slipping joint to enable it to
cope with any changes in the angle or length.
10-44 HM400-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AXLE
AXLE
FRONT
1. Drive shaft
3. Brake
4. Final drive
HM400-1 10-45
CENTER
2. Center axle
3. Brake
4. Final drive
5. Drain plug
10-46 HM400-1
REAR
1. Drain plug
3. Rear axle
4. Brake
5. Final drive
HM400-1 10-47
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL
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
10-48 HM400-1
6
Unit: mm

Wear of coupling oil seal con-
9 0
tact surface 95 94.9 Repair or
-0.087
replace
Wear of coupling oil seal con- 0
10 110 109.9
tact surface -0.087
Thickness of side gear thrust
11
washer
4 0.05 3.5
Replace
12 Thickness of disc 3.5 0.1 3.1
13 Thickness of plate 2.1 0.1 1.9
Backlash between bevel gear
14 0.42 – 0.65 (in circumferential direction at outside diameter) Adjust
and pinion
HM400-1 10-49
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)
10-50 HM400-1
Unit: mm

Wear of coupling oil seal con- Repair or
9 0
tact surface 95 94.9 replace
-0.087
10
washer
4 0.05 3.5
Replace
and pinion
HM400-1 10-51
REAR
1. Pinion gear (No. of teeth: 14)

2. Shaft
3. Differential case
4. Plate
5. Disc
6. Side gear (No. of teeth: 24)
7. Bevel gear (No. of teeth: 41)
8. Bevel pinion (No. of teeth: 12)
10-52 HM400-1
Unit: mm

9 0
-0.087
10
washer
4 0.05 3.5
Replace
13 0.42 – 0.65 Adjust
and pinion
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 1, has its speed reduced, and is
transmitted through pinion gear (6) and side
gear (3) to the axle shaft.
• The power transmitted to the axle shaft has its
speed further reduced by the planetary gear
type final drive, and is transmitted to the wheels.
When turning
• When the machine is turned, the speed that the
wheels turn on the left and right sides is differ-
ent, so pinion gear (6) and side gear (3) inside
the differential rotate according to the difference
in the turning speed on the left and right sides,
and transmit the power of differential case (2) to
the left and right shafts.
When traveling in a straight line

• When the machine is traveling in a straight line,
the speed that the wheels turn on the left and
right sides is the same, so pinion gear (6) inside
the differential assembly does not turn, and the
power of differential case (2) is transmitted
equally through side gear (3) to the left and right
shafts.
HM400-1 10-53
When differential lock is actuated

• If the load resistance on the wheel on one side
is lost (such as when the wheel is in mud), only
the wheel on the side where there is little load re-
sistance turns, and as a result, the power cannot
be transmitted.
In such a case, it becomes impossible to travel,
so differential lock (7) is actuated to stop the
rotation of pinion gear (4) and transmit the
power equally to left and right axle shafts (2).
10-54 HM400-1

FRONT
1. Bevel gear (No. of teeth: 41) 6. Shaft

2. Bevel pinion (No. of teeth: 12) 7. Shaft
3. Limited slip differential 8. Disc
4. Side gear (No. of teeth: 24) 9. Plate
10-54-2 HM400-1
6
Unit: mm

Wear of coupling oil seal con-
10 0
tact surface 95 94.9 Repair or
-0.087
replace
Wear of coupling oil seal con- 0
11 110 109.9
tact surface -0.087
and pinion
HM400-1 10-54-3
6
CENTER

2. Disc
3. Plate
5. Limited slip differential
8. Shaft
10-54-4 HM400-1
6
Unit: mm

9 0
-0.087
and pinion
HM400-1 10-54-5
6
REAR

2. Plate
3. Disc
5. Shaft
6. Limited slip differential
10-54-6 HM400-1
6
Unit: mm

9 0
-0.087
and pinion
HM400-1 10-54-7
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LIMITED SLIP DIFFERENTIAL
LIMITED SLIP DIFFERENTIAL
1. Washer Operation of limited slip differential

2. Disc The power transmitted from the transmission goes
3. Plate from bevel gear (4) to case (9), pressure ring (5),
4. Bevel gear shaft (8), pinion gear (7), side gear (6), and is then
5. Pressure ring divided and sent to left and right shafts (11). A brake
6. Side gear mechanism consisting of disc (2) and plate (3) is as-
7. Pinion gear sembled at the rear face of side gear (6), and the
8. Shaft brake torque is generated in proportion to the torque
9. Case transmitted from pressure ring (5) to shaft (8).
10. Cover In order for this brake torque to act to suppress the
11. Shaft rotation in relation to side gear (6) and case (9), it is
made difficult for left and right side gears (6) to rotate
mutually, and the action of the differential is sup-
pressed.
10-54-8 HM400-1
6
Unit: mm

1 Plate thickness 3.4
±0.03 3.3
3.5
+0.04
2 Disc thickness — 3.55
–0.03
Clearance between disc and
3 0.2 – 0.75
plate (Total on both sides)
4 Replace
4 Washer thickness ±0.05 3.8
4.1
End play of side gear in axial
5 —
direction (Each side)
Backlash between case and
6 0 – 0.4
plate
Backlash between side gear
7 0.13 – 0.36
and disc
HM400-1 10-55
6
<Mechanism for generation of brake torque of

left and right side gears (6)>
Shaft (8) is supported by the cam surface cut into the
mating surfaces of left and right pressure rings (4).
The power (= torque) transmitted from pressure ring
(4) to shaft (8) is transmitted by the cam surface, but
force Fa to separate left and right pressure rings (4)
is generated in proportion to the torque transmitted
by the angle of this cam surface.
This separation load Fa acts as a brake on the rear
face of left and right side gears (6) and generates
brake torque.
<When travelling is straight line >

1. When there is no imbalance between drive force
of left and right wheels.
(The road surface condition (friction coeffident)
for the left and right wheels and the load on the
wheels are uniform.)
The power from the transmission is divided uni-
formly to the left and right by the limited slip dif-
ferential. Under these conditions, the limit for
wheel slip for the left and right wheels is the
same, so even if the power from the transmis-
sion exceeds the wheel slip limit, the wheels on
both sides slip and the differential is not actuat-
ed.
No load is applied to the brake at the rear sur-
face of the side gear.
10-55-1 HM400-1
6
2. When there is imbalance between drive force

of left and right wheels
(The road surface condition (friction coefficient)
for the left and right wheels and the load on the
wheels are not uniform and the wheel on one
side tends to slip more than the wheel on the
other side.)
• When wheel on one side is on soft ground sur-

face.
• The power from the transmission is divided uni-

formly to the left and right by the side gear.
However, if the divided drive force exceeds the
wheel slip limit on the side where the wheel is
slipping, a drive force equal to the excess is sent
through the brake at the rear face of the side
gear and the case to the brake on the opposite
side (side where wheel is locked), and is sup-
plied to the wheel on the side which is locked.
If this excess drive force becomes greater than
the braking force, the differential starts to be ac-
tuated.
Difference in wheel drive force for each type of differ-

ential when wheel on one side is slipping
Wheel drive force (taken as 1 for wheel

that is slipping)
Slipping Locked Total

wheel wheel (proportional)
Limited slip 1 2.64 3.64 (1.82)

differential
Normal 1 1 2 (1)
differential
On road surfaces where the wheel on one side is

likely to slip, the limited slip differential increases the
drive force 1.82 times that of the normal differential
supplied as standard.
<When turning>
The side gear built into the limited slip differential is
the same as the gear used on the normal differential,
so the difference in rotation of the inside and outside
wheels generated when turning can be generated
smoothly.
HM400-1 10-55-2
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 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
10-56 HM400-1
Unit: mm
Backlash between planet gear

8 0.19 – 0.43
and sun gear
Replace
9 0.19 – 0.53
and ring gear
10 Curvature of drive shaft Repair limit: 0.7TIR Repair or replace
11 Thickness of spacer Replace
12 0.1 11.5
Wear of outside diameter of
0
12 portion of axle tube inserted 180 179.8
-0.025
into bearing
Correct
0
-0.025
into bearing

Clearance between shaft (out- size Shaft Hole clearance limit
14 Replace
side diameter) and bushing
0 +0.337 0.251 –
65 0.4
-0.013 +0.251 0.350
HM400-1 10-57
CENTER, REAR
1. Axle shaft 5. Sun gear (No. of teeth: 17)

2. Ring gear (No. of teeth: 67) 6. Drain plug
3. Planet gear (No. of teeth: 24) 7. Brake
4. Planet carrier
Unit: mm

8 0.19 – 0.43
and sun gear
Replace
9 0.19 – 0.53
and ring gear
10 Curvature of drive shaft Repair limit: 1.5TIR Repair or replace
11 Thickness of spacer Replace
26 0.1 11.5
0
-0.025
into bearing
Correct
0
-0.025
into bearing
10-58 HM400-1
Function
• The final drive uses a planetary gear mechanism
to reduce the speed in order to give a large drive
force, and transmits this drive force to the tires.
Operation
• The power from the differential passing through
axle shaft (1) is transmitted to sun gear (5) and
then goes to planet gear (3).
The planet gear rotates on the inside of fixed
ring gear (2) and transmits the reduced speed
to planetary carrier (4). This power is then
transmitted to the wheels that are installed to
the planetary carrier.
HM400-1 10-59
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING COLUMN
STEERING COLUMN
1. Steering shaft
2. Steering column
3. Lock lever
4. Yoke
5. Join shaft
6. Steering valve
10-60 HM400-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE PIPING
BRAKE PIPING
10-62 HM400-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE PIPING
1. Accumulator charge valve

2. Shuttle valve
3. Slack adjuster
4. Brake filter
5. Brake valve
6. Brake system tank
7. Accumulator (for front)
8. Accumulator (for rear)
9. Accumulator (for parking)
10. Proportional reducing valve
11. Parking brake solenoid
HM400-1 10-63
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
1. Pilot piston A. To center, rear brake

2. Rod B. To front brake
3. Lower cylinder C. To brake system tank
4. Spool D. From front accumulator
5. Upper cylinder E. From rear accumulator
6. Spool
10-64 HM400-1
OPERATION Applying brake when upper valve fails

• Even if there is leakage of oil in the upper piping,
Upper portion spool (5) is moved down mechanically when
• When brake pedal (1) is depressed, the operat- pedal (1) is depressed, and the lower portion is
ing force is transmitted to spool (3) through rod actuated normally.
(2) and spring (4). When spool (3) goes down, The upper brake is not actuated.
drain port a is closed, and the oil from the pump
and accumulator flows from port A to port C and Applying brake when lower valve fails
actuates the center and rear brake cylinders. • Even if there is leakage of oil in the lower piping,
the upper portion is actuated normally.
Lower portion
• When brake pedal (1) is depressed, the operat-
ing force is transmitted 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 happens, drain port b is closed, and
the oil from the pump and accumulator flows
from port B to port D and actuates the front
brake cylinders.
When actuation is balanced

Upper portion
• When oil fills the center and rear brake cylinders
and the pressure between port A and port C be-
comes 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 cyl-
inder is held and the brake remains applied.
HM400-1 10-65
Lower portion Brake released

• When spool (3) in the upper portion moves up
and the circuit between port A and port C is shut Upper portion
off, oil also fills the front brake cylinder at the • When pedal (1) is released and the operating
same time, so the pressure in the circuit be- force is removed from the top of the spool, the
tween port B and port D rises. The oil entering back pressure from the brake cylinder and the
port J from orifice f of spool (5) pushes up spool force of the spool return spring move spool (3)
(5) by the same amount that spool (3) moves, up. Drain port a is opened and the oil from the
and shuts off port B and port D. Drain port b is brake cylinder flows to the brake system tank re-
closed, so the oil entering the brake cylinder is turn circuit to release the center and rear brakes.
held, and the brake is applied.
• The pressure in the space in the upper portion is
balanced with the operating force of the pedal, Lower portion
and the pressure in the space in the lower por- • When the pedal is released, spool (3) in the up-
tion is balanced with the pressure in the space in per portion moves up. At the same time, the
the upper portion. When spools (3) and (5) move back pressure from the brake cylinder and the
to the end of their stroke, the circuits between force of the spool return spring move spool (5)
ports A and C and between ports B and D are up. Drain port b is opened and the oil from the
fully opened, so the pressure in the space in the brake cylinder flows to the brake system tank re-
upper and lower portions and the pressure in the turn circuit to release the front brake.
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.
10-66 HM400-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR CHARGE VALVE
ACCUMULATOR CHARGE VALVE
ACC. To accumulator Function

P. From hydraulic pump • The accumulator charge valve is actuated to
PP. To accumulator maintain the oil pressure from the pump at the
T. To brake tank specified pressure and to store it in the accumu-
lator.
• When the oil pressure reaches the specified
pressure, the oil from the pump is connected to
the drain circuit to reduce the load of the pump.
HM400-1 10-67
6
1. Main relief valve (R3) 4. Relief valve (H1)

2. Valve body 5. Filter
3. Relief valve (R1) 6. Filter
10-68 HM400-1
OPERATION 2. When oil supplied to accumulator

1) Cut-in condition
1. When no oil is being supplied to accumulator • When the pressure at port B is lower than the set
(cut-out condition) pressure of the relief valve (R1), piston (8) is
• The pressure at port B is higher than the set pushed back down by spring (5).
pressure of the relief valve (R1), so piston (8) is Valve seat (7) and poppet (6) are brought into
forcibly pushed up by the oil pressure at port B. tight contact, and port C and port T are shut off.
Poppet (6) is opened, so port C and port T are • The spring chamber at the right end of spool (15)
short circuited. is also shut off from port T, so the pressure rises,
• The spring chamber at the right end of spool (15) and the pressure at port P also rises in the same
is connected to port C of the relief valve (R1), so way.
the pressure becomes the brake oil tank pres- • When the pressure at port P goes above the
sure. The oil from the pump enters port P, push- pressure at port B (accumulator pressure), the
es spool (15) to the right at a low pressure supply of oil to the accumulator starts immedi-
equivalent to the load on spring (14). ately. In this case, it is decided by the size (area)
It also passes through orifices (17), (18) and of orifice (17) and the pressure difference
(16), and flows to the brake oil tank. (equivalent to the load on spring (14)) generated
on both sides of the orifice. A fixed amount is
supplied regardless of the engine speed.
HM400-1 10-69
2) When cut-out pressure is reached 3. Main relief valve (R3)

• When the pressure at port B (accumulator pres- • If the pressure at port P (pump pressure) goes
sure) reaches the set pressure of the relief valve above the set pressure of the relief valve (R3),
(R1), poppet (6) separates from valve seat (7), the oil from the pump pushes spring (3). Ball (11)
so an oil flow is generated and the circuit is re- is pushed up and the oil flows to the brake oil
lieved. tank circuit, so this set the maximum pressure in
• When the circuit is relieved, a pressure differ- the brake circuit and protects the circuit.
ence is generated above and below piston (8),
so piston (8) moves up, poppet (6) is forcibly
o pen ed, and p ort C and p ort T are sh ort
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 pres-
sure.
• 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.
10-70 HM400-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR
ACCUMULATOR
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function
• The accumulator is installed between the accu-
mulator charge valve and the brake valve. It is
charged with nitrogen gas between cylinder (3)
and free piston (4), and uses the compressibility
of the gas to absorb the pulse of the hydraulic
pump or to maintain the braking force and to
make it possible to operate the machine if the
engine should stop.
Specifications
Gas used: Nitrogen gas
Charge amount: 4,000 cc
Charging pressure: 4.4 0.15MPa
{45 1.5kg/cm2}
HM400-1 10-71
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
1. Bleeder
2. Cylinder
3. Check valve
4. Spring
5. Piston
A. Outlet port
B. Inlet port
Unit: mm

size Shaft Hole clearance limit
Clearance Front
6 between body and -0.030 +0.074 0.030 –
55 0.25
piston -0.076 0 0.150
Center -0.030 +0.074 0.030 –
55 0.25
rear -0.076 0 0.150
Standard size Repair limit Replace
Free Installed Installed Free Installed
Front length length load length load
Slack adjuster
7 118 N
spring 230 88 – –
{12 kg}
Center 43.2 N
198 38 – –
rear {4.4 kg}
10-72 HM400-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SLACK ADJUSTER
FUNCTION • If the brake pedal is depressed further, and the

• The slack adjuster is installed in the brake oil line oil pressure discharged from the brake valve
from the brake valve to the brake piston. It acts goes above to set pressure, check valve (3)
to keep the clearance between the brake piston opens and the pressure is applied to port C to
and discs constant even when the brake discs act as the braking force.
are worn. in this way it acts to keep a constant Therefore, when the brake is applied, the time
time lag when the brake is operated. lag is a fixed value.
OPERATION
1. When brake pedal is depressed

• Before the brake is depressed, piston (4) is re-
turned by the distance of stoke S (full stroke).
When the brake pedal is depressed, the oil dis-
charged 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.
2. When brake pedal is released

• When the brake is released, piston (4) is re-
turned 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 regardless of the
wear of the brake disc.
• 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 dics
is to 0, the greater the braking force becomes.
HM400-1 10-73
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 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)
10-74 HM400-1
Unit: mm
Backlash between outer gear Standard size Repair limit
1
and plate 0.52 – 0.90 1.5
Backlash between hub gear
2 0.52 – 0.90 1.5
and plate
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
7 Max 0.50 0.7
friction surface
Assemble thickness of plate Standard warping Repair limit
8
and disc 56.4 51.4
Retainer oil seal contact sur- Correct or
9 430 0 – -0.155
face replace
HM400-1 10-75
CENTER, REAR
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)
10-76 HM400-1
Unit: mm
Backlash between outer gear Standard size Repair limit
1
and plate 0.52 – 0.90 1.5
Backlash between hub gear
2 0.52 – 0.90 1.5
and plate
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
7 Max 0.50 0.7
friction surface
Assemble thickness of plate Standard warping Repair limit
8
and disc 56.4 51.4
Retainer oil seal contact sur- Correct or
9 430 0 – -0.155
face replace
HM400-1 10-77
Function
• There are wet-type multiple disc brakes installed
to all of the six wheels.
Operations
• When the brake pedal is depressed, pressure oil
from the brake valve moves brake piston (3) to
the right in the direction of the arrow. This press-
es disc (7) and plate (6) together and generates
friction between the disc and plate. The wheel is
rotating together with the disc, so this friction re-
duces the travel speed and stops the machine.
• 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 re-
leases the brake.
10-78 HM400-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PROPORTIONAL REDUCING VALVE
PROPORTIONAL REDUCING VALVE
1. Filter Function
2. Connector • The proportional reducing valve is a valve used
3. Solenoid assembly for retarder control. It is installed between the
brake valve and the slack adjuster in the brake
A. To slack adjuster circuit.
P. To brake valve (inlet) It varies the discharge pressure of the pressure
T. To brake system tank oil in accordance with the turning angle of the
retarder control lever, so the retarder control
can be carried out as desired.
HM400-1 10-79
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE SYSTEM TANK
BRAKE SYSTEM TANK
1. Boss
2. Return tube
3. Suction tube
A. To hydraulic pump
B. From accumulator charge valve
C. Oil filler port
D. Drain port
10-80 HM400-1
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
1. Spring cylinder Function

2. Parking brake disc • The parking brake is a disc type and is installed
to the front axle.
• It is actuated mechanically by the force of the
spring inside the spring cylinder and is released
by hydraulic pressure.
• The parking brake caliper is fixed to the front dif-
ferential.
The disc is installed to the differential yoke and
rotates together with the coupling.
10-82 HM400-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE
Unit: mm
Standard backlash Repair limit Repair or

3 Face runout of disc
0.4 0.8 replace
Rebuid
(Thickness of
Min. 20
4 Thickness of disc 25 disc must not be
under 20 mm)
Max. 20
Thickness of pad (including Replace
5 21.5 11.5
thickness of plate)
Standard dim en- Standard Allowable
Tolerance
sion of blade clearance clearance
0
22.3
-0.3
Clearance between blade and Correct or
6 Standard
brake assembly Tolerance replace
dim ension of 1.0 0.4 1.5
brake assem bly
+0.4
22.3
-0.1
HM400-1 10-83
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE CALIPER
PARKING BRAKE CALIPER
1. Adjuster Outline
2. Piston • A piston guide is installed to caliper (5). Piston
3. Piston shaft (2) and piston shaft (3) are inserted, and the ro-
4. Pad tation of piston shaft (3) moves piston (2) in the
5. Caliper axial direction to bring pad (4) into tight contact.
• The 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 posi-
tion.
10-84 HM400-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPRING CYLINDER
SPRING CYLINDER
1. Outer spring OUTLINE

2. Inner spring • The oil pressure from the parking brake solenoid
3. Piston valve pushes the spring and releases the park-
4. Cylinder ing brake.
5. Boot When the engine is stopped, the parking brake
6. Rod is applied by springs (1) and (2), so the machine
is prevented from moving.
HM400-1 10-85
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE SOLENOID
PARKING BRAKE SOLENOID
1. Solenoid valve assembly Function

2. Block • The parking brake solenoid is installed on the
right rearside the front frame. When the parking
A: Outlet port brake switch is turned ON, the solenoid valve is
P: Inlet port energized. This sends the brake oil to the park-
T: Drain port ing brake spring cylinder and sets the parking
brake to the PARKING position. When the park-
ing brake is turned OFF, the solenoid valve is
de-energized, and the brake oil pressure is re-
moved from the parking brake spring cylinder to
set the machine to the TRAVEL condition.
• Parking brake solenoid energized: TRAVEL
de-energized : PARKING
10-86 HM400-1
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SUSPENSION
SUSPENSION
FRONT
10-88 HM400-1
1. Front suspension cylinder

2. Arm
3. Lateral rod
4. Dust cover
Unit: mm

Clearance between pin and size Shaft Hole clearance limit
5
bushing
60 -0.030 +0.046 0.030 – 0.3 Replace
-0.076 0 0.122
Clearance between pin and -0.030 +0.046 0.030 –
6 bushing 60 -0.076 0 0.122 0.3
HM400-1 10-89
REAR
10-90 HM400-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SUSPENSHION
1. Arm
2. Equalizer bar
3. Lateral rod (center)
4. Spring
5. Rear suspension
6. Lateral rod (rear)
10-92 HM400-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SUSPENSHION
Unit: mm

Clearance between pin and size Shaft Hole clearance limit
7
bushing
60 -0.030 +0.046 0.030 – 0.3
-0.076 0 0.122
Replace
8 bushing 60 -0.076 0 0.122 0.3

9 60 0.3
bushing -0.076 0 0.122
Outline 2. Center, rear suspension

• The suspension supports the weight of the ma- The center axle and rear axle are both fixed to arms.
chine. It also reduces any impact caused by un- The center axle is joined to the equalizer bar through
evenness in the road surface and provides a a spring, and the rear axle is joined through the rear
comfortable ride for the operator. By ensuring suspension cylinder. The arm and equalizer bar os-
that all the tires are always in contact with the cillate in accordance with the condition
road surface, it maintains the stability of the ma- of the road surface to keep the wheels in contact with
chine, and also fulfills the operating perform- the road surface.
ance by ensuring that the machine can carry out The main frame and arm are connected by a lateral
acceleration, braking, and turning. rod and receive the lateral load.
• The suspension cylinders reducing the impact
from the road surface are a hydropneumatic
type. The inside of the suspension cylinder is
charged (sealed) with oil and nitrogen gas. In
this way, the compression 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.
HM400-1 10-93
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SUSPENSION CYLINDER
SUSPENSION CYLINDER
1. Oil level valve

2. Feed valve
3. Retainer
4. Rod
5. Flange
6. Cylinder
10-94 HM400-1
(7)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SUSPENSION CYLINDER
Unit: mm

Clearance between piston rod size Shaft Hole clearance limit
7 and bushing
-0.043 +0.277 0.104 –
140 -0.106 +0.061 0.383 0.4
Replace
8 Clearance between piston rod 140 -0.043 +0.277 0.104 – 0.7
and bushing -0.106 +0.061 0.383
Clearance between cylinder 0 +0.010
9 and wear ring 180 -0.21 0 0 – 0.22 0.8
Structure and operation

The suspension cylinder has the function of both a
shock absorber and spring.
When a fixed amount of oil is sent from oil chamber
(1) through orifices (4) and (5) to cavity (3), the oil is
throttled by the orifices and a shock-absorbing effect
is obtained.
1. Retracting action
When the machine is traveling and it hits a
bump or object on the road, the wheels are
pushed up, and the cylinder rod is pushed
inside the cylinder.
When this happens, the nitrogen gas inside
chamber (2) is compressed, the oil in chamber
(1) is sent through both orifices (4) and (5) to
cavity (3), and cavity (3) is filled more quickly
than when extending.
2. Extending action
When the machine has passed any bump or
object on the road surface, the cylinder rod is
pushed up by the weight of the wheels and axle
and the pressure of the nitrogen inside chamber
(2).
As a result, the amount of oil in cavity (3) is
reduced, and pressure is applied to the oil
remaining in cavity (3).
This pressurized oil closes orifice (4) with check 1. Oil chamber
ball (6), and is sent to chamber (1) through only 2. Nitrogen gas chamber
orifice (5), so the flow of oil passing through the 3. Cavity
orifice is controlled so that it is less than during 4. Orifice
retraction. 5. Orifice
In this way, the amount of oil returning to cham- 6. Check ball
ber (1) is restricted to provide a shock absorb-
ing effect.
HM400-1 10-95
(7)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD OSCILLATION HITCH
OSCILLATION HITCH
1. Steering cylinder 7. Hitch frame

2. Front frame 8. Disc
3. Center drive shaft 9. Coupling
4. Rear frame 10. Shaft
5. Rear drive shaft (front) 11. Coupling
6. Pin 12. Pin
10-96 HM400-1
10-98 HM400-1
Unit: mm

1 Standard shim thickness size Shaft Hole clearance limit
–
2 Standard shim thickness –
Clearance between bushing -0.036 +0.054 0.036 –
3 115 –
and front frame -0.090 0 0.144
4 Clearance between shaft and 85 -0.036 +0.054 0.036 – –

bushing -0.066 0 0.120
Clearance between shaft and -0.036 0 0.016 –
5 bearing 85 -0.058 -0.020 0.058 –
Clearance between shaft and -0.036 +0.054 0.036 –

6 bushing 85 -0.058 0 0.112 –
7 Clearance between front frame 85 -0.036 +0.054 0.036 – –

and shaft -0.058 0 0.112
Clearance between front frame -0.036 +0.054 0.036 –
9 and pin 85 -0.058 0 0.112 – Replace
10 Clearance between pin and 85 -0.036 0 0.016 – –

bearing -0.058 -0.020 0.058
11 Clearance between front frame 85 -0.036 +0.054 0.036 – –

and pin -0.058 0 0.112
Clearance between hitch frame 0 0 -0.040 –
12 and bearing 150 -0.018 -0.040 0.018 –
13 Clearance between hitch frame 340 0 0 -0.040 – –

and bearing -0.057 -0.040 0.057
14 Clearance between rear frame 460 0 -0.017 -0.080 – –

and bearing -0.045 -0.080 0.028
Clearance between rear frame -0.020 +0.063 0.020 –
15 and bearing 435 -0.083 0 0.146 –
16 Clearance between rear frame 420 0 -0.013 -0.080 – –

and bearing -0.045 -0.080 0.032
17 Clearance between bearing 300 -0.056 0 0.020 – –

and hitch frame -0.108 -0.036 0.108
Outline
• The front frame and the rear frame are connect- • In addition, the output from the transmission is
ed by the oscillation hitch. transmitted from center drive shaft (3) to cou-
• Front frame (2) is connected with bearings and pling (9). It is then transmitted from coupling
pins (6) and (12); rear frame (4) is connected (11) through the rear drive shaft to the rear axle.
with a spacer, retainer, and bearing. This makes
it possible for the front and rear frames to articu-
late and oscillate.
HM400-1 10-99
STEERING, HOIST OIL PRESSURE
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PIPING DIAGRAM
STEERING, HOIST OIL PRESSURE PIPING DIAGRAM
1. Steering, hoist control pump

(SAR(3)100+100+(1)8)
2. Steering cylinder
3. Hydraulic tank
4. Flow amp valve
5. Steering valve
6. Check valve
7. Hoist valve
8. Hoist cylinder
9. Line strainer
10-100 HM400-1
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DUMP BODY CONTROL
DUMP BODY CONTROL
1. Dump control lever Function

2. Pilot check valve • This control is carried out by the body position
3. EPC valve sensors. The body position sensor senses the
4. Hoist cylinder position of the dump body and the retarder con-
5. Hoist valve troller (brake controller: E-SPEC) controls it.
6. Hydraulic pump (SAR(3)100+100+(1)8) • The signal from the dump control lever is con-
7. Body positioner sensor trolled by the retarder controller (brake control-
ler: E-SPEC), and actuates the EPC valve. The
pilot pressure generated by the EPC valve
moves the spool of the hoist valve and controls
the hoist cylinder.
HM400-1 10-101
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK AND FILTER
HYDRAULIC TANK AND FILTER
1. Hydraulic oil filter

2. Breather
3. Oil level gauge
4. Drain plug
5. Bypass valve
6. Element
7. Strainer
10-102 HM400-1
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FLOW AMP VALVE
FLOW AMP VALVE
1. Valve CL. To steering cylinder Outline

2. Valve L. To steering valve • The flow amp valve consists of the directional
3. Orifice P. To steering valve valve, amplifying stage, priority valve, relief
4. Spring PP. From steering valve valve, pressure control valve, and suction valve.
5. Pin HP. From hydraulic pump • It amplifies the oil flow sent from ports L and R of
6. Valve LS. From steering valve the steering unit by the specified ratio. The am-
7. Valve HT. From hoist valve plified oil then goes from ports CL and CR of the
8. Plug T. To steering valve flow amp valve and flows to the steering cylin-
9. Valve EF. To hoist valve der.
10. Spool R. From steering valve The amplified oil flow is proportional to the
11. Valve body CR.To steering cylinder amount the steering wheel is turned.
12. Stopper
HM400-1 10-103
Operation
Operation
1. At neutral
• Port P of steering unit (7) is closed and the flow • For priority valve (2) also, the oil is drained from
amp valve is closed at chamber M of pressure relief valve (1).
control valve (3). Before starting, priority valve (2) is pushed
• Ports L, R, and T of steering unit (7) are connect- strongly to the left by the spring, so in reality,
ed to each other, so the oil passes through port port EF of the flow amp valve is almost closed.
T of the flow amp valve and is drained to the hy- • At the same time as the engine starts, oil flows
draulic tank. to port HP of the flow amp valve and then flows
By connecting in this way, directional valve (6) to port P of steering unit (7). At the same time,
is always held at the neutral position by the the pilot pressure that is connected to port PP
springs on both sides. For this reason, at the suddenly rises. As a result of balancing with
neutral position, the reaction or impact from the the spring and moving to the right, port EF opens
steering cylinder is not transmitted to steering and the oil flows to the hoist piping.
unit (7).
10-104 HM400-1
2. When turning
• When steering unit (7) is actuated, the oil sent • The oil at the steering cylinder head end goes
from port P of priority valve (2) passes through out from suction valve (5). It then goes from port
ports P and L of steering unit (7) and enters port CR of directional valve (6) through check valve
L of directional valve (6). (4) and is drained to the hydraulic tank from port
At the same time, oil from priority valve (2) also HT of the flow amp valve.
enters chamber M of pressure control valve (3). • If there are rocks on the road or the the road sur-
• When the oil entering directional valve (6) rises face is uneven, and any abnormal external force
to a pressure greater than the force of the is applied to the tires and steering cylinder, relief
spring, it pushes the spool to the right, and en- valves (8) and (9) of suction valve (5) open at a
ters chamber C of pressure control valve (3). pressure of 23.5 Mpa {240 kg/cm2}, so the oil
When it rises to a pressure greater than the passes through directional valve (6) and is
force of the spring in chamber C also, it pushes drained to the hydraulic tank.
the spool to the left.
• The oil that is already in chamber M of pressure
control valve (3) enters chamber N when the
spool is pushed to the left by the action of steer-
ing 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.
HM400-1 10-105
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING VALVE
STEERING VALVE
1. Cover L. To flow amp valve

2. Drive shaft LS. To flow amp valve
3. Valve body P. From flow amp valve
4. Center pin R. To flow amp valve
5. Bearing T. To flow amp valve
6. Spool
7. Centering spring
8. Sleeve
9. Stator
10. Rotor
11. Lover cover
10-106 HM400-1
Outline Structure
• The steering valve is connected directly to the • Spool (9) is connected to the drive shaft of the
shaft of the steering wheel. It switches the flow steering wheel, and is connected to sleeve (8)
of oil from the steering pump to the left and right by center pin (7) (this is not touching the spool
steering cylinders to determine the direction of when the steering wheel is at the neutral posi-
travel of the machine. tion) and centering spring (2).
• The orbit-roll valve, broadly speaking, consists • Drive shaft (3) is meshed at the top with center
of the following components: rotary type spool pin (7) and forms one unit with sleeve (8). The
(9) and sleeve (8), which have the function of se- bottom is meshed with the spline of rotor (5) of
lecting the direction, and the Girotor set (a com- the Gerotor set.
bination of rotor (5) and stator (10)), which acts • Valve body (4) has five ports. These are con-
as hydraulic motor during normal steering oper- nected to the pump circuit, tank circuit, steering
ations, and as a hand pump (in fact, the operat- cylinder head end, bottom end, and flow amp
ing force of the steering wheel is too high, so it valve pilot end. In addition, the port at the pump
cannot be operated) when the steering pump or end and the port at the tank end are connected
engine have failed and the supply of oil is by the check valve inside the body. If there is
stopped. any failure in the pump or engine, this check
valve acts to suck in oil directly from the tank.
HM400-1 10-107
CONNECTION BETWEEN HAND PUMP AND SLEEVE
• The diagrams above show the connections with

the sleeve ports used to connect the suction and Suctiion /
discharge port
discharged ports of the Girotor.
• If the steering wheel has been turned to the
right, ports a, c, e, g, i, and k are connected by
the vertical grooves in the spool to the pump
side. At the same time, ports b, d, f, h, j, and l are
connected to the head end of the left steering
cylinder in the same way.
In the condition in Fig. 1, ports 1, 2, and 3 are
the discharge ports of the Girotor set.
They are connected to ports l, b, and d, so the SBW00727
oil is sent to the cylinder.

Ports 5, 6, and 7 are connected and the oil
flows in from the pump. • In this way, the ports of the Girotor acting as de-
In the steering wheel is turned 90°, the condi- livery ports are connected to ports which are
tion changes to the condition shown in Fig. 2. In connected to the end of the steering valve spool.
this case, ports 1, 2, and 3 are the suction ports, The ports acting as suction ports are connected
and are connected to ports i, k, and c. Ports 5, to the pump circuit.
6, and 7 are discharge ports, and are connected • Adjusting delivery in accordance with angle of
to ports d, f, and h. steering wheel:
For every 1/7 turn of the steering wheel, the
inner teeth of the Girotor gear advance one
po sitio n s o the oil flo w fr om the p ump is
adjusted by this movement. In this way, the oil
delivered from the pump is directly proportional
to the amount the steering wheel is turned.
10-108 HM400-1
FUNCTION OF CENTER SPRING

• Centering spring (2) consists of four layers of
leaf springs crossed to form an X shape.
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 difference 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 cylin-
der. When the turning of the steering wheel is
stopped, the Girotor also stops turning, so no
more oil is sent to the cylinder and the oil pres-
sure 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 vari-
ation a) of the sleeve and spool, so the steering
wheel returns to the NEUTRAL position.
HM400-1 10-109
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING CYLINDER
STEERING CYLINDER
Unit: mm

Clearance between piston rod size Shaft Hole clearance limit
1
and bushing
-0.030 +0.271 0.105 –
70 0.475
-0.104 +0.075 0.375
Clearance between piston rod 0 +0.174 0.100 –
2 65 1.0
support shaft and bushing -0.074 +0.100 0.248
Replace
Clearance between cylinder
0 +0.174 0.100 –
3 bottom support shaft and 65 1.0
-0.074 +0.100 0.248
bushing
4 Cylinder bore +0.15
120 –
0
10-110 HM400-1
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HOIST VALVE
HOIST VALVE
10-112 HM400-1
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

Free length Installed Installed Free Installed
A Spool return spring x O.D. length load length load
308 N 277 N
63.4 x 61 61 –
{31.4 kg} {28.2 kg}
0N
B Spool return spring 47 x 36 47 – –
{0 kg} Replace spring
308 N 277 N if damaged or
C Spool return spring 47.5 x 41 45.2 –
{31.4 kg} {28.2 kg} deformed
1372 N 1235 N
D Spool return spring 87.6 x 52 60 –
{140 kg} {126 kg}
822 N 740 N
E Spool return spring 97.8 x 35 86 –
{83.9 kg} {75.5 kg}
13 N 11 N
F Check valve return spring 84.7 x 26.6 47.5 –
{1.3 kg} {1.12 kg}
HM400-1 10-113
OPERATION
1. Hoist valve at HOLD position
• The oil from the demand of valve enters port C. • The ports to the hoist cylinder are blocked at
The passage to the hoist cylinder is blocked by both the bottom end and head end, so the hoist
hoist spool (2), so the oil is drained from tank D cylinder is held in position.
to the tank.
10-114 HM400-1
2. Hoist valve at RAISE position
• When the hoist lever inside the cab is operated • At the same time, the return oil from the head
to the RAISE position, hoist spool (2) is moved end flows from port B to port D, and flows to the
to the left by the solenoid valve. tank circuit.
• As a result, the oil flows from chamber C, opens
check valve (3), and enters chamber A.
• From chamber A, the oil enters the bottom end
of the hoist cylinder, extends the hoist cylinder,
and raises the dump body.
HM400-1 10-115
3. Hoist valve at FLOAT position
• When the hoist lever inside the cab is operated • The bottom end and head end of the hoist cylin-
to the FLOAT position, hoist spool (2) is moved der are connected inside the hoist valve, so the
to the right by the solenoid valve. As a result, hoist cylinder is placed in the free condition.
chamber C and chamber D, and chamber B and
chamber H and chamber D are connected.
• The oil from the demand valve passes from
chamber C through chamber B and flows to the
hoist cylinder. Oil also flows from chamber C to
chamber D, and then flows to the brake oil cool-
er circuit.
10-116 HM400-1
4. Hoist valve at LOWER position
• When the hoist lever inside the cab is operated • At the same time, the return oil from the head
from the FLOAT position to the LOWER posi- end of the hoist cylinder flows from chamber A to
tion, hoist spool (2) is moved further to the right chamber H.
from the FLOAT position by the solenoid valve. • When the dump body is lowered, the output
As a result, the oil flows from chamber C, push- pressure of the solenoid valve rises and be-
es open check valve (3), and enters chamber comes greater than the cracking pressure of the
B. pilot check valve. As a result, the return oil from
• The oil from chamber B enters the head end of chamber H returns to the tank through two lines:
the hoist cylinder, retracts the cylinder, and low- one from chamber D to the tank, and the other
ers the dump body. from chamber E to the tank.
HM400-1 10-117
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EPC VALVE
EPC VALVE
1. Manual operation button Function

2. Solenoid assembly • With the EPC valve, the oil from the hydraulic
3. Relief valve pump is controlled by the retarder controller
4. Solenoid assembly (EPC) (brake controller: E-SPEC). It is then sent to the
spool of the hoist valve, and switches the pilot
A. To hoist valve pressure to control the hoist valve.
B. To hoist valve
P1. From hydraulic pump
T1. To hydraulic tank
T2. To hydraulic tank
10-118 HM400-1
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PILOT CHECK VALVE
PILOT CHECK VALVE
1. Body A. From hoist valve

2. Check valve B. To hydraulic tank
3. Retainer P.P. From EPC valve
4. Spring
5. Cover
Unit: mm

Free length Installed Installed Free Installed Replace spring
6 Spring x O.D. length load length load if damaged or
deformed
821.2 N 739 N
198.5 x 53 70 –
{83.7 kg} {75.4 kg}
HM400-1 10-118-1
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HOIST CYLINDER
HOIST CYLINDER
Unit: mm

Clearance between cylinder size Shaft Hole clearance limit
1
and bushing
-0.043 +0.277 0.104 –
140 -0.143 +0.061 0.420 0.720
Clearance between piston rod -0.036 +0.270 0.097 – Replace

2 and bushing 90 -0.123 +0.061 0.393 0.693
3 Clearance between piston rod 60 – +0.004 – 1.0

support pin and bearing -0.019
Clearance between cylinder +0.004
4 support pin and bushing 60 – -0.019 – 1.0
HM400-1 10-119
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
STEERING·HOIST+PILOT PUMP
SAR(3) 100+100+(1)8
Unit: mm
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 SAR(3)-100
diameter of plain bearing and 0.060 – 0.149 0.20
2 SAR(3)-100
outside of diameter of gear Replace
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 {0.9 – 2.1 kgm}
Delivery Standard
Rotating Delivery
pressure delivery
Model speed amount limit
{MPa amount
Discharge amount (rpm) (l/min) –
– Oil: EO10-CD (kg/cm2)} (l/min)
Oil temperature: 45–55°C SAR(3)-100
20.6 231.5 213.5
SAR(3)-100 2,500
{210}
SAR(1)-8 17.2 15.8
10-120 HM400-1
TRANSMISSION+DIFFERENTIAL LOCK PUMP (Machine with differential lock differential)

SAR(3)100+(1)12+8
Unit: mm
SAR100 0.13 – 0.18 0.21
1 Side clearance
SAR12
0.10 – 0.15 0.19
SAR8
Clearance between inside SAR100 0.06 – 0.149
diameter of plain bearing and SAR12 Replace
2 0.20
outside of diameter of gear 0.06 – 0.144
shaft SAR8
3
Depth for knocking in pin 14 0
–
4 10 -0.5
Delivery Standard
Rotating Delivery
pressure delivery
{MPa amount
Discharge amount (rpm) (l/min) –
– Oil: EO10-CD (kg/cm2)} (l/min)
Oil temperature: 45–55°C SAR100 231.5 213.5
20.6
SAR12 2,500 26.8 24.6
{210}
SAR8 17.2 15.8
HM400-1 10-121
6
BRAKE COOLING+BRAKE PUMP

SAR(3)80+(1)25
Unit: mm

1 Side clearance SAR80
0.10 – 0.15 0.19
SAR25
Clearance between inside SAR80 0.06 – 0.149
diameter of plain bearing and
2 0.20 Replace
outside of diameter of gear SAR25 0.06 – 0.144
shaft
3
Depth for knocking in pin 14 0
–
4 10 -0.5

Delivery Standard
Rotating Delivery
pressure delivery
{MPa amount
(rpm) (l/min)
Discharge amount (kg/cm2)} (l/min) –
– Oil: EO10-CD
2.9
Oil temperature: 45–55°C SAR80 200 –
{30}
2,500
20.6
SAR25 57.0 50.7
{210}
10-122 HM400-1
EMERGENCY STEERING PUMP

SBL(1)21
Unit: mm
Standard clearance Clearance limit

1 Side clearance
0.10 – 0.15 0.19
Clearance between inside
2 0.060 – 0.119 0.20
outside of diameter of gear Replace
shaft
3 Depth for knocking in pin 0
10 –
-0.5
Delivery Standard
Rotating Delivery
pressure delivery
Discharge amount speed amount limit
{MPa amount –
– Oil: EO10-CD (rpm) (l/min)
(kg/cm2)} (l/min)
Oil temperature: 45–55°C
20.6
3,500 67.6 62.4
{210}
HM400-1 10-123
DIFFERENTIAL LOCK PUMP (Machine with differential lock differential)

SBR(1)8+8
Unit: mm

1 Side clearance
0.10 – 0.15 0.19
Clearance between inside Replace
2 0.060 – 0.119 0.20
outside of diameter of gear
shaft
Delivery Standard
Rotating Delivery
pressure delivery
Discharge amount speed amount limit
{MPa amount
3 Oil: EO10-CD (rpm) (l/min) –
(kg/cm2)} (l/min)
Oil temperature: 45–55°C
20.6
3,500 25.2 23.7
{210}
10-124 HM400-1
6
TRANSMISSION PUMP (Machine with limited slip differential)

SAR(3)100
Unit: mm

1 Clearance between gear
case and side plate, gear
0.13 – 0.18 0.21
Clearance between inside

diameter of plain bearing
2 0.06 – 0.149 0.20
and outside diameter of
gear shaft Replace
Tolerance Repair limit

3 Insertion depth of pin
0 –
-0.5
Rotating torque of spline
4 6.9 – 11.8 Nm {0.7 – 1.2 kgm}
shaft
Standard Repair limit

Revolution Pressure
Discharge discharge discharge
(rpm) MPa{kg/cm2} (l/min.)
– Oil: EO10-CD (l/min.) –
Temperature: 45 – 55°C 20.6
2,500 231.5 213.5
{210}
HM400-1 10-124-1
(8)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CAB TILT
CAB TILT
1. Tilt stopper bar

2. Tilt cylinder
3. Breather
4. Adapter
5. Pin
HM400-1 10-125
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
1. Air conditioner unit FUNCTION

2. Filter • The air conditioner makes a pleasant operating
3. Control panel environment for the operator and acts to reduce
4. Compressor fatigue.
5. Receiver dryer
6. Condenser
10-126 HM400-1
6
AIR CONDITIONER UNIT
1. FRESH/RECIRC selector damper

2. Evaporator
3. Heater core
4. Blower motor
A. Hot water inlet port

B. Hot water outlet port
C. Refrigerant gas inlet port
D. Refrigerant gas outlet port
E. Dehumidified water drain port
HM400-1 10-127
RECEIVER DRYER
1. Body
2. Sight glass
3. Dryer
4. Dryer
10-128 HM400-1
CONDENSER
1. Fin
2. Tube
A. Refrigerant gas inlet port

B. Refrigerant gas outlet port
HM400-1 10-129
COMPRESSOR
1. Case
2. Clutch
A. Suction service valve

B. Discharge service valve
10-130 HM400-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
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
HM400-1 10-131
6
Outline 4. Reduced cylinder mode

• With the machine monitor system, the control- This function is used to stop the supply of
lers on the network use the data from the sen- fuel sprayed from the fuel injector. This
sors installed to all parts of the machine to makes it possible to determine the cylinder
observe and control the condition of the machine where there is defective combustion.
and transmit that data as network data to the 5. ECMV compensation
machine monitor. This is used for the initial adjustment of the
The machine monitor is a system to display transmission.
these data and inform the operator of the condi- 6. Changing replacement time for filter, oil
tion of the machine. This changes the original setting for the
• There are two types of display on the machine replacement interval.
monitor: the normal mode and the service mode. 7. Controller initialize
• The items that are always displayed for the op- This function is used to set the machine
erator are the normal mode items. Their main monitor when the machine is shipped from
content is as follows. the factory.
1. Normal display items
• Meters (speedometer, tachometer) The service mode has the following functions.
• Gauges (engine water temperature, Setting service meter
torque converter oil temperature, retard- • This can set service meter values recorded
er oil temperature, fuel level) in machine monitor memory
• Pilot display • However, values can only be increased from
• Service meter, odometer (character dis- present value (they cannot be decreased).
play)
2. Items displayed when there is abnormality Setting total travel distance
Caution, action code display (if an action • This can set travel distance values recorded
code is being displayed, press machine in machine monitor memory
monitor mode selector switch (2), then • However, values can only be increased
release it. A failure code (6-digit) is then dis- from present value (they cannot be de-
played.) creased).
3. When the filter, oil replacement interval is
reached, the item needing replacement is Setting distance traveled in reverse
displayed in the character display. • This can set values for distance traveled in
4. Other functions using the character display reverse recorded in machine monitor mem-
and the machine monitor mode selector ory.
switch to operate include the following: Total • However, values can only be increased from
reverse distance traveled display, filter, oil present value (they cannot be decreased).
replacement interval reset, telephone
number input, and language selection. • The machine monitor system consists of the
monitor panel, buzzer, and switches, network,
• To make it easier to carry out troubleshooting of controllers on the network, and the sensors in-
the controllers (including the monitor panel it- putting data to the monitor panel.
self), a service mode function is provided. Its
main content is as follows.
1. Displaying trouble data for electrical compo-
nents, deleting from memory
• Displays electrical components failure
data from each controller that is saved
in machine monitor
• Deletes data from memory
2. Trouble data for machine
• Displays machine failure data from each
controller that is saved in machine mon-
itor
3. 3. Real-time monitor
• Takes input and output signal values
recognized by each controller on net-
work and displays in real time
10-132 HM400-1
MACHINE MONITOR
1. Speedometer 23. Machine monitor, option system caution lamp

2. Engine tachometer 24. Engine system caution lamp
3. Brake cooling oil temperature gauge 25. Transmission system caution lamp
4. Torque converter oil temperature gauge 26. Retarder system caution lamp
5. Engine water temperature gauge (Brake system caution lamp: E-SPEC)
6. Fuel gauge 27. Tilt caution lamp
7. Character display 28. Seat belt caution lamp
8. Turn signal pilot lamp (R, H) 29. Parking brake pilot lamp
9. Turn signal pilot lamp (L, H) 30. Retarder pilot lamp
10. Front lamp high beam pilot lamp (Overrun protection brake pilot lamp: E-SPEC)
11. Gearshift lever position pilot lamp 31. Exhaust brake pilot lamp (option)
12. Shift indicator 32. Inter-axle differential lock pilot lamp
13. Lock-up pilot lamp 33. Left and right differential lock pilot lamp
14. Shift hold pilot lamp (Machine with differential lock differential)
15. Power mode pilot lamp (high power mode) 34. Dump body pilot lamp
16. Power mode pilot lamp (economy mode) 35. Emergency steering pilot lamp
17. Central warning lamp 36. Preheating pilot lamp
18. Maintenance caution lamp 37. Brake cooling oil temperature caution lamp
19. Battery charge circuit caution lamp 38. Torque converter oil temperature caution lamp
20. Steering oil temperature caution lamp 39. Engine water temperature caution lamp
21. Engine oil pressure caution lamp 40. Fuel level caution lamp
22. Retarder oil pressure caution lamp
(Brake oil pressure caution lamp: E-SPEC)
HM400-1 10-133
(7)
41. Travel speed compensation switch [SW1]

42. Rotary switch [SW2]
43. Rotary switch [SW3]
44. Switch for setting left and right differential lock [SW5-4]
45. Dipswitch [SW5-3]
46. Switch for setting exhaust brake [SW5-2]
51. Dipswitch (SW6-1]
10-134 HM400-1
OPTION SETTING CONNECTOR DIAGRAM
52. Option setting connector [OP1]

58. Setting connector [OP7]
ADJUSTING MACHINE MONITOR

1. For details of the setting of the rotary switches, the switches, and options setting connectors at the rear
face of the machine monitor, see TESTING AND ADJUSTING, Adjusting machine monitor.
2. Precautions
1) When setting, follow the instructions in TESTING AND ADJUSTING, Adjusting machine monitor, and
do not change them.
2) When moving the switches, use a precision screwdriver and turn slowly.
3) Be careful not to touch anything except the switches inside the grommet.
4) Be careful not to let any dirt or dust get in.
5) After completing the setting, return the grommet securely to its original position.
HM400-1 10-135
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS
?: Lights up 7: Sounds intermittently

✩1: ? means that lamps light up while machine monitor check switch is ON
✩2: ? shows that all lamps light up for approx. 2 seconds after starting→ all off for 1 second
Related actuation ✩1 When ✩2

machine Im m e d iate ly
Display Display Display range/ Method of Central monitor a fte r
No. item category Device Color conditions display Alarm check s ta rtin g Remarks
warning buzzer
lamp switch is sw itch is
operated tu rne d O N
Note: When machine monitor
[
Scale: 0 - 80 km/h or 0 - 50
White mph Analog check switch is operated, display
Meter Movement Background (mph display is only display   (Note)  starts from present position,
Travel color: Black when non-SI is used) completes one cycle, and
1 speed returns to the starting position
? ?
When side lamps light Lights up
Backlight LED Amber up when  
actuated
[
Scale:
? [
0 - 3400 rpm (red check switch is operated, display
Meter Movement White, red zone: More than 2500 Analog  starts from present position,
Background rpm) display (Note) completes one cycle, and
2 Engine color: Black
speed returns to the starting position
? ?
Lights up
Backlight LED Amber When side lamps light when  
up
actuated
[
Scale:
White, red 50 - 150°C Analog check switch is operated, display
Gauge Movement Background (red zone: More than display   (Note)  starts from present position,
color: Black 120°) completes one cycle, and
returns to the starting position
3 Re ta rde r oil
? [ ? ?
Lights up
37 tem p era tu re Caution LED Red
When temperature is
when
more than 120° abnormal
? ?
Lights up
up actuated
[
Scale: 50 - 135°C check switch is operated, display
Gauge Movement White, red (red zone: More than Analog    starts from present position,
Background 120°) display (Note) completes one cycle, and
color: Black
To rqu e returns to the starting position
4 con ve rter
? [ ? ?
o il When temperature is Lights up
38 Caution LED Red when
tem p era tu re more than 120°
abnormal
? ?
When side lamps light Lights up
actuated
[
Scale:
50 - 135°C check switch is operated, display
Gauge Movement White, red (red zone: More than Analog    starts from present position,
Background 102°) display (Note) completes one cycle, and
color: Black returns to the starting position
5 E n gine
? [ ? ?
w a te r Lights up
39 tem p era tu re Caution LED Red When temperature is when
more than 102° abnormal
? ?
Lights up
When side lamps light
actuated
[
Scale:
White, red Analog check switch is operated, display
Gauge Movement Background EMPTY-FULL display   (Note)  starts from present position,
color: Black completes one cycle, and
returns to the starting position
6 Fuel level When below specified
? ?
Lights up
40 gauge level (amount of fuel
Caution LED Red remaining in tank is when  
less than 75 L) abnormal
? ?
Lights up
up actuated
Actuated
Service when
0 - 65535.0h
meter Service * Displayed on top engine is When time exceeds 65535.0h,
(normal meter
Display
line of character running   stops at 65535.0h
display letters: Ratio of
Black display
7 items) LCD movement
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
items) display traveling 999999.9km
10-136 HM400-1
Related actuation When

Immediately
machine
after
Display Display range/ Central monitor
No Display item Device Color Method of display Alarm starting Remarks
category conditions warning check
buzzer switch is
lamp switch is
turned ON
operated
When abnormality or orWhen abnormality Note 1: Top line displays

failure occurs on
failure occurs on "HM400-1"
machine, top line
machine Note 2: Top line displays
Action code Action code shows action   Note 1 Note 2
* Displayed on top and code; "KOMATSU", bottom
bottom line
bottom lines of displays "SYSTEM
displays remedy or
character display CHECK"
nature of failure
Top line displays
failure code (6
When there is digit) and
abnormality or failure, controller that
Failure press mode switch ">". detected problem; See separate information
Failure code   for details of failure
code * Displayed on top bottom line
display
and bottom lines of displays system
character display that is abnormal or
nature of
7 abnormality
Reverse
travel
distance
meter, filter, Operate machine
oil Press machine monitor monitor mode See separate information
Other displays replacement mode selector switch selector switch ">" for details of failure
time reset, "<!>" or "<" to switch display
telephone screen
No. setting,
language
selection
Brightness
When side lamps light reduced one level
Night lighting Backlight LED Green up when side lamps   " "
light up
When operated:
Right turn Lights up
8 signal LED Green When operated When not   " "
operated: Goes
out
When operated:
Lights up
9 Left turn signal LED Green When operated When not   " "
operated: Goes
out
When operated:
Lights up
10 High beam LED Blue When operated When not   " "
operated: Goes
out
11 Gearshift lever When gearshift lever is * Flashes when neutral
LED Green Lights up (*)   " "
(R2) position R2 at R2 safety is actuated
(R1) position R1 at R1 safety is actuated
11 Gearshift lever
Orange When gearshift
lever is
LED Lights up   " "
(N) position N at N
(D) position D Pilot at D safety is actuated
(5) position 5 at 5 safety is actuated
(4) position 4 LED Green a4 Lights up (*)   " " safety is actuated
F1,F2,F3,F4,F5,F6,N,R
1,R2,R3
* According to shift
range signal received When shift range
Back-
from transmission
Shift indicator LED
ground
controller
signal is received
  " "
12 color: from transmission All light up All light up
* When alarm is
Gray controller
actuated when making
emergency escape, "E"
and "N" are displayed in
turn
Night lighting LED Amber
HM400-1 10-137

Immediately
machine
after
Display Display Display range/ Method of Central monitor
No Device Color Alarm starting Remarks
item category conditions display warning check
buzzer switch is
lamp switch is
turned ON
operated
When
When torque
operated:
converter lock-up is
Lights up
13 Lock-up LED Green actuated and   c c
When not
transmission is set to
operated:
direct drive
Goes out
When
operated:
When shift hold Lights up
14 Shift hold LED Green   c c
switch is operated When not
operated:
Goes out
Pilot
High power
Output mode:
mode Lights up
15 (high LED Green High power mode   c c
power When not
mode) actuated:
Goes out
Economy
Output mode:
mode Lights up
16 LED Green Economy mode   c c
(economy When not
mode) actuated:
Goes out
Central Lights up
When there is
17 warning LED Red when
abnormality in system abnormal c U c c
lamp
Note 1: Lamp lights up and at
When warning is
issued for same time action code E01 and
location for warning is displayed
18 Maintenance LED Red
maintenance system, Lights up or
  c c on character display
caution or when filter, oil flashes
Note 2: See Operation and
replacement interval
Maintenance Manual for details
has passed
of applicable item
Battery When there is Lights up
charge
19
circuit
LED Red abnormality in charge when c U c c
circuit abnormal
caution
Steering oil When steering oil Lights up
20 temperature LED Red when c U c c
temperature rises
caution abnormal
Engine oil Lights up
When engine oil
21 pressure LED Red
pressure drops
when c U c c
caution abnormal
Brake
Lights up
cooling oil When brake cooling Note: Actuated only when
22 pressure LED Red oil pressure drops when c(Note) U(Note) c c alternator R terminal = ON
abnormal
caution
Machine When there is
monitor or abnormality in Lights up Actually only used when failure
23 option Caution LED Red machine monitor or when U U c c occurs in machine monitor
system option controller abnormal
caution system
Engine When there is Lights up
24 system LED Red abnormality in engine when U U c c
caution control system abnormal
When there is
Transmission Lights up
abnormality in
25 system LED Red when U U c c
transmission control
caution abnormal
system
When there is
Retarder
abnormality in
system
retarder control
caution Lights up
system
26 (Brake LED Red when U U c c
(When there is
system abnormal
abnormality in brake
caution:
control system:
E-SPEC)
E-SPEC)
When dump body is
Lights up
raised and there is
27 Tilt caution LED Red when c U c c
excessive tilt to left or
abnormal
right
When
actuated:
Seat belt When seat belt is not Lights up
28 LED Red   c c
caution fastened When not
actuated:
Goes outs
10-138 HM400-1
(7)

Immediately
machine
after
Display Display Display range/ Method of Central monitor
No Device Color Alarm starting Remarks
item category conditions display warning check
buzzer switch is
lamp switch is
turned ON
operated
Parking Lights up Note: Actuated when parking
When parking brake
29 brake pilot Red
is applied
when c(Note) U(Note) c c brake is applied and gearshift
lamp applied lever is at position other than N
Retarder
pilot lamp When retarder brake
(Overrun is applied Lights up
30 protection Orange (When overrun when   c c
brake pilot protection brake is applied
lamp: applied: E-SPEC)
E-SPEC)
Exhaust
brake Lights up
When exhaust brake
31 actuation LED Orange when   c c
is actuated
lamp actuated
(option)
When
Inter-axle
Lights up when inter- operated:
differential Lights up
32 LED Orange axle differential lock is When not   c c
lock pilot
operated
lamp operated:
Goes out
Left and
right
When
differential
lock lamp Pilot Lights up when left actuated:
Lights up
33 (Machine LED Orange and right differential
with lock is actuated When not
actuated:
differential Goes out
lock
differential)
When
For details, see operated:
Body pilot Operation and Lights up Note: Actuated when gearshift
When not c(Note) U(Note)
34 LED Red c c
lamp Maintenance Manual lever is at position other than N
operated:
Goes out
When
operated:
Emergency Lights up when
Lights up
35 steering LED Red emergency steering is When not   c c
ready lamp actuated
operated:
Goes out
When
operated:
Lights up when
Lights up
36 Preheating
electric heater for
LED Red When not   c c
pilot lamp engine preheating is
operated:
actuated
Goes out
Self-diagnostic function when operating starting switch

1. When the starting switch is turned to the ON position before starting the engine, the system check is carried
out for 3 seconds.
2. If the starting switch is turned to the START position before 3 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 3 seconds have
passed after the starting switch was turned to the ON position.
Check function of central warning lamp, alarm buzzer, monitor lamps, and meters
To check the normal display functions of the machine monitor, press the machine monitor check switch to check
the actuation. For details of the actuation, see "When operating machine monitor normal display functions with
machine monitor check switch".
HM400-1 10-139
6
Self-diagnostic function when operating starting switch

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 approx. 2 seconds and then go out for 1 second to carry out a
system check.
• The alarm buzzer sounds for 2 seconds and then stops for 1 second.
• The shift indicator displays 88 for 2 seconds and then goes out for 1 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 3 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 3 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.
Service meter display

The service meter shows the total number of hours of operation of the machine on the top line of the character
display.
If the engine is running, the service meter will advance even if the machine is not moving.
The service meter will advance by 0.1 for every 0.1 hour that the engine is running, regardless of the engine
speed.
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 monitor mode selector switch 1 is not being pressed, there is probably a failure on the
machine, so carry out inspection and maintenance.
Example of service meter and odometer display
10-140 HM400-1
(7)
OUTLINE OF SERVICE MODE

1. Outline
1) Trouble data for electrical system
The system is used to check the trouble data for the electrical system of each controller saved in the
machine monitor. For details of the failure codes displayed for the trouble data of the electrical system,
see the troubleshooting section. After repairing the failure, check that the system works properly, then
delete the trouble data.
The trouble data display for the electrical system is displayed on the character display as shown below.
*** : Displays order of trouble data items

###### : Displays failure code
$$$ : Displays number of times that applicable failure code has occurred
%%%%% : Displays time that has elapsed since failure first occurred (Present service meter read-
ing - Service meter reading when problem first occurred = Time elapsed)
@@@@@ : Displays time that has elapsed since failure last occurred (Present service meter read-
ing - 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.
2) Trouble data for machine system
The system is used to check the trouble data for the machine system of each controller saved in the
machine monitor. For details of the failure codes displayed for the trouble data of the machine sys-
tem, see the troubleshooting section. After repairing the failure, check that the system works properly,
then delete the trouble data.
The trouble data display for the machine system is displayed on the character display as shown below.
*** : Displays order of trouble data items

###### : Displays failure code
$$$ : Displays number of times that applicable failure code has occurred
%%%%% : Displays time that has elapsed since failure first occurred
@@@@@ : Displays time that has elapsed since failure last occurred
The failure code flashes for failures that are still occurring at present. The number of times that the fail-
ure code for the machine system has occurred is saved in memory.
HM400-1 10-151
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 below.
*** : Displays name of item

##### : Displays ID No. given to each item
%%% : Displays data. If units are used, the unit is displayed on the right side of the data
By specifying the ID No. given to each item, it is possible to display the desired 2 items at the same
*** : Displays specified ID No

%%% : Displays data. If units are used, the unit is displayed on the right side of the data
10-152 HM400-1
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.
6) Changing filter, oil replacement time
For details of this function, see the Operation and Maintenance Manual, OPERATION, Character
display portion, Filter, oil replacement time display. This is used when changing the replacement
interval.
7) Controller initialize
This function is used only at the factory, so do not touch it.
HM400-1 10-153
(11)
2. Method of operation
For details of the method of operating each service mode function, see TROUBLESHOOTING.
REMARK : When the starting switch is turned OFF, it returns to the normal mode.
10-154 HM400-1
(11)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SHIFT CONTROL SYSTEM
AUTOMATIC SHIFT CONTROL SYSTEM

(Transmission control system with all-range electronic modulation)
HM400-1 10-155
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SHIFT CONTROL SYSTEM
OUTLINE
• The transmission controller receives the shift po-
sition signal for the gearshift lever, the accelera-
tor signal for the accelerator pedal, the speed
signal for the transmission, and the other signals
from the switches and sensors. It then automat-
ically 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 pre-
vent overrun.
Each clutch pack of the clutch packs and torque
converter lock-up clutch in the transmission is
equipped with an electronically controlled mod-
ulation valve, and each clutch pack is independ-
ently 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, and in this way contributes to
improving the durability of the clutches.
• The transmission shift controller uses the sig-
nals from the switches and sensors to drive the
machine monitor displays and caution and pilot
lamps, and transmits these data to the network.
10-156 HM400-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION CONTROLLER
TRANSMISSION CONTROLLER
1. Self-diagnostic display window 6. Speed sensors are installed at three places

2. Connector (transmission input shaft, intermediate
3. Case shaft, and output shaft). This makes it pos-
4. Motherboard sible to detect slippage of the transmission
5. Model selector switch (rotary switch 1) clutches and to protect the transmission
6. Model selector switch (rotary switch 2) when there is any abnormality in the hydrau-
lic system.
Outline 7. It connects to the network and shares vari-
• The transmission controller controls the trans- ous data with other controllers.
mission system. 8. It receives input of the model selection data
It has the following features and functions. (what model it is mounted on), and uses the
1. It has a high power mode and economy mode, network to contact other controllers. (For
and the gearshifting pattern can be selected. details of the method of setting, see IN-
2. The braking mode is the mode when the SPECTION, MAINTENANCE, AND TROU-
brake is used. By raising the gearshifting BLESHOOTING.)
point and increasing the speed of the brake 9. It has a self-diagnostic function which di-
cooling pump it is possible to raise the cool- vides the input and output systems further
ing effect of the retarder and make effective into small parts.
use of the engine brake. 10. The self-diagnostic function is displayed in
3. It controls the torque converter lock-up sole- two digits.
noid valve, overrun prevention solenoid 11. When an abnormality is detected, it trans-
valve, and exhaust brake solenoid valve. mits the details to the network and displays
4. It controls the inter-axle differential lock so- it on the other displays.
lenoid valve according to the output com- 12. It uses the machine monitor to display if the
mand from the retarder controller (brake failure is still existing.
controller: E-SPEC). 13. It provides an escape function for use when
5. To reduce the shock when shifting gear, it there is a failure in the electrical system.
outputs the throttle correction command to 14. It is separate from the gearshift lever.
the engine controller when shifting gear and
limits the engine speed.
HM400-1 10-157
6
ATC1 ATC3A ATC4 ATC5A

1  1 Connector check 1  1 Connector check
2  Transmission input shaft speed 2  Hydraulic tank level signal input

2 2
input (opt)
Power source output (24V) for 3 
3 torque converter oil pressure
3 Transmission
output shaft speed
3 Radiator
cooling water level signal
sensor input 4  input
Power source input (24V) for 4 Engine load condition signal input 5  4 
4 overrun prevention solenoid output
command 
5 Throttle
correction command 6 Network signal output 5
output
Power source input (24V) for 7  6 Transmission oil filter condition
5 exhaust brake solenoid output
6 Potentiometer power source signal input
command output (5V) 8 
7 Speed
range N action command 1
6  
7 Torque
converter oil pressure 9 signal input
signal input
7 Battery
direct power source input
8 Speed
10 Network signal GND range N action command 2
(24V)
8 Inter-axle
differential lock signal input
command input 11 
8 GND Hydraulic filter condition signal
9 input
9  12 Network signal output
9 Power source input (24V)
10 Emergency escape switch input 10 Fill switch input Low
10 
11 Steering
oil temperature signal 11 Fill switch input lock-up
11  input
12 Fill switch input High
12 
12 Transmission
intermediate shaft
speed input 13 Fill switch input 1st
13 Overrun
prevention solenoid
output command 13 Engine speed input 14 Fill switch input 2nd
Exhaust brake solenoid output 14 GND (for speed input) 15 Fill switch input 3rd
14 command
15  16 Fill switch input Rev
15 Transmission cut relay
16 GND (for sensor)
17 Fill
switch input inter-axle
16 GND differential lock
17 GND input for torque converter oil
17 Power source input (24V) pressure 18 Start signal input
18 GND
input for inter-axle differential
19 Emergency
steering actuation
lock signal 1 input
19 Air
cleaner filter condition signal 20 
input
20 Learning data reset switch input
ATC2 ATC3B ATC5B

1 Proportional
solenoid power 1 Alternator terminal R input
1 Emergency
steering actuation
source input 24V signal 2 input
2 
2 ECMV output 1st (+)
2 Gearshift lever position R1 signal
3 Brake
cooling oil temperature input
3 ECMV output 3rd (+) (front wheel) signal input
3 Gearshift
4 Fuel level signal input lever position R2 signal
4 ECMV output High (+) input
5 
4 Gearshift
5 ECMV output Rev (+) lever position N signal
input
6 
6 
5 Gearshift lever position D signal
7 Torque
converter oil temperature input
7 ECMV output Low (+) signal input
6 Gearshift
lever position 1 signal
8 ECMV output inter-axle differential 8 Brake
cooling oil temperature input
lock (+) (center wheel) signal input
9 ECMV output 2nd (+) 7 Gearshift lever position 2 signal
9 Transmission
oil temperature input
signal input
10 ECMV output lock-up (+)
8 Gearshift lever position 3 signal
10 Brake
cooling oil temperature (rear
11  wheel) signal input
input
9 Gearshift
lever position 4 signal
12 Proportional
solenoid power 11 Accelerator signal input
source input 24V input
13 ECMV output 1st, 3rd (-) 10 Gearshift lever position 5 signal

input
14 Sensor power source output (12V)
11 Shift hold signal input
15 ECMV output High, Rev (-)
12 
16 
13 
17 ECMV output Low (-)
14 Model selection 1 input
18 ECMV output inter-axle differential
15 Model selection 2 input
lock (-)
19 ECMV output 2nd (-) 16 Model selection 3 input
20 ECMV output lock-up (-)
21 GND
10-158 HM400-1
6
GEARSHIFT LEVER POSITION AND AUTOMATIC GEARSHIFTING RANGE

• The relationship between each gearshift position and the automatic gearshifting range is as as shown in the
table below.
Gearshifting characteristics High power mode:

• Shifting the transmission up and down is carried The high power mode uses the power of the
out according to the shift map saved in the con- machine to the maximum to provide the maximum
troller memory. payload. However, when the machine is unloaded
There are three types of shift map, depending or has only a light load (high acceleration), an
on the condition of the input signals. acceleration sensitive type variable shifting point is
The settings for each mode are as shown in the used. This detects
table below. the acceleration of the machine and shifts the trans-
mission up sooner to provide better acceleration and
Mode Set conditions to improve the fuel consumption, noise, and trans-
When either of the following conditions is fulfilled mission shock.
1. Brake signal ON
Braking mode
(footbrake, retarder brake operated)
2. Accelerator pedal released Economy mode:
When the machine is being used under light load,
When the following three conditions are fulfilled
1. Brake signal OFF such as when traveling unloaded or on flat ground,
High power
mode
(footbrake, retarder brake not operated) the shift-up point and shift-down point are both low-
2. Accelerator pedal depressed
3. Power mode selector switch is at high power ered, the engine speed is maintained at a lower lev-
el, and the fuel consumption, noise, and transmis-
When the following three conditions are fulfilled
1. Brake signal OFF sion shock are improved. In this mode, the engine
Economy
mode
(footbrake, retarder brake not operated) output is limited to 90% of the maximum engine out-
2. Accelerator pedal depressed
3. Power mode selector switch is at economy put.
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.
HM400-1 10-159
(7)
AUTOMATIC GEARSHIFTING GRAPH

• The shift-up/shift-down points, the torque converter lock-up ON/OFF points, and the automatic braking (for
overrun prevention) ON/OFF points of each mode are as shown in the figure below.
Note:
1. High power mode • If the travel speed lowers below 4 km/h or the
• For the shift-up point, the optimum point be- foot brake is not applied or the lock-up is kept
tw ee n 1 7 50 a n d 2 0 9 0 m i n - 1 i s s el e c te d turned on for a long period, the lock-up is turned
according to the amount the accelerator pedal is off and a gear speed proper for the travel speed
depressed, the acceleration of the machine, and is selected. Accordingly, if the machine travels
the speed range. downhill with the foot brake applied and the en-
• For the shift-down point also, the optimum point gine speed kept low by the lock-up, the brake
between 1120 and 1300 min - 1 is selected cooling oil flow becomes insufficient and the en-
according to the amount the accelerator pedal is gine overheats easily.
depressed and the speed range.
4. Lock-up
2. Economy mode • For the lock-up ON point, the optimum point be-
• For the shift-up point, the optimum point between 1050 and 1400 min-1 is selected accord-
tween 1750 and 1900 min-1 is selected according to the torque converter input speed (engine
ing to the amount the accelerator pedal is speed) and output speed (transmission input
depressed, the acceleration of the machine, and shaft speed).
the speed range. • The lock-up OFF point when the footbrake or re-
• For the shift-down point also, the optimum point tarder brake are operated is 950 min-1.
between 1120 and 1200 min -1 is selected ac- • When the footbrake or retarder brake are not op-
cording to the amount the accelerator pedal is erated, it is 850 min-1.
depressed and the speed range. • When the machine moves off downhill with the
accelerator pedal released, the lock-up is not
3. Keeping gear speed in braking mode (foot brake) engaged until the accelerator pedal is de-
• If the travel speed lowers below 10 km/h while pressed or the footbrake is applied.
the foot brake is applied, the gear speed at that
time (F3, F4, F5) is held. 5. The auto brake ON point when traveling in F6 is
2400 min- 1.
10-160 HM400-1
(7)
Gearshift lever positions and method of shifting (Manual shift)

1) Gearshift lever position D The safety functions related to travel in reverse
When shifting up (in high power mode) are the directional inhibitor and reverse safety.
I) When the gearshift lever is set at position D, the If the operation is not correct, gearshifting is
transmission is set to F2 torque conver ter restricted.
range. 4) Gearshift lever position N
II) When the accelerator pedal is depressed, the At the neutral position, none of the transmission
engine speed rises and accelerates. When the clutches are actuated.
transmission input shaft speed reaches 1050 -
1400 min-1, the lock-up clutch is engaged, so Shift hold function
the torque converter is directly engaged and the • Press the hold switch on the gearshift lever once
transmission is set to direct travel. to hold the transmission in the present speed
III) As the engine speed rises further and reaches range.
1750 - 2070 min-1, the transmission shifts up to Press the hold switch again to cancel the shift
F3. hold function.
While the transmission is shifting up, the engine If the speed of the transmission input shaft goes
speed is also lowered (a command is output to below 750 min-1 while the shift hold function is
the engine controller) in order to reduce the being actuated, the shift hold function is auto-
shock when shifting gear. matically canceled.
IV) Immediately after shifting up, the engine speed
momentarily goes down, but as the machine Gearshifting time delay
accelerates, it rises again and the transmission • In the automatic shift range, to prevent mistaken
shifts up in turn to F4 to F6 in the same way as operation caused by excessive variation in the
in III) above. speed when shifting gear, a time delay is used to
prevent the gears from being shifted within the
When shifting down (in high power mode) set time.
I) When the load increases and the engine speed The gearshifting time delay is controlled pre-
drops to 1120 - 1250 min-1, the transmission cisely by each gearshifting pattern through the
shifts down one speed. use of the all-range electronic modulation sys-
(For example, when traveling in F6, the trans- tem.
mission shifts down to F5.) The approximate values for the gearshifting pat-
While the transmission is shifting up, the engine tern and gearshifting time delay are shown in
speed is also raised (a command is output to the diagram below.
the engine controller) in order to reduce the
shock when shifting gear.
II) As the engine speed goes down further and the
transmission shifts down in turn to F2, the
torque converter lock-up clutch is disengaged
and the transmission enters the torque con-
verter drive.
* In the above explanation, the set speed or actu-

ation may differ according to the travel condi-
t i o n s . Fo r d e t a i l s , s e e t h e a u t o m a t i c
gearshifting graph.
2) Gearshift lever positions 5, 4, 3, 2, 1

The method of shifting automatically from F1 to
F5 (F4, F3, F2) is the same as for gearshift
lever position D above.
3) Gearshift lever positions R1, R2
These are the gearshift lever positions for
traveling in reverse. The transmission shifts to
the range (R1 or R2) specified by the gearshift
lever position.
HM400-1 10-161
6
Safety functions If the engine speed rises to more than 2400

1) Down-shift inhibitor function min-1 (more than 2350 min-1 in F6), the central
If gearshift lever is operated D → 5 - 1, 5 → 4 - warning lamp flashes and the alarm buzzer
1, 4 → 3 - 1, 3 → 2 - 1, 2 → 1 sounds.
For example, when traveling in D (F6), even if If the engine speed rises to more than 2450
the gearshift lever is operated to 4, the trans- min-1 (more than 2400 min-1 in F6), the rear
mission does not shift directly F6 → F4. It shifts brake is automatically actuated.
down F6 → F5 → F4 in turn according to the (To prevent overrun of engine, torque converter,
engine speed. and transmission, to improve durability and reli-
(The transmission does not jump two speed ability)
ranges if the operator makes a mistake when 5) REVERSE safety
operating the gearshift lever. This is to prevent The machine will not travel in reverse if the
the engine from overrunning.) dump control lever is not at FLOAT and the
2) Neutral safety function dump body is not completely lowered.
This circuit prevents the engine from starting if (Turnover prevention function)
the gearshift lever is not at the N position, even However, if the gearshift lever is at the R1 posi-
if the starting switch is turned to the START tion and the shift hold switch is pressed, it is
position. possible to travel in reverse while the switch is
(This is a safety circuit to prevent the machine being pressed, even if the dump body is not
from moving unexpectedly when the engine is fully lowered.
started.) 6) Speed range limit function when dump body is
3) Directional inhibit function raised
When traveling in reverse at a speed of more After dumping the load, if the body is not com-
than 3.8 km/h, even if the gearshift lever is pletely lowered, shifting up is limited.
operated to D or positions 5 to 1, the transmis- If the gearshift lever is at D, the machine starts
sion will not be shifted immediately to travel for- in F2, and if it is at positions 5 to 1, the machine
ward. The engine speed is lowered to reduce starts in F1. The transmission does not shift up
the travel speed, and when the travel speed until the body is completely lowered.
goes below 3.8 km/h, the transmission is shifted
to FORWARD. Self-diagnostic function
When traveling forward at a speed of more than The controller carries out self-diagnosis of the sys-
1.9 km/h, even if the gearshift lever is operated tem and displays any abnormalities.
to positions R1 or R2, the transmission will not The details of the self-diagnosis are displayed as a
be shifted immediately to travel in reverse. The 2-digit code with LEDs.
speed range is shifted to N and the engine If any abnormality is detected by the self-diagnosis
speed is lowered to reduce the travel speed. function, the abnormality data is transmitted to the
When the travel speed goes below 1.9 km/h, network and is displayed as an action code on the
the transmission is shifted to REVERSE. machine monitor. The transmission system caution,
When traveling in reverse at a speed of more warning lamp, or alarm buzzer may also be actuat-
than 7.2 km/h with the gearshift lever at position ed.
R2, even if the gearshift lever is operated from
R2 to R1, the transmission does not shift to R1.
When the travel speed goes below 1.9 km/h,
the transmission is shifted to R1.
When starting the engine, if the machine is
already traveling forward or in reverse at a
speed of more than 3.8 km/h, even if the gear-
shift lever is operated to a position other than N,
the machine will not move and the transmission
will be held at N.
When the travel speed goes below 1.9 km/h, it
is permitted to move the machine off.
(To prevent overload on power train, to improve
durability and reliability)
4) Power train overrun prevention rear brake func-
tion
10-162 HM400-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AUTO EMERGENCY STEERING SYSTEM
AUTO EMERGENCY STEERING SYSTEM
1. Emergency steering motor Outline

2. Emergency steering pump • If the engine stops or an abnormality occurs in
3. Hydraulic tank the hydraulic pump when the machine is
4. Steering oil pressure sensor traveling, and the oil in the steering circuit goes
5. Steering valve below the specified oil pressure, the auto emer-
6. Battery relay gency steering system automatically actuates
the emergency steering pump to ensure the
steering oil pressure and to make it possible to
operate the steering. It is also possible to oper-
ate it manually.
HM400-1 10-163
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS, SWITCHES
SENSORS, SWITCHES
ENGINE SPEED SENSOR
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.
10-164 HM400-1
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 potentiome-
ter inside the accelerator sensor.
As a result, the resistance changes. A fixed
voltage is impressed between the No. 1 – 3 pins
of the potentiometer. A voltage signal corre-
sponding to the angle of the accelerator pedal is
sent from the No. 2 pin to the transmission con-
troller.
Idling validation signal

• This is installed under the operator’s cab.
When the accelerator pedal is released, signal
2 (No. 5 pin) is connected to the ground; when
the accelerator pedal is depressed, signal 3
(No. 6 pin) is connected to the ground.
The engine controller then detects the condi-
tion.
HM400-1 10-165
ENGINE WATER TEMPERATURE SENSOR

BRAKE COOLING OIL TEMPERATURE 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 control-
ler through the network to the machine monitor
panel to display the temperature level. When the
display on the monitor panel reaches the speci-
fied position, the lamp flashes and the buzzer
sounds to warn of an abnormality.
STEERING OIL TEMPERATURE SENSOR
1. Sensor
2. Terminal
3. Connector
Function
• The steering oil temperature sensor is installed
to the steering and hoist piping. The sensor por-
tion detects the temperature, and when the oil
temperature goes above the specified level, the
warning lamps lights up and a message is dis-
played on the character display of the monitor
panel.
10-166 HM400-1
6
Fuel level sensor
1. Connector Function
2. Float • The fuel sensor is installed to the side face of the
3. Arm fuel tank. The float moves up and down accord-
4. Body ing to the fuel level. This movement of the float
5. Spring is transmitted by the arm and actuates a variable
6. Contact resistance. This sends a signal to the monitor
7. Spacer panel to indicate the remaining fuel level. When
the display of the monitor panel reaches a cer-
tain level, a warning lamp flashes.
HM400-1 10-167
TILT SENSOR
1. Magnetic resistance particle

2. Leaf spring
3. Damper oil
Function
• The tilt sensor is installed to the rear of the chas-
sis. A magnet supported by a leaf spring is in-
stalled to a case charged with damper oil. It uses
the position in relation to the magnetic resist-
ance element to detect the tilt angle of the chas-
sis.
The magnet is supported by the leaf spring, so
it does not detect the front-to-rear tilt of the
chassis.
10-168 HM400-1
AIR CLEANER CLOGGING 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 abnormal-
ity.
HM400-1 10-169
HYDRAULIC OIL LEVEL 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 mainte-
nance caution lamp lights up to warn of the ab-
normality.
10-170 HM400-1
6
BODY POSITIONER 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.
HM400-1 10-171
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RETARDER CONTROL SYSTEM
RETARDER CONTROL SYSTEM
q1. Serial No. 1001 and up.
10-172 HM400-1
6
RETARDER CONTROLLER
1. Self-diagnostic display window

2. Rotary switch
3. Motherboard
4. Case
5. Connector
Outline
The retarder controller has the following functions.
1. Retarder control
The electromagnetic proportional valve for the front and rear wheels is controlled according to the operat-
ing angle of the retarder control lever and actuates the retarder brake.
2. Overrun prevention, retarder control when there is transmission abuse

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 retarder brake by a fixed amount.
3. Hoist control
This controls the hoist EPC valve (electromagnetic proportional valve) and hoist selector valve (ON/OFF
valve) according to the position of the dump control lever and actuates the dump body.
4. Differential lock control

1) Inter-axle differential lock control
The differential lock command is output to the transmission controller according to the condition of the
machine (differential lock switch, travel speed, etc.).
Based on the command from the retarder controller, the transmission controller drives the ECMV and
actuates the inter-axle differential lock.
HM400-1 10-173
6
2) Left and right differential lock control

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 actu-
ated.
5. Exhaust brake control

Based on the command from the transmission controller, the exhaust brake solenoid is driven and the
exhaust brake is actuated.
6. Transmission of network data

1) Retarder actuation, float caution, parking brake actuation, exhaust brake actuation, inter-axle differen-
tial lock actuation, accumulator oil pressure drop warning, and other data are transmitted to the moni-
tor panel.
2) The exhaust brake command, overrun prevention, retarder command when there is abuse, and other
data sent from the transmission controller are received.
3) The inter-axle differential lock actuation command, reverse inhibit, and other data are transmitted to
the transmission controller.
10-174 HM400-1
BRC1 BRC3A BRC4 BRC5A

Power source for +24V output 1 Connector check 1 RS422 TX(+) 1 Connector check 2
1
sensor
2  2 RS422 RX(+) 2 Exhaust brake switch
Rear wheel differential lock
2
solenoid 3  3 RS232 TXD 3 Service brake switch
3 Exhaust brake solenoid 4  4 RS232C TXD 4 Retarder switch
4 Brake cut relay (+24V IN) 5  5 RS485 (+)

5 Parking
brake emergency brake
switch
5 
6 Sensor
power source +5V (hoist 6 S-NET (+)
lever potentiometer, body position) 6 Lever validation switch 1
6 Neutral signal 1 7 RS422 TX(-)
7  7 Lever validation switch 2
7 Battery direct power source input 8 FLASH SW. (ON/OFF)
8  8 Brake system filter switch
8 GND 9 RS422 RX(-)
9  9 Brake cooling filter switch
9 Power source +24V 10 GND. (SERIAL)
10  10 
Front wheel differential lock 11 RS485(-)
10 solenoid
11  11 
12 S-NET (+)
11 Kick-out solenoid 12 Transmission front axle speed 12 
12 Hoist selector valve 13 Transmission output shaft speed 13 
13 Brake cut relay 14 GND (pulse) 14 
14  15  15 
15 Neutral signal 2 16 GND (analog) 16 
16 GND 17  17 
17 Power source +24V 18 

18 Starting
switch terminal C (engine
start signal)
19 
19 
20 
20 
BRC2 BRC3A BRC5B

 
1 Proportional
solenoid power 1 1
source +24V
2  2 Brake wear switch FL
2 
3  3 Brake wear switch FR
3 
4 
4 Exhaust
brake command (FRONT
4  TRANSMISSION)
5 Accumulator oil pressure (FRONT)
5 
5 Overrun
command (FRONT
6 Accumulator oil pressure (REAR) TRANSMISSION)
6 Inter-axle
differential lock
command 6 Brake wear switch RL
7 Accumulator gas pressure
(FRONT)
7  7 Brake wear switch RR
8 Accumulator gas pressure (REAR)
Front wheel retarder 8 Brake wear switch ML
8 electromagnetic proportional 9 
reducing valve (+) 9 Brake wear switch MR
10 
Rear wheel retarder 10 
9 electromagnetic proportional 11 
reducing valve (+) 11 
12 Hoist lever potentiometer 2
10 Hoist EPC valve (+) 12 
13 Body position sensor
11  13 

12 Proportional
solenoid power 14
source +24V 15 Steering angle potentiometer
15 
13 
16 Manual
retarder lever
potentiometer 16 
14 Sensor power source +12V (pulse)
15 
16 Sensor
power source +5V
(retarder lever potentiometer)
17 
Front wheel retarder

18 electromagnetic proportional
reducing valve (-)
Rear wheel retarder

19 electromagnetic proportional
reducing valve (-)
20 Hoist EPC valve (-)
21 GND
HM400-1 10-175
6
RETARDER CONTROL FUNCTION

RETARDER CONTROL SYSTEM DIAGRAM
Retarder lever control

The operating angle of the retarder lever is detected by the potentiometer and a current corresponding to this
is output to the electromagnetic proportional valve for the front and rear wheels to actuate the retarder.
Overrun prevention, retarder control when there is transmission abuse

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 retarder by a fixed amount.
10-176 HM400-1
6
Relationship between retarder lever potentiometer and output to electromagnetic proportional valve
To improve the initial response of the electromagnetic proportional reducing valve, the output (trigger out-
put) is set to a high value.
To make the actuation of the hydraulic pressure smooth in the low pressure range, the output is set to a
high value.
In the range where the retarder is normally used, the output is proportional to the angle of the lever.
To make the opening of the hydraulic pressure smooth in the low pressure range, the output is set to a low
value.
HM400-1 10-177
HOIST CONTROL FUNCTION
HOIST CONTROL SYSTEM DIAGRAM
1. Hoist control function

When the engine is running, the EPC and valve (electromagnetic proportional valve) and selector valve
are controlled according to the operation of the dump control lever and operate the dump body.
2. Lever positioner function

The dump control lever has four positions: RAISE, HOLD, FLOAT, and LOWER.
If the dump control lever is operated to the RAISE position, the dump body is raised, and when the top of
the dump body reaches the set position of the body position sensor, the lever is returned to the HOLD posi-
tion.
If the lever is kept at the RAISE position, the RAISE output continues to be given.
3. Body seating speed control

When the dump body is lowered and reaches the position just before it is seated, the area of opening of
the EPC valve is throttled to control the lowering speed of the dump body and reduce the shock when the
dump body comes into contact with the chassis.
10-178 HM400-1
4. Control when starting switch is turned to ON, OFF, or START

Starting switch at ON:
The output is set to HOLD, regardless of the position of the lever.
If the engine is not started, even if the hoist lever is operated, the condition remains at HOLD.
Starting switch at OFF:
The dump body is held in position regardless of the position of the lever.
Engine started:
Immediately after the engine is started, the output is set to HOLD, regardless of the position of the lever.
After the lever is moved to the HOLD position, it becomes possible to carry out normal operations.
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
6. Reverse inhibit function

The retarder controller judges if it is permissible to travel in reverse or not, and transmits the result of the
judgment through the network to the transmission controller.
"FLOAT OUTPUT" and "SEATED" → Reverse travel permitted
"NO FLOAT OUTPUT" or "NOT SEATED" → Reverse travel not permitted
7. Calibration function
To absorb any inherent error in the dump body potentiometer, calibration is carried out 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, carry out
calibration in the following order.
Order of dump control calibration (hydraulic oil temperature: 80 - 90fC)
(1) 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.
(2) Operate the lever to the RAISE position until 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 5 seconds.
(3) Lower the dump body completely and keep the lever at HOLD for at least 5 seconds.
(4) Run the engine at low idling and operate RAISE → FLOAT with the dump body raised to the maximum
height, then lower the dump body completely. Repeat this operation 10 times.
(5) Run the engine at high idling and operate RAISE → FLOAT with the dump body raised to the maxi-
mum height, then lower the dump body completely. Repeat this operation 10 times.
HM400-1 10-179
5
DIFFERENTIAL LOCK CONTROL FUNCTION
DIFFERENTIAL LOCK CONTROL SYSTEM DIAGRAM
1. Inter-axle differential lock control

The inter-axle differential lock is actuated automatically, or manually by turning the inter-axle differential
lock switch ON/OFF.
• Manual differential lock:
In low speed ranges (F1, F2, F3, R1, R2) or N, the inter-axle differential lock command is output when
the differential lock switch is ON.
• Emergency braking control (automatic):
The inter-axle differential lock command is output when the travel speed is more than 35 km/h and the
brake is ON.
• Brake ON control (automatic):
The inter-axle differential lock command is output according to the difference in speed between the
front and rear axles when the brake is ON.
• Control (automatic) when there is variation in transmission output shaft speed:
The inter-axle differential lock command is output when the variation in the transmission output shaft
speed exceeds the set value.
The inter-axle differential lock command is an analog signal and is transmitted to the transmission con-
troller. To cancel the inter-axle differential lock the transmission controller outputs electric current to the
electromagnetic proportional valve.
2. Left and right differential lock control

Depending on the setting of the left and right differential lock selector switch, one of the following is
selected: 1 rear wheel left and right differential lock ON; 2 front and rear wheel left and right differential
lock ON; or 3 front and rear wheel left and right differential lock OFF.
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 differential lock command is output.
10-180 HM400-1
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 outputs electric current to the electromagnetic proportional
valve.
The differential lock clutch is engaged by a pressure proportional to the current

.
Output specification from retarder controller to transmission controller

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 controller.
The lever validation switches output 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.
HM400-1 10-181
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE CONTROL SYSTEM (E-SPEC)
BRAKE CONTROL SYSTEM (E-SPEC)
q1. Since the retarder function is not used in E-SPEC, the retarder control lever potentiometer is used to bleed
q2. Serial No. 1001 and up.

air from the brake oil circuit.
10-181-1 HM400-1
6
BRAKE CONTROLLER (E-SPEC)
1. Self-diagnostic display window

2. Rotary switch
3. Motherboard
4. Case
5. Connector
Outline
The brake controller has the following functions.
1. Overrun prevention, brake control when there is transmission abuse
(ON/OFF command) from the transmission controller and actuates the brake by a fixed amount.
2. Hoist control
This controls the hoist EPC valve (electromagnetic proportional valve) and hoist selector valve (ON/OFF
valve) according to the position of the dump control lever and actuates the dump body.
3. Differential lock control

1) Inter-axle differential lock control
The differential lock command is output to the transmission controller according to the condition of the
machine (differential lock switch, travel speed, etc.).
Based on the command from the brake controller, the transmission controller drives the ECMV and
actuates the inter-axle differential lock.
2) 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 actu-
ated.
HM400-1 10-181-2
6
4. Exhaust brake control

Based on the command from the transmission controller, the exhaust brake solenoid is driven and the
exhaust brake is actuated.
5. Transmission of network data

1) Brake actuation, float caution, parking brake actuation, exhaust brake actuation, inter-axle differential
lock actuation, accumulator oil pressure drop warning, and other data are transmitted to the monitor
panel.
2) The exhaust brake command, overrun prevention, brake command when there is abuse, and other
data sent from the transmission controller are received.
3) The inter-axle differential lock actuation command, reverse inhibit, and other data are transmitted to
the transmission controller.
10-181-3 HM400-1
6
BRC1 BRC3A BRC4 BRC5A

Power source for +24V output 1 Connector check 1 RS422 TX(+) 1 Connector check 2
1
sensor
2  2 RS422 RX(+) 2 Exhaust brake switch
Rear wheel differential lock
2 solenoid
3  3 RS232 TXD 3 Brake switch
3 Exhaust brake solenoid 4  4 RS232C TXD 4 Overrun protection brake switch
4 Brake cut relay (+24V IN) 5  5 RS485 (+)

5 Parking
brake emergency brake
switch
5 
6 Sensor
power source +5V (hoist 6 S-NET (+)
lever potentiometer, body position) 6 Lever validation switch 1
6 Neutral signal 1 7 RS422 TX(-)
7  7 Lever validation switch 2
7 Battery direct power source input 8 FLASH SW. (ON/OFF)
8  8 Brake system filter switch
8 GND 9 RS422 RX(-)
9  9 Brake cooling filter switch
9 Power source +24V 10 GND. (SERIAL)
10  10 
10 Front
wheel differential lock 11 RS485(-)
solenoid 11  11 
12 S-NET (+)
11 Kick-out solenoid 12 Transmission front axle speed 12 
12 Hoist selector valve 13 Transmission output shaft speed 13 
13 Brake cut relay 14 GND (pulse) 14 
14  15  15 
15 Neutral signal 2 16 GND (analog) 16 
16 GND 17  17 
17 Power source +24V 18  18 Starting

switch terminal C (engine
start signal)
19 
19 
20 
20 
BRC2 BRC3A BRC5B

 
1 Proportional
solenoid power 1 1
source +24V
2  2 Brake wear switch FL
2 
3  3 Brake wear switch FR
3 
4  Exhaust brake command (FRONT
4 TRANSMISSION)
4 
5 Accumulator oil pressure (FRONT)
5 
5 Overrun
command (FRONT
6 Accumulator oil pressure (REAR) TRANSMISSION)
6 Inter-axle
differential lock
command 6 Brake wear switch RL
7 Accumulator
gas pressure
(FRONT)
7  7 Brake wear switch RR
8 Accumulator gas pressure (REAR)
8 Front
wheel brake electromagnetic 8 Brake wear switch ML
proportional reducing valve (+) 9 
9 Brake wear switch MR
Rear wheel brake electromagnetic 10 
9 proportional reducing valve (+)
10 
11 
10 Hoist EPC valve (+) 11 
11  12 
13 Body position sensor
12 Proportional
solenoid power 13 
source +24V 14 Hoist lever potentiometer 1
14 
13  15 Steering angle potentiometer
15 
14 Sensor power source +12V (pulse) Manual retarder lever
16 ( potentiometer ) 16 
15 
16 Sensor power source +5V

(retarder lever potentiometer)
17 
18 Front
wheel brake electromagnetic
proportional reducing valve (-)
19 Rear
wheel brake electromagnetic
proportional reducing valve (-)
20 Hoist EPC valve (-)
21 GND
HM400-1 10-181-4
6
BRAKE CONTROL FUNCTION

BRAKE CONTROL SYSTEM DIAGRAM
q1. 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.
• Overrun prevention, brake control when there is transmission abuse

(ON/OFF command) from the transmission controller and actuates the brake by a fixed amount.
10-181-5 HM400-1
6
HOIST CONTROL FUNCTION
HOIST CONTROL SYSTEM DIAGRAM
1. Hoist control function

When the engine is running, the EPC and valve (electromagnetic proportional valve) and selector valve are
controlled according to the operation of the dump control lever and operate the dump body.
2. Lever positioner function

The dump control lever has four positions: RAISE, HOLD, FLOAT, and LOWER.
If the dump control lever is operated to the RAISE position, the dump body is raised, and when the top of
the dump body reaches the set position of the body position sensor, the lever is returned to the HOLD posi-
tion.
If the lever is kept at the RAISE position, the RAISE output continues to be given.
3. Body seating speed control

When the dump body is lowered and reaches the position just before it is seated, the area of opening of the
EPC valve is throttled to control the lowering speed of the dump body and reduce the shock when the
dump body comes into contact with the chassis.
HM400-1 10-181-6
6
4. Control when starting switch is turned to ON, OFF, or START

Starting switch at ON:
The output is set to HOLD, regardless of the position of the lever.
If the engine is not started, even if the hoist lever is operated, the condition remains at HOLD.
Starting switch at OFF:
The dump body is held in position regardless of the position of the lever.
Engine started:
Immediately after the engine is started, the output is set to HOLD, regardless of the position of the lever.
After the lever is moved to the HOLD position, it becomes possible to carry out normal operations.
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
6. Reverse inhibit function

The brake controller judges if it is permissible to travel in reverse or not, and transmits the result of the
judgment through the network to the transmission controller.
"FLOAT OUTPUT" and "SEATED" → Reverse travel permitted
"NO FLOAT OUTPUT" or "NOT SEATED" → Reverse travel not permitted
7. Calibration function
To absorb any inherent error in the dump body potentiometer, calibration is carried out 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, carry out
calibration in the following order.
Order of dump control calibration (hydraulic oil temperature: 80 - 90fC)
(1) 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.
(2) Operate the lever to the RAISE position until 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 5 seconds.
(3) Lower the dump body completely and keep the lever at HOLD for at least 5 seconds.
(4) Run the engine at low idling and operate RAISE → FLOAT with the dump body raised to the maximum
(5) Run the engine at high idling and operate RAISE → FLOAT with the dump body raised to the maximum
10-181-7 HM400-1
6
DIFFERENTIAL LOCK CONTROL FUNCTION


lock switch ON/OFF.
brake is ON.

HM400-1 10-181-8
6


lock switch ON/OFF.
brake is ON.

10-181-9 HM400-1
6
Inter-axle differential lock output

The inter-axle differential lock command is an analog signal and is transmitted from the brake controller to the
transmission controller. The transmission controller outputs electric current to the electromagnetic proportional
valve.
The differential lock clutch is engaged by a pressure proportional to the current.
Output specification from brake controller to transmission controller

The brake 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 brake 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 brake controller.
The lever kick-out solenoid fixes the lever at the RAISE position when it receives the ON signal from the brake
controller and returns the lever to the HOLD position when it receives the OFF signal.
HM400-1 10-181-10
6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DUMP CONTROL LEVER
DUMP CONTROL LEVER
10-182 HM400-1
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
HM400-1 10-183
Function
• When lever (1) is operated, rod (18) moves up or
down according to the amount the lever is oper-
ated, and rotates potentiometer (16).
• The amount the control lever is operated (trav-
els) is detected by the potentiometer, and this is
sent as a signal voltage to the controller.
• One potentiometer is installed and outputs two
related signal voltages as shown in the "Output
voltage characteristics" graph.
Operation
1. Dump control lever operated to FLOAT
• When LOWER rod (2) is pushed by lever (1) and
moves down, ball (14) contacts protrusion a of
rod (11) during the stroke. (Before start of actu-
ation of mechanical detent)
• When rods (2) and (11) are pushed in further,
ball (14) is being held by detent spring (12).
While pushing retainer (13) up, it escapes to the
outside, and rod (11) passes over protrusion a.
• When this happens, rod (18) on the opposite
side is pushed up by spring (4). Ball (14) is
moved to the small diameter side of protrusion b
of rod (19) by retainer (13) that is being held by
detent spring (20).
• Even if the lever is released, rod (18) is held in
position by the pushing force of the ball and pro-
trusion b of rod (19), so the lever is held at the
FLOAT position.
10-184 HM400-1
2. Dump control lever FLOAT canceled 4. Dump control lever operated to RAISE
• When lever (1) is returned from the FLOAT posi- • When RAISE rod (18) is pushed by lever (1) and
tion, it is pushed down by a force greater than moves down, ball (14) contacts protrusion a of
the holding force of rod (19), detent spring (20), rod (19) during the stroke. (Before start of actu-
retainer (13), and ball (14). ation of mechanical detent)
• When rods (18) and (19) are pushed in further,
3. Dump control lever operated to LOWER ball (14) is being held by detent spring (20).
• When lever (1) is operated further from the While pushing retainer (13) up, it escapes to the
FLOAT position, it moves to the LOWER posi- outside, and rod (19) passes over protrusion a.
tion. • When this happens, rod (2) on the opposite side
• Rod (18) is pushed up by the spring (4) in ac- is pushed up by spring (4).
cordance with the amount lever (1) is operated. • When an electric current is flowing to solenoid
• Lever (17) and rod (19), which are installed to (19), if rod (2) is pushed up, nut (10) is held in
the rotating shaft of potentiometer (16), are inter- contact with bushing (8).
connected, so a voltage matching the up or • As a result, rod (2) is held at the pushed up po-
down movement of the rod is output from poten- sition, so even if the lever is released, it is held
tiometer (16). at the RAISE position.
HM400-1 10-185
5. Dump control lever RAISE canceled

• When lever (1) is returned from the RAISE posi-
tion, it is pushed down by a force greater than
the attraction force of the solenoid.
Or, when the solenoid power source is turned
OFF, the RAISE position is canceled and the
lever returns to the N position.
10-186 HM400-1
PLM-HM
Structure of system
SJH01469
1. Shift lever neutral detection switch (relay)

2. Body sensor
3. Inclinometer
4. Pressure sensor (for front left)
5. Pressure sensor (for front right)
6. Pressure sensor (for rear left)
7. Pressure sensor (for rear right)
8. Suspension cylinder
9. Payload meter
10. Lamp drive relay
11. External display lamp
12. Battery
13. Fuse (for external display lamp)
14. Fuse (for controller)
15. Memory card
16. Travel signal sensor
17. RS232C output (PC cable communication) socket
18. Battery charge signal (alternator terminal R)
19. Articulate angle sensor
HM400-1 10-187
(10)
Principle of calculation
1. Outline
The articulate dump truck is suspended by 6 wheels, front, central and rear pair of wheels. The front & rear
wheels are suspended by hydro-pneumatic suspension cylinder. The force Fr, which the rear wheel sus-
pends 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×Fr
The force Ff = Af × Pf ( Af : Suspension cylinder cross section, Pf : Suspension gas pressure )
1470
2. Measurement of weight when empty(calibration)

Drive the empty dump truck with 2nd gearshift and full throttle for 30 seconds. PLM-HM measures the
average of the suspended weight F(empty). PLM-HM uses this value as the weight when empty.
The reason why the weight is measured while the dump truck is traveling is that the frictional resistance of
the suspension cylinders must be averaged by extracting and retracting the cylinders by changing the con-
dition of the dump truck. The measured weight when empty is saved as a calibration data in the memory in
the controller.
3. Measurement of weight when full

Payload is measured by subtracting the suspended force F(empty) when empty from the suspended force
F(loaded) when loaded.
The PLM-HM has 3 measurement methods in which the timing to measure the payload is different.
1) Loading(during loading)
2) Traveling(during traveling)
3) Dumping(just before dumping)
These 3 methods are executed for each cycle. The result of the one method can be recorded for the cycle
data. The method to be recorded can be selected by the switch operation(service check mode). Which
method to be selected has to be considered the site conditions and the customer's needs.
Basically the accuracy of traveling method (default setting) is the best for normal conditions.
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°)
10-188 HM400-1
(10)
Method of using accurately
1. Suspension cylinder length

1) The PLM-HM calculate the payload by the signal of the suspension cylinder pressure sensors. Please
maintained the length of the suspension cylinder to be within nominal length. Please ask Komatsu dis-
tributor.
2. Calibration run
Calibration run has to be carried out when
1) The dump truck is shipped to the site
2) The dump body is modified(the weight of the dump truck is changed)
3) The gas of the suspension cylinder is maintained
4) Periodically(each season)
Calibration run need the flat, horizontal 100m straight course. If the course is not flat, horizontal or straight,
the accuracy of the calibration run could have error. It influence to the accuracy of payload measurement.
3. Traveling method
When the traveling method is selected to be stored,
1) The accuracy of traveling method depends on the road condition. The more flat the road is, the more
accurate. Please maintained the road conditions to get the higher accuracy.
2) The accuracy of traveling method depends on the distance of traveling. The longer the distance is, the
more accurate. It needs 100m measurement at shortest to get accuracy. The traveling measurement is
carried out only when the dump truck speed exceeds 8km/h and the incline of the road is within ±5°.
The haul road has to contain more than 100m which meets the condition above for Traveling method.
3) Rapid acceleration, braking and steering cause that the accuracy might be worre.
4. Dumping method (same as PLM II for rigid dump truck)

When the dumping method is selected,
1) The ground in the dumping area has to be well maintained.
2) The incline of the loading spot has to be within ±5°. If the incline exceeds ±5°, the accuracy is getting
worse.
3) Do not hit the dump truck to the wheel stopper too much. If the dump truck is hit to the wheel stopper
too much, the calculated payload might be much higher than the actual payload.
4) When the dump truck is stopped, please activate the parking brake and release the service brake or
retarder brake.
5) Please wait for raising the body until the pitching of the dump truck by braking is suspended. Normally
wait for dumping for 3 to 5 seconds to get accuracy after the parking brake is activated and the service
brake or retarder brake is released.
HM400-1 10-189
(10)
5. Loading method
To keep the accuracy of loading method(including external display lamps)
1) The better maintained the ground of loading spot is, the more accurate.
2) The incline of the loading spot has to be within ±5°. If the incline exceeds ±5°, the accuracy is getting
worse.
3) Stop the dump truck gently. Do not change the shift to neural position until the dump truck is stopped
completely.
4) 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.
5) Do not load the material before the dump truck is stopped completely.
6) The controller recognize the loading is finished when the dump truck travels more than 5m
after the loading is stared.
7) The equalizer bar hit the stopper
(1)If the equalizer bar hit the stopper, the accuracy would become very bad.
(2)The PLM-HM detect this hit when the empty dump truck stops at the loading spot. The PLM-HM
detects the equalizer bar to be hit the stopper, then the error code 'F-FL' is displayed in the PLM-HM
payload meter display, and all the external display lamps are flashed.
(3)Do not load when all the external display lamps are flashed.
(4)If the error code 'F-FL' comes out, please move the dump truck forward a little bit and stop until the
'F-FL' disappears.
(5)When move the dump truck forward, please shift the transmission to drive range. When stop the
dump truck, please shift the transmission to neutral range after the dump track is completely
stopped.
1471
6. Download
1) The PLM-HM stores the cycle data for 2,900 cycles(normally more than 1 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 the all data before overwriting.
10-190 HM400-1
(10)
General locations of payload meter
1. Display
2. Communication "receiving" lamp
(Rx busy)
3. Communication "transmitting" lamp I
(Tx busy)
4. Memory card access lamp SVH00461
(CARD busy) (not used)
5. Mode switch
6. Calibration/clear switch
7. Total/shift switch
8. Light/increment switch
9. Memory card (not used)
10. Cover
★ Communication "transmitting" lamp (3) lights up

even when the communication cable is not con-
nected to a.
★ PC or when there is defective connection.
When not inserting or removing memory card
(9),always keep cover(10) closed.
HM400-1 10-191
(10)
Left face
SVH00722
★ The switches are adjusted before the machine is shipped.

Do not touch any other switch.
10-192 HM400-1
(10)
Basic functions
1. Power ON
When the power is turned ON, all functions are checked and displayed.
Power ON
Display portion 8.8.:8.8. (3 seconds) External display lamps all ON

Buzzer sounds (green, yellow and red)
(30 sec)
Machine model display (8 seconds)

C0 : 00 o HM400-1
Weight unit setting

US : - - o Metric tons
US : oo o Short tons (US tons)
Machine ID (3 seconds)
d.xxx (xxx o 0 - 200 shows code for set input)
Opened ID (3 seconds)
o.xxx (xxx o 0 - 200 shows code for set input)
Normal operation display
2. Measuring empty weight (calibration)

The weight of the dump truck when empty is measured and this is used as the calibration data.
These data are retained even when the power is turned OFF.
HM400-1 10-193
(10)
3. Normal operation display
Display during normal operations

Gearshift lever Dump truck Payload meter External display
Condition of the machine
position position display lamps
Stopped N seated Time OFF
When empty
Traveling Except N seated Time OFF
Payload display and
Stopped N seated Payload[ton]
During display of estimate
loading Traveling
Traveling(*1) Except N seated OFF
distance[m]
Stopped N seated Payload[ton] Payload display
When loaded
Traveling Except N seated Time OFF
Total payload
When dumping N unseated o seated OFF
(*2)[100 ton]
When
See ABNORMALITY DISPLAY
abnormality is — — —
(error code)
happened
*1. When load is less than 50% of correct weight, display shows 0 t.
*2. The aggregate weight display is shown in units of 100 t. (rounded to the nearest 100)
4. External display lamp drive

(estimated display)
The chart on the below shows the payload display level for the external display lamps during the normal
operation display.
This threshold can be modified by the key operation in the service check mode.
Color of lamp HM400-1

1 Green 18.5 tons and up
2 Yellow 33.3 tons and up
3 Red 38.3 tons and up
9JR01841
The estimated display shows the estimation of
the total payload when one more load is added.
The applicable lamp flashes to prevent overload.
If current payload is 30 ton and the last bucket
was 7 ton for example, the green lamp is turned
on from the table above. The estimated payload
for next bucket is 37 ton. Then the yellow lamp is
flashed.
If the red lamp is flashed, one more bucket reaches over the red threshold and it will be overloaded.
10-194 HM400-1
(10)
5. Content of memory (for details, see operation manual)
1) Cycle data
• The period between one dumping operation and the next dumping operation is taken as one cycle and
the data are recorded.
• The cycle data are 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 cycles, the error message 'F-11' is coming out in the display.
Item Unit Range
Engine operation number Integer 1 – 65,535
Month Month 1 – 12
Day Day 1 – 31
Time hour Hour Displayed as 0 – 23

Displays value and set value
Time minute Minute 0 – 59 at time of dumping
Machine ID Integer 0 – 200
Open ID Integer 0 – 200
Payload MT OR ST 0 – 6,553.5
Warning items/cycle
(MT: Metric ton, ST: Short ton)
HM400-1 10-195
(10)
2) Engine ON/OFF data

• Each time the engine was stopped and started is recorded.
• The maximum limit in memory for engine ON/OFF data is 115.
• If the data is over 105, the error message 'F-12' is coming out. In this case, please download the data
and clear the data.
Item Unit Range
Engine operation number Integer 1 – 65,535 Consecutive number for operation of engine
Year (last 2 digits) Year 0 – 99
Shows when engine was
Day Day 1 – 31
switched ON
Time minute Minute 0 – 59
Shows when engine was
Day Day 1 – 31
switched OFF
Aggregate payload MT OR ST 0 – 9,999,000 Total value between engine ON and

engine OFF
Total number of cycles Times 0 – 9,999
10-196 HM400-1
(10)
3) Abnormality, warning data

a Each time a payload meter abnormality or warning is generated or cancelled is recorded.
The maximum limit in memory for abnormality or warning data is 230 generated/cancelled sets.
Item Unit Range
Engine operation number when

Integer 1 – 65,535
error code was generated
Frequency of generation
Times 1 – 255
after engine is switched ON
Day Day 1 – 31 Shows when error code was

generated
Time hour Hour(0 – 23) Displayed as 0 – 23
Engine operation number

Integer 0 – 65,535
when cancelled
Month Month 1 – 12 Shows when error code was

cancelled
Day Day 1 – 31
Time hour Hour (0 – 23) Displayed as 0 – 23
HM400-1 10-197
(10)
6. Forced display of aggregate payload, total number of cycles

By operating the [TOTAL/SFT] switch of PLM-HM, it is possible to carry
out forcible display of these items. For details, see the Operation Manual.
7. Operator check mode

By operating the switch of PLM-HM, it is possible to carry out the following items.
For details, see the Operation and Maintenance Manual.
1) Data all clear
2) Machine ID setting
3) Open ID setting
4) Time, date correction
8. Dimming of display portion

It is possible to adjust the brightness of PLM-HM display portion to 10 levels with the [LIGHT/INC] switch
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 software manual provided by Komatsu.
10. Service check mode

By operating the switches of PLM-HM, it is possible to forcibly carry out display, setting, and correction of
the following items.
a) Detailed calibration data display
The display shows the date, suspension pressure, etc. when the latest calibration was carried
b) Data all clear (service area)
This forcibly deletes all the calibration data and analog data, except for the latest calibration data.
a Before clearing the data, always download the data to a PC or carry out (a) Card dump.
c) Input signal condition display
This displays some of the signal conditions for the sensors input to PLM-HM and the present recogni-
tion condition of the payload meter.
d) Forced initialization
This forcibly deletes all the data in PLM-HM. PLM-HM becomes just same as the one when the control-
ler is shipped from the factory.
• Before carrying out this operation, check the time and date. Always carry out the 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 the calibration run
are necessary to be done again.
10-198 HM400-1
(10)
e) Parameter setting
This allows to modify the parameter setting.
Display Item Unit Default Min Max

1. 5 Loading completion travel distance m 5 5 999
2. 10 Loading start threshold % 10 5 25
3. 0.0 Payload offset ton 0.0 -5.0 5.0
4.100 Payload gain % 100 80 120
5. 0.0 Loading payload offset ton 0.0 -5.0 5.0
6. 05 Travel mode min. speed km/h 8 1 20
7. 05 Travel mode max incline deg 5 5 10
8. 50 Green lamp threshold(X1) % 50 50 X1
9.090 Orange lamp threshold(X2) % 90 X1 X3
A.105 Red lamp threshold(X3) % 105 X2 120
b. 2 Store mode — 2 1 3
C. 2.0 Stopper-hit threshold ton 2.0 2.0 5.0
d. 50 Dump completion threshold % 50 10 50
E. 1.0 Stable payload threshold ton 2.0 0.5 3.0
F. 0 External display lamps check mode — 0 0 3
H.000 Machine Code (0:HM400) — 0 0 0
J.000 payload unit (0:ton,1:short ton) — 0 0 1
L.000 Area code (1:Australia, 0:other) — 0 0 1
P.100 C1 % 100 80 120
U.100 C2 % 100 80 120
G.100 C3 % 100 80 120
y.100 C4 % 100 80 120
1) Loading completion travel distance

If the truck moves this distance after loading, PLM-HM recognize the loading is completed. After the
recognize of loading completion, the estimate function of the external display doesn't work. The default
setting is 5m.
2) Loading start threshold

If the calculated payload becomes over this threshold, PLM-HM recognizes the loading is started. And
the difference between the current payload and the last payload is over this threshold, PLM-HM recog-
nizes one more bucket is loaded. The default is 10%. This default setting must work for 8 bucket load-
ing. If the bucket of the loader or excavator is too small for this truck, the count of buckets might be less
than actual. In this case, this setting has to be modified less value(7 to 8%).
HM400-1 10-199
(10)
3) Payload offset, payload gain

If the calculated payload has an error compared with the payload measured by the scale, this setting
and the next setting(payload gain) allows to adjust the payload.
(The adjusted payload) = (Payload gain) × (Calculated payload) + (Payload off set)
To modify these setting, do not set the value by few data because the data has deviation. To do this, at
least 5 cycles measuremet is necessary.
If the error is almost constant according to the payload, 'Payload offset' has to be modified. For exam-
ple, HM-PLM shows 1 ton more than the actual for 25.9 ton(70%) payload and 37.0 ton(100%) payload.
'Payload gain' has to be set as '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, HM-PLM shows 1 ton more for 70% payload and 2 ton more for 100% payload, 'Payload
offset' has to be set as '-1.5' and 'Payload gain' has to be set as ‘91’.
4) Loading payload offset

If only the calculated payload when loading has an error and the stored paylaod doesn't have an error,
this setting allows to adjust the payload display when loading. Normally the ground condition impacts to
the accuracy of the paylaod when loading. Please check the ground condition first.
5) Travel mode min. speed

PLM-HM calculates the paylaod by averaging the data during the traveling in the traveling mode. Nor-
mally the ground condition is very rough when the vehicle speed is low. If the ground condition is very
rough, the accuracy tends to be worse. PLM-HM averages the data only when the vehicle speed is over
this threshold. The default setting is 8 km/h. This setting is all right for almost all condition. But if the
truck speed is very slow for a long time and the accuracy of traveling mode is not good enough, this
threshold can be modified to less value(5-6 km/h).
6) Travel mode max incline

PLM-HM calculates the paylaod by averaging the data during the traveling in the traveling mode. Nor-
mally when the slope is steep, the accuracy tends to be worse. PLM-HM averages the data only when
the slope is less steep than this thireshold. The default setting is 5 degree. This setting is all right for
almost all condition. But if the major part of the haul load has more than 5 degree slope and the accu-
racy of traveling mode is not good enough, this threshold can be modifed to larger value(7-8 degree).
7) Green/Yellow/Red lamp threshold

The default setting is 50% for green, 90% for yellow and 105% for red lamp same as the rigid dump
truck. The more tight setting, for example 80% for green, 95% for yellow and 105% for red, enables
more precise indication. We never recommend to make the red lamp threshold to be higher than 105%.
8) Store mode
PLM-HM has 3 measurement methods as described before. But only 1 measurement method is stored
and can be downloaded. Komatsu service has to recommend 1 method corresponding to the site con-
dition and the customer needs and set it to PLM-HM controller.
Guideline is
• Traveling mode is the most accurate. If not any special reason, choose traveling mode.
• If the haul road is very rough or very short(less than 200m) and the dumping area is well maintained,
choose Dumping mode.
• If the customer wants to store the payload displayed during loading, choose loading mode.
9) Stopper-hit threshold
If the equalizer bar hits to the stopper, the accuracy of the payload when loading becomes very bad as
described before. PLM-HM recognize the hitting if the calculated payload is over this threshold when
the empty vehicle stops at the loading spot. The default setting is 2 ton. If PLM-HM recognize the hit-
ting, the error message 'F-FL' is coming out. If this detection is too sensitive, this threshold can be mod-
ifed to the higher value(3.0 ton). But this causes the fail to detect the hitting. Please take care when the
setting is modified.
10-200 HM400-1
(10)
10) Dump completion threshold

PLM-HM recognize the dump completion when the paylaod becomes under this threshold during the
dumping. There is no need to modify this parameter.
11) Stable payload threshold

The calculated payload changes dynamically when loading. PLM-HM waits for the calcula-
tion until the calculated payload becomes stable. This threshold is the one PLM-HM recog-
nize the calculated payload to be stable. This setting(2 ton) is all right for almost all condition. This
impacts to 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(1 ton). In this case, the time delay to display the
lamps after loading might be longer.
12) Externa lamps check mode

This is used for the local installation of HM-PLM. See LOCAL INSTALLATION.
13) Machine Code

HM-PLM is available for only HM400-1. '0' means 'HM-400-1'. This setting cannot be modified right
now.
14) payload unit

PLM-HM has 2 units for payload display. '0' means 'metric ton', '1' means 'short ton(US ton)'.
15) Area code
16)
If the area is in Australia, it has to be set '1' and to be set '0' for the other area. It impacts to the open
ID in the download data. If the area code is set '1'(Australia), the open ID is not recorded in the down-
load data.
17) C1,C2,C3,C4
The formaulation to calculate the payload is described simply as below.
(Calculated paylaod) = C1*(Sum of the front suspension cylinder pressure)
+ C2*(Sum of the rear suspension cylinder pressure)
+ C3*(incline) + C4(offset)
This setting can modify these parameter. If the accuracy is not good enough even if the parameter
tuning for 'payload offset' and 'payload gain', this parameter tuning is necessary. Do not change these
setting without confirmation to the development center.
HM400-1 10-201
(10)
Key operation
The chart below describes the key operation tree.
(Power on)
3sec 8888
8sec C0:00
3sec US:--
3sec dX:XX
3sec oX:XX
(normal display)
empty 12:34 clock

loading 34.5 payload
run 3 distance
loaded 12:34 clock
stop 34.5 payload
run 12:34 clock
dumping 12 total payload
empty 12:34 clock
(Calibration run)
CAL(2sec) CAL Calibration run mode
CAL(2sec) CAL Calibration run ready
>9Km/h 13 elapsed time
30sec 0.5 calculated payload
MODE normal display
(Open ID)
MODE o0:00 Open ID
MODE normal display
(Operator check mode)

MODE(2sec) o.CHE
MODE Cd.dP
TOTAL Cd.dP memory card dump ready
TOTAL (blank) momory card dump
MODE d.000 Machine ID

MODE :0.4 calendar set
TOTAL :04 year
TOTAL 12:23 month:date
TOTAL 12:23 month:date
TOTAL 12:34 hour:min
TOTAL 12:34 hour:min
MODE aC:LE all clear
CAL(2sec) aC:LE all clear ready
CAL(2sec) : executing
MODE normal display
(Service check mode)

MODE+LIGHT C.HEC
(Service input signal check mode)
CAL+TOTAL
(2sec) S.CHE
CAL 11.50 Pressure sensor[FL][V]

MODE S.CHE return to S.CHE by MODE switch
CAL 21.50 Pressure sensor[FR][V]
CAL 31.50 Pressure sensor[RL][V]
CAL 41.50 Pressure sensor[RR][V]
CAL 53.00 Inclinometer[V]
CAL 63.80 Backup battery[V]
CAL 78.31 R-terminal[V]
CAL 83.00 Articulate sensor[V]
CAL 9312 Pressure sensor[FL][MPa]
CAL a312 Pressure sensor[FR][MPa]
CAL b312 Pressure sensor[RL][MPa]
CAL C312 Pressure sensor[RR][MPa]
CAL d3.12 Inclinometer[deg]
CAL E12.3 Articulate sensor[deg]
CAL F 1 Neutral signal
CAL H 1 Body seated signal
CAL J12.3 Velocity[km/h]
CAL L34.5 Current payload[t]
CAL P 2.3 Calibrate load[t]
CAL U 1 Vehicle state mode
CAL G18.0 Sensor power supply[V]
CAL y27.2 Power supply
CAL S.CHE Service check mode
10-202 HM400-1
(10)
MODE C.HEC
(Service setting mode)

TOTAL+INC(2sec) S.SEL
CAL 1. 5 Loading completion travel distance[m]

MODE S.SEL return to S.SEL by MODE switch
CAL 2. 10 Loading start threshold[t]
CAL 3. 0.0 Payload offset[t]
CAL 4.100 Payload gain[%]
CAL 5. 0.0 Loading payload offset[t]
CAL 6. 05 Travel mode min. speed[km/h]
CAL 7. 05 Travel mode max incline[deg]
CAL 8. 50 Green lamp threshold[%]
CAL 9.090 Orange lamp threshold[%]
CAL A.105 Red lamp threshold[%]
CAL b. 2 Store mode
CAL C. 2.0 Stopper-hit threshold[t]
CAL d. 50 Dump completion threshold[%]
CAL E. 1.0 Stable payload threshold[t]
CAL F. 0 External lamps check mode
Machine Code
CAL H.000 0:HM400
payload unit
CAL J.000 0:ton,1:short ton
Area code
CAL L.000 1:Australia, 0:other
CAL P.100 C1
CAL U.100 C2
CAL G.100 C3
CAL y.100 C4
CAL S.SEL
MODE C.HEC
(Service calibration mode)

CAL(2sec) CAL.0
(Service calibration check mode)
CAL YY year of calibration
MODE CAL.0 Return to CAL.0 by MODE switch
CAL MM:DD Month:Date of calibration
CAL HH:mm Hour:Min. of calibration
CAL 4XXX Pressure sensor[FL][MPa]
CAL 5XXX Pressure sensor[FR][MPa]
CAL 6XXX Pressure sensor[RL][MPa]
CAL 7XXX Pressure sensor[RR][MPa]
CAL 8XX.X Calibration payload[t]
CAL CAL.0
(Inclinometer calibration)
CAL+TOTAL(2sec) CAL.1
3sec CAL.2
CAL(2sec) CAL.2
3sec CHEC
MODE C.HEC
(Forcibly initialize mode)

CAL+TOTAL+
LIGHT(2sec) AC:LE Forcibly initialize ready
CAL(2sec) AC:LE execution
completed normal display
HM400-1 10-203
(10)
Key operation and the display includes

1) Power on procedure
2) Normal display
3) Calibration run mode
4) Open ID input
5) Operator check mode
6) Service check mode
1) to 5) are explained in operation manual. The key switch operation for 6)Service check mode is explained in
this section.
10-204 HM400-1
(10)
Service check mode
Service check mode has

1) Service input signal check mode
2) Service calibration data mode
3) Service setting mode
4) Forcibly initialize mode
1) To enter the service check mode

When the display is in normal display mode, press [MODE] switch (1) and [LIGHT/INC] switch (2) simulta-
neously for more than 2 seconds, 'CHEC' is flashing. This means service check mode.
2) To return to the normal display mode

Press [MODE] switch (1), then the display is returned to normal display.
HM400-1 10-205
(10)
1. Service input signal check mode
1) To enter the service input signal check mode

• When the display is in service check
mode('CHEC' is flashed), press [CAL/CLR]
switch (1) and [TOTAL/SFT] switch (2)
simultaneously for more than 2 seconds.
• 'S.CHE' is flashed. This means the service
input signal check mode.
2) To check the signal input

.
• Then press [CAL/CLR] switch (1), then Display Contents

'1X.XX'(the most left digit is flashed) is
11.50 Pressure sensor[FL][V]
displayed. The most left digit flashed shows
the number of the item. X.XX means the 21.50 Pressure sensor[FR][V]
voltage of the pressure sensor for the front 31.50 Pressure sensor[RL][V]
left suspension cylinder. 41.50 Pressure sensor[RR][V]
• Press [CAL/CLR] switch (1) to see the next
53.00 Inclinometer[V]
content according to the table as right.
When [CAL/CLR] is pressed at the last 63.80 Backup battery[V]
content of power supply voltage 'y27.2', the 78.31 R-terminal[V]
display is returned to 'S.CHE'. 83.00 Articulate sensor[V]
• If you want to check the signal again, press
9312 Pressure sensor[FL][MPa]
[CAL/CLR] switch (1) again.
a312 Pressure sensor[FR][MPa]
3) To return to the service check mode b312 Pressure sensor[RL][MPa]
Press [MODE] switch (3) at any process above, C312 Pressure sensor[RR][MPa]
the display is returned to service check mode
d3.12 Inclinometer[deg]
and 'CHEC' is flashed
E12.3 Articulate sensor[deg]
F 1 Neutral signal
H 1 Body seated signal
J12.3 Velocity[km/h]
L34.5 Current payload[t]
P 2.3 Calibrate load[t]
U 1 Vehicle state mode
G18.0 Sensor power supply[V]
y27.2 Power supply
10-206 HM400-1
(10)
2. Service calibration data mode
1) To enter the service calibration data mode

• When the display is in the service check
mode('CHEC' is flashed), press [CAL/CLR]
switch (1) for more than 2 seconds.
• 'CAL0' is flashed. This means the service
calibration data mode.
2) To check the calibration data

• Then press [CAL/CLR] switch (1), then 'XX' Display Content
is displayed. XX means the year of the
YY Year of calibration
calibration executed.
• Press [CAL/CLR] switch (1) to see the next MM:DD Month:Date of calibration
content according to the table as right. HH:mm Hour:Min. of calibration
When [CAL/CLR] switch (1) is pressed at 4XXX Pressure sensor[FL][MPa]
the last content of calibration
5XXX Pressure sensor[FR][MPa]
paylaod[8XX.X], the display is returned to
'CAL0'. 6XXX Pressure sensor[RL][MPa]
• If you want to check the signal again, press 7XXX Pressure sensor[RR][MPa]
[CAL/CLR] switch (1) again. 8XX.X Calibration payload[t]
3) To return to the service check mode
Press [MODE] switch (3) at any process above.
'CHEC' is flahsed and the display is returned to
the service check mode.
4) To enter the inclinometer calibration mode Key operation Display

• When the display is 'CAL0' flashed, press CAL+TOTAL(2sec) CAL.1
[CAL/CLR] switch (1) and [TOTAL/SFT]
3sec CAL.2
switch (2) simultaneously for more than 2
seconds. CAL(2sec) CAL.2
• 'CAL1' is flashed. See LOCAL INSTALLA- 3sec CHEC
TION about the detail of this procudure.
HM400-1 10-207
(10)
3. Service setting mode
1) To enter service setting mode

• When the display is in the service check
mode('CHEC' is flashed), press [TOTAL/
SFT] switch (2) and [LIGHT/INC] switch (3)
simultaneously for more than 2 seconds.
• '5.5EL' is flashed. Press [CAL/CLR] switch
(1) to move to the next item.
2) To modify the parameter setting

• The most left digit flashed shows the Display Item
number of the item selected. The 3 right
1. 5 Loading completion travel distance[m]
digits are the parameter value. The flashed
digit in this 3 digits is the one which is 2. 10 Loading start threshold[t]
selected to be modified. 3. 0.0 Payload offset[t]
• Press [TOTAL/SFT] switch (2) to change the 4.100 Payload gain[%]
digit to be modified. The flashed digit moves
5. 0.0 Loading payload offset[t]
from right to left. Press [LIGHT/INC] switch
(3) to increase the value one by one. 6. 05 Travel mode min. speed[km/h]
• If [LIGHT/INC] switch (3) is pressed when 7. 05 Travel mode max incline[deg]
the flashed digit is '9', then change to '0'. 8. 50 Green lamp threshold[%]
3) To return to service check mode 9.090 Orange lamp threshold[%]

Press [MODE] switch (4) then 'CHEC' is flashed A.105 Red lamp threshold[%]
and the display is returned to the service check b. 2 Store mode
mode.
C. 2.0 Stopper-hit threshold[t]
d. 50 Dump completion threshold[%]
E. 1.0 Stable payload threshold[t]
F. 0 External lamps check mode
H.000 Machine Code 0:HM400
J.000 Payload unit 0:ton,1:short ton
L.000 Area code 1:Australia, 0:other
P.100 C1
U.100 C2
G.100 C3
y.100 C4
10-208 HM400-1
(10)
4. Forcibly initialization mode
• Press [CAL/CLR] switch (1), [TOTAL/SFT]

switch (2) and [LIGHT/INC] switch (3)
simultaneously for more than 2 seconds,
then 'ACLE' is flashed.
• This means the forcibly initialize mode is
ready. Press [CAL/CLR] switch (1) for more
than 2 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 initialization is
completed.
Remarks
• Do not carry out this forcibly initialize mode
if not necessary. All the data including the
calibration data is cleared.
• After the execution of this mode, all procedure
for local installation is necessary.
HM400-1 10-209
(10)
Sensors
1) Pressure sensor
• The pressure sensor is installed at the
bottom end of the suspension 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) include a check valve and
prevents the pressure from going down.
• The out put characteristics of the sensor are

as shown in the diagram on the right.
2) Inclinometer
• To carry out compensation on slopes, the
inlinometer measures the longitudinal tilt
angle of the chassis. It is installed at the real
frame.
• The out put characteristics of the inclinometer

are as shown in the diagram on the right.
10-210 HM400-1
(10)
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 6.3mm.
4) Articulate angle sensor

Articulate angle sensor detects the articulate an-
gle between the front and rear frame.
HM400-1 10-211
(10)
Error code table

External
Problems if Pand Error code
NO. Content Explanation display Trouble shooting Remarks
this happen display recorded
lamps
When engine
Battery voltage
Drop in backup is shut off, F-09 Change the battery
1
battery voltage
lower than the
stored data flashes — 000-009
to new one (*1)
nominal. might be lost.
It impacts to Check the signal

the function condition display
Disconnection Voltage of R- F-18
2 at R terminal terminal out of range and flashes — 000-018 check the (*1)
performance connector PM1,
of PLM D01A, D01B
Check the signal

condition display
Abnormality in Voltage of sensor It impacts to F-20 ALL check the
3 sensor power power lower than
the accuracy flashes flash
000-020 connector PM2 or (*1),(*2)
source(18V) the nominal. the harness for
Suspension
pressure sensors.
Short circuit or Check the signal

disconnection in
front left Voltage of pressure It impacts to F-21 ALL condition display
4
suspension sensor out of range the accuracy flashes flash
000-021 check the (*1),(*2)
connector SUFL,
pressure sensor
system JPLM, PM2
Short circuit or
disconnection in Check the signal
condition display
front right Voltage of pressure It impacts to F-22 ALL
5
000-022 check the (*1),(*2)
pressure sensor connector SUFR,
JPLM, PM2
system
Short circuit or
Check the signal
disconnection in condition display
rear left Voltage of pressure It impacts to F-23 ALL
6 suspension sensor out of range the accuracy flashes flash 000-023 check the (*1),(*2)
connector SURL,
pressure sensor JPLM, PM2
system
Short circuit or Check the signal

disconnection in
rear right Voltage of pressure It impacts to F-24 ALL condition display
7
000-024 check the (*1),(*2)
connector SURR,
pressure sensor
JPLM, PM2
system
Short circuit
Check the signal
with power condition display
source for front Voltage of pressure It impacts to F-25 ALL
8 left suspension sensor out of range the accuracy flashes flash 000-025 check the (*1),(*2)
connector SUFL,
pressure sensor JPLM, PM2
system
Short circuit
Check the signal
with power
condition display
source for front Voltage of pressure It impacts to F-26 ALL
9
right suspension sensor out of range the accuracy flashes flash
000-026 check the (*1),(*2)
connector SUFR,
pressure sensor
JPLM, PM2
system
Short circuit
Check the signal
with power
condition display
source for rear Voltage of pressure It impacts to F-27 ALL
10
left suspension sensor out of range the accuracy flashes flash
000-027 check the (*1),(*2)
connector SURL,
pressure sensor
JPLM, PM2
system
Short circuit
Check the signal
with power
condition display
source for rear Voltage of pressure It impacts to F-28 ALL
11
right suspension sensor out of range the accuracy flashes flash
000-028 check the (*1),(*2)
connector SURR,
pressure sensor
JPLM, PM2
system
10-212 HM400-1
(10)
External
Problems if Pand Error code
NO. Content Explanation display Trouble shooting Remarks
this happen display recorded
lamps
Check the signal

Short circuit or
Voltage of condition display
disconnection in It impacts to F-31 ALL
12
inclinometer
inclinometer out of
the accuracy flashes flash
000-031 check the (*1),(*2)
range connector PCL,
system
JPLM, PM2
Check the signal

Short circuit or
Voltage of articulate condition display
disconnection in F-33
13
articulate angle
angle sensor out of
flashes
— 000-033 check the (*1),(*2)
range connector PANG,
sensor system
JPLM, PM2
External
Short circuit in Check the relay
display lamp F-41 ALL
14 green external —
doesn't work flashes flash
000-041 RPM,RPMG or (*1)
display lamp harness
correctly
External
15 yellow external —
000-042 RPM,RPMY or (*1)
correctly
External
16 red external —
000-043 RPM,RPMR or (*1)
correctly
Cycle data is Download the

Cycle data Old data is F-11
17
memory FULL
recorded for more
over-written flashes
— 000-011 cycle data and (*3)
than 2,600 cycles clear the data
Engine data is Download the

Engine data Old data is F-12
18
memory FULL
recorded for more
over-written flashes
— 000-012 Engine data and (*4)
than 105 times clear the data
Calibration run
PLM doesn't F-19 ALL Carry out the
19 not yet carried —
work. flashes flash
—
calibration run
(*1)
out
Inclinometer Carry out the

PLM doesn't F-17 ALL
20 calibration not —
work. flashes flash
— inclinometer (*1)
yet carried out calibration
Accuracy Move the vehicle

Equalizer bar hit when loading F-FL ALL for the equalizer
21
to the stopper
—
becomes very flashes flash

bar not to be hit to
(*5)
bad the stopper
Too much Accuracy

F-AC ALL Steer the vehicle
22 articulated when — when dumping
flashes flash

straight
(*6)
dumping becomes bad
*1. Please call KOMATSU distributor.
*2. Calibration run cannot be carried out when this has occurred.
*3.Cycle data memory FULL.

1) If more than 2,600 cycles are recorded (less than 300 cycles remaining),L:FULL flashes.
2) If more cycle are recorded. Cycles 2,901 and 2,902 are recorded, the older cycle data is deleted in
turn to make space to recorded the new cycle.
3) If this warning occur, please download the data and clear the all data[see Data all clear].
HM400-1 10-213
(10)
*4. Engine ON/OFF data

1) If more than 105 sets are recorded(less than 10 sets remaining) :E:FULL flashes.
2) If more sets are recorded, sets 116 and 117 are recorded, the oldest ON/OFF data is deleted in
turn to make space to record the new set.
3) This warning occur, please download the data and clear the all data{see Data all clear}
*5. Equalizer bar hit the stopper

1) If the equalizer bar hit the stopper, the accuracy would become very bad. The PLM-HM detect this
hit when the empty dump truck is stopped at the loading spot.
2) If the error code ‘F-FLEis displayed in the PLM-HM display panel, please move forward the dump
truck a little bit and stop the dump truck until the ‘F-FLEdisappears. When move the dump truck
forward, please shift the transmission to drive range. When stop the dump truck, please shift the
transmission to Neutral range after the dump truck is completely stopped.
*6. Too much articulated 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 worse. The articulated angle is more than 22.5 degree
(half of full range), this fault code is activated. If this fault code is activated, please steer the dump truck
to be straight.
10-214 HM400-1
(10)
Local installation
1. Preparation
1) Before this procedure is carried out, check the suspension length. If the suspension length is out of
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.
2) Check the dump body to be empty. If mud is on the dump body or on the chassis, clean it. It impacts
the accuracy.
3) The procedure below has to be carried out with Installation checklist for articulate dump truck PLM.
4) Calibration needs about 120m straight course with flat and horizontal ground.
5) The more straight, the more accurate. The more flat and horizontal, the more accurate.
6) Park the dump truck on the flat and horizontal ground.
7) Set the articulate straight. Mark the dump truck position on the ground.
8) Turn off engine.
Remarks
1) If 'press switch' without 'for more than 2 seconds' in the direction below, press switch for 0.5 seconds to
1 seconds.
2) If you make a mistake of switch operation, MODE switch is effective for recovering in most situations.
3) If you fail to the procedure below, turn off the key and start from the beginning again.
HM400-1 10-215
(10)
2. PLM-HM controller check
1) Turn on the key switch.
2) Display '8.8.:8.8.' and buzzer sounds for 3 seconds.
3) Display 'C0:00' (it means machine model code = 0[HM400-1]) for about 8 seconds. Buzzer sounds 1
second again(error detection for F.ICL, and F.CAL).
4) Display 'd0:00' (it means machine ID = 0) for 3 seconds.
5) Display 'o0:00' (it means open ID = 0) for 3 seconds.
6) Display 2 fault 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.
7) If there are the other fault codes displayed, please check.
3. External display lamp check

1) Press MODE switch and LIGHT switch simultaneously for more than 2 seconds. The display flashes
'CHEC' (it means service check mode).
2) Press TOTAL switch and LIGHT switch simultaneously for more than 2 seconds. The display flashes
'S.SEL' (it means service setting mode).
3) Press CAL switch 15 times. The display is changing from '1._ _ 5' to 'f._ _ 0'('f' means 'external display
lamp check mode'). The symbol '_' above means the 'space'.
4) Make sure that all the external lamps has to be flashed(it means error 'F-FL' and 'F.ICL' to be
detected).
5) Press LIGHT switch. The display is 'f._ _ 1'. Make sure that only the green lamp has to be turned on.
10-216 HM400-1
(10)
6) Press LIGHT switch. The display is 'f._ _ 2'. Make sure that only the yellow lamp has to be turned on.
7) Press LIGHT switch. The display is 'f._ _ 3'. Make sure that only the red lamp has to be turned on.
8) Press LIGHT switch. The display is 'f._ _ 0'. Make sure that all the lamps has to be flashed.
9) If the lamps does not work correctly, please check the connector around the lamps or around the relay
circuit.
4. Setting
1) Press CAL switch 2 times. The display is 'J._ _ 0'('J' means 'payload weight unit setting mode'. '0'
means metric ton unit). If you want to change the unit to short ton, press TOTAL switch, then the dis-
play is 'J._ _ 1'(short ton).
2) 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).
3) Press MODE switch. The display flashes 'CHEC' (it means service check mode).
5. Input signal check

1) Start engine.
2) Press CAL switch and TOTAL switch simultaneously for more than 2 seconds. The display flashes
'S.CHE' (it means service input signal check mode).
3) Press CAL switch. The display is '1X . XX' ('1' is flashed). The right 3 digit shows the voltage of front
left suspension pressure sensor. Write down the value on the check sheet. ). If the value is out of
range, check the wiring or sensor install.
4) Press CAL switch. The display is '2X . XX' ('2' is flashed). The right 3 digit shows the voltage of front
right suspension pressure sensor. Write down the value on the check sheet. ). If the value is out of
5) Press CAL switch. The display is '3X . XX' ('3' is flashed). The right 3 digit shows the voltage of rear left
suspension pressure sensor. Write down the value on the check sheet. ). If the value is out of range,
check the wiring or sensor install.
6) Press CAL switch. The display is '4X . XX' ('4' is flashed). The right 3 digit shows the voltage of rear
right suspension pressure sensor. Write down the value on the check sheet. ). If the value is out of
7) Press CAL switch. The display is '5X . XX' ('5' is flashed). The right 3 digit shows the voltage of Incli-
nometer. ). If the value is out of range, check the wiring or sensor install.
8) Press CAL switch. The display is '6X . XX' ('6' is flashed). The right 3 digit shows the voltage of the
backup battery. Write down the value on the check sheet. ). If the value is out of range, the backup bat-
tery has to be replaced to new one.
9) Press CAL switch. The display is '7X . XX' ('7' is flashed). The right 3 digit shows the voltage of R ter-
minal. 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.
HM400-1 10-217
(10)
10) Press CAL switch. The display is '8X . XX' ('8' is flashed). The right 3 digit shows the voltage of articu-
late sensor. (write down the value on the check sheet. ). If the value is out of range, check the wiring or
sensor install.
11) Press CAL switch 6 times. The display is 'F_ _ 1' ('F' is flashed). The most right digit shows the neutral
signal( 1 : neutral, 0 : 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.
12) Press CAL switch. The display is 'H_ _ 1' ('H' is flashed). The most right digit shows the body seated
signal( 1 : seated, 0 : not seated ). Raise the dump body and the display on 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.
13) Press CAL switch. The display is 'J_ _.0' ('J' is flashed). The most 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 12Km/h. (Check on the check sheet. ). If the value is not correct, check the wiring.
14) Press MODE switch. The display flashes 'CHEC'. Press Mode switch again. Display 2 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.
6. Inclinometer & articulate sensor calibration
1) Start engine.
2) Inclinometer will be calibrated by measuring

2 opposite direction of the vehicle and by
averaging sensor inputs of these 2 times.
The longitudinal incline of the ground must
be canceled. But the more horizontal the
ground is, the more accurate. Please find
the flat and horizontal area for this calibra-
tion. The accuracy of the inclinometer
impacts the accuracy of payload meter.
This process has to be done very carefully.
3) Make sure the articulate to be straight. The articulate sensor will be calibrated as 'straight' at this posi-
tion. Please set the articulate to be straight carefully.
5) Press CAL switch for more than 2 seconds. The display flashes 'CAL.0'(service calibration data check
mode)
10-218 HM400-1
(10)
6) Press CAL switch and TOTAL switch simultaneously for more than 2 seconds. 'CAL.1'(it means Incli-
nometer calibration mode) will be displayed and the calibration for Inclinometer and articulate sensor
are executed for 3 seconds. 'CAL.2' will be flashed after 3 seconds.
7) Turn around the dump trck and park the

dump truck with opposite direction on the
exactly same position above.
8) Press CAL switch for more than 2 seconds.
'CAL.2' will be turned on and the calibration
for Inclinometer and articulate sensor are
calibrated for 3 seconds again for opposite
direction. 'CHEC' will be flashed after the
calibration is finished.
9) Press MODE switch. The error code 'F.ICL'
must be turned off and only 'F.CAL' is
flashed. This means the inclinometer cali-
bration was successfully finished. 'F-.FL'
might be flashed, it's no problem.
7. Calibration run
1) 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.
2) Park the dump truck on the flat and horizontal ground. Calibration run needs about 120m straight and
flat course.
3) Press CAL switch for more than 2 seconds. ' CAL' will be flashed.
4) If you are ready to start, press CAL switch. ' CAL' will be lighted up.
5) Shift the transmission to 2nd range.
6) Press throttle pedal full. After the velocity becomes over 9Km/h, the display counts up the elapsed
time(seconds). Calibration run needs 30 seconds run.
7) After 30 seconds counted up, the current calculated payload[ton] will be displayed.
8) 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.
9) Write down the current payload. The displayed payload has to be around 0 ton because the dump
truck is empty.
10) 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.
11) Write down the current payload.
12) All external lamp has to be turned off.
13) This calibration run has to be done periodically by the customer. Please induce the way to do it to the
customer.
HM400-1 10-219
(10)
8. Clock set
1) Clock is set for Japanese standard time. The date and the hour might be modified to the local time.
2) Press MODE switch for more than 2 seconds. The display flashes 'oCHE' (it means operator check
mode).
3) Press MODE switch. The display is 'd000' (it means machine ID).
4) Press MODE switch. The display is '_ _ YZ' ('Z' is flashed, YZ means lower 2 digits of year. 'YZ' for
2003 is '03').
5) If 'Z' has to be corrected, press LIGHT switch, then 'Z' is increased.
6) Press TOTAL switch. The display is '_ _ YZ' ('Y' is flashed, YZ means lower 2 digits of year. 'YZ' for
2003 is '03').
7) If 'Y' has to be corrected, press LIGHT switch, then 'Y' is increased.
8) Press TOTAL switch. The display is 'MM:dd' ('MM' is flashed, MM means month, dd means day).
9) If 'MM' has to be corrected, press LIGHT switch, then 'MM' is increased.
10) Press TOTAL switch. The display is 'MM:dd' ('dd' is flashed, MM means month, dd means day).
11) If 'dd' has to be corrected, press LIGHT switch, then 'dd' is increased.
12) Press TOTAL switch. The display is 'HH.mm' ('HH' is flashed, HH means hour, mm means minutes ).
13) If 'HH' has to be corrected, press LIGHT switch, then 'HH' is increased.
14) Press TOTAL switch. The display is 'HH:mm' ('mm' is flashed ).
15) If 'mm' has to be corrected, press LIGHT switch, then 'mm' is increased.
16) Press MODE switch. The display is 'A.CLE'('CLE' is flashed).
17) Press MODE switch. The clock has to be displayed.
9. Set store mode

1) This PLM-HM has 3 measurement method, dumping method, traveling method and loading method,
are implemented. These 3 methods are carried out for corresponding stage of each cycle. But only the
payload by 1 method is stored and can be downloaded. Komatsu service can set which method to be
recorded by switch operation in the PLM-HM controller.
2) Each method has its pros and cons. The method to be recorded has to be decided by the site condition
and the customers request.
3) The general guide line is as below

(1) Traveling method is the most accurate for almost site.
(2) If all the haul road is very rough or the distance of haul road is less than 200m,
a. If the ground of the dumping area is flat and the incline is less than ±5°., dumping method can be
selected.
b. If the ground of the dumping area is not flat or the incline is more than ±5°., the dumping method
cannot be selected.
(3) If the customer wants to have the payload data at the loading spot, loading method can be selected.
10-220 HM400-1
(10)
5) Press TOTAL switch and LIGHT switch simultaneously for more than 2 seconds. The display flashes
'S.SEL' (it means service setting mode).
6) 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) o 'b _ _ 1'(dumping method) o 'b._ _ 2'(traveling
mode). Write down the mode you set on the check sheet.
7) After the mode is selected, press MODE switch. The display flashes 'CHEC' (it means service check
mode).
8) Press MODE switch again. The display shows the clock.
10.Trial test
1) Try 1 cycle including loading, traveling and dumping with almost 100% payload.
2) Please read 'To keep the accuracy' in the operation manual.
3) Check the display working correctly as the table below.
Gearshift Payload
Condition of machine Dump truck position External display lamp
lever position display panel
Stopped N Seated Time OFF

When empty
Traveling Except N Seated Time OFF
Payload display and

Stopped N Seated Payload
display of estimate
During loading
Traveling
Traveling(*1) Except N Seated OFF
distance
Stopped N Seated Payload Payload display

When loaded
Traveling Except N Seated Time OFF
Total payload
When dumping N Unseated o seated OFF
(*2)
When abnormal- See ABNORMALITY DISPLAY

— — —
ity is happened (error code)
*1. When load is less than 50% of correct weight, display shows 0 t.
*2. The aggregate weight display is shown in units of 100 t. (rounded to the nearest 100)
4) Download the data. Check the data in the cycle data (payload, dumping time) to be correct.
HM400-1 10-221
(10)
11.Data clear
1) Press MODE switch for more than 2 seconds. The display flashes 'oCHE' (it means operator check
mode).
2) Press MODE switch. The display is 'd000' (it means machine ID).
3) Press MODE switch. The display is '_ _ YZ' ('Z' is flashed, YZ means lower 2 digits of year. 'YZ' for
2003 is '03').
4) Press MODE switch. The display is 'A.CLE'('CLE' is flashed).
5) Press CAL switch for more than 2 seconds. The display is 'A.CLE'('A.CLE' is flashed).
6) Press CAL switch for more than 2 seconds. The display is 'A.CLE'('A.CLE is lighted up). All clear of the
cycle data and fault history will be started.
7) After all clear, the display becomes clock set.
8) Turn off engine.
10-222 HM400-1
(10)
20 TESTING AND ADJUSTING
STANDARD VALUE TABLES

Standard value table for engine.......................................................................................................... 20- 2
Standard value table for chassis......................................................................................................... 20- 3
Standard value table for electrical parts ............................................................................................. 20- 7
TESTING AND ADJUSTING ..................................................................................................................... 20-101
TROUBLESHOOTING .............................................................................................................................. 20-301
HM400-1 20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE
Machine model HM400-1
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) {mmHg} {min. 1,000) {min. 840}
Whole speed range (ambient

Exhaust temperature ºC Max. 650 Max. 700
temperature: 20ºC)
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 0.35 –

mm
(normal temperature) Exhaust valve 0.57 –
kPa
Oil temperature: 40 – 60ºC 4.12 {42} 2.84 {29}
Compression pressure {kg/cm2}
(engine speed) (200 - 250) (200 - 250)
(rpm)
Water temperature: Within

kPa 1.96 3.92
Blow-by pressure operating range
{mmH2O} {200} {400}
At rated output
Water temperature:
Within operating range
At high idling
SAE30 or SAE15W-40 oil 0.34 – 0.54 {3.5 – 5.0} Min. 0.21 {min. 2.1}
MPa
Oil pressure SAE10W oil 0.29 – 0.49 {3.0 – 5.0} Min. 0.18 {min. 1.8}
{kg/cm2}
At low idling
SAE30 or SAE15W-40 oil 0.12 {1.2} Min. 0.07 {min. 0.7}
SAE10W oil 0.10 {1.0} Min. 0.07 {min. 0.7}
Whole speed range

Oil temperature ºC 80 – 110 Max. 120
(inside oil pan)
Deflection when pressed 13 – 15 (When new) 13 – 15 (When new)

Fan belt tension with finger force of approx. mm 17 – 19 (When 17 – 19 (When
98 N {10 kg} adjusting tension) adjusting tension)
Deflection when pressed

Alternator belt tension with finger force of approx. mm 13 – 16 13 – 16
98 N {10 kg} (for 1 belt)
Deflection when pressed

Air conditioner compres-
with finger force of approx. mm 10 10
sor belt tension
58.8 N {6 kg}
20-2 HM400-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS
Cate- Standard value Service limit

Item Measurement conditions Unit
gory for new machine value
Operating effort • Point 150 mm from Starting to 17.7 ± 4.9 17.7 ± 4.9
pedal fulcrum depress N {1.8 ± 0.5} {1.8 ± 0.5}
Fully {kg} 42.2 +2.0
–4.9 42.2 +2.0
–4.9
depressed {4.3 +0.2
–0.5
} {4.3 +0.2
–0.5
}
Travel Point 150 mm from pedal fulcrum mm 45 ± 5 45 ± 5
Torque converter • Engine water tem-

lock-up actuation perature: Within 1,400 ± 50 1,400 ± 50
speed operating range
Torque converter • Torque converter oil Brake ON 950 ± 50 950 ± 50
temperature: Within rpm
lock-up cancel
speed operating range Brake OFF 850 ± 50 850 ± 50
• Hydraulic oil temper-
Torque converter
ature: 45 - 55ºC 1,809 ± 100 1,809 ± 100
stall speed
Transmission shift- • Engine water tem-
2,150 ± 50 2,150 ± 50
up speed perature: Within Normal
Transmission shift- operating range mode
• Torque converter oil 1,250 ± 50 1,250 ± 50
down speed
temperature: Within
Transmission shift-
operating range rpm 2,200 ± 50 2,200 ± 50
up speed
• Hydraulic oil temper- Brake mode
Transmission shift- ature: 45 - 55ºC 1.550 ± 50 1.550 ± 50
down speed • Brake mode: Accel-
Transmission down- erator OFF or brake
1.550 ± 50 1.550 ± 50
shift inhibit speed ON
Overrun prevention
2,600 ± 10 2,600 ± 10
actuation speed
rpm
Overrun prevention
2,350 ± 10 2,350 ± 10
cancel speed
• Center of lever grip N 21.6 ± 3.9 Max. 19.6
Operating effort • Between each position {kg} {2.2 ± 0.45} {Max. 2.0}
mm
Travel 24.5 ± 1 24.5 ± 2
• Torque converter oil 2.62 ± 0.15 2.62 ± 0.15

Low idling
Power train main temperature: Within MPa {26.7 ± 1.5} {26.7 ± 1.5}
relief pressure operating range {kg/cm2} 2.33 ± 0.15 2.33 ± 0.15
• Gearshift lever: N High idling
{23.8 ± 1.5} {23.8 ± 1.5}
Torque converter • Torque converter oil temperature: 0.90 ± 0.10 0.90 ± 0.10
inlet port pressure Within operating range {9.2 ± 1.0} {9.2 ± 1.0}
Torque converter • Engine speed: High idling 0.59 ± 0.10 0.59 ± 0.10
MPa
outlet port pressure {6.0 ± 1.0} {6.0 ± 1.0}
{kg/cm2}
Torque converter
1.81 ± 0.15 1.81 ± 0.15
lock-up clutch pres-
{18.5 ± 1.5} {18.5 ± 1.5}
sure
Transmission Lo • Torque converter oil temperature: 2.55 ± 0.15 2.55 ± 0.15
clutch pressure Within operating range MPa {26.0 ± 1.5} {26.0 ± 1.5}
Transmission Hi • Engine speed: High idling {kg/cm2} 2.55 ± 0.15 2.55 ± 0.15
clutch pressure {26.0 ± 1.5} {26.0 ± 1.5}
HM400-1 20-3
1
6

Transmission 1st • Torque converter oil temperature: 2.55 ± 0.15 2.55 ± 0.15
clutch pressure Within operating range {26.0 ± 1.5} {26.0 ± 1.5}
Transmission 2nd • Engine speed: High idling 2.55 ± 0.15 2.55 ± 0.15
clutch pressure {26.0 ± 1.5} {26.0 ± 1.5}
Transmission 3rd 2.45 ± 0.15 2.45 ± 0.15
Oil pressure
clutch pressure {25.0 ± 1.5} {25.0 ± 1.5}

MPa
Transmission R 2.55 ± 0.15 2.55 ± 0.15
{kg/cm2}
clutch pressure {26.0 ± 1.5} {26.0 ± 1.5}
Inter-axle differential 2.55 ± 0.15 2.55 ± 0.15
lock clutch pressure {26.0 ± 1.5} {26.0 ± 1.5}
Transmission lubri-
Power train
0.20 ± 0.04 0.20 ± 0.04

cating pressure
{2.0 ± 0.4} {2.0 ± 0.4}
(reference)
F1 • Flat ground 7.2 ± 5% 7.2 ± 5%
F2 • Engine water temperature: Within 11.0 ± 5% 11.0 ± 5%
operating range
F3 16.9 ± 5% 16.9 ± 5%
Travel speed
• Torque converter oil temperature:

F4 Within operating range 25.8 ± 5% 25.8 ± 5%
km/h
F5 • Dump body: Unloaded 39.4 ± 5% 39.4 ± 5%
F6 • Travel resistance: 3.3% 58.6 ± 5% 58.6 ± 5%
R1 7.4 ± 5% 7.4 ± 5%
R2 17.5 ± 5% 17.5 ± 5%
• Standard tire: 29.5 - R25 MPa 0.372 0.372
Tire inflation pressure
• Dump body: Unloaded {kg/cm2} {3.8} {3.8}
• Engine speed: High idling 25 ± 2.5 25 ± 2.5
Front differential
Differential lock
• Left and right differential lock {2.45 ± 0.25} {2.45 ± 0.25}

Oil pressure
switch: ON
MPa
• Left and right differential lock 25 ± 2.5 25 ± 2.5
Center differential {kg/cm2}
pedal: Depressed {2.45 ± 0.25} {2.45 ± 0.25}
25 ± 2.5 25 ± 2.5
Rear differential
{2.45 ± 0.25} {2.45 ± 0.25}
• Tip of pedal N Max. 294 Max. 294
Brake pedal
Operating effort
{kg} {max. 30} {max. 30}
Travel mm 40 ± 5 40 ± 5
Brakes
• Point 10 mm from tip of lever N 5.9 – 9.8 3.0 – 14.7

lever (q1)
Operating effort
Retarder
{kg} {0.6 – 1.0} {0.3 – 1.5}
Travel mm 78 –20 78 –40
q1. Not installed in E-SPEC.
20-4 HM400-1
(7)
1

Charge valve cut-in • Wheel brake actuation pressure: 11.77 +0.29
0 11.77 +0.29
0
pressure Actuation pressure when brake is {120 +3.00 } {120 +3.00 }
Charge valve cut-out operated for first time after engine 20.59 +0.98 20.59 +0.98
0 0
pressure is stopped {120 +100 } {120 +100 }
• Drop in wheel brake actuation
Wheel brake actua- 4.9 ± 0.49 4.9 ± 0.49
pressure: Drop in pressure 5 min-
tion pressure MPa {50 ± 5} {50 ± 5}
utes after specified oil pressure
Drop in wheel brake (4.9 MPa {50 kg/cm2}) is applied {kg/cm2} Max. 40.49 Max. 40.49
actuation pressure • Parking, exhaust brake actuation {max. 5} {max. 5}
Parking brake actu- pressure: Engine at high idling 3.92 ± 0.25 3.92 ± 0.25
ation pressure Parking brake switch: ON {40 ± 2.5} {40 ± 2.5}
Exhaust brake actu- Exhaust brake switch: ON 0.59 ± 0.10 0.59 ± 0.10
ation pressure {6.0 ± 1.0} {6.0 ± 1.0}
Foot brake braking • Engine speed: High idling
1,510 1,510
performance • Gearshift lever: D
Retarder brake • Torque converter stall speed
braking performance rpm
Overrun protection 1,400 1,400
brake braking per-
formance
• Flat, dry road surface
Foot brake braking
• When load is 36.3 t m Max. 22.3 Max. 22.3
distance
• Travel speed: 32 km/h
• Engine at high idling
Braking perform-
• Gearshift lever: D rpm 1,400 1,400
ance
• Engine stall speed
• When load is 36.3 t
Braking slope angle % Min. 25 Min. 25
• Slope angle (sin θ)
• 9 ± 1% downhill slope
Emergency brake braking
• When load is 36.3 t m Max. 102 Max. 102
distance
• Travel speed: 50 ± 3 km/h
• Engine speed: Low idling N Max. 29.4 Max. 35.3
Operating effort
• Gearshift lever: N (stopped) {kg} {max. 3.0} {max. 3.6}
Play • Measure at circumference of steer- mm Max. 150 Max. 150
ing wheel
No. of turns Turns 4.0 ± 0.4 4.0 ± 0.6
• Operating effort: When turning at
10 rpm
• Play: Until point where tires start to
Turning time move Sec. Max. 4 Max. 5
• No. of turns: Lock - lock
• Turning time: Lock - lock
• Hydraulic oil temperature: 45 - 55ºC MPa 20.59 +0.49
-0.39 20.59 +0.49
-0.39
Steering relief pressure
• Engine speed: High idling {kg/cm2} {210 +5
-4 } {210 +5
-4 }
Installed length (a) • Horizontal road surface mm 163 ± 5 163 ± 5

• Dump body: Unloaded MPa 3.92 ± 0.15 3.92 ± 0.15
Pressure
{kg/cm2} {40.0 ± 1.5} {40.0 ± 1.5}
Installed length (a) mm 101 ± 5 101 ± 5
MPa 3.92 ± 0.15 3.92 ± 0.15

Pressure
{kg/cm2} {40.0 ± 1.5} {40.0 ± 1.5}
HM400-1 20-5
1
6

• Engine stopped HOLD → Max. 29.4 Max. 35.3
• Center of grip RAISE {max. 3.0} {max. 3.6}
RAISE → Must return smoothly when
HOLD engine is at high idling
HOLD → Max. 29.4 Max. 35.3
FLOAT N {max. 3.0} {max. 3.6}
Dump lever operating effort
FLOAT → {kg} Max. 29.4 Max. 35.3
HOLD {max. 3.0} {max. 3.6}
FLOAT → Max. 29.4 Max. 35.3
LOWER {max. 3.0} {max. 3.6}
LOWER → Must return smoothly when
FLOAT engine is at 2000 rpm
Lifting time • Hydraulic oil temperature: 70 - 90ºC 12 ± 1.5 12 ± 1.5
• Engine speed: High idling
Sec.
Lowering time • Lowering time when operating Max. 13 Max. 13
FLOAT
• Hydraulic oil temperature: 70 - 90ºC
• Hold at point where No. 2 cylinder
is extended 100 mm
Hydraulic drift Sec. Max. 85 Max. 170
• Engine stopped
• Downward movement at tip of
dump body over 5 minutes
• Hydraulic oil temperature: 45 - 55ºC 20.59 ± 0.49 20.59 ± 0.49
Dump main relief pressure
• Engine speed: High idling {210 ± 5} {210 ± 5}
• Hydraulic oil temperature: 45 - 55ºC 3.4 ± 0.49 3.4 ± 0.49
MPa
• Engine speed: High idling {35 ± 5} {35 ± 5}
{kg/cm2}
Dump pilot relief pressure • Hydraulic oil temperature: 45 - 55ºC
2.6 ± 0.49 2.6 ± 0.49
• Engine speed: High idling
{27 ± 5} {27 ± 5}
(Reference value)
20-6 HM400-1
1
6
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Connector Inspection Measurement
System Name of component Judgement table
No. method conditions
If the condition is as shown in the table below, 1) Insert T-adapter

it is normal to AS1.
2) Turn starting
Potentiometer
switch ON.
Between (3) and (1) 4.6 – 5.4 V
Between (2) and (3) 0.3 – 4.5 V
Acceleration pedal Measure Switch

AS1
(throttle sensor) voltage Potentiome-
Pin Voltage
ter voltage
Between (5) Max. 0.446V Max. 1V
and (4) Min. 0.446V 15 – 30V
Between (6) Max. 0.446V 20 – 30V
and (4) Min. 0.446V Max. 1V
If the condition is as shown in the table below, 1) Turn starting

it is normal switch OFF.
Engine Ne rotation Measure
NE (male) Between (1) and (2) 85 – 210 2) Disconnect NE.
sensor resistance
Between (1)(2) and ground Min. 1MΩ

Engine G rotation sen- Measure it is normal switch OFF.
G (male) Between (1) and (2) 1.4kΩ – 3.5kΩ 2) Disconnect G.
sor resistance
Engine controller system

Resistance 2) Disconnect PSL.
Position Engine value
Engine oil low-pressure PSL Measure
switch (terminal) resistance Engine Max. 1Ω
Between stopped
switch terminal
and ground At 600 rpm and Min. 1 MΩ
above

Resistance 2) Disconnect PSH.
Position Engine value
Engine oil high- PSH Measure
pressure switch (terminal) resistance Engine Max. 1Ω
Between stopped
switch terminal
and ground At 1,300 rpm Min. 1 MΩ
and above

Engine water low- TWL Measure
Between (1) and (2) 9kΩ – 0.3kΩ 2) Disconnect TWL.
temperature sensor (male) resistance

switch OFF.
Engine water high- TWH Measure it is normal
Between (1) and (2) 90kΩ – 3.5kΩ 2) Disconnect TWH.

Fuel temperature Measure
THL (male) Between (1) and (2) 9kΩ – 0.3kΩ 2) Disconnect THL.
sensor resistance
HM400-1 20-7


2) Disconnect OF.
Position Oil filter Resistance
Engine oil filter clog- OF Measure value
ging switch (terminal) resistance
Between When normal Max. 1 Ω
switch terminal
and ground When clogged Min. 1 MΩ

2) Disconnect OL.
Pin Oil level Resistance
value
Measure
Engine oil level switch OL (male) When normal Max. 1 Ω
resistance Between (1)
and ground When low Min. 1 MΩ

it is normal to PIM.
Measure
Boost pressure sensor PIM (male) Between (1) and (3) 4.6 – 5.4 V 2) Turn starting
voltage
Between (2) and (3) 0.3 – 4.7 V switch ON.

it is normal to PFUEL.
Common rail fuel pres- PFUEL Measure
2) Turn starting
sure sensor (male) voltage Between (1) and (3) 4.6 – 5.4 V

Fuel supply pump PCV1 Measure
Between (1) and (2) 2.3 – 5.3 Ω 2) Disconnect PCV1.
PCV1 (male) resistance

Fuel supply pump PCV2 Measure
Between (1) and (2) 2.3 – 5.3 Ω 2) Disconnect PCV2.
PCV2 (male) resistance
Between (1)(2) and ground Min. 1 MΩ

Measure it is normal switch OFF.
No. 1 injector solenoid CN1 (male) Between (1) and (2) 0.4 – 1.1 Ω 2) Disconnect CN1.
resistance

Measure
resistance
1) Turn starting
If the condition is as shown in the table below,
it is normal
switch OFF.
Measure
No. 3 injector solenoid CN3 (male) 2) Disconnect CN3.
resistance Between (1) and (2) 0.4 – 1.1 Ω

1) Turn starting
Measure 2) Disconnect CN4.
No. 4 injector solenoid CN4 (male) Between (1) and (2) 0.4 – 1.1 Ω
resistance
20-8 HM400-1



Measure
resistance

Measure
resistance

it is normal to SF1.
Pin Gearshift lever position and 2) Turn starting
voltage switch ON.
Between (1) 20 – 30 V
and (2)
Between (3) R2: 20 – 30 V Other than
and (2) R2: Max. 1 V
Between (4) R1: 20 – 30V Other than
and (2) R1: Max. 1V
Between (5) N: 20 – 30 V Other than N:
and (2) Max. 1 V
Measure Between (6) D: 20 – 30 V Other than D:
Gearshift lever SF1 and (2) Max. 1 V
voltage
Between (7) 5: 20 – 30 V Other than 5:
and (2) Max. 1 V
and (2) Max. 1 V
and (2) Max. 1 V
and (2) Max. 1 V
Transmission controller system
and (2) Max. 1 V

Between (12) HOLD: 20 – Canceled:
and (2) 30 V Max. 1 V

it is normal to AS2.
Acceleration pedal Measure 2) Turn starting
AS2 Between (1) and (3) 4.5 – 5.4 V
(throttle sensor) voltage switch ON.
Between (2) and (3) 1.0 – 4.0 V

EREV Measure 2) Disconnect EREV.
Engine speed sensor Between (1) and (2) 500 – 1000Ω
(male) resistance

Resistance
2) Disconnect T11.
Air cleaner clogging Measure Pin Air cleaner value
T11 (male)
sensor resistance
Between (1) When normal Max. 1 Ω
and (2) When clogged Min. 1 MΩ

Radiator water Resistance 2) Disconnect T01.
Radiator water level Measure Pin level value
T01 (male)
switch resistance
and (2) When low Min. 1 MΩ
HM400-1 20-9

If the condition is as shown in the table below, 1) Disconnect termi-
it is normal nal R.
Position Engine Voltage 2) Start engine.
R, E Measure Between R Mid-range
Alternator speed or 27.6 – 29.5 V
terminal voltage and E above
★ If the battery is old, or after starting in
cold areas, the voltage may not rise for
some time.

2) Disconnect T08.
Pin Fuel level Resistance
Measure value
Fuel level sensor T08 (male)
resistance
Between (1) Full Max. 12 Ω
and (2) Empty 74 – 100 Ω

Transmission input Measure
N1 (male) Between (1) and (2) 500 – 1000 2) Disconnect N1.
shaft speed sensor resistance
Between (2) and (3) Min. 1 MΩ

Transmission it is normal switch OFF.

Measure
intermediate shaft N2 (male) Between (1) and (2) 500 – 1000 2) Disconnect N2.
resistance
speed sensor Between (1)(2) and ground Min. 1 MΩ

Transmission output Measure
N3 (male) Between (1) and (2) 500 – 1000 Ω 2) Disconnect N3.
shaft R speed sensor resistance

Resistance 2) Disconnect L/U-
Pin Clutch SW.
Lock-up clutch ECMV L/U-SW Measure value
fill switch (male) resistance When
Between (1) disengaged Min. 1 MΩ
and ground
When engaged Max. 1 Ω

Resistance 2) Disconnect R-SW.
Pin Clutch
R clutch ECMV fill R-SW Measure value
switch (male) resistance When
and ground

Resistance 2) Disconnect H-SW.
Pin Clutch value
Hi clutch ECMV fill H-SW Measure
and ground
20-10 HM400-1

Pin Clutch Resistance 2) Disconnect L-SW.
Lo clutch ECMV fill L-SW Measure value
switch (male) resistance When Min. 1 MΩ
Between (1) disengaged
and ground

Resistance
2) Disconnect 1-SW.
1st clutch ECMV fill 1-SW Measure Pin Clutch value
and ground

Resistance 2) Disconnect 2-SW.
Pin Clutch value
2nd clutch ECMV fill 2-SW Measure
switch (male) resistance When Min. 1 MΩ
Between (1) disengaged
and ground


Resistance 2) Disconnect 3-SW.
3rd clutch ECMV fill 3-SW Measure Pin Clutch value
and ground

Resistance 2) Disconnect D/L-
Differential lock clutch D/L-SW Measure Pin Clutch value SW.
ECMV fill switch (male) resistance When
and ground

Torque 2) Disconnect TC-
Resistance
Torque converter oil TC-SE Measure Pin converter oil value SE.
temperature
Between (1) 25 ºC 37kΩ – 50kΩ
and (2) 100 ºC 3.5kΩ – 4.0 kΩ

it is normal to TC-INT.
Torque converter oil TC-INT Measure
Between (2) and (1) 20 – 30 V 2) Turn starting
pressure sensor (male) voltage

Transmission Resistance 2) Disconnect T03.
Transmission oil filter Measure Pin oil filter value
T03 (male)
clogging switch resistance Max. 1 Ω
Between (1) When normal
HM400-1 20-11

Pin Transmission Resistance 2) Disconnect LUB-
Transmission valve oil LUB-T Measure oil temperature value
T.
temperature sensor (male) resistance 25 ºC 37kΩ – 50kΩ
Between (1)
and (2) 100 ºC 3.5kΩ – 4.0kΩ

Hydraulic oil Resistance
2) Disconnect T06.
Hydraulic tank oil level Measure Pin level value
T06 (male)
switch resistance
and (2) When low Min. 1 MΩ

Hydraulic oil Resistance 2) Disconnect T05.
Hydraulic oil filter Measure Pin filter value
T05 (male)
clogging switch resistance Max. 1 Ω
Between (1) When normal

switch OFF.
it is normal
Steering oil Resistance 2) Disconnect T04.
Steering oil Measure Pin temperature value
T04 (male)
temperature switch resistance 25 ºC Max. 1 Ω
Between (1)
and ground 123 ºC Min. 1 MΩ

Brake oil Resistance 2) Disconnect T15.
Front brake oil Measure Pin temperature value
T15 (male)
temperature sensor resistance
and (2) 100 ºC 3.5kΩ – 4.0 kΩ

Center brake oil Measure Pin temperature value
T14 (male)
and (2) 100 ºC 3.5kΩ – 4.0kΩ

Rear brake oil Measure Pin
T13 (male) temperature value
and (2) 100 ºC 3.5kΩ – 4 .0kΩ

it is normal to T10.
Measure Between (1) and (3) 11 – 13 V 2) Turn starting
Inclination sensor T10 (male) switch ON.
voltage 1.4 – 4.6 V
Between (2) and (3) (when horizontal:
2.9 – 3.1 V)
20-12 HM400-1


Lock-up clutch ECMV L/U-PS Measure 2) Disconnect L/U-
Between (1) and (2) 5 – 15 Ω
solenoid (male) resistance PS.

R clutch ECMV R-PS Measure 2) Disconnect R-PS.
Between (1) and (2) 5 – 15 Ω
solenoid (male) resistance

Hi clutch ECMV H-PS Measure
solenoid (male) resistance Between (1) and (2) 5 – 15 Ω 2) Disconnect H-PS.

Lo clutch ECMV L-PS Measure
Between (1) and (2) 5 – 15 Ω 2) Disconnect L-PS.

1st clutch ECMV 1-PS Measure
Between (1) and (2) 5 – 15 Ω 2) Disconnect 1-PS.

2nd clutch ECMV 2-PS Measure

3rd clutch ECMV 3-PS Measure

Differential lock clutch D/L-PS Measure
Between (1) and (2) 5 – 15 Ω 2) Disconnect D/L-
ECMV solenoid (male) resistance
Between (1)(2) and ground Min. 1MΩ PS.
1) Turn starting
q

it is normal
switch OFF.
Transmission output FE1 Measure
2) Disconnect FE1.
shaft F speed sensor (male) resistance Between (1) and (2) 500 – 1000 Ω

1) Disconnect B39.
it is normal 2) Start engine.
Pin Differential lock Resistance

oil pressure value
Front differential lock Measure
B39 (male) Max. 0.39 MPa
oil pressure switch resistance 2 Min. 1 MΩ
Between (1) {Max. 4 kg/cm }
and (2) Min. 0.59 MPa
Max. 1 Ω
{Min. 6 kg/cm2}
q1. Used as the brake controller in E-SPEC.
HM400-1 20-13
6
1

If the condition is as shown in the table below, 1) Disconnect B40.
Pin Differential lock Resistance
oil pressure value
Rear differential lock Measure
oil pressure switch resistance 2 Min. 1 MΩ
Max. 1 Ω
{Min. 6 kg/cm2}
If the condition is as shown in the table below, 1) Insert T-adapter to

it is normal B25.
Front accumulator oil Measure
B25 (male) Between (2) and (1) 20 – 30V 2) Turn starting
pressure sensor voltage
If the condition is as shown in the table below, 1) Insert T-adapter to

Rear accumulator oil Measure it is normal B24.
B24 (male) Between (1) and (2) 20 – 30 V 2) Turn starting
pressure sensor voltage
Between (1)(2) and ground 1.8 – 3.5 V switch ON.
If the condition is as shown in the table below, Measuring voltage

it is normal 1) Insert T-adapter to
RTL.
Potentiometer
2) Turn starting
Between (1) and (3) 4.1 – 4.8 V
switch ON.
Between (2) and (3) 0.3 – 4.7 V
Measuring resistance
1) Turn starting
Measure Switch
q
Resistance switch OFF.

voltage, Pin (male) Lever position
Retarder lever RTL value 2) Disconnect RTL.
measure
resistance Released Max. 1 Ω
Between (4) position
and (6) Applied
position Min. 1 MΩ
Released Min. 1 MΩ
Between (5) position
and (6) Applied
position Max. 1 Ω

Resistance 2) Disconnect B03.
Brake cooling filter Measure Pin Retarder filter
B03 (male) value
clogging sensor resistance

Pin Brake oil Resistance
Foot brake oil pressure Measure pressure value
switch resistance 2 Min. 1 MΩ
Max. 1 Ω
{Min. 6 kg/cm2}

Pin Brake oil Resistance

Retarder oil pressure Measure pressure value
switch resistance 2 Min. 1 MΩ
Max. 1 Ω
{Min. 6 kg/cm2}
20-14 HM400-1
1
6

Pin Parking brake Resistance
Parking brake oil Measure value
B17 (male)
pressure switch resistance
Between (1) When released Min. 1 MΩ
and (2) When applied Max. 1 Ω

Exhaust brake oil Measure Pin Exhaust brake Resistance

B30 (male) value
pressure switch resistance
Between (1) When released Min. 1 MΩ
and (2) When applied Max. 1 Ω

Front brake (L.H.) Measure Pin Brake value
B01 (male)
wear switch resistance When normal Max. 1 Ω
Between (1)
and (2) When worn Min. 1 MΩ

q
Front brake (R.H.) Measure Pin Brake value

B28 (male)
Between (1)

Center brake (L.H.) Measure Pin Brake value
B02 (male)
wear switch resistance

Center brake (R.H.) Measure Pin Brake value
B26 (male)

Rear brake (L.H.) Measure Pin Brake value
B05 (male)
Between (1)

Resistance
2) Disconnect B05.
Rear brake (R.H.) Measure Pin Brake value
B08 (male)
HM400-1 20-15
6
1


it is normal to HSL.
2) Turn starting
Dump lever Measure Between (4) and (1) 4.6 – 5.4 V
HSL switch ON.
(potentiometer) voltage Between (3) and (1) 0.3 – 4.7 V
Between (2) and (1) 0.3 – 4.7 V

it is normal to B34.
Body positioner Measure 2) Turn starting
B34 (male) Between (3) and (1) 4.6 – 5.4 V
sensor voltage switch ON.
Between (2) and (1) 0.3 – 4.7 V

Front differential lock Measure
B35 (male) Between (1) and (2) 20 Ω 2) Disconnect B35.
solenoid resistance

Rear differential lock Measure
solenoid resistance
q

Front brake pressure Measure
reducing valve resistance

Rear brake pressure Measure
reducing valve resistance

switch OFF.
Exhaust brake Measure it is normal
B29 (male) Between (1) and (2) 20 – 60 Ω 2) Disconnect B29.
solenoid resistance

Dump lever (kick-out Measure
LKO (male) Between (1) and (2) 39Ω ± 5% 2) Disconnect LKO.
solenoid) resistance
1) Turn starting
it is normal
switch OFF.
Dump pilot valve Measure
B31 (male) 2) Disconnect B31.
(selector solenoid) resistance Between (1) and (2) Approx. 30 Ω

1) Turn starting
Dump pilot valve (EPC Measure 2) Disconnect B32.
B32 (male) Between (1) and (2) Approx. 30 Ω
solenoid) resistance
20-16 HM400-1
1
6

Pin Switch Resistance 2) Disconnect CK1.
Machine monitor Measure value
CK1 (male)
check switch resistance Released Max. 1 Ω
Between (3)
and (6) Pressed Min. 1 MΩ

Resistance 2) Disconnect CH1.
Pin Switch value
Machine mode Measure
CH1 (male) Between (2) [!] Pressed Max. 1Ω
selector switch 1 resistance and (3) Neutral Min. 1 MΩ
Between (1) Neutral Min. 1 MΩ
and (3) ["] Pressed Max. 1 Ω

Resistance 2) Disconnect CH2.
Pin Switch value
Machine mode Measure [>] Pressed Max. 1 Ω
CH2 (male) Between (2)
selector switch 2 resistance and (3) Neutral Min. 1 MΩ
and (3) [<] Pressed Max. 1 Ω
Machine monitor system

Resistance 2) Disconnect PWM.
Power mode selector PWM Measure Pin Switch value
switch (male) resistance
Between (1) Up Min. 1 MΩ
and (3) Down Max. 1 Ω

Resistance 2) Disconnect AISS.
AISS Measure Pin Switch value
AISS LOW switch
(male) resistance

Resistance 2) Disconnect DFL.
Pin Switch value
Left and right Measure Up Max. 1 Ω
DFL (male) Between (1)
differential lock switch resistance and (3) Neutral Min. 1 MΩ

Resistance 2) Disconnect DFS.
Left and right Measure Pin Pedal value
DFS (male)
differential lock pedal resistance Released Min. 1 MΩ
Between (A)
and (B) Depressed Max. 1 Ω
HM400-1 20-17

Pin Switch Resistance 2) Disconnect DEF.
Inter-axle differential Measure value
DEF (male)
lock switch resistance Up Min. 1 MΩ
Between (1)

Machine monitor system

2) Disconnect EXH.
Pin Switch Resistance
value
Measure
Exhaust brake switch EXH (male) Between (1) Up Max. 1 Ω
resistance and (2) Neutral Min. 1 MΩ

Resistance 2) Disconnect SBS.
Measure Pin Belt value
Seat belt switch SBS (male)
resistance Removed Min. 1 MΩ
Between (1)
and (2) Fitted Max. 1 Ω

Resistance 2) Disconnect WRF.
Working lamp (front) WRF Measure Pin Switch value

Resistance 2) Disconnect WRR.
Working lamp (rear) WRR Measure Pin Switch value
Others (other than controllers)

Resistance 2) Disconnect HAZ.
Measure Pin Switch value
Hazard lamp switch HAZ (male)
resistance

it is normal to LS.
Night lighting dimmer Measure Between (1) and (3) 20 – 30 V
2) Turn starting
LS
switch voltage switch ON.
Between (2) and (3) 6 – 27 V

Resistance
2) Disconnect FOG.
FOG Measure Pin Switch
Fog lamp switch value
(male) resistance
20-18 HM400-1

Yellow rotating lamp Measure Pin Switch Resistance 2) Disconnect BLS.
BLS (male) value
switch resistance Up Min. 1 MΩ
Between (1)

Resistance 2) Disconnect SDE.
Measure Pin Switch value
Side lamp switch SDE (male)
resistance

Position Switch Resistance 2) Disconnect ST1
Emergency steering ST Measure value
and ST2.
switch (terminal) resistance OFF Min. 1 MΩ
Between ST1
and ST2 ON Max. 1 Ω

Measure Resistance 2) Disconnect R33.
Pin Switch
Parking brake switch R33 (male) value

resistance

Differential lock Resistance 2) Disconnect B21.
Pin oil pressure value
Front accumulator oil Measure
pressure switch resistance 2 Min. 1 MΩ
Max. 1 Ω
{Min. 60 kg/cm2}

Differential lock Resistance 2) Disconnect B20.
Pin oil pressure value
Rear accumulator oil Measure
Min. 1 MΩ
pressure switch resistance 2
Max. 1 Ω
{Min. 60 kg/cm2}

Parking brake Measure Between (1) and (2) 30 – 50 Ω 2) Disconnect B14.
B14 (male)
solenoid resistance
Between (1)(2) and Min. 1 MΩ
ground

Between (1) and (2) 100 – 500 Ω 2) Disconnect relay
Measure
Relay (5-pin type) (male) connector.
resistance Between (5) and (5) Min. 1 MΩ
Between (3) and (6) Max. 1 Ω
HM400-1 20-19


Between (5) and (6) 100 – 500 Ω 2) Disconnect relay
Measure connector.
Relay (6-pin type) – (male)
resistance Between (1) and (2) Min. 1 MΩ
Between (3) and (4) Max. 1 Ω

2) Disconnect CM.
Switch (1) (2) (3) ★ Between con-
Measure
Lamp switch CM (male) OFF nected pins:
resistance
Small # # Max. 1 Ω
Between other
Head # # #
pins: Min. 1 MΩ
Combination switch

it is normal
Measure Switch (4) (5)
Dimmer switch CM (male)
resistance OFF
PASS # #

it is normal
Switch (6) (7) (8)
Turn signal Measure
CM (male) L (left) # #
switch resistance
N #
R (right) # #

2) Disconnect WPS.
Switch (1) (2) (3) (4) (5) (6)
★ Between con-
OFF # # nected pins:
Front wiper WPS Measure # # Max. 1 Ω
INT Between other
switch (male) resistance # #
pins: Min. 1 MΩ
LOW # #
Wiper switchES
HIGH # #
WASH # #

it is normal
Switch (7) (8) (9) (10)
WASH # #
Rear wiper WPS Measure
OFF # #
ON # #
# #
WASH
# #
20-20 HM400-1
Tools for testing, adjusting, and troubleshooting ......................................................................................20-102

Measuring air supply pressure (boost pressure) ......................................................................................20-104
Measuring exhaust temperature ..............................................................................................................20-105
Measuring exhaust color .........................................................................................................................20-107
Measuring compression pressure ...........................................................................................................20-108
Adjusting valve clearance ........................................................................................................................20-109
Measuring blow-by pressure ...................................................................................................................20-110
Measuring engine oil pressure ................................................................................................................20-111
Handling equipment in fuel circuit ............................................................................................................20-112
Releasing remaining pressure in fuel system ..........................................................................................20-112
Measuring fuel pressure ..........................................................................................................................20-113
Bleeding air from fuel circuit ....................................................................................................................20-114
Reduced cylinder mode operation ...........................................................................................................20-115
Checking for leakage in fuel circuit ..........................................................................................................20-116
Adjusting engine speed sensor ...............................................................................................................20-117
Testing and adjusting fan belt tension ....................................................................................................20-118
Testing and adjusting alternator belt tension ...........................................................................................20-119
Testing and adjusting air conditioner compressor belt tension ................................................................20-119
Testing torque converter stall speed .......................................................................................................20-120
Measuring power train oil pressure .........................................................................................................20-121
Testing and adjusting left and right differential lock oil pressure
(machine with differential lock differential) ...............................................................................................20-129
Adjusting transmission speed sensor ......................................................................................................20-134
Testing and adjusting brake oil pressure .................................................................................................20-135
Testing brake performance ......................................................................................................................20-140
Bleeding air from brake circuit .................................................................................................................20-142
Testing wear of wheel brake disc ............................................................................................................20-144
Testing wear of parking brake pad ..........................................................................................................20-145
Method for emergency release of parking brake .....................................................................................20-147
Testing and adjusting steering circuit pressure .......................................................................................20-148
Testing and adjusting suspension cylinder ..............................................................................................20-150
Method of tilting cab up ...........................................................................................................................20-154
Testing and adjusting dump circuit pressure ...........................................................................................20-156
Adjusting body positioner sensor .............................................................................................................20-157
Procedure for adjusting length of spring in body heating spherical joint ..................................................20-158
Handling engine controller high-voltage circuit ........................................................................................20-158
Adjusting transmission controller .............................................................................................................20-159
Method for emergency escape when there is failure in electrical system ...............................................20-160
Adjusting machine monitor ......................................................................................................................20-164
Special functions of machine monitor ......................................................................................................20-168
HM400-1 20-101
(12)
1
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Measurement Item Symbol Part Number Part Name Remarks
-101 - -199.9kPa
Air supply pressure A 799-201-2202 Boost gauge kit
{-760 - 1,500mmHg}
Exhaust, water, and oil Digital temperature
B 799-101-1502 –99.9 – 1,299ºC
temperatures gauge
Handy Smoke
1 799-201-9001
Checker
Exhaust color C Bosch index: 0 – 9
Commercially
2 Smoke meter
available
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}
2.5 , 5.9, 39.2 , 58.8 MPa

799-101-5002 Hydraulic tester
{25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 58.8 MPa {600 kg/cm2}
799-401-2320 Hydraulic gauge 0.98 MPa {10 kg/cm2}
799-101-5220 Nipple
Oil pressure F M10 x P1.25
07002-11023 O-ring
799-101-5260 Nipple
M12 x P1.5
799-101-5270 Seal washer
799-101-5230 Nipple
M14 x P1.5
07002-11423 Seal washer
Brake oil pressure G 793-520-1805 Brake test kit
1 792-610-1000 Suspension tool H2 - H6: Pump assembly
Kit Part No.: 792-610-1100
2 792-610-1130 Pump
3 792-610-1110 Hose H7 - H13: Charging tool assembly
Kit Part No.: 792-610-1200
4 792-610-1120 Joint
5 07020-21732 Fitting
6 792-610-1140 Pump
Suspension cylinder H 7 792-610-1250 Valve

8 792-610-1260 Nipple
9 792-610-1480 Stem
10 792-610-1640 Joint
11 792-610-1400 Regulator
12 792-610-1430 Gauge 24.5MPa {250kg/cm2}
13 792-610-1440 Gauge 9.8MPa {100kg/cm2}
79A-264-0021 Push-pull scale 0 – 294 N {0 – 30 kg}
Operating effort H
79A-264-0091 Push-pull scale 0 – 490 N {0 – 50 kg}
20-102 HM400-1
(12)
1
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Measurement Item Symbol Part Number Part Name Remarks
Commercially
Stroke, hydraulic drift J Scale
available
Commercially
Work equipment speed K Stop watch
available
Voltage, resistance L 79A-264-0211 Tester
★ For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the machine
monitor, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, T-adapters list.
HM400-1 20-103
(11)
1
TESTING AND ADJUSTING MEASURING AIR SUPPLY PRESSURE
MEASURING AIR SUPPLY PRESSURE
k
(BOOST PRESSURE)
Be careful not to touch any hot parts when re- 5. Turn the parking brake switch ON, depress the
moving or installing the measuring tools. parking brake pedal, then set the gearshift lever
1. Open the engine hood.
2. Remove air supply pressure measurement plug

(1).
k
to the D position.
If the gearshift lever is operated to any po-
sition other than the D position, the ma-
chine may move off even if the brake is
being depressed, so always measure at the
D position.
6. Depress the accelerator pedal gradually, run the
engine at high idling and stall the torque convert-
k
er, then measure the air supply pressure.
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 opera-
tion.
★ After completing the measurement, run the
engine at low idling, then return the gearshift
lever to the N position.
3. Fit nipple and hose (1), then connect to boost
gauge A.
7. After completing the measurement, remove the

4. Run the engine at a mid-range speed or above measuring equipment and set to the original
to bleed the oil from inside the hose. condition.
★ Insert the connection of the hose and pressure

gauge about half way, repeat the action to open
the self-seal portion at the hose end, and bleed
the oil.
★ If Pm kit (A) is available, the air bleed coupling
(790- 261-1130) inside the kit can be used.
★ If there is oil inside the hose, the gauge will not
work, so always bleed the oil.
20-104 HM400-1
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
k
MEASURING EXHAUST TEMPERATURE
Wait for the temperature of the exhaust pipe to
go down before removing or installing the meas- 1) Start the engine and raise the temperature
uring equipment. of the cooling water to the operating range.
1. Open the engine hood and remove the adiabatic 2) Turn the parking brake switch ON, depress
cover of the turbocharger. the parking brake pedal, then set the gear-
2. Remove exhaust temperature measurement

plug (1).
k
shift lever to the D position.
If the gearshift lever is operated to any
position other than the D position, the
machine may move off even if the
brake is being depressed, so always
measure at the D position.
3) Depress the accelerator pedal gradually,
run the engine at high idling and stall the
torque converter. At the same time, oper-
ate the dump lever to the LOWER position
f
and relieve the oil pressure (full stall).
★ Continue until the exhaust temperature
k reaches the standard value of 650 C.

There is danger of damage to the inter-
nal parts of the transmission, so never
operate the gearshift lever to any posi-
3. Install sensor (1), then connect to digital temper- tion other than the D position during
ature gauge B. the stall operation.
★ Clamp the wiring harness of the tempera- 4) When the temperature stabilizes at near the
ture gauge at a suitable place to prevent it target temperature, return the dump lever to
from touching any hot part. HOLD and measure the temperature with
only the torque converter stalled.
★ The exhaust temperature will start to go
down from the full stall condition, so
measure the temperature when it stabi-
lizes.
★ If the exhaust temperature does not go
down but rises, make the set tempera-
ture at full stall higher.
★ After completing the measurement, low-
er the engine speed to low idling, then
return the gearshift lever to the N posi-
tion.
4. When measuring the exhaust temperature at

torque converter stall, do as follows.
★ To prevent the torque converter from over-
heating, use the full stall (torque converter
stall + hydraulic relief) to stabilize the ex-
haust temperature, then stall only the torque
converter and measure the temperature.
HM400-1 20-105
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
5. When measuring the maximum value for the ex-

haust temperature during actual operation, do
as follows.
Carry out actual work and record the maximum
exhaust temperature during operation.
★ Set the temperature gauge to the PEAK
mode. The maximum temperature is auto-
matically recorded.

measuring equipment and set to the original
condition.
20-106 HM400-1
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
k
MEASURING EXHAUST COLOR
Be careful not to touch any hot parts when re-
moving or installing the measuring tools. 2. Measuring with Smoke Meter C2
★ When measuring in the field where there is no 1) Insert probe (1) of Smoke Meter C2 into the
air or electric power supply, use Handy Smoke outlet port of the exhaust pipe, then tighten
Checker C1; when recording formal data, use the clip to secure it to the exhaust pipe.
Smoke Meter C2.
1. Measuring with Handy Smoke Checker C1

1) Install filter paper to Handy Smoke Checker
C1.
2) Insert the exhaust gas suction port into the
exhaust pipe.
3) Start the engine and raise the temperature
of the cooling water to the operating range.
4) Accelerate the engine suddenly, and oper-
ate the handle of Handy Smoke Checker
C1 while running at high idling to collect the
exhaust gas on the filter paper.
2) Connect the air hose and the socket of the

p ro be ho se a nd ac celer ato r switch to
Smoke Meter C2.
★ Keep the pressure of the air supply be-
low 1.5 MPa (15 kg/cm2).
3) Connect the power cord to the AC100V
socket.
★ Before connecting the cord, check that
the power switch of the Smoke Meter is
OFF.
4) Loosen the cap nut of the suction pump,
and fit the filter paper.
5) Turn the power switch of Smoke Meter C2
5) Remove the filter paper and compare it with ON.
the scale supplied to judge the condition.
HM400-1 20-107
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE

of the cooling water to the operating range.
MEASURING COMPRESSION
7) Accelerate the engine suddenly, and PRESSURE
depress the accelerator pedal of Smoke
★ For details of the procedure for measuring the
Meter C2 while running at high idling to col-
compression pressure, see the shop manual for
lect the exhaust gas on the filter.
the 140-3 Series Engine.
8) Place the filter paper used to catch the
exhaust gas color on top of at least 10
sheets of unused filter paper inside the filter
paper holder, and read the value shown.
9) After completing the measurement, remove
the measuring equipment and set to the
original condition.
20-108 HM400-1
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE
3
1. Open the engine hood. 5. Tighten locknut (6) to hold adjustment screw (5)
in position.
2. Remove cylinder head cover (1). Locknut :
53.0 - 64.7 Nm {5.4 - 6.6 kgm}
★ After tightening the locknut, check the valve
clearance again.
3. Rotate the crankshaft in the normal direction to

set No. 1 cylinder at compression top dead cent-
er, and align pointer (2) with the [1.6] mark on
the damper.
★ Crank the crankshaft with the hexagonal
portion at the tip of the water pump drive
shaft.
★ At compression top dead center, the rocker
arm can be moved by hand by the amount of
the valve clearance. If the rocker arm does
not move, the crankshaft is not at compres-
sion dead center, so rotate it one more turn.
f
6. Turn the crankshaft 120 each time in the normal
direction and repeat the procedure in Steps 3 to
5 to adjust the valves of each cylinder according
to the firing order.
★ Firing order : 1-5-3-6-2-4
3
7. After completing the measurement, set to the
original condition.
Cylinder head cover mounting bolt:
4. To adjust the valve clearance, insert feeler 29.4 - 34.3 Nm {3.0 - 3.5 kgm}
gauge D into clearance b between rocker arm
(3) and crosshead (4), and adjust the valve
clearance with adjustment screw (5).
★ Insert the feeler gauge and turn the adjust-
ment screw until the clearance is a sliding fit.
HM400-1 20-109
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

1. Remove the engine undercover (small).
2. Install nozzle and hose (1) to blow-by hose (1),

then connect to blow-by checker E.

3. Start the engine and raise the temperature of the condition.
cooling water to the operating range.
4. Turn the parking brake switch ON, depress the

parking brake pedal, then set the gearshift lever
N
to the D position.
If the gearshift lever is operated to any po-
sition other than the D position, the ma-
chine may move off even if the brake is
being depressed, so always measure at the
D position.

N
er, and measure the blow-by pressure.
There is danger of damage to the internal
parts of the transmission, so never operate
than the D position during the stall opera-
tion.
★ After completing the measurement, run the
engine at low idling, then return the gearshift
20-110 HM400-1
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE

2. Remove oil pressure measurement plug (1).

3. Fit nipple and hose (1), then connect oil pres- measuring equipment and set to the original
sure gauge F. condition.
★ Use a 0.98 MPa {10 kg/cm2} oil pressure
gauge.
4. Start the engine and raise the temperature of the

cooling water to the operating range.
5. Measure the oil pressure with the engine at both

low idling and high idling.
HM400-1 20-111
TESTING AND ADJUSTING HANDLING EQUIPMENT IN FUEL CIRCUIT
HANDLING EQUIPMENT IN RELEASING REMAINING

FUEL CIRCUIT PRESSURE IN FUEL SYSTEM
★ Precautions when carrying out inspection and ★ When the engine is running, pressure is gener-
maintenance of fuel system ated in both the low-pressure circuit and high-
With the common rail type fuel injection system, pressure circuit of the fuel line.
more precise equipment is used than on the Low-pressure circuit: Feed pump - fuel filter -
conventional fuel injection pump and nozzle, so fuel supply pump
problems may occur if dirt or dust get in. High-pressure circuit: Fuel supply pump - com-
When carrying out inspection or maintenance of mon rail - fuel injector
the fuel line, pay more attention than usual to ★ For both the low-pressure circuit and high-pres-
prevent dirt or dust from getting in. If there is any sure circuit, the pressure automatically goes
dirt stuck to any part, use clean fuel to wash it off down to a safe level 30 seconds after the engine
completely. is stopped.
★ Precautions when replacing fuel filter cartridge ★ The remaining pressure in the fuel circuit must
Always use a genuine Komatsu part for the fuel be completely released before carrying out in-
filter cartridge. spection of the fuel system or removal or instal-
With the common rail type fuel injection system, lation of the equipment. Always obey the
more precise equipment is used than on the following precautions when carrying out the op-
conventional fuel injection pump and nozzle. To
prevent dirt or dust from getting in, so a special
filter with highly efficient filtering performance is
used.
k eration.
When inspecting the fuel line or removing or in-
stalling equipment, wait for at least 30 seconds
after the engine is stopped to release the re-
For this reason, do not use imitation filters. If
maining pressure in the fuel system before
they are used, there is danger of problems oc-
starting the operation. (There is still pressure
curring in the fuel line.
remaining in the circuit, so do not start opera-
tions immediately after the engine is stopped).
20-112 HM400-1
TESTING AND ADJUSTING MEASURING FUEL PRESSURE
MEASURING FUEL PRESSURE

★ Measure the fuel pressure only for the low-
pressure circuit between the feed pump - fuel
filter - fuel supply pump.
k The high-pressure circuit between the fuel
supply pump - common rail - fuel injector is
under extremely high pressure, so it cannot be
measured.
2. Remove fuel pressure measurement plug (1).

condition.
3. Fit nipple and hose (1), then connect pressure

gauge F.
gauge.
4. Start the engine and measure the fuel pressure

at high idling.
★ If the fuel pressure is in the following range,
it is normal.
0.15 – 0.3MPa {1.5 – 3kg/cm2}
HM400-1 20-113
(11)
1
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL CIRCUIT
★ Bleed the air as follows if the engine has run out

of fuel or the fuel circuit equipment has been re-
moved and installed.
1. Remove fuel filter (1), fill with fuel, then install

again.
★ When filling, use clean fuel and be careful
not to let dirt get in.
★ Add fuel through inlet port a (8 places) of the
filter. Portion b is the outlet port after the fuel
has been filtered (clean side), so never add
fuel from here.
★ If no clean fuel is available, do not remove
the filter. Fill the inside of the filter by oper-
ating the priming pump. 2. Remove air bleed plug (2) of the fuel filter and
operate priming pump (3).
★ Continue operating the priming pump until
3
fuel flows out from the plug hole. When fuel
comes out, install the plug.
Air bleed plug:
7.8 - 9.8 Nm {0.8 - 1.0 kgm}
20-114 HM400-1
TESTING AND ADJUSTING REDUCED CYLINDER MODE OPERATION
REDUCED CYLINDER MODE

OPERATION
3. Loosen air bleeder (4) of the fuel supply pump ★ Reduced cylinder mode operation means set-
and operate priming pump (3) 90 - 100 times. ting the fuel injectors of a single cylinder or mul-
★ Continue operating the priming pump until tiple cylinders electrically to the NO INJECTION
fuel flows out from the bleeder. When fuel condition to run the engine on a reduced number
comes out, tighten the bleeder, then operate of cylinders. The reduced cylinder mode opera-
3
the priming pump several times until it be- tion is used when it is thought that one of the en-
comes stiff. gine cylinders is not giving normal output
Air bleeder: (combustion). It is a method to determine which
4.9 - 6.9 Nm {0.5 - 0.7 kgm} cylinder is not operating normally.
★ Use the special function of the machine monitor
4. Crank the engine with the starting motor and when operating the reduced cylinder mode of
start the engine. the engine.
★ When the engine is cranked, the air in the ★ For details of the method of operation, see SPE-
high-pressure circuit is automatically bled. CIAL FUNCTIONS OF MACHINE MONITOR.
★ If the engine does not start, the air has prob-
ably not been properly bled from the low-
pressure circuit, so repeat the procedure
from Step 2.
HM400-1 20-115
TESTING AND ADJUSTING CHECKING FOR LEAKAGE IN FUEL CIRCUIT
CHECKING FOR LEAKAGE IN
k
FUEL CIRCUIT
With the fuel system, the high-pressure circuit is 8. Start the engine, run it at high idling, then apply
under extremely high pressure, so if fuel leaks load to the engine.
when the engine is running, there is danger of ★ Carry out dump relief.
fire.
Check for fuel leakage as follows when check- 9. Check the fuel piping and equipment for fuel
ing the fuel circuit or when equipment has been leakage.
removed and installed. ★ Check the high-pressure circuit for fuel leak-
★ To make it easier to check for fuel leakage, wipe age, particularly at the places sprayed with
the engine itself and the surrounding area clean color checker.
and remove all oil and grease before starting the ★ If there is fuel leakage, carry out repairs,
inspection. then repeat the check from Step 2.
★ If no fuel leakage is found, the check is com-
1. Spray the fuel supply pump, common rail, fuel plete.
injector, and high-pressure piping connections
with a color checker (developing solution).
2. Start the engine, run it at under 1000 rpm, and

when the speed stabilizes, stop the engine.
3. Check the fuel piping and equipment for fuel

leakage.
★ Check the high-pressure circuit for fuel leak-
age, particularly at the places sprayed with
color checker.
★ If there is fuel leakage, carry out repairs,
then repeat the check from Step 2.
4. Start the engine and run it at low idling.

leakage.
color checker.
6. Start the engine and run it at high idling.

leakage.
color checker.
20-116 HM400-1
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED

SENSOR
★ The G speed sensor and Ne speed sensor for
the engine controller cannot be adjusted.
★ Adjust the engine speed sensor (EREV) for the
transmission controller as follows.
1. Tilt the cab up.

★ For details, see METHOD OF TILTING CAB
UP.
2. Screw in until the tip of sensor (1) contacts the

tip of the tooth of flywheel ring gear (2).
★ Be careful not to let the tip of the sensor be
2
scratched or to let any iron particles stick to
the sensor tip.
Thread: Hydraulic Sealant
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.
2
4. Tighten sensor (1) with nut (3).
Locknut : 69 - 74 Nm (7.0 - 7.5 kgm)
HM400-1 20-117
TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING FAN BELT TENSION
1. Testing
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 Nm {10 kg}
★ Deflection: 13 - 15 mm (new part)
17 - 19 mm (when adjusting tension)
2. Adjusting
★ If the deflection is not within the specified
range, adjust as follows.
1) Install 2 belts (1).
2) Move tension pulley (3) with adjustment bolt
(2) and adjust the tension of the belts.
★ After adjusting, check the belt tension again.
20-118 HM400-1
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING TESTING AND ADJUSTING

ALTERNATOR BELT TENSION AIR CONDITIONER COM-
1. Testing PRESSOR BELT TENSION
1. Testing
with a finger at a point (marked by the arrow)
midway between the alternator pulley and drive
with a finger at a point (marked by the arrow)
pulley.
midway between the compressor pulley and
★ Pushing force:
crankshaft pulley.
Approx. 98 Nm {approx. 10 kg}
★ Pushing force:
★ Deflection: 13 - 16 mm
Approx. 58.8 Nm {approx. 6 kg}
★ Deflection: 10 mm
2. Adjusting
2. Adjusting
1) Loosen 3 mounting bolts of alternator (1)
and adjustment rod (2).
1) Loosen 3 mounting bolts of compressor
2) Loosen locknut (3), move alternator (1) with
assembly (1) and adjustment rod (2).
adjustment nut (4), and adjust the tension
2) Loosen locknut (3), move compressor
of the belt.
assembly (1) with adjustment nut (4), and
3) Tighten locknut (3).
adjust the tension of the belt.
4) Tighten 3 mounting bolts of alternator (1)
3) Tighten locknut (3).
and adjustment rod (2).
4) Tighten 3 mounting bolts of compressor
assembly (1) and adjustment rod (3).
HM400-1 20-119
TESTING AND ADJUSTING TESTING TORQUE CONVERTER STALL SPEED
TESTING TORQUE CON-
k k
VERTER STALL SPEED
Stop the machine on flat ground, turn the park- There is danger of damage to the internal
ing brake switch ON, and block the tires. parts of the transmission, so never operate
1. Switch the machine monitor display to the mon- than the D position during the stall opera-
itoring function of service mode 1 and display tion.
f
the following 2 items at the same time with the
monitoring function. 5. When the torque converter oil temperature goes
★ Monitoring items above 90 C, run the engine immediately at low
(1) Code No. 01001: Engine speed idling and return the gearshift lever to the N po-
(2) Code No. 30100:
Torque converter oil temperature
★ For details of the method of operation, see
SP ECIAL FU NC TION S O F MA CHIN E
k
sition.
Never operate the gearshift lever with the
accelerator pedal depressed. It will cause
a big shock and will also lead to a reduction
MONITOR.
in the service life of the machine.
f
6. Run the engine at a mid-range speed, and when
the torque converter oil temperature goes down
to approx. 80 C, run at low idling.
★ Keep the gearshift lever at the N position.
7. Repeat Steps 3 - 6 and equalize the oil temper-

ature in the torque converter and transmission.
f
8. At the same time as repeating Steps 3 and 4,
measure the stall speed when the torque con-
verter oil temperature is 80 C.
★ Measure the stall speed 2 or 3 times.
ff
2. Start the engine and raise the temperature of the ★ The stall speed may vary according to the fol-
hydraulic oil and transmission oil. lowing conditions, so always measure the stall
★ Transmission oil temperature: 60 - 80 C speed at the time of delivery.
Hydraulic oil oil temperature: 45 - 55 C 1) Variations according to the engine serial
number
3. Turn the parking brake switch ON, depress the 2) Variations in engine output due to atmos-
parking brake pedal, then set the gearshift lever pheric pressure and temperature
to the D position. 3) Variations due to consumption torque of
★ If the gearshift lever is operated to any posi- accessories
tion other than the D position, the machine 4) Variations due to features of the torque con-
may move off even if the brake is being de- verter
pressed, so always measure at the D posi- 5) Variations according to the method of
tion. measuring the stall

er to raise the torque converter oil temperature.
20-120 HM400-1
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE
MEASURING POWER TRAIN OIL PRESSURE
★ Table of oil pressure measurement port posi-

tions and gauges to use
Gauge
No. Measurement location
({kg/cm2})
1 Transmission main relief pressure 5.9{60}
2 Torque converter inlet port pressure 5.9{60}
3 Torque converter outlet port pressure 0.98{10}
4 Torque converter lock-up clutch pressure 5.9{60}
5 Transmission Lo clutch pressure 5.9{60}
6 Transmission Hi clutch pressure 5.9{60}
7 Transmission 1st clutch pressure 5.9{60}
8 Transmission 2nd clutch pressure 5.9{60}
9 Transmission 3rd clutch pressure 5.9{60}
10 Transmission R clutch pressure 5.9{60}
11 Inter-axle differential lock clutch pressure 5.9{60}
★ The transmission lubrication temperature is rep-

resented by the torque converter outlet port
pressure, so there is no need to measure it.
HM400-1 20-121
k Stop the machine on flat ground, turn the park- Power train overall
k ing brake switch ON, and block the tires.

Wait for the oil temperature to go down fully be-
1. Measuring power train main relief pressure
1) Tilt the cab up.
k
2) Remove oil pressure measurement plug
fore removing or installing the measuring tools.
(1), then install nipple and hose (1).
When measuring the oil pressure when ★ Pull the hose out to the rear of the trans-
traveling, make sure that there is a wide travel mission.
area and check the safety in the surrounding ar-
ea.
★ When tilting the cab up or down, see METHOD
OF TILTING CAB UP for details.
3) Tilt the cab down and return it to its original

position.
4) Connect oil pressure gauge F.
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.

original condition.
20-122 HM400-1
Torque converter related

2. Measuring torque converter inlet oil pressure 3. Measuring torque converter outlet oil pressure
1) Install hose (1) to oil pressure measure- 1) Tilt the cab up.
ment coupler (2). 2) Remove oil pressure measurement plug
★ Pull the hose out to the rear of the trans-
mission.

range. 3) Tilt the cab down and return it to its original
4) Keep the gearshift lever at the N position position.
and measure the oil pressure at high idling. 4) Connect oil pressure gauge F.
range.
and measure the oil pressure at high idling.

original condition.

original condition.
HM400-1 20-123
4. Measuring torque converter lock-up clutch Transmission related

pressure ★ Table of gearshift lever positions, speed ranges,
1) Remove the ECMV cover. and clutches actuated
Speed range
Gearshift lever Clutches
R2 R1 N D 5 4 3 2 1 Lo Hi 1st 2nd 3rd R

c c c c c F1 z z
c c c c c F2 z
c c c c F3 z
c c c F4
c c F5 z
c F6
c N
c R1 z
c R2
4) Start the engine and raise the temperature ★ The c mark indicates the speed ranges that are
of the torque converter oil to the operating actuated for each position of the gearshift lever.
range. ★ The mark and z
mark indicate the clutches
5) Turn the parking brake switch OFF, depress that are actuated for each travel speed.
the parking brake pedal, then set the gear- ★ The z mark indicates the speed range when
shift lever to position 1. measuring the oil pressure for each clutch.
6) Release the brake, travel at high idling, and
measure the oil pressure when the lock-up
k pilot lamp lights up.

In F1, a maximum travel speed of approx. 7
km/h is reached, so check carefully that the
surrounding area is safe.

original condition.
20-124 HM400-1
5. Measuring transmission Lo clutch pressure 6. Measuring transmission Hi clutch pressure

1) Remove the ECMV cover. 1) Remove the ECMV cover.
2) Remove oil pressure measurement plug 2) Remove oil pressure measurement plug
(5), then install nipple and hose (1). (6), then install nipple and hose (1).

3) Connect oil pressure gauge F. 4) Start the engine and raise the temperature
4) Start the engine and raise the temperature of the torque converter oil to the operating
of the torque converter oil to the operating range.
range. 5) Turn the parking brake switch OFF, depress
5) Turn the parking brake switch OFF, depress the parking brake pedal, then set the gear-
the parking brake pedal, then set the gearshift lever to position 2.
shift lever to position 1. 6) Release the brake, travel at high idling, and
6) Release the brake and measure the oil measure the oil pressure when the shift
N
pressure when traveling at high idling.
In F1, a maximum travel speed of ap-
prox. 7 km/h is reached, so check
N indicator shows "2".
In F2, a maximum travel speed of approx.
11 km/h is reached, so check carefully that
carefully that the surrounding area is the surrounding area is safe.
safe.

7) After completing the measurement, remove the measuring equipment and set to the
the measuring equipment and set to the original condition.
original condition.
HM400-1 20-125
7. Measuring transmission 1st clutch pressure 8. Measuring transmission 2nd clutch pressure
3) Connect oil pressure gauge F. 3) Connect oil pressure gauge F.

4) Start the engine and raise the temperature 4) Start the engine and raise the temperature
of the torque converter oil to the operating of the torque converter oil to the operating
range. range.
5) Turn the parking brake switch OFF, depress 5) Turn the parking brake switch OFF, depress
the parking brake pedal, then set the gear- the parking brake pedal, then set the gear-
shift lever to position 1. shift lever to position 3.
6) Release the brake and measure the oil 6) Release the brake, travel at high idling, and
N pressure when traveling at high idling.

In F1, a maximum travel speed of approx. 7
km/h is reached, so check carefully that the
measure the oil pressure when the shift
N
indicator shows "3".
surrounding area is safe. prox. 16 km/h is reached, so check
carefully that the surrounding area is
safe.
7) After completing the measurement, remove the

measuring equipment and set to the original condi-
tion. 7) After completing the measurement, remove
original condition.
20-126 HM400-1
9. Measuring transmission 3rd clutch pressure 10. Measuring transmission R clutch pressure
3) Connect oil pressure gauge F. 3) Connect oil pressure gauge F.

4) Start the engine and raise the temperature 4) Start the engine and raise the temperature
of the torque converter oil to the operating of the torque converter oil to the operating
range. range.
5) Turn the parking brake switch OFF, depress 5) Turn the parking brake switch OFF, depress
the parking brake pedal, then set the gear- the parking brake pedal, then set the gear-
shift lever to position 5. shift lever to position R1.
6) Release the brake, travel at high idling, and 6) Release the brake and measure the oil
measure the oil pressure when the shift
N
indicator shows "5".
N
pressure when traveling at high idling.
In R1, a maximum travel speed of ap-
prox. 7 km/h is reached, so check
prox. 38 km/h is reached, so check carefully that the surrounding area is
carefully that the surrounding area is safe.
safe.

7) After completing the measurement, remove the measuring equipment and set to the
the measuring equipment and set to the original condition.
original condition.
HM400-1 20-127
11. Measuring inter-axle differential lock clutch

pressure
1) Remove the ECMV cover.

range.
and move the inter-axle differential lock
switch to the MANUAL position.
6) Measure the oil pressure when the engine
is at high idling.

original condition.
20-128 HM400-1
TESTING AND ADJUSTING TESTING AND ADJUSTING LEFT AND RIGHT DIFFERENTIAL LOCK OIL
PRESSURE (Machine with differential lock differential)
TESTING AND ADJUSTING LEFT AND RIGHT DIFFERENTIAL

LOCK OIL PRESSURE
k Stop the machine on flat ground, turn the park- 5) Run the engine and push in manual opera-
ing brake switch ON, and block the tires. tion button (2) of the differential lock sole-
k Wait for the oil temperature to go down fully be-
noid valve and measure the oil pressure at
high idling.
fore removing or installing the measuring tools.
★ This work shall be performed by two
persons. One person shall push in the
TESTING
manual operation button of the solenoid
1. Measuring front axle differential lock oil
valve and the other person shall operate
pressure
the accelerator pedal and measure the
1) Tilt the cab up.
oil pressure in the operator's seat.
★ For details, see METHOD OF TILTING
★ The differential lock oil pressure is actu-
CAB UP.
ated only while the manual operation
2) Remove oil pressure pickup plug (1).
button is pushed in, if the machine is
stopped.
3) Install nipple and hose [1].
4) Tilt the cab down and connect oil pressure

gauge F.
★ When lowering the cab, take action to
original condition.
prevent the measurement hose from in-
terfering with the cab.
HM400-1 20-129
1
6
2. Measuring center axle differential lock oil 5) Run the engine and push in manual opera-
pressure tion button (2) of the differential lock sole-
1) Raise the dump body fully. noid valve and measure the oil pressure at
2) Remove oil pressure pickup plug (3). high idling.
★ This work shall be performed by two
stopped.
4) Lower the dump body and connect oil pres-

sure gauge F.
★ When lowering the dump body, take ac-
tion to prevent the measurement hose
from interfering with the dump body.

original condition.
20-130 HM400-1
1
6
3. Measuring rear axle differential lock oil pres- 5) Run the engine and push in manual opera-
sure tion button (2) of the differential lock sole-
1) Raise the dump body fully. noid valve and measure the oil pressure at
2) Remove oil pressure measurement plug high idling.
(4). ★ This work shall be performed by two
stopped.
4) Lower the dump body and connect oil pres-

sure gauge F.
★ When lowering the dump body, take ac-
tion to prevent the measurement hose
from interfering with the dump body.

original condition.
HM400-1 20-131
1
6
ADJUSTING 2. Adjusting center axle differential lock oil

1. Adjusting front axle differential lock oil pres- pressure
sure ★ If the center axle differential lock oil pres-
★ If the front axle differential lock oil pressure sure is not correct, adjust relief valve (9) of
is not correct, adjust relief valve (5) of the the center axle differential lock valve as fol-
front axle differential lock valve as follows. lows.
1) Remove cap (6). 1) Remove cap (10).

2) Loosen locknut (7). 2) Loosen locknut (11).
3) Turn adjustment screw (8) and adjust the oil 3) Turn adjustment screw (12) and adjust the
pressure. oil pressure.
★ Adjust with the adjustment screw as fol- ★ Adjust with the adjustment screw as fol-
lows. lows.
• To INCREASE pressure, turn clock- • To INCREASE pressure, turn clock-
wise wise
• To DECREASE pressure, turn • To DECREASE pressure, turn
counterclockwise counterclockwise
4) Hold adjustment screw (8) in position and 4) Hold adjustment screw (12) in position and
tighten locknut (7). tighten locknut (11).
5) Install cap (6). 5) Install cap (10).
★ After completing the adjustment, repeat the ★ After completing the adjustment, repeat the
procedure for measurement to check the oil procedure for measurement to check the oil
pressure again. pressure again.
20-132 HM400-1
1
6
3. Adjusting rear axle differential lock oil pres-

sure
★ If the rear axle differential lock oil pressure is
not correct, adjust relief valve (13) of the
rear axle differential lock valve.
★ The procedure for adjusting is the same as

for the center differential lock valve.
HM400-1 20-133
1
6
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
ADJUSTING TRANSMISSION SPEED SENSOR
★ There are 4 speed sensors installed to the 4) Fixing sensor (1), tighten nut (3).
transmission. Adjust each sensor as follows. 3 Nut: 49.0 – 68.6Nm {5 – 7kgm}
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.
1. Adjusting input shaft speed sensor (N1)

1) Remove input shaft speed sensor (1) and
check that its tip is free from steel chips and
flaws, and then reinstall it temporarily.
2 Threads: Gasket sealant (LG-5)
2) Screw in sensor (1) until its tip touches the
tooth tip of input shaft gear (2).
3) Return sensor (1) by 1/2 - 1 turn.
★ At this time, clearance (a) between the
sensor tip and gear tooth tip is 0.75 - 1.5
mm.
20-134 HM400-1
(11)
1
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
2. Adjusting intermediate shaft speed sensor 4. Adjusting output shaft F speed sensor (FE1)
(N2) ★ If the speed sensor of adjustment type is in-
1) Remove intermediate shaft speed sensor (4) stalled, adjust it according to the following
and check that its tip is free from steel chips procedure.
and flaws, and then reinstall it temporarily. 1) Remove output shaft F speed sensor (10)
2 Threads: Gasket sealant (LG-5) and check that its tip is free from steel chips
and flaws, and then reinstall it temporarily.
2 Threads: Gasket sealant (LG-5)
2) Screw in sensor (4) until its tip touches the
tooth tip of intermediate shaft gear (5).
3) Return sensor (4) by 1/2 - 1 turn. 2) Screw in sensor (10) until its tip touches the
★ At this time, clearance (b) between the tooth tip of front output shaft gear (11).
sensor tip and gear tooth tip is 0.75 - 1.5 3) Return sensor (10) by 1/2 - 1 turn.
mm. ★ At this time, clearance (d) between the
4) Fixing sensor (4), tighten nut (6). sensor tip and gear tooth tip is 0.75 - 1.5
3 Nut: 49.0 – 68.6Nm {5 – 7kgm} mm.
4) Fixing sensor (10), tighten nut (12).
3 Nut: 49.0 – 68.6Nm {5 – 7kgm}
3. Adjusting output shaft R speed sensor (N3)

1) Remove output shaft R speed sensor (7) and
check that its tip is free from steel chips and 5. Checking sensor input signal
flaws, and then reinstall it temporarily. After finishing the adjustment, check that the
2 Threads: Gasket sealant (LG-5) monitoring function of the machine monitor indi-
cates each transmission shaft speed normally.
2) Screw in sensor (7) until its tip touches the ★ For details of the monitoring function, see
tooth tip of rear output shaft gear (8). Special function of machine monitor.
3) Return sensor (7) by 1/2 - 1 turn.
★ At this time, clearance (c) between the
sensor tip and gear tooth tip is 0.75 - 1.5
mm.
4) Fixing sensor (7), tighten nut (9).
3 Nut: 49.0 – 68.6Nm {5 – 7kgm}
HM400-1 20-134-1
(11) ! !
TESTING AND ADJUSTING TESTING AND ADJUSTING BRAKE OIL PRESSURE
TESTING AND ADJUSTING BRAKE OIL PRESSURE

k Stop the machine on flat ground, turn the park- ii)Measure the pressure at the point
ing brake switch ON, and block the tires. where the indicator of oil pressure
gauge F stops going down and starts to
Testing go up again.
1. Measuring charge valve cut-in pressure and 4) Measure the cut-out pressure at high idling.
cut-out pressure Measure the oil pressure when the pressure
★ Measure the charge valve oil pressure at re- goes up after the cut in and the indicator of
mote pressure detection port (1). pressure gauge F stops.
1) Install hose [1] and connect oil pressure 5) After completing the measurement, remove
gauge F. the measuring equipment and set to the
★ Use a 39.2 MPa {400 kg/cm2} oil pres- original condition.
sure gauge.
2) Start the engine.

3) Measure the cut-in pressure at high idling.
i) Repeatedly depress and release the
brake pedal to gradually lower the pres-
sure inside the accumulator.
HM400-1 20-135
1
6
2. Measuring wheel brake actuation pressure 4) Measure the actuation pressure of the
and drop in pressure retarder brake under the following condi-
★ Use the same procedure to measure the tions.
front brake circuit, center brake circuit, and i) Run the engine for several minutes at
rear brake circuit. low idling to charge the accumulator,
1) Remove air bleeder (2) of the slack then stop the engine.
adjuster. ii) Turn the starting switch ON.
iii) Pull the retarder lever fully and meas-
ure the oil pressure.
5) Measure the drop in the pressure of the foot
brake under the following conditions.
★ Check that the foot brake actuation
pressure and the retarder actuation
pressure are correct before starting.
i) Run the engine for several minutes at
low idling to charge the accumulator,
then stop the engine.
ii) Depress the brake pedal fully and
measure the oil pressure.
★ Keep the brake pedal depressed.
iii) Measure the oil pressure after 5 min-
2) Install brake test kit G and bleed the air utes and calculate the drop in pressure.
from the brake circuit. 6) After completing the measurement, remove
★ For details, see BLEEDING AIR FROM the measuring equipment and set to the
BRAKE CIRCUIT. original condition.
★ Bleed the air from the brake circuit.
For details, see BLEEDING AIR FROM
BRAKE CIRCUIT.
3) Measure the actuation pressure of the foot

brake under the following conditions.
i) Run the engine for several minutes at
low idling to charge the accumulator,
then stop the engine.
ii) Depress the brake pedal fully and
measure the oil pressure.
20-136 HM400-1
1
3. Measuring actuation pressure of parking

brake
1) Remove inlet port plug (3) of parking brake
cylinder.
k Check that the parking brake switch is ON
before carrying out the operation.

original condition.
k Check that the parking brake switch is ON
before carrying out the operation.
2) Install nipple [1] and hose [2], and connect
oil pressure gauge F.
gauge.
3) Start the engine and operate the parking

brake switch several times at high idling to
bleed the air from the circuit.
4) Stop the engine and turn the starting switch
ON.
5) Measure oil pressure when parking brake
switch is turned OFF.
HM400-1 20-137
(7)
1
4. Measuring actuation pressure of exhaust 5) Turn the parking brake OFF.

brake solenoid (machine equipped with ex- 6) Drive the machine forward and measure the
haust brake) oil pressure when the exhaust brake pilot
1) Open the engine hood. lamp lights up.
k During the measuring operation, check
2) Disconnect hose (4) of the exhaust brake
cylinder.
that the surrounding area is safe and
drive carefully.
★ 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 condi-
tion, the exhaust brake is actuated.
3) Install adapter [1] and nipple and hose [2],

and connect oil pressure gauge F.
gauge.

original condition.
k Check that the parking brake switch is
ON before carrying out the operation.
4) Start the engine and set the exhaust brake

switch to position (a).
20-138 HM400-1
1
6
ADJUSTING
Adjusting charge valve cut-in pressure and cut-
out pressure
★ If the cut-in pressure and cut-out pressure of the
charge valve are not correct, adjust the R1 relief
valve of charge valve (5) as follows.
★ If the R1 relief valve is adjusted, the cut-in pres-
sure and cut-up pressure will both change.
1. Remove mudguard sheet inside left front tire
housing.
2. Loosen locknut (6).

3. Turn adjustment screw (7) and adjust oil pres-
sure.
★ Adjust with the adjustment screw as follows.
• To INCREASE pressure, turn clockwise
• To DECREASE pressure, turn counter-
clockwise
4. Hold adjustment screw (7) in position and tight-
3 Locknut : 10.2 Nm {1 kgm}

en locknut (8).
★ After completing the adjustment, repeat the

procedure for measurement to check the oil
pressure again.
HM400-1 20-139
1
TESTING AND ADJUSTING TESTING BRAKE PERFORMANCE
TESTING BRAKE PERFORMANCE

k Stop the machine on flat ground and turn the 2. Testing braking performance of retarder
parking brake switch ON. brake (which is not used in E-SPEC)
1) Start the engine and turn the parking brake
1. Testing braking performance of foot brake switch OFF.
1) Start the engine and turn the parking brake 2) Pull the retarder lever fully, then set the
switch OFF. gearshift lever to the D position.
2) Depress the brake pedal fully, then set the ★ Testing of the performance of the re-
gearshift lever to the D position. tarder brake must be carried out with the
★ Testing of the performance of the foot gearshift lever at the D position. Do not
brake must be carried out with the gear- place the gearshift lever at any other po-
shift lever at the D position. Do not sition.
place the gearshift lever at any other po- 3) Depress the accelerator pedal gradually
sition. and check that the machine does not move
3) Depress the accelerator pedal gradually when the torque converter is stalled at the
and check that the machine does not move specified speed.
when the torque converter is stalled at the
specified speed.
4) After completing the inspection, run the

engine at low idling and set the gearshift
4) After completing the inspection, run the lever to the N position.
20-140 HM400-1
1
6
TESTING AND ADJUSTING TESTING BRAKE PERFORMANCE
3. Testing braking performance of parking 4. Testing braking performance of overrun pro-

brake tection brake (E-SPEC)
k If the machine moves, it can cause serious
1) Start the engine and turn the parking brake
switch OFF.
injury or death. Accordingly, if the machine
2) Insert a screwdriver in hole (a) on the side
starts moving during performance test, low-
of the combination switch box and move it
er the engine speed immediately and set
to the lower end and place the gearshift
the gearshift lever to the N position and de-
lever at the D position.
press the foot brake pedal.
★ Testing of the performance of the over-
1) Turn the parking brake switch ON and start
run protection brake must be carried out
the engine.
with the gearshift lever at the D position.
2) Place the gearshift lever at the D position.
Do not place the gearshift lever at any
★ Testing of the performance of the foot
other position.
brake must be carried out with the gear-
★ If the screwdriver is inserted in hole (a)
shift lever at the D position. Do not
on the side of the combination switch
place the gearshift lever at any other po-
box and moved to the lower end, the po-
sition.
tentiometer in the switch box is rotated
3) Depress the accelerator pedal gradually
and the overrun protection brake pilot
and check that the machine does not move
lamp lights up.
specified speed.
4) If the machine moves while the torque con-
verter speed is below the specified speed,
adjust the brakepad clearance, referring to
TESTING WEAR OF PARKING BRAKE
PAD, 2. Adjusting pad clearance.
5) After completing the inspection, run the

3) Depress the accelerator pedal gradually

and check that the machine does not move
specified speed.
★ After completing the inspection, move
the screwdriver inserted in hole (a) to
the upper end and remove it.
HM400-1 20-141
1
6
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE CIRCUIT
BLEEDING AIR FROM BRAKE CIRCUIT

★ If the equipment in the brake circuit has been re- 5) Bleed air from the overrun protection brake
moved and installed again, bleed the air from the circuit in the following procedure (E-SPEC).
brake circuit as follows. i) Insert a screwdriver in hole (a) on the
★ When bleeding the air from the wheel brake cir- side of the combination switch box and
cuit, always bleed the air from the slack adjuster move it to the lower end and keep it in
first, then bleed the air from the wheel brake. that position.
ii) Loosen air bleeder approx. 1/2 turn,
1. Bleeding air from slack adjuster portion of then drain the air mixed with the oil.
wheel brake circuit iii) When no more air comes out with the
3 Air bleeder :
★ Use the same procedure to measure the oil, tighten air bleeder (1).
front brake circuit, center brake circuit, and
rear brake circuit. 10 - 20 Nm {1 - 2 kgm}
1) Connect air bleed hose [1] to air bleeder ★ After bleeding air, be sure to move the
(1). screwdriver inserted in hole (a) to the
upper end and remove it.
2) Start the engine and operate at low idling.

3) Bleed the air from the brake pedal circuit as
follows.
i) Depress the brake pedal fully and hold
it in position.
ii) Loosen air bleeder (1) approx. 1/2 turn,
then drain the air mixed with the oil.
iii) When no more air comes out with the
3 Air bleeder :
oil, tighten air bleeder (1).
10 - 20 Nm {1 - 2 kgm}
4) Bleed air from retarder brake circuit in the

following procedure. (Which is not used in
E-SPEC) 6) After completing the adjustment, set to the
i) Pull the retarder lever fully and hold it in original condition.
position.
then drain oil mixed with oil.
iii) When no more air comes out with the
3 Air bleeder :
oil, tighten air bleeder (1).
10 - 20 Nm {1 - 2 kgm}
20-142 HM400-1
1
6
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE CIRCUIT
2. Bleeding air from wheel brake portion of foot 3. Bleeding air from parking brake circuit
brake circuit 1) Start the engine and operate at low idling.
★ Use the same procedure to measure the 2) Use the parking brake switch to actuate and
front brake circuit, center brake circuit, and cancel the circuit several times.
rear brake circuit. ★ This operation automatically bleeds the
1) Connect air bleed hose [1] to air bleeder air.
(1).
2) Start the engine and operate at low idling.

3) Bleed the air from the brake pedal circuit as
follows.
i) Depress the brake pedal fully and hold
it in position.
then drain the air mixed with the oil.
4) When no more air comes out with the oil,
tighten air bleeder (1).
HM400-1 20-143
1
6
TESTING AND ADJUSTING TESTING WEAR OF WHEEL BRAKE DISC
TESTING WEAR OF WHEEL BRAKE DISC

k Stop the machine on flat ground, turn the park- ★ Limit mark b indicates the wear limit for the
ing brake switch ON, and block the tires. disc. If limit mark b reaches the end face of
k Carry out the inspection when the brake oil tem-

guide (3), the disc has reached the wear lim-
it.
perature is less than 60fC.
k When the disk comes close to the wear limit,

carry out the inspection more frequently. Be
sure to carry out inspection of the retarder brak-
ing performance at the same time.
1. Check that the brakes other than parking brake

are not being actuated.
2. Turn the starting switch ON and check that the

retarder oil pressure caution lamp is not lighted
up.
★ If the lamp is lighted up, the oil pressure in
the brake circuit has dropped, so start the
3 Cap nut :
6. Install cap nut (1) of the gauge.
engine and run it at approx. 2000 rpm.
When the lamp goes out, stop the engine. 14.7 - 19.6 Nm {1.5 - 2.0 kgm}
3. Remove cap nut (1) of the gauge.
4. Depress the brake pedal fully and hold it in posi-

tion.
★ When the engine is started, the brake cool-
ing oil is actuated and the inspection cannot
be carried out accurately, so always stop the
engine before carrying out inspection.
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, 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 of
guide (3) except when replacing the disc.
20-144 HM400-1
1
TESTING AND ADJUSTING TESTING WEAR OF PARKING BRAKE PAD

TESTING WEAR OF PARKING BRAKE PAD
Stop the machine on flat ground, turn the park-
ing brake switch ON, and block the tires.
★ Before carrying out the inspection, start the en-
gine and raise the dump body fully. Then insert
the lock pin and stop the engine.
1. Testing wear of pad

1) Remove top cover of parking brake.
2) Turn adjustment nut (1) counterclockwise to
release the parking brake.
3) Remove left and right brackets (2), then

remove 2 each of spring (3) and (4).
4) Remove 2 pads (5).
5) Measure thickness a of pad (5).

★ Thickness limit of pad: 1.5 mm
★ If either the front or rear pad has
reached the thickness limit, replace
both pads at the same time.
HM400-1 20-145
TESTING AND ADJUSTING TESTING WEAR OF PARKING BRAKE PAD
2. Adjusting pad clearance 5) Start the engine.

★ If the pad wear has been inspected or the 6) Repeatedly actuate and cancel with the
pad has been replaced with a new part, ad- parking brake switch to adjust the pad
just the clearance as follows. clearance.
1) Install 2 pads (5). ★ When the parking brake is actuated in
2) Install 2 each of springs (4) and (3) to left the direction of release, adjustment nut
and right brackets (2), then install left and (1) will turn clockwise, so repeat this op-
right brackets (2). eration until it does not turn anymore.
★ There are two types of springs, so check 7) Release the parking brake and check the
the color, and be careful not to mistake clearance of the pad again.
the mounting position. ★ Clearance (total of b and c): 1.5 mm
Spring (4): Yellow ★ If the clearance is not correct, carry out
Spring (3): Black the adjustment again from Step 3).
★ Screw 2 or 3 mounting bolts into the 8) Tighten the mounting bolts of left and right
bracket and tighten temporarily. brackets (2).
3) Turn adjustment nut (1) clockwise until pad ★ Be careful not to let the mounting posi-
(5) is brought into tight contact with disc (6). tion move out of alignment.
4) Measure clearances b and c between pad 9) Check the clearance between pad (5) and
(5) and disc (6) and turn adjustment nut (1) disc (6) again.
counterclockwise to loosen it until the clear- ★ Target clearance (b + c on one side):
ance is the specified amount. Min. 0.5 mm
★ Standard clearance (total of b and c): ★ If the clearance on one side is narrow,
1.5 mm move the mounting position of the left
and right brackets to adjust.
20-146 HM400-1
TESTING AND ADJUSTING METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE
METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE

★ If any problem occurs in in the electrical system
or hydraulic system of the parking brake and the
parking brake is not released, it is possible to re-
k If any problem occurs in the hydraulic system,

lease the brake temporarily as follows.
there is a strong possibility that the wheel brake

will not work properly, so after releasing the
parking brake, always tow the machine at low
k When carrying out the operation to release the

speed to a safe place.
parking brake, stop the machine on flat ground

and check that the surrounding area is safe be-
fore 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.
1. Turn adjustment screw (1) of the parking brake

counterclockwise to create a gap between the
pad and disc.
2. Tow the machine and move it to a safe place.

★ After moving the machine, fit blocks secure-
ly under the tires.
HM400-1 20-147
1
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE
TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE

k Stop the machine on flat ground, turn the park-
ing brake switch ON, and block the tires.
1. Measuring steering relief oil pressure

★ Measure the steering relief pressure at re-
mote pressure detection port (1).

original condition.
1) Install hose [1] and connect oil pressure

gauge F.
★ Use a 39.2 MPa {400 kg/cm2} oil pres-
sure gauge.
2) Start engine and operate the steering fully

to one side (either left or right).
3) Measure the oil pressure when the steering
is relieved with the engine at high idling.
20-148 HM400-1
1
6
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE
2. Adjusting steering relief oil pressure

★ If the steering relief oil pressure is not cor-
rect, adjust relief valve (2) of the flow amp
valve as follows.
1) Remove plug (3), then remove locknut (4).

2) Turn adjustment screw (5) and adjust oil
pressure.
★ Adjust with the adjustment screw as fol-
lows.
• To INCREASE pressure, turn clock-
wise
• To DECREASE pressure, turn
counterclockwise
3) Fit locknut (4) and install plug (3).
★ After completing the adjustment, repeat the
procedure for measurement to check the oil
pressure again.
HM400-1 20-149
1
6
TESTING AND ADJUSTING TESTING AND ADJUSTING SUSPENSION CYLINDER
TESTING AND ADJUSTING SUSPENSION CYLINDER

k Stop the machine on flat ground, turn the park- 2. Releasing nitrogen gas
ing brake switch ON, and block the tires. 1) Set a hydraulic jack under the frame of the
machine and raise the tires slightly from the
1. Testing cylinder length ground.
Test the installed length of the suspension cylin- ★ Use a 50 ton {490,000 N} jack.
k Set the jack securely under the frame.
der under the following conditions.
• Machine standing on horizontal road sur-
★ When carrying out work at the front, jack
face
up the front frame until the front tires
• Engine stopped
come slightly off the ground.
• Dump body unloaded
★ When carrying out work at the rear, jack
★ Installed length a of front cylinder:
up the frame until either the center or
168 ± 10 mm
rear tires come slightly off the ground.
★ Installed length b of front cylinder:
2) Remove cover (1).
111 ± 5 mm
3) Loosen oil level valve (2) slowly, and when
★ If the length of the cylinder is not correct, use
the nitrogen gas starts to come out, hold
the procedure in Steps 2 to 5 to adjust.
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.
k Operate 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
★ Specified rear oil volume length:
81 ± 3 mm
20-150 HM400-1
1
3. Adjusting oil level

★ Adjust the oil level after completing the re-
lease of the nitrogen gas.
1) Check that the suspension cylinder is the
specified oil volume length.
★ Specified front oil volume length:
68 ± 3 mm
★ Specified rear oil volume length:

81 ± 3 mm
Operate the hydraulic jack carefully.

2) Remove oil level valve (2).
3) Remove the valve body from air supply
valve (3), then install joint H6.
4) Install fitting H5 to joint H4, then connect
hose H3 and pump H2.
5) Operate pump H2 to release the gas from
the mounting port of oil level valve (2).
★ 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 (refer-

ence): 6.0
★ Rear cylinder oil charge amount (refer-

ence): 6.0
6) Install oil level valve (2).
Oil level valve:
39.2 - 49.0 Nm {4 - kgm}

7) Remove suspension tools H2 - H5, then
remove air supply valve (3).
Air supply valve:
39.2 - 49.0 Nm {4 - kgm}
HM400-1 20-151
4. Charging with nitrogen gas 8) Remove suspension tools H7 - H12.

★ Charge with nitrogen gas after completing ★ Be careful not to lose the O-ring of the
the adjustment of the oil level. air supply valve.
1) Remove the cap at the top of air supply 9) Install the cap at the top of air supply valve
valve (3). (3).
2) Connect suspension tools H7 - H12 as 10) Install the cover of the suspension cylinder.
shown in the diagram.
★ Connect joint H10 to the air supply
valve.
★ Before installing the regulator, blow the
filter at the mouthpiece thoroughly with
nitrogen gas (min. 0.98 MPa {10 kg/
cm2}) to prevent the entry of dirt or dust.
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 {10 kg/cm2}).
★ Internal pressure of cylinder (both front
and rear): 4.03 MPa {41.5 kg/cm2}.
4) Turn the handle of regulator H11 gradually

to the left and set the indicated pressure of

gauge H13.
Never charge the cylinder with nitro-
gen gas at a pressure of more than 3.9
MPa {40 kg/cm2} and extend the cylin-
der fully.
5) Operate the handle of joint H10 and valve
H7 and the suspension cylinder with nitro-
gen gas.
★ Pump nitrogen gas into the left and right
cylinders at the same time.
6) When the length of the left and right cylin-
ders reaches the specified installation
length, turn the handle of regulator H11 to
the left to stop charging with nitrogen gas.
168 ± 10 mm
111 ± 5 mm
7) Return the handle of joint H10 fully, loosen
the air bleed plug of valve H7, and dis-
charge the gas inside the hose.
20-152 HM400-1
5. Adjusting cylinder length Note 2: Checking cylinder length according to

★ Adjust the cylinder length after completion of change in ambient temperature
charging with nitrogen gas. The gas in the suspension will expand or
★ When adjusting the cylinder length, stop the contract according to the change in the am-
machine on a horizontal surface with the bient temperature when the machine is
dump body unloaded. working, so the length of the cylinder will
1) Drive the machine approx. 15 m forward, change.
then stop suddenly. Next, drive in reverse For this reason, in areas where there is a big differ-
and stop the machine suddenly at the origi- ence in temperature during the year, carry out daily
nal point. Repeat this procedure 3 or 4 inspection and adjust so that the installed length of
times. Finally, apply the retarder brake a lit- the cylinder is within the specified range.
tle at a time and stop slowly.
★ When using the retarder brake, stop as
slowly as possible to remove any sliding
resistance in the cylinder (packing,
catching of the bushing).
2) Measure the installed length of the cylinder.
168 ± 10 mm
111 ± 5 mm
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 in-
stalled 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 cylin-
der gland.
★ Use soapy water to check for leakage of
gas.
Note 1: Checking after changing oil or gas

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 de-
crease and the length of the cylinder will go
below the permissible value.
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.
HM400-1 20-153
1
TESTING AND ADJUSTING METHOD OF TILTING CAB UP
METHOD OF TILTING CAB UP

★ When carrying out inspection and maintenance 2. Tilting cab up
work around the hydraulic pump or at the top of Method using built-in cylinder
the torque converter or transmission, tilt the cab 1) Move pin (1) of the rear mount of the cab
up to the rear of the machine as follows. from hole (2) to hole (4).
★ 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.
• Recommended pump:
1. Preparatory work
k To prevent interference between the cab
and dump body, set the steering facing
directly to the front.
k Turn the parking brake switch ON and
2) Disconnect cylinder hose (3), then connect
the hydraulic pump to the hose.
block the tires. ★ Connecting adapter (Adapter unit):
1) Open the engine hood. 56B-54-16391
2) Remove lock bar (1) from the storage (Size of hose connection side: RC 1/4)
place. 3) Operate the hydraulic pump and tilt the cab
3) Remove 4 mounting bolts (2) each from the up.
left and right mounts at the front of the cab. ★ Operate the pump within the specified
pressure.
Specified pressure for pump:
20.6 - 34.3 MPa {210 - 350 kg/cm2}
20-154 HM400-1
(11)
1
TESTING AND ADJUSTING METHOD OF TILTING CAB UP
Method using external crane

1) Install the lifting tool [1] to the top of the cab.
2) Raise the cab to tilt it up.
3. Fixing cab in position

1) Set lock bar (1) at the front left of the cab,
then lower the cab slowly and fix it in posi-
tion.
k When the cab is tilted up with the built-
in cylinder, release the hydraulic pres-
sure gradually, and lower the cab slow-
ly.
2) Remove the external pump or external
crane.
k Check that the cab is held securely in
position by the lock bar.
4. Tilting cab down

★ Tilt the cab down in the reverse order from
tilting the cab up.
★ After tilting the cab down, tighten the mount-
ing bolts and return the lock bar to the stor-
age place.
HM400-1 20-155
1
6
TESTING AND ADJUSTING TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE
TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE

k Stop the machine on flat ground, turn the park- 3) Run at high idling, operate the dump lever,
ing brake switch ON, and block the tires. and measure the oil pressure when there is
RAISE relief or LOWER relief.
1. Testing dump main relief oil pressure
★ The dump main circuit uses both the steer-
ing circuit and hydraulic pump (basic pres-
sure). The steering is a priority circuit
structure, so check that the steering circuit
pressure is correct before measuring.
★ Measure the dump main relief oil pressure
at remote pressure detection port (1).

the measurement equipment and set to the
original condition.
2. Adjusting dump main relief oil pressure

★ If the dump main relief oil pressure is abnor-
mal, adjust it with relief valve (1) of the hoist
valve according to the following procedure.
1) Install hose [1] and connect oil pressure
gauge F.
★ Use a 39.2 MPa {400 kg/cm2} oil pres-
sure gauge.
2) Start the engine and operate the dump

body fully to LOWER and RAISE.
20-156 HM400-1
1
6
1) Loosen locknut (2) and rotate adjustment 3) Install a nipple and hose [1] and connect oil
screw (3). pressure gauge F.
★ If the adjustment screw is ★ Use a 5.9 MPa {60 kg/cm2} oil pressure
• rotated to the right, the oil pressure gauge.
is heightened.
• rotated to the left, the oil pressure is
lowered.
★ If the adjustment screw is rotated 1 turn,
the pressure is heightened or lowered
by 19.6 MPa {200 kg/cm2}.
4) Run the engine at high idling and measure

the oil pressure.
(Set the dump lever in neutral.)
2) Support adjustment screw (3) with a screw-
3 Tightening torque for locknut:

driver and tighten locknut (2).
29 - 39 Nm {3 - 4 kgm}
★ After completing the adjustment, check the

oil pressure again according to the proce-
dure for measurement.
3. Measuring dump pilot relief oil pressure

1) Remove the side cover of the hydraulic
tank. 5) After completing the measurement, remove
2) Remove oil pressure pickup plug (1). the measurement equipment and set to the
original condition.
HM400-1 20-156-1
6
4. Adjusting dump pilot relief oil pressure

★ If the dump pilot relief oil pressure is abnor-
mal, adjust it with relief valve (1) according
to the following procedure.
1) Remove the cap and loosen locknut (2) and

rotate adjustment screw (3).
★ If the adjustment screw is
• rotated to the right, the oil pressure
is heightened.
• rotated to the left, the oil pressure is
lowered.
★ If the adjustment screw is rotated 1 turn,
the pressure is heightened or lowered
by 1.8 MPa {18.6 kg/cm2}.
2) Hold adjustment screw (3) and tighten lock-
3 Tightening torque for locknut:

nut (2).
40 Nm {4.1 kgm}
★ After completing the adjustment, check the

oil pressure again according to the proce-
dure for measurement.
20-156-2 HM400-1
6
TESTING AND ADJUSTING ADJUSTING BODY POSITIONER SENSOR
ADJUSTING BODY POSITIONER SENSOR

★ If the body positioner rod has been disconnected 4) Install mounting bolt (2).
and connected again or the body positioner sen- 5) Tighten locknut (1).
sor has been removed and installed again, in- 6) Repeat the checking procedure above to
spect and adjust the body positioner sensor as check that the input voltage is within the
follows. normal range.
1. Checking sensor output/input voltage

1) Switch the machine monitor display to the
monitoring function of service mode 1 and
display the body positioner sensor input
voltage.
★ Monitoring item
Code No. 34400: BODY POSITION
★ For details of the method of operation,
see SPECIAL FUNCTIONS OF MA-
CHINE MONITOR.
3. Calibrating system
1) Start the engine and raise the hydraulic oil
temperature to 80 - 90fC.
2) Lower the dump body fully and continue the
LOWER relief at this position for at least 5
seconds.
★ Check that the dump body pilot lamp is
not lighted up.
3) Run the engine at low idling and operate
the dump body to the RAISE and FLOAT
positions 10 times.
2) Start the engine. ★ Operate to the end of the stroke for both
3) Operate the dump lever and check the mon- the RAISE and FLOAT operations.
itoring voltage when the dump lever is oper- 4) Run the engine at high idling and operate
ated fully to the LOWER position and the dump body to RAISE and LOWER 10
RAISE position. times.
★ When operated fully to LOWER: ★ Operate to the end of the stroke for both
0.38 - 0.44 V the RAISE and LOWER operations.
★ When operated fully to RAISE:
4.00 - 4.70 V
2. Adjusting link length

★ If the monitoring voltage is not within the
normal range, adjust the length of the link as
follows.
1) Loosen locknut (1).
2) Remove mounting bolt (2).
3) Turn rod end (3) to adjust the length of the
link.
★ Adjust the input voltage as follows.
• INCREASE link length to DE-
CREASE voltage
• DECREASE link length to IN-
CREASE voltage
★ Change in voltage for 1 turn of rod end:
Approx. 0.04 V
HM400-1 20-157
1
6
PROCEDURE FOR ADJUSTING LENGTH OF SPRING IN BODY HEATING SPHERICAL JOINT
TESTING AND ADJUSTING PROCEDURE FOR ADJUSTING
HANDLINGLENGTH OF SPRINGHIGH-VOLTAGE
ENGINE CONTROLLER IN BODY HEATING
CIRCUIT
PROCEDURE FOR HANDLING ENGINE

ADJUSTING LENGTH OF CONTROLLER
SPRING IN BODY HEATING HIGH-VOLTAGE CIRCUIT
SPHERICAL JOINT
★ When the machine is steered or oscillated, if the
body heating bellows does not operate
smoothly, or when the bellows is replaced,
adjust the length of the spring according to the
following procedure.
1. Adjust length "a" of spring (1) to 60 ± 1 mm.
(On both front side and rear side)
At this time, check that dispersion of dimension
"b" of each stud is 1 mm or less.
★ Standard dimension "b" of stud: 58 mm
(Reference)
2. After finishing adjustment
1) Check that exhaust gas does not leak.
2) Check that the spherical joint is free from k The engine controller uses a high-voltage circuit
sticking and scuffing and it rotates (110 - 130 V) for the fuel injector drive.
smoothly. 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.
k If you touch the high-voltage circuit directly,
there is danger of electrocution, so when
carrying out inspection, always obey the
following precautions.
1. The connectors included in the high-voltage
circuit are as follows.
• Engine controller connectors: CN6, CN7
• Relay connectors: EG4, CJAA
• Injector connectors: CN1, CN2, CN3, CN4,
CN5, CN6
• Terminals at injector ahead (inside the head
cover)
2. Always turn the starting switch OFF before
disconnecting or connecting the connectors.
3. Never start the engine if a T-adapter has been
inserted or connected to the connector.
★ Operate the starting switch only to the OFF
or ON positions. Never turn it to the START
position.
20-158 HM400-1
(12)
1
TESTING AND ADJUSTING ADJUSTING TRANSMISSION CONTROLLER
ADJUSTING TRANSMISSION CONTROLLER

1. Setting rotary switch 2. Adjusting transmission
★ If the transmission controller has been re- ★ After carrying out any of the following oper-
placed, set the rotary switches for the net- ations, adjust the transmission in order to
work data and model selection as follows. adjust the fitting between the transmission
★ Use a precision cross-head screwdriver and and the transmission controller.
turn the rotary switch slowly. • When the transmission has been over-
★ The ? mark on the rotary switch is the hauled or replaced
guideline for setting. • When the transmission control valve
1) Remove 2 grommets at the top of the con- has been repaired or replaced
troller. • When the transmission controller has
2) Align the SW1 rotary switch and SW2 rotary been replaced
switch with the set position. • When the power train speed sensor has
★ Rotary switches and set position been repaired or replaced
• When the transmission oil temperature
sensor has been repaired or replaced
Switch Purpose of switch Position • When the transmission oil filter has be-
come clogged and has been cleaned
SW1 Network data 0
★ When adjusting the transmission, use the
SW2 Model data 0 service function of the machine monitor.
★ For details of the method of operation, see
SP ECIAL FUNC TION S O F MA CH IN E
MONITOR.
HM400-1 20-159
TESTING AND ADJUSTING METHOD FOR EMERGENCY ESCAPE WHEN THERE IS
FAILURE IN ELECTRICAL SYSTEM
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS

If any problem occurs in the electrical system of the engine control system or transmission control system, it
may become impossible to start the engine or to move the machine off.
If such a problem occurs, temporarily restore the engine electrical system or transmission electrical system,
move the machine to a safe place, then carry out troubleshooting.
1. 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.
1 2
Did [Engine system
caution lamp] on NO Is there fuel in fuel tank? NO Tow machine to safe
machine monitor flash place (see note)
when engine stopped?
YES YES
3 4 5
Does engine start when Does engine start when
Is following service code following fuse is following relay is If there is no relay to
displayed or recorded? YES replaced? NO replaced? NO replace or engine does
• DB22K (ENG) • Fuse unit (30A) • R36 (engine power not start, tow machine to
• BT2-No. 2 (10A) safe place (see note)
• BT4-No. 2 (10A) relay)
NO YES YES
Start engine and move
machine (do not turn
electric power ON except
when absolutely
necessary)
6 7
Is following service code If there is no controller to
displayed or recorded? NO Does engine start when NO replace, tow machine to
• DB20KT (ENG) engine controller is
replaced? safe place (see note)
absolutely necessary)
YES YES
8 9
Is following service code Does engine start when If there is no speed
displayed or recorded? NO following speed sensor is NO sensor to replace or
• DLE3LC (ENG) replaced? engine does not start,
• DLH1LC (ENG) • Ne speed sensor (Ne) tow machine to safe
• G speed sensor (G) place (see note)
NO 10 YES
Does engine start when Start engine and move
following relay is machine (do not turn
replaced? NO electric power ON except
• R02 (transmission when absolutely
neutral relay) necessary)
NO
Tow machine to safe

place (see note)
Note: If the engine cannot be started and the machine is towed, the parking brake cannot be released by oper-
ating the switch, so carry out the operation to release it temporarily. For details, see METHOD FOR
EMERGENCY RELEASE OF PARKING BRAKE.
20-160 HM400-1
2. 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 failure Lever position for speed range to move

Service code Escape method Remarks
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 Z 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
15SCL1 Occurrence condition 3 Escape procedure 1 D - 1: F2 in 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, trans-
15SFL1 Occurrence condition 3 Escape procedure 1 D - 1: F3, R1 - R2: R2 mission stays in neutral even
when lever is operated, and
15SFMA Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R1 machine does not move off
15SGL1 Occurrence condition 3 Escape procedure 1 D - 1: F5, R1 - R2: R3 or equivalent Occurrence condition 5:
15SGMA Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R1 Response of lever becomes
abnormal; lever does not
15SJL1 Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1 work as operated
15SJMA Occurrence condition 2 Escape procedure 1 D - 1: F2, R1 - R2: R1 When lever is operated,
Normal travel possible if display returns transmission shifts to neutral
D1B0KZ Occurrence condition 2 Escape procedure 4 Occurrence condition 6:
to normal (Note 1)
Speed range remains fixed;
Normal travel possible if display returns when the machine is moved
DAQ0KK Occurrence condition 2 Escape procedure 5
to normal (Note 1) off again, speed range does
Normal travel possible if display returns not shift
DAQ2KK Occurrence condition 2 Escape procedure 4
to normal (Note 1) Z When lever is returned to
Normal travel possible if display returns N, transmission shifts to
DAQ3KK Occurrence condition 4 Escape procedure 6 neutral, but after that,
to normal (Note 1)
transmission does not
Normal travel possible if display returns shift to any speed range
DAQ9KM Occurrence condition 4 Escape procedure 7
to normal (Note 1) Note 1:
Normal travel possible if display returns Even when the machine con-
DAQ9KQ Occurrence condition 4 Escape procedure 7
to normal (Note 1) dition is restored after a fail-
Normal travel possible if display returns ure, the neutral condition is
DAQAKQ Occurrence condition 1 Escape procedure 7 maintained until the lever is
to normal (Note 1)
returned to the N position.
DDTGKA Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1 Note 2:
DDTHKA Occurrence condition 1 Escape procedure 1 D - 1: F2 This phenomenon applies
DDTJKA Occurrence condition 1 Escape procedure 1 D - 1: F1 when there is no display on
the machine monitor and
DDTKKA Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1 there is also no display in the
DDTLKA Occurrence condition 1 Escape procedure 1 D - 1: F3, R1 - R2: R2 display window of the trans-
DDTMKA Occurrence condition 1 Escape procedure 1 D - 1: F5, R1 - R2: R3 or equivalent mission 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)
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
HM400-1 20-161
Condition when failure Lever position for speed range to move

Service code Escape method Remarks
occurred off after escape operation
DLF2KA Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1 Note 1:
DLF2LC Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1 Even when the machine con-
dition is restored after a fail-
DLT3KA Occurrence condition 6 Escape procedure 3 D - 1: F2, R1 - R2: R1 ure, the neutral condition is
DLT3LC Occurrence condition 6 Escape procedure 3 D - 1: F2, R1 - R2: R1 maintained until the lever is
DXH1KB Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1 returned to the N position.
Note 2:
DXH2KA Occurrence condition 3 Escape procedure 1 D - 1: F1, R1 - R2: R1 This phenomenon applies
DXH2KB Occurrence condition 3 Escape procedure 1 D - 1: F1 when there is no display on
DXH3KA Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R1 the machine monitor and
there is also no display in the
DXH3KB Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R1 display window of the trans-
DXH4KA Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R2 mission controller.
DXH4KB Occurrence condition 3 Escape procedure 1 D - 1: F3, R1 - R2: R2
DXH5KA Occurrence condition 3 Escape procedure 1 D - 1: F1, R1 - R2: R1
DXH6KA Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R1
DXH7KA Occurrence condition 3 Escape procedure 1 D - 1: F2
DXH7KB Occurrence condition 3 Escape procedure 1 D - 1: F1
- (Note 2) Occurrence condition 2 Escape procedure 5
to normal (Note 1)
Escape procedure 1:
1) Stop traveling and return the gearshift lever to the N position.
2) 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:
Tow the machine.
★ If the engine cannot be started and the machine is towed, the parking brake cannot be released by operating
the switch, so carry out the operation to release it temporarily. For details, see METHOD FOR EMERGEN-
CY RELEASE OF PARKING BRAKE.
Escape procedure 3:
1) Stop traveling and return the gearshift lever to the N position.
2) 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 starting switch at ON or with the engine started.
3) 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 starting switch is turned OFF.
20-162 HM400-1
Escape procedure 4:
Replace the transmission cut relay.
• Transmission cut relay: R15
Escape procedure 5:
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:
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)
HM400-1 20-163
TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR
ADJUSTING MACHINE MONITOR

Machine monitor rotary switches (SW1, SW2, SW3), dipswitches (SW5, SW6), and option setting connectors
(OP1 - OP7)
20-164 HM400-1
• In the following cases, check the settings of the rotary switches, dipswitches, 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 set-
ting)
• When parts have been replaced with new parts (service meter, odometer, reverse travel odometer set-
ting)
★ 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 TROUBLESHOOT-
ING OF MACHINE MONITOR SYSTEM (MON MODE) for details.
• Condition of switch setting functions and option setting connectors
Switch Position Purpose of switch Connector Remarks
For standard tires, set to posi-

SW1 0-F Travel speed compensation Not needed
tion 7
SW2 0-F Not used (always set to 0) OP3 always released
SW3 0-F Not used (always set to 0) Not needed
OFF Odometer display unit: km

Set to ON only in areas where
1 Not needed
mile display is used
ON Odometer display unit: Mile
OFF Exhaust brake: Not installed Released

2 OP1
ON Exhaust brake: Installed Connected
SW5
OFF
3 Not used (always set to 0) OP2 always released
ON
Left and right differential lock: Not

OFF Released
installed
4 OP4
ON Left and right differential lock: Installed Connected
OFF
ON
OFF
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.
HM400-1 20-165
★ All setting operations are carried out with the 1. Setting rotary switch SW1
starting switch OFF and the monitor panel re- Rotary switch SW1 is used to set the travel
moved. speed compensation. The machine monitor
★ Always set each switch and connector as in- uses the size of the standard tire to calculate the
structed. travel speed.
★ Be careful not to touch anything inside the grom- If the tire size is changed, adjust the position of
met except for the switch. the switch to compensate for the speed display.
★ When turning the rotary switch, use a precision ★ Tire size and setting position
cross-head screwdriver and turn slowly.
★ The protruding triangular part of the rotary Tire size SW1 Connector Remarks
switch is the setting arrow.
29.5 R25 7 Not needed HM400-1 standard tire
★ When changing the dipswitch, use a precision
flat-headed screwdriver and turn slowly.
★ When setting, always avoid foreign matters or ★ The connector in the table indicates the
dust. number of the connector to be connected or
★ After setting, be sure to install grommet. released when changing the setting. (In the
case of SW1, there is no need to connect or
release the connector.)
★ Travel speed compensation using SW1
Position Speed compensation Position Speed compensation
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%
2. Setting rotary switch SW2

Rotary switch SW2 is set as follows. The setting
must not be changed.
• Set position of SW2: 0
• Connector OP3: Released
3. Setting rotary switch SW3

Rotary switch SW3 is set as follows. The setting
• Set position of SW3: 0
• Connector setting: Not needed
20-166 HM400-1
4. Setting dipswitch SW5-1 8. Setting dipswitch SW6-1

Dipswitch SW5-1 is set as follows. The setting Dipswitch SW6-1 is set as follows. The setting
must not be changed. must not be changed.
• Set position of dipswitch SW6-1: OFF
Monitor Part No SW5-1 Connector Remarks • Connector OP2: Released
Distance: Displayed
7831-46-100* OFF
in km 9. Setting dipswitch SW6-2
Not Needed Dipswitch SW6-3 is set as follows. The setting
Distance: Displayed must not be changed.
7861-46-200* ON
in Miles
★ The connector in the table indicates the
number of the connector to be connected or 10. Setting dipswitch SW6-3
released when changing the setting. (In the Dipswitch SW6-3 is set as follows. The setting
case of SW5-1, there is no need to connec- must not be changed.
tor or release the connector.) • Set position of dipswitch SW6-3: OFF
• Connector operation: Not needed
5. Setting dipswitch SW5-2
Use dipswitch SW5-2 to set the exhaust brake. 11. Setting dipswitch SW6-4
When the exhaust brake has been installed or Dipswitch SW6-3 is set as follows. The setting
removed, set as follows. must not be changed.
Connector • Connector operation: Not needed
Exhaust brake SW5-2 Remarks
OP1
Not installed OFF Released
Installed ON Connected

Dipswitch SW5-3 is set as follows. The setting

Use dipswitch SW5-4 to set the left and right dif-
ferential lock.
When the left and right differential lock has been
installed or removed, set as follows.
Left and right SW5-2 Connector Remarks

differential lock OP4
Not installed OFF Released
Installed ON Connected
HM400-1 20-167
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR
SPECIAL FUNCTIONS OF MACHINE MONITOR
Normal functions and the special functions of machine monitor

The machine monitor is equipped with normal functions and special functions. Various items of data are dis-
played on the character display in the middle of the machine monitor. The display items are divided by the in-
ternal setting of the machine monitor, into automatic display items and items displayed when the machine
monitor switches are operated.
1) Normal functions: Operator mode
Functions for which the content is normally displayed or which can be displayed and operated by the oper-
ator operating the switches.
2) Special functions: Service mode
Functions which the serviceman can display and operate with the special switches to carry out inspection,
maintenance, and troubleshooting.
Operator mode ↔ Service mode 1

Service meter, odometer display Electrical system trouble data
1 8
function (default) display function
Distance traveled in reverse display Mechanical system trouble data
2 9
function display function
Filter, oil replacement interval 10 Machine data monitoring function
3
display function 11 Reduced cylinder mode
4 Telephone number input function 12 Adjustment function
5 Language selection function Filter, oil replacement time setting
13
6 Action code display function function
7 Failure code display function Initialize function (exclusive
14
function for factory)
20-168 HM400-1
(11)
1
Flow of modes and functions

Operator mode
2 Distance traveled in reverse display function
3 Filter, oil replacement interval

display function
Service meter, odometer
1
display function (default)
4 Telephone number input function
5 Language selection function
(Automatic) 2 Distance traveled in reverse display function 1 Meter display function
6 Action code display function 7 Failure code display function
(ID input:
& + 6491)
Service mode
8 Electrical system trouble data display function
9 M ec hanical system trouble data display function
10 Machine data monitoring function Sub menu: 5 types
11 Reduced cylinder mode
12 Adjustment function Sub menu: 2 types
13 Filter, oil replacement time

setting function
14 Initialize function (Exclusive function for factory)
8 Electrical system trouble data display function
HM400-1 20-169
(11)
1
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 automati-
cally 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
★ 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 starting switch is turned OFF.
Character display
The character display consists of a top line and bot-
tom line with 16 characters each. A combination of
the following characters (alphabet and numerals)
and symbols is displayed according to the content.
1) Numerals: 1, 2, 3 . . .
2) Small letters: a, b, c . . .
3) Capital letters: A, B, C . . .
4) Katakana: Japanese display only
5) Symbols: @, ¥, $ . . .
6) Special characters
Control switches
Control of the machine monitor display is all carried
out with machine monitor mode selector switches (1)
and (2).
The following functions are provided for the buttons
of each switch.
1) !: Select, Run
2) ": Cancel, Release, Select (YES/NO only)
3) >: Right, Next, Continue
4) <: Left, Previous, Return
20-170 HM400-1
(11)
1
Operation and displays for operator mode

1. Service meter, odometer display function
When the starting 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 FUNC-
TION, Machine monitor system.
2. Distance traveled in reverse display function

Use the switch to display the total distance
traveled in reverse of the machine monitor (Fig.
2)
3. Filter, oil replacement interval display func-

tion
1) Filter, oil replacement time display (auto-
matic display)
When the replacement interval for the filters
or oil approaches, this information is auto-
matically displayed on the machine monitor
to recommend the operator to carry out
maintenance (Fig. 3: example).
2) Resetting replacement time (selection menu)

When the maintenance operation for the fil-
ters and oil replacement has been complet-
ed, the switches on the machine monitor
can be used to reset the interval (Fig. 4)
★ The replacement time can be set using
Service mode.
HM400-1 20-171
(11)
1
4. Telephone number input function

The telephone number set inside the machine
monitor can be input, corrected, or canceled by
operating the switches (Fig. 5).
★ When action code [E03] is displayed, the tel-
ephone number is displayed at the same
time as [CALL].
5. Language selection function

The language used for the machine monitor dis-
play can be selected by operating the switches
(Fig. 6)
★ The functions of Service mode are not in-
cluded in the functions for display selection,
so they are always displayed in English.
6. Action code display function

If any abnormality occurs on the machine, the
degree of the abnormality is automatically dis-
played 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 dis-
played, [CALL+ Telephone number] is not
displayed.
★ Correspondence between user code and
recommendation to operator
Action code CALL+ Telephone number Action recommended to operator
• Carry out inspection and maintenance after

E01 Not displayed completion of operations or when changing shifts
between operators
• When overrun related display is shown:

Reduce engine speed and machine speed while
continuing operations.
E02 Not displayed
• When overheat related display is shown:
Stop machine and keep engine running at mid-range
speed under no load.
• Stop engine and machine immediately and contact

E03 Displayed
serviceman.
20-172 HM400-1
(11)
1
7. Failure code display function

While the action code is being displayed on the
machine monitor, press the [>] button once to
display the failure codes for the existing failures
(Fig. 8: example).
• [>] Button: Displays failure code
★ The failure codes detected in the past are di-
vided into failures of the electrical system
and the mechanical system and are record-
ed as trouble data. (For details, see Service
mode.)
★ If more than one failure is occurring, press
the [>] button once more to display the other
failure codes.
★ After pressing the [>] button to display all the
existing failures, press the [>] button once
more to return to the service meter/odome-
ter display screen.
If the [>] button is pressed once more, the
failure codes will be displayed again from
the beginning.
If the switch is not operated for 10 seconds,
the display will switch automatically to the
action code screen.
★ With the service code display function, the
following data are displayed (Fig. 9).
A: Failure code
(4 digits for location code + 2 digits for
problem code)
B: Controller code
(MON: Machine monitor)
(ENG: Engine controller)
(TM: Transmission controller)
(BK: Retarder controller)
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), the data that are displayed are par-
tially different.
★ If no switch is operated on the failure code
display screen for more than 30 seconds,
the display automatically returns to the ac-
tion code display screen.
HM400-1 20-173
(11)
1
Failure code table
Location of failure Nature of failure

Failure code Controller Action code
(location, component with failure) (problem, nature of failure)
1380MW Lock-up clutch Slipping (MW) TM E03
1500LO Transmission clutch * See separate table (L0) TM E03
15BONX Transmission oil filter Clogged (NX) TM E01
15GOMW R clutch Slipping (MW) TM E03
15HOMW Hi clutch Slipping (MW) TM E03
15JOMW Lo clutch Slipping (MW) TM E03
15KOMW 1st clutch Slipping (MW) TM E03
15LOMW 2nd clutch Slipping (MW) TM E03
15MOMW 3rd clutch Slipping (MW) TM E03
15SBL1 ECMV for R clutch * See separate table (L1) TM E03
15SBMA ECMV for R clutch Function impossible (MA) TM E03
15SCL1 ECMV for Hi clutch * See separate table (L1) TM E03
15SCMA ECMV for Hi clutch Function impossible (MA) TM E03
15SDL1 ECMV for Lo clutch * See separate table (L1) TM E03
15SDMA ECMV for Lo clutch Function impossible (MA) TM E03
15SEL1 ECMV for 1st clutch * See separate table (L1) TM E03
15SEMA ECMV for 1st clutch Function impossible (MA) TM E03
15SFL1 ECMV for 2nd clutch * See separate table (L1) TM E03
15SFMA ECMV for 2nd clutch Function impossible (MA) TM E03
5SGL1 ECMV for 3rd clutch * See separate table (L1) TM E03
15SGMA ECMV for 3rd clutch Function impossible (MA) TM E03
15SJL1 ECMV for lock-up clutch * See separate table (L1) TM E03
15SJMA ECMV for lock-up clutch Function impossible (MA) TM E03
15SKL1 ECMV for inter-axle differential lock clutch * See separate table (L1) TM E03
15SKMA ECMV for inter-axle differential lock clutch Function impossible (MA) TM E01
2A62L1 Front wheel differential lock control valve * See separate table (L1) BK E01
2A62LH Front wheel differential lock control valve * See separate table (LH) BK E01
2B61MW Inter-axle differential lock clutch Slipping (MW) TM E01
2B62L1 Rear wheel differential lock control valve * See separate table (L1) BK E01
2B62LH Rear wheel differential lock control valve * See separate table (LH) BK E01
2C4MNX Brake cooling filter Clogged (NX) BK E01
2D01CA Front brake (right) Wear (CA) BK E01
2D02CA Front brake (left) Wear (CA) BK E01
2D03CA Center brake (right) Wear (CA) BK E01
2D04CA Center brake (left) Wear (CA) BK E01
2D05CA Rear brake (right) Wear (CA) BK E01
2D06CA Rear brake (left) Wear (CA) BK E01
Mistaken operation or mistaken
2F00KM Parking brake TM -
setting (KM)
2G42ZG Accumulator (front) Drop in oil pressure (ZG) BK E03
2G43ZG Accumulator (rear) Drop in oil pressure (ZG) BK E03
20-174 HM400-1
1
6

6014NX Hydraulic tank filter Clogged (NX) TM E01
989A00 Engine overrun prevention command signal Actuated (OO) TM E02
989AKZ Engine overrun prevention command signal Disconnection or short circuit (KZ) TM E01
989D00 Rear overturn signal Actuated (OO) TM -
A00N1 Engine Overrun (N1) ENG E02
A570NX Engine oil filter Clogged (NX) ENG E01
AA10NX Air cleaner element Clogged (NX) TM E01
AB00MA Alternator Function impossible (MA) TM E03
AD00L2 Common rail * See separate table (L2) ENG E03
AD00MA Common rail Function impossible (MA) ENG E03
AD10L3 Fuel supply pump * See separate table (L3) ENG E03
AD10MA Fuel supply pump Function impossible (MA) ENG E03
AD10MB Fuel supply pump Drop in function (MB) ENG E03
AD11KA Fuel supply pump solenoid valve 1 Disconnection (KA) ENG E03
AD11KB Fuel supply pump solenoid valve 1 Short circuit (KB) ENG E03
AD51KA Fuel supply pump solenoid valve 2 Disconnection (KA) ENG E03
AD51KB Fuel supply pump solenoid valve 2 Short circuit (KB) ENG E03
ADA1KA No. 1 injector solenoid valve Disconnection (KA) ENG E03
ADAZKB No. 1, 2, 3 injector solenoid valve Short circuit (KB) ENG E03
ADB1KA No. 2 injector solenoid valve Disconnection (KA) ENG E03
ADC1KA No. 3 injector solenoid valve Disconnection (KA) ENG E03
ADD1KA No. 4 injector solenoid valve Disconnection (KA) ENG E03
ADDZKB No. 4, 5, 6 injector solenoid valve Short circuit (KB) ENG E03
ADE1KA No. 5 injector solenoid valve Disconnection (KA) ENG E03
ADF1KA No. 6 injector solenoid valve Disconnection (KA) ENG E03
B@BAZG Engine oil Drop in oil pressure (ZG) ENG E03
B@BAZK Engine oil Drop in level (ZK) ENG E01
B@BAZG Radiator water Overheat (NS) ENG E02
B@BCZK Radiator water Drop in level (ZK) TM E01
B@C6NS Front brake oil Overheat (NS) MON E02
B@C7NS Rear brake oil Overheat (NS) MON E02
B@C8NS Center brake oil Overheat (NS) MON E02
B@CENS Torque converter Overheat (NS) MON E02
B@HAZK Hydraulic tank oil Drop in level (ZK) TM E01
B@JANS Steering oil Overheat (NS) TM E02
D181KZ Preheating relay contact Disconnection or short circuit (KZ) ENG E03
D182KZ Preheating relay coil Disconnection or short circuit (KZ) ENG E03
D1B0KZ Transmission cut relay Disconnection or short circuit (KZ) TM E03
D1C0KZ Brake cut relay Disconnection or short circuit (KZ) BK E03
D1D0KB Engine controller load power source relay Short circuit (KB) ENG E01
HM400-1 20-175
1

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)
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 TM E03
(KP)
(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 (q1) Drop in power source voltage, input (KK) BK E03
DB11KK Retarder controller (q1) main power supply line Drop in power source voltage, input (KK) BK E03
DB12KK Retarder controller (q1) load power supply line Drop in power source voltage, input (KK) BK E03
Retarder controller (q1) battery direct power
DB13KK Drop in power source voltage, input (KK) BK E03
supply line
(DB19KM) Retarder controller (q1) wiring harness BK E03
(KM)
DB1SKQ Retarder controller (q1) S-NET line Non match in model selection signal (KQ) BK E03
DB1SKR Retarder controller (q1) S-NET MON E03
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
DB2SKR Engine controller S-NET MON E03
DD11KB Starting 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
20-176 HM400-1
1
6

DDTKKA Fill switch for 1st clutch Disconnection (KA) TM E03
DDTLKA Fill sw itch for 2nd clutch Disconnection (KA) TM E03
DDTMKA Fill sw itch for 3rd clutch Disconnection (KA) TM E03
DDTNKA Fill switch for R clutch Disconnection (KA) TM E03
DF10KA Gearshift lever Disconnection (KA) TM E03
DF10KB Gearshift lever Short circuit (KB) TM E03
Engine water temperature sensor (for high tem-
DGE2KX Input signal outside range (KX) ENG E01
perature)
Engine water temperature sensor (for low tem-
DGE3L6 * See separate table (L6) ENG E01
perature)
DGE4KX Fuel temperature sensor Input signal outside range (KX) ENG E01
DGF1KX Transmission valve oil temperature sensor Input signal outside range (KX) TM E03
DGR2L8 Brake oil temperature sensor (rear) * See separate table (L8) TM E01
DGR3L8 Brake oil temperature sensor (center) * See separate table (L8) TM E01
DGR4L8 Brake oil temperature sensor (front) * See separate table (L8) TM E01
DGT1KX Torque converter oil temperature sensor Input signal outside range (KX) TM E01
DH30KX Boost pressure sensor Input signal outside range (KX) ENG E01
DH40KX Common rail pressure sensor Input signal outside range (KX) ENG E03
DHT5KX Torque converter oil pressure sensor Input signal outside range (KX) TM E01
DHT5L6 Torque converter oil pressure sensor * See separate table (L6) TM E01
DHU2KX Accumulator oil pressure sensor (front) Input signal outside range (KX) BK E01
DHU3KX Accumulator oil pressure sensor (rear) Input signal outside range (KX) BK E01
DJF1KA Fuel level sensor Disconnection (KA) TM E01
DK10KX Throttle angle sensor Input signal outside range (KX) ENG E03
DK11KX Throttle angle sensor Input signal outside range (KX) TM E03
DK51L5 Retarder lever potentiometer * See separate table (L5) BK E03
DK52KX Dump lever potentiometer 1 Input signal outside range (KX) BK E03
DK53L8 Dump lever potentiometer 2 * See separate table (L8) BK E03
DK54KX Body position sensor Input signal outside range (KX) BK E03
DLE2KA Engine speed sensor Disconnection (KA) TM E03
DLE2LC Engine speed sensor * See separate table (LC) TM E03
DLE3LC Engine Ne speed sensor * See separate table (LC) ENG E03
DLF1KA Transmission input shaft speed sensor Disconnection (KA) TM E03
DLF1LC Transmission input shaft speed sensor * See separate table (LC) TM E03
DLF2KA Transmission intermediate shaft speed sensor Disconnection (KA) TM E03
DLF2LC Transmission intermediate shaft speed sensor * See separate table (LC) TM E03
DLT4KA Transmission output shaft F speed sensor Disconnection (KA) BK E01
DLH1LC Engine G speed sensor * See separate table (LC) ENG E03
DLT3KA Transmission output shaft R speed sensor Disconnection (KA) TM E03
DLT3KA Transmission output shaft R speed sensor Disconnection (KA) BK E01
DLT3LC Transmission output shaft R speed sensor Separate table (LC) TM E03
HM400-1 20-177

DV00KB Alarm buzzer Short circuit (KB) MON E01
DW71KZ E xhaust brake solenoid Disconnection or short circuit (KZ) BK E01
DW72KZ Dum p lever kick-out solenoid Disconnection or short circuit (KZ) BK E01
DW73KZ Dump selector valve solenoid Disconnection or short circuit (KZ) BK E03
DX11KA Rear brake reducing pressure valve solenoid Disconnection (KA) BK E03
DX11KB Rear brake reducing pressure valve solenoid Short circuit (KB) BK E03
DX11KY Rear brake reducing pressure valve solenoid Short circuit in power supply line ((KY) BK E03
DX12KA Front brake reducing pressure valve solenoid Disconnection (KA) BK E03
DX12KB Front brake reducing pressure valve solenoid Short circuit (KB) BK E03
DX12KY Front brake reducing pressure valve solenoid Short circuit in power supply line ((KY) BK E03
DX13KA Dump EPC valve solenoid Disconnection (KA) BK E03
DX13KB Dump EPC valve solenoid Short circuit (KB) BK E03
DX13KY Dump EPC valve solenoid Short circuit in power supply line ((KY) BK E03
DX14KZ Rear wheel differential lock solenoid Disconnection or short circuit (KZ) BK E03
DX15KZ Front wheel differential lock solenoid Disconnection or short circuit (KZ) BK E03
DXH0KA Solenoid for inter-axle differential lock Disconnection (KA) TM E01
DXH0KB Solenoid for inter-axle differential lock Short circuit (KB) TM E01
DXH1KA Solenoid for lock-up clutch Disconnection (KA) TM E03
DXH1KB Solenoid for lock-up clutch Short circuit (KB) TM E03
DXH2KA Solenoid for Hi clutch Disconnection (KA) TM E03
DXH2KB Solenoid for Hi clutch Short circuit (KB) TM E03
DXH3KA Solenoid for Lo clutch Disconnection (KA) TM E03
DXH3KB Solenoid for Lo clutch Short circuit (KB) TM E03
DXH4KA Solenoid for 1st clutch Disconnection (KA) TM E03
DXH4KB Solenoid for 1st clutch Short circuit (KB) TM E03
DXH5KA Solenoid for 2nd clutch Disconnection (KA) TM E03
DXH5KB Solenoid for 2nd clutch Short circuit (KB) TM E03
DXH6KA Solenoid for 3rd clutch Disconnection (KA) TM E03
DXH6KB Solenoid for 3rd clutch Short circuit (KB) TM E03
DXH7KA Solenoid for R clutch Disconnection (KA) TM E03
DXH7KB Solenoid for R clutch Short circuit (KB) TM E03
20-178 HM400-1
* Separate table: Detailed phenomena of L Series problem codes (L*)
Problem code Nature
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, water 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
★ Failure codes with ( )

These failure codes are not recorded as trouble data for either the electrical system or the mechanical sys-
tem.
★ Controller codes and troubleshooting mode names
The controller code name shown in the Controller column and the troubleshooting mode name in the trou-
bleshooting section are linked, so check the controller code for the failure code displayed, then go to the
applicable troubleshooting mode.
ENG: Troubleshooting of engine controller system (ENG MODE)
TM: Troubleshooting of transmission controller system (TM MODE)
BK: Troubleshooting of retarder controller (q1) system (BK MODE)
MON: Troubleshooting of machine monitor system (MON MODE)
HM400-1 20-179
1
6
Procedure for switching to Service mode and

screen display
★ When using Service mode, carry out the follow-
ing special operation to switch the screen dis-
play.
1) Checking screen display

With the machine monitor in the operator mode,
check that the screen is one of the following dis-
plays: Service meter/odometer, action code, or
failure code.
2) Initial screen display for ID input

Press the following 2 buttons at the same time
for at least 5 seconds to display the initial screen
display for the ID input (Fig. 1).
• [!] button and [<] button
★ If the buttons are held pressed for at least 5
sec, the whole screen will give no display, so
check this condition, then release the but-
tons.
3) Inputting ID, confirming

Operate the buttons to input the ID (Fig. 2).
★ ID: 6491
• [>] 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)
Note: When the cursor is at the left side, the
screen returns to the normal screen (oper-
ator mode).
If the cursor is not at the left side, the cur-
sor returns to the left side.
★ If the switch on the ID input screen is not op-
erated for more than 60 seconds, the screen
returns automatically to the normal screen.
4) Displaying menu initial screen

After confirming all four digits of the ID, the menu
initial screen of Service mode is displayed (Fig.
3).
★ Once the ID has been input and confirmed,
it remains effective until the starting switch is
turned OFF.
20-180 HM400-1
(11)
1
5) Menu selection in Service mode

Press the [>] or [<] buttons on the menu screen
and the menus of Service mode are displayed
endlessly in the following order (Fig. 4).
★ The menu is displayed in the places marked
with [*].
• [>] button: Goes on to next menu
• [<] button: Goes back to previous menu
(1) ELECTRICAL FAULT: Trouble data display
function for electrical system
(2) MACHINE FAULT: Trouble data display
function for mechanical system
(3) REAL-TIME MONITOR: Machine data mon-
itoring function
(4) CYLINDER CUT-OUT: Reduced cylinder
mode
(5) TUNING: Adjustment function
(6) MAINTENANCE MONITOR: Filter, oil re-
placement time setting function
(7) INITIALIZE: Initialize function (exclusive
function for factory)
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.
(1) When continuing operations in another
mode or function:
Press the [!] button and return to the mode
screen to be used or menu screen to be
used.
★ Note that if the [!] button is pressed on
the YES/NO screen, the function will be
executed.
★ If you return to the normal screen (oper-
ator mode) by mistake, repeat the pro-
cedure from Step 1) above (there is no
need to input the ID again).
(2) When completing all operations:
Turn the starting switch OFF.
HM400-1 20-181
(11)
1
8. Electrical system trouble data display func-

tion (ELECTRIC FAULT)
The machine monitor retains the data for prob-
lems that occurred in the electrical system in the
past as failure codes. They can be displayed as
follows.
1) Menu selection
Select the display function for trouble data
on the menu screen of Service mode (Fig.
1).
★ The total number of trouble data items re-
corded in memory is displayed in the [**]
portion.
2) Trouble data display

With the menu selected, press the ["] but-
ton and display the trouble data recorded in
memory (Fig. 2: example).
• ["] button: Runs menu
3) Displayed trouble data

With the display function for trouble data of the
electrical system, the following data can be dis-
played (Fig. 3).
1: Record number (recorded up to a maximum
of 20 items)
A: Failure code (4-digit location code + 2-digit
problem code)
2: Number of occurrences (number of occur-
rences of same code in past)
3: Elapsed time 1 (time elapsed on service me-
ter since first occurrence)
4: Elapsed time 2 (time elapsed on service me-
ter since last occurrence)
★ Failure codes for problems that are still ex-
isting are shown on a flashing display.
★ For details of the failure codes displayed,
see FAILURE CODE TABLE in the explana-
tion for the failure code display function.
★ Note that with the trouble data display func-
tion and failure code display function for the
electrical system, the displayed data are
partially different.
★ If no trouble data are recorded, [0] is dis-
played on the display portion for 1, and [-] is
displayed on the display portion for A, 2, 3,
and 4.
20-182 HM400-1
(11)
1
4) Switching trouble data display

If the [>] button or [<] button is pressed dur-
ing the display of trouble data, the display
switches to the other recorded trouble data.
• [>] button: Goes on to data for next
record number
• [<] button: Goes back to data for last
record number
5) Deleting individual trouble data

i) Display the trouble data to be deleted,
then press the ["] button once to dis-
play the individual item CLEAR screen
(Fig. 4).
• ["] button: Display CLEAR screen
ii) Operate the buttons according to the
explanation on the screen (Fig. 4).
• [<] button: Select YES
• [>] button: Select NO
• [!] button: Run
★ The data for an existing problem (flash-
ing display) cannot be deleted.
6) Deleting all trouble data

i) Display the trouble data, then press the
[>] button or [<] button to display the
ALL CLEAR menu (Fig. 5).
ii) Press the ["] button once to display
the ALL CLEAR screen (Fig. 6).
• ["] button: Run ALL CLEAR menu
iii) 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.
HM400-1 20-183
1
9. Mechanical system trouble data display

function (MACHINE FAULT)
The machine monitor retains the data for prob-
lems that occurred in the electrical system in the
past as failure codes. They can be displayed as
follows.
1) Menu selection
Select the display function for trouble data
1).
★ The total number of trouble data items
recorded in memory is displayed in the
[**] portion.
2) Trouble data display

ton and display the trouble data recorded in
memory (Fig. 2: example).
3) Displayed trouble data

With the display function for trouble data of
the mechanical system, the following data
can be displayed (Fig. 3).
1: Record number
A: Failure code (4-digit location code + 2-
digit problem code)
2: Number of occurrences (number of oc-
currences of same code in past)
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 dis-
played, see FAILURE CODE TABLE in
the explanation for the failure code dis-
play function.
★ Note that with the trouble data display
function and failure code display func-
tion for the mechanical system, the dis-
played data are partially different.
★ If no trouble data are recorded, [0] is dis-
played on the display portion for 1, and
[-] is displayed on the display portion for
A, 2, 3, and 4.
20-184 HM400-1
(11)
1
4) Switching trouble data display

If the [>] button or [<] button is pressed dur-
ing the display of trouble data, the display
switches to the other recorded trouble data.
• [>] button: Goes on to data for next
record number
• [<] button: Goes back to data for last
record number
5) Deleting trouble data (not permitted)

★ The trouble data for the mechanical sys-
tem cannot be deleted.
HM400-1 20-185
1
10. Machine data monitoring function (REAL-

TIME MONITOR)
The machine monitor can monitor the condition
of the machine in real time through the signals
from the sensors installed to various parts of the
machine.
In the machine data monitoring function, the fol-
lowing 2 types of display can be shown.
• 1st item independent display (for each con-
troller)
• 2nd item simultaneous display (code input)
1) Menu selection
Select the machine data monitoring function
1).
2) Display sub menu

ton and display the initial screen of the sub
menu (Fig. 2).
3) Select sub menu

If the [>] button or [<] button is pressed on
the sub menu screen, the sub menu dis-
plays endlessly in the following order (Fig.
3).
★ The sub menu is displayed in the [*] por-
tion.
• [>] button: Goes on to next menu
• [<] button: Goes back to last menu
(1) MONITOR PANEL: Machine monitor
system
(2) TRANSMISSION: Transmission con-
troller system
(3) ENGINE: Engine controller system
(4) BRAKE: Retarder controller system
(5) 2 ITEMS: 2-item display
20-186 HM400-1
(11)
1
4) Setting 1st item individual monitoring

i) Select the controller system for moni-
toring on the sub menu screen (Fig. 4:
example).
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 monitor-
ing, the monitor data is held and the [ ]

mark flashes. If the [ ] button is pressed
again, it becomes active again.
5) Display data for 1st item individual monitor-

ing
On the 1st item individual monitoring
screen, the following data are displayed
(Fig. 6).
A: Item display
B: Monitoring code (5-digit)
1: Monitoring data (including unit)
★ For details, see MONITORING CODE
TABLE.
HM400-1 20-187
6) Setting 2nd item simultaneous monitoring

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 con-
firmed

• [ ] button: Returns to code input
screen
iv) When both of the monitoring codes

h a v e b e e n co n fir m e d , th e s c re e n
switches to the 2nd item display screen
(Fig. 9: example).
★ To hold or cancel monitoring data:

If the [ ] button is pressed during mon-
itoring, the monitor data is held and the

[ ] mark flashes. If the [ ] button is
pressed again, it becomes active again.
7) Display data for 2nd item simultaneous

monitoring
On the 2nd item simultaneous monitoring
screen, the following data are displayed
(Fig. 5).
A: Monitoring code 1
1: Monitoring data 1 (including unit)
B: Monitoring code 2
2: Monitoring data 2 (including unit)
★ For details, see MONITORING CODE
TABLE.
20-188 HM400-1
Monitoring Code Table
MONITOR PANEL [Monitor panel system]

Monitoring
No. Monitoring item Item display Display range Unit
code
1 E ngine speed ENG SPEED 01001 0 - 65535 rpm
2 E ngine water te m perature (for high tem pe ra ture) COOLANT TEMP H 04102 0 - 160 1
3 Torque converter oil temperature T/C OIL TEMP 30100 0 - 160 1
4 Brake oil temperature BRAKE OIL TEMP 30200 0 - 160 1
5 Fuel level sensor input resistance value FUEL SENSOR 04201 0 - 150 Ω
6 Rheostat input voltage RHEOSTAT 30300 0.0 - 51.0 V
7 Operation status of AISS switch AISS SW 30400 ON/OFF Status display
UPPER/NEU-
8 Operation status of exhaust brake switch EXH BRAKE SW 30500 Status display
TRAL/LOWER
UPPER/
9 Operation status of inter-axle differential lock switch INTER AXLE SW 30600 Status display
LOWER
UPPER/NEU-
10 Operation status of left and right differential lock switch L-R DIFF SW 30610 Status display
TRAL/LOWER
11 Operation status of left and right differential lock pedal FOOT DIFF SW 30620 ON/OFF Status display
ON/OFF, ON/
12 Input status of connector check (1 & 2) CONN CHK 1, 2 30700 Status display
OFF
0 - F, 0 - F, 0 -
13 Setting status of rotary switch (SW1 & SW2 & SW3) SW1, SW2, SW3 30800 Status display
F,
ON/OFF, ON/
14 Setting status of dip switch (SW5-1 & SW5-2) SW5-1, SW5-2 30900 Status display
OFF
ON/OFF, ON/
OFF
ON/OFF, ON/
OFF
ON/OFF, ON/
OFF
ON/OFF, ON/
18 Setting status of option selection connector (OP1 & OP2) OPTION 1, 2 31000 Status display
OFF
ON/OFF, ON/
OFF
ON/OFF, ON/
OFF
★ Note: 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)
• No. 14: Setting status of dipswitch (displays 2 items at same time)
• No. 18: Setting status of option selection connector (displays 2 items at same time)
HM400-1 20-189
TRANSMISSION [Transmission controller system]

Monitoring
No. Monitoring item Item display display range Unit
code
1 Transm ission se rvice m eter SERVICE METER 31100 0 - 65535 h
2 Transm ission in put sha ft speed T/M SPEED: IN 31200 0 - 65535 rpm
3 Transmission intermediate shaft speed T/M SPEED: MID 31300 0 - 65535 rpm
4 Transmission output shaft (R) speed T/M SPEED: OUT 31400 0 - 65535 rpm
5 Actuation status of Lo clutch fill switch FILL SW (L) 31510 ON/OFF Status display
6 Actuation status of Hi clutch fill switch FILL SW (H) 31511 ON/OFF Status display
7 Actuation status of 1st clutch fill switch FILL SW (1st) 31512 ON/OFF Status display
8 Actuation status of 2nd clutch fill switch FILL SW (2nd) 31513 ON/OFF Status display
9 Actuation status of 3rd clutch fill switch FILL SW (3rd) 31514 ON/OFF Status display
10 Actuation status of R clutch fill switch FILL SW (R) 31516 ON/OFF Status display
11 Actuation status of L/U clutch fill switch FILL SW (L/U) 31509 ON/OFF Status display
Actuation status of transmission differential lock clutch FILL SW (DIFF) 31517 ON/OFF Status display
12
fill switch
13 Output current command value for Hi clutch solenoid ECMV H DIR 31600 0 - 1020 mA
14 Output current detection value for Hi clutch solenoid ECMV H 31610 0 - 1020 mA
15 Output current command value for Lo clutch solenoid ECMV L DIR 31601 0 - 1020 mA
16 Output current detection value for Lo clutch solenoid ECMV L 31611 0 - 1020 mA
17 Output current command value for 1st clutch solenoid ECMV 1 DIR 31602 0 - 1020 mA
18 Output current detection value for 1st clutch solenoid ECMV 1 31612 0 - 1020 mA
19 Output current command value for 2nd clutch solenoid ECMV 2 DIR 31603 0 - 1020 mA
20 Output current detection value for 2nd clutch solenoid ECMV 2 31613 0 - 1020 mA
21 Output current command value for 3rd clutch solenoid ECMV 3 DIR 31604 0 - 1020 mA
22 Output current detection value for 3rd clutch solenoid ECMV 3 31614 0 - 1020 mA
23 Output current command value for R clutch solenoid ECMV R DIR 31606 0 - 1020 mA
24 Output current detection value for R clutch solenoid ECMV R 31616 0 - 1020 mA
25 Output current command value for L/U clutch solenoid ECMV LU DIR 31609 0 - 1020 mA
26 Output current detection value for L/U clutch solenoid ECMV LU 31619 0 - 1020 mA
Output current command value for transmission differ- ECMV D DIR 31607 0 - 1020 mA
27
ential lock clutch solenoid
Output current detection value for transmission differ- ECMV D 31617 0 - 1020 mA
28
ential lock clutch solenoid
29 Hi clutch fill time FILL TIME H 41801 0 - 2550 ms
30 Lo clutch fill time FILL TIME L 41800 0 - 2550 ms
31 R clutch fill time FILL TIME R 41806 0 - 2550 ms
32 1st clutch fill time FILL TIME 1 41802 0 - 2550 ms
33 2nd clutch fill time FILL TIME 2 41803 0 - 2550 ms
34 3rd clutch fill time FILL TIME 3 41804 0 - 2550 ms
35 Hi clutch fill status FILL H 31501 0-2 Status display
36 Lo clutch fill status FILL L 31500 0-2 Status display
37 R clutch fill status FILL R 31506 0-2 Status display
38 1st clutch fill status FILL 1 31502 0-2 Status display
39 2nd clutch fill status FILL 2 31503 0-2 Status display
20-190 HM400-1
MONITOR PANEL [Monitor panel system]

Monitoring
code
40 3rd clutch fill status FILL 3 31504 0-2 Status display
41 A xle 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 starting 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 1
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/NOR-
55 Transmission oil level OIL LEVEL 33000 Status display
MAL
LOW/NOR-
56 Radiator water level COOLANT LEVEL 33100 Status display
MAL
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
★ 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)
HM400-1 20-191
ENGINE [Engine controller system]

Monitoring
code
1 E ngine spe ed ENG SPEED 01002 0 - 3000 rpm
2 A ccelerator sensor an gle THROTTLE POS 31701 0 - 100 %
3 Fuel temperature FUEL TEMP 04203 -30 - 100 1C
4 Transmission throttle correction value MODIFY SIGNAL 36000 -100 - 100 %

5 Axle sensor input voltage THROTTLE POS 31702 0.00 - 5.00 V
6 Target fuel injection level FUEL DELIVERY 36100 -30 - 600 mm3
7 Target common rail pressure RAIL PRESS (C) 36200 0 -150 MPa
8 Target injection timing INJECT TIMING 36300 -30.0 - 31.0 1CA
9 Common rail pressure RAIL PRESS (A) 36400 0 - 150 MPa

10 Boost pressure BOOST PRESS 36500 0 - 300 kPa
11 Operating mode status ENG STATUS 36600 0 - 255 Status display
12 Water temperature for engine high temperature COOLANT TEMP H 04102 0 - 150 1C
13 Water temperature for engine low temperature COOLANT TEMP L 04101 -30 - 100 1C
14 Converted torque value TORQUE RATIO 36700 0 - 100 %

Setting status of fuel injection quantity control switch (1
15 Q ADJUST SW1, 2 36800 0 - F. 0 - F Status display
& 2)
16 Input status of model selection 1 MACHINE SEL1 02704 GND/OPEN Status display
19 Controller ROM No. ENGINE ROM 20203 Numeral Status display
★ Note: The following monitoring item displays data for 2 systems at the same time.
• No. 15: Setting status of fuel injection quantity control switch (displays 2 items at same time)
20-192 HM400-1
BRAKE [Retarder controller (q1) system]

Monitoring
code
1 Brake service meter SERVICE METER 31101 0 - 65535 h
Output current command value for front brake EPC sole-
2 F BK OUTP DIR 33700 0 - 1020 mA
noid
Output current detection value for front brake EPC
3 F BRAKE OUTPUT 33701 0 - 1020 mA
solenoid
Output current command value for rear brake EPC
4 R BK OUTP DIR 33800 0 - 1020 mA
solenoid
Output current detection value for rear brake EPC sole-
5 R BRAKE OUTPUT 33801 0 - 1020 mA
noid
Retarder lever (q2) input (voltage & conversion 0.00 - 5.10 0 -
6 RETARD LEVER 33900 V (%)
amount) 100
Input status of retarder lever (q2) validation switch (1 & ON/OFF, ON/
7 RLV SW 1,2 34000 Status display
2) OFF
WORKING/
8 Operation status of retarder lever (q2) switch RETARDER 34100 Status display
RELEASE
9 Dump lever potentiometer 1 input voltage DUMP LEVER 1 34300 0.00 - 5.10 V
10 Dump lever potentiometer 2 input voltage DUMP LEVER 2 34301 0.00 - 5.10 V
11 Body position sensor input voltage BODY POSITION 34400 0.00 - 5.10 V
12 Input status of body seat switch BODY SEATING 34600 ON/OFF Status display
13 Output status of dump lever solenoid KICKOUT SOL 34700 ON/OFF Status display
14 Output status of dump selector solenoid SWV FOR HOIST 34800 ON/OFF Status display
15 Output current command value for dump EPC solenoid EPC HOIST DIR 34900 0 - 1020 mA
16 Output current detection value for dump EPC solenoid EPC HOIST 34901 0 - 1020 mA
17 Input status of overrun command OVERRUN SIG 35000 ON/OFF Status display
18 Input status of service brake oil pressure switch SERVICE BRAKE 35100 ON/OFF Status display
19 Input status of starting switch terminal C KEY SW C 32300 ON/OFF Status display
ON/OFF, ON/
20 Input status of connector check (1 & 2) CONN CHK 1,2 30702 Status display
OFF
21 Front & rear differential slipping condition INT DIFF SLIDE 35200 SLIDE/NO Status display
22 Input status manual differential lock command INT M DIFF SIG 35300 ON/OFF Status display
23 Transmission output shaft F speed T/M SPEED:OUT 31401 0 - 65535 rpm
24 Transmission output shaft R speed T/M DIFF OUT 31402 0 - 65535 rpm
25 Front accumulator oil pressure ACC OIL PRE F 35500 0.00 - 50.26 MPa
26 Rear accumulator oil pressure ACC OIL PRE R 35501 0.00 - 50.26 MPa
CLOGGED/
27 Clogging status of brake filter BK OIL FILTER 35600 Status display
NORMAL
CLOGGED/
28 Clogging status of brake cooling filter RETARD FILTER 35700 Status display
NORMAL
CLOGGED/
29 Wear status of R.H. front brake DISK WEAR FR 35800 Status display
NORMAL
CLOGGED/
30 Wear status of L.H. front brake DISK WEAR FL 35801 Status display
NORMAL
CLOGGED/
31 Wear status of R.H. center brake DISK WEAR RFR 35802 Status display
NORMAL
CLOGGED/
32 Wear status of L.H. center brake DISK WEAR RFL 35803 Status display
NORMAL
CLOGGED/
33 Wear status of R.H. rear brake DISK WEAR RRR 35804 Status display
NORMAL
CLOGGED/
34 Wear status of L.H. rear brake DISK WEAR RRL 35805 Status display
NORMAL
Exhaust brake solenoid output (detection status & ON/OFF, (ON/
35 EXH BRAKE 35900 Status display
command status) OFF)

q2. The lever is not installed in E-SPEC.
HM400-1 20-193
1
6
★ 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 ( ))
20-194 HM400-1
1
11. Reduced cylinder mode (CYLINDER CUT-OUT)

As one method of troubleshooting for the en-
gine, the machine monitor has a reduced cylin-
der function that can set the desired cylinder to
the NO INJECTION condition.
1) Starting engine
★ With this function, it is possible to use
the engine speed in the reduced cylin-
der mode to judge if there is a problem
with any cylinder, so the engine can be
used during the operation.
2) Menu selection
i) Select the reduced cylinder mode on
the menu screen of Service mode (Fig.
1).
ii) With the menu selected, press the [!]
button and display the cylinder selec-
tion screen (Fig. 2: example).
• [!] button: Runs menu
★ The cylinder No. and engine speed are
display at the same time.
3) Setting cut-out cylinder

Operate each button and select the cylinder
to be cut out (Fig. 3: example).
• [>] button: Selector cursor moves to
right
• [<] button: Selector cursor moves to left
• [!] button: Cylinder is confirmed
• ["] button: Returns to menu screen
★ When the [!] button is used to confirm
the cut-out cylinder, communication is
carried out between the machine moni-
tor and engine controller. During this
time, the cylinder No. flashes. After
completion of the communication, the
segment under the cylinder No. be-
comes black to show that the cylinder
has been cut out.
★ Single cylinders or multiple cylinders
can be cut out.
4) Canceling cylinder cut out

★ Cancel the cylinder cut out in the same
way as when setting the cut out (Fig. 4:
example).
HM400-1 20-195
(11)
1
12. Adjustment function (TUNING)

Through the transmission controller, the ma-
chine monitor can carry out the the adjustment
function to correct the difference in operating
feeling to a constant level caused by the the in-
dividual differences in the ECMV. It can also car-
ry out the self-adjusting learning function so
that a constant gearshifting feeling is maintained
in accordance with the wear of the transmission
clutch.
When the following operations related to the
power train have been carried out, perform the
adjustments.
• When the transmission has been over-
hauled or replaced
• When the transmission valve has been re-
placed Failure code Component name
• When the transmission controller has been DLF1KA Transmission input shaft
replaced speed sensor
DLF1LC
• When an abnormality has occurred in the
power train speed sensor and it has been re- DLF2KA Transmission intermediate
paired (for details, see the failure code in the DLF2LC shaft speed sensor
chart on the right) DLF2KA Transmission output shaft R
• When an abnormality has occurred in the DLF2LC speed sensor
transmission oil temperature sensor and it Transmission valve oil tem-
has been repaired (for details, see the fail- DLF2KA
perature sensor
ure 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 de-
tails, see the failure code in the chart on the
right)
For the adjustment operation, operate the ma-

chine monitor and machine itself, and carry out
the following items in order (Fig. 2).
★ ( ) indicates the menu to use for the adjust-
ment operation.
(1) Adjusting individual difference of valve (02:
ECMV TUNING AUTO)
(2) Resetting gearshifting feeling stabilized
learning data (01: TM TRIGGER)
(3) Gearshifting 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.
20-196 HM400-1
Preparatory work:
Adjusting ECMV oil temperature
★ It is necessary to carry out the adjustment oper-
ation at the specified oil temperature, so check
that there is no abnormality on the machine and
adjust the ECMV oil temperature as follows.
1) Start the engine.
2) Display [ECMV oil temperature] with the machine

data monitoring function. (Fig. 1).
• TRANSMISSION No. 50
3) Raise ECMV oil temperature to 60 - 70fC by

raising engine speed.
4) Keep engine speed in low idling for 3 minutes.

Before carrying out adjustment, be sure to check
that ECMV oil temperature is kept within 60 -
70fC.
HM400-1 20-197
(7)
1
Adjustment operation (1): Adjusting individual

difference of valve
★ See Preparatory work and check that the ECMV
oil temperature is at the specified temperature.
★ The adjustment operation is carried out auto-
matically three times for the Lo, Hi, R, 1st, 2nd,
and 3rd valves.
1) Set the machine to the following conditions.
• Parking brake switch: ON
• AISS LOW switch: LOW
• Gearshift lever: N position
• Engine: Low idling
• Accelerator pedal: OFF (released)
2) Operate the machine monitor and display the
adjustment menu screen (Fig. 4).
• Adjustment menu: 02: ECMV TUNING
AUTO
3) Check the condition of the machine again,

press the [ ] button, and start the adjustment
operation (Fig. 5).

• [ ] button: Runs adjustment menu
★ The adjustment is carried out consecutively
three times for the applicable clutches and dis-
plays a screen like the one shown on the right.
★ For each adjustment operation, the result is dis-
played as normal or abnormal, so take action ac-
cording to the display (Fig. 6).
• If [3-3 OK] is displayed:
The adjustment operation has been completed
correctly.
(When the starting switch is turned OFF, the ad-
justed value is recorded in the controller.)
• If [NG 1] (Outside compensation condition) is
displayed: No. Valve 1st time 2nd time 3rd time
Adjust the ECMV oil temperature correctly, 1 Lo IP L-1 IP L-2 IP L-3
check the set conditions of the machine again, 2 Hi IP H-1 IP H-2 IP H-3
then repeat from Step 1).
3 R IP R-1 IP R-2 IP R-3
• If [NG 2] (No fill) is displayed:
4 1st IP 1-1 IP 1-2 IP 1-3
Carry out troubleshooting for failure codes
U U
[15S[ ]MA] [DDT[ ]KA], and if it is found to be 5 2nd IP 2-1 IP 2-2 IP 2-3
normal, repeat from Step 1). 6 3rd IP 3-1 IP 3-2 IP 3-3
• If [NG 3] (Compensation value over] is dis-
played:
Carry out troubleshooting for failure code
U
[15S[ ]L1], and if it is found to be normal, repeat
from Step 1).
20-198 HM400-1
Adjustment operation (2): Resetting gearshifting

feeling stabilized learning data
1) Operate the machine monitor and display the
initial menu screen (Fig. 7).
• Initial menu: 01: TM TRIGGER
★ The present initial status is displayed on the
bottom line of the screen.
• Initializing completed: INITIAL STATUS
• Initializing not performed: TUNED
★ With the transmission adjustment, the learn-
ing data is initialized from the following oper-
ation, regardless of the present initial status.
[
2) With the menu selected, press the [ ] button
and display the initial screen of the sub menu
(Fig. 2).
[
• [ ] button: Runs initialize menu
3) Operate the buttons according to the screen

display.
T
• [ ] button: Run
★ After carrying out initializing, check that INI-
TIAL STATUS is displayed on the bottom
line of the screen.
HM400-1 20-199
Adjustment operation (3): Initial learning of gear-

shifting feeling stabilization
★ Check that the ECMV oil temperature is the
specified temperature. For details, see Prepar-
N
atory work.
Carry out the adjustment operation in a place

with ample room for traveling and where the sur-
rounding area is safe.
1) With the machine data monitoring function, dis-
play (R clutch fill status] (Fig. 10).
• TRANSMISSION No. 37
2) 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
3) Check the fill status with the monitoring display.
★ If the display is [0], go on to the next step.
★ If the display is [1], repeat Step 2) until it be-
comes [0].
4) 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 trans-
mission shifts up to F5, start the procedure
again and move the machine off in F2.
5) After traveling for 10 seconds in F4, release the
accelerator pedal, and allow the machine to
coast and shift down from F4 to F2.
★ Shift down: F4 > F3 > F2
★ Do not operate the brake while coasting.
6) Use the machine data monitoring function to
display [Lo clutch fill status] and [1st clutch fill
status] and check the fill status (Fig. 11).
• Lo clutch: TRANSMISSION No. 36
• Hi clutch: TRANSMISSION No. 38
★ If the display is [0], the correction is com-
plete.
★ If the display is [1], repeat Steps 4) and 5)
until it becomes [0].
20-200 HM400-1
13. Filter, oil replacement time setting function

(MAINTENANCE MONITOR)
The machine monitor can set the maintenance
interval for filters and oil, which form the base for
the filter and oil replacement time and display.
1) Menu selection
Select Filter, oil replacement time setting
function on the menu screen of Service
mode (Fig. 1).
2) Selecting filter, oil replacement time setting

item
i) With the menu selected, press the [!]
button and display the initial screen of
the set item (Fig. 2).
• [!] button: Runs menu
ii) 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).
3) If the maintenance items in the display for

the filter and oil replacement time set items
are selected, the following content is dis-
played (Fig. 3).
1: Code (2 digits)
A: Filter and oil replacement time set items
2: Remaining time to set replacement time
3: Number of times of replacement up to
present
4) Changing replacement interval

i) With the set items selected, press the
[!] button and display the interval input
screen (Fig. 4: example).
• [!] button: Executes change func-
tion
★ The presently set interval is dis-
played on the screen.
HM400-1 20-201
(11)
1
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 con-
firmed
T
• [ ] button: Returns to item selec-
tion screen
★ The time must always be input with
four digits. For numbers of less
than four digits, input 0s at the be-
ginning.
iii) When all the interval times are con-
firmed, the change confirmation screen
is displayed, so operate the buttons
according to the screen display (Fig. 5).
T
• [ ] button: Run
Table of filter and oil replacement time set items
No. Item Code Display Replacement time

1 Fuel filter 03 FUEL FILT 0500
2 Engine oil filter 02 ENG FILT 0500
3 Engine oil 01 ENG OIL 0500
4 Corrosion resistor 06 CORR RES 1000
5 Transmission oil 12 TM OIL 1000
6 Transmission oil filter 13 TM FILT 1000
7 Brake oil 17 BK OIL 1000
8 Brake oil filter 14 BK OIL FIL 1000
9 Brake cooling oil filter 16 BK C FIL 1000
10 Hydraulic filter 04 HYD FILT 2000
11 Differential case oil 11 DIFF OIL 2000
12 Final drive oil 08 FNL OIL 2000
13 Hydraulic oil 10 HYD OIL 4000
20-202 HM400-1
14. Initialize function (INITIALIZE)

(exclusive function for factory)
★ This is a special function for the factory and
is not used for service.
HM400-1 20-203
TROUBLESHOOTING
TROUBLESHOOTING
Points to remember when troubleshooting ................................................................................................ 20-302

Sequence of events in troubleshooting ..................................................................................................... 20-303
Points to remember when carrying out maintenance ................................................................................ 20-304
Checks before troubleshooting.................................................................................................................. 20-312
Connector types and mounting locations .................................................................................................. 20-313
Connection table for connector pin numbers............................................................................................. 20-327
Categories, procedure, and method of using troubleshooting charts ........................................................ 20-342
Troubleshooting of engine controller system (ENG MODE) ...................................................................... 20-401

Troubleshooting of transmission controller system (TM MODE) ............................................................... 20-501
Troubleshooting of retarder controller (q1) system (BK MODE) ............................................................... 20-701
Troubleshooting of machine monitor system (MON MODE) ..................................................................... 20-801
Troubleshooting of hydraulic, mechanical system (H MODE) ................................................................... 20-901
Troubleshooting of the engine body (S MODE)....................................................................................... 20-1001
HM400-1 20-301
(7)
1
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

¤ Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
¤ 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.
¤ If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
¤ Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
¤ When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
¤ When removing the plug or cap from a location which is under pressure from oil, water, 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, and important point is of course to understand the structure and function.
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 3) Other inspection items.

to disassemble the components. 4) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
• Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- Confirm the extent of the failure yourself, and
sembled. judge whether to handle it as a real failure or as
• It will become impossible to find the cause a problem with the method of operation, etc.
of the failure. fl When operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that may
the confidence of the user or operator. make the problem worse.
For this reason, when carrying out troubleshoot- 5. Troubleshooting
ing, it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting in tion in Items 2 – 4 to narrow down the causes of
accordance with the fixed procedure. failure, then use the troubleshooting flowchart to
2. Points to ask user or operator locate the position of the failure exactly.
1) Have any other problems occurred apart from fl The basic procedure for troubleshooting is
the problem that has been reported? as follows.
2) Was there anything strange about the ma- 1) Start from the simple points.
chine before the failure occurred? 2) Start from the most likely points.
3) Did the failure occur suddenly, or were there 3) Investigate other related parts or infor-
problems with the machine condition before mation.
this? 6. Measures to remove root cause of failure
4) Under what conditions did the failure occur? Even if the failure is repaired, if the root cause of
5) Had any repairs been carried out before the the failure is not repaired, the same failure will
failure? occur again.
When were these repairs carried out? To prevent this, always investigate why the prob-
6) Has the same kind of failure occurred be- lem occurred. Then, remove the root cause.
fore?
3. Check before troubleshooting
1) Check for symptoms of any abnormality in
the machine.
2) Check the CHECKS BEFORE STARTING items.
20-302 HM400-1
1
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Office, shop Jobsite

TEW00180 TEW00181
Step 1
Examination, confirmation of symptoms
1) When a request for repairs is received, first

ask the following points. Ring Ring
• Name of customer
• Type, serial number of machine
• Details of jobsite, etc.
2) Ask questions to gain an outline of the prob-
lem.
• Condition of failure
• Work being carried out at the time of the TEW00182
failure
• Operating environment
• Past history, details of maintenance, etc. Breakdown
Step 2
Determining probable location of cause TEW00183
1) Look at the troubleshooting section of the

shop manual to find locations of possible Step
causes.
Repair at jobsite
Hurray !
TEW00184 It's repalred
Step 3
Preparation of troubleshooting tools
TEW00185
1) Look at the table of troubleshooting tools in
the shop manual and prepare the necessary Step 7
tools. • Pinpoint locations of failure (carry out
• T-adapter troubleshooting)
• Hydraulic pressure gauge kit, etc. • Decide action to take
2) Look in the parts book and prepare the nec-
essary replacement parts. 1) Before starting troubleshooting, locate and
TEW00186 repair simple failures.
• Check before starting items
• Other check items
Step 8 2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
Repair at workshop that matches the symptoms, and carry out
troubleshooting.
TEW00187
Step 6
Machine
volume Re-enacting failure
• Drive and operate the machine to confirm

Shop manual the condition and judge if there is really a
failure.
TEW00188
Step 4 Step 5
Go to jobsite Ask operator questions to confirm details of
failure.
• Was there anything strange about the ma-

chine before the failure occurred?
• Did the failure occur suddenly?
• Had any repairs been carried out before the
TEW00189 failure?
TEW00190
HM400-1 20-303
1
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and re-
pairs must be carried out. This section deals particularly with correct repair procedures for mechatronics
and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling
electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
1. POINTS TO REMEMBER WHEN HANDLING

ELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during
inspection and repair operations, they are fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
TEW00191
Main failures occurring in wiring harness

1 Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
Improper insertion
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
TEW00192
2 Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or Crimped portion
soldered portion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the joint will peel and cause improper
connection or breakage.
TEW00193
20-304 HM400-1
1
3 Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
TEW00194
4 High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water should
get into the connector, the pins will be short-
TEW00195
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity through it.
5 Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con- TEW00196
tact restorer.
fl When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
fl If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.
HM400-1 20-305
1
2) Removing, installing, and drying connectors and

wiring harnesses
‡ Disconnecting connectors
1 Hold the connectors when disconnecting.
When disconnecting the connectors, hold the Press lightly
when removing
connectors and not the wires. For connec-
tors held by a screw, loosen the screw fully, Lock stopper
then hold the male and female connectors
in each hand and pull apart. For connectors
which have a lock stopper, press down the
stopper with your thumb and pull the con-
TEW00197
nectors apart.
fl Never pull with one hand.
2 When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
fl If the connector is twisted up and down
or to the left or right, the housing may
break.
TBW00484
Catches
TBW00485
3 Action to take after removing connectors

After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
fl If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
TEW00198
20-306 HM400-1
1
· Connecting connectors
1 Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
★ If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
★ If there is any damage or breakage, re-
place the connector.
2 Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
Since the DT 8-pole and 12-pole heavy duty
wire connectors have 2 latches respectively,
push them in until they click 2 times.
★ 1: Mail connector, 2: Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
3 Correct any protrusion of the boot and any
misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct po-
sition.
★ If the connector cannot be corrected eas-
ily, remove the clamp and adjust the
TEW00200
position.
4 If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.
TBW00487
HM400-1 20-307
1
6
‡ 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 wa-
ter or steam directly on the wiring harness.
If water gets directly on the connector, do as

follows.
1 Disconnect the connector and wipe off the
water with a dry cloth.
fl If the connector is blown dry with com- TEW00196
pressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the com-
pressed air before blowing with air.
2 Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer
to dry the connector.
fl Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or
related parts too hot, as this will cause
deformation or damage to the connec-
tor.
TEW00202
3 Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
fl After completely drying the connector,
blow it with contact restorer and reas-
semble. T-adapter
TEW00203
20-308 HM400-1
1
3) Handling control box

1 The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
2 Do not open the cover of the control box
unless necessary.
TEW00204
3 Do not place objects on top of the control

box.
4 Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with your
hand.
5 During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
TEW00205
6 Do not place the control box on oil, water,

or soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
7 Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors con-
nected to the control box. Fit an arc welding
ground close to the welding point.
TEW00206
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
fl If the 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
change in the reading of the tester.
fl If there is any change, there is probably defective contact in that circuit.
HM400-1 20-309
1
3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

draulic equipment, the most common cause of fail-
ure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling
or assembling hydraulic equipment, it is necessary
to be particularly careful.
1) Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2) Disassembly and maintenance work in the field

If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially pre-
pared dustproof workshop, and the performance
should be confirmed with special test equipment.
TEW00207
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from en-
tering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by leak-
ing oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
TEW00208
4) Do not let any dirt or dust get in during refilling

operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
TEW00209
20-310 HM400-1
1
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 pos-
sible of the old hydraulic oil must be drained
out. (Do not drain the oil from the hydraulic
tank; also 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 hy-
draulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil Flushing oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
TEW00210
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the ma-
chine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.
TEW00211
HM400-1 20-311
1
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Item Judgement
Action
value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
Lubricating oil, coolant
4. Check hydraulic strainer — Clean, drain

5. Check power train oil level — Add oil
6. Check engine oil level — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check power train oil filter — Replace
10. Check hydraulic filter — Replace
11. Check final drive oil level — Add oil
12. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace
equipment
Electrical
13. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace
14. Check for looseness, corrosion of starting motor terminal, — Tighten or replace
wiring
15. Check operation of gauges — Repair or replace
Hydraulic, mechani-
16. Check for abnormal noise, smell — Repair

cal equipment
17. Check for oil leakage — Repair

18. Carry out air bleeding — Bleed air
19. Check battery voltage (engine stopped) 24 – 26 V Replace

Electrics, electrical equipment
20. Check battery electrolyte level — Add or replace

21. Check for discolored, burnt, exposed wiring — Replace
22. Check for missing wiring clamps, hanging wiring — Repair
23. Check for water leaking on wiring (pay particularly careful — Disconnect connec-
attention to water leaking on connectors or terminals) tor and dry
24. Check for blown, corroded fuses — Replace

25. Check alternator voltage (engine running at 1/2 throttle After running for
or above) several minutes: Replace
27.5 – 29.5 V
26. Check operating sound of battery relay (starting switch
ON, OFF) — —
20-312 HM400-1
1
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
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)
HM400-1 20-313
1
6
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 (q1) 2/4 (Overall drawing: Right)
BRC2 MIC 21 Retarder controller (q1) 2/4 (Overall drawing: Right)
BRC3A 040 20 Retarder controller (q1) 2/4 (Overall drawing: Right)
BRC3B 040 16 Retarder controller (q1) 2/4 (Overall drawing: Right)
BRC4 040 12 Retarder controller (q1) 2/4 (Overall drawing: Right)
BRC5A 040 20 Retarder controller (q1) 2/4 (Overall drawing: Right)
BRC5B 040 16 Retarder controller (q1) 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)
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)
q1. Used as the retarder controller in E-SPEC.
20-314 HM400-1
1
6
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
CNS1 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)
D04 DT2 2 Diode 2/4 (Overall drawing: Left)
HM400-1 20-315
4
"
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)
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)
DT4 DT2 12 Intermediate connector 1/4 (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)
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)
EREV DT2 2 Engine speed sensor 3/4
20-316 HM400-1
4
"
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 -
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)
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)
HM400-1 20-317
"4
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)
M ON1 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)
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)
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)
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)
20-318 HM400-1
4
"
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)
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)
PW M M 6 Power mode switch 2/4 (Overall drawing: Left)
PW R 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)
HM400-1 20-319
4
"
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)
RW R 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)
20-320 HM400-1
4
"
20-322 HM400-1
4
"
HM400-1 20-323
4
"
20-324 HM400-1
4
"
HM400-1 20-324-1
4
"
HM400-1 20-325
1
20-326 HM400-1
1
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
HM400-1 20-327
1
20-328 HM400-1
1
HM400-1 20-329
1
799-601-7340
20-330 HM400-1
(7)
1
HM400-1 20-331
1
20-332 HM400-1
1
HM400-1 20-333
1
20-334 HM400-1
1
HM400-1 20-335
1
20-336 HM400-1
1
HM400-1 20-337
1
20-338 HM400-1
1
HM400-1 20-339
1
20-340 HM400-1
1
HM400-1 20-341
(1
7)
20 Tro
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell size T-adapter
code) Body (plug) Body (receptacle)
Part No.
Pin (male terminal) Pin (female terminal)
799-601-9210
Part number: 08191-11201, 08191-11202, Part number: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male terminal)
799-601-9210

08191-11205, 08191-12206 08191-13105, 08191-13106
799-601-9220

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220

08191-22205, 08191-22206 08191-23105, 08191-23106
20-341-1 HM400-1
! 6 !

Part No.
799-601-9230
18-20 Part number: 08191-31201, 08191-31202 Part number: 08191-34101, 08191-34102

799-601-9230
Part number: 08191-32201, 08191-32202 Part number: 08191-33101, 08191-33102

799-601-9240

799-601-9240
HM400-1 20-341-2
6 ! !

Part No.
799-601-9250

799-601-9250

799-601-9260

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260

08191-62205, 08191-62206 08191-63105, 08191-63106
20-341-3 HM400-1
! 6 !

Part No.
799-601-9270

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280

08191-81203, 08191-81204, 08191-84103, 08191-84104,
24-23 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280

08191-82203, 08191-82204, 08191-83103, 08191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106
HM400-1 20-341-4
(9)
6 ! !

Part No.
799-601-9290

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290

08191-92205, 08191-92206 08191-93105, 08191-93106
20-341-5 HM400-1
! 6 !
DT Series connector
No. of
pins T-adapter
Body (plug) Body (receptacle) Part No.
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
4 799-601-9040
6 799-601-9050
HM400-1 20-341-6
6 ! !
DT Series connector
No. of
pins T-adapter
8GR : 799-601-9060
8B : 799-601-9070
8
8G : 799-601-9080
8BR : 799-601-9080
12GR : 799-601-9110
12B : 799-601-9120
12
12G : 799-601-9130
12BR : 799-601-9140
20-341-7 HM400-1
c (7)
6 c
DTM Series connector

No. of
pins T-adapter
2 799-601-9010
Part number: 08192-02200 Part number: 08192-02100
DTHD Series connector

No. of
pins T-adapter
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)
HM400-1 20-341-8
(9)
6 ! !
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

DRC26 Series connector

No. of
pins T-adapter
24 799-601-9360
— Part No.: 7821-93-3110
40
799-601-9350
(A)
— Part No.: 7821-93-3120
40
799-601-9350
(B)
— Part No.: 7821-93-3130
20-341-9 HM400-1
! (11)
6 !
TROUBLESHOOTING T-ADAPTER TABLE
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.
—
799-601-2600 For measuring box Econo-21P Q Q Q Q Q Q
799-601-3100 For measuring box MS-37P Q
799-601-3200 For measuring box MS-37P Q
799-601-3300 For measuring box Econo-24P Q
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P Q Q
799-601-3420 BENDIX (MS) 24P Q Q
799-601-3430 BENDIX (MS) 17P Q Q
799-601-3440 BENDIX (MS) 17P Q Q
799-601-3450 BENDIX (MS) 5P Q Q
799-601-3460 BENDIX (MS) 10P Q Q
799-601-3510 BENDIX (MS) 5P Q Q
799-601-3520 BENDIX (MS) 14P Q Q
799-601-3530 BENDIX (MS) 19P Q Q
799-601-2910 BENDIX (MS) 14P Q Q
799-601-3470 CASE Q
799-601-2710 MIC 5P Q Q Q Q
799-601-2720 MIC 13P Q Q Q Q
799-601-2730 MIC 17P Q Q Q Q Q Q Q
799-601-2740 MIC 21P Q Q Q Q Q Q Q
799-601-2950 MIC 9P Q Q Q Q
799-601-2750 ECONO 2P Q Q
799-601-2760 ECONO 3P Q Q
799-601-2770 ECONO 4P Q Q
799-601-2780 ECONO 8P Q Q
799-601-2790 ECONO 12P Q Q
799-601-2810 DLI 8P Q Q
799-601-2820 DLI 12P Q Q
799-601-2830 DLI 16P Q Q
799-601-2840 Extension cable Q Q Q
799-601-2850 CASE Q
799-601-7010 X 1P Q Q
799-601-7020 X 2P Q Q Q Q
799-601-7030 X 3P Q Q Q Q
799-601-7040 X 4P Q Q Q Q
799-601-7050 SWP 6P Q Q Q
799-601-7060 SWP 8P Q Q Q
799-601-7310 SWP 12P Q
799-601-7070 SWP 14P Q Q
799-601-7320 SWP 16P Q
HM400-1 20-341-10
(11)
6 ! !
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
—
799-601-7080 M 1P Q Q
799-601-7090 M 2P Q Q Q Q
799-601-7110 M 3P Q Q Q Q
799-601-7120 M 4P Q Q Q Q
799-601-7130 M 6P Q Q Q Q
799-601-7340 M 8P Q
799-601-7140 S 8P Q Q Q Q
799-601-7150 S 10P-White Q Q Q Q
799-601-7160 S 12P-Blue Q Q Q
799-601-7170 S 16P-Blue Q Q Q Q
799-601-7330 S 16P-White Q
799-601-7350 S 12P-White Q
799-601-7180 AMP040 8P Q
799-601-7190 AMP040 12P Q Q
799-601-7210 AMP040 16P Q Q Q Q
799-601-7220 AMP040 20P Q Q Q Q
799-601-7230 Short connector X-2 Q Q Q Q
799-601-7240 Case Q Q
799-601-7270 Case Q
799-601-7510 070 10P Q
799-601-7520 070 12P Q
799-601-7530 070 14P Q
799-601-7540 070 18P Q
799-601-7550 070 20P Q
799-601-7360 Relay connector 5P Q
799-601-7370 Relay connector 6P Q
799-601-7380 JFC connector 2P Q
799-601-9010 DTM 2P Q Q
799-601-9020 DT 2P Q Q
799-601-9030 DT 3P Q Q
799-601-9040 DT 4P Q Q
799-601-9050 DT 6P Q Q
799-601-9060 DT 8P-Gray Q Q
799-601-9070 DT 8P-Black Q Q
799-601-9080 DT 8P-Green Q Q
799-601-9090 DT 8P-Blown Q Q
799-601-9110 DT 12P-Gray Q Q
799-601-9120 DT 12P-Black Q Q
799-601-9130 DT 12P-Green Q Q
799-601-9140 DT 12P-Blown Q Q
799-601-9210 HD30 18-8 Q Q
799-601-9220 HD30 18-14 Q Q
20-341-11 HM400-1
! (11)
6 !
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
—
799-601-9230 HD30 18-20 Q Q
799-601-9240 HD30 18-21 Q Q
799-601-9250 HD30 24-9 Q Q
799-601-9260 HD30 24-16 Q Q
799-601-9270 HD30 24-21 Q Q
799-601-9280 HD30 24-23 Q Q
799-601-9290 HD30 24-31 Q Q
799-601-9310 Plate For HD30 Q Q Q
799-601-9320 For measuring box For DT, HD Q Q Q
799-601-9330 Case Q
799-601-9340 Case Q
799-601-9350 DRC26 40P Q
799-601-9360 DRC26 24P Q
799-601-9410 For NE, G sensor 2P Q
799-601-9420 For boost pressure, fuel 3P Q
799-601-9430 PVC socket 2P Q
HM400-1 20-341-12
(11)
6 ! !
TROUBLESHOOTING CATEGORIES, PROCEDURE, AND METHOD OF USING
TROUBLESHOOTING CHARTS
CATEGORIES, PROCEDURE, AND METHOD OF USING

1. Category of troubleshooting code
★ If the machine monitor displays a failure code, it also displays the controller name at the same time, so
the troubleshooting codes are categorized to match each controller name (this may also include the
electrical system, where some failure codes are not displayed).
★ The hydraulic and mechanical system, for which the machine monitor cannot display a failure code, is
categorized as H Mode.
Troubleshooting Code Troubleshooting system
ENG Troubleshooting of engine controller system
TM Troubleshooting of transmission controller system
BK Troubleshooting of retarder controller (q1) system
MON Troubleshooting of machine monitor system
H Troubleshooting of hydraulic, mechanical system
S Troubleshooting of the engine body
2. Troubleshooting procedure
★ If a problem occurs on the machine, or if it is felt that there is a problem, carry out troubleshooting as
follows.
1) When machine monitor displays failure code

If a failure code is displayed on the machine monitor at the same time as the problem occurs, check the
content of the display, then go to the applicable troubleshooting chart for the failure code.
2) When machine monitor does not display failure code, but trouble data is recorded
If a problem occurs but the failure code display cannot be checked on the machine monitor, use the trou-
ble data display function in the machine monitor service mode to check for a failure code.
If a failure code is recorded, there is a high probability that this is the cause, so go to the applicable trou-
bleshooting chart.
3) When machine monitor does not display failure code and trouble data is also not recorded
If a problem occurs but the failure code display cannot be checked on the machine monitor, and the
problem is also not recorded by the trouble data display function in the machine monitor service mode,
there is a probability that it is a problem in the electrical system that cannot be detected by a controller
or that a problem has occurred in the hydraulic and mechanical system.
In this case, check the nature of the problem and go to the applicable troubleshooting chart.
20-342 HM400-1
(7)
1
3. Method of using YES/NO troubleshooting flowchart (ENG mode, TM mode, BK mode, MON mode)
1) Troubleshooting code number and problem
The title at the top of the troubleshooting chart gives the failure code and problem with the machine.
Example: M-13 Abnormality in buzzer
2) General precautions
When carrying out troubleshooting, precautions are given at the top of the page under the title and
marked with !.
The precautions common to all troubleshooting are marked ! in the Contents, so they must always be
followed checked before carrying out the troubleshooting.
Example: ! Before carrying out troubleshooting, check that all the related connectors are properly
inserted.
! Always connect any disconnected connectors before going on the next step.
3) Distinguishing conditions
Even with the same problem, the method of troubleshooting may differ according to the model, com-
ponent, or problem. In such cases, the failure mode is further divided into sections marked with small
letters (for example, a)), so go to the appropriate section to carry out troubleshooting.
If the troubleshooting chart is not divided into sections, start troubleshooting from the first check item in
the flowchart.
Example: a) When starting switch is turned ON (3 sec), buzzer does not sound
b) Buzzer always sounds
4) Method of following troubleshooting chart
NO
● Check or measure the item inside YES
, and according to the answer follow either the YES
line or the NO line to go to the next . (Note: The number written at the top right corner of
the is an index number; it does not indicate the order to follow.)
● Following the YES or NO lines according to the results of the check or measurement will lead finally
to the Cause box. Check the cause and take the action given in the Remedy box on the right.
● To the left of the there is (a box formed by a broken line). This contains the
methods for inspection or measurement, and the judgement values. If the judgment values to the
left of the [ ] are correct or the answer to the question inside the is YES, follow the YES
line; if the judgement value is not correct, or the answer to the question is NO, follow the NO line.
● The gives the preparatory work needed for inspection and measurement, and the judge-
ment values. If this preparatory work is neglected, or the method of operation or handling is mis-
taken, there is danger that it may cause mistaken judgment, or the equipment may be damaged.
Therefore, before starting inspection or measurement, always read the instructions carefully, and
start the work in order from the first item.
5) Mounting location, pin number
For details of the connector pin number and check and measurement locations of the connector pin
numbers appearing in the flowchart, see CONNECTOR TYPE AND MOUNTING LOCATION.
HM400-1 20-343
1
4. Method of using YES-NO type troubleshooting (ENG mode, TM mode, BK mode, MON mode)
20-344 HM400-1
1
HM400-1 20-345
1
TROUBLESHOOTING
TROUBLESHOOTING OF
ENGINE CONTROLLER SYSTEM
(ENG MODE)
Eng mode related electrical circuit diagram ......................................................................................... 20-403
Content of display and problem that appears on machine for each failure code ................................. 20-406
ENG-1 Failure code [A000N1] (Engine: Overrun N1)) ................................................................... 20-418
ENG-2 Failure code [A570NX] (Engine oil filter: Clogged (NX)) .................................................... 20-419
ENG-3 Failure code [AD00L2] (Common rail: * See Contents (L2)) .............................................. 20-420
ENG-4 Failure code [AD00MA] (Common rail: Function impossible (MA)) ................................... 20-420
ENG-5 Failure code [AD10L3] (Fuel supply pump: * See Contents (L3)) ...................................... 20-421
ENG-6 Failure code [AD10MA] (Fuel supply pump: Function impossible (MA)) ........................... 20-423
ENG-7 Failure code [AD10MB] (Fuel supply pump: Drop in function (MB)) .................................. 20-423
ENG-8 Failure code [AD11KA] (Fuel supply pump solenoid valve 1: Disconnection (KA)) ........... 20-424
ENG-9 Failure code [AD11KB] (Fuel supply pump solenoid valve 1: Short circuit (KB)) ............... 20-425
ENG-10 Failure code [AD51KA] (Fuel supply pump solenoid valve 2: Disconnection (KA)) ........... 20-426
ENG-11 Failure code [AD51KB] (Fuel supply pump solenoid valve 2: Short circuit (KB)) .............. 20-427
ENG-12 Failure code [ADA1KA] (No. 1 injector solenoid valve: Disconnection (KA)) ..................... 20-428
ENG-13 Failure code [ADZKKB] (No. 1, 2, 3 injector solenoid valve: Short circuit (KB)) ................ 20-429
ENG-14 Failure code [ADB1KA] (No. 2 injector solenoid valve: Disconnection (KA)) ..................... 20-433
ENG-15 Failure code [ADC1KA] (No. 3 injector solenoid valve: Disconnection (KA)) .................... 20-434
ENG-16 Failure code [ADD1KA] (No. 4 injector solenoid valve: Disconnection (KA)) .................... 20-435
ENG-17 Failure code [ADDZKB] (No. 4, 5, 6 injector solenoid valve: Short circuit (KB)) ................ 20-436
ENG-18 Failure code [ADE1KA] (No. 5 injector solenoid valve: Disconnection (KA)) ..................... 20-440
ENG-19 Failure code [ADF1KA] (No. 6 injector solenoid valve: Disconnection (KA)) ..................... 20-441
ENG-20 Failure code [B@BAZG] (Engine oil: Drop in oil pressure (ZG)) ....................................... 20-442
ENG-21 Failure code [B@BAZK] (Engine oil: Drop in level (ZK)) ................................................... 20-443
ENG-22 Failure code [B@BCNS] (Radiator water: Overheat (NS)) ................................................ 20-444
ENG-23 Failure code [D181KZ] (Preheating relay contact: Disconnection or short circuit (KZ)) .... 20-445
ENG-24 Failure code [D182KZ] (Preheating relay coil: Disconnection or short circuit (KZ)) ........... 20-447
ENG-25 Failure code [D1D0KB] (Engine controller load power source relay: Short circuit (KB)) ... 20-448
ENG-26 Failure code [D5ZAKX] (Engine throttle modify 1 signal: Input signal outside range (KX)) 20-450
ENG-27 Failure code [DB20KT] (Engine controller: Abnormality inside controller (KT)) ................. 20-451
ENG-28 Failure code [DB22KK] (Engine controller load power source relay:
Drop in power supply voltage, input (KK)) .......................................................................... 20-452
ENG-29 Failure code [DB29KQ] (Engine controller connection wiring harness:
Model selection signal mismatch (KQ)) ............................................................................. 20-454
ENG-30 Failure code [DB2AMA] (Engine controller fuel injection quantity control switch:
Function impossible (MA)) ................................................................................................. 20-455
ENG-31 Failure code [KK11KB] (Starting switch: Short circuit (KB)) ............................................... 20-456
ENG-32 Failure code [DDA1L5] (Acceleration switch: * See Contents (L5)) ................................... 20-457
ENG-33 Failure code [DDE2L6] (Engine oil pressure switch: * See Contents (L6)) ........................ 20-459
ENG-34 Failure code [DGE2KX] (Engine water temperature sensor (for high-temperature):
Input signal outside range (KX)) ........................................................................................ 20-461
HM400-1 20-401
(9)
1
TROUBLESHOOTING
ENG-35 Failure code [DGE3LC] (Engine water temperature sensor (for low-temperature):
* See Contents (L6)) .......................................................................................................... 20-462
ENG-36 Failure code [DGE4KX] (Fuel temperature sensor: Input signal outside range (KX)) ....... 20-463
ENG-37 Failure code [DH30KX] (Boost pressure sensor: Input signal outside range (KX)) ........... 20-464
ENG-38 Failure code [DH40KX] (Common rail pressure sensor: Input signal outside range (KX)) 20-466
ENG-39 Failure code [DK10KX] (Throttle angle sensor: Input signal outside range (KX)) .............. 20-468
ENG-40 Failure code [DLE3LC] (Engine Ne speed sensor: * See Contents (LC)) ......................... 20-470
ENG-41 Failure code [DLE1LC] (Engine G speed sensor: * See Contents (LC)) ........................... 20-471
ENG-42 Failure code (Engine does not start (starting motor does not turn) ................................... 20-472
* Failure phenomena of L Series problem codes (L*)*

Problem code Nature of problem (phenomenon, nature of problem that occurs)
L6 Engine speed signal, terminal C signal, signals for oil pressure switch, water temperature
20-402 HM400-1
1
TROUBLESHOOTING ENG MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
ENG MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
HM400-1 20-403
14
"
★ This circuit diagram has been made by extracting the engine controller related circuits and starting motor re-
lated circuits from the overall electrical circuit diagram
20-404 HM400-1
41"
HM400-1 20-405
14
"
CONTENT OF DISPLAY AND PROBLEM THAT
TROUBLESHOOTING APPEARS ON MACHINE FOR EACH FAILURE CODE
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON

MACHINE FOR EACH FAILURE CODE
Failure
Location of failure Nature of failure Probable cause
code
A000N1 Engine: Overrun (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 run- • Defective engine oil filter clogging
ning switch
• Disconnection in switch signal cir-
cuit wiring harness
• Defective engine controller
AD00L2 Common rail: * See Contents (L2) Common rail fuel pressure has risen • Viscosity of fuel is too high (un-
(ENG-3) to high pressure (level 1) suitable fuel)
• Defective overflow valve
• Clogged overflow piping
• Defective pressure limiter
• Defective common rail fuel pres-
sure 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 N o n - f o r c e f e e d ( l e v e l 1 ) h a s • Defective fuel low-pressure cir-
(ENG-5) (L3) occurred in fuel supply pump cuit (etc.)
• Defective fuel supply pump PCV
• Defective pressure limiter
• Defective common rail fuel pres-
sure sensor
• Defective fuel injector
• Leakage from high-pressure fuel
piping
AD10MA Fuel supply pump: Function impos- Abnormal pressure has occurred in • Same as failure code [AD00L2]
(ENG-6) sible (MA) common rail fuel pressure
AD10MB Fuel supply pump: Drop in function N o n - f o r c e f e e d ( l e v e l 2 ) h a s • Same as failure code [AD10L3]
(ENG-7) (MB) occurred in fuel supply pump
AD11KA Fuel supply pump solenoid valve 1: D iscon nect ion ha s oc curred i n • Defective fuel supply pump PCV1
(ENG-8) Disconnection (KA) PCV1 circuit of fuel supply pump • Disconnection in PCV1 (+) circuit
wiring harness
• Disconnection or short circuit with
chassis ground in PCV1 (-) circuit
wiring harness
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
20-406 HM400-1
1
★ The code (ENG-**) given below the failure code is the troubleshooting number.
Action
Condition when normal Action by controller Problem that appears on machine
code
• Stops fuel injection until engine Engine speed varies abnormally E02
speed goes down to operating
range
A. Sensor resistance value • Carries out operation under nor- • If machine continues to be used E01
OF terminal - terminal mal control as it is, there is danger that dirt
• When normal: Max. 1 Ω will circulate inside engine
• When clogged: Min. 1 MΩ
• Carries out operation with limited • Engine output is reduced E03

output
• Carries out operation with limited • Engine output and speed are re- E03
output and engine speed duced
• Carries out operation with limited • Engine output is reduced E03
output
• Carries out operation under nor- • Engine output is reduced E03

mal control
• Carries out operation with limited • Engine output and speed are re- E03
output and engine speed duced
• Solenoid resistance value • Turns output to PCV1 OFF • No great effect on machine E03
PCV1 (male) (1) - (2): 2.3 - 5.3 Ω (however, if failure code
[AD51KA] occurs at the same
time, the engine stops)
[AD51KB] occurs at the same
HM400-1 20-407
1
Failure
code
AD51KA Fuel supply pump solenoid valve 2: A disconnection has occurred in the • Defective fuel supply pump PCV2
(ENG-10) Disconnection (KA) PCV2 circuit of the fuel supply pump • Disconnection in PCV2 (+) circuit
wiring harness
chassis ground in PCV2 (-) circuit
wiring harness
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
in PCV2 (+) circuit wiring harness
• Short circuit with power source in
PCV1 (-) circuit wiring harness
ADA1KA No. 1 injector solenoid valve: Dis- Disconnection has occurred in No. 1 • Defective No. 1 injector solenoid
(ENG-12) connection (KA) injector solenoid circuit • Disconnection in solenoid (+) cir-
cuit wiring harness
• Disconnection in solenoid (-) cir-
cuit wiring harness
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 • Defective No. 2 injector solenoid
injector solenoid circuit, or No. 3 • Defective No. 3 injector solenoid
injector solenoid circuit • Short circuit with chassis ground
in No. 1 solenoid (+) circuit and
(-) circuit wiring harness
• Short circuit with chassis ground
ADB1KA No. 2 injector solenoid valve: Dis- Disconnection has occurred in No. 2 • Defective No. 2 injector solenoid
cuit wiring harness
cuit wiring harness
ADC1KA No. 3 injector solenoid valve: Dis- Disconnection has occurred in No. 3 • Defective No. 3 injector solenoid
cuit wiring harness
cuit wiring harness
ADD1KA No. 4 injector solenoid valve: Dis- Disconnection has occurred in No. 4 • Defective No. 4 injector solenoid
cuit wiring harness
cuit wiring harness
20-408 HM400-1
1
Action
code
[AD11KA] occurs at the same
[AD11KB] occurs at the same
• Solenoid resistance value • Turns output to No. 1 injector so- • Engine output is reduced E03
CN1 (male) (1) - (2): 0.4 - 1.1 Ω lenoid OFF
• Solenoid resistance value • Turns output to No. 1 injector so- • Engine output is greatly reduced E03
CN2 (male) (1) - (2): 0.4 - 1.1 Ω • Turns output to No. 2 injector so-
• Turns output to No. 3 injector so-
lenoid OFF
HM400-1 20-409
1
Failure
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 • Defective No. 5 injector solenoid
injector solenoid circuit, or No. 6 • Defective No. 6 injector solenoid
injector solenoid circuit • Short circuit with chassis ground
ADE1KA No. 5 injector solenoid valve: Dis- Disconnection has occurred in No. 5 • Defective No. 5 injector solenoid
cuit wiring harness
cuit wiring harness
ADF1KA No. 6 injector solenoid valve: Dis- Disconnection has occurred in No. 6 • Defective No. 6 injector solenoid
cuit wiring harness
cuit wiring harness
B@BAZG Engine oil: Drop in oil pressure (ZG) When running at low idling, signal • Drop in oil pressure (when sys-
(ENG-20) circuit of engine oil pressure low- tem is working normally)
pressure switch became closed • Defective engine oil low-pressure
( c o n n e ct e d t o G N D ) , o r w h e n switch
engine speed was more than 1300 • Defective engine oil high-pres-
rpm, signal circuit of oil pressure
sure switch
h i g h - p r e s s u r e sw i t c h b e c a m e
closed (connected to GND) • Short circuit with chassis ground
in low-pressure switch signal cir-
cuit wiring harness
in high-pressure switch signal cir-
cuit wiring harness
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
• Disconnection in switch circuit
wiring harness
B@BCNS Radiator water: Overheat (NS) Engine water temperature went • Engine water temperature over-
(ENG-22) above operating range heats (when system is working
normally)
D181KZ Preheating relay contact: Discon- Disconnection, shor t circuit with • Defective heater relay
(ENG-23) nection or short circuit (KZ) ground, or short circuit with power • Defective preheater relay
source has occurred in signal circuit • Disconnection, short circuit with
of heater relay chassis ground, or short circuit
with power source in relay signal
circuit wiring harness
20-410 HM400-1
1
Action
code
• Solenoid resistance value • Turns output to No. 4 injector so- • Engine output is greatly reduced E03
CN4 (male) (1) - (2): 0.4 - 1.1Ω lenoid OFF
CN5 (male) (1) - (2): 0.4 - 1.1Ω • Turns output to No. 5 injector so-
CN6 (male) (1) - (2): 0.4 - 1.1Ω lenoid OFF
• Turns output to No. 6 injector so-
lenoid OFF
• Low-pressure switch resistance • Carries out operation under nor- • If the machine continues to be E03
value mal control used as it is, the engine may
PSL - ground seize up
• When engine is stopped:
Max. 1Ω
• When engine speed is 600 rpm or
more: Min. 1 MΩ
PSH - ground
Max. 1Ω
• When engine speed is 1300 rpm
or more: Min. 1 MΩ
• Switch resistance value • Carries out operation under nor- • If the machine continues to be E01
OL (male) (1) - ground mal control used as it is, the engine may
• When oil level is normal: Max. 1 Ω seize up
• When oil level is low: Min. 1 MΩ
• Limits fuel injection until tempera- • Engine output is reduced E02

ture goes down to operating
range
• Preheating input signal voltage • Carries out operation under nor- • It is difficult to start the engine in E03
CN4 (3) - ground mal control low temperatures
• When preheating is stopped:
Max. 1 V
• When preheating is being used:
20 - 30 V
HM400-1 20-411
1
Failure
code Location of failure Nature of failure Probable cause
D182KZ Preheating relay coil: Disconnec- Disconnection or short circuit with • Defective preheater relay
(ENG-24) tion or short circuit (KZ) ground has occurred in drive cir- • Disconnection or short circuit with chassis
cuit of preheater relay ground in relay power source circuit wiring
harness
• Disconnection or short circuit with chassis
ground in relay drive circuit wiring harness
D1DDKB Engine controller load power Voltage was generated in power • Defective engine power source relay
(ENG-25) source relay: Short circuit (KB) supply circuit of controller when • Short circuit with power source circuit wiring
starting switch was OFF harness
D5ZAKX Engine throttle modify 1 signal: Voltage in throttle modify signal • Defective transmission controller
(ENG-26) Input signal outside range (KX) circuit went outside normal range • Disconnection or short circuit with chassis
(6 - 15 V) ground in signal circuit wiring harness
DB20KT Engine controller: Abnormality Abnormality has occurred inside • Disconnection in GND circuit wiring harness
(ENG-27) inside controller (KT) controller • Defective engine controller
DB22KK Engine controller load power Voltage in controller power supply • Defective engine power source relay
(ENG-28) s o u r ce r e l ay : D ro p i n p owe r voltage circuit dropped when • Disconnection or short circuit with chassis
source voltage (KT) starting switch was ON ground in relay (1) circuit wiring harness
ground in relay (2) circuit wiring harness
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 • Disconnection in signal 1 circuit wiring har-
nal mismatch (KQ) ness
• Disconnection in signal 2 circuit wiring har-
ness
• Disconnection in signal 3 circuit wiring har-
ness
• Disconnection in GND circuit wiring harness
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 Starting switch: Short circuit (KB) Terminal C signal from starting • Defective starting switch
(ENG-31) switch came ON when engine • Short circuit with power source in signal cir-
was running cuit wiring harness
DDA1L5 Acceleration switch: * See Con- Idling validation switch of acceler- • Defective accelerator pedal
(ENG-32) tents (L5) ator pedal does not match throttle • Disconnection, short circuit with chassis
angle signal ground, or short circuit with power source in
switch signal 2 wiring harness
• Disconnection, short circuit with chassis
ground, or short circuit with power source in
switch signal 3 wiring harness
• Disconnection in switch GND circuit wiring
harness
20-412 HM400-1
1
Condition when normal Action by controller Problem that appears on machine Action code
• Relay resistance value • Cannot turn preheater relay ON • It is difficult to start the engine in low E03
R37 (male) (1) - (2): 100 - 500Ω temperatures
• Power source voltage • Carries out operation under normal • No great effect on machine E01
CN7 (6)(14) - (5)(13) control
When starting switch is OFF: Max.
1V
When starting switch is ON:
20 - 30 V
• Signal voltage • Does not modify throttle • There is shock when shifting trans- E01
CN4 (16) - ground: 6 - 15 V mission
• Carries out operation under normal • If the machine continues to be used E03
control as it is, the engine may seize up
• Engine stops during operation
• Engine cannot be started
• Power source voltage • Engine stops during operation E03
CN7 (6)(14) - (5)(13) • Engine cannot be started
When starting switch is OFF: Max.
1V
20 - 30 V
• Signal voltage • Uses model with default setting to • Does not give specified engine out- E03
CN4 (13) - ground: Max. 1 V carry out control put
CN4 (14) - ground: 20 - 30 V
CN4 (15) - ground: Max. 1 V
• Carries out operation under normal • Fuel injection quantity control set- E01
control ting cannot be changed
• Signal voltage • Carries out operation under normal • Operates normally 10 seconds af- E03
CN4 (2) - ground control ter starting
Max. 1 V
When starting switch is at START:
20 - 30 V
• CN4 (11) - ground (signal 2) • Carries out operation under normal • No great effect on machine E01
Throttle voltage 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
HM400-1 20-413
1
Failure
code Location of failure Nature of failure Probable cause
DDE2L6 Engine oil pressure switch: * See Engine oil pressure switch signal • Defective engine oil low-pressure switch
(ENG-33) Contents (L6) d o e s n o t m a t c h c o n d i ti o n o f • Defective engine oil high-pressure switch
engine • Disconnection or short circuit with chassis
ground in low-pressure switch signal circuit
wiring harness
• Disconnection in high-pressure switch signal
DGE2KX Engine water temperature sensor Signal from engine water high- • Defective engine water high-temperature
(ENG-34) (for high temperature): Input sig- temperature sensor is outside sensor
nal outside range (KX) normal range • Disconnection or short circuit with chassis
ground in sensor signal circuit wiring harness
• Disconnection in sensor GND circuit wiring
harness
DGE3LC Failure code [DGE3LC] (Engine Engine water temperature sensor • Defective engine water low-temperature
(ENG-35) water temperature sensor (low- (for low temperature): * See Con- sensor
temperature): * See Contents tents (L6) • Disconnection or short circuit with chassis
(L6))
harness
DGE4KX Fuel temperature sensor: Input Signal from fuel temperature sen- • Defective fuel temperature sensor
(ENG-36) signal outside range (KX) sor is outside normal range • Disconnection or short circuit with chassis
harness
DH30KX Boost pressure sensor: Input sig- Signal from boost sensor is out- • Defective boost pressure sensor
(ENG-37) nal outside range (KX) side normal range • Disconnection or short circuit with chassis
ground in sensor power source circuit wiring
harness
ground in sensor GND circuit wiring harness
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- • Disconnection or short circuit with chassis
mal range ground in sensor power source circuit wiring
harness
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 • Disconnection or short circuit with chassis
range ground in sensor power source circuit wiring
harness
20-414 HM400-1
1
• Low-pressure switch resistance • Carries out operation under normal • If the machine continues to be used E01
value control as it is, the engine may seize up
PSL - ground
• When engine is stopped: Max.
1Ω
• When engine speed is 600 rpm
or more: Min. 1 MΩ
• High-pressure switch resistance
value
PSH - ground
Max. 1Ω
• When engine speed is 1300
rpm or more: Min. 1 MΩ
• Sensor resistance value • Carries out operation under normal • Water temperature display on ma- E01
(water temperature: 10 - 100°C) control chine monitor is not correct
• TWH (male) (1) - (2): 90 - 3.5 kΩ • Fixes water temperature signal out-
put to machine monitor to 90°C
• Sensor resistance value • Carries out operation under normal • Exhaust gas color in low tempera- E01
(water temperature: 10 - 100°C) control tures is poor
• TWL (male) (1) - (2): 9 - 0.3 kΩ • It is difficult to start the engine in low
temperatures
• Sensor resistance value (fuel tem- • Carries out operation under normal • Output drops slightly in low temper- E01
perature: 10 - 100°C)THL (male) control atures
(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
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 vali- or high idling, it is impossible to
• Sensor signal voltage dation switch control acceleration at medium
AS1 (2) - (1): 0.3 - 4.5 V range
HM400-1 20-415
1
Failure
code
DLE3LC Engine Ne speed sensor: * See Signal from engine Ne speed sen- • Defective engine Ne speed sen-
(ENG-40) Contents (LC) sor does not match signal from sor
engine G speed sensor • Disconnection or short circuit with
chassis ground in sensor signal
chassis ground in sensor GND
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 • Disconnection or short circuit with
Ne speed sensor chassis ground in sensor signal
chassis ground in sensor GND
20-416 HM400-1
1
Action
code
• Sensor resistance value • Carries out operation with limited • Engine output is reduced E03
• NE (male) (1) - (2): 85 - 210Ω output
• Sensor resistance value • Carries out operation with limited • Engine output is reduced E03
• G (male) (1) - (2): 1.4 - 3.5 kΩ output
HM400-1 20-417
1
TROUBLESHOOTING ENG-1
ENG-1 Failure code [A000N1] (Engine: Overrun N1))
★ Nature of failure: The engine speed went above the operating range
Cause Remedy
1
• Turn starting switch ON.
Is another failure code also NO
• Operate machine monitor.
displayed or recorded at same
time?
YES Go to
troubleshooting
for displayed
code
2
Was machine operated in way NO
that would cause engine to
overrun?
YES Check cause of
failure and
repair damage
to engine
3 Go to
NO troubleshoot-
• Turn starting switch ON. Can engine speed be read ing for failure
• Operate machine monitor. normally? code
[DEL3LC]
YES [DLH1LC]
Defective engine controller Replace
20-418 HM400-1
1
ENG-2 Failure code [A570NX] (Engine oil filter: Clogged (NX))
★ Nature of failure: The signal circuit of the engine oil filter clogging switch became open (shut off from GND)
while the engine was running
Cause Remedy
1
NO
• Stop engine Is engine oil filter clogged?
YES
Clogged engine oil filter Clean or
replace
2
• Turn starting switch Is resistance between terminal NO
OFF. Defective engine oil filter clogging Replace
OF (switch end) and ground less
• Disconnect OF. switch
than 1
YES
3
• Turn starting switch Is resistance between terminal NO Defective contact or disconnection
OFF. CN6 (female) (5) and ground less in wiring harness between CN6 Clean or
• Disconnect CN6. than 1 (female) (5) and OF replace
YES
ENG-2 Related electrical circuit diagram
HM400-1 20-419
1
TROUBLESHOOTING ENG-3, ENG-4
ENG-3 Failure code [AD00L2] (Common rail: * See Contents (L2))
★ Nature of failure: The common rail fuel pressure has risen to high pressure (level 1)
Cause Remedy
• Turn starting switch ON. Is another failure code also NO

• Operate machine monitor. displayed or recorded at same
time? Go to
YES troubleshoot
ing for
displayed
code
Is suitable fuel for ambient NO

temperature being used? Unsuitable fuel being used Replace
YES
• Loosen joint of fuel Does fuel leak out from joint NO

supply pump overflow
valve. when priming pump is operated?
YES
• Disassemble fuel supply In overflow valve, is spring NO

pump overflow valve. damaged, seat worn, or ball Go to
stuck? troubleshoot
ing No. 7.
YES
Defective overflow valve Replace
Does fuel leak out from joint NO

• Loosen joint of common
rail pressure limiter
when priming pump is operated?
YES
When troubleshooting is carried out NO

for failure code [DH40KX], does Defective pressure limiter Replace
problem occur in electrical system?
YES Defective electric system of
common rail fuel pressure Repair or
sensor replace
NO Defective mechanical system of

Is overflow piping clogged? common rail fuel pressure Replace
sensor
YES
Clogged overflow piping Repair or
replace
ENG-4 Failure code [AD00MA] (Common rail: Function impossible (MA))

★ Nature of failure: The common rail fuel pressure has risen to high pressure (level 2)
★ Carry out troubleshooting for Troubleshooting No. ENG-3 (failure code [AD00L2].
20-420 HM400-1
1
ENG-5 Failure code [AD10L3] (Fuel supply pump: * See Contents (L3))
★ Nature of failure: Non-force feed (level 1) has occurred in the fuel supply pump
Cause Remedy
• Turn starting switch ON. Is another failure code also NO

time?
Go to
YES troubleshooting
for displayed
code
Is suitable fuel for ambient NO

temperature being used? Unsuitable fuel being used Replace
YES
Is filter or strainer clogged? NO

(See Note 1)
YES Clean or
Clogged filter, strainer replace
• Measure fuel pressure (see Is fuel low-pressure circuit NO

TESTING AND ADJUSTING). pressure 0.15 - 0.3 MPa {1.5 - 3 Defective low-pressure circuit Repair or
• Run engine at high idling. kg/cm2}? equipment (see Note 2) replace
YES
• Disconnect outlet piping of

common rail pressure Is fuel drain amount from NO
limiter. pressure limiter less than 10 Defective pressure limiter Replace
• Start engine. cc/min?
YES
• Disconnect PCV connector Does engine stop if PCV connector on NO

on one side. one side is disconnected from fuel pump
• Start engine. and engine is operated on one lung?
YES
• Disconnect spill centralized

hose from injector. Is spill flow from injector normal? NO Defective fuel injector Replace
• Start engine. (See Note 3)
YES Defective common rail fuel Replace
pressure sensor
When troubleshooting is carried out for failure NO

codes [AD11KA], [AD11KB], [AD51KA], [AD51KB], Defective fuel supply pump Replace
does problem occur in electrical system?
YES Defective electric system of fuel Repair or
supply pump PCV replace
HM400-1 20-421
(11)
1
Note 1: Carry out inspection, maintenance, and replacement of the filter and strainer as follows.
1) Gauze filter: Disassemble and inspect. If it is clogged, clean it.
2) Gauze filter upstream strainer: If the gauze filter is clogged, clean the upstream strainer also.
3) Fuel filter: If the problem is not solved even when Steps 1) and 2) above have been carried out, replace
the fuel filter.
Note 2: If the equipment in the low-pressure circuit is defective, inspect the following points.
1) Remaining amount of fuel
2) Stuck, worn feed pump
3) Leakage, clogged low-pressure fuel piping
4) Defective operation of bypass valve, mistaken assembly of other parts (see Fig. 1)
5) Clogged fuel filter
6) Fuel entering oil pan (fuel leakage inside head cover)
Fig. 1 Mounting positions of overflow valve (1), bypass valve (2), and fuel inlet port joint (with gauze filter) (3)
• Overflow valve (1) : Spring is seen through both holes.
• Bypass valve (2) : Spring is seen through one hole (on nut side).
• Fuel inlet joint (3) : Gauze filter is seen through both holes.
20-422 HM400-1
(11)
1
TROUBLESHOOTING ENG-5, ENG-6, ENG-7
Note 3: Method of measuring amount of fuel spill flow Limits for fuel spill amount (total for 6 cylinders)
The fuel in the spill line is at high temperature Stall speed (rpm) Spill limit (cc/min)
(up to 90°C), so be careful not to burn your-
self during the operation. 1,600 960
1) Disconnect the hose connected to the spill 1,700 1,020
tube return collection portion (rear of engine).
1,800 1,080
2) Connect another hose to the tip of the spill
tube and collect the spill fuel in a container. 1,900 1,140
3) Start the engine, stall the engine at each 2,000 1,200
speed, and measure the spill fuel amount for
1 minute.
ENG-6 Failure code [AD10MA] (Fuel supply pump: Function impossible (MA))
★ Nature of failure: Abnormal pressure has occurred in the common rail fuel pressure
ENG-7 Failure code [AD10MB] (Fuel supply pump: Drop in function (MB))
★ Nature of failure: Non-force feed (level 2) has occurred in the fuel supply pump
HM400-1 20-423
1
ENG-8 Failure code [AD11KA] (Fuel supply pump solenoid valve 1: Disconnection (KA))
★ Nature of failure: A disconnection has occurred in the PCV1 circuit of the fuel supply pump
Cause Remedy
• Turn starting switch OFF.

Is resistance between PCV1 NO
(male) (1) - (2), and between (2) Defective fuel supply pump Replace
• Disconnect PCV1. PCV1
- ground as shown in Table 1?
YES
Defective contact or disconnection

in wiring harness between CN7
• Turn starting switch OFF. Is resistance between CN7 NO (female) (10) - PCV1 (female) (1) Repair or
• Disconnect CN7. (female) (10) and (11) 3.5 - 5.3Ω? replace
or between CN7 (female) (11) -
PCV1 (female) (2)
YES
Is resistance between CN7 NO Short circuit with chassis ground

(female) (11) and ground more in wiring harness between CN7 Repair or
• Disconnect CN7, PCV1. (female) (11) and PCV1 (female) replace
than 1 MΩ?
(2)
YES
Table 1
PCV1 (male) Resistance
Between (1) and (2) 2.3~5.3Ω
Between (2) and ground Min. 1 MΩ
20-424 HM400-1
1
ENG-9 Failure code [AD11KB] (Fuel supply pump solenoid valve 1: Short circuit (KB))
★ Nature of failure: Excessive current has flowed in the PCV1 circuit of the fuel supply pump
Cause Remedy

YES
Short circuit with chassis ground

Is resistance between CN7 (female) NO or short circuit with power source
• Disconnect CN7, PCV1. in wiring harness between CN7 Repair or
• Turn starting switch ON. (10) and ground more than 1 MΩ
and is voltage less than 1 V? (female) (10) and PCV1 (female) replace
(1)
YES
Short circuit with power source

• Disconnect CN7, PCV1. Is voltage between CN7 (female) NO in wiring harness between CN7 Repair or
• Turn starting switch ON. (11) and ground less than 1 V? (female) (11) and PCV1 (female) replace
(2)
YES
Table 1
Between (1) and (2) 2.3~5.3Ω
HM400-1 20-425
1
ENG-10 Failure code [AD51KA] (Fuel supply pump solenoid valve 2: Disconnection (KA))
★ Nature of failure: A disconnection has occurred in the PCV2 circuit of the fuel supply pump
Cause Remedy

YES

• Turn starting switch OFF. Is resistance between CN7 (female) NO (female) (4) - PCV2 (female) (1) or Repair or
• Disconnect CN7. (4) and (12) 3.5 - 5.3Ω? replace
between CN7 (female) (12) -
PCV2 (female) (2)
YES
Is resistance between CN7 NO Short circuit with chassis ground

(female) (12) and ground more in wiring harness between CN7 Repair or
• Disconnect CN7, PCV2. (female) (12) and PCV2 (female) replace
than 1 MΩ?
(2)
YES
Table 1
Between (1) and (2) 2.3~5.3Ω
20-426 HM400-1
1
ENG-11 Failure code [AD51KB] (Fuel supply pump solenoid valve 2: Short circuit (KB))
★ Nature of failure: Excessive current has flowed in the PCV2 circuit of the fuel supply pump
Cause Remedy

YES

Is resistance between CN7 (female) NO or short circuit with power source
• Disconnect CN7 and PCV2. in wiring harness between CN7 Repair or
• Turn starting switch ON. (4) and ground more than 1 MΩ
and is voltage less than 1 V? (female) (4) and PCV2 (female) replace
(1)
YES

• Disconnect CN7 and PCV2. Is voltage between CN7 (female) NO in wiring harness between CN7 Repair or
• Turn starting switch ON. (12) and ground less than 1 V? (female) (12) and PCV2 (female) replace
(2)
YES
Table 1
Between (1) and (2) 2.3~5.3Ω
HM400-1 20-427
1
ENG-12 Failure code [ADA1KA] (No. 1 injector solenoid valve: Disconnection (KA))
★ Nature of failure: A disconnection has occurred in the No. 1 injector solenoid circuit
High voltage (110 - 130V) is used for the electrical circuit of the fuel injector, so be careful of electrocution
and electrical leakage. For details, see TESTING AND ADJUSTING, Handling high-voltage circuit of engine
controller.
Cause Remedy
• Turn starting switch OFF. Is resistance between CN1 NO Defective No. 1 injector
• Disconnect CN1 (solenoid). Replace
(male) (1) and (2) 0.4 - 1.1Ω? solenoid
YES

NO in wiring harness between CN6
• Turn starting switch OFF. Is resistance between CN6 (female) (7) - CN1 (female) (1) or Repair or
• Disconnect CN6 (controller). (female) (7) and (8) 0.4 - 1.1Ω? between CN6 (female) (8) - CN1 replace
(female) (2)
YES
20-428 HM400-1
1
ENG-13 Failure code [ADZKKB] (No. 1, 2, 3 injector solenoid valve: Short circuit (KB))
★ Nature of failure: Excessive current has flowed in the No. 1 injector solenoid circuit, No. 2 injector solenoid
circuit, or No. 3 injector solenoid circuit
controller.
a) Determining location of problem
Cause Remedy
Is resistance between CN6 (female) NO Abnormality in No. 1 injector Go to

(7) - (8), and between (7)(8) - solenoid system troubleshooting
• Disconnect CN6 (controller).
ground as shown in Table 1? procedure b)
Go to
• Disconnect CN6 (controller). Is voltage between CN6 (female) NO Abnormality in No. 1 injector troubleshooting
• Turn starting switch ON. (7)(8) - ground less than 1 V? solenoid system procedure b)
YES
Is resistance between CN6 (female) NO Go to

• Turn starting switch OFF. Abnormality in No. 2 injector troubleshooting
• Disconnect CN6 (controller).
(4) - (10), and between (4)(10) -
ground as shown in Table 1? solenoid system procedure c)
YES
• Disconnect CN6 (controller).• Is voltage between CN6 (female) NO Abnormality in No. 2 injector Go to
• Turn starting switch ON. (4)(10) - ground less than 1 V? solenoid system troubleshooting
procedure c)
YES

(3) - (9), and between (3)(9) - ground Abnormality in No. 3 injector
• Disconnect CN6 (controller). solenoid system troubleshooting
as shown in Table 1? procedure d)
YES
• Disconnect CN6 (controller). Is voltage between CN6 (female) NO Abnormality in No. 3 injector Go to
• Turn starting switch ON. (3)(9) - ground less than 1 V? solenoid system troubleshooting
procedure d)
YES
Table 1
CN6 (female) CN6 (female) CN6 (female) Resistance
Between (7) and (8) Between (4) and (10) Between (3) and (9) 0.4~1.1Ω
Between (7)(8) and ground Between (4)(10) and ground Between (3)(9) and ground Min. 1 MΩ
HM400-1 20-429
1
b) Troubleshooting No. 1 fuel injector system
Cause Remedy

Is resistance between CN1 (male) NO
(1) - (2), and between (1)(2) - Defective No. 1 injector Replace
• Disconnect CN1 (solenoid). solenoid
ground as shown in Table 2?
YES
Is resistance between CN6 Short circuit with chassis ground or

• Disconnect CN6 and CN1. NO short circuit with power source in Repair or
(female) (7) and ground more than
1 MΩ and is voltage less than 1 V? wiring harness between CN6 replace
(female) (7) and CN1 (female) (1)
YES Short circuit with chassis ground
or short circuit with power source Repair or
in wiring harness between CN6 replace
Table 2
CN1 (male) Resistance
Between (1) and (2) 0.4~1.1Ω
ENG-13 a) b) Related electrical circuit diagram
20-430 HM400-1
1
c) Troubleshooting No. 2 fuel injector system
Cause Remedy

YES

(female) (10) and CN2 (female)
(2)
Table 3
Between (1) and (2) 0.4~1.1Ω
ENG-13 a) c) Related electrical circuit diagram
HM400-1 20-431
1
d) Troubleshooting No. 3 fuel injector system
Cause Remedy

YES

Table 4
Between (1) and (2) 0.4~1.1Ω
ENG-13 a) d) Related electrical circuit diagram
20-432 HM400-1
1
ENG-14 Failure code [ADB1KA] (No. 2 injector solenoid valve: Disconnection (KA))
controller.
Cause Remedy
• Turn starting switch OFF. Is resistance between CN2 (male) NO Defective No. 2 injector
• Disconnect CN2 (solenoid). (1) and (2) 0.4 - 1.1Ω? Replace
solenoid
YES

• Turn starting switch OFF. Is resistance between CN6 NO in wiring harness between CN6 Repair or
• Disconnect CN6 (controller). (female) (4) and (8) 0.4 - 1.1Ω? (female) (4) - CN2 (female) (1) or replace
between CN6 (female) (10) - CN2
(female) (2)
YES
HM400-1 20-433
1
ENG-15 Failure code [ADC1KA] (No. 3 injector solenoid valve: Disconnection (KA))
controller.
Cause Remedy
solenoid
YES

(female) (2)
YES
20-434 HM400-1
1
ENG-16 Failure code [ADD1KA] (No. 4 injector solenoid valve: Disconnection (KA))
controller.
Cause Remedy
solenoid
YES

(female) (2)
YES
HM400-1 20-435
1
ENG-17 Failure code [ADDZKB] (No. 4, 5, 6 injector solenoid valve: Short circuit (KB))
★ Nature of failure: Excessive current has flowed in the No. 4 injector solenoid circuit, No. 5 injector solenoid
circuit, or No. 6 injector solenoid circuit
controller.
a) Determining location of problem
Cause Remedy

• Turn starting switch OFF. Abnormality in No. 4 injector troubleshooting
• Disconnect CN7 (controller). (3) - (9), and between (3)(9) - solenoid system
ground as shown in Table 1? procedure b)
NO Go to
• Disconnect CN7 (controller). Is voltage between CN7 (female) Abnormality in No. 4 injector troubleshooting
• Turn starting switch ON. (3)(9) - ground less than 1 V? solenoid system procedure b)
YES
• Turn starting switch OFF. Is resistance between CN7 (female) NO Go to

(1) - (7), and between (1)(7) - ground Abnormality in No. 5 injector troubleshooting
• Disconnect CN7 (controller). solenoid system
as shown in Table 1? procedure c)
YES
• Disconnect CN7 (controller). NO Go to

Is voltage between CN7 (female) Abnormality in No. 5 injector troubleshooting
• Turn starting switch ON. (1)(7) - ground less than 1 V? solenoid system procedure c)
YES

• Turn starting switch OFF. Abnormality in No. 6 injector
(2) - (8), and between (2)(8) - ground troubleshooting
• Disconnect CN7 (controller). solenoid system
as shown in Table 1? procedure d)
YES
Go to
• Disconnect CN7 (controller). Is voltage between CN7 (female) NO Abnormality in No. 6 injector troubleshooting
• Turn starting switch ON. (2)(8) - ground less than 1 V? solenoid system procedure d)
YES
Table 1
CN7 (female) CN7 (female) CN7 (female) Resistance
Between (3) and (9) Between (1) and (13) Between (2) and (8) 0.4~1.1Ω
Between (3)(9) and ground Between (1)(13) and ground Between (2)(8) and ground Min. 1 MΩ
20-436 HM400-1
1
b) Troubleshooting No. 4 fuel injector system
Cause Remedy

Is resistance between CN4 (male) (1) NO
- (2), and between (1)(2) - ground as Defective No. 4 injector Replace
shown in Table 2?
YES
Short circuit with chassis ground or

Is resistance between CN7 NO short circuit with power source in Repair or
• Disconnect CN7 and CN4.
(female) (3) and ground more than wiring harness between CN7 replace
1 MΩand is voltage less than 1 V? (female) (3) and CN4 (female) (1)
Table 2
Between (1) and (2) 0.4~1.1Ω
ENG-17 a) b) Related electrical circuit diagram
HM400-1 20-437
1
c) Troubleshooting No. 5 fuel injector system
Cause Remedy

shown in Table 3?
YES

1 MΩand is voltage less than 1 V? (female) (1) and CN5 (female) (1)
Table 3
Between (1) and (2) 0.4~1.1Ω
ENG-17 a) c) Related electrical circuit diagram
20-438 HM400-1
1
d) Troubleshooting No. 6 fuel injector system
Cause Remedy

shown in Table 4?
YES

1 MΩ and is voltage less than 1 V? (female) (2) and CN6 (female) (1)
Table 4
Between (1) and (2) 0.4~1.1Ω
ENG-17 a) d) Related electrical circuit diagram
HM400-1 20-439
1
ENG-18 Failure code [ADE1KA] (No. 5 injector solenoid valve: Disconnection (KA))
controller.
Cause Remedy
• Turn starting switch OFF. Is resistance between CN5 (male) (1) NO Defective No. 5 injector
• Disconnect CN5 (solenoid). and (2) 0.4 - 1.1Ω? Replace
solenoid
YES

(female) (2)
YES
20-440 HM400-1
1
ENG-19 Failure code [ADF1KA] (No. 6 injector solenoid valve: Disconnection (KA))
controller.
Cause Remedy
• Turn starting switch OFF. Is resistance between CN6 (male) (1) NO Defective No. 6 injector
• Disconnect CN6 (solenoid). and (2) 0.4 - 1.1Ω? Replace
solenoid
YES

(female) (2)
YES
HM400-1 20-441
1
ENG-20 Failure code [B@BAZG] (Engine oil: Drop in oil pressure (ZG))
★ Nature of failure: When running at low idling, the signal circuit of the engine oil pressure low-pressure switch
became closed (connected to GND), or when the engine speed was more than 1300 rpm,
the signal circuit of the oil pressure high-pressure
Cause Remedy
Check
• See TESTING AND NO cause of
Is engine oil pressure normal? Drop in engine oil pressure
ADJUSTING. failure and
repair
YES damage to
engine
• Insert T-adapter to CN4. Is voltage between CN4 (5) and NO

• Engine at low idling ground 20 - 30 V?
YES
Short circuit with chassis

• Turn starting switch OFF. Is resistance between CN4 (female) NO ground in wiring harness be- Repair or
• Disconnect CN4 and PSL. (5) and ground more than 1 MΩ? tween CN4 (female) (5) and replace
PSL
YES Defective engine oil low-pressure
switch Replace
• Insert T-adapter to CN4. NO

• Engine at midrange speed
Is voltage between CN4 (6) and
(Min. 1300 rpm)
ground 20 - 30 V?
YES
NO Short circuit with chassis ground Repair or

• Turn starting switch OFF. Is resistance between CN4 (female) in wiring harness between CN4
• Disconnect CN4 (solenoid). (6) and ground more than 1 MΩ? replace
(female) (6) and PSH
YES
Defective engine oil high-pressure
switch Replace
20-442 HM400-1
1
ENG-21 Failure code [B@BAZK] (Engine oil: Drop in level (ZK))
★ Nature of failure: The signal circuit of the engine oil pressure switch became open (shut off from GND)
Cause Remedy
NO
• Stop engine. Is engine oil level low?
YES Defective engine oil level Replace

switch
• Turn starting switch OFF. Is resistance between OL (male) NO

• Disconnect OL. (1) and ground less than 1Ω? Drop in engine oil level Add
YES
• Turn starting switch OFF. Is resistance between CN6 (female) NO Defective contact or disconnection
• Disconnect CN6. (1) and ground less than 1Ω? in wiring harness between CN6 Repair or
(female) (1) and OL (female) (1) replace
YES
HM400-1 20-443
1
ENG-22 Failure code [B@BCNS] (Radiator water: Overheat (NS))
★ Nature of failure: The engine water temperature went above the operating range
Cause Remedy
NO
Stop engine. Is engine overheated? Defective engine controller Replace
YES Check cause

of failure and
Engine is overheated repair
damage to
20-444 HM400-1
1
ENG-23 Failure code [D181KZ] (Preheating relay contact: Disconnection or short circuit (KZ))
★ Nature of failure: A disconnection, short circuit with the ground, or short circuit with the power source has
occurred in the signal circuit of the heater relay
★ Before starting troubleshooting, check that fuse BT4-4 is normal (if the fuse is blown, there has probably been
a surge of current caused by a short circuit, so check the related circuits).
Cause Remedy
Does condition become normal NO

• Turn starting switch ON. when preheater relay (R37) is
interchanged with other relay?
YES
Defective preheater relay (R37) Replace
• Disconnect R37 and heater Short circuit with power source

relay (3). Is voltage between R37 (female) NO in wiring harness between R37 Repair or
• Turn starting switch ON. (5) and ground less than 1 V? (female) (5) and heater relay replace
(3)
YES
• Turn starting switch OFF. Is resistance between R37 Short circuit with chassis
NO ground in wiring harness Repair or
• Disconnect R37 and heater (female) (5) and ground more
relay (3). than 1 MΩ? between R37 (female) (5) and replace
heater relay (3) or diode (2)
YES
• Turn starting switch OFF. Is resistance between R37 NO Defective contact or disconnection
• Disconnect R37 and heater (female) (5) and heater relay (3) in wiring harness between R37 Repair or
relay (3). less than 1Ω? (female) (5) and heater relay (3) replace
YES
• Disconnect CN4 and heater Is voltage between CN4 (female) NO Short circuit with power source
relay (2). in wiring harness between CN4 Repair or
• Turn starting switch ON. (3) and ground less than 1 V? replace
(female) (5) and heater relay (2)
YES
• Turn starting switch OFF. Is resistance between CN4 NO Short circuit with chassis ground in
• Disconnect CN4 and heater (female) (3) and ground more wiring harness between CN4 Repair or
relay (2). than 1 MΩ? (female) (3) and heater relay (2) replace
YES
• Turn starting switch OFF. Is resistance between CN4 NO Defective contact or disconnection
• Disconnect CN4 and heater (female) (3) and heater relay (2) in wiring harness between CN4 Repair or
relay (2). less than 1Ω? (female) (3) and heater relay (2) replace
YES

• Turn starting switch ON. Defective transmission controller Replace
when heater relay is replaced?
YES
Defective heater relay Replace
HM400-1 20-445
14
"
20-446 HM400-1
41
"
ENG-24 Failure code [D182KZ] (Preheating relay coil: Disconnection or short circuit (KZ))
★ Nature of failure: A disconnection or short circuit with the ground has occurred in the drive circuit of the pre-
heater relay
★ Before starting troubleshooting, check that fuse BT4-4 is normal (if the fuse is blown, there has probably been
Cause Remedy

• Turn starting switch ON. when preheater relay (R37) is
YES
Defective preheater relay (R37) Replace

• Disconnect R37. Is voltage between R37 (female) NO in wiring harness between fuse Repair or
• Turn starting switch ON. (1)(3) - ground 20 - 30 V? BT4-4 outlet and R37 (female) replace
(1)(3)
YES
Defective contact, disconnection, or

• Disconnect CN2. NO short circuit with chassis ground in
Is voltage between CN2 (female) (5) wiring harness between CN2 Repair or
• Turn starting switch ON. and ground 20 - 30 V? (female) (5) and R37 (female) (2) or replace
diode (2)
YES
HM400-1 20-447
1
4
ENG-25 Failure code [D1D0KB] (Engine controller load power source relay: Short circuit (KB))
★ Nature of failure: Voltage was generated in the power supply circuit of the controller when the starting switch
was OFF
Cause Remedy
Does condition become normal when NO

• Turn starting switch OFF. engine power source relay (R36) is
YES in wiring harness between CN7 Repair or
(female) (6)(14) and R36 replace
(female) (5)
• Turn starting switch OFF. Is voltage between CN7 (6)(14) - NO Defective engine power source Repair or
• Insert T-adapter to CN7. (5)(13) less than 8 V? relay (R36) replace
YES
20-448 HM400-1
(9)
1
HM400-1 20-449
(9)
1
ENG-26 Failure code [D5ZAKX] (Engine throttle modify 1 signal: Input signal outside
range (KX))
★ Nature of failure: The voltage in the throttle modify signal circuit went outside the normal range (6 - 15 V)
Cause Remedy
• Insert T-adapter to CN4. Is voltage between CN4 (female) (16) NO

• Turn starting switch ON. and ground 6 - 15 V?
YES
Defective contact,
• Disconnect ATC3A. Is voltage between ATC3A (female) NO disconnection, or short circuit
with chassis ground in wiring Repair or
harness between CN4 (female)
(16) and ATC3A (female) (5)
YES
Defective transmission controller Replace
20-450 HM400-1
1
ENG-27 Failure code [DB20KT] (Engine controller: Abnormality inside controller (KT))
★ Nature of failure: An abnormality has occurred inside the controller
Cause Remedy
Defective contact or
Turn starting switch OFF. Is resistance between CN7 (female) NO disconnection in wiring harness Repair or
Disconnect CN7. (5)(13) - ground less than 1Ω? between CN7 (female) (5)(13) - replace
ground
YES
HM400-1 20-451
1
ENG-28 Failure code [DB22KK] (Engine controller load power source relay: Drop in
power supply voltage, input (KK))
★ Nature of failure: The voltage in the controller power supply voltage circuit dropped when the starting switch
was ON
★ Before starting troubleshooting, check that fuse BT2-4 and fuse BT4-4 are normal (if either fuse is blown,
there has probably been a surge of current caused by a short circuit, so check the related circuits).
Cause Remedy

• Turn starting switch ON. engine power source relay relay (R36)
is interchanged with other relay?
YES Defective engine power source
relay (R36) Replace
Defective contact or disconnec-

• Disconnect R36. Is voltage between R36 (female) (1) NO tion in wiring harness between Repair or
• Turn starting switch ON. and ground 20 - 30 V? R36 (female) (1) - fuse BT2-4 - replace
starting switch ACC
YES
• Turn starting switch OFF. Is resistance between R36 (female) NO Defective contact or disconnection
in wiring harness between R36 Repair or
• Disconnect R36. (2) and ground less than 1Ω? replace
(female) (2) and ground
YES
• Disconnect R36. Is voltage between R36 (female) (3) NO Defective contact or disconnection Repair or
• Turn starting switch ON. and ground 20 - 30 V? in wiring harness between R36 replace
(female) (3) and fuse BT4-4
YES
• Insert T-adapter to CN7. Is voltage between CN7 (female) NO Defective contact or disconnection
in wiring harness between CN7 Repair or
• Turn starting switch ON. (6)(14) - ground 20 - 30 V? replace
(female) (6)(14) - R36 (female) (5)
YES
Defective engine controller. Replace
20-452 HM400-1
1
HM400-1 20-453
(9)
1
ENG-29 Failure code [DB29KQ] (Engine controller connection wiring harness: Model
selection signal mismatch (KQ))
★ Nature of failure: The model selection signal does not match the setting inside the controller
Cause Remedy
• Turn starting switch OFF. Is resistance between MS (male) NO Defective model selection
• Disconnect MS. (1)(2)(3) - (4) as shown in Table 1? connector Replace
YES
• Turn starting switch OFF. Is resistance between MS (female) NO Defective contact or disconnec-
• Disconnect MS. (1) and ground less than 1Ω? tion in wiring harness between Repair or
MS (female) (1) and ground replace
YES
• Turn starting switch OFF. Is resistance between CN4 (female) NO Defective contact or disconnection
• Disconnect CN4. (13) and ground less than 1Ω? replace
(female) (13) and MS (female) (2)
YES
• Turn starting switch OFF. Is resistance between CN4 (female) NO Short circuit with chassis ground Repair or
• Disconnect CN4. (14) and ground more than 1 MΩ? in wiring harness between CN4 replace
YES
Is resistance between CN4 (female) NO Defective contact or disconnection

• Turn starting switch OFF. in wiring harness between CN4 Repair or
• Disconnect CN4. (15) and ground less than 1Ω? replace
YES
Table 1
MS (male) Resistance value
Between (1) and (4) Max. 1Ω
Between (2) and (4) Max. 1Ω
Between (3) and (4) Min. 1 MΩ
20-454 HM400-1
1
TROUBLESHOOTING ENG-29, ENG-30
ENG-30 Failure code [DB2AMA] (Engine controller fuel injection quantity control
switch: Function impossible (MA))
★ Nature of failure: The fuel injection quantity control set switch inside the controller is not set at the correct
position
Cause Remedy
Are both fuel injection quantity NO

control switches 1 and 2 set to [F]? Defective engine controller Replace
YES
Defective setting of fuel injection Adjust
quantity control switch again
Troubleshooting No. 1 fuel injector system

Table 2
IJ1 (female) Resistance value
Between (1) and (2) 0.4 – 1.1 Ω

Table 3
IJ2 (female) Resistance value
Between (1) and (2) 0.4 – 1.1 Ω
HM400-1 20-455
1
ENG-31 Failure code [KK11KB] (Starting switch: Short circuit (KB))
★ Nature of failure: The terminal C signal from the starting switch came ON when the engine was running
Cause Remedy
• Connect T-adapter to CN4. Is voltage between CN4 (2) and NO

• Turn starting switch ON. ground less than 1 V?
YES
• Disconnect starting switch Is voltage between starting switch NO

terminal C. terminal C and ground less than 1 V? Defective starting switch Replace
YES Short circuit with power source in

wiring harness between CN4 Repair or
(female) (2) and starting switch replace
terminal C
20-456 HM400-1
1
ENG-32 Failure code [DDA1L5] (Acceleration switch: * See Contents (L5))
★ Nature of failure: The idling validation switch of the accelerator pedal does not match the throttle angle signal
• Insert T-adapter to AS1. Does voltage (signal 2) between NO

• Turn starting switch ON. AS1 (5) and (4) change as Defective accelerator pedal Repair or
shown in Fig. 1? (switch) replace
YES
• Insert T-adapter to AS1. Does voltage (signal 3) between NO Defective accelerator pedal Repair or
• Turn starting switch ON. AS1 (6) and (4) change as (switch)
shown in Fig. 1? replace
YES
• Turn starting switch OFF. Is resistance between AS1 NO

• Disconnect AS1. (female) (4) and ground less
than 1Ω?
YES
• Turn starting switch OFF. Is resistance between CN4 NO Defective contact or disconnection
(female) (8) and AS1 (female) (4) in wiring harness between CN4 Repair or
• Disconnect CN4 and AS1. replace
less than 1Ω? (female) (8) and AS1 (female) (4)
YES
Defective contact, disconnection,

Does voltage (signal 2) between NO short circuit with chassis ground, or
• Insert T-adapter to CN4.
CN4 (11) and (8) change as short circuit with power source in Repair or
shown in Fig 1? wiring harness between CN4 replace
(female) (11) and AS1 (female) (5)
YES

• Insert T-adapter to CN4. Does voltage (signal 3) between NO short circuit with chassis ground, or
• Turn starting switch ON. CN4 (12) and (8) change as short circuit with power source in Repair or
shown in Fig. 1? wiring harness between CN4 replace
(female) (12) and AS1 (female) (6)
YES
Fig. 1
HM400-1 20-457
1
20-458 HM400-1
1
ENG-33 Failure code [DDE2L6] (Engine oil pressure switch: * See Contents (L6))
★ Nature of failure: The engine oil pressure switch signal does not match the condition of the engine
Cause Remedy
Is voltage between CN4 (5) and NO

• Insert T-adapter to CN4.
YES
Is resistance between PSL NO Defective engine oil low-pres-

• Disconnect PSL. (switch end) and ground as sure switch Replace
shown in Table 2?
YES Defective contact, disconnection,
or short circuit with chassis ground Repair or
(female) (5) and PSL
Is voltage between CN4 (6) and NO

• Insert T-adapter to CN4. ground as shown in Table 3?
YES
Is resistance between PSH NO Defective engine oil high-pressure

• Disconnect PSH. (switch end) and ground as Replace
switch
shown in Table 4?
YES
(female) (5) and PSH replace
Table 1 Table 2
CN4 Engine Voltage PSL (switch end) Engine Resistance value
When stopped Max. 1 V When stopped Max. 1Ω
Between (5) and Between PSL
When more When more
ground 20~30V and ground Min. 1 MΩ
than 600 rpm than 600 rpm
Table 3 Table 4
CN4 Engine Voltage PSL (switch end) Engine Resistance value
When stopped Max. 1 V When stopped Max. 1Ω
Between (6) and Between PSH
When more When more
ground 20~30V and ground Min. 1 MΩ
than 1,300 rpm than 1,300 rpm
HM400-1 20-459
1
20-460 HM400-1
1
ENG-34 Failure code [DGE2KX] (Engine water temperature sensor (for high-tempera-
ture): Input signal outside range (KX))
★ Nature of failure: The signal from the engine water high-temperature sensor is outside the normal range
Cause Remedy
• Turn starting switch OFF. Is resistance between TWH (male) NO

• Disconnect TWH. (1) and (2), and between (1) and Defective engine water high- Replace
• Water temperature:10 - 100 C ground as shown in Table 1? temperature sensor
YES

• Turn starting switch OFF. in wiring harness between CN2
• Disconnect CN2. Is resistance between CN2 (female) NO (female) (4) and TWH (female) (1) Repair or
• Water temperature:10 - 100 C (4) and (10) 90k - 3.5 kΩ? or between CN2 (female) (10) and replace
TWH (female) (2)
YES

• Turn starting switch OFF. Is resistance between CN2 (female) NO in wiring harness between CN2 Repair or
• Disconnect CN2 and TWH. (4) and ground more than 1 MΩ? (female) (4) and TWH (female) replace
(1)
YES
Table 1
TWH (male) Resistance
Between (1) and (2) 90k~3.5kΩ
HM400-1 20-461
1
ENG-35 Failure code [DGE3LC] (Engine water temperature sensor (for low-tempera-
ture): * See Contents (L6))
★ Nature of failure: The signal from the engine water high-temperature sensor has not been input
Cause Remedy
• Turn starting switch OFF. Is resistance between TWL (male) NO

• Disconnect TWL. (1) and (2), and between (1) and Defective engine water low- Replace
• Water temperature:10 - 100 C ground as shown in Table 1? temperature sensor
YES

• Disconnect CN2. Is resistance between CN2 (female) NO (female) (3) and TWL (female) (1) Repair or
• Water temperature:10 - 100 C (3) and (10) 9 k - 0.3 kΩ? or between CN2 (female) (10) and replace
TWL (female) (2)
YES

• Disconnect CN2 and TWL. (3) and ground more than 1 MΩ? (female) (3) and TWL (female) replace
(1)
YES
Table 1
TWL (male) Resistance
20-462 HM400-1
1
ENG-36 Failure code [DGE4KX] (Fuel temperature sensor: Input signal outside range (KX))
★ Nature of failure: The signal from the fuel temperature sensor is outside the normal range
Cause Remedy
• Turn starting switch OFF. Is resistance between THL (male) NO

• Disconnect THL. (1) and (2), and between (1) and Defective fuel temperature Replace
• Water temperature:10 - 100 C ground as shown in Table 1? sensor
YES

• Disconnect CN2. Is resistance between CN2 (female) NO (female) (11) and THL (female) (1) Repair or
• Water temperature:10 - 100 C (11) and (10) 9 k - 0.3 kΩ? or between CN2 (female) (10) and replace
THL (female) (2)
YES

• Disconnect CN2 and THL. (11) and ground more than 1 MΩ? (female) (11) and THL (female) replace
(1)
YES
Table 1
THL (male) Resistance
HM400-1 20-463
1
ENG-37 Failure code [DH30KX] (Boost pressure sensor: Input signal outside range (KX))
★ Nature of failure: The signal from the boost sensor is outside the normal range
Cause Remedy
• Insert T-adapter to CN1

Is voltage between CN1 (3) and CN2 NO
and CN2.
(10) 0.3 - 4.7 V?
YES
• Disconnect PIM. Is voltage between PIM (female) (1) NO

• Turn starting switch ON. and ground 4.6 - 5.4 V?
YES

• Disconnect CN2 and PIM. Is resistance between CN2 (female) NO ground in wiring harness be- Repair or
• Turn starting switch OFF. (2) and ground more than 1 MΩ? tween CN2 (female) (2) and replace
PIM (female) (1)
YES

ground 4.6 - 5.4 V?

YES tion in wiring harness between Repair or
CN2 (female) (2) and PIM (fe- replace
male) (1)
• Turn starting switch OFF. Is resistance between PIM (female)

• Disconnect PIM. (3) and ground less than 1Ω?
YES
Is resistance between CN2 Defective contact or disconnec-

• Turn starting switch OFF. NO tion in wiring harness between Repair or
• Disconnect CN2 and PIM. (female) (10) and PIM (female)
(3) less than 1Ω? CN2 (female) (10) and PIM (fe- replace
male) (3)
YES

• Turn starting switch OFF. Is resistance between CN2 NO ground in wiring harness be-
(female) (10) and ground more Repair or
• Disconnect CN2 and PIM. tween CN2 (female) (10) and replace
than 1 MΩ? PIM (female) (3)
YES
• Insert T-adapter to PIM. Is voltage between PIM (2) and NO

• Turn starting switch ON. ground 0.3 - 4.7 V?
YES Defective contact or disconnec-

tion in wiring harness between Repair or
CN1 (female) (3) and PIM (fe- replace
male) (2)
Is resistance between CN1 Short circuit with chassis

• Turn starting switch OFF. NO ground in wiring harness be-
• Disconnect CN1 and PIM. than 1 MΩ? tween CN1 (female) (3) and replace
PIM (female) (2)
YES
Defective boost pressure sensor Replace
20-464 HM400-1
1
HM400-1 20-465
1
ENG-38 Failure code [DH40KX] (Common rail pressure sensor: Input signal outside
range (KX))
★ Nature of failure: The signal from the common rail fuel pressure sensor is outside the normal range
Cause Remedy
• Insert T-adapter to CN1

Is voltage between CN1 (1) and CN2 NO
and CN2.
(10) 0.3 - 4.7 V?
YES
• Disconnect PFUEL. Is voltage between PFUEL (female) NO

• Turn starting switch ON. (1) and ground 4.6 - 5.4 V?
YES

• Disconnect CN2 and PFUEL. Is resistance between CN2 (female) NO ground in wiring harness be- Repair or
PFUEL (female) (1)
YES

ground 4.6 - 5.4 V?

CN2 (female) (2) and PFUEL replace
(female) (1)
• Turn starting switch OFF. Is resistance between PFUEL

• Disconnect PFUEL. (female) (3) and ground less than 1Ω?
YES

• Disconnect CN2 and PFUEL. (female) (10) and PFUEL
(female) (3) less than 1Ω? CN2 (female) (10) and PFUEL replace
(female) (3)
YES
hort circuit with chassis ground

• Disconnect CN2 and PFUEL. (female) (10) and ground more (female) (10) and PFUEL (fe-
than 1 MΩ? replace
male) (3)
YES
• Insert T-adapter to PFUEL. Is voltage between PFUEL (2) NO


CN1 (female) (1) and PFUEL replace
(female) (2)

• Disconnect CN1 and PFUEL. than 1 MΩ? tween CN1 (female) (1) and replace
PFUEL (female) (2)
YES
Defective common rail fuel pres- Replace
sure sensor
20-466 HM400-1
1
HM400-1 20-467
1
ENG-39 Failure code [DK10KX] (Throttle angle sensor: Input signal outside range (KX))
★ Nature of failure: The throttle angle signal from the accelerator pedal is outside the normal range
Cause Remedy
• Insert T-adapter to CN1. Is voltage between CN1 (6) and (11) NO

• Turn starting switch ON. 0.3 - 4.7 V?
YES
• Disconnect AS1. Is voltage between AS1 (female) (3) NO

YES

• Disconnect CN1 and AS1. Is resistance between CN1 (female) NO ground in wiring harness be- Repair or
AS1 (female) (3)
YES

ground 4.6 - 5.4 V?

CN1 (female) (4) and AS1 (fe- replace
male) (3)
• Turn starting switch OFF. Is resistance between AS1 (female)

• Disconnect AS1. (1) and ground less than 1Ω?
YES

• Disconnect CN1 and AS1. (female) (11) and AS1 (female)
(1) less than 1Ω? CN1 (female) (11) and AS1 (fe- replace
male) (1)
YES

. Disconnect CN1 and AS1 than 1 MΩ? tween CN1 (female) (11) and replace
AS1 (female) (1)
YES
• Insert T-adapter to AS1. Is voltage between AS1 (2) and NO


CN1 (female) (6) and AS1 (fe- replace
male) (2)

• Disconnect CN1 and AS1. than 1 MΩ? tween CN1 (female) (6) and replace
AS1 (female) (2)
YES
Defective accelerator pedal (po- Replace
tentiometer)
20-468 HM400-1
1
HM400-1 20-469
1
ENG-40 Failure code [DLE3LC] (Engine Ne speed sensor: * See Contents (LC))
★ Nature of failure: The signal from the engine Ne speed sensor does not match the signal from the engine G
speed sensor
Cause Remedy
• Turn starting switch OFF. Is resistance between NE (male) (1) - NO Defective engine Ne speed
• Disconnect NE. (2), and between (1)(2) - ground as sensor Replace
shown in Table 1?
YES

• Turn starting switch OFF. Is resistance between CN1 (female) NO tion in wiring harness between Repair or
• Disconnect NE. (5) and (12) 85 - 210 1Ω? CN1 (female) (5) and NE (fe- replace
male) (1) or between CN1 (fe-
male) (12) and NE (female) (2)
YES
• Turn starting switch OFF. Is resistance between CN1 (male) (5) NO Short circuit with chassis ground in
• Disconnect CN1 and NE. and ground more than 1 1Ω? replace
(female) (5) and NE (female) (1)
YES
NO Short circuit with chassis ground

• Turn starting switch OFF. Is resistance between CN1 (male) Repair or
• Disconnect CN1 and NE. (12) and ground more than 1 MΩ? replace
(female) (5) and NE (female) (2)
YES
Table 1
NE (male) Resistance
Between (1) and (2) 85~210Ω
20-470 HM400-1
1
ENG-41 Failure code [DLE1LC] (Engine G speed sensor: * See Contents (LC))
★ Nature of failure: The signal from the engine Ne speed sensor does not match the signal from the engine G
speed sensor
Cause Remedy
• Turn starting switch OFF. Is resistance between G (male) (1) - NO Defective engine G speed
• Disconnect G. (2), and between (1)(2) - ground as sensor Replace
shown in Table 1?
YES

• Turn starting switch OFF. Is resistance between CN2 (female) NO tion in wiring harness between Repair or
• Disconnect CN2. (1) and (9) 1.4 - 3.5 kΩ? CN2 (female) (1) and G (fe- replace
male) (1) or between CN2 (fe-
male) (9) and G (female) (2)
YES
• Turn starting switch OFF. Is resistance between CN2 (male) (1) NO Short circuit with chassis ground in
• Disconnect CN2 and G. and ground more than 1 MΩ? replace
(female) (1) and G (female) (1)
YES

• Turn starting switch OFF. Is resistance between CN2 (male) (9) NO in wiring harness between CN2
Repair or
• Disconnect CN2 and G. and ground more than 1 MΩ? replace
(female) (12) and G (female) (2)
YES
Table 1
G (male) Resistance
Between (1) and (2) 1.4k~3.5kΩ
HM400-1 20-471
1
ENG-42 Failure code (Engine does not start (starting motor does not turn)
★ Nature of failure: Even when the starting switch is turned to the START position, the starting motor does not
turn (no failure code is displayed)
★ If the engine does not start even when it is cranked, there is probably a problem in the engine mechanical
system, so see the Shop Manual for the 140-3 Engine.
★ Before starting troubleshooting, check that the circuit breaker is not OFF, and that the fusible link, fuse BT2-
20, and fuse BT3-30 are normal (if the circuit breaker is OFF or any fuse is blown, there has probably been
Cause Remedy
• Disconnect CN78. Is voltage between CN78 (female) (2) NO

• Turn starting switch ON. and ground less than 1 V?
YES
Is voltage between CN78 (female) (2) and NO

• Disconnect CN78 and CN80. ground less than 1 V when alternator
• Turn starting switch ON. terminal R (CN80) is disconnected?
YES
Defective alternator Replace
• Disconnect CN78 and D01. Is voltage between CN78 (female) (2) NO Short circuit with power source in
and ground less than 1 V when diode wiring harness between CN78 Repair or
• Turn starting switch ON. replace
(D01) is disconnected? (female) (2) - alternator terminal R
(CN80) - D01 (female) (2)
YES
Defective diode (D01) Replace
• Disconnect CN78. Is voltage between CN78 (female) (1) NO

• Turn starting switch to START. and ground 20 - 30 V?
• Turn starting switch to Does condition become normal when engine NO

START. starting relay (R01) or transmission neutral
relay (R02) is interchanged with other relay?
YES Defective engine starting relay
(R01) or defective transmission Replace
neutral relay (R02)
• Disconnect R01. Is voltage between R01 (female) (1) NO Defective contact or disconnection
• Turn starting switch ON. and ground 20 - 30 V? in wiring harness between fuse Repair or
BT3-10 outlet and R01 (female) (1) replace
YES
To 12 To 7
20-472 HM400-1
1
From 4 From 6
Cause Remedy

• Disconnect R02. Is voltage between R02 (female) (6) NO in wiring harness between R01 Repair or
• Turn starting switch ON. and ground 20 - 30 V? (female) (2) and R02 (female) (6) replace
NO Defective contact or disconnection

• Turn starting switch OFF. Is resistance between R02 (female) (3) in wiring harness between R02 Repair or
• Disconnect R02. and ground less than 1Ω? (female) (3) and ground replace
YES
• Disconnect R02. NO Defective contact or disconnection

Is voltage between R02 (female) (1) in wiring harness between R02 Repair or
• Turn starting switch ON. and ground 20 - 30 V? replace
(female) (1) and wiring harness
dividing point
YES
• Turn starting switch OFF. NO Defective contact or disconnection Repair or

Is resistance between R02 (female) in wiring harness between R02
• Disconnect R02. (2) and ground less than 1Ω? replace
YES
Defective starting switch or defective

• Disconnect R01. Is voltage between R01 (female) (3) NO contact or disconnection in wiring Repair or
• Turn starting switch START. and ground 20 - 30 V? harness between starting switch replace
terminal C and R01 (female) (3)
YES Defective contact or disconnection Repair or
in wiring harness between R01 replace
NO Defective contact or disconnection Repair or

• Turn starting switch OFF. Is voltage between starting motor in wiring harness between battery -
terminal B and ground 20 - 30 V? replace
battery relay - starting motor
terminal B
YES
Defective starting motor Replace
HM400-1 20-473
1
20-474 HM400-1
1
TROUBLESHOOTING TM MODE
TROUBLESHOOTING OF
TRANSMISSION CONTROLLER
SYSTEM (TM MODE)
TM Mode related electrical circuit diagram ................................................................................................ 20-504

Content of display and problem that appears on machine for each failure code....................................... 20-510
TM-1 Failure code [1380MW] (Lock-up clutch: Slipping (MW)) ................................................................. 20-536
TM-2 Failure code [1500LO] (Transmission clutch: * See Contents (LO)) ................................................ 20-537
TM-3 Failure code [15BONX] (Transmission oil filter: Clogged (NX)) ....................................................... 20-538
TM-4 Failure code [15GOMW] (R clutch: Slipping (MW)) ......................................................................... 20-539
TM-5 Failure code [15HOMW] (Hi clutch: Slipping (MW))......................................................................... 20-540
TM-6 Failure code [15JOMW] (Lo clutch: Slipping (MW))......................................................................... 20-541
TM-7 Failure code [15KOMW] (1st clutch: Slipping (MW))........................................................................ 20-542
TM-8 Failure code [15LOMW] (2nd clutch: Slipping (MW))....................................................................... 20-543
TM-9 Failure code [15MOMW] (3rd clutch: Slipping (MW))....................................................................... 20-544
TM-10 Failure code [15SBL1] (ECMV for R clutch: * See Contents (L1)) ................................................. 20-545
TM-11 Failure code [15SBMA] (ECMV for R clutch: Function impossible (MA))....................................... 20-546
TM-12 Failure code [15SCL1] (ECMV for Hi clutch: * See Contents (L1)) ................................................ 20-547
TM-13 Failure code [15SCMA] (ECMV for Hi clutch: Function impossible (MA))...................................... 20-548
TM-14 Failure code [15SDL1] (ECMV for Lo clutch: * See Contents (L1)) ............................................... 20-549
TM-15 Failure code [15SDMA] (ECMV for Lo clutch: Function impossible (MA)) ..................................... 20-550
TM-16 Failure code [15SEL1] (ECMV for 1st clutch: * See Contents (L1))............................................... 20-551
TM-17 Failure code [15SEMA] (ECMV for 1st clutch: Function impossible (MA)) .................................... 20-552
TM-18 Failure code [15SFL1] (ECMV for 2nd clutch: * See Contents (L1)) .............................................. 20-553
TM-19 Failure code [15SFMA] (ECMV for 2nd clutch: Function impossible (MA)) ................................... 20-554
TM-20 Failure code [15SGL1] (ECMV for 3rd clutch: * See Contents (L1)) .............................................. 20-555
TM-21 Failure code [15SGMA] (ECMV for 3rd clutch: Function impossible (MA)) .................................... 20-556
TM-22 Failure code [15SJL1] (ECMV for lock-up clutch: * See Contents (L1))......................................... 20-557
TM-23 Failure code [15SJMA] (ECMV for lock-up clutch: Function impossible (MA)) .............................. 20-558
TM-24 Failure code [15SKL1] (ECMV for inter-axle differential lock clutch: * See Contents (L1))............ 20-559
TM-25 Failure code [15SKMA] (ECMV for inter-axle differential lock clutch: Function impossible (MA)).. 20-560
TM-26 Failure code [2B61MW] (Inter-axle differential lock clutch: Slipping (MW)) ................................... 20-561
TM-27 Failure code [2F00KM] (Parking brake: Mistaken operation or mistaken setting (KM))................. 20-562
TM-28 Failure code [6014NX] (Hydraulic tank filter: Clogged (NX)).......................................................... 20-564
TM-29 Failure code [989A00] (Engine overrun prevention command signal: Actuated (00)).................... 20-565
TM-30 Failure code [989AKZ] (Engine overrun prevention command signal:
Disconnection or short circuit (KZ)) ................................................................................................ 20-566
TM-31 Failure code [989D00] (Rear overturn signal: Actuated (00)) ........................................................ 20-567
TM-32 Failure code [AA10NX] (Air cleaner element: Clogged (NX)) ........................................................ 20-569
TM-33 Failure code [AB00MA] (Alternator: Function impossible (MA))..................................................... 50-570
HM400-1 20-501
TM-34 Failure code [B@BCZK] (Radiator water: Drop in level (ZK)) ........................................................20-571
TM-35 Failure code [B@HAZK] (Hydraulic tank oil: Drop in level (ZK)) ....................................................20-572
TM-36 Failure code [B@JANS] (Steering oil: Overheat (ZK)) ...................................................................20-573
TM-37 Failure code [D1B0KZ] (Transmission cut relay: Disconnection or short circuit (KZ)) ....................20-574
TM-38 Failure code [D5ZBKX] (Inter-axle differential lock command signal:
Input signal outside range (KX)) .....................................................................................................20-576
TM-39 Failure code [D5ZCKZ] (Exhaust brake command signal: Disconnection or short circuit (KZ)) .....20-577
TM-40 Failure code [D5ZDL4] (Forced neutral demand signal: * See Contents (L4)) ...............................20-578
TM-41 Failure code [D5ZEKX] (Engine load signal: Input signal outside range (KX))...............................20-579
TM-42 Failure code [DAQ0KK] (Transmission controller: Drop in power source voltage, input (KK)) .......20-581
TM-43 Failure code [DAQ1KK] (Transmission controller main power supply line:
Drop in power source voltage, input (KK)) ......................................................................................20-582
TM-44 Failure code [DAQ2KK] (Transmission controller load power supply line:
TM-45 Failure code [DAQ3KK] (Transmission controller battery direct power supply line:
TM-46 Failure code [DAQ5KP] (Transmission controller power supply output 1:
Drop in output voltage (KP)) ...........................................................................................................20-585
TM-47 Failure code [DAQ9KM] (Transmission controller wiring harness:
Mistaken operation or mistaken setting (KP)) .................................................................................20-586
TM-48 Failure code [DAQ9KQ] (Transmission controller wiring harness:
Non match in model selection signal (KP)) .....................................................................................20-587
TM-49 Failure code [DAQAKQ] (Transmission controller rotary switch:
Non match in model selection signal (KP)) .....................................................................................20-588
TM-50 Failure code [DAQSMA] (Transmission controller: Function impossible (MA)) ..............................20-588
TM-51 Failure code [DDTFKA] (Fill switch for inter-axle differential lock clutch: Disconnection (KA)) ......20-589
TM-52 Failure code [DDTGKA] (Fill switch for lock-up clutch: Disconnection (KA)) ..................................20-590
TM-53 Failure code [DDTHKA] (Fill switch for Hi clutch: Disconnection (KA)) ..........................................20-591
TM-54 Failure code [DDTJKA] (Fill switch for Lo clutch: Disconnection (KA))...........................................20-592
TM-55 Failure code [DDTKKA] (Fill switch for 1st clutch: Disconnection (KA)) .........................................20-593
TM-56 Failure code [DDTLKA] (Fill switch for 2nd clutch: Disconnection (KA)) ........................................20-594
TM-57 Failure code [DDTMKA] (Fill switch for 3rd clutch: Disconnection (KA)) ........................................20-595
TM-58 Failure code [DDTNKA] (Fill switch for R clutch: Disconnection (KA)) ...........................................20-596
TM-59 Failure code [DF10KA] (Gearshift lever: Disconnection (KA)) ........................................................20-597
TM-60 Failure code [DF10KB] (Gearshift lever: Short circuit (KB)) ...........................................................20-599
TM-61 Failure code [DGF1KX] (Transmission valve oil temperature sensor:
TM-62 Failure code [DGR2L8] (Brake oil temperature sensor (rear): * See Contents (L8))......................20-602
TM-63 Failure code [DGR3L8] (Brake oil temperature sensor (center): * See Contents (L8)) ..................20-603
TM-64 Failure code [DGR4L8] (Brake oil temperature sensor (front): * See Contents (L8)) .....................20-604
TM-65 Failure code [DGT1KX] (Torque converter oil temperature sensor:
T M -66 F ailure code [D H T 5K X ] (Torque converter oil pressure sensor: Input signal outside range ( K X)) ...20-606
TM-67 Failure code [DHT5L6] (Torque converter oil pressure sensor: * See Contents (L6)) ....................20-608
TM-68 Failure code [DJF1KA] (Fuel level sensor: Disconnection (L6)) .....................................................20-609
TM-69 Failure code [DK11KX] (Throttle angle sensor: Input signal outside range (KX)) ...........................20-610
TM-70 Failure code [DLE2KA] (Engine speed sensor: Disconnection (KA)) .............................................20-612
TM-71 Failure code [DLE2LC] (Engine speed sensor: * See Contents (LC)) ............................................20-613
TM-72 Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection (KA))..................20-614
TM-73 Failure code [DLF1LC] (Transmission input shaft speed sensor: * See Contents (LC)) ................20-615
TM-74 Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection (KA))......20-616
TM-75 Failure code [DLF2LC] (Transmission intermediate shaft speed sensor: * See Contents (LC)) ....20-617
TM-76 Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection (KA)) ................20-618
TM-77 Failure code [DLT3LC] (Transmission output shaft speed sensor: * See Contents (LC))...............20-619
TM-78 Failure code [DXH0KA] (Solenoid for inter-axle differential lock: Disconnection (KA)) ..................20-620
TM-79 Failure code [DXH0KB] (Solenoid for inter-axle differential lock: Short circuit (KB))......................20-621
TM-80 Failure code [DXH1KA] (Solenoid for lock-up clutch: Disconnection (KA)) ....................................20-622
20-502 HM400-1
TM-81 Failure code [DXH1KB] (Solenoid for lock-up clutch: Short circuit (KB)) ....................................... 20-623
TM-82 Failure code [DXH2KA] (Solenoid for Hi clutch: Disconnection (KA))............................................ 20-624
TM-83 Failure code [DXH2KB] (Solenoid for Hi clutch: Short circuit (KB)) ............................................... 20-625
TM-84 Failure code [DXH3KA] (Solenoid for Lo clutch: Disconnection (KA)) ........................................... 20-626
TM-85 Failure code [DXH3KB] (Solenoid for Lo clutch: Short circuit (KB))............................................... 20-627
TM-86 Failure code [DXH4KA] (Solenoid for 1st clutch: Disconnection (KA)) .......................................... 20-628
TM-87 Failure code [DXH4KB] (Solenoid for 1st clutch: Short circuit (KB)) .............................................. 20-629
TM-88 Failure code [DXH5KA] (Solenoid for 2nd clutch: Disconnection (KA)) ......................................... 20-630
TM-89 Failure code [DXH5KB] (Solenoid for 2nd clutch: Short circuit (KB))............................................. 20-631
TM-90 Failure code [DXH6KA] (Solenoid for 3rd clutch: Disconnection (KA)) .......................................... 20-632
TM-91 Failure code [DXH6KB] (Solenoid for 3rd clutch: Short circuit (KB)).............................................. 20-633
TM-92 Failure code [DXH7KA] (Solenoid for R clutch: Disconnection (KA))............................................. 20-634
TM-93 Failure code [DXH7KB] (Solenoid for R clutch: Short circuit (KB)) ................................................ 20-635
TM-94 Backup lamp, backup buzzer do not work properly ....................................................................... 20-636
* Failure phenomena of L Series problem codes (L*)
Problem code Nature

Lo Fill signals on 2 or more channels for clutches not forming a set are input at same time
HM400-1 20-503

TROUBLESHOOTING TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
20-504 HM400-1
4
"
★ This circuit diagram has been made by extracting the transmission controller related circuits and emergency
steering related circuits from the overall electrical circuit diagram.
HM400-1 20-505
4"
20-506 HM400-1
4
"
HM400-1 20-507
4"
20-508 HM400-1
"4
HM400-1 20-509
4"
TROUBLESHOOTING CONTENT OF DISPLAY AND PROBLEM THAT APPEARS
ON MACHINE FOR EACH FAILURE CODE
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH

FAILURE CODE
Failure code Location of failure Nature of failure Probable cause
Lock-up clutch: Slipping (MW) When there is output to the lock-up • Defective lock-up clutch solenoid
clutch solenoid, there is an abnormality • Excessive resistance in solenoid (+) circuit
in the value calculated from the signals wiring harness
1380MW from the engine speed sensor, trans- • Excessive resistance in solenoid (-) circuit
(TM-1) mission input shaft speed sensor, wiring harness
transmission intermediate shaft speed • Defective lock-up clutch, pressure control
sensor, and transmission valve hydraulic, mechanical system
output shaft R speed sensor. • Defective transmission controller
Transmission clutch: * See Con- Fill switch signals have been input • Other problem occurs at same time (failure
tents (LO) from 2 clutches that do not form a nor- code [15S*L1] is displayed)
1500L0
mal combination. • Defective pressure control valve hydraulic,
(TM-2)
mechanical system
• Defective transmission controller
Transmission oil filter: Clogged When the torque converter oil temper- • Clogged transmission oil filter (when actu-
(NX) ature is more than 50fC, the signal cir- ating system normally)
cuit of the transmission filter clogging • Defective transmission oil filter clogging
switch is open (shut off from the switch
15BONX
ground). • Disconnection in switch signal circuit wir-
(TM-3)
ing harness
harness
R clutch: Slipping (MW) When there is output to the R clutch • Defective R clutch solenoid
solenoid, there is an abnormality in the • Excessive resistance in solenoid (+) circuit
value calculated from the signals from wiring harness
15G0MW the transmission input shaft speed • Excessive resistance in solenoid (-) circuit
(TM-4) sensor, intermediate shaft speed sen- wiring harness
sor, and output shaft R speed sensor. • Defective R clutch, pressure control valve
hydraulic, mechanical system
Hi clutch: Slipping (MW) When there is output to the Hi clutch • Defective Hi clutch solenoid
15H0MW the transmission input shaft speed • Excessive resistance in solenoid (-) circuit
sor, and output shaft R speed sensor. • Defective Hi clutch, pressure control valve
Lo clutch: Slipping (MW) When there is output to the Lo clutch • Defective Lo clutch solenoid
15J0MW the transmission input shaft speed • Excessive resistance in solenoid (-) circuit
sor, and output shaft R speed sensor. • Defective Lo clutch, pressure control valve
1st clutch: Slipping (MW) When there is output to the 1st clutch • Defective 1st clutch solenoid
15K0MW the transmission input shaft speed • Excessive resistance in solenoid (-) circuit
sor, and output shaft R speed sensor. • Defective 1st clutch, pressure control
valve hydraulic, mechanical system
20-510 HM400-1

★ The code (TM-**) given below the service code is the troubleshooting number.
Action
code
• Solenoid resistance value • Holds speed range during travel, turns • Lock-up is canceled and transmission
L/U-PS (male) (1) - (2): 5 - 15 Ω lock-up actuation OFF. cannot be shifted
• Holds at Neutral if gearshift lever is op- • If gearshift lever is operated to N, ma-
erated to N. chine cannot move off again until it is
E03
stopped
• Turns transmission cut relay OFF. • Suddenly shifts to Neutral when

• Sets transmission to Neutral. traveling and cannot move off again
E03
• Switch resistance value • Takes no action • If machine continues to be used as it is,

T03 (male) (1) - (2): there is danger that dirt will circulate in
• When normal: Max. 1 Ω transmission circuit
E01
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
L-PS (male) (1) - (2): 5 - 15 Ω traveling
is stopped
E03
1-PS (male) (1) - (2): 5 - 15 Ω traveling
E03
HM400-1 20-511
2nd clutch: Slipping (MW) When there is output to the 2nd clutch • Defective 2nd clutch solenoid
15L0MW the transmission input shaft speed • Excessive resistance in solenoid (-) circuit
sor, and output shaft R speed sensor. • Defective 2nd clutch, pressure control
(TM-9) 3rd clutch: Slipping When there is output to the 3rd clutch • Defective 3rd clutch solenoid
(MW) solenoid, there is an abnormality in the • Excessive resistance in solenoid (+) circuit
15M0MW the transmission input shaft speed • Excessive resistance in solenoid (-) circuit
sor, and output shaft R speed sensor. • Defective 3rd clutch, pressure control
ECMV for R clutch: * See Con- Even when the output to the R clutch • Defective R clutch fill switch
tents (L1) solenoid is turned OFF, the signal from • Short circuit with chassis ground in switch
15SBL1 the fill switch stays ON and the clutch circuit wiring harness
(TM-10) is not disengaged. • Defective R clutch pressure control valve
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 fill • Excessive resistance in solenoid (+) circuit
switch stays OFF and the clutch is not wiring harness
15SBMA engaged. • Excessive resistance in solenoid (-) circuit
(TM-11) wiring harness
• Defective R clutch or pressure control
ECMV for Hi clutch: * See Con- Even when the output to the Hi clutch • Defective Hi clutch fill switch
15SCL1 the fill switch stays ON and the clutch circuit wiring harness
(TM-12) is not disengaged. • Defective Hi clutch or pressure control
ECMV for Hi clutch: Function Even when there is output to the Hi • Defective Hi clutch solenoid
15SCMA engaged. • Excessive resistance in solenoid (-) circuit
• Defective Hi clutch pressure control valve
ECMV for Lo clutch: * See Con- Even when the output to the Lo clutch • Defective Lo clutch fill switch
15SDL1 the fill switch stays ON and the clutch circuit wiring harness
(TM-14) is not disengaged. • Defective Lo clutch pressure control valve
20-512 HM400-1
Action
code
E03
E03
Switch resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
R-SW (male) (1) - ground: traveling
• When clutch is released: Min. 1 • Cannot move off again unless machine
E03
MΩ is stopped
• W hen clutch is engaged: M ax. 1 Ω
R-PS (male) (1) - (2): 5 - 15 Ω traveling
is stopped
E03
• Switch resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
H-SW (male) (1) - ground: traveling
E03
MΩ is stopped
H-PS (male) (1) - (2): 5 - 15 Ω traveling
is stopped
E03
L-SW (male) (1) - ground: traveling
• W hen clutch is released: M in. 1 Ω • Cannot move off again unless machine
E03
• W hen clutch is engaged: M ax. 1 Ω is stopped
HM400-1 20-513
ECMV for Lo clutch: Function Even when there is output to the Lo • Defective Lo clutch solenoid
engaged. • Excessive resistance in solenoid (-) circuit
15SDMA
wiring harness
(TM-15)
• Defective Lo clutch or pressure control
ECMV for 1st clutch: * See Even when the output to the 1st clutch • Defective 1st clutch fill switch
Contents (L1) solenoid is turned OFF, the signal from • Short circuit with chassis ground in switch
the fill switch stays ON and the clutch circuit wiring harness
15SEL1
is not disengaged. • Defective 1st clutch pressure control valve
(TM-16)
ECMV for 1st clutch: Function Even when there is output to the 1st • Defective 1st clutch solenoid
15SEMA engaged. • Excessive resistance in solenoid (-) circuit
• Defective 1st clutch or pressure control
ECMV for 2nd clutch: * See Even when the output to the 2nd clutch • Defective 2nd clutch fill switch
15SFL1 the fill switch stays ON and the clutch circuit wiring harness
(TM-18) is not disengaged. • Defective 2nd clutch pressure control
ECMV for 2nd clutch: Function Even when there is output to the 2nd • Defective 2nd clutch solenoid
15SFMA engaged. • Excessive resistance in solenoid (-) circuit
• Defective 2nd clutch or pressure control
ECMV for 3rd clutch: * See Even when the output to the 3rd clutch • Defective 3rd clutch fill switch
15SGL1 the fill switch stays ON and the clutch circuit wiring harness
(TM-20) is not disengaged. • Defective 3rd clutch pressure control valve
ECMV for 3rd clutch: Function Even when there is output to the 3rd • Defective 3rd clutch solenoid
15SGMA engaged. • Excessive resistance in solenoid (-) circuit
• Defective 3rd clutch or pressure control
20-514 HM400-1
Action
code
L-PS (male) (1) - (2): 5 - 15 Ω traveling
is stopped
E03
1-SW (male) (1) - ground: traveling
MΩ is stopped E03
is stopped
E03
E03
MΩ is stopped
•
is stopped
E03
E03
MΩ is stopped
is stopped
E03
HM400-1 20-515
ECMV for lock-up clutch: * See Even when the output to the lock-up • Defective lock-up clutch fill switch
Contents (L1) clutch solenoid is turned OFF, the sig- • Short circuit with chassis ground in switch
nal from the fill switch stays ON and circuit wiring harness
15SJL1
the clutch is not disengaged. • Defective lock-up clutch pressure control
(TM-22)
ECMV for lock-up clutch: Func- Even when there is output to the lock- • Defective lock-up clutch solenoid
tion impossible (MA) up clutch solenoid, the signal from the • Excessive resistance in solenoid (+) circuit
fill switch stays OFF and the clutch is wiring harness
not engaged. • Excessive resistance in solenoid (-) circuit
15SJMA
wiring harness
(TM-23)
• Defective lock-up clutch or pressure con-
trol valve hydraulic, mechanical system
ECMV for inter-axle differential Even when the output to the differential • Defective differential lock clutch fill switch
lock clutch: * See Contents (L1) lock clutch solenoid is turned OFF, the • Short circuit with chassis ground in switch
signal from the fill switch stays ON and circuit wiring harness
15SKL1
the clutch is not disengaged. • Defective differential lock clutch pressure
(TM-24)
control valve hydraulic, mechanical sys-
tem
ECMV for inter-axle differential Even when there is output to the differ- • Defective differential lock clutch solenoid
lock clutch: Function impossi- ential lock clutch solenoid, the signal • Excessive resistance in solenoid (+) circuit
ble (MA) from the fill switch stays OFF and the wiring harness
clutch is not engaged. • Excessive resistance in solenoid (-) circuit
15SKMA
wiring harness
(TM-25)
• Defective differential lock clutch or pres-
sure control valve hydraulic, mechanical
system
Inter-axle differential lock When there is output to the differential • Defective differential lock clutch solenoid
clutch: Slipping (MW) lock clutch solenoid, there is an abnor- • Excessive resistance in solenoid (+) circuit
mality in the value calculated from the wiring harness
signals from the transmission output • Excessive resistance in solenoid (-) circuit
2B61MW
shaft F speed sensor and output shaft wiring harness
(TM-26)
R speed sensor (retarder controller is • Defective differential lock clutch or pres-
responsible for calculating value). sure control valve hydraulic, mechanical
system
Parking brake: Mistaken opera- Travel operation was carried out when • Forgot to release parking brake (when
tion or mistaken setting (KM) parking brake signal circuit was closed system is working normally)
(connected with ground) • Defective fuse
• Defective parking brake oil pressure
switch
• Defective parking brake relay
2F00KM
ground in switch power source circuit wir-
(TM-27)
ing harness
ground in switch signal circuit wiring har-
ness
• Disconnection in relay GND circuit wiring
harness
• Defective retarder controller
20-516 HM400-1
Action
code
• Switch resistance value • Holds speed range when traveling and • Lock-up is canceled and it becomes im-
L/U-SW (male) (1) - ground: turns lock-up actuation OFF possible to shift gear
• When clutch is released: Min. 1 • When gearshift lever is returned to N, • If gearshift lever is returned to N, ma-
MΩ holds in Neutral chine cannot move off again until it is E03
• W hen clutch is engaged: M ax. 1 Ω stopped
• Lock-up pilot lamp does not give dis-
play normally
• Solenoid resistance value • Holds speed range when traveling and • Lock-up is canceled and it becomes im-
L/U-PS (male) (1) - (2): 5 - 15 Ω turns lock-up actuation OFF possible to shift gear
• When gearshift lever is returned to N, • If gearshift lever is returned to N, ma-
holds in Neutral chine cannot move off again until it is
stopped E03
• Switch resistance value • Turns inter-axle differential lock com- • Inter-axle differential lock does not work
D/L-SW (male) (1) - ground: mand OFF
• When clutch is released: Min. 1
MΩ E03
• Solenoid resistance value • Turns inter-axle differential lock com- • Inter-axle differential lock does not work
D/L-PS (male) (1) - (2) : 5 - 15 Ω mand OFF
E01
D/L-PS (male) (1) - (2) : 5 - 15 Ω mand OFF
E01
• Switch resistance value • Takes no action • If the machine is used as it is, there is
B17 (male) (1) - (2) : • User code is not displayed danger that the parking brake may be
• Brake released: Min. 1 MΩ damaged
• Brake applied: Max. 1 Ω
• Relay resistance value
R32 (male) (1) - (2) : 100 - 500 Ω
None
HM400-1 20-517
Hydraulic tank filter: Clogged When the torque converter oil temper- • Clogged hydraulic oil filter (when system is
(NX) ature is more than 50fC, the signal cir- working normally)
cuit of the transmission filter clogging • Defective hydraulic oil filter clogging
6014NX
switch is open (shut off from the switch
(TM-28)
ground). • Disconnection in switch circuit wiring har-
ness
Engine overrun prevention The transmission input shaft speed • Engine overrun
989A00
command signal: Actuated (00) became more than 2450 rpm when the • Defective transmission controller
(TM-29)
speed range was other than Neutral.
Engine overrun prevention Disconnection, short circuit with • Defective retarder controller
command signal: Disconnec- ground, short circuit with power source • Disconnection, short circuit with chassis
989AKZ
tion or short circuit (KZ) occurred in overrun prevention com- ground, or short circuit with power source
(TM-30)
mand circuit, or did not match commu- in signal circuit wiring harness
nications data (S-NET) • Defective transmission controller
Rear overturn signal: Actuated Dump body was operated to RAISE • Dump operated when machine is inclined
(00) when machine was inclined more than (when system is working normally)
15f • Defective inclination sensor
• Disconnection or short circuit with power
source in sensor power source circuit wir-
989D00 ing harness
(TM-31) • Disconnection in sensor GND circuit wiring
harness
ground, or short circuit with power source
in sensor signal circuit wiring harness
Air cleaner element: Clogged Air cleaner clogging signal circuit • Clogged air cleaner element (when sys-
(NX) became open (shut off from ground) tem is working normally)
when engine was running • Defective air cleaner clogging sensor
• Defective dust indicator relay
• Short circuit with chassis ground in sensor
AA10NX
signal circuit wiring harness
(TM-32)
• Disconnection in relay signal circuit wiring
harness
• Disconnection in relay GND circuit wiring
harness
Alternator: Function impossible Electricity generation signal was not • Defective alternator
AB00MA (MA) input from alternator when engine was • Disconnection or short circuit with chassis
(TM-33) running. ground in alternator signal circuit
Radiator water: Drop in level Radiator water level switch signal cir- • Drop in radiator water level (when system
(ZK) cuit became open (shut off from is working normally)
ground) when engine was running • Defective radiator water level switch
B@BCZK • Disconnection in switch signal circuit wir-
(TM-34) ing harness
harness
20-518 HM400-1
Action
code
• Sensor resistance value • Takes no action • If the machine is used as it is, dirt may
T05 (male) (1) - (2) circulate in the dump circuit
• When normal: Max. 1 Ω
• When clogged: Min. 1 MΩ E01
• Issues order to retarder controller to • Brake is applied, travel speed is re-

apply brake (retarder) duced E02
• Signal voltage • Continues control with signal on S- • No great effect on machine

ATC1 (13) - (8)(16) NET
• When command is ON: 20 - 30 V E01
• When command is OFF: Max. 1 V
• A. Sensor power source voltage • Takes no action • If the dump RAISE operation is contin-
T10 (1) - (3): 11 - 13 V • User code is not displayed ued in this condition, the machine may
• Sensor signal voltage tip over
T10 (2) - (3):
• When machine is horizontal: 2.9
- 3.1 V
None
• When machine is inclined 15o to
left: 1.4 - 1.6 V
• When machine is inclined 15o to
right: 4.4 - 4.6 V
• Sensor resistance value • Takes no action • If the machine is used as it is, the en-
T11 (male) (1) - (2) gine 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 power
Alternator R - E: 27.5 - 29.5 V supply voltage will drop and it may
become impossible for the machine to
E03
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 en-
T01 (male) (1) - (2): gine may overheat
• When normal: Max. 1 Ω
E01
HM400-1 20-519
(7)
Hydraulic tank oil: Drop in level When the engine was stopped, the sig- • Drop in hydraulic tank oil level (when sys-
(ZK) nal circuit of the hydraulic tank level tem is working normally)
B@HAZK switch became open (shut off from • Defective hydraulic tank level switch
(TM-35) GND) • Disconnection in switch circuit wiring har-
ness
Steering oil: Overheat (ZK) The signal circuit of the steering oil • Steering oil temperature overheating
temperature switch became open (shut (when system is working normally)
B@JANS off from GND) • Defective steering oil temperature switch
(TM-36) • Disconnection in switch circuit wiring har-
ness
Transmission cut relay: Discon- Abnormal voltage was generated in • Defective transmission cut relay
nection or short circuit (KZ) the transmission cut relay circuit • Disconnection or short circuit with chassis
When relay is actuated: 10 V or more ground in relay power source circuit wiring
D180KZ When relay is stopped: Less than 4 V harness
(TM-37) • Disconnection, short circuit with chassis
in relay output circuit wiring harness
Inter-axle differential lock com- The voltage in the differential lock sig- • Defective retarder controller
mand signal: Input signal out- nal circuit became less than 0.5 V or • Disconnection, short circuit with chassis
D5ZBKX
side range (KX) more than 4.5 V ground, or short circuit with power source
(TM-38)
in signal circuit wiring harness
Exhaust brake command sig- A disconnection, short circuit with • Defective retarder controller
nal: Disconnection or short cir- ground, or short circuit with power • Disconnection, short circuit with chassis
D5ZCKZ cuit (KZ) source was generated in the exhaust ground, or short circuit with power source
(TM-39) brake command circuit, or there was a in signal circuit wiring harness
mismatch with the communication (S- • Defective transmission controller
NET) data
Forced neutral demand signal: There was a mismatch between forced • Defective retarder controller
* See Contents (L4) neutral demand signal 1 and signal 2 • Disconnection, short circuit with chassis
D5ZDL4 in signal 1 circuit wiring harness
(TM-40) • Disconnection, short circuit with chassis
in signal 2 circuit wiring harness
Engine load signal: Input signal The engine load signal circuit was out- • Defective engine controller
outside range (KX) side the correct range • Disconnection, short circuit with chassis
D5ZEKX
(TM-41)
in signal circuit wiring harness
Transmission controller: Drop When the engine was running, both • Another problem is occurring at the same
in power source voltage, input the main power supply voltage circuit time (failure code AB00MA is displayed)
(KK) and the direct power supply voltage • Battery tends to lose power
circuit became less than 18 V • Disconnection or short circuit with chassis
DAQ0KK
ground in power source circuit wiring har-
(TM-42)
ness
• Disconnection in GND circuit wiring har-
ness
20-520 HM400-1
Action
code
• Sensor resistance value • Takes no action • If the machine is used as it is, it may be-
T06 (male) (1) - ground: come impossible to carry out dump op-
• W hen oil level is no rmal: Max. 1 Ω erations
E01
• When oil level has dropped: Min.
1 MΩ
• Sensor resistance value • Takes no action • If the machine is used as it is, oil leak-
T04 (male) (1) - ground: age may occur
• When oil temperature is 25fC:
E02
Max 1 Ω
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 off
• When relay actuated: Max. 1 V again
• When relay stopped: 20 - 30 V
E03
• Signal voltage • Turns inter-axle differential lock com- • Inter-axle differential lock does not work
ATC3A (8) - (18): 0.47 - 4.3 V mand OFF
E01
• Signal voltage • Continues control with signal on S- • No great effect on machine

ATC1 (14) - (8)(16): NET
• W hen com mand is OFF: Max. 1 V
E01
• W hen com m and is ON : 20 - 30 V
• Continues control with signal on S- No great effect on machine

NET
E01
• Signal voltage • Carries out control with load taken as • Gearshift feeling may change slightly
ATC3A (4) - (16): 0 - 15 V heavy load
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 off
• Direct power source voltage again
ATC1 (7) - (8)(16): 20 - 30 V
E03
HM400-1 20-521
Transmission controller main The voltage difference between the • Disconnection or short circuit with chassis
power supply line: Drop in main power supply voltage circuit and ground in main power source circuit wiring
DAQ1KK
power source voltage, input the direct power supply voltage circuit harness
(TM-43)
(KK) became more than 5 V • Defective transmission controller
Transmission controller load When the controller power supply volt- • Defective transmission cut relay
power supply line: Drop in age circuit was normal, the solenoid • Disconnection or short circuit with chassis
power source voltage, input power supply voltage circuit became ground in relay power source circuit wiring
(KK) less than 18 V harness
DAQ2KK
(TM-44)
ground in relay output circuit wiring har-
ness
Transmission controller battery The voltage in the direct power supply • Disconnection or short circuit with chassis
DAQ3KK direct power supply line: Drop voltage circuit became less than 5 V ground in direct power source circuit wiring
(TM-45) in power source voltage, input harness
(KK) • Defective transmission controller
Transmission controller power The voltage in the 12V power supply • Defective inclination sensor
DAQ5KP supply output 1: Drop in output circuit for the sensor became less than • Short circuit with chassis ground in sensor
(TM-46) voltage (KP) 6V power source circuit wiring harness
Transmission controller wiring When the starting switch is ON, the • Mistaken connection of connector ATC3
harness: Mistaken operation or input connector check signal does not (A, B) and connector ATC5 (A, B) (when
DAQ9KM mistaken setting (KP) match the setting inside the controller system is working normally)
(TM-47) • Disconnection in signal 1 circuit wiring har-
ness
Transmission controller wiring When the starting switch is ON, the • Disconnection in model selection signal
DAQ9KQ
harness: Non match in model input model selection signal is different circuit wiring harness
(TM-48)
selection signal (KP) from the setting of the controller • Defective transmission controller
Transmission controller rotary The model setting of the rotary switch • Defective setting of rotary switch
DAQAKQ
switch: Non match in model does not match the setting inside the • Defective transmission controller
(TM-49)
selection signal (KP) controller
Transmission controller: Func- The communication (S-NET) with the • Another problem is occurring at the same
DAQSMA tion impossible (MA) machine monitor is defective and the time (failure code DAQSKR is displayed)
(TM-50) option setting cannot be made • Defective machine monitor
Fill switch for inter-axle differ- When the output is made to the differ- • Defective differential clutch fill switch
ential lock clutch: Disconnec- ential lock clutch solenoid, the clutch • Disconnection or short circuit with power
DDTFKA
tion (KA) engages, but the signal from the fill source in switch circuit wiring harness
(TM-51)
switch does not come ON • Defective transmission controller
20-522 HM400-1
Action
code
• Main power source voltage • Does not allow updating of input relat- • Condition before problem occurred is
ATC1 (9)(17) - (8)(16): 20 - 30 V ed data 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 off
30 V 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 off
E03
again
• Controller output voltage • Shuts off output of sensor 12V power • Does not judge rear overturn alarm
ATC2 (14) - ATC3A (16): 11 - 13 V supply
E03
• Wiring harness resistance value • Turns transmission cut relay OFF. • Machine does not move off even when
ATC5A (female) (1) - ground: Max. • Holds transmission in Neutral. operation is carried out to move ma-
1Ω • Does not record in trouble data. chine off
E03
• Wiring harness resistance value • Turns transmission cut relay OFF. • Machine does not move off even when
ATC5B (female) (14)(15)(16) - • Holds transmission in Neutral. operation is carried out to move ma- E03
ground: Max. 1 Ω • Does not record in trouble data. chine off
• Rotary switch setting position • Turns transmission cut relay OFF. • Machine does not move off even when
See TESTING AND ADJUSTING. • Holds transmission in Neutral. operation is carried out to move ma- E03
• Does not record in trouble data. chine off
• Sets transmission to Neutral. • Machine does not move off even when
operation is carried out to move ma-
E03
chine off
• Fill switch resistance value • Takes no action • Inter-axle differential lock is actuated,
ATC5A (male) (17) - ground: but pilot lamp does not light up
• When clutch is released: Min. 1 E01
MΩ
HM400-1 20-523
Fill switch for lock-up clutch: When the output is made to the lock- • Defective lock-up clutch fill switch
Disconnection (KA) up clutch solenoid, the clutch engages, • Disconnection or short circuit with power
DDTGKA
but the signal from the fill switch does source in switch circuit wiring harness
(TM-52)
not come ON • Defective transmission controller
Fill switch for Hi clutch: When the output is made to the Hi • Defective Hi clutch fill switch
Disconnection (KA) clutch solenoid, the clutch engages, • Disconnection or short circuit with power
DDTHKA
(TM-53)
Fill switch for Lo clutch: When the output is made to the Lo • Defective Lo clutch fill switch
DDTJKA
(TM-54)
•
Fill switch for 1st clutch: When the output is made to the 1st • Defective 1st clutch fill switch
DDTKKA
(TM-55)
•
Fill switch for 2nd clutch: When the output is made to the 2nd • Defective 2nd clutch fill switch
DDTLKA
(TM-56)
•
Fill switch for 3rd clutch: When the output is made to the 3rd • Defective 3rd clutch fill switch
DDTMKA
(TM-57)
Fill switch for R clutch: When the output is made to the R • Defective R clutch fill switch
DDTNKA
(TM-58)
Gearshift lever: Disconnection Nothing is input for the gearshift lever • Defective gearshift lever
(KA) signal • Disconnection or short circuit with chassis
ground in lever power source circuit wiring
harness
DF10KA • Disconnection in lever GND circuit wiring
(TM-59) harness
ground in lever signal circuit wiring har-
ness
20-524 HM400-1
Action
code
• Fill switch resistance value • Holds speed range during travel • Cannot shift gear
ATC5A (male) (11) - ground: • When gearshift lever is returned to N, • If gearshift lever is returned to N, ma-
• When clutch is released: holds in Neutral chine cannot move off again until it is E03
Min. 1 MΩ stopped
• W hen clutch is engaged: M ax. 1 Ω • Lock-up pilot lamp does not light up
Min. 1 MΩ stopped
Min. 1 MΩ stopped
Min. 1 MΩ stopped
Min. 1 MΩ stopped
• When clutch is released: holds in Neutral chine cannot move off again until it is
Min. 1 MΩ stopped
E03
• When clutch is released: holds in Neutral chine cannot move off again until it is
Min. 1 MΩ stopped E03
• Gearshift lever power source volt- • Condition before abnormality occurred • Shifts to higher speed range than
age 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 (3)(4)(5)(6)(7)(8)(9)(10)(11) • Impossible to change direction of travel
E03
- (2): between FORWARD and REVERSE
• Selected circuit: 20 - 24 V • All gearshift lever position lamps go out
• Not selected circuit: Max. 1 V
HM400-1 20-525
Gearshift lever: Short circuit The gearshift lever signal was input at • Defective shift lever
(KB) the same time from 2 or more systems • Short circuit with power source in lever sig-
nal circuit wiring harness
DF10KB • Defective transmission controller
(TM-60)
Transmission valve oil temper- The voltage of the signal circuit for the • Defective transmission valve oil tempera-
ature sensor: Input signal out- transmission valve oil temperature ture sensor
side range (KX) sensor became less than 0.97 V, or • Disconnection, short circuit with chassis
there was a big difference from the ground, or short circuit with power source
DGF1KX
torque converter oil temperature in sensor signal circuit wiring harness
(TM-61)
harness
Brake oil temperature sensor When the front brake oil temperature • Defective rear brake oil temperature sen-
(rear): * See Contents (L8) sensor signal and center brake oil tem- sor
perature sensor signal were more than • Disconnection or short circuit with power
DGR2L8 60oC, the rear brake oil temperature source in sensor signal circuit wiring har-
(TM-62) sensor was less than 10f C ness
harness
Brake oil temperature sensor When the front brake oil temperature • Defective center brake oil temperature
(center): * See Contents (L8) sensor signal and rear brake oil tem- sensor
DGR3L8 60oC, the center brake oil temperature source in sensor signal circuit wiring har-
harness
Brake oil temperature sensor When the center brake oil temperature • Defective front brake oil temperature sen-
(front): * See Contents (L8) sensor signal and rear brake oil tem- sor
DGR4L8 60oC, the front brake oil temperature source in sensor signal circuit wiring har-
harness
Torque converter oil tempera- The voltage of the signal circuit for the • Defective torque converter oil temperature
ture sensor: Input signal out- torque converter oil temperature sen- sensor
side range (KX) sor became less than 0.97 V, or there • Disconnection, short circuit with chassis
DGT1KX
was a big difference from the transmis- ground, or short circuit with power source
(TM-65)
sion valve oil temperature sensor sig- in sensor signal circuit wiring harness
nal • Disconnection in sensor GND circuit
Torque converter oil pressure The voltage in the signal circuit of the • Defective torque converter oil pressure
sensor: Input signal outside torque converter oil pressure sensor sensor
range (KX) became less than 0.5 V or more than • Disconnection or short circuit with chassis
4.5 V ground in sensor power source circuit wir-
ing harness
DHT5KX
(TM-66)
harness
20-526 HM400-1
Action
code
• Gearshift lever power source volt- • Controls using signal in order of high • Shifts to higher speed range than
age 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 dif-
- (2): system (2) are input at the same time, ferent from position of lever
• Selected circuit: 20 - 24 V shifts transmission to Neutral
• Not selected circuit: Max. 1 V
• Sensor resistance value • Controls clutch oil pressure with clutch • Transmission shock becomes exces-
LUB-T (male) (1) - (2): oil temperature before abnormality oc- sive
• When oil temperature is 25fC: curred
37 - 50 kΩ
• When oil temperature is 100fC: E03
3.5 - 4.0 kΩ
• Sensor resistance value • Takes no action • Retarder oil temperature gauge does
T13 (male) (1) - (2): not give correct display
• When oil temperature is 25fC: • If it is used as it is, the braking effect
37 - 50 kΩ may become weaker
E01
3.5 - 4.0 kΩ
E01
3.5 - 4.0 kΩ
E01
3.5 - 4.0 kΩ
• Sensor resistance value • Takes no action • Torque converter oil temperature

TC-SE (male) (1) - (2): gauge does not give correct display
• When oil temperature is 25fC: If it is used as it is, the braking effect
37 - 50 kΩ may become weaker E01
3.5 - 4.0 kΩ
• Sensor power source voltage • Fixes torque converter oil pressure to • Excessive shock when lock-up is actu-
TC-INT (2) - (1): 20 - 30 V oil pressure set inside controller and ated
• Sensor signal voltage carries out control
TC-INT (3) - (1): 0.8 - 2.0 V
E01
HM400-1 20-527
Torque converter oil pressure When the engine is stopped, the • Defective torque converter oil pressure cir-
sensor: * See Contents (L6) torque converter oil pressure sensor cuit (when actuating system normally)
signal circuit inputs the oil pressure • Defective torque converter oil pressure
DHT5L6 sensor
(TM-67) • Short circuit with power source in sensor
signal circuit wiring harness
Fuel level sensor: Disconnec- The voltage of the signal circuit of the • Defective fuel level sensor
tion (L6) fuel level sensor became more than • Disconnection or short circuit with power
4.0 V source in sensor signal circuit wiring har-
DJF1KA ness
harness
Throttle angle sensor: Input The voltage in the signal circuit of the • Defective accelerator sensor or defective
signal outside range (KX) acceleration sensor became less than accelerator pedal
0.6 V or more than 4.7 V • Disconnection, short circuit with chassis
in sensor power source circuit wiring har-
DK11KX ness
harness
Engine speed sensor: Discon- There is a disconnection in the signal • Defective engine speed sensor or defec-
nection (KA) circuit of the engine speed sensor and tive adjustment
the signal is not input • Disconnection in sensor signal circuit wir-
DLE2KA
ing harness
(TM-70)
harness
Engine speed sensor: * See When the signal of the engine speed • Defective engine speed sensor
Contents (LC) sensor is less than 350 rpm, the signal • Short circuit with chassis ground or short
DLE2LC of the transmission input shaft speed circuit with power source in sensor signal
(TM-71) sensor inputs more than 500 rpm circuit wiring harness
Transmission input shaft speed There is a disconnection in the signal • Defective transmission input shaft speed
sensor: Disconnection (KA) circuit of the transmission input shaft sensor or defective adjustment
speed sensor and the signal is not • Disconnection in sensor signal circuit wir-
DLF1KA
input ing harness
(TM-72)
harness
Transmission input shaft speed There is an abnormality in the speed • Defective transmission input shaft speed
sensor: * See Contents (LC) calculated from the engine speed sen- sensor
sor signal, transmission intermediate • Short circuit with chassis ground or short
DLF1LC
shaft speed sensor signal, and output circuit with power source in sensor signal
(TM-73)
shaft R speed sensor signal, and the circuit wiring harness
speed of the transmission input shaft • Defective transmission controller
sensor signal
20-528 HM400-1
Action
code
• Sensor power source voltage • Fixes torque converter oil pressure to • Excessive shock when lock-up is actu-
TC-INT (2) - (1): 20 - 30 V oil pressure set inside controller and ated
• Sensor signal voltage 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 dis-
T08 (male) (1) - (2): play
• When full: Max. 12 Ω
• When empty: 74 - 100 Ω
E01
• Sensor power source voltage • Carries out automatic shifting in nor- • Transmission shock becomes exces-
AS2 (1) - (3): 4.6 - 5.4 V mal mode (but controls with clutch oil sive
• Sensor signal voltage pressure taken as engine at full throt- • Immediately shifts up when traveling
• AS3 (2) - (3): tle) 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 Ω • When gearshift lever is returned to N, • If gearshift lever is returned to N, ma-
stopped E03
• Tachometer does not work (displays 0
rpm)
EREV (male) (1) - (2): 500 - 1000 Ω • When gearshift lever is returned to N, • If gearshift lever is returned to N, ma-
E03
stopped
• Tachometer does not go above 350
rpm
• Sensor resistance value • Holds speed range during travel and • Lock-up is canceled and transmission
N1 (male) (1) - (2): 500 - 1000 Ω turns actuation of lock-up OFF cannot be shifted
holds in Neutral chine cannot move off again until it is E03
stopped
• Sensor resistance value • Holds speed range during travel and • Lock-up is canceled and transmission
N1 (male) (1) - (2): 500 - 1000 Ω turns actuation of lock-up OFF cannot be shifted
holds in Neutral chine cannot move off again until it is E03
stopped
HM400-1 20-529
Transmission intermediate There is a disconnection in the signal • Defective transmission intermediate shaft
shaft speed sensor: Discon- circuit of the transmission intermedi- speed sensor or defective adjustment
nection (KA) ate shaft speed sensor and the signal • Disconnection in sensor signal circuit wir-
DLF2KA is not input ing harness
harness
Transmission intermediate There is an abnormality in the speed • Defective transmission intermediate shaft
shaft speed sensor: * See Con- calculated from the engine speed sen- speed sensor
tents (LC) sor signal, transmission input shaft • Short circuit with chassis ground or short
DLF2LC
speed sensor signal, and output shaft circuit with power source in sensor signal
(TM-75)
R speed sensor signal, and the speed circuit wiring harness
of the transmission intermediate shaft • Defective transmission controller
sensor signal
Transmission output shaft There is a disconnection in the signal • Defective transmission output shaft R
speed sensor: Disconnection circuit of the transmission output shaft speed sensor or defective adjustment
(KA) R speed sensor and the signal is not • Disconnection in sensor signal circuit wir-
DLT3KA
input ing harness
(TM-76)
harness
Transmission output shaft There is an abnormality in the speed • Defective transmission output shaft R
speed sensor: * See Contents calculated from the engine speed sen- speed sensor or defective adjustment
(LC) sor signal, transmission input shaft • Short circuit with chassis ground or short
DLT3LC
speed sensor signal, and intermediate circuit with power source in sensor signal
(TM-77)
shaft speed sensor signal, and the circuit wiring harness
speed of the transmission output shaft • Defective transmission controller
R sensor signal • efective retarder controller
Solenoid for inter-axle differen- No electric current flows when there is • Defective differential lock clutch solenoid
tial lock: Disconnection (KA) output to the differential lock clutch • Disconnection in solenoid (+) circuit wiring
DXH0KA solenoid harness
(TM-78) • Disconnection in solenoid (-) circuit wiring
harness
Solenoid for inter-axle differen- An extremely large electric current • Defective differential lock clutch solenoid
tial lock: Short circuit (KB) flows when there is output to the differ- • Short circuit, short circuit with chassis
ential lock clutch solenoid or electric ground, or short circuit with power source
DXH0KB
current flows when it is OFF in solenoid (+) circuit wiring harness
(TM-79)
• Short circuit with power source in solenoid
Solenoid for lock-up clutch: No electric current flows when there is • Defective lock-up clutch solenoid
DXH1KA Disconnection (KA) output to the lock-up clutch solenoid • Disconnection in solenoid (+) circuit
(TM-80) • Disconnection in solenoid (-) circuit
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 lock- • Short circuit, short circuit with chassis
up clutch solenoid or electric current ground, or short circuit with power source
DXH1KB flows when it is OFF in solenoid (+) circuit wiring harness
(TM-81) • Short circuit with power source in solenoid
20-530 HM400-1
Action
code
N2 (male) (1) - (2): 500 - 1000 Ω • When gearshift lever is returned to N, • If gearshift lever is returned to N, ma-
stopped
E03
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 N, • Cannot shift gear
holds in Neutral • If gearshift lever is returned to N, ma-
chine cannot move off again until it is E03
stopped
stopped E03
• Speedometer displays abnormal speed
• Solenoid resistance value • Continues output as it is • Inter-axle differential lock does not work
D/L-PS (male) (1) - (2): 5 - 15 Ω
E01
D/L-PS (male) (1) - (2): 5 - 15 Ω mand OFF 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 and • Lock-up is always canceled or always
L/U-PS (male) (1) - (2): 5 - 15 Ω turns actuation of lock-up OFF actuated and transmission cannot be
• When gearshift lever is returned to N, shifted
holds in Neutral • If gearshift lever is operated to N, ma-
E03
chine cannot move off again until it is
stopped (depending on condition of fail-
ure, machine may not be able to move
off again)
HM400-1 20-531
Solenoid for Hi clutch: Discon- No electric current flows when there is • Defective Hi clutch solenoid
nection (KA) output to the Hi clutch solenoid • Disconnection in solenoid (+) circuit
DXH2KA
• Disconnection in solenoid (-) circuit
(TM-82)
Solenoid for Hi clutch: Short cir- An extremely large electric current • Defective Hi clutch solenoid
cuit (KB) flows when there is output to the Hi • Short circuit, short circuit with chassis
clutch solenoid or electric current flows ground, or short circuit with power source
DXH2KB when it is OFF in solenoid (+) circuit wiring harness
Solenoid for Lo clutch: Discon- No electric current flows when there is • Defective Lo clutch solenoid
DXH3KA nection (KA) output to the Lo clutch solenoid • Disconnection in solenoid (+) circuit
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
DXH3KB
when it is OFF in solenoid (+) circuit wiring harness
(TM-85)
Solenoid for 1st clutch: Discon- No electric current flows when there is • Defective 1st clutch solenoid
DXH4KA nection (KA) output to the 1st clutch solenoid • Disconnection in solenoid (+) circuit
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
DXH4KB
(TM-87)
Solenoid for 2nd clutch: Dis- No electric current flows when there is • Defective 2nd clutch solenoid
DXH5KA connection (KA) output to the 2nd clutch solenoid • Disconnection in solenoid (+) circuit
Solenoid for 2nd clutch: Short An extremely large electric current • Defective 2nd clutch solenoid
circuit (KB) flows when there is output to the 2nd • Short circuit, short circuit with chassis
DXH5KB
(TM-89)
20-532 HM400-1
Action
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 not be able to
E03
move off again)
L-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine cannot E03
move off again
L-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine cannot
E03
move off again)
1-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine cannot
E03
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
of failure, machine may not be able to E03
move off again)
E03
move off again
move off again)
HM400-1 20-533
Solenoid for 3rd clutch: Discon- No electric current flows when there is • Defective 3rd clutch solenoid
nection (KA) output to the 3rd clutch solenoid • Disconnection in solenoid (+) circuit
DXH6KA
(TM-90)
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
DXH6KB when it is OFF in solenoid (+) circuit wiring harness
Solenoid for R clutch: Discon- No electric current flows when there is • Defective R clutch solenoid
DXH7KA nection (KA) output to the R clutch solenoid • Disconnection in solenoid (+) circuit
Solenoid for R clutch: Short cir- An extremely large electric current • Defective R clutch solenoid
cuit (KB) flows when there is output to the R • Short circuit, short circuit with chassis
DXH7KB
(TM-93)
20-534 HM400-1
Action
code
Solenoid resistance value • Sets transmission to Neutral. • Shifts to Neutral during travel
move off again E03
E03
move off again)
R-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine cannot
E03
move off again
R-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine cannot
move off again)
HM400-1 20-535
TROUBLESHOOTING TM-1
TM-1 Failure code [1380MW] (Lock-up clutch: Slipping (MW))

★ Nature of failure: When there is output to the lock-up clutch solenoid, there is an abnormality in the value
calculated from the signals from the engine speed sensor, transmission input shaft speed sensor, transmis-
sion intermediate shaft speed sensor, and transmission output shaft R speed sensor.
Cause Remedy
1
• Turn starting switch OFF. Is resistance between L/U-PS NO Defective lock-up clutch
(male) (1) and (2) 5 – 15 Ω? Replace
• Disconnect L/U-PS. solenoid
YES
2 Excessive resistance in wiring

NO harness between ATC2 (female) Repair or
• Turn starting switch OFF. Is resistance between ATC2 (10) and L/U-PS (female) (1) or replace
• Disconnect ATC2. (female) (10) and (20) 5 – 15Ω? ATC2 (female) (20) and L/U-PS
(female) (2)
YES
Carry out
3 troubleshoot-
Does condition become normal NO Defective hydraulic, mechanical ing for
• Turn starting switch ON. when transmission controller is system of lock-up clutch or mechanical
replaced? pressure control valve system
YES
Defective transmission Replace
controller
TM-1 Related electrical circuit diagram
20-536 HM400-1
TM-2 Failure code [1500LO] (Transmission clutch: * See Contents (LO))

★ Nature of failure: Fill switch signals have been input from 2 clutches that do not form a normal combination.
Cause Remedy
1
Is other failure code [15S*L1] also NO
time? Go to
troubleshooting
YES of displayed
Other problem occurring at
same time code
Carry out
2 troubleshoot-
Does condition become normal Defective hydraulic, mechanical ing for
NO system of clutch pressure mechanical
when transmission controller is
replaced? control valve system
YES
controller
HM400-1 20-537
TM-3 Failure code [15BONX] (Transmission oil filter: Clogged (NX))

★ Nature of failure: When the torque converter oil temperature is more than 50fC, the signal circuit of the
transmission filter clogging switch is open (shut off from the ground).
★ After remedy and comfirming that the machine is normal, carry out intial input to transmission controller in
accordance with the SPECIAL FUNCTION OF MACHINE MONITOR in TESTING AND ADJUSTING.
Cause Remedy
1
• Stop engine. Is transmission oil filter clogged?
NO
YES Clean or
Clogged transmission oil filter
replace
2
• Turn starting switch OFF. Is resistance between T03 (male) NO Defective transmission oil filter Replace
• Disconnect T03. (1) and (2) less than 1 Ω? clogging sensor
YES
3
Is resistance between T03 NO Defective contact or disconnection Repair or
in wiring harness between T03
(female) (2) and ground less than replace
• Disconnect T03. 1 Ω? (female) (2) and ground
YES
4
Is resistance between ATC5A NO Defective contact or disconnection Repair or
(female) (6) and ground less than in wiring harness between ATC5A replace
• Disconnect ATC5A. 1 Ω? (female) (6) and T03 (female) (1)
YES
controller
20-538 HM400-1
TM-4 Failure code [15GOMW] (R clutch: Slipping (MW))

★ Nature of failure: When there is output to the R clutch solenoid, there is an abnormality in the value calcu-
lated from the signals from the transmission input shaft speed sensor, transmission intermediate shaft
speed sensor, and transmission output shaft R speed sensor.
Cause Remedy
1
• Turn starting switch OFF. Is resistance between R-PS NO
Defective R clutch solenoid Replace
• Disconnect R-PS. (male) (1) and (2) 5 – 15 Ω?
YES

• Turn starting switch OFF. Is resistance between ATC2 (5) and R-PS (female) (1) or ATC2 replace
• Disconnect ATC2. (female) (5) and (15) 5 – 15Ω? (female) (15) and R-PS (female)
(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of R clutch or pressure mechanical
YES
controller
HM400-1 20-539
TM-5 Failure code [15HOMW] (Hi clutch: Slipping (MW))

★ Nature of failure: When there is output to the Hi clutch solenoid, there is an abnormality in the value calcu-
Cause Remedy
1
• Turn starting switch OFF. Is resistance between H-PS NO
Defective Hi clutch solenoid Replace
• Disconnect H-PS. (male) (1) and (2) 5 – 15 Ω?
YES

• Turn starting switch OFF. Is resistance between ATC2 (4) and H-PS (female) (1) or ATC2 replace
• Disconnect ATC2. (female) (4) and (15) 5 – 15Ω? (female) (15) and H-PS (female)
(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of Hi clutch or pressure mechanical
YES
controller
20-540 HM400-1
TM-6 Failure code [15JOMW] (Lo clutch: Slipping (MW))

★ Nature of failure: When there is output to the Lo clutch solenoid, there is an abnormality in the value calcu-
Cause Remedy
1
• Turn starting switch OFF. Is resistance between L-PS NO
Defective Lo clutch solenoid Replace
• Disconnect L-PS. (male) (1) and (2) 5 – 15 Ω?
YES

• Turn starting switch OFF. Is resistance between ATC2 (7) and L-PS (female) (1) or ATC2 replace
• Disconnect ATC2. (female) (7) and (17) 5 – 15Ω? (female) (17) and L-PS (female)
(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of Lo clutch or pressure mechanical
YES
controller
HM400-1 20-541
TM-7 Failure code [15KOMW] (1st clutch: Slipping (MW))

★ Nature of failure: When there is output to the 1st clutch solenoid, there is an abnormality in the value calcu-
Cause Remedy
1
• Turn starting switch OFF. Is resistance between 1-PS NO
Defective 1st clutch solenoid Replace
• Disconnect 1-PS. (male) (1) and (2) 5 – 15 Ω?
YES

• Turn starting switch OFF. Is resistance between ATC2 (2) and 1-PS (female) (1) or ATC2 replace
• Disconnect ATC2. (female) (2) and (13) 5 – 15Ω? (female) (13) and 1-PS (female)
(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of 1st clutch or pressure mechanical
YES
controller
20-542 HM400-1
TM-8 Failure code [15LOMW] (2nd clutch: Slipping (MW))

★ Nature of failure: When there is output to the 2nd clutch solenoid, there is an abnormality in the value cal-
culated from the signals from the transmission input shaft speed sensor, transmission intermediate shaft
Cause Remedy
1
Defective 2nd clutch solenoid Replace
YES

(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of 2nd clutch or mechanical
YES
controller
HM400-1 20-543
TM-9 Failure code [15MOMW] (3rd clutch: Slipping (MW))

★ Nature of failure: When there is output to the 3rd clutch solenoid, there is an abnormality in the value calcu-
Cause Remedy
1
Defective 3rd clutch solenoid Replace
YES

(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of 3rd clutch or pressure mechanical
YES
controller
20-544 HM400-1
TM-10 Failure code [15SBL1] (ECMV for R clutch: * See Contents (L1))
★ Nature of failure: Even when the output to the R clutch solenoid is turned OFF, the signal from the fill switch
stays ON and the clutch is not disengaged.
Cause Remedy
1
Is resistance between R-SW NO
• Turn starting switch OFF. (male) (1) and ground more than 1 Defective R clutch fill switch Replace
• Disconnect R-SW. MΩ?
YES
2
• Turn starting switch OFF. Is resistance between ATC5A NO in wiring harness between ATC5A Repair or
• Disconnect ATC5A. (female) (16) and ground more (female) (16) and R-SW (female) replace
than 1 MΩ? (1)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of R clutch pressure mechanical
YES
controller
HM400-1 20-545
TM-11 Failure code [15SBMA] (ECMV for R clutch: Function impossible (MA))
★ Nature of failure: Even when there is output to the R clutch solenoid, the signal from the fill switch stays OFF
and the clutch is not engaged.
Cause Remedy
1
Is resistance between R-PS (male) NO
• Turn starting switch OFF. (1) and (2) 5 – 15 Ω? Defective R clutch solenoid Replace
• Disconnect R-PS.
YES

• Turn starting switch OFF. Is resistance between ATC2 NO harness between ATC2 (female) Repair or
• Disconnect ATC2. (female) (5) and (15) 5 – 15Ω? (5) and R-PS (female) (1) or ATC2 replace
(female) (15) and R-PS (female)
(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of R clutch or pressure mechanical
YES
controller
20-546 HM400-1
TM-12 Failure code [15SCL1] (ECMV for Hi clutch: * See Contents (L1))
★ Nature of failure: Even when the output to the Hi clutch solenoid is turned OFF, the signal from the fill switch
Cause Remedy
1
Is resistance between H-SW NO
• Turn starting switch OFF. (male) (1) and ground more than 1 Defective Hi clutch fill switch Replace
• Disconnect H-SW. MΩ?
YES
2
• Disconnect ATC5A. (female) (12) and ground more (female) (12) and H-SW (female) replace
than 1 MΩ? (1)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of Hi clutch pressure mechanical
YES
controller
HM400-1 20-547
TM-13 Failure code [15SCMA] (ECMV for Hi clutch: Function impossible (MA))
★ Nature of failure: Even when there is output to the Hi clutch solenoid, the signal from the fill switch stays
OFF and the clutch is not engaged.
Cause Remedy
1
• Turn starting switch OFF. Is resistance between H-PS (male) NO Defective Hi clutch solenoid Replace
• Disconnect H-PS. (1) and (2) 5 – 15Ω?
YES

harness between ATC2 (female) Repair or
• Turn starting switch OFF. Is resistance between ATC2 NO (4) and H-PS (female) (1) or ATC2 replace
• Disconnect ATC2. (female) (4) and (15) 5 – 15Ω? (female) (15) and H-PS (female)
(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of Hi clutch or pressure mechanical
YES
controller
20-548 HM400-1
TM-14 Failure code [15SDL1] (ECMV for Lo clutch: * See Contents (L1))
★ Nature of failure: Even when the output to the Lo clutch solenoid is turned OFF, the signal from the fill switch
Cause Remedy
1
Is resistance between L-SW NO
• Turn starting switch OFF. (male) (1) and ground more than 1 Defective Lo clutch fill switch Replace
• Disconnect L-SW. MΩ?
YES
2
• Disconnect ATC5A. (female) (10) and ground more (female) (10) and L-SW (female) replace
than 1 MΩ? (1)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of Lo clutch pressure mechanical
YES
controller
HM400-1 20-549
TM-15 Failure code [15SDMA] (ECMV for Lo clutch: Function impossible (MA))
★ Nature of failure: Even when there is output to the Lo clutch solenoid, the signal from the fill switch stays
Cause Remedy
1
• Turn starting switch OFF. Is resistance between L-PS (male) NO
Defective Lo clutch solenoid Replace
• Disconnect L-PS. (1) and (2) 5 – 15Ω?
YES

• Turn starting switch OFF. Is resistance between ATC2 NO (7) and L-PS (female) (1) or ATC2 replace
• Disconnect ATC2. (female) (7) and (17) 5 – 15Ω? (female) (17) and L-PS (female)
(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of Lo clutch or pressure mechanical
YES
controller
20-550 HM400-1
TM-16 Failure code [15SEL1] (ECMV for 1st clutch: * See Contents (L1))
★ Nature of failure: Even when the output to the 1st clutch solenoid is turned OFF, the signal from the fill switch
Cause Remedy
1
Is resistance between 1-SW NO
• Turn starting switch OFF. (male) (1) and ground more than 1 Defective 1st clutch fill switch Replace
• Disconnect 1-SW. MΩ?
YES
2 Short circuit with chassis ground

in wiring harness between ATC5A Repair or
• Turn starting switch OFF. Is resistance between ATC5A NO replace
(female) (13) and ground more (female) (13) and 1-SW (female)
• Disconnect ATC5A. (1)
than 1 MΩ?
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of 1st clutch pressure mechanical
YES
controller
HM400-1 20-551
TM-17 Failure code [15SEMA] (ECMV for 1st clutch: Function impossible (MA))
★ Nature of failure: Even when there is output to the 1st clutch solenoid, the signal from the fill switch stays
Cause Remedy
1
• Turn starting switch OFF. Is resistance between 1-PS (male) NO
Defective 1st clutch solenoid Replace
• Disconnect 1-PS. (1) and (2) 5 – 15Ω?
YES

• Turn starting switch OFF. Is resistance between ATC2 NO (2) and 1-PS (female) (1) or ATC2
• Disconnect ATC2. replace
(female) (2) and (13) 5 – 15Ω? (female) (13) and 1-PS (female)
(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of 1st clutch or pressure mechanical
YES
controller
20-552 HM400-1
TM-18 Failure code [15SFL1] (ECMV for 2nd clutch: * See Contents (L1))
★ Nature of failure: Even when the output to the 2nd clutch solenoid is turned OFF, the signal from the fill
switch stays ON and the clutch is not disengaged.
Cause Remedy
1
• Turn starting switch OFF. (male) (1) and ground more than 1 Defective 2nd clutch fill switch Replace
YES

than 1 MΩ?
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of 2nd clutch pressure mechanical
YES
controller
HM400-1 20-553
TM-19 Failure code [15SFMA] (ECMV for 2nd clutch: Function impossible (MA))
★ Nature of failure: Even when there is output to the 2nd clutch solenoid, the signal from the fill switch stays
Cause Remedy
1
Defective 2nd clutch solenoid Replace
YES

(2)
YES
Carry out
3 troubleshoot-
NO system of 2nd clutch or pressure mechanical
YES
controller
20-554 HM400-1
TM-20 Failure code [15SGL1] (ECMV for 3rd clutch: * See Contents (L1))
★ Nature of failure: Even when the output to the 3rd clutch solenoid is turned OFF, the signal from the fill
Cause Remedy
1
• Turn starting switch OFF. (male) (1) and ground more than 1 Defective 3rd clutch fill switch Replace
YES

than 1 MΩ?
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of 3rd clutch pressure mechanical
YES
controller
HM400-1 20-555
TM-21 Failure code [15SGMA] (ECMV for 3rd clutch: Function impossible (MA))
★ Nature of failure: Even when there is output to the 3rd clutch solenoid, the signal from the fill switch stays
Cause Remedy
1
Defective 3rd clutch solenoid Replace
YES

(2)
YES
Carry out
3 troubleshoot-
NO system of 3rd clutch or pressure mechanical
YES
controller
20-556 HM400-1
TM-22 Failure code [15SJL1] (ECMV for lock-up clutch: * See Contents (L1))
★ Nature of failure: Even when the output to the lock-up clutch solenoid is turned OFF, the signal from the fill
Cause Remedy
1
Is resistance between L/U-SW NO
• Turn starting switch OFF. (male) (1) and ground more than 1 Defective lock-up clutch fill Replace
• Disconnect L/U-SW. MΩ? switch
YES
2 Short circuit with chassis ground in

• Turn starting switch OFF. Is resistance between ATC5A NO wiring harness between ATC5A Repair or
• Disconnect ATC5A. (female) (15) and ground more (female) (11) and L/U-SW (female) replace
than 1 MΩ? (1)
YES
Carry out
3 troubleshoot-
NO system of lock-up clutch pressure mechanical
YES
controller
HM400-1 20-557
TM-23 Failure code [15SJMA] (ECMV for lock-up clutch: Function impossible (MA))
★ Nature of failure: Even when there is output to the lock-up clutch solenoid, the signal from the fill switch stays
Cause Remedy
1
• Turn starting switch OFF. Is resistance between L/U-PS NO
Defective lock-up clutch Replace
• Disconnect L/U-PS. (male) (1) and (2) 5 – 15Ω? solenoid
YES

• Turn starting switch OFF. Is resistance between ATC2 NO (10) and L/U-PS (female) (1) or
(female) (10) and (20) 5 – 15Ω? ATC2 (female) (20) and L/U-PS
(female) (2)
YES
Carry out
3 troubleshoot-
NO system of lock-up clutch or mechanical
YES
controller
20-558 HM400-1
TM-24 Failure code [15SKL1] (ECMV for inter-axle differential lock clutch:
* See Contents (L1))
★ Nature of failure: Even when the output to the differential lock clutch solenoid is turned OFF, the signal from
the fill switch stays ON and the clutch is not disengaged.
Cause Remedy
1
Is resistance between D/L-SW NO
• Turn starting switch OFF. (male) (1) and ground more than 1 Defective differential lock Replace
• Disconnect D/L-SW. MΩ? clutch fill switch
YES
2 Short circuit with chassis ground in

• Turn starting switch OFF. Is resistance between ATC5A NO wiring harness between ATC5A Repair or
• Disconnect ATC5A. (female) (15) and ground more (female) (17) and D/L-SW (female) replace
than 1 MΩ? (1)
YES
Carry out
3 troubleshoot-
NO system of differential lock clutch mechanical
YES
controller
HM400-1 20-559
TM-25 Failure code [15SKMA] (ECMV for inter-axle differential lock clutch:
Function impossible (MA))
★ Nature of failure: Even when there is output to the differential lock clutch solenoid, the signal from the fill
switch stays OFF and the clutch is not engaged.
Cause Remedy
1
• Turn starting switch OFF. Is resistance between D/L-PS NO
Defective differential lock Replace
• Disconnect D/L-PS. (male) (1) and (2) 5 – 15Ω? clutch solenoid
YES

• Turn starting switch OFF. Is resistance between ATC2 NO (8) and D/L-PS (female) (1) or
(female) (8) and (18) 5 – 15Ω? ATC2 (female) (18) and D/L-PS
(female) (2)
YES
Carry out
3 troubleshoot-
replaced? or pressure control valve system
YES
controller
20-560 HM400-1
TM-26 Failure code [2B61MW] (Inter-axle differential lock clutch: Slipping (MW))
★ Nature of failure: When there is output to the differential lock clutch solenoid, there is an abnormality in the
value calculated from the signals from the transmission input shaft speed sensor, transmission intermediate
shaft speed sensor, and transmission output shaft R speed sensor (retarder controller is responsible for
calculating value).
Cause Remedy
1
• Turn starting switch OFF. Is resistance between D/L-PS NO Defective differential lock Replace
• Disconnect D/L-PS. (male) (1) and (2) 5 – 15Ω? clutch solenoid
YES

• Turn starting switch OFF. Is resistance between ATC2 (8) and D/L-PS (female) (1) or
• Disconnect ATC2. (female) (8) and (18) 5 – 15Ω? replace
ATC2 (female) (18) and D/L-PS
(female) (2)
YES
Carry out
3 troubleshoot-
replaced? or pressure control valve system
YES
controller
HM400-1 20-561
TM-27 Failure code [2F00KM] (Parking brake: Mistaken operation or mistaken setting (KM))
★ Nature of failure: Travel operation was carried out when parking brake signal circuit was closed (connected
with ground)
★ Before starting troubleshooting, check that fuse BT3-16 is normal (if the fuse is blown, there has probably
been a surge of current caused by a short circuit, so check the related circuits).
Cause Remedy
1
Did machine travel with parking NO
brake switch at PARKING position?
YES Mistaken operation of parking

brake switch —
2
• Start engine. Does condition become normal when NO
• Operate gearshift lever. parking brake relay (R03) is
YES Defective parking brake relay Replace
(R03)
3
• Disconnect R03.
Is voltage between R03 (female) NO
• Start engine.
• Parking brake switch: RELEASED (1) and ground 20 – 30 V?
YES
4
Is resistance between R03 Defective contact or
• Turn starting switch OFF. NO disconnection in wiring harness Repair or
• Disconnect R03.
(female) (2) and ground less than
1 Ω? between R03 (female) (2) and replace
ground
YES

• Turn starting switch OFF. Is resistance between BRC5A NO in wiring harness between Repair or
• Disconnect R03 and (female) (50 and ground more than BRC5A (female) (5) and R03
BRC5A. 1 MΩ? replace
(female) (3)
YES
Defective retarder controller Replace
6
• Disconnect B17. Is resistance between B17 (male) NO Defective parking brake
• Start engine. (1) and (2) less than 1Ω? Replace
• Parking brake switch: RELEASED pressure switch
YES
7
NO Defective contact or disconnection Repair or
• Disconnect B17. Is voltage between B17 (female) in wiring harness between fuse
• Turn starting switch ON. replace
(2) and ground 20 – 30 V? BT3-16 outlet – B17 (female) (2)
YES Defective contact or

disconnection in wiring harness Repair or
between B17 (female) (1) and replace
R03 (female) (1)
20-562 HM400-1
HM400-1 20-563
4"
TM-28 Failure code [6014NX] (Hydraulic tank filter: Clogged (NX))

★ Nature of failure: When the torque converter oil temperature is more than 50fC, the signal circuit of the
transmission filter clogging switch is open (shut off from the ground).
Cause Remedy
1
• Stop engine. Is hydraulic oil filter clogged?
NO
YES Clean or
Clogged hydraulic oil filter
replace
2
• Turn starting switch OFF. Is resistance between T05 (male) NO Defective hydraulic oil filter Replace
• Disconnect T05. (1) and (2) less than 1 Ω? clogging sensor
YES
3
YES
4
YES
controller
20-564 HM400-1

TM-29 Failure code [989A00] (Engine overrun prevention command signal: Actuated (00))
★ Nature of failure: The transmission input shaft speed became more than 2450 rpm when the speed range
was other than Neutral.
Cause Remedy
1
Did machine travel with Operate for
NO Defective transmission a short time
transmission input shaft speed at
more than 2450 rpm? controller and watch
condition
YES
Engine overrun —
HM400-1 20-565
TM-30 Failure code [989AKZ] (Engine overrun prevention command signal:

Disconnection or short circuit (KZ))
★ Nature of failure: Disconnection, short circuit with ground, short circuit with power source occurred in over-
run prevention command circuit, or did not match communications data (S-NET)
Cause Remedy
1
Short circuit with power source in
• Disconnect ATC1 and Is voltage between ATC1 (female) NO wiring harness between ATC1 Repair or
BRC5A. (13) and ground less than 1 V?
• Turn starting switch ON. (female) (13) and BRC5B replace
(female) (6)
YES
2
Is resistance between ATC1 Defective contact or disconnection
• Turn starting switch OFF. NO in wiring harness between ATC1 Repair or
• Disconnect ATC1 and (female) (13) and BRC5B (female)
BRC5A. (5) less than 1 Ω? (female) (13) and BRC5B replace
(female) (6)
YES
3
• Turn starting switch OFF. Short circuit with chassis ground
Is resistance between ATC1 NO Repair or
• Disconnect ATC1 and (female) (13) and ground more in wiring harness between ATC1
BRC5A. than 1 MΩ? (female) (13) and BRC5B replace
(female) (6)
YES
4
• Turn starting switch ON. when transmission controller is Defective retarder controller Replace
replaced?
YES
controller
20-566 HM400-1
TM-31 Failure code [989D00] (Rear overturn signal: Actuated (00))

★ Nature of failure: Dump body was operated to RAISE when machine was inclined more than 15f.
★ Stop the machine on horizontal ground when carrying out the troubleshooting.
Cause Remedy
1
Was dump operation carried out NO
on slope of more than 15f
YES
Normal warning display
2
• Insert T-adapter to ATC3A Is voltage between ATC3B (16) NO
and ATC3B.
• Turn starting switch ON. and ATC3A (16) 2.9 – 3.1 V?
YES Defective transmission Replace

controller
3
• Disconnect T10. Is voltage between T10 (female) NO
• Turn starting switch ON. (1) and ground 11 – 13 V?
YES
4
NO Short circuit with power source
• Disconnect ATC2 and T10. Is voltage between T10 (female) in wiring harness between Repair or
ATC2 (female) (14) and T10
YES
5
• Insert T-adapter to ATC2. Is voltage between ATC2 (14) NO Defective transmission
• Disconnect T10. Replace
• Turn starting switch ON. and ground 11 – 13 V? controller
YES Defective contact or Repair or

disconnection in wiring harness replace
6
• Turn starting switch OFF. Is resistance between T10 NO
• Disconnect T10. (female) (3) and ground less
than 1 Ω?
YES
7
• Turn starting switch OFF. Is resistance between ATC3A NO Defective contact or
(female) (16) and T10 (female) disconnection in wiring harness Repair or
• Disconnect ATC3A and T10. replace
(3) less than 1 Ω? between ATC3A (female) (16)
controller
To 8
HM400-1 20-567
From 7
Cause Remedy
8
• Insert T-adapter to T10. Is voltage between T10 (2) and NO
• Turn starting switch ON. ground 2.9 – 3.1 V?

between ATC3B (female) (16) replace
and T10 (female) (2)
9
• Disconnect ATC3B and Is voltage between T10 (female) NO in wiring harness between Repair or
T10. (2) and ground less than 1 V? ATC3B (female) (16) and T10 replace
• Turn starting switch ON. (female) (2)
YES
10
• Turn starting switch OFF. Is resistance between T10 NO Short circuit with chassis ground Repair or
• Disconnect ATC3B and (female) (2) and ground more in wiring harness between ATC3B replace
T10. than 1 MΩ (female) (16) and T10 (female) (2)
YES
Defective inclination sensor Replace
20-568 HM400-1
TM-32 Failure code [AA10NX] (Air cleaner element: Clogged (NX))

★ Nature of failure: Air cleaner clogging signal circuit became open (shut off from ground) when engine was
running
1
NO Cause Remedy
Is dust indicator red?
YES Clean or
Clogged air cleaner element
replace
2
• Start engine. when dust indicator relay (R32)
YES Defective dust indicator relay
(R32) Replace
3
• Disconnect R32.
Is resistance between R32 NO
• Start engine. (female) (2) and ground more
than 1 MΩ?
YES
4
• Turn starting switch OFF. Is resistance between T11 NO Defective air cleaner clogging
• Disconnect T11. (female) (1) and (2) less than 1 Ω? Replace
switch
YES Short circuit with chassis
ground in wiring harness Repair or
between R32 (female) (2) and replace
T11 (female) (1)
5 Defective contact or
Is resistance between ATC3A disconnection in wiring harness
• Turn starting switch OFF. NO between ATC3A (female) (19) Repair or
• Disconnect ATC3A. (female) (19) and (16) less than and R32 (female) (3) or
1 Ω? replace
between ATC3A (female) (16)
and R32 (female) (6)
YES
controller
HM400-1 20-569
TM-33 Failure code [AB00MA] (Alternator: Function impossible (MA))

★ Nature of failure: Electricity generation signal was not input from alternator when engine was running.
Dump body cannot be controlled (Dump body does not move).
Cause Remedy
1
• Disconnect ATC3B. NO
• Start engine (mid-range Is voltage between ATC3B (female)
speed). (1) and ground 27.5 – 29.5 V?
YES
controller
• Disconnect alternator
2
terminal R. Is voltage between alternator R and NO Defective alternator Replace
• Start engine (mid-range E 27.5 – 29.5 V?
speed).
YES Defective contact, disconnection, or

short circuit with chassis ground in Repair or
wiring harness between ATC3B replace
(female) (1) and alternator terminal R
20-570 HM400-1
(7)
TM-34 Failure code [B@BCZK] (Radiator water: Drop in level (ZK))

★ Nature of failure: Radiator water level switch signal circuit became open (shut off from ground) when engine
was running
★ If the level of the water in the radiator has dropped, check around the engine and radiator for signs of water
leakage before adding water.
Cause Remedy
1
• Stop engine. Has radiator water level NO
dropped?
YES Check for

Drop in radiator water level water
leakage, add
water
2
• Turn starting switch OFF. Is resistance between T01 (male) NO Defective radiator water level Replace
• Disconnect T01. (1) and (2) less than 1 Ω? switch
YES
3
YES
4
YES
controller
HM400-1 20-571
TM-35 Failure code [B@HAZK] (Hydraulic tank oil: Drop in level (ZK))
★ Nature of failure: When the engine was stopped, the signal circuit of the hydraulic tank level switch became
open (shut off from GND)
★ If the level of the oil in the hydraulic tank has dropped, check the hydraulic equipment and hydraulic piping
for signs of oil leakage before adding oil.
Cause Remedy
1
Has oil level in hydraulic tank NO
• Stop engine.
dropped?
YES Check for oil

Drop in hydraulic tank oil level leakage, add
oil
2
• Turn starting switch OFF. Is resistance between T06 (male) NO Defective hydraulic tank level Replace
• Disconnect T06. (1) and ground less than 1 Ω? switch
YES
3
Is resistance between ATC5A Defective contact or
(female) (2) and ground less
• Disconnect ATC5A. between ATC5A (female) (2) replace
than 1Ω?
YES
controller
20-572 HM400-1
TM-36 Failure code [B@JANS] (Steering oil: Overheat (ZK))

★ Nature of failure: The signal circuit of the steering oil temperature switch became open (shut off from GND)
Cause Remedy
1
Did steering oil temperature go NO
above 123fC?
YES Overheating of steering oil —
2
• Turn starting switch OFF. Is resistance between T04 (male) NO Defective steering oil Replace
• Disconnect T04. (1) and ground less than 1 Ω? temperature switch
YES
3
• Disconnect ATC3A. (female) (11) and ground less than
1 Ω? between ATC3A (female) (11) replace
YES
controller
HM400-1 20-573
TM -37 Failure code [D1B0KZ] (Transm ission cut relay: D isconnection or short circuit (K Z))
★ Nature of failure: Abnormal voltage was generated in the transmission cut relay circuit (relay actuated: 10
V or more; relay stopped: Less than 4 V)
Cause Remedy
1
• Turn starting switch OFF. when transmission cut relay (R15)
YES Defective transmission cut relay Replace
(R15)
2
• Disconnect R15. Is voltage between R15 (female) NO disconnection in wiring harness Repair or
• Turn starting switch ON. (2) and ground 20 - 30 V? between fuse BT3 - 14 outlet - replace
R15 (female) (2)
YES
3
Is voltage between ATC1 NO
• Disconnect ATC1 and R15. (female) (15) and ground less
than 1 V?
YES
4 Short circuit between wiring

• Turn starting switch OFF. Is resistance between R15 NO harness at R15 (female) (1) end Repair or
• Disconnect ATC1 and (female) (1) and R15 (female) (2) and wiring harness at R15 replace
R15. more than 1 MΩ? (female) (2) end
YES Short circuit with power source Repair or
in wiring harness between replace
ATC1 (female) (15) and R15
(female) (1)
• Turn starting switch OFF. Is resistance between ATC1 NO disconnection in wiring harness
• Disconnect ATC1 and (female) (15) and R15 (female) Repair or
between ATC1 (female) (15) replace
R15. (1) less than 1 Ω? and R15 (female) (1)
YES
6 Short circuit with chassis

• Turn starting switch OFF. Is resistance between ATC1 NO ground in wiring harness
• Disconnect ATC1 and (female) (15) and ground more Repair or
between ATC1 (female) (15) replace
R15. than 1 MΩ? and R15 (female) (1)
YES
controller
20-574 HM400-1
HM400-1 20-575
TM-38 Failure code [D5ZBKX] (Inter-axle differential lock command signal:

Input signal outside range (KX))
★ Nature of failure: The voltage in the differential lock signal circuit became less than 0.5 V or more than 4.5 V
Cause Remedy
1
• Insert T-adapter to Is voltage between ATC3A (3) NO
ATC3A.
• Turn starting switch ON. and (18) 0.7 - 4.3 V?

controller
2
ATC3A.

between ATC3A (female) (18) replace
and (16)
3
• Disconnect ATC3A and Is voltage between ATC3A NO in wiring harness between Repair or
BRC2. (female) (8) and ground less
• Turn starting switch ON. than 1 V? ATC3A (female) (8) and BRC2 replace
(female) (6)
YES
4
• Disconnect ATC3A and (female) (8) and BRC2 (female)
(6) less than 1 Ω? between ATC3A (female) (8) and replace
BRC2 (female) (6)
YES

• Turn starting switch OFF. Is resistance between ATC3A NO in wiring harness between Repair or
• Disconnect ATC3A and (female) (8) and ground more ATC3A (female) (8) and BRC2
BRC2. than 1 MΩ? replace
(female) (6)
YES
6
replaced?
YES
controller
20-576 HM400-1
TM-39 Failure code [D5ZCKZ] (Exhaust brake command signal:

Disconnection or short circuit (KZ))
★ Nature of failure: A disconnection, short circuit with ground, or short circuit with power source was generated
in the exhaust brake command circuit, or there was a mismatch with the communication (S-NET) data
Cause Remedy
1
• Disconnect ATC1 and Is voltage between ATC1 (female) NO wiring harness between ATC1 Repair or
BRC5B. (14) and ground less than 1 V?
• Turn starting switch ON. (female) (14) and BRC5B replace
(female) (4)
YES
2
Is resistance between ATC1 Defective contact or disconnection
• Turn starting switch OFF. NO in wiring harness between ATC1 Repair or
• Disconnect ATC1 and (female) (14) and BRC5B (female)
BRC5B. (4) less than 1 Ω? (female) (14) and BRC5B replace
(female) (4)
YES
3
Is resistance between ATC1 NO Repair or
• Disconnect ATC1 and (female) (14) and ground more in wiring harness between ATC1
BRC5B. than 1 MΩ? (female) (14) and BRC5B replace
(female) (4)
YES
4
replaced?
YES
controller
HM400-1 20-577
TM-40 Failure code [D5ZDL4] (Forced neutral demand signal: * See Contents (L4))
★ Nature of failure: There was a mismatch between forced neutral demand signal 1 and signal 2
Cause Remedy
1
• Disconnect ATC5A and Is voltage between ATC5A Short circuit with power source
NO in wiring harness between Repair or
BRC1. (female) (7) and ground less
• Turn starting switch ON. than 1 V? ATC5A (female) (7) and BRC1 replace
(female) (6)
YES
• Turn starting switch OFF. Is resistance between ATC5A NO disconnection in wiring harness Repair or
• Disconnect ATC5A and (female) (7) and BRC1 (female) between ATC5A (female) (7) replace
BRC1. (6) less than 1 Ω?
and BRC1 (female) (6)
YES

• Disconnect ATC5A and (female) (7) and ground more ATC5A (female) (7) and BRC1 replace
BRC1. than 1 MΩ?
(female) (6)
YES
4 Short circuit with power source

BRC1. (female) (8) and ground less ATC5A (female) (8) and BRC1 replace
than 1 V? (female) (15)
YES
• Turn starting switch OFF. Is resistance between ATC5A NO disconnection in wiring harness Repair or
• Disconnect ATC5A and (female) (8) and BRC1 (female)
BRC1. (15) less than 1 Ω? between ATC5A (female) (8) replace
and BRC1 (female) (15)
YES

• Disconnect ATC5A and (female) (8) and ground more ATC5A (female) (8) and BRC1 replace
BRC1. than 1 MΩ? (female) (6)
YES
7
replaced?
YES
controller
20-578 HM400-1
HM400-1 20-579
TM-41 Failure code [D5ZEKX] (Engine load signal: Input signal outside range (KX))
★ Nature of failure: The engine load signal circuit was outside the correct range
Cause Remedy
1
Is voltage between ATC3A Short circuit with power source in
• Disconnect ATC3A and NO wiring harness between ATC3A Repair or
CN2. (female) (4) and ground less than
• Turn starting switch ON. 1 V? (female) (4) and CN2 (female) replace
(14)
YES
2
Is resistance between ATC3A Defective contact or disconnection
• Turn starting switch OFF. NO in wiring harness between ATC3A Repair or
• Disconnect ATC3A and (female) (4) and CN2 (female) (14)
CN2. less than 1 Ω? (female) (4) and CN2 (female) replace
(14)
YES
3
Is resistance between ATC3A NO Repair or
• Disconnect ATC3A and (female) (4) and ground more than in wiring harness between ATC3A
CN2. 1 MΩ? (female) (4) and CN2 (female) replace
(14)
YES
4
• Turn starting switch ON. when transmission controller is Defective engine controller Replace
replaced?
YES
controller
20-580 HM400-1
TM-42 Failure code [DAQ0KK] (Transmission controller:

Drop in power source voltage, input (KK))
★ Nature of failure: When the engine was running, both the main power supply voltage circuit and the direct
power supply voltage circuit became less than 18 V
★ Before starting troubleshooting, check that the circuit breaker is not OFF, and that the fusible link, fuse BT2-
22, and fuse BT3-16 are normal (if the circuit breaker is OFF or any fuse is blown, there has probably been
Cause Remedy
1
• Turn starting switch ON. Is other failure code [AB00MA] NO
• Operate machine displayed or recorded at same
monitor. time? Go to
YES troubleshoot
Another problem is occurring at ing for
the same time displayed
code
2
• Insert T-adapter to ATC1. Is voltage between ATC1 (7) - NO
• Start engine (mid-range (8)(16) and between ATC1
speed). (9)(17) - (8)(16) 20 - 30 V?
controller
3
Is resistance between ATC1 Defective contact or
• Disconnect ATC1. (female) (8)(16) and ground less
than 1 Ω? between ATC1 (female) (8)(16) replace
and ground
YES
4
Is battery voltage more than 24 NO Defective battery or defective
• Turn starting switch OFF. V and specific gravity more than Charge or
1.26? charging replace

between battery - battery relay - replace
transmission controller
HM400-1 20-581
TM-43 Failure code [DAQ1KK] (Transmission controller main power supply line:
★ Nature of failure: The voltage difference between the main power supply voltage circuit and the direct power
supply voltage circuit became more than 5 V
★ Before starting troubleshooting, check that the circuit breaker is not OFF and that BT3-14 is normal (if the
circuit breaker is OFF or the fuse is blown, there has probably been a surge of current caused by a short
circuit, so check the related circuits).
Cause Remedy
1
• Insert T-adapter to ATC1. Is voltage between ATC1 (9)(17) NO
• Turn starting switch ON. and (8)(16) 20 – 30 V?
YES
controller
2
• Remove fuse BT3-14. Is voltage between fuse BT3-14 inlet NO in wiring harness between fuse Replace
• Turn starting switch ON. and ground 20 – 30 V? BT3-14 inlet – circuit breaker –
battery relay terminal M
YES Defective contact or disconnection in
wiring harness between fuse BT3-14 Repair or
outlet and ATC1 (female) (9)(17) replace
20-582 HM400-1
TM-44 Failure code [DAQ2KK] (Transmission controller load power supply line:
★ Nature of failure: When the controller power supply voltage circuit was normal, the solenoid power supply
voltage circuit became less than 18 V
Cause Remedy
1
• Insert T-adapter to ATC1 Is voltage between ATC2 (1)(12) NO
and ATC2.
• Turn starting switch ON. and ATC1 (8)(16) 20 - 30 V?
YES
controller
2
• Turn starting switch ON. when transmission cut relay (R15)
is replaced with other relay?
YES
Defective transmission cut relay Replace
3
• Disconnect R15. Is voltage between R15 (3) and NO disconnection in wiring harness Repair or
• Turn starting switch ON. ground 20 - 30 V? between fuse BT3-14 outlet - replace
R15 (female) (3)
ATC2 (female) (1)(12)
HM400-1 20-583
TM-45 Failure code [DAQ3KK] (Transmission controller battery direct power supply
line: Drop in power source voltage, input (KK))
★ Nature of failure: The voltage in the direct power supply voltage circuit became less than 5 V
Cause Remedy
1
• Insert T-adapter to ATC1. Is voltage between ATC1 (7) and NO
• Turn starting switch ON. (8)(16) 20 – 30 V?
YES
controller
2
• Remove fuse BT2-22. Is voltage between fuse BT2-22 inlet NO in wiring harness between fuse Repair or
• Turn starting switch ON. and ground 20 – 30 V? BT2-22 inlet – fusible link – battery replace
relay terminal B
wiring harness between fuse BT2-22 Repair or
outlet and ATC1 (female) (7) replace
20-584 HM400-1
TM-46 Failure code [DAQ5KP] (Transmission controller power supply output 1:

Drop in output voltage (KP))
★ Nature of failure: The voltage in the 12V power supply circuit for the sensor became less than 6 V
Cause Remedy
1
• Insert T-adapter to ATC2 NO
and ATC3A. Is voltage between ATC2 (14) and
• Turn starting switch ON. ATC3A (16) 11 – 13 V?
YES
controller
2
• Disconnect ATC2 and Is resistance between ATC2 (female) NO in wiring harness between ATC2 Repair or
T10. (14) and ground more than 1 MΩ (female) (14) and T10 (female) (1) replace
YES
Defective inclination sensor Replace
HM400-1 20-585

Mistaken operation or mistaken setting (KP))
★ Nature of failure: When the starting switch is ON, the input connector check signal does not match the set-
ting inside the controller
Cause Remedy
1
Are connectors ATC3 (A, B) and NO
• Turn starting switch OFF. ATC5 (A, B) connected at correct Mistaken connection of Connect
place? controller connector again
YES
2
Is resistance between ATC5A NO disconnection in wiring harness
(female) (1) and ground less than Repair or
• Disconnect ATC5A. between ATC5A (female) (1) replace
1 Ω? and ground
YES
controller
20-586 HM400-1

Non match in model selection signal (KP))
★ Nature of failure: When the starting switch is ON, the input model selection signal is different from the setting
of the controller
Cause Remedy
1
Is resistance between ATC5B NO Defective contact or disconnection
• Turn starting switch OFF. (female) (14) and ground less in wiring harness between ATC5B Repair or
• Disconnect ATC5B. than 1 Ω? (female) (14) and ground replace
YES
2
Is resistance between ATC5B NO Defective contact or disconnection Repair or
• Turn starting switch OFF. in wiring harness between ATC5B replace
• Disconnect ATC5B. (female) (15) and ground less
than 1Ω? (female) (15) and ground
YES
3
Is resistance between ATC5B NO Defective contact or disconnection Repair or
• Turn starting switch OFF. (female) (16) and ground less in wiring harness between ATC5B replace
• Disconnect ATC5B. than 1Ω? (female) (16) and ground
YES
controller
HM400-1 20-587
4"
TROUBLESHOOTING TM-49, TM-50
TM-49 Failure code [DAQAKQ] (Transmission controller rotary switch:

Non match in model selection signal (KP))
★ Nature of failure: The model setting of the rotary switch does not match the setting inside the controller
Cause Remedy
1
Is setting of transmission controller
NO
• See TESTING AND Defective setting of rotary switch Set again
ADJUSTING. rotary switch correct?
YES
TM-50 Failure code [DAQSMA] (Transmission controller: Function impossible (MA)

★ Nature of failure: The communication (S-NET) with the machine monitor is defective and the option setting
cannot be made
Cause Remedy
1
Is other failure code [DAQSKR] NO
time?
YES Go to
Another problem is occurring at troubleshooting
the same time for displayed
code
2
• Turn starting switch ON. when transmission controller is Defective machine monitor Replace
replaced?
YES
20-588 HM400-1

TM-51 Failure code [DDTFKA] (Fill switch for inter-axle differential lock clutch:
Disconnection (KA))
★ Nature of failure: When the output is made to the differential lock clutch solenoid, the clutch engages, but
the signal from the fill switch does not come ON
Cause Remedy
1
• Insert T-adapter to ATC5.
• Start engine. Is voltage between ATC5A (17) NO
• When actuating and ground less than 1 V?
differential lock.
YES
controller
2
• Disconnect D/L-SW. Is resistance between D/L-SW
• Start engine. NO Defective fill switch for inter-axle Replace
• When actuating differential (male) (1) and ground less than 1
Ω? differential lock clutch
lock.
YES or short circuit with power source Repair or
in wiring harness between ATC5A replace
(female) (17) and D/L-SW
(female) (1)
HM400-1 20-589
TM-52 Failure code [DDTGKA] (Fill switch for lock-up clutch: Disconnection (KA))
★ Nature of failure: When the output is made to the lock-up clutch solenoid, the clutch engages, but the signal
from the fill switch does not come ON
Cause Remedy
1
• Insert T-adapter to ATC5. Is voltage between ATC5A (11) NO
• Start engine.
• When traveling at lock-up. and ground less than 1 V?
YES
controller
2
• Disconnect L/U-SW. Is resistance between L/U-SW NO
• Start engine. (male) (1) and ground less than 1 Defective fill switch for lock-up Replace
• When traveling at lock-up. Ω? clutch
(female) (11) and L/U-SW
(female) (1)
20-590 HM400-1
TM-53 Failure code [DDTHKA] (Fill switch for Hi clutch: Disconnection (KA))
★ Nature of failure: When the output is made to the Hi clutch solenoid, the clutch engages, but the signal from
the fill switch does not come ON
Cause Remedy
1
• Start engine.
• When traveling in F2. and ground less than 1 V?
YES
controller
2
• Disconnect H-SW. Is resistance between H-SW (male) NO
• Start engine. (1) and ground less than 1 Ω? Defective fill switch for Hi clutch Replace
• When traveling in F2.

(female) (12) and H-SW (female)
(1)
HM400-1 20-591
TM-54 Failure code [DDTJKA] (Fill switch for Lo clutch: Disconnection (KA))
★ Nature of failure: When the output is made to the Lo clutch solenoid, the clutch engages, but the signal from
Cause Remedy
1
• Start engine.
YES
controller
2
• Disconnect L-SW. Is resistance between L-SW (male) NO
• Start engine. (1) and ground less than 1 Ω? Defective fill switch for Lo clutch Replace

(female) (10) and L-SW (female)
(1)
20-592 HM400-1
TM-55 Failure code [DDTKKA] (Fill switch for 1st clutch: Disconnection (KA))
★ Nature of failure: When the output is made to the 1st clutch solenoid, the clutch engages, but the signal from
Cause Remedy
1
• Start engine.
YES
controller
2
• Disconnect 1-SW. Is resistance between 1-SW (male) NO
• Start engine. (1) and ground less than 1 Ω? Defective fill switch for 1st clutch Replace

(female) (13) and 1-SW (female)
(1)
HM400-1 20-593
TM-56 Failure code [DDTLKA] (Fill switch for 2nd clutch: Disconnection (KA))
★ Nature of failure: When the output is made to the 2nd clutch solenoid, the clutch engages, but the signal
from the fill switch does not come ON
Cause Remedy
1
• Start engine.
YES
controller
2
• Start engine. (1) and ground less than 1 Ω? Defective fill switch for 2nd clutch Replace

(1)
20-594 HM400-1
TM-57 Failure code [DDTMKA] (Fill switch for 3rd clutch: Disconnection (KA))
★ Nature of failure: When the output is made to the 3rd clutch solenoid, the clutch engages, but the signal from
Cause Remedy
1
• Start engine.
YES
controller
2
• Start engine. (1) and ground less than 1 Ω? Defective fill switch for 3rd clutch Replace

(1)
HM400-1 20-595
TM-58 Failure code [DDTNKA] (Fill switch for R clutch: Disconnection (KA))
★ Nature of failure: When the output is made to the R clutch solenoid, the clutch engages, but the signal from
Cause Remedy
1
• Start engine.
• When traveling in R1. and ground less than 1 V?
YES
controller
2
• Disconnect R-SW. Is resistance between R-SW (male) NO
• Start engine. (1) and ground less than 1 Ω? Defective fill switch for R clutch Replace
• When traveling in R1.

(female) (16) and R-SW (female)
(1)
20-596 HM400-1
TM-59 Failure code [DF10KA] (Gearshift lever: Disconnection (KA))

★ Nature of failure: Nothing is input for the gearshift lever signal
1
• Insert T-adapter to Is voltage between each pin of NO Cause Remedy
ATC3A and ATC5B. ATC5B and ATC3A (14) as
• Turn starting switch ON. shown in Table 1?
controller
2
• Insert T-adapter to SF1. Is voltage between SF1 (1) and NO
• Turn starting switch ON. (2) 20 - 30 V?
YES
• Insert T-adapter to SF1. Is voltage between SF1 (1) and NO disconnection in wiring harness Repair or
• Turn starting switch ON. ground 20 - 30 V? between fuse BT3-10 outlet and replace
SF1 (female) (1)
YES Defective contact or Repair or
disconnection in wiring harness replace
between SF1 (female) (2) and
ATC3A (female) (14)
• Turn starting switch OFF. Is resistance between each pin of NO disconnection in wiring harness
• Disconnect ATC5B and ATC5B (female) and each pin of between SF1 (female) and Repair or
SF1. SF1 (female) as shown in Table 2? ATC5B (female) where replace
resistance value is not normal
YES

• Turn starting switch OFF. Is resistance between each pin NO ground in wiring harness
• Disconnect ATC5B and of ATC5B (female) and ground between SF1 (female) and Repair or
SF1. as shown in Table 3? ATC5B (female) where replace
resistance value is not normal
YES
Defective gearshift lever Replace
Table 1 Table 2 Table 3
Shift ATC5B (female), Resistance Resistance

ATC5B, ATC3A Voltage ATC5B (female)
position SF1 (female) value value
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
ATC5B(5) - ATC3A(14) D ATC5B(5) - SF1(6) (5) - and ground
ATC5B(6) - ATC3A(14) 1 20 - 30 V ATC5B(6) - SF1(11) Max. 1 Ω (6) - and ground Min. 1 MΩ
ATC5B(7) - ATC3A(14) 2 ATC5B(7) - SF1(10) (7) - and ground
HM400-1 20-597
20-598 HM400-1
TM-60 Failure code [DF10KB] (Gearshift lever: Short circuit (KB))

★ Nature of failure: The gearshift lever signal was input at the same time from 2 or more systems
Cause Remedy
1
• Turn starting switch OFF. Is resistance between ATC2 NO
• Disconnect ATC2. (female) (4) and (15) 5 – 15 Ω?
YES
controller
2
Replace
• Turn starting switch OFF. Is resistance between H-PS (male) NO Defective Hi clutch solenoid
• Disconnect H-PS. (1) and (2) 5 – 15 Ω?

YES in wiring harness between ATC2
(female) (4) and H-PS (female) (1) Repair or
or between ATC2 (female) (15) replace
and H-PS (female) (2)
Table 1 Table 2
Shift Resistance
ATC5B, ATC3A Voltage ATC5B (female)
position value
ATC5B(2) - ATC3A(14) R1 (2) - and ground
ATC5B(3) - ATC3A(14) R2 (3) - and ground
ATC5B(4) - ATC3A(14) N (4) - and ground
ATC5B(5) - ATC3A(14) D (5) - and ground
ATC5B(6) - ATC3A(14) 1 Max. 1 V (6) - and ground Max. 1 V
ATC5B(7) - ATC3A(14) 2 (7) - and ground
HM400-1 20-599
20-600 HM400-1
TM-61 Failure code [DGF1KX] (Transmission valve oil temperature sensor:

★ Nature of failure: The voltage of the signal circuit for the transmission valve oil temperature sensor became
less than 0.97 V, or there was a big difference from the torque converter oil temperature
Cause Remedy
1
Is voltage between ATC3B NO
• Disconnect ATC3A and (female) (9) and ground less than
ATC3B.
1 V?
YES

• Disconnect ATC3B and Is voltage between ATC3B (female) NO in wiring harness between Repair or
LUB-T.
• Turn starting switch ON. (9) and ground less than 1 V? ATC3B (female) (9) and LUB-T replace
(female) (1)
YES
Defective transmission valve oil Replace
temperature sensor
3
• Turn starting switch OFF. Is resistance between ATC3B (female) NO
• Disconnect ATC3A and (9) - ATC3A (female) (16) and between
ATC3B. (9) - ground as shown in Table 1?
YES
controller
4
Is resistance between LUB-T NO
. Turn starting switch OFF. (male) (1) - (2) and between (1) - Defective transmission valve oil
. Disconnect LUB-T. temperature sensor Replace
Defective contact,
YES disconnection, or short circuit
harness between ATC3B replace
(female) (9) and LUB-T (female)
(1), or defective contact or
disconnection in wiring harness
and LUB-T (female) (2)
Table 1 Table 2
Between ATC3B Between LUB-T (male) Between LUB-T (male)

Between ATC3B Oil temperature
Oil temperature (female) (9) and (1) and (2) (1) and ground
ATC3A (female) (16)
25f C 37 - 50 KΩ
25fC 37 - 50 KΩ Min. 1 MΩ
Min. 1 MΩ 100fC 3.5 - 4.0 KΩ
100fC 3.5 - 4.0 KΩ
HM400-1 20-601
TM-62 Failure code [DGR2L8] (Brake oil temperature sensor (rear):

* See Contents (L8))
★ Nature of failure: When the front brake oil temperature sensor signal and center brake oil temperature sen-
sor signal were more than 60 fC, the rear brake oil temperature sensor was less than 10fC
Cause Remedy
1
• Disconnect ATC3A and Is voltage between ATC3B NO
ATC3B. (female) (10) and ground less
• Turn starting switch ON. than 1 V?
YES

• Disconnect ATC3B and Is voltage between ATC3B NO in wiring harness between Repair or
T13. (female) (10) and ground less
• Turn starting switch ON. ATC3B (female) (10) and T13 replace
than 1 V?
(female) (1)
YES Defective rear brake oil
temperature sensor Replace
3
• Turn starting switch OFF. Is resistance between ATC3B NO
• Disconnect ATC3A and (female) (10) and ATC3A (female)
ATC3B. (16) as shown in Table 1?
controller
4
• Turn starting switch OFF. Is resistance between T13 (male) NO Defective rear brake oil
• Disconnect T13. (1) and (2) as shown in Table 2? temperature sensor Replace
YES disconnection in wiring harness
between ATC3B (female) (10) - Repair or
T13 (female) (1) or between replace
ATC3A (female) (16) - T13
(female) (2)
Table 1 Table 2
Between ATC3B (female) (10) Oil temperature Between T13 (male) (1) and (2)
Oil temperature
and ATC3A (female) (16)
25fC 37 - 50 KΩ
25f C 37 - 50 KΩ 100fC 3.5 - 4.0 KΩ
100fC 3.5 - 4.0 KΩ
20-602 HM400-1
TM-63 Failure code [D G R3L8] ( Brake oil te mperature sensor (center): * See Contents (L8))
★ Nature of failure: When the front brake oil temperature sensor signal and rear brake oil temperature sensor
signal were more than 60 fC, the center brake oil temperature sensor was less than 10fC
Cause Remedy
1
ATC3B. (female) (8) and ground less than
• Turn starting switch ON. 1 V?
YES
2
than 1 V?
(female) (1)
YES Defective center brake oil
3
YES
controller
4
• Turn starting switch OFF. Is resistance between T14 (male) NO Defective center brake oil
(female) (2)
Table 1 Table 2
Oil temperature
25f C 37 - 50 KΩ
25fC 37 - 50 KΩ 100fC 3.5 - 4.0 KΩ
100fC 3.5 - 4.0 KΩ
HM400-1 20-603
TM-64 Failure code [DGR4L8] (Brake oil temperature sensor (front): * See Contents (L8))
★ Nature of failure: When the center brake oil temperature sensor signal and rear brake oil temperature sensor
signal were more than 60fC, the front brake oil temperature sensor was less than 10 fC
Cause Remedy
1
YES
2
than 1 V?
(female) (1)
YES Defective front brake oil
3
YES
controller
4
• Turn starting switch OFF. Is resistance between T15 (male) NO Defective front brake oil
(female) (2)
Table 1 Table 2
Oil temperature
25fC 37 - 50 KΩ
25f C 37 - 50 KΩ 100fC 3.5 - 4.0 KΩ
100fC 3.5 - 4.0 KΩ
20-604 HM400-1
TM-65 Failure code [DGT1LX] (Torque converter oil temperature sensor:

★ Nature of failure: The voltage of the signal circuit for the torque converter oil temperature sensor became
less than 0.97 V, or there was a big difference from the transmission valve oil temperature sensor signal
Cause Remedy
1
YES
2
TC-SE. (female) (7) and ground less
• Turn starting switch ON. ATC3B (female) (7) and TC-SE replace
than 1 V?
(female) (1)
YES Defective torque converter oil
3
• Disconnect ATC3A and (female) (7) - ATC3A (female)
ATC3B. (16) and between(7) - ground as
YES
controller
4
Is resistance between TC-SE NO
• Turn starting switch OFF. (male) (1) - (2) and between (1) - Defective torque converter oil
• Disconnect TC-SE. temperature sensor Replace
Defective contact,
harness between ATC3B replace
(female) (7) and TC-SE
(female) (1), or defective
contact or disconnection in
wiring harness between ATC3A
(female) (16) and TC-SE
(female) (2)
Table 1 Table 2
Between ATC3B Between TC-SE (male) Between TC-SE (male)

Between ATC3B Oil temperature
Oil temperature (female) (7) and (1) and (2) (1) and ground
ATC3A (female) (16)
25f C 37 - 50 KΩ
25fC 37 - 50 KΩ Min. 1 MΩ
Min. 1 MΩ 100fC 3.5 - 4.0 KΩ
100fC 3.5 - 4.0 KΩ
HM400-1 20-605
TM-66 Failure code [DHT5KX] (Torque converter oil pressure sensor:

★ Nature of failure: The voltage in the signal circuit of the torque converter oil pressure sensor became less
than 0.5 V or more than 4.5 V
Cause Remedy
1
ATC3A.
• Turn starting switch ON. and (16)(17) 0.8 - 2.0 V?
YES
Defective transmission
controller Replace
2
Is voltage between TC-INT NO
• Disconnect TC-INT.
• Turn starting switch ON. (female) (2) and ground 20 - 30
V?
YES

• Disconnect ATC1 and Is resistance between TC-INT NO ground in wiring harness Repair or
TC-INT. (female) (2) and ground less than between ATC1 (female) (2) and replace
• Turn starting switch ON. 1 MΩ?
TC-INT (female) (2)
YES
4
• Insert T-adapter to ATC1. Is voltage between ATC1 (2) and NO Defective transmission Replace
• Disconnect TC-INT.
• Turn starting switch ON. ground 20 - 30 V? controller
YES disconnection in wiring harness Repair or
between ATC1 (female) (2) and replace
TC-INT (female) (2)
5
• Turn starting switch OFF. Is resistance between TC-INT NO
• Disconnect TC-INT. (female) (1) and ground less
than 1 Ω?
YES
• Turn starting switch OFF. Is resistance between ATC3A NO disconnection in wiring harness
• Disconnect ATC3A and (female) (16)(17) and TC-INT Repair or
TC-INT. (female) (3) less than 1 Ω? (17) and TC-INT (female) (1)
YES Defective transmission
controller Replace
7
• Insert T-adapter to TC- Is voltage between TC-INT (3) NO
INT.
YES in wiring harness between Repair or
ATC3A (female) (7) and TC-INT replace
(female) (3)
To 8
20-606 HM400-1
From 7
Cause Remedy
• Disconnect ATC3A and Is voltage between TC-INT NO
TC-INT. (female) (3) and ground less in wiring harness between Repair or
• Turn starting switch ON. than 1 V? ATC3A (female) (7) and TC-INT replace
(female) (3)
YES
• Turn starting switch OFF. Is resistance between TC-INT NO ground in wiring harness Repair or
• Disconnect ATC3A and (female) (3) and ground more between ATC3A (female) (7) replace
TC-INT. than 1 MΩ? and TC-INT (female) (3)
YES Defective torque converter oil Replace
temperature sensor
HM400-1 20-607
TM-67 Failure code [DHT5L6] (Torque converter oil pressure sensor: * See Contents (L6))
★ Nature of failure: When the engine is stopped, the torque converter oil pressure sensor signal circuit inputs
the oil pressure
Cause Remedy
1
• Insert T-adapter to NO
ATC3A. Is voltage between ATC3A (7) and
• Turn starting switch ON. (16) 0.8 V?
YES
controller
2
• Disconnect ATC3A and Short circuit with power source in
TC-INT. Is voltage between ATC3A (female) NO wiring harness between ATC3A Repair or
• Turn starting switch ON. (7) and ground less than 1 V? (female) (7) and TC-INT (female) replace
(3)
YES
Defective torque converter oil Replace
pressure sensor
20-608 HM400-1
TM-68 Failure code [DJF1KA] (Fuel level sensor: Disconnection (L6))

★ Nature of failure: The voltage of the signal circuit of the fuel level sensor became more than 4.0 V
Cause Remedy
1
YES
2
than 1 V?
(female) (1)
YES
Defective fuel level sensor Replace
3
• Disconnect ATC3A and (female) (4) - ATC3A (female)
YES
controller
4
• Turn starting switch OFF. Is resistance between T08 (male) NO Defective fuel level sensor
Replace
• Disconnect T08. (1) – (2) as shown in Table 2?
between ATC3B (female) (4) Repair or
and T08 (female) (1) or replace
Table 1 Table 2
Between ATC3B (female) (4) Fuel tank Between T08 (male) (1) and (2)
Fuel tank
Full Max. 12 Ω
Full Max. 12 Ω Empty 74 - 100 Ω
Empty 74 - 100 Ω
HM400-1 20-609
TM-69 Failure code [DK11KX] (Throttle angle sensor: Input signal outside range (KX))
★ Nature of failure: The voltage in the signal circuit of the acceleration sensor became less than 0.6 V or more
than 4.7 V
Cause Remedy
1
• Insert T-adapter to
Is voltage between ATC3B (11) NO
ATC3A and ATC3B.
• Turn starting switch ON. and ATC3A (16) 1.0 - 4.0 V?
YES Defective transmission

controller Replace
2
YES

• Disconnect ATC3A and Is voltage between AS2 (female) NO ground in wiring harness Repair or
AS2. between ATC3A (female) (6)
and ground
YES

• Disconnect ATC3A and (female) (1) and ground more ground in wiring harness Repair or
AS2. than 1 MΩ? between ATC3A (female) (6) replace
and AS2 (female) (1)
YES
5
ATC3A. Is voltage between ATC3A (6) NO Defective transmission
Replace
• Disconnect AS2. and ground 4.6 - 5.4 V? controller
6
• Disconnect AS2. (female) (6) and ground less
than 1 Ω?
YES
7
• Turn starting switch OFF. Is resistance between ATC3A NO
• Disconnect ATC3A and (female) (16) and AS2 (female) Defective contact or Repair or
AS2. (3) less than 1 Ω? disconnection in wiring harness replace
controller
To 8
20-610 HM400-1
From 7
Cause Remedy
8
between ATC3B (female) (11) replace
• Disconnect ATC3B and Is voltage between AS2 (female) NO in wiring harness between Repair or
AS2.
• Turn starting switch ON. (2) and ground less than 1 V? ATC3B (female) (11) and AS2 replace
(female) (2)
YES
10
• Turn starting switch OFF. Is resistance between AS2 NO ground in wiring harness Repair or
• Disconnect ATC3B and (female) (2) and ground more between ATC3B (female) (11) replace
AS2. than 1 MΩ? and AS2 (female) (2)
YES
Defective accelerator sensor or
defective accelerator pedal Replace
HM400-1 20-611
TM-70 Failure code [DLE2KA] (Engine speed sensor: Disconnection (KA))

★ Nature of failure: There is a disconnection in the signal circuit of the engine speed sensor and the signal is
not input
Cause Remedy
1
• Disconnect ATC3A. (female) (13) and (16) 500 - 1000
Ω?
YES
2
• Turn starting switch OFF. Is resistance between EREV NO
• Disconnect ECRV. (male) (1) and (2) 500 - 1000 Ω? Defective engine speed sensor Replace
and EREV (female) (1) or
3 and EREV (female) (2)
• See TESTING AND Does condition become normal NO
ADJUSTING. when engine speed sensor is Defective transmission Replace
• Start engine. adjusted? controller
YES
Defective adjustment of engine Adjust
speed sensor
20-612 HM400-1
TM-71 Failure code [DLE2LC] (Engine speed sensor: * See Contents (LC))
★ Nature of failure: When the signal of the engine speed sensor is less than 350 rpm, the signal of the trans-
mission input shaft speed sensor inputs more than 500 rpm
Cause Remedy
1
• Disconnect ATC3A. Is voltage between ATC3A NO
• Turn starting switch ON. (female) (13) and ground less
than 1 V?
YES
2
EREV. (female) (13) and ground less
• Turn starting switch ON. ATC3A (female) (13) and EREV replace
than 1 V?
(female) (1)
YES
Defective engine speed sensor Replace
3
Is resistance between ATC3A NO
• Turn starting switch OFF. (female) (13) and ground more
• Disconnect ATC3A. than 1 MΩ?
YES
controller
4
Is resistance between EREV NO
• Turn starting switch OFF. (male) (1) and ground more than
• Disconnect EREV Defective engine speed sensor Replace
1 MΩ?

and EREV (female) (1)
HM400-1 20-613
TM-72 Failure code [DLF1KA] (Transm ission input shaft speed sensor: Disconnection (KA))
★ Nature of failure: There is a disconnection in the signal circuit of the transmission input shaft speed sensor
and the signal is not input
Cause Remedy
1
Ω?
YES
2
• Turn starting switch OFF. Is resistance between N1 (male) NO Defective transmission input
• Disconnect N1. (1) and (2) 500 - 1000 Ω? shaft speed sensor Replace
and N1 (female) (1) or between
ATC3A (female) (16) and N1
3 (female) (2)
ADJUSTING. when transmission input shaft Defective transmission Replace
• Start engine. speed sensor is adjusted? controller
YES Defective adjustment of
transmission input shaft speed Adjust
sensor
20-614 HM400-1
TM-73 Failure code [DLF1LC] (Transmission input shaft speed sensor:

* See Contents (LC))
★ Nature of failure: There is an abnormality in the speed calculated from the engine speed sensor signal,
transmission intermediate shaft speed sensor signal, and output shaft R speed sensor signal, and the speed
of the transmission input shaft sensor signal
Cause Remedy
1
• Turn starting switch ON. (female) (2) and ground less than
1 V?
YES
2
N1. (female) (2) and ground less
• Turn starting switch ON. ATC3A (female) (2) and N1 replace
than 1 V?
(female) (1)
YES Defective transmission input Replace
shaft speed sensor
3
YES
controller
4
• Turn starting switch OFF. Is resistance between N1 (male) NO Defective transmission input
• Disconnect N1. (1) and ground more than 1 MΩ? shaft speed sensor Replace

and N1 (female) (1)
HM400-1 20-615
TM-74 Failure code [DLF2KA] (Transmission intermediate shaft speed sensor:

Disconnection (KA))
★ Nature of failure: There is a disconnection in the signal circuit of the transmission intermediate shaft speed
sensor and the signal is not input
Cause Remedy
1
Ω?
YES
2
• Turn starting switch OFF. Is resistance between N2 (male) NO Defective transmission
• Disconnect N2. (1) and (2) 500 - 1000 Ω? intermediate shaft speed sensor Replace
3 (female) (2)
ADJUSTING. when transmission intermediate Defective transmission Replace
• Start engine. shaft speed sensor is adjusted? controller
transmission intermediate shaft Adjust
speed sensor
20-616 HM400-1
TM-75 Failure code [DLF2LC] (Transmission intermediate shaft speed sensor:

transmission input shaft speed sensor signal, and output shaft R speed sensor signal, and the speed of the
transmission intermediate shaft sensor signal
Cause Remedy
1
• Turn starting switch ON. (female) (12) and ground less
than 1 V?
YES

N2. (female) (12) and ground less
• Turn starting switch ON. ATC3A (female) (12) and N2 replace
than 1 V?
(female) (1)
intermediate shaft speed sensor
3
controller
4
• Turn starting switch OFF. Is resistance between N2 (male) NO Defective transmission
• Disconnect N2. (1) and ground more than 1 MΩ? intermediate shaft speed sensor Replace

and N2 (female) (1)
HM400-1 20-617
TM-76 Failure code [DLT3KA] (Transmission output shaft speed sensor:

Disconnection (KA))
★ Nature of failure: There is a disconnection in the signal circuit of the transmission output shaft R speed sen-
sor and the signal is not input
Cause Remedy
1
Ω?
YES
2
• Turn starting switch OFF. Is resistance between N3 (male) NO Defective transmission output
• Disconnect N3. (1) and (2) 500 - 1000 Ω? shaft R speed sensor Replace
3 (female) (2)
ADJUSTING. when transmission output shaft R Defective transmission Replace
• Start engine. speed sensor is adjusted? controller
transmission output shaft R Adjust
speed sensor
20-618 HM400-1
TM-77 Failure code [DLT3LC] (Transmission output shaft speed sensor:

transmission input shaft speed sensor signal, and intermediate shaft speed sensor signal, and the speed of
the transmission output shaft R sensor signal
Cause Remedy
1
• Disconnect ATC3A, Is voltage between ATC3A NO
BRC3A, and N3. (female) (12) and ground less
• Turn starting switch ON. than 1 V?
YES

BRC3A. (female) (12) and ground less
• Turn starting switch ON. ATC3A (female) - BRC3A replace
than 1 V? (female) (13) - N3 (female) (1)
YES Defective transmission output R
shaft speed sensor Replace
3
• Disconnect ATC3A and (female) (3) and ground more
BRC3A. than 1 MΩ?
YES
4
• Turn starting switch OFF. Is resistance between N3 (male) NO Defective transmission output R
• Disconnect N3. (1) and ground more than 1 MΩ? shaft speed sensor Replace
YES ground in wiring harness Repair or
between ATC3A (female) (3) - replace
BRC3A (female) (13) - N3
(female) (1)
5
replaced?
YES
controller
HM400-1 20-619
TM-78 Failure code [DXH0KA] (Solenoid for inter-axle differential lock: Disconnection (KA))
★ Nature of failure: No electric current flows when there is output to the differential lock clutch solenoid
Cause Remedy
1
YES
controller
2
NO Defective differential lock clutch Replace
• Turn starting switch OFF. Is resistance between D/L-PS solenoid
• Disconnect D/L-PS. (male) (1) and (2) 5 – 15 Ω?

(female) (8) and D/L-PS (female) Repair or
(1) or between ATC2 (female) (18) replace
and D/L-PS (female) (2)
20-620 HM400-1
TM-79 Failure code [DXH0KB] (Solenoid for inter-axle differential lock:

Short circuit (KB))
★ Nature of failure: An extremely large electric current flows when there is output to the differential lock clutch
solenoid or electric current flows when it is OFF
Cause Remedy
1
• Disconnect ATC2. (female) (3) and (16) 500 - 1000
Ω?
YES
2
• Turn starting switch OFF. Is resistance between N3 (male) NO Defective differential lock clutch
• Disconnect D/L-PS. (1) and (2) 500 - 1000 Ω? solenoid Replace
YES in wiring harness between ATC2 Repair or
(female) (8) and D/L-PS (female)
(1) or short circuit in wiring replace
harness between ATC2 (female)
(18) and D/L-PS (female) (2)
3
• Disconnect ATC2 and Does condition become normal NO wiring harness between ATC2 Repair or
D/L-PS. when transmission output shaft R (female) (8) and D/L-PS (female) replace
• Turn starting switch ON. speed sensor is adjusted? (1) or between ATC2 (female) (18)
and D/L-PS (female) (2)
YES
controller
Table 1 Table 2
ATC2 (female) Resistance value D/L-PS (male) Resistance value

Between (8) and (18) 5 - 15 Ω Between (1) and (2) 5 - 15 Ω
Between (8) and ground Min. 1 MΩ Between (1) and ground Min. 1 MΩ
HM400-1 20-621
TM-80 Failure code [DXH1KA] (Solenoid for lock-up clutch: Disconnection (KA))
★ Nature of failure: No electric current flows when there is output to the lock-up clutch solenoid
Cause Remedy
1
YES
controller
2
NO Defective lock-up clutch Replace
• Turn starting switch OFF. Is resistance between L/U-PS
• Disconnect L/U-PS. (male) (1) and (2) 5 – 15 Ω? solenoid

(female) (10) and L/U-PS (female) Repair or
(1) or between ATC2 (female) (20) replace
and L/U-PS (female) (2)
20-622 HM400-1
TM-81 Failure code [DXH1KB] (Solenoid for lock-up clutch: Short circuit (KB))
★ Nature of failure: An extremely large electric current flows when there is output to the lock-up clutch solenoid
or electric current flows when it is OFF
Cause Remedy
1
• Disconnect ATC2. (female) (10) - (20) and between
(10) - ground as shown in Table 1?
YES
2
Is resistance between L/U-PS NO Defective lock-up clutch
• Disconnect L/U-PS. (male) (1) - (2) and between (1) - solenoid Replace
(female) (10) and L/U-PS (female)
(20) and L/U-PS (female) (2)
3
• Disconnect ATC2 and Is voltage between ATC2 NO wiring harness between ATC2 Repair or
L/U-PS. (female) (10)(20) - ground less (female) (10) and L/U-PS (female) replace
• Turn starting switch ON. than 1 V? (1) or between ATC2 (female) (20)
and L/U-PS (female) (2)
YES
controller
Table 1 Table 2
ATC2 (female) Resistance value D/L-PS (male) Resistance value

HM400-1 20-623
TM-82 Failure code [DXH2KA] (Solenoid for Hi clutch: Disconnection (KA))

★ Nature of failure: No electric current flows when there is output to the Hi clutch solenoid
Cause Remedy
1
YES
controller
2
Replace
• Turn starting switch OFF. Is resistance between H-PS (male) NO Defective Hi clutch solenoid
• Disconnect H-PS. (1) and (2) 5 – 15 Ω?

(female) (4) and H-PS (female) (1) Repair or
20-624 HM400-1
TM-83 Failure code [DXH2KB] (Solenoid for Hi clutch: Short circuit (KB))
★ Nature of failure: An extremely large electric current flows when there is output to the Hi clutch solenoid or
electric current flows when it is OFF
Cause Remedy
1
• Disconnect ATC2. (female) (4) - (15) and between (4)
YES
2
Is resistance between H-PS NO Defective Hi clutch solenoid
• Disconnect H-PS. (male) (1) - (2) and between (1) - Replace
(female) (4) and H-PS (female)
(15) and H-PS (female) (2)
3
• Disconnect ATC2 and H- Is voltage between ATC2 NO wiring harness between ATC2 Repair or
PS. (female) (4)(15) - ground less (female) (4) and H-PS (female) replace
• Turn starting switch ON. than 1 V? (1) or between ATC2 (female) (15)
YES
controller
Table 1 Table 2
ATC2 (female) Resistance value H-PS (male) Resistance value

HM400-1 20-625
TM-84 Failure code [DXH3KA] (Solenoid for Lo clutch: Disconnection (KA))

★ Nature of failure: No electric current flows when there is output to the Lo clutch solenoid
Cause Remedy
1
YES
controller
2
NO Defective Lo clutch solenoid Replace
• Turn starting switch OFF. Is resistance between L-PS (male)
• Disconnect L-PS. (1) and (2) 5 – 15 Ω?

(female) (7) and L-PS (female) (1) Repair or
and L-PS (female) (2)
20-626 HM400-1
TM-85 Failure code [DXH3KB] (Solenoid for Lo clutch: Short circuit (KB))
★ Nature of failure: An extremely large electric current flows when there is output to the Lo clutch solenoid or
Cause Remedy
1
YES
2
Is resistance between L-PS NO
• Disconnect L-PS. (male) (1) - (2) and between (1) - Defective Lo clutch solenoid Replace
(female) (7) and L-PS (female) (1)
or short circuit in wiring harness replace
between ATC2 (female) (17) and
L-PS (female) (2)
3
• Disconnect ATC2 and L- Is voltage between ATC2 NO wiring harness between ATC2 Repair or
PS. (female) (7)(17) - ground less (female) (7) and L-PS (female) (1) replace
• Turn starting switch ON. than 1 V? or between ATC2 (female) (17)
and L-PS (female) (2)
YES
controller
Table 1 Table 2
ATC2 (female) Resistance value L-PS (male) Resistance value

HM400-1 20-627
TM-86 Failure code [DXH4KA] (Solenoid for 1st clutch: Disconnection (KA))
★ Nature of failure: No electric current flows when there is output to the 1st clutch solenoid
Cause Remedy
1
YES
controller
2
NO Defective 1st clutch solenoid Replace
• Turn starting switch OFF. Is resistance between 1-PS (male)
• Disconnect 1-PS. (1) and (2) 5 – 15 Ω?

(female) (2) and 1-PS (female) (1) Repair or
and 1-PS (female) (2)
20-628 HM400-1
TM-87 Failure code [DXH4KB] (Solenoid for 1st clutch: Short circuit (KB))
★ Nature of failure: An extremely large electric current flows when there is output to the 1st clutch solenoid or
Cause Remedy
1
YES
2
Is resistance between 1-PS NO
• Disconnect 1-PS. (male) (1) - (2) and between (1) - Defective 1st clutch solenoid Replace
(female) (2) and 1-PS (female) (1)
1-PS (female) (2)
3
• Disconnect ATC2 and 1- Is voltage between ATC2 NO wiring harness between ATC2 Repair or
PS. (female) (2)(13) - ground less (female) (2) and 1-PS (female) (1) replace
YES
controller
Table 1 Table 2
ATC2 (female) Resistance value 1-PS (male) Resistance value

HM400-1 20-629
TM-88 Failure code [DXH5KA] (Solenoid for 2nd clutch: Disconnection (KA))
★ Nature of failure: No electric current flows when there is output to the 2nd clutch solenoid
Cause Remedy
1
YES
controller
2
NO Defective 2nd clutch solenoid Replace
• Turn starting switch OFF. Is resistance between 2-PS (male)
• Disconnect 2-PS. (1) and (2) 5 – 15 Ω?

20-630 HM400-1
TM-89 Failure code [DXH5KB] (Solenoid for 2nd clutch: Short circuit (KB))
★ Nature of failure: An extremely large electric current flows when there is output to the 2nd clutch solenoid
or electric current flows when it is OFF
Cause Remedy
1
YES
2
• Disconnect 2-PS. (male) (1) - (2) and between (1) - Defective 2nd clutch solenoid Replace
2-PS (female) (2)
3
YES
controller
Table 1 Table 2

HM400-1 20-631
TM-90 Failure code [DXH6KA] (Solenoid for 3rd clutch: Disconnection (KA))
★ Nature of failure: No electric current flows when there is output to the 3rd clutch solenoid
Cause Remedy
1

controller
2
• Disconnect 3-PS. (1) and (2) 5 – 15 Ω? Defective 3rd clutch solenoid Replace

20-632 HM400-1
TM-91 Failure code [DXH6KB] (Solenoid for 3rd clutch: Short circuit (KB))
★ Nature of failure: An extremely large electric current flows when there is output to the 3rd clutch solenoid or
Cause Remedy
1
YES
2
• Disconnect 3-PS. (male) (1) - (2) and between (1) - Defective 3rd clutch solenoid Replace
3-PS (female) (2)
3
YES
controller
Table 1 Table 2

HM400-1 20-633
TM-92 Failure code [DXH7KA] (Solenoid for R clutch: Disconnection (KA))

★ Nature of failure: No electric current flows when there is output to the R clutch solenoid
Cause Remedy
1
YES
controller
2
Replace
• Turn starting switch OFF. Is resistance between R-PS (male) NO Defective R clutch solenoid
• Disconnect R-PS. (1) and (2) 5 – 15 Ω?

(female) (5) and R-PS (female) (1) Repair or
and R-PS (female) (2)
20-634 HM400-1
TM-93 Failure code [DXH7KB] (Solenoid for R clutch: Short circuit (KB))
★ Nature of failure: An extremely large electric current flows when there is output to the R clutch solenoid or
Cause Remedy
1
YES
2
Is resistance between R-PS NO
• Disconnect R-PS. (male) (1) - (2) and between (1) - Defective R clutch solenoid Replace
(female) (5) and R-PS (female) Repair or
(15) and R-PS (female) (2)
3 Short circuit with power source in
• Disconnect ATC2 and R- Is voltage between ATC2 NO wiring harness between ATC2 Repair or
PS. (female) (5)(15) - ground less (female) (5) and R-PS (female)
• Turn starting switch ON. than 1 V? (1) or between ATC2 (female) (15) replace
and R-PS (female) (2)
YES
controller
Table 1 Table 2
ATC2 (female) Resistance value R-PS (male) Resistance value

HM400-1 20-635
TM-94 Backup lamp, backup buzzer do not work properly

★ Nature of failure: Backup lamp or backup buzzer do not work properly (no failure code is displayed)
a) Even when gearshift lever is operated to R1 or R2, backup lamp and backup buzzer do not work
★ The lamp and buzzer GND circuits are centralized at joint connector (CJK), so check that the continuity is
normal.
Cause Remedy
1
• Turn starting switch ON. backup lamp and buzzer relay (R05) is
YES
Defective backup lamp, buzzer Replace
relay (R05)
2
• Disconnect R05.
Is voltage between R05 (female) NO disconnection in wiring harness Repair or
• Gearshift lever: R1, R2 (5) and ground 20 - 30 V? between R05 (female) (5) and replace
wiring harness at dividing point
YES
3
Is resistance between R05 Defective contact or
NO
• Turn starting switch OFF. (female) (6) and ground less disconnection in wiring harness Repair or
• Disconnect R05. between R05 (female) (6) and
than 1 Ω? replace
ground
YES
4
• Disconnect R05. Is voltage between R05 (female) NO Defective contact or Repair or
• Turn starting switch ON. (2)(4) - ground 20 - 30 V? disconnection in wiring harness replace

disconnection in wiring harness Repair
between CJK (female) (6) and replace
ground
b) Backup lamp and backup buzzer do not work when gearshift lever is operated to R1 (work normally
at R2)
Cause Remedy
between CNS2 (female) (3) - replace
D05 - wiring harness at dividing
point
c) Backup lamp and backup buzzer do not work when gearshift lever is operated to R2 (work normally
at R1)
Cause Remedy
between CNS2 (female) (4) - replace
D06 - wiring harness at dividing
point
20-636 HM400-1
d) Right backup lamp and backup buzzer do not work (left backup lamp works normally)
★ The lamp and buzzer GND circuits are centralized at joint connector (CJK), so check that the continuity is
normal.
★ The right lamp and buzzer signal circuits are common, so if only one side does not work, there is probably
a blown backup lamp bulb, defective backup buzzer, defective wiring harness of signal circuit (after divid-
ing), or defective wiring harness in the GND circuit.
Cause Remedy
1
• Turn starting switch ON. backup lamp and buzzer relay (R05)
YES Defective backup lamp, buzzer
relay (R05) Replace
2
• Turn starting switch ON. (4) and ground 20 - 30 V? between R05 (female) (4) and replace
between R05 (female) (3) CJK replace
e) Left backup lamp and backup buzzer do not work (right backup lamp and backup buzzer work nor-
mally)
Cause Remedy
1
• Turn starting switch ON. backup lamp and buzzer relay (R05) is
YES
Defective backup lamp, buzzer Replace
relay (R05)
• Turn starting switch ON. (4) and ground 20 - 30 V? between R05 (female) (4) and replace
YES
3
• Disconnect BL47. Is voltage between BL47 (female) NO disconnection in wiring harness
• Turn starting switch ON. Repair or
• Gearshift lever: R1, R2 (1) and ground 20 - 30 V? between R05 (female) (1) and replace
BL47 (female) (1)
YES
4
Is resistance between BL47 Defective contact or
• Disconnect BL47. (female) (2) and ground less
than 1 Ω? between BL47 (female) (2) and replace
CJZ (female) (2)
YES
Defective left backup lamp Replace
HM400-1 20-637
f) Gearshift lever is not operated to R1 or R2, but backup lamp and backup buzzer are actuated
Cause Remedy
1
• Turn starting switch ON. backup lamp and buzzer relay (R05)
YES Defective backup lamp, buzzer Replace
relay (R05)

• Disconnect R05. Is voltage between R05
• Turn starting switch ON. NO in wiring harness between R05 Repair or
• Gearshift lever: Other (female) (5) and ground less (female) (5) - D05 (female) (1) - replace
than R1, R2 than 1 V? D06 (female) (1)
YES

. Disconnect R05. Is voltage between R05 (female) NO in wiring harness between R05 Repair or
. Turn starting switch ON. (4) and ground less than 1 V? (female) (4) CJK (female) (8) replace
and ground
wiring harness between R05 Repair or
(female) (2) BL47 (female) (1) replace
and ground
20-638 HM400-1
TROUBLESHOOTING
q1)
TROUBLESHOOTING OF
RETARDER CONTROLLER (q
SYSTEM (BK MODE)
BK mode related electrical circuit diagram ..........................................................................................................20-704

Content of display and problem that appears on machine for each failure code ................................................20-710
BK-1 Failure code [2A62L1] (Front differential lock control valve: * See Contents (L1))
(Machine with differential lock differential) ............................................................................... 20-724
BK-2 Failure code [2A62LH] (Front differential lock control valve: * See Contents (LH))
BK-3 Failure code [2B62L1] (Rear differential lock control valve: * See Contents (L1))
BK-4 Failure code [2B62LH] (Rear differential lock control valve: * See Contents (LH))
BK-5 Failure code [2C4MNX] (Brake cooling filter: Clogged (NX)) ................................................... 20-728
BK-6 Failure code [2D01CA] (Front brake (right): Wear (CA)) .......................................................... 20-729
BK-7 Failure code [2D02CA] (Front brake (left): Wear (CA)) ............................................................ 20-730
BK-8 Failure code [2D03CA] (Center brake (right): Wear (CA)) ....................................................... 20-731
BK-9 Failure code [2D04CA] (Center brake (left): Wear (CA)) ......................................................... 20-732
BK-10 Failure code [2D05CA] (Rear brake (right): Wear (CA) ........................................................... 20-733
BK-11 Failure code [2D06CA] (Rear brake (left): Wear (CA)) ............................................................ 20-734
BK-12 Failure code [2G42ZG] (Accumulator (front): Drop in oil pressure (ZG)) ................................. 20-735
BK-13 Failure code [2G43ZG] (Accumulator (rear): Drop in oil pressure (ZG)) .................................. 20-735
BK-14 Failure code [D1C0KZ] (Brake cut relay: Disconnection or short circuit (KZ)) ........................ 20-736
BK-15 Failure code [D5ZFKZ] (Neutral signal 1: Disconnection or short circuit (KZ)) ........................ 20-737
BK-16 Failure code [D5ZGKZ] (Neutral signal 2: Disconnection or short circuit (KZ)) ....................... 20-738
BK-17 Failure code [DB10KK] (Retarder controller: Drop in power supply voltage, input (KK)) ........ 20-739
BK-18 Failure code [DB11KK] (Retarder controller main power supply line:
Drop in power supply voltage, input (KK)) ............................................................................... 20-740
BK-19 Failure code [DB12KK] (Retarder controller load power supply line:
BK-20 Failure code [DB13KK] (Retarder controller battery direct power supply line:
BK-21 Failure code [DB19KM] (Retarder controller wiring harness:
Mistaken operation or mistaken setting (KM)) ......................................................................... 20-743
BK-22 Failure code [DB1SKQ] (Retarder controller S-NET line:
Model selection signal mismatch (KQ)) .................................................................................. 20-744
BK-23 Failure code [DHU2KX] (Accumulator oil pressure sensor (front):
Input signal outside range (KX)) .............................................................................................. 20-745
BK-24 Failure code [DHU3KX] (Accumulator oil pressure sensor (rear):
Input signal outside range (KX)) .............................................................................................. 20-747
BK-25 Failure code [DK51L5] (Retarder lever potentiometer: * See separate table (BK)) .............. 20-749
BK-26 Failure code [DK52KX] (Dump lever potentiometer 1: Input signal outside range (KX)) ......... 20-752
BK-27 Failure code [DK53L8] (Dump lever potentiometer 2: * See Contents (L8)) ............................ 20-754
HM400-1 20-701
6
1
TROUBLESHOOTING
BK-28 Failure code [DK54KX] (Body positioner sensor: Input signal outside range (KX)) .............. 20-755
BK-29 Failure code [DLF4KA] (Transmission output shaft F speed sensor: Disconnection (KA)) ..... 20-757
BK-30 Failure code [DLT3KA] (Transmission output shaft R speed sensor: Disconnection (KA)) ..... 20-758
BK-31 Failure code [DW71KZ] (Exhaust brake solenoid: Disconnection or short circuit (KZ))
(Machine with exhaust brake) .................................................................................................. 20-759
BK-32 Failure code [DW72KZ] (Dump lever kick-out solenoid: Disconnection or short circuit (KZ)) . 20-760
BK-33 Failure code [DW73KZ] (Dump selector valve solenoid: Disconnection or short circuit (KZ)) 20-761
BK-34 Failure code [DX11KA] (Rear brake pressure reducing valve solenoid:
Disconnection (KA)) ................................................................................................................. 20-762
BK-35 Failure code [DX11KB] (Rear brake pressure reducing valve solenoid: Short circuit (KB)) .. 20-763
BK-36 Failure code [DX11KY] (Rear brake pressure reducing valve solenoid:
Short circuit in power supply line (KY)) .................................................................................... 20-764
BK-37 Failure code [DX12KA] (Front brake pressure reducing valve solenoid: Disconnection (KA)) 20-765
BK-38 Failure code [DX12KB] (Front brake pressure reducing valve solenoid: Short circuit (KB)) ... 20-766
BK-39 Failure code [DX12KY] (Front brake pressure reducing valve solenoid:
Short circuit in power supply line (KY)) .................................................................................... 20-767
BK-40 Failure code [DX13KA] (Dump EPC valve solenoid: Disconnection (KA)) ............................... 20-768
BK-41 Failure code [DX13KB] (Dump EPC valve solenoid: Short circuit (KB)) .................................. 20-769
BK-42 Failure code [DX13KY] (Dump EPC valve solenoid: Short circuit in power supply line (KY)) . 20-770
BK-43 Failure code [DX14KZ] (Rear differential lock solenoid: Disconnection or short circuit (KZ))
BK-44 Failure code [DX15KZ] (Front differential lock solenoid: Disconnection or short circuit (KZ))
BK-45 Parking brake does not work properly ..................................................................................... 20-774
* Failure phenomena of L Series problem codes (L*)*

Problem code Nature of problem (phenomenon, nature of problem that occurs)
20-702 HM400-1
6
1
TROUBLESHOOTING BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
20-704 HM400-1
41
"
★ This circuit diagram has been made by extracting the retarder controller related circuits and starting motor
related circuits from the overall electrical circuit diagram.
HM400-1 20-705
14
"
20-706 HM400-1
41
"
HM400-1 20-707
1"
4
20-708 HM400-1
41
"
HM400-1 20-709
1
4
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON

MACHINE FOR EACH FAILURE CODE
Failure
code
2A62L1 Front differential lock control valve: * Even when output to front differen- • Defective front differential lock oil
(BK-1) See Contents (L1) tial lock solenoid circuit is turned pressure switch
(Machine with differential lock differ- OFF, signal from front differential • Short circuit with chassis ground
ential) lock oil pressure switch remains ON in switch signal circuit wiring har-
ness
• Defective retarder controller (q1)
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 • Disconnection in switch signal cir-
ential) lock solenoid circuit when engine is cuit wiring harness
running, signal from front differential • Disconnection in switch GND cir-
lock oil pressure switch remains
cuit wiring harness
OFF
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
ential) pressure switch remains ON in switch signal circuit wiring har-
ness
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 • Disconnection in switch signal cir-
ential) lock solenoid circuit when engine is cuit wiring harness
running, signal from rear differential • Disconnection in switch GND cir-
lock oil pressure switch remains
cuit wiring harness
OFF
2C4MNX Brake cooling filter: Clogged (NX) When brake cooling oil temperature • Clogged brake cooling filter
(BK-5) went above 50°C when engine was (when system is working normal-
running, signal circuit of brake cool- ly)
ing filter clogging switch became • Defective brake cooling filter
open (shut off from GND) clogging switch
• Disconnection in switch signal cir-
cuit wiring harness
• Disconnection in switch GND cir-
cuit wiring harness
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
chassis ground in sensor power
source circuit wiring harness
chassis ground in sensor signal
20-710 HM400-1
6
1
Action
code
• Switch resistance value • Takes no action • No great effect on machine E01
B39 (male) (1) - (2):
• Oil pressure less than 0.39 MPa
{4 kg/cm2}: Min. 1 MΩ
• Oil pressure more than 0.59 MPa
{6 kg/cm2}: Max. 1Ω
B39 (male) (1) - (2):

B40 (male) (1) - (2):
B39 (male) (1) - (2):
• Switch resistance value • Takes no action • If machine continues to be used E01

B03 (male) (1) - (2): as it is, there is danger that dirt
• When normal: Max. 1Ω will circulate in brake cooling cir-
• When clogged: Min. 1 MΩ cuit
• Switch resistance value • Takes no action • If the machine is used as it is, E01
B28 (male) (1) - (2): there is danger that the brake will
• When normal: Max. 1Ω lose its effect
• When worn: Min. 1Ω
HM400-1 20-711
6
1
Failure
code
2D02CA Front brake (left): Wear (CA) When gearshift lever was at N posi- • Worn front brake (left) (when system is
(BK-7) tion, signal circuit of front brake working normally)
(left) wear switch became open • Defective front brake (left) wear switch
ground in sensor power source circuit wir-
ing harness
ground in sensor signal circuit wiring har-
ness
2D03CA Center brake (right): Wear (CA) When gearshift lever was at N posi- • Worn center brake (right) (when system is
(BK-8) tion, signal circuit of center brake working normally)
(right) wear switch became open • Defective center brake (right) wear switch
ground in sensor power source circuit wir-
ing harness
ness
2D04CA Center brake (left): Wear (CA) When gearshift lever was at N posi- • Worn center brake (left) (when system is
(BK-9) tion, signal circuit of center brake working normally)
(left) wear switch became open • Defective center brake (left) wear switch
ground in sensor power source
• circuit wiring harness
ness
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 working normally)
brake (right) wear switch became • Defective rear brake (right) wear switch
open
ness
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 working normally)
brake (left) wear switch became • Defective rear brake (left) wear switch
open
ness
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/
cm2} was input for front accumulator
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/
cm2} was input for rear accumulator
oil pressure sensor signal
20-712 HM400-1
6
1
• Switch resistance value • Takes no action • If the machine is used as it is, there E01
B01 (male) (1) - (2): is danger that the brake will lose its
• When normal: Max. 1Ω effect
• Takes no action • If the machine is used as it is, there E03

is danger that the brake will lose its
effect
• Takes no action • If the machine is used as it is, there E03

is danger that the brake will lose its
effect
HM400-1 20-713
1
Failure
code
D1C0KZ Brake cut relay: Disconnection or When output is sent to brake cut • Defective brake cut relay
(BK-14) short circuit (KZ) relay circuit, excessive electric cur- • Disconnection, short circuit with
rent flows; when there is output, no chassis ground, or short circuit
electric current flows; when output with power source in relay signal
is OFF, electric current flows circuit wiring harness
• Disconnection in relay GND cir-
cuit wiring harness
D5ZFKZ Neutral signal 1: Disconnection or When output is sent to neutral sig- • Defective transmission controller
(BK-15) short circuit (KZ) nal 1 circuit, excessive electric cur- • Disconnection or short circuit
rent flows; when there is output, no with chassis ground in signal 1
electric current flows circuit wiring harness
D5ZGKZ Neutral signal 2: Disconnection or When output is sent to neutral sig- • Defective transmission controller
(BK-16) short circuit (KZ) nal 2 circuit, excessive electric cur- • Disconnection or short circuit
rent flows; when there is output, no with chassis ground in signal 2
electric current flows circuit wiring harness
DB10KK Retarder controller (q1): Drop in Both main power source voltage • Other problem occurs at same
(BK-17) power source voltage, input (KK) circuit and direct power source time (failure code AB00MA is dis-
voltage circuit went below 17 V played)
• Battery tends to lose power
chassis ground in power source
circuit
• wiring harness
• Disconnection in GND circuit wir-
ing harness
DB11KK Retarder controller (q1) main power Voltage difference between main • Disconnection or short circuit with
(BK-18) supply line: Drop in power supply power source voltage circuit and chassis ground in main power
voltage, input (KK) direct power source voltage went source circuit wiring harness
below 5 V (main power source < • Defective retarder controller (q1)
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 • Disconnection or short circuit with
voltage, input (KK) power source voltage circuit went chassis ground in relay power
below 17 V source circuit wiring harness
chassis ground in relay output cir-
cuit wiring harness
DB13KK Retarder controller (q1) battery Voltage of direct power source volt- • Disconnection or short circuit with
(BK-20) direct power supply line: Drop in age circuit went below 5 V chassis ground in direct power
power supply voltage, input (KK) source circuit wiring harness
DB19KM Retarder controller (q1) wiring har- When starting switch is ON, input • Mistaken connection of connec-
(BK-21) ness: Mistaken operation or mis- connector check signal does not tor BRC3 (A, B) and connector
taken setting (KM) match setting inside controller BRC5 (A, B) (when system is
working normally)
• Disconnection in signal 2 circuit
wiring harness
20-714 HM400-1
6
1
Action
code
• Relay resistance value • Turns output to brake cut relay • The whole system of the retarder E03
R14 (male) (1) - (2): 100 - 500Ω OFF controller (q1) stops working (re-
tarder, inter-axle differential lock,
left and right differential lock, dump,
exhaust brake, neutral signal)
• Failure codes (DB12KK,
DHU2KX, DHU3KX) are dis-
played at same time
• Turns neutral signal 1 and signal • Even when transmission output E01
2 OFF shaft F speed goes above 4200
rpm, the transmission does not
shift to N
• Turns neutral signal 1 and signal • Even when transmission output E01
2 OFF shaft F speed goes above 4200
shift to N
• Main power source voltage • Takes no action (moves as long • No great effect on machine E03
BRC1 (9)(17) - (8)(16): 20 - 30 V as 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 sen- controller (q1) stops working (re-
20 - 30 V sor OFF tarder, inter-axle differential lock,
• 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: • Does not record in trouble data controller (q1) stops working (re-
Max. 1Ω tarder, inter-axle differential lock,
• Failure codes (DB12KK, DHU2KX,
DHU3KX) are displayed at same
time
HM400-1 20-715
6
1
Failure
code
DB1SKQ Retarder controller (q1) S-NET Communication (S-NET) with • Other problem occurs at same time (failure
(BK-22) line: Model selection signal mis- transmission controller is defec- codes [DAFSKQ] [DAQAKR] [DAQSKQ] is
match (KQ) tive and it is impossible to obtain displayed)
model selection data
• Disconnection in S-NET circuit wiring har-
ness
DHU2KZ Accumulator oil pressure sensor Voltage of signal circuit of front • Defective front accumulator oil pressure sensor
(BK-23) (front): Input signal outside range accumulator oil pressure sensor • Disconnection or short circuit with chassis
(KX) went below 0.5 V or above 4.5 V ground in sensor power source circuit wiring
harness
harness
sensor signal circuit wiring harness
DHU3KX Accumulator oil pressure sensor Voltage of signal circuit of rear • Defective rear accumulator oil pressure sensor
(BK-24) (rear): Input signal outside range accumulator oil pressure sensor • Disconnection or short circuit with chassis
(KX) went below 0.5 V or above 4.5 V ground in sensor power source circuit wiring
harness
harness
DK51L5 Retarder lever potentiometer: * Signal voltage of potentiometer of • Defective retarder lever (q2) (potentiometer,
(BK-25) See separate table (BK) retarder lever circuit went below switch)
0.3 V or above 4.7 V, or potenti- • Disconnection, short circuit with chassis
ometer signal and switch signal
do not match ground, or short circuit with power source
in potentiometer power source circuit signal
• Disconnection in potentiometer GND circuit
wiring harness
potentiometer signal signal circuit wiring har-
ness
switch 1 circuit wiring harness
switch 2 circuit wiring harness
harness
DK52KX Du mp leve r po te ntio meter 1 : Voltage of potentiometer 1 signal • Defective dump lever (potentiometer)
(BK-26) Input signal outside range (KX) circuit or potentiometer 2 signal • Disconnection, short circuit with chassis
circuit went below 0.3 V or above ground, or short circuit with power source in
4.7 V
power source circuit wiring harness
signal 1 circuit wiring harness
q2. The lever is not installed in E-SPEC.
20-716 HM400-1
6
1
• Only inter-axle differential lock sys- • Inter-axle differential lock system E03
tem is not controlled does not work
• Sensor power source voltage • Takes no action • No great effect on machine E01
B25 (2) - (1): 20 - 30 V
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
B24 (3) - (1): 1.8 - 3.5 V
• Potentiometer power source voltage Depending on condition of occurrence Depending on nature of action E01
RTL (1) - (3): 4.1 - 4.8 V of failure • No great effect on machine
• Potentiometer signal voltage • Carries out control with potentiom- • Fine control of retarder is impossi-
RTL (2) - (3): 0.3 - 4.7 V eter signal ble (which is not used in E-SPEC)
• Switch resistance value • Limits output to solenoid to 70% • Retarder does not work (foot brake
(lever at RELEASED position) • Turns output to solenoid OFF works) (which is not used in E-
• RTL (male) (4) - (6): Max. 1Ω SPEC)
• RTL (male) (5) - (6): Min. 1 MΩ
• Switch resistance value (lever at
APPLIED position)
• RTL (male) (4) - (6): Min. 1 MΩ
• RTL (male) (5) - (6): Max. 1Ω
• Potentiometer power source volt- Recognizes dump lever position as • Dump body does not move E03
age 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
HM400-1 20-717
6
1
Failure
code
DK53L8 Dump lever potentiometer 2: * Total voltage of potentiometer 1 • Defective dump lever (potentiometer)
(BK-27) See Contents (L8) signal circuit and potentiometer 2 • Disconnection, short circuit with chassis
signal circuit went below 4.4 V or ground, or short circuit with power source in
above 5.6 V
power source circuit wiring harness
DK54KX Body positioner sensor: Input sig- Voltage of body positioner sensor • Defective body positioner sensor
(BK-28) nal outside range (KX) signal circuit went below 0.3 V or • Disconnection, short circuit with chassis
above 4.7 V ground, or short circuit with power source in
sensor power source circuit wiring harness
harness
DLF4KA Tra n s m is s i o n o u tp u t s h a f t F Disconnection has occurred in • Defective transmission output shaft F speed
(BK-29) speed sensor : Disconnection signal circuit of transmission out- sensor or defective adjustment
(KA) put shaft F speed sensor and • Disconnection in sensor signal wiring har-
signal is not input
ness
harness
DLT3KA Tra n s m is s i o n o u tp u t s h a f t R Disconnection has occurred in • Defective transmission output shaft R speed
(BK-30) speed sensor : Disconnection signal circuit of transmission out- sensor or defective adjustment
(KA) put shaft R speed sensor and • Disconnection in sensor signal wiring har-
signal is not input
ness
harness
DW71KZ Exhaust brake solenoid: Discon- When output is sent to exhaust • Defective exhaust brake solenoid
(BK-31) nection or short circuit (KZ) brake solenoid circuit, excessive • Disconnection, short circuit with chassis
(Machine with exhaust brake) electric current flows; when there ground, or short circuit with
is o utp ut, no elec tr ic curre nt
flows; when output is OFF, elec- • power source in solenoid signal circuit wiring
tric current flows harness
• Disconnection in solenoid GND circuit wiring
harness
DW72KZ Dump lever kick-out solenoid: When output is sent to dump • Defective dump lever (kick-out solenoid)
(BK-32) Disconnection or shor t circuit lever kick-out solenoid circuit, • Disconnection, short circuit with chassis
(KZ) excessive electric current flows; ground, or short circuit with power source in
when there is output, no electric
current flows; when output is solenoid signal circuit wiring harness
OFF, electric current flows • Disconnection in solenoid GND circuit wiring
harness
DW73KZ Dump selector valve solenoid: When output is sent to dump • Defective dump pilot valve (selector sole-
(BK-33) Disconnection or shor t circuit selector valve solenoid circuit, noid)
(KZ) excessive electric current flows; • Disconnection, short circuit with chassis
when there is output, no electric
current flows; when output is ground, or short circuit with power source in
OFF, electric current flows solenoid signal circuit wiring harness
• Disconnection in solenoid GND circuit wiring
harness
20-718 HM400-1
6
1
• Potentiometer power source volt- • Recognizes dump lever position as • Dump body does not move E03
age 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
• Sensor power source voltage • Carries out dump control according • here is a big shock when dump E03
B34 (3) - (1): 4.6 - 5.4 V 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 lim-
When fully raised: 4.00 - 4.70 V ited
• 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
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-out • Dump lever is not locked in detent E01
LKO (male) (1) - (2): 39Ω ± 5% 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
HM400-1 20-719
1
Failure
code
DX11KA Rear brake pressure reducing valve When output is sent to rear brake • Defective rear brake pressure re-
(BK-34) solenoid: Disconnection (KA) pressure reducing valve solenoid cir- ducing valve solenoid
cuit, no electric current flows • Disconnection in solenoid (+) circuit
wiring harness
• Disconnection in solenoid (–) cir-
cuit wiring harness
DX11KB Rear brake pressure reducing valve When output is sent to rear brake • Defective rear brake pressure re-
(BK-35) solenoid: Short circuit (KB) pressure reducing valve solenoid cir- ducing valve solenoid
cuit, excessive electric current flows • Short circuit or short circuit with
chassis ground in solenoid (+) cir-
cuit wiring harness
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 source reducing valve solenoid circuit is OFF, solenoid (+) circuit wiring harness
line (KY) electric current flows • Short circuit with power source in
solenoid (–) circuit wiring harness
DX12KA Front brake pressure reducing valve When output is sent to front brake • Defective front brake pressure re-
(BK-37) solenoid: Disconnection (KA) pressure reducing valve solenoid cir- ducing valve solenoid
cuit, no electric current flows • Disconnection in solenoid (+) circuit
wiring harness
wiring harness
DX12KB Front brake pressure reducing valve When output is sent to front brake • Defective front brake pressure re-
(BK-38) solenoid: Short circuit (KB) pressure reducing valve solenoid cir- ducing valve solenoid
cuit, excessive electric current flows • Short circuit or short circuit with
cuit wiring harness
DX12KY Front brake pressure reducing valve When output to front brake pressure • Short circuit with power source in
(BK-39) solenoid: Shor t 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
DX13KA Dump EPC valve solenoid: Discon- When output is sent to dump EPC • Defective dump pilot valve (EPC
(BK-40) nection (KA) valve solenoid circuit, no electric cur- solenoid)
rent flows • Disconnection in solenoid (+) circuit
wiring harness
wiring harness
20-720 HM400-1
6
1
• Solenoid resistance value • Turns output to rear brake pressure • Rear brake (center brake, rear E03
B18 (male) (1) - (2): 10~30Ω reducing valve solenoid OFF brake) does not work
• Solenoid resistance value • Turns output to rear brake pressure • Rear brake (center brake, rear E03
B18 (male) (1) - (2): 10~30Ω reducing valve solenoid OFF brake) does not work
• Turns output to rear brake pressure • The whole system of the retarder E03
reducing valve solenoid OFF controller (q1) stops working (re-
• Turns output to brake cut relay OFF tarder, inter-axle differential lock, left
and right differential lock, dump, ex-
haust brake, neutral signal)
time
• Solenoid resistance value • Turns output to front brake pres- • Front brake does not work E03
B19 (male) (1) - (2): 10~30Ω sure reducing valve solenoid OFF
• Solenoid resistance value • Turns output to front brake pres- • Front brake does not work E03
B19 (male) (1) - (2): 10~30Ω sure reducing valve solenoid OFF
• • Turns output to front brake pres- • The whole system of the retarder E03
sure reducing valve solenoid OFF controller (q1) stops working (re-
• Turns output to brake cut relay OFF tarder, inter-axle differential lock, left
and right differential lock, dump, ex-
haust brake, neutral signal)
time
• Solenoid resistance value • Turns output to dump selector • Dump body does not work E03
B32 (male) (1) - (2): Approx. 5~20Ω valve solenoid OFF
solenoid OFF
HM400-1 20-721
6
1
Failure
code
DX13KB Dump EPC valve solenoid: Short cir- When output is sent to dump EPC • Defective dump pilot valve (EPC
(BK-41) cuit (KB) valve solenoid circuit, excessive elec- solenoid)
tric current flows • Short circuit or short circuit with
cuit wiring harness
DX13KY Dump EPC valve solenoid: Short cir- When output to dump EPC valve sole- • Short circuit with power source in
(BK-42) cuit in power source line (KY) noid circuit is OFF, electric current solenoid (+) circuit wiring harness
flows • Short circuit with power source in
solenoid (-) circuit wiring harness
DX14KZ Rear differential lock solenoid: Dis- When output is sent to rear differential • Defective rear differential lock sole-
(BK-43) connection or short circuit (KZ) lock solenoid circuit, excessive elec- noid
(Machine with differential lock differen- tric current flows; when there is out- • Disconnection, short circuit with
tial) put, no electric current flows; when
output is OFF, electric current flows chassis ground, or short circuit
with power source in solenoid sig-
• Disconnection in solenoid GND cir-
cuit wiring harness
DX15KZ Front differential lock solenoid: Dis- When output is sent to front differen- • efective front differential lock sole-
(BK-44) connection or short circuit (KZ) tial lock solenoid circuit, excessive noid
(Machine with differential lock differen- electric current flows; when there is • Disconnection, short circuit with
tial) output, no electric current flows; when
output is OFF, electric current flows chassis ground, or short circuit
with power source in solenoid sig-
• Disconnection in solenoid GND cir-
cuit wiring harness
20-722 HM400-1
6
1
• Solenoid resistance value • Turns output to dump selector • Dump body does not work E03
B32 (male) (1) - (2): 15~20Ω valve solenoid OFF
solenoid OFF
• Turns output to dump selector • Dump body does not work E03
valve solenoid OFF
solenoid OFF
• Solenoid resistance value • Turns output to rear differential lock • Rear differential lock (center differ- E03
B36 (male) (1) - (2): 15~30Ω solenoid OFF ential, rear differential) does not
work
• Solenoid resistance value • Turns output to front differential • Front differential lock does not work E03
B35 (male) (1) - (2): 15~30Ω lock solenoid OFF
HM400-1 20-723
1
TROUBLESHOOTING BK-1
BK-1 Failure code [2A62L1] (Front differential lock control valve: * See Contents (L1))
★ Nature of failure: Even when the output to the front differential lock solenoid circuit is turned OFF, the signal
from the front differential lock oil pressure switch remains ON
Cause Remedy
1 Carry out
• Start engine. NO troublesho
• Turn differential lock Is front differential lock Defective hydraulic, mechanical
canceled? system of front differential lock oting for
OFF. hydraulic,
YES mechanical
system
2
• Turn starting switch Is resistance between BRC5A NO
OFF. (female) (11) and ground more
• Disconnect BRC5A. than 1 M ?
YES
Defective retarder controller (q1) Replace
3
• Turn starting switch
OFF. Is resistance between B39 (male) NO Defective front differential lock oil Replace
• Disconnect B39. (1) and ground more than 1 M pressure switch

in wiring harness between Repair or
BRC5A (female) (11) and B39 replace
(female) (1)
BK-1 Related electrical circuit diagram
20-724 HM400-1
6
1
BK-2 Failure code [2A62LH] (Front differential lock control valve: * See Contents (LH))
★ Nature of failure: When at least 30 seconds have passed after starting the engine, even if output is sent to
the front differential lock solenoid circuit when the engine is running, the signal from the
front differential lock oil pressure switch remains OFF
Cause Remedy
Carry out
• Start engine. NO troubleshoo
Is front differential lock actuated? Defective hydraulic, mechanical ting for
• Turn differential lock ON.
system of front differential lock hydraulic,
mechanical
YES system
• Insert T-adapter to BRC5A. Is voltage between BRC5A (female) (11) NO

• Start engine. and ground less than 1 V after more than 2
• Turn differential lock ON. minutes have passed in condition on left?
YES
• Disconnect B39. Is resistance between B39 (male) (1) NO Defective front differential lock
• Start engine. Replace
and (2) less than 1 MΩ? oil pressure switch
YES
• Turn starting switch OFF. Is resistance between B39 (female) NO disconnection in wiring harness Repair or
• Disconnect B39. (2) and ground less than 1 MΩ? between B39 (female) (2) and replace
ground
between BRC5A (fe-male) (11) replace
and B39 (female) (1)

HM400-1 20-725
6
1
BK-3 Failure code [2B62L1] (Rear differential lock control valve: * See Contents (L1))
★ Nature of failure: Even when the output to the rear differential lock solenoid circuit is turned OFF, the signal
from the rear differential lock oil pressure switch remains ON
Cause Remedy
1
Carry out
• Start engine. NO
Is rear differential lock canceled? Defective hydraulic, mechanical troublesho
• Turn differential lock
system of rear differential lock oting for
OFF. hydraulic,
YES mechanical
system
2
• Turn starting switch Is resistance between BRC5A NO
OFF. (female) (12) and ground more
• Disconnect BRC5A. than 1 M ?
YES
3
OFF. Is resistance between B40 (male) NO Defective center differential lock oil
(1) and ground more than 1 M Replace
• Disconnect B40. pressure switch

in wiring harness between Repair or
BRC5A (female) (12) and B40 replace
(female) (1)

20-726 HM400-1
6
1
BK-4 Failure code [2B62LH] (Rear differential lock control valve: * See Contents (LH))
★ Nature of failure: When at least 30 seconds have passed after starting the engine, even if output is sent to
the rear differential lock solenoid circuit when the engine is running, the signal from the rear
differential lock oil pressure switch remains OFF
Cause Remedy
Carry out
• Start engine. NO troubleshoo
Is rear differential lock actuated? Defective hydraulic, mechanical ting for
system of rear differential lock hydraulic,
YES mechanical
system
• Insert T-adapter to Is voltage between BRC5A
BRC5A. (female) (12) and ground less than NO
• Start engine. 1 V after more than 2 minutes
• Turn differential lock ON. have passed in condition on left?

YES
• Disconnect B40. Is resistance between B40 (male) NO Defective front differential lock
• Start engine. Replace
(1) and (2) less than 1 MΩ? oil pressure switch
YES
• Turn starting switch OFF. Is resistance between B40 NO disconnection in wiring harness Repair or
• Disconnect B40. (female) (2) and ground less than between B40 (female) (2) and replace
1 MΩ? ground
between BRC5A (fe-male) (12) replace

HM400-1 20-727
6
1
BK-5 Failure code [2C4MNX] (Brake cooling filter: Clogged (NX))
★ Nature of failure: When the brake cooling oil temperature went above 50°C when the engine was running,
the signal circuit of the brake cooling filter clogging switch became open (shut off from
GND)
Cause Remedy
NO
• Stop engine. Is brake cooling filter clogged?
YES Clean or
Clogged brake cooling filter replace

OFF. Is resistance between B03 (male) NO Defective brake cooling filter
(1) and (2) less than 1 MΩ? clogging sensor Replace
• Disconnect B03.
YES
• Turn starting switch Is resistance between B03 NO disconnection in wiring harness Repair or
OFF. (female) (2) and ground less than between B03 (female) replace
• Disconnect B03. 1 MΩ? (2) and ground
YES
• Turn starting switch Is resistance between BRC5A NO disconnection in wiring harness Repair or
OFF. (male) (9) and ground less than between BRC5A (fe- replace
• Disconnect BRC5A. 1 MΩ? male) (9) and B03 (female) (1)
YES

20-728 HM400-1
(7)
1
BK-6 Failure code [2D01CA] (Front brake (right): Wear (CA))
★ Nature of failure: When the gearshift lever was at the N position, the signal circuit of the front brake (right)
wear switch became open 1. Is front brake (right) worn?
Cause Remedy
• Stop engine. NO
• See TESTING AND Is front brake (right) worn?
ADJUSTING.
YES
Worn front brake (right) Replace disc

OFF. Is resistance between B28 (male) NO Defective front brake (right)
(1) and (2) less than 1 MΩ? wear switch Replace
• Disconnect B28.
YES
• Disconnect B28. Is voltage between B28 (female) NO

• Turn starting switch (1) and ground 20 - 30 V?
ON.
YES

• Turn starting switch OFF. Is resistance between B28 NO in wiring harness between Repair or
• Disconnect BRC1 and (female) (1) and ground more BRC1 (female) replace
B28. than 1 MΩ? (1) and B28 (female) (1)
YES
• Disconnect B28.
• Turn starting switch Is voltage between BRC1 (1) and NO Defective retarder controller (q1) Replace
ON. ground 20 - 30 V?
between BRC1 (female) replace
(1) and B28 (female) (1)
• Insert T-adapter to Is voltage between BRC5B (3) NO or short circuit with chassis Repair or
BRC5B. ground in wiring harness between
BRC5B (female) (3) and B28
YES (female) (2)
HM400-1 20-729
6
1
BK-7 Failure code [2D02CA] (Front brake (left): Wear (CA))
★ Nature of failure: When the gearshift lever was at the N position, the signal circuit of the front brake (left)
wear switch became open 1. Is front brake (left) worn?
Cause Remedy
• Stop engine. NO
• See TESTING AND Is front brake (left) worn?
ADJUSTING.
YES
Worn front brake (left) Replace disc

OFF. Is resistance between B01 (male) NO Defective front brake (left) wear
(1) and (2) less than 1 MΩ? switch Replace
• Disconnect B01.
YES

ON.
YES

YES
• Disconnect B01.
YES (female) (2)

20-730 HM400-1
6
1
BK-8 Failure code [2D03CA] (Center brake (right): Wear (CA))
★ Nature of failure: When the gearshift lever was at the N position, the signal circuit of the center brake (right)
wear switch became open
Cause Remedy
• Stop engine. NO
• See TESTING AND Is center brake (right) worn?
ADJUSTING.
YES
Worn center brake (right) Replace disc

OFF. Is resistance between B26 (male) NO Defective center brake (right)
• Disconnect B26.
YES

ON.
YES

YES
• Disconnect B26.
YES (female) (2)

HM400-1 20-731
6
1
BK-9 Failure code [2D04CA] (Center brake (left): Wear (CA))
★ Nature of failure: When the gearshift lever was at the N position, the signal circuit of the center brake (left)
Cause Remedy
• Stop engine. NO
• See TESTING AND Is center brake (left) worn?
ADJUSTING.
YES
Worn center brake (left) Replace disc

OFF. Is resistance between B02 (male) NO Defective center brake (left)
• Disconnect B02.
YES

ON.
YES

YES
• Disconnect B02.
YES (female) (2)

20-732 HM400-1
6
1
BK-10 Failure code [2D05CA] (Rear brake (right): Wear (CA)
★ Nature of failure: When the gearshift lever was at the N position, the signal circuit of the rear brake (right)
Cause Remedy
• Stop engine. NO
• See TESTING AND Is rear brake (right) worn?
ADJUSTING.
YES
Wornrear brake (right) Replace disc

OFF. Is resistance between B02 (male) NO Defective rear brake (right)
• Disconnect B05.
YES

ON.
YES

YES
• Disconnect B05.
YES (female) (2)

HM400-1 20-733
6
1
BK-11 Failure code [2D06CA] (Rear brake (left): Wear (CA))
★ Nature of failure: When the gearshift lever was at the N position, the signal circuit of the rear brake (left) wear
switch became open
Cause Remedy
• Stop engine. NO
• See TESTING AND Is rear brake (left) worn?
ADJUSTING.
YES
Wornrear brake (left) Replace disc

OFF. Is resistance between B08 (male) NO Defective rear brake (left) wear
(1) and (2) less than 1 MΩ? switch Replace
• Disconnect B08.
YES

ON.
YES

YES
• Disconnect B08.
YES (female) (2)

20-734 HM400-1
6
1
TROUBLESHOOTING BK-12, BK-13
BK-12 Failure code [2G42ZG] (Accumulator (front): Drop in oil pressure (ZG))
★ Nature of failure: With the engine running (continuously for at least 30 seconds), oil pressure of less than
6.86 MPa {70 kg/cm2} was input for the front accumulator oil pressure sensor signal
Cause Remedy
Defective retarder controller (q1)

• See TESTING AND Has accumulator oil pressure NO
ADJUSTING. (brake oil pressure) dropped? Repair
YES Carry out

Defective hydraulic, mechanical troubleshooting
system of accumulator oil of mechanical
pressure (brake oil pressure) system
BK-13 Failure code [2G43ZG] (Accumulator (rear): Drop in oil pressure (ZG))
★ Nature of failure: With the engine running (continuously for at least 30 seconds), oil pressure of less than
6.86 MPa {70 kg/cm2} was input for the rear accumulator oil pressure sensor signal
Cause Remedy
Defective retarder controller (q1)

• See TESTING AND Has accumulator oil pressure NO
ADJUSTING. (brake oil pressure) dropped? Repair
YES Defective hydraulic, mechanical Carry out

system of accumulator oil troubleshooting
pressure (brake oil pressure) of mechanical
system
HM400-1 20-735
6
1
BK-14 Failure code [D1C0KZ] (Brake cut relay: Disconnection or short circuit (KZ))
★ Nature of failure: When output is sent to the brake cut relay circuit, excessive electric current flows; when
there is output, no electric current flows; when the output is OFF, electric current flows
Cause Remedy
• Turn starting switch OFF. Is resistance between BRC1 (female) NO

• Disconnect BRC1. (13) and ground 100 - 500 MΩ?
YES

• Turn starting switch ON. brake cut relay (R14) is interchanged
with other relay?
YES
Defective brake cut relay (R14) Replace

• Disconnect BRC1 and Is resistance between BRC1 (female) NO ground in wiring harness be- Repair or
(13) and ground more than 1 MΩ? tween BRC1 (female) (13) and replace
R14. R14 (female) (1)
YES
NO Defective contact or disconnec-

• Turn starting switch OFF. Is resistance between R14 (female) tion in wiring harness between Repair or
• Disconnect R14. (2) and ground less than 1 MΩ? R14 (female) (2) and ground replace
.
between BRC1 (female) (13) and replace
R14 (female) (1)

• Turn starting switch OFF. Is resistance between CN4 (female) NO wiring harness between BRC1 Repair or
• Disconnect CN4 (solenoid). (6) and ground more than 1 MΩ? (female) (13) and R14 (female) replace
(1)
YES

20-736 HM400-1
6
1
BK-15 Failure code [D5ZFKZ] (Neutral signal 1: Disconnection or short circuit (KZ))
★ Nature of failure: When output is sent to the neutral signal 1 circuit, excessive electric current flows; when
there is output, no electric current flows
Cause Remedy
• Turn starting switch OFF. Is resistance between BRC1 NO disconnection in wiring
• Disconnect BRC1 and (female) (6) and ATC5A (female) (7) Repair or
harness between BRC1 replace
ATC5A. less than 1 Ω? (female) (6) and ATC5A
YES (female) (7)
• Turn starting switch OFF. Is resistance between BRC1 Short circuit with chassis
• Disconnect BRC1 and (female) (6) and ground more than 1
ATC5A. Ω? between BRC1 (female) replace
YES

• Disconnect BRC1 and Is voltage between BRC1 (female) NO in wiring harness between Repair or
ATC5A. (6) and ground less than 1 V? BRC1 (female) (6) and ATC5A replace
YES

• Turn starting switch ON. when retarder controller is Defective transmission Repair
replaced? controller
YES
Defective retarder controller (q1) Repair
HM400-1 20-737
6
1
BK-16 Failure code [D5ZGKZ] (Neutral signal 2: Disconnection or short circuit (KZ))
★ Nature of failure: When output is sent to the neutral signal 2 circuit, excessive electric current flows; when
there is output, no electric current flows
Cause Remedy
• Turn starting switch OFF. Is resistance between BRC1 NO disconnection in wiring
• Disconnect BRC1 and (female) (15) and ATC5A (female) Repair or
harness between BRC1 replace
ATC5A. (8) less than 1 Ω? (female) (15) and ATC5A
YES (female) (8)
• Turn starting switch OFF. Is resistance between BRC1 Short circuit with chassis
• Disconnect BRC1 and (female) (15) and ground more than
ATC5A. 1 Ω? between BRC1 (female) replace
YES

• Disconnect BRC1 and Is voltage between BRC1 (female) NO in wiring harness between Repair or
ATC5A. (15) and ground less than 1 V? BRC1 (female) (15) and replace
• Turn starting switch ON. ATC5A (female) (8)
YES

• Turn starting switch ON. when retarder controller is Defective transmission Repair
replaced? controller
YES
Defective retarder controller (q1) Repair
20-738 HM400-1
6
1
BK-17 Failure code [DB10KK] (Retarder controller: Drop in power supply voltage, input (KK))
★ Nature of failure: Both the main power source voltage circuit and the direct power source voltage circuit
went below 17 V
★ Before starting troubleshooting, check that the circuit breaker is not OFF, and that the fusible link, fuse
BT2-22, and fuse BT3-12 are normal (if the circuit breaker is OFF or any fuse is blown, there has probably
Cause Remedy
• Turn starting switch ON. Is other failure code [AB00MA] NO

• Operate machine displayed or recorded at same time?
monitor. Go to
YES troubleshoo
Another problem is occurring at ting for
the same time displayed
code
• Insert T-adapter to BRC1. Is voltage between BRC1 (7) and (8) (16) NO
• Start engine (mid-range and between BRC (9)(17) and (8) (16) 20
speed). - 30 V?
YES

• Turn starting switch OFF. Is resistance between BRC1 (female) NO tion in wiring harness between Repair or
• Disconnect BRC1. (8)(16) and ground less than 1 MΩ? BRC1 (female) (8) (16) and replace
ground
YES
Is voltage of battery more than 24V NO Defective battery or defective Charge or

• Turn starting switch OFF. replace
and gravity more than 1.26? charge
between battery - battery relay - Repair or
retarder controller BRC1 (female) replace
(7) (9) (17) I. Repair or replace
HM400-1 20-739
6
1
BK-18 Failure code [DB11KK] (Retarder controller main power supply line: Drop in
★ Nature of failure: The voltage difference between the main power source voltage circuit and the direct pow-
er source voltage went below 5 V (main power source < direct power source)
★ Before starting troubleshooting, check that the circuit breaker is not OFF, and that fuse BT3-12 is normal
(if the circuit breaker is OFF or the fuse is blown, there has probably been a surge of current caused by a
short circuit, so check the related circuits).
Cause Remedy
1
Is voltage between BRC (9)(17)
BRC1. and (8)(16) 20 - 30 V?
YES
2 Defective contact or disconnection

• Remove fuse BT3-12. Is voltage between fuse BT3-12 NO in wiring harness between fuse Repair or
• Turn starting switch inlet and ground 20 - 30 V? BT3-12 inlet - circuit breaker - replace
ON. battery relay terminal M
in wiring harness between fuse replace
BT3-12 outlet and BRC1 (female)
(9) (17)
20-740 HM400-1
6
1
BK-19 Failure code [DB12KK] (Retarder controller load power supply line: Drop in
★ Nature of failure: When the controller power source voltage circuit was normal, the solenoid power source
voltage circuit went below 17 V
Cause Remedy
• Turn starting switch ON. Is other failure code [D1C0KZ] NO

• Operate machine displayed or recorded at same time?
monitor.
Go to
YES troubleshoo
Another problem is occurring at
the same time ting for
displayed
code
• Insert T-adapter to BRC1 NO
and BRC2. Is voltage between BRC2 (1)(12) - BRC1
• Turn starting switch ON. (8)(16) 20 - 30 V?
YES

• Turn starting switch ON. brake cut relay (R14) is interchanged
with other relay?
YES
Defective brake cut relay (R14) Replace
• Disconnect R14. Is voltage between R14 (female) (5) NO disconnection in wiring harness Repair or
• Turn starting switch ON. and ground 20 - 30 V? between fuse BT3-12 outlet replace
and R14 (female) (5)
BRC2 (female) (1) (12)

HM400-1 20-741
6
1
BK-20 Failure code [DB13KK] (Retarder controller battery direct power supply line:
Drop in power supply voltage, input (KK))
★ Nature of failure: The voltage of the direct power source voltage circuit went below 5 V
★ Before starting troubleshooting, check that the fusible link and fuse BT2-22 are normal (if the fuse is blown,
there has probably been a surge of current caused by a short circuit, so check the related circuits).
Cause Remedy
1
Is voltage between BRC1 (7)
BRC1. and (8)(16) 20 - 30 V?
YES

• Remove fuse BT2-22. Is voltage between fuse BT2-22 NO in wiring harness between fuse Repair or
• Turn starting switch inlet and ground 20 - 30 V? BT2-22 inlet - fusible link - battery replace
ON. relay terminal B
YES Defective contact or disconnection
in wiring harness between fuse Repair or
BT2-22 outlet and BRC1 (female) replace
(7)
20-742 HM400-1
6
1
BK-21 Failure code [DB19KM] (Retarder controller wiring harness: Mistaken opera-
tion or mistaken setting (KM))
★ Nature of failure: When the starting switch is ON, the input connector check signal does not match the set-
ting inside the controller
Cause Remedy
Are connectors BRC3 (A, B) and NO

• Turn starting switch OFF. BRC5 (A, B) connected in correct Mistaken connection of Connect
position? controller connector again
YES
Is resistance between BRC5A NO Defective contact or disconnection Repair or

• Turn starting switch OFF. in wiring harness between BRC5A
• Disconnect BRC5A. (female) (1) and ground less than replace
1Ω? (female) (1) and ground
YES
HM400-1 20-743
6
1
BK-22 Failure code [DB1SKQ] (Retarder controller S-NET line: Model selection signal
mismatch (KQ))
★ Nature of failure: The communication (S-NET) with the transmission controller is defective and it is impos-
sible to obtain the model selection data
Cause Remedy
1
• Turn starting switch ON. Is other failure code [DAFSKQ] NO
• Operate machine [DAQAKQ] [DAQSKR] displayed
monitor. or recorded at same time? Go to
YES Another problem is occurring at troublesho
the same time Defective oting for
retarder controller displayed
code
2
• Turn starting switch when retarder controller is
ON.
replaced?
YES
20-744 HM400-1
6
1
BK-23 Failure code [DHU2KX] (Accumulator oil pressure sensor (front): Input signal outside
range (KX))
★ Nature of failure: The voltage of the signal circuit of the front accumulator oil pressure sensor went below
0.5 V or above 4.5 V
Cause Remedy
• Insert T-adapter to Is voltage between BRC3B (5) and NO

BRC3A and BRC3B. BRC3A (16) 0.5 - 4.5 V?
YES
• Disconnect B25. Is voltage between B25 (female) (2) NO

YES

• Turn starting switch OFF. NO ground in wiring harness be- Repair or
• Disconnect BRC1 and Is resistance between B25 (female)
(2) and ground less than 1 MΩ? tween BRC1 (female) replace
B25. (1) and B25 (female) (2)
YES
NO Defective retarder controller (q1)

• Insert T-adapter to BRC1. Is voltage between BRC1 (1) and Replace
• Disconnect B25. ground 20 - 30 V?
B25 (female) (2)
• Turn starting switch OFF. Is resistance between B25 (female) NO

• Disconnect B25. (1) and ground less than 1 Ω?
YES
• Turn starting switch OFF. Is resistance between BRC3A NO disconnection in wiring harness Repair or
• Disconnect BRC3A and (female) (16) and B25 (female) (3) between BRC3A (female) (16) replace
B25. less than 1 Ω? and B25 (female) (1)
YES
• Insert T-adapter to B25. Is voltage between B25 (3) and NO

between BRC3B (female) (5) replace
• Disconnect BRC3B and NO Short circuit with power source in

Is voltage between B25 (female) (3) wiring harness between BRC3B Repair or
B25. and ground less than 1 V? replace
• Turn starting switch ON. (female) (5) and B25 (female) (3)
YES

• Turn starting switch OFF. Is resistance between B25 (female) NO in wiring harness between Repair or
• Disconnect BRC3B and (3) and ground more than 1 MΩ? BRC3B (female) (5) and B25 replace
B25. (female) (3)
Defective front accumulator oil

pressure sensor Replace
HM400-1 20-745
6
1
20-746 HM400-1
1
BK-24 Failure code [DHU3KX] (Accumulator oil pressure sensor (rear): Input signal out-
side range (KX))
★ Nature of failure: The voltage of the signal circuit of the rear accumulator oil pressure sensor went below 0.5
V or above 4.5 V
Cause Remedy

YES
• Disconnect B24. Is voltage between B25 (female) (2) NO

YES

• Turn starting switch OFF. NO ground in wiring harness be- Repair or
• Disconnect BRC1 and Is resistance between B24 (female)
(2) and ground less than 1 MΩ? tween BRC1 (female) replace
B24. (1) and B24 (female) (2)
YES
NO Defective retarder controller (q1)

• Insert T-adapter to BRC1. Is voltage between BRC1 (1) and Replace
• Disconnect B24. ground 20 - 30 V?
B24 (female) (2)

YES
YES

• Disconnect BRC3B and NO Short circuit with power source in

Is voltage between B24 (female) (3) wiring harness between BRC3B Repair or
B24 and ground less than 1 V? replace
• Turn starting switch ON. (female) (6) and B24 (female) (3)
YES

• Turn starting switch OFF. NO in wiring harness between Repair or
• Disconnect BRC3B and Is resistance between B24 (female)
(3) and ground more than 1 MΩ? BRC3B (female) (6) and B24 replace
B24. (female) (3)
Defective front accumulator oil

pressure sensor Replace
HM400-1 20-747
6
1
20-748 HM400-1
1
BK-25 Failure code [DK51L5] (Retarder lever potentiometer: * See separate table (BK))
★ Nature of failure: The signal voltage of the potentiometer of the retarder lever circuit went below 0.3 V or
above 4.7 V, or the potentiometer signal and switch signal do not match
Cause Remedy

YES
• Insert T-adapter to RTL. Is voltage between RTL (1) and NO

YES

• Disconnect BRC2 and NO in wiring harness between Repair or
RTL. Is voltage between RTL (female) (1)
and ground less than 1 V? BRC2 (female) (16) and RTL replace
YES
• Turn starting switch OFF. Is resistance between RTL (female) NO in wiring harness between BRC2 Repair or
• Disconnect BRC2 and (1) and ground more than 1 Ω? (female) (16) and RTL (female) replace
RTL. (1)
YES

• Insert T-adapter to BRC2. Is voltage between BRC2 (16) and NO
• Disconnect RTL. ground 4.1 - 4.8 V?
YES in wiring harness between BRC2 Repair or
(female) (16) and RTL (female) (1) replace
(includes resistor)
• Turn starting switch OFF. Is resistance between RTL (female) NO

• Disconnect RTL. (3) and ground less than 1 Ω?
YES
• Disconnect BRC3A and (female) (16) and RTL (female) (3) between BRC3A (female) (16) replace
RTL. less than 1 Ω? and RTL (female) (3)
YES
• Insert T-adapter to RTL. Is voltage between RTL (2) and NO

and RTL (female) (2)
• Disconnect BRC3B and Is voltage between RTL (female) (2) NO wiring harness between BRC3B Repair or
RTL. and ground less than 1 V? (female) (16) and RTL (female) replace
• Turn starting switch ON. (2)
YES

• Turn starting switch OFF. Is resistance between RTL (female) NO in wiring harness between Repair or
• Disconnect BRC3B and (2) and ground more than 1 MΩ? BRC3B (female) (16) and RTL replace
RTL.
(female) (2)
YES
Defective retarder lever Replace
q1. Used as the brake controller

potentiometer
in E-SPEC.
HM400-1 20-749
6
1
Cause Remedy
• Insert T-adapter to Is voltage between BRC5A (female) NO

BRC5A. (6) and ground, and between (7)
• Turn starting switch ON. and ground as shown in Table 1?
YES
Is resistance between RTL (male) (4) and NO

• Turn starting switch OFF. (6), and between (5) and (6) as Defective retarder lever switch Replace
• Disconnect RTL. shown in Table 2?
YES

• Turn starting switch OFF. Is resistance between RTL (female) NO tion in wiring harness between Repair or
• Disconnect RTL. (6) and ground less than 1 Ω? RTL (female) (6) and ground replace
YES short circuit with chassis ground, Repair or
or short circuit with power source replace
in wiring harness between
BRC5A (female) (6) and RTL
(female) (4) or between BRC5A
(female) (7) and RTL (female) (5)
Table 1 Table 2
Lever at Lever at Lever at Lever at
BRC5A (female) RELEASED APPLIED RTL (male) RELEASED APPLIED
position (q2) position (q2) position (q2) position (q2)
Between (6) and Between (4)
Max. 1 V 20~30V Max. 1Ω Min. 1MΩ
ground and (6)
20~30V Max. 1 V Min. 1MΩ Max. 1Ω
ground and (6)
q2. Since the lever is not installed in E-SPEC, insert a screwdriver in the hole for the lever and move it to the RELEASE or
APPLY position.
20-750 HM400-1
6
1
HM400-1 20-751
1
BK-26 Failure code [DK52KX] (Dump lever potentiometer 1: Input signal outside range (KX))
★ Nature of failure: The voltage of potentiometer 1 signal circuit or potentiometer 2 signal circuit went below
0.3 V or above 4.7 V
Cause Remedy
• Insert T-adapter to HSL. Is voltage between HSL (4) and (1) NO

YES
• Disconnect HSL. Is voltage between HSL (4) and (1) NO

YES

• Disconnect BRC3A and
HSL. Is voltage between HSL (female) (4) NO in wiring harness between Repair or
and ground less than 1 V? BRC3A (female) (6) and HSL replace
YES
• Turn starting switch OFF. Is resistance between HSL (female) NO in wiring harness between Repair or
• Disconnect BRC3A and (4) and ground more than 1 M Ω? BRC3A (female) (6) and HSL replace
HSL. (female) (4)
YES
• Insert T-adapter to BRC3A, NO

Disconnect HSL.
Is voltage between BRC3A (6) and Defective retarder controller (q1) Replace
(1) 4.6 - 5.4 V?
in wiring harness between BRC3A replace
(female) (6) and HSL (female) (4)
• Turn starting switch OFF. Is resistance between HSL (female) NO

• Disconnect HSL. (1) and ground less than 1 Ω?
YES Defective dump body

(potentiometer) Replace
• Turn starting switch OFF. Is resistance between BRC3A NO Defective contact or disconnection Repair or
• Disconnect BRC3A and (female) (16) and HSL (female) (1) in wiring harness between BRC3A replace
HSL. less than 1 Ω? (female) (16) and HSL (female) (1)
YES

YES
• Insert T-adapter to HSL. Is voltage between HSL (3) and NO

YES in wiring harness between Repair or
BRC3B (female) (12) and HSL replace
(female) (3)
• Disconnect BRC3B and Is voltage between HSL (3) and NO disconnection in wiring harness Repair or
HSL. ground less than 1 V? between BRC3B (female) (12) replace
• Turn starting switch ON. and HSL (female) (3)
YES
• Turn starting switch OFF. Is resistance between HSL (3) and NO in wiring harness between Repair or
• Disconnect BRC3B and ground more than 1 MΩ? BRC3B (female) (12) and HSL replace
HSL. (female) (3)
YES Defective dump body Replace
q1. Used as the brake controller
(potentiometer)
in E-SPEC.
20-752 HM400-1
6
1
Cause Remedy

YES
• Insert T-adapter to HSL. Is voltage between HSL (2) and ground 0.3 - NO
• Turn starting switch ON. 4.7 V?

BRC3B (female) (14) and HSL replace
(female) (2)
• Turn starting switch OFF. Is resistance between BRC1 (female) NO in wiring harness between Repair or
• Disconnect BRC1. (8)(16) and ground less than 1 MΩ? BRC3B (female) (14) and HSL replace
(female) (2)
YES

Is voltage of battery more than 24V NO in wiring harness between Repair or
• Turn starting switch OFF. BRC3B (female) (14) and HSL replace
and gravity more than 1.26?
(female) (2)
YES
Defective dump lever Replace
(potentiometer)

HM400-1 20-753
6
1
BK-27 Failure code [DK53L8] (Dump lever potentiometer 2: * See Contents (L8))
★ Nature of failure: The total voltage of potentiometer 1 signal circuit and potentiometer 2 signal circuit went
below 4.4 V or above 5.6 V
Cause Remedy

Is other failure code [DK52KX] NO Defective dump lever
displayed or recorded at same (potentiometer) Replace
time?
YES Go to
Another problem is occurring at troubleshooting
the same time for displayed
code
20-754 HM400-1
1
BK-28 Failure code [DK54KX] (Body positioner sensor: Input signal outside range (KX))
★ Nature of failure: The voltage of the body positioner sensor signal circuit went below 0.3 V or above 4.7 V
Cause Remedy

YES

YES

• Disconnect BRC3A and NO in wiring harness between Repair or
B34. Is voltage between B34 (female) (3)
and ground less than 1 V? BRC3A (female) (6) and B34 replace
YES
• Disconnect BRC3A and (3) and ground more than 1 MΩ? BRC3A (female) (6) and B34 replace
B34.. (female) (3)
YES
• Insert T-adapter to BRC3A,

Is voltage between BRC3A (6) and NO
Disconnect B34.
YES in wiring harness between BRC3A Repair or
(female) (6) and B34 (female) (3) replace

YES
YES

• Disconnect BRC3B and Is voltage between B34 (female) (2) NO wiring harness between BRC3B Repair or
B34. and ground less than 1 V? (female) (13) and B34 (female) replace
• Turn starting switch ON. (2)
YES

• Disconnect BRC3B and (2) and ground more than 1 MΩ? BRC3B (female) (13) and B34 replace
B34.
(female) (2)
YES
Defective body positioner sensor Replace
HM400-1 20-755
6
1
20-756 HM400-1
1
BK-29 Failure code [DLF4KA] (Transmission output shaft F speed sensor: Disconnec-
tion (KA))
★ Nature of failure: A disconnection has occurred in the signal circuit of the transmission output shaft F speed
Cause Remedy
• Turn starting switch OFF. Is resistance between BRC3A NO

• Disconnect BRC3A. (female) (12) and (14) 500 - 1000 Ω?
YES
• Turn starting switch OFF. Is resistance between FE1 (male) (1) NO Defective transmission output
• Disconnect FE1. and (2) 500 - 1000 Ω? Replace
shaft F speed sensor
YES tion in wiring harness between
BRC3A (female) (12) and Repair or
FE1 (female) (1) or between replace
BRC3A (female) (14) and
FE1 (female) (2)
• See TESTING AND Does condition become normal when NO
ADJUSTING. transmission output shaft F speed Defective retarder controller (q1) Replace
• Start engine. sensor is adjusted?
transmission output shaft F Adjust
speed sensor
HM400-1 20-757
6
1
BK-30 Failure code [DLT3KA] (Transmission output shaft R speed sensor: Disconnec-
tion (KA))
★ Nature of failure: A disconnection has occurred in the signal circuit of the transmission output shaft R speed
Cause Remedy
• Turn starting switch OFF. Is resistance between BRC3A NO

BRC3A. (16) 500 - 1000 Ω?
YES
• Turn starting switch OFF. Is resistance between N3 (male) (1) NO Defective transmission output
• Disconnect N3. and (2) 500 - 1000 Ω? Replace
shaft R speed sensor

BRC3A (female) (13) and N3 replace
(female) (1)
• See TESTING AND Does condition become normal when NO

ADJUSTING. transmission output shaft R speed Defective retarder controller (q1) Replace
• Start engine and travel. sensor is adjusted?
transmission output shaft R Adjust
speed sensor
20-758 HM400-1
6
1
BK-31 Failure code [DW71KZ] (Exhaust brake solenoid: Disconnection or short

circuit (KZ)) (Machine with exhaust brake)
★ Nature of failure: When output is sent to the exhaust brake solenoid circuit, excessive electric current
flows; when there is output, no electric current flows; when the output is OFF, electric
current flows
Cause Remedy

• Disconnect BRC1. (3) and ground 20 - 60 Ω?
YES
• Turn starting switch OFF. Is resistance between B29 (male) (1) and NO Defective exhaust brake Replace
• Disconnect B29. (2), and between (1) and ground as shown solenoid
in Table 1?
YES
Defective contact, disconnec-

NO tion, or short circuit with chassis Repair or
• Turn starting switch OFF. Is resistance between B29 (female) ground in wiring harness be-
• Disconnect B29. (2) and ground less than 1 Ω? tween BRC1 (female) (3) and
replace
B29 (female) (1)
between B29 (female) (2) and replace
ground
• Disconnect BRC1. Is voltage between BRC1 (female) NO Short circuit with power source in
wiring harness between BRC1 Repair or
(female) (3) and B29 (female) (1)
YES
Table 1 q1. Used as the brake controller in E-SPEC.
B29 (male) Resistance

HM400-1 20-759
6
1
BK-32 Failure code [DW72KZ] (Dump lever kick-out solenoid: Disconnection or short
circuit (KZ))
★ Nature of failure: When output is sent to the dump lever kick-out solenoid circuit, excessive electric current
flows; when there is output, no electric current flows; when the output is OFF, electric cur-
rent flows
Cause Remedy

• Disconnect BRC1. (11) and ground 39 Ω ± 5%?
YES
• Turn starting switch OFF. Is resistance between LKO (male) (1) and NO Defective dump lever (kick-out Replace
• Disconnect LKO. (2), and between (1) and ground solenoid)
as shown in Table 1?
YES

NO tion in wiring harness between Repair or
• Turn starting switch OFF. Is resistance between LKO (female) LKO (female)
(2) and ground less than 1 Ω? replace
• Disconnect LKO. (2) and ground
Defective contact,
harness between BRC1(female) replace
(11) and LKO (female) (1)
NO Short circuit with power source in
• Disconnect BRC1. Is voltage between BRC1 (female) wiring harness between BRC1 Repair or
• Turn starting switch ON. (11) and ground less than 1 V? (female) (11) and LKO (female) replace
(1)
YES
LKO (male) Resistance

Between (1) and (2) 39Ω±5%
20-760 HM400-1
6
1
BK-33 Failure code [DW73KZ] (Dump selector valve solenoid: Disconnection or short
circuit (KZ))
★ Nature of failure: When output is sent to the dump selector valve solenoid circuit, excessive electric current
rent flows
Cause Remedy

• Disconnect BRC1. (12) and ground approx. 30 Ω?
YES
• Turn starting switch OFF. Is resistance between B31 (male) (1) and NO Defective dump lever (kick-out Replace
• Disconnect B31. (2), and between (1) and ground solenoid)
as shown in Table 1?
YES
Is resistance between B31 (female) NO Defective contact or disconnec-

• Turn starting switch OFF. tion in wiring harness between Repair or
• Disconnect B31. (2) and ground less than 1 Ω? replace
B31 (female) (2) and ground
Defective contact,
YES disconnection, or short circuit Repair or
with chassis ground in wiring replace
harness between BRC1(female)
• Disconnect BRC1.• Is voltage between BRC1 (female) NO Short circuit with power source in
Turn starting switch ON. (11) and ground less than 1 V? replace
(female) (12) and B31 (female)
(1)
YES

HM400-1 20-761
6
1
BK-34 Failure code [DX11KA] (Rear brake pressure reducing valve solenoid: Discon-
nection (KA))
★ Nature of failure: When output is sent to the rear brake pressure reducing valve solenoid circuit, no electric
current flows
Cause Remedy
1
• Turn starting switch NO
Is resistance between BRC2
OFF. (female) (9) and (19) 20 Ω?
• Disconnect BRC2.
YES
2
• Turn starting switch Is resistance between B18 (male) (1) NO Defective rear brake pressure Replace
OFF. and (2) 20 Ω? reducing valve solenoid
• Disconnect B18.
YES in wiring harness between BRC2 Repair or
(female) (9) and B18 (female) (1) or replace
between BRC2 (female) (19) and
B18 (female) (2)
20-762 HM400-1
6
1
BK-35 Failure code [DX11KB] (Rear brake pressure reducing valve solenoid: Short
circuit (KB))
★ Nature of failure: When output is sent to the rear brake pressure reducing valve solenoid circuit, excessive
electric current flows
Cause Remedy
1
• Turn starting switch Is resistance between BRC2 NO
OFF. (female) (9) and (19), and between
• Disconnect BRC2. (9) and ground as shown in Table 1?
YES
2
• Turn starting switch Is resistance between B18 (male) (1) NO Defective rear brake pressure
OFF. and (2), and between (1) and reducing valve solenoid Replace
• Disconnect B18. ground as shown in Table 2?
Short circuit with chassis ground in
YES wiring harness between BRC2 Repair or
or short circuit in wiring harness
B18 (female) (2)
Table 1 Table 2
Resistance Resistance
BRC2 (female) B18 (male)
value value
10~30Ω 10~30Ω
(19) and (2)
Min. 1MΩ Min. 1Ω
ground and ground
HM400-1 20-763
6
1
BK-36 Failure code [DX11KY] (Rear brake pressure reducing valve solenoid: Short circuit
in power supply line (KY))
★ Nature of failure: When the output to the rear brake pressure reducing valve solenoid circuit is OFF, electric
current flows
Cause Remedy
1
Is voltage between BRC2 NO
• Disconnect BRC2. (female) (9) and ground less Repair or
Defective retarder controller
than 1 V? replace
YES
2
• Disconnect BRC2. Is voltage between BRC2 NO Short circuit with power source in
• Turn starting switch (female) (19) and ground less wiring harness between BRC2 Repair or
ON. than 1 V? (female) (19) and B18 (female) (2) replace
YES
Defective retarder controller ( q 1) Replace
20-764 HM400-1
6
1
BK-37 Failure code [DX12KA] (Front brake pressure reducing valve solenoid: Disconnec-
tion (KA))
★ Nature of failure: When output is sent to the front brake pressure reducing valve solenoid circuit, no electric
current flows
Cause Remedy
1
• Turn starting switch NO
Is resistance between BRC2
OFF. (female) (8) and (18) 10 - 30 Ω?
YES
2
• Turn starting switch Is resistance between B19 NO Defective front brake pressure
OFF. (male) (1) and (2) 10 - 30 Ω? reducing valve solenoid Replace
• Disconnect B19.
YES in wiring harness between BRC2
(female) (8) and B19 (female) (1) or Repair or
B19 (female) (2)
HM400-1 20-765
6
1
BK-38 Failure code [DX12KB] (Front brake pressure reducing valve solenoid: Short
circuit (KB))
★ Nature of failure: When output is sent to the front brake pressure reducing valve solenoid circuit, excessive
electric current flows
Cause Remedy
1
OFF. (female) (8) and (18), and between
• Disconnect BRC2. (8) and ground as shown in Table 1?
YES
2
• Turn starting switch Is resistance between B19 (male) (1) NO Defective front brake pressure
OFF. and (2), and between (1) and ground reducing valve solenoid Replace
• Disconnect B19. as shown in Table 2?
YES wiring harness between BRC2
(female) (8) and B19 (female) (1) Repair or
B19 (female) (2)
Table 1 Table 2
value value
10~30Ω 10~30Ω
(18) and (2)
ground and ground
20-766 HM400-1
6
1
BK-39 Failure code [DX12KY] (Front brake pressure reducing valve solenoid: Short
circuit in power supply line (KY))
★ Nature of failure: When the output to the front brake pressure reducing valve solenoid circuit is OFF, electric
current flows
Cause Remedy
Is voltage between BRC2 NO in wiring harness between Repair or
• Disconnect BRC2. (female) (8) and ground less than
• Turn starting switch ON. BRC2 (female) (8) and B19 replace
1 V? (female) (1)
YES
Is voltage between BRC2 NO Short circuit with power source in Repair or

• Disconnect BRC2. wiring harness between BRC2
• Turn starting switch ON. (female) (18) and ground less replace
than 1 V? (female) (18) and B19 (female) (2)
YES
HM400-1 20-767
6
1
BK-40 Failure code [DX13KA] (Dump EPC valve solenoid: Disconnection (KA))
★ Nature of failure: When output is sent to the dump EPC valve solenoid circuit, no electric current flows
Cause Remedy
1
OFF. (female) (10) and (20) approx. 5
• Disconnect BRC2. - 20Ω?
YES
2
• Turn starting switch Is resistance between B32 (male) NO Defective dump EPC valve
OFF. (1) and (2) approx. 5 - 20Ω? solenoid Replace
• Disconnect B32.
YES in wiring harness between BRC2
or between BRC2 (female) (20) and replace
B32 (female) (2)
20-768 HM400-1
6
1
BK-41 Failure code [DX13KB] (Dump EPC valve solenoid: Short circuit (KB))
★ Nature of failure: When output is sent to the dump EPC valve solenoid circuit, excessive electric current flows
Cause Remedy
1
Is resistance between BRC2 (female) NO
• Turn starting switch OFF. (10) and (20), and between (10) and
• Disconnect BRC2. ground as shown in Table 1?
YES
Defective dump pilot valve (EPC Replace
solenoid)
2
IIs resistance between B32 (male) (1) NO
• Disconnect B32.
and (2), and between (1) and ground as
shown in Table 2? Short circuit with chassis ground in
YES wiring harness between BRC2
B32 (female) (2)
Table 1 Table 2
value value
Between (10) Between (1)
5~20Ω 5~20Ω
and (20) and (2)
and ground and ground
HM400-1 20-769
6
1
BK-42 Failure code [DX13KY] (Dump EPC valve solenoid: Short circuit in power sup-
ply line (KY))
★ Nature of failure: When the output to the dump EPC valve solenoid circuit is OFF, electric current flows
Cause Remedy
1
• Disconnect BRC2. Is voltage between BRC2 (female) (10) NO
• Turn starting switch ON. and ground less than 1 V?

2
NO Short circuit with power source in Repair or
• Disconnect BRC2. Is voltage between BRC2 (female) wiring harness between BRC2
YES

20-770 HM400-1
6
1
BK-43 Failure code [DX14KZ] (Rear differential lock solenoid: Disconnection or short
circuit (KZ)) (Machine with differential lock differential)
★ Nature of failure: When output is sent to the rear differential lock solenoid circuit, excessive electric current
rent flows
Cause Remedy
Is resistance between B36 (male) (1) and NO

• Turn starting switch OFF. (2), and between (1) and ground as
shown in Table 1?
YES

• Turn starting switch OFF. (2), and between (1) and ground as Defective rear differential lock Replace
• Disconnect B36.
shown in Table 1? solenoid
YES

• Turn starting switch OFF. Is resistance between B36 (female) in wiring harness between B36 Repair or
• Disconnect B36. (2) and ground less than 1 Ω? (female) (2) and ground replace

in wiring harness between BRC1 replace

• Disconnect BRC1. Is voltage between BRC1 (female)
• Turn starting switch ON. (2) and ground less than 1 V? BRC1 (female) (2) and B36 replace
(female) (1)
YES

HM400-1 20-771
6
1
BK-44 Failure code [DX15KZ] (Front differential lock solenoid: Disconnection or short
circuit (KZ)) (Machine with differential lock differential)
★ Nature of failure: When output is sent to the front differential lock solenoid circuit, excessive electric current flows;
when there is output, no electric current flows; when the output is OFF, electric current flows
Cause Remedy
• Turn starting switch OFF. Is resistance between BRC1 NO

• Disconnect BRC1. (female) (10) and ground 20 Ω?
YES

• Turn starting switch OFF. (2), and between (1) and ground as Defective rear differential lock Replace
• Disconnect B35.
shown in Table 1? solenoid
YES

• Turn starting switch OFF. Is resistance between B35 (female) in wiring harness between B35 Repair or
• Disconnect B35. (2) and ground less than 1 Ω? (female) (2) and ground replace

in wiring harness between BRC1 replace

• Disconnect BRC1. Is voltage between BRC1 (female)
• Turn starting switch ON. (10) and ground less than 1 V? BRC1 (female) (2) and B35 replace
(female) (1)
YES

20-772 HM400-1
6
1
BK-45 Parking brake does not work properly
★ Nature of failure: The parking brake does not work properly (no failure code is displayed)
a) Even when parking brake switch is turned OFF, parking brake is not released
★ When the engine is stopped with the parking brake OFF, turn the switch to the PARKING position after
starting the engine. If it is not turned to PARKING, the parking brake cannot be released.
Cause Remedy

• Turn starting switch ON. parking brake safety relay (R19) is
YES
Defective parking brake safety Replace
relay (R19)

• Turn starting switch OFF. (2), and between (1) and ground as
• Disconnect B14. Defective parking brake solenoid Replace
shown in Table 1?
YES
Is resistance between R33 (male) (1) and NO

• Turn starting switch OFF. (2), and between (1) and (3) as shown in
• Disconnect R33. Defective parking brake switch Replace
Table 2?
YES
• Disconnect B21.
• Start engine. Is voltage between B21 (female) (1) NO
• Cancel parking brake switch. and ground 20 - 30 V?
YES
• Disconnect R33. Defective contact or disconnection

• Start engine. Is voltage between R33 (female) (3) NO in wiring harness between fuse Repair or
• Cancel parking brake switch. and ground 20 - 30 V? BT2-6 and R33 (female) (3) replace
YES

• Disconnect R19.
• Start engine. Is voltage between R19 (female) NO in wiring harness between R33 Repair or
• Cancel parking brake switch. (1)(3) and ground 20 - 30 V? (female) (1) and R19 (female) replace
(1)(3)
YES
Go to 9 Go to 7
20-774 HM400-1
1
From 4 From 6
Cause Remedy
• Turn starting switch OFF. Is resistance between R19 (female) NO Defective contact or disconnection
• Disconnect R19. (2) and ground less than 1Ω? in wiring harness between R19 Repair or
(female) (2) and ground replace
YES
• Disconnect R19. Defective contact or disconnection

• Start engine. Is voltage between R19 (female) (5) NO in wiring harness between fuse Repair or
• Cancel parking brake switch. and ground 20 - 30 V? BT2-6 and R19 (female) (5) replace

in wiring harness between R33 Repair or
• Disconnect B20.
• Start engine. Is voltage between B20 (female) (1) NO
YES
• Disconnect B21. Is resistance between B21 (male) (1) NO Defective front accumulator oil Replace
• Start engine.. and (2) less than 1 Ω? pressure switch
in wiring harness between B21 Repair or
D. Repair or replace
Is voltage between B14 (female) (1) NO

• Disconnect B14.
• Start engine.
(female) (2) and ground replace
• Disconnect B20. Is resistance between B20 (male) (1) NO Defective rear accumulator oil
• Start engine. and (2) less than 1Ω? pressure switch Replace

Table 1 Table 2
When parking When parking
B14 (male) Resistance R33 (male) brake switch is brake switch
at PARKING OFF
30~50Ω Min. 1 MΩ Max. 1Ω
and (2) and (2)
Min. 1 MΩ Max. 1Ω Min. 1 MΩ
and ground and (3)
HM400-1 20-775
1
b) Even when parking brake switch is at PARKING position, parking brake is not applied
Cause Remedy
• Disconnect R33.
• Start engine. Does parking brake work when R33 NO
• Set parking brake switch to is disconnected?
PARKING.
YES
Defective parking brake switch Replace
• Disconnect B21.
• Start engine. Does parking brake work when B21 NO
• Set parking brake switch to is disconnected?
PARKING.
wiring harness between R33 Repair or
(female) (2) and B21 (female )(1) replace
• Disconnect B20. Short circuit with power source in

• Start engine. Does parking brake work when B20 is NO wiring harness between B20 Repair or
• Set parking brake switch to disconnected? (female) (2) and B14 (female) (1) replace
PARKING.
wiring harness between B21 Repair or
20-776 HM400-1
1
TROUBLESHOOTING
TROUBLESHOOTING OF
MACHINE MONITOR SYSTEM
(MON MODE)
MON Mode related electrical circuit diagram ........................................................................................20-802

Content of display and problem that appears on machine for each failure code ...................................20-806
MON-1 Failure code [B@C6NS] (Front brake oil: Overheat (NS)).........................................................20-810
MON-2 Failure code [B@C7NS] (Rear brake oil: Overheat (NS)) .........................................................20-810
MON-3 Failure code [B@C8NS] (Center brake oil: Overheat (NS)) ......................................................20-811
MON-4 Failure code [B@CENS] (Torque converter: Overheat (NS))....................................................20-811
MON-5 Failure code [DAF0KM] (Monitor panel: Mistaken operation or mistaken setting (KM)) ...........20-812
MON-6 Failure code [DAF9KM] (Monitor panel: Mistaken operation or mistaken setting (KM)) ...........20-813
MON-7 Failure code [DAFSKQ] (Monitor panel: Non match in model selection signal (KQ)) ..............20-814
MON-8 Failure code [DAQSKR] (Transmission controller S-NET:
Defective communication, abnormality in corresponding component system (KR)) .................20-815
MON-9 Failure code [DB1SKR] (Retarder controller (q1) S-NET:
Defective communication, abnormality in corresponding component system (KR)) .................20-817
MON-10 Failure code [DB2SKR] (Engine controller S-NET: Defective communication,
abnormality in corresponding component system (KR)) .........................................................20-819
MON-11 Failure code [DV00KB] (Alarm buzzer: Short circuit (KB)) ......................................................20-821
MON-12 When starting switch is turned ON, machine monitor gives no display ..................................20-822
MON-13 When starting switch is OFF, machine monitor cannot be operated ......................................20-823
MON-14 Alarm buzzer does not sound .................................................................................................20-824
MON-15 Gauges, caution lamps, character display on machine monitor do not give correct display ..20-825
MON-16 Actuation check of machine monitor cannot be performed properly .......................................20-827
MON-17 Character display cannot be switched properly ......................................................................20-828
MON-18 Power mode selector function does not work properly ...........................................................20-831
MON-19 AISS function does not work properly.....................................................................................20-832
MON-20 Left and right differential lock does not work properly
(Machine with differential lock differential)...............................................................................20-833
MON-21 Inter-axle differential lock does not work properly...................................................................20-836
MON-22 Exhaust brake does not work properly (machines equipped with exhaust brake) ..................20-837
MON-23 Seat belt caution lamp display is not shown properly .............................................................20-839
MON-24 Turn signal lamp, hazard lamp do not work properly ..............................................................20-840
MON-25 Night lighting is not normal .....................................................................................................20-845
HM400-1 20-801
1
6
TROUBLESHOOTING MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
20-802 HM400-1
1
4
★ This circuit diagram has been made by extracting the machine monitor related circuits from the overall elec-
trical circuit diagram.
HM400-1 20-803
4"
20-804 HM400-1
"4
HM400-1 20-805
1
4
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH

FAILURE CODE
Front brake oil: Overheat (NS) Front brake cooling oil is overheated • Front brake cooling oil is overheated
B@C6NS
(when system is working normally)
(MON-1)
• Defective machine monitor
Rear brake oil: Overheat (NS) Rear brake cooling oil is overheated • Rear brake cooling oil is overheated (when
B@C7NS
system is working normally)
(MON-2)
Center brake oil: Overheat Center brake cooling oil is overheated • Center brake cooling oil is overheated
B@C8NS
(NS) (when system is working normally)
(MON-3)
Torque converter: Overheat Torque converter is overheated • Torque converter oil is overheated (when
B@CENS
(NS) system is working normally)
(MON-4)
Monitor panel: Mistaken opera- Option setting of rotary switch at rear • Defective setting of rotary switch,
tion or mistaken setting (KM)) of machine monitor and dipswitches dipswitch, or option connector (when sys-
does not match signal from option set- tem is working normally)
DAFOKM
ting connector • Disconnection or short circuit with chassis
(MON-5)
ground in option connector circuit wiring
harness
Monitor panel: Mistaken opera- Check signal of connector does not • Mistaken connection of connector DPC2
tion or mistaken setting (KM)) match internal setting of machine mon- (A, B) and connector DPC3 (A, B) (when
DAF9KM itor system is working normally)
(MON-6) • Disconnection or short circuit with chassis
ground in signal 1 circuit wiring harness
Monitor panel: Monitor panel: Communication (S-NET) with trans- • Disconnection, short circuit with chassis
Non match in model selection mission controller is defective and ground, or short circuit with power source
DAFSKQ signal (KQ) model selector information cannot be in S-NET (+) circuit wiring harness
(MON-7) received, or setting of transmission • Disconnection in S-NET (-) circuit
controller rotary switch is not correct • Defective transmission controller
Transmission controller S-NET: S-NET data cannot be received from • Disconnection, short circuit with chassis
Defective communication, transmission controller ground, or short circuit with power source
DAQSKR abnormality in corresponding in S-NET (+) circuit wiring harness
(MON-8) component system (KR) • Defective transmission controller
Retarder controller (q1) S-NET: S-NET data cannot be received from • Disconnection, short circuit with chassis
Defective communication, retarder controller ground, or short circuit with power source
DB1SKR abnormality in corresponding in S-NET (+) circuit wiring harness
(MON-9) component system (KR) • Defective retarder controller (q1)
Engine controller S-NET: Unable to receive S-NET information • Wiring harness in S-NET (+) circuit discon-
Defective communication, from engine controller nected or connected defectively or short-
DB2SKR abnormality in corresponding circuited
(MON-10) component system (KR) • Engine controller faulty
• Machine monitor faulty
Alarm buzzer: Short-circuiting Alarm buzzer output circuit short- • Alarm buzzer faulty
DV00KB (KB) circuited • Wiring harness in alarm buzzer output cir-
(MON-11) cuit short-circuited
• Machine monitor faulty
20-806 HM400-1
1
6
★ The code (MON-**) given below the failure code is the troubleshooting number.
Action
code
• Takes no action • If machine continues to be used as it is,
there is danger that front brake will E02
break
there is danger that rear brake will E02
break
there is danger that center brake will E02
break
there is danger that torque converter E02
will break
• Wiring harness resistance value • Holds abnormal condition until starting • Some functions (options) do not work
DPC3A (female) switch is turned OFF
(4)(6)(7)(13)(14)(15) - ground • Does not recognize functions (options)
• When connector is connected: where setting does not match E03
Max. 1 Ω
• Does not record as trouble data
• When connector is disconnected:
Min. 1 MΩ
• Signal voltage • Holds abnormal condition until starting

DPC2A (female) (5) - ground: switch is turned OFF
20 - 30 V • Does not record as trouble data
E03
• Holds abnormal condition until starting • No meters or gauges give display

switch is turned OFF • Some panel switches and lamps do not
• Controls as HM400 work
E03
• S-NET voltage • Holds condition existing when problem • Meters, gauges, cautions, special func-
Between DPC4 (1)(2) and (4)(5): occurred tion receiving data from transmission
6-9V controller do not work or give any dis- E03
Between ATC4 (6)(12) and (10): play
6-9V
• S-NET voltage • Holds condition existing when problem • Cautions, special function receiving
Between DPC4 (1)(2) and (4)(5): 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 problem • Cautions, special function receiving
• Between DPC4 (1)(2) and (4)(5): occurred data from engine controller do not work
6-9V or give any display E03
• Between CN2 (8)(18) and (6):
6-9V
• Output circuit voltage • Holds abnormal condition until starting • Alarm buzzer does not sound
DPC1 (13) - (9)(10): switch is turned OFF
E01
When buzzer is stopped: 20 - 30 V • Turns buzzer output circuit OFF
When buzzer is sounding: Max. 1 V
HM400-1 20-807
1
6
TROUBLESHOOTING MON-1, MON-2
MON-1 Failure code [B@C6NS] (Front brake oil: Overheat (NS))

★ Nature of failure: The front brake cooling oil is overheated
Cause Remedy
1
Is front brake cooling oil NO
• Stop engine Defective machine monitor Replace
overheated?
YES
Front brake cooling oil is —
overheated
MON-2 Failure code [B@C7NS] (Rear brake oil: Overheat (NS))

★ Nature of failure: The rear brake cooling oil is overheated
Cause Remedy
1
Is rear brake cooling oil NO
overheated?
YES
Rear brake cooling oil is —
overheated
20-810 HM400-1
1
TROUBLESHOOTING MON-3, MON-4
MON-3 Failure code [B@C8NS] (Center brake oil: Overheat (NS))

★ Nature of failure: The center brake cooling oil is overheated
Cause Remedy
1
Is center brake cooling oil NO
overheated?
YES
Center brake cooling oil is —
overheated
MON-4 Failure code [B@CENS] (Torque converter: Overheat (NS))

★ Nature of failure: The torque converter is overheated
Cause Remedy
1
NO
• Stop engine. Is torque converter overheated? Defective machine monitor Replace
YES
Torque converter is overheated —
HM400-1 20-811
TROUBLESHOOTING MON-5
M O N-5 Failure code [DAF0KM ] (M onitor panel: M istaken operation or m istaken setting
(KM))
★ Nature of failure: The option setting of the rotary switch at the rear of the machine monitor and dipswitches
does not match the signal from the option setting connector
Cause Remedy
1
• See TESTING AND Is setting of rotary switch, NO Defective setting of rotary
ADJUSTING. dipswitch, or option connector switch, dipswitch, or option Set again
normal? connector
YES
2 Defective contactor
• Turn starting switch OFF. Is resistance between DPC3A
• Disconnect DPC3A. NO disconnection in wiring harness Repair or
• OP connector connection
(female)(4)(6)(7)(13)(14)(15) between DPC3A (female)
and ground less than 1W? replace
circuit (4)(6)(7)(13)(14)(15) and ground
YES
3
• Turn starting switch OFF. Is resistance between DPC3A NO Short circuit with chassis ground
• Disconnect DPC3A. (female)(4)(6)(7)(13)(14)(15) and in wiring harness between Repair or
• OP connector ground more than 1 MW? DPC3A(female) (4)(6)(7)(13) replace
disconnection circuit (14)(15) and ground
YES
Defective machine monitor Replace
MON-5 Related electrical circuit diagram
20-812 HM400-1
M ON-6 Failure code [DAF9KM ] (M onitor panel: M istaken operation or m istaken setting
(KM ))
★ *Nature of failure: The check signal of the connector does not match the internal setting of the machine
monitor
Cause Remedy
1
Are connectors DPC2 (A, B) and NO
• Turn starting switch OFF. DPC5 (A, B) connected at Mistaken connection of machine Connect
correct position? monitor connectors again
YES
2
• Insert T-adapter to DPC2A. Is voltage between DPC2A (5) NO disconnection in wiring harness Repair or
• Turn starting switch ON. and ground 20 – 30 V? between DPC2A (female) (5) replace
and fuse BT2-2
YES
HM400-1 20-813
MON-7 Failure code [DAFSKQ] (Monitor panel: Non match in model selection signal
(KQ))
★ Nature of failure: Communication (S-NET) with the transmission controller is defective and the model selec-
tor information cannot be received, or the setting of the transmission controller rotary switch is not correct
Cause Remedy
1
• Turn starting switch ON. Is other failure code [DAQAKQ] NO
• Operate machine monitor. also displayed or recorded at
same time?
Defective S-NET
YES communication circuit between Repair or
machine monitor and replace
transmission controller
2
When troubleshooting for failure Go to
code [DAQSKR] is carried out, is troubleshoot-
condition normal (S-NET NO Other problem is occurring at ing of
communication circuit between same time displayed
machine monitor and transmission
controller)? code
YES
3
• Turn starting switch ON. when machine monitor is Defective transmission controller Replace
replaced?
YES
20-814 HM400-1
MON-8 Failure code [DAQSKR] (Transmission controller S-NET: Defective communi-

cation, abnormality in corresponding component system (KR))
★ Nature of failure: The S-NET data cannot be received from the transmission controller
★ Check that the continuity of the junction connectors (JCB, JCC, JCD, JCE, JCF, JCG) is normal.
Cause Remedy
1
Are other failure codes [DB1SKR] NO
• Turn starting switch ON. and [DB2SKR] also displayed or
recorded at same time?
YES

• Disconnect ATC4. Is voltage between ATC4 NO in wiring harness between ATC4 Repair or
• Turn starting switch ON. (female) (6)(12) and ground 6 – (female) (6) – JCB (female) (3) and replace
9 V? ATC4 (female) (12) – JCD (female)
(3)
YES Defective transmission controller Replace
3 wiring harness between DPC4
(female) (1) - JCD - BRC4 (female)
• Disconnect DPC4, Is voltage between DPC4 NO (12), ATC4 (female) (12), CN2
BRC4, ATC4,and CN2. (female) (1)(2) and ground less (female) 18) and between DPC4 Repair or
• Turn starting switch ON. than 1V? (female) (2) - JCB - BRC4 (female) replace
(6), ATC4 (female) (6), CN2
(female) (8)
YES wiring harness between DPC4
4 (12), ATC4 (female) (12), CN2
(female) (18) and between DPC4
• Turn starting switch OFF. Is resistance between DPC4 NO (female) (2) - JCB - BRC4 (female) Repair or
• Disconnect DPC4, BRC4, (female) (1)(2) and ground more (6), ATC4 (female) (6), CN2 replace
ATC4,and CN2. than 1 MΩ? (female) (8) Short circuit with
chassis ground in wiring harness
between DPC4 (female) (1) - JCD -
BRC4 (female) (12), ATC4 (female)
YES (12), CN2 (female) (18) and
between DPC4 (female) (2) - JCB -
5 (6), CN2 (female) (8)
• Disconnect JCD and JCB. Is voltage between JCD (female) NO
(1), JCB (female) (1) and ground Defective contact or disconnection Repair or
• Turn starting switch ON. in wiring harness between DPC4 replace
6 – 9 V? (female) (1) - JCD (female) (1) and
between DPC4 (female) (2) - JCB (2)
YES
One of machine monitor, retarder
controller, transmission controller, Replace
or engine controller is defective
HM400-1 20-815
20-816 HM400-1
q1) S-NET: Defective communi-

MON-9 Failure code [DB1SKR] (Retarder controller (q
cation, abnormality in corresponding component system (KR))
★ Nature of failure: The S-NET data cannot be received from the retarder controller (q1)
Cause Remedy
1
Are other failure codes [DB1SKR] NO
• Turn starting switch ON. and [DBQSKR] also displayed or
YES

• Disconnect BRC4. Is voltage between BRC4 NO in wiring harness between BRC4 Repair or
• Turn starting switch ON. (female) (6)(12) and ground 6 - (female) (6) – JCB (female) (2) and replace
9 V? BRC4 (female) (12) – JCD (female)
(2)
YES Defective retarder controller (q1) Replace
(female) (8)
4 (12), ATC4 (female) (12), CN2
5 (6), CN2 (female) (8)
YES
HM400-1 20-817
1
6
20-818 HM400-1
1
MON-10 Failure code [DB2SKR] (Engine controller S-NET: Defective communication,

abnormality in corresponding component system (KR))
★ Nature of failure: The S-NET data cannot be received from the engine controller
Cause Remedy
1
Are other failure codes [DAQSKR] NO
• Turn starting switch ON. and [DB1SKR] also displayed or
YES
2
• Disconnect CN2. Is voltage between CN2 NO in wiring harness between CN2 Repair or
• Turn starting switch ON. (female) (8)(18) and ground 6 – (female) (8) –JCB (female) (4) and replace
9 V? CN2 (female) (18) – JCD (female) (4)
YES Defective engine controller Replace
(female) (8)
4 (12), ATC4 (female) (12), CN2
5 (6), CN2 (female) (8)
YES
HM400-1 20-819
20-820 HM400-1
MON-11 Failure code [DV00KB] (Alarm buzzer: Short circuit (KB))

★ Nature of failure: A short circuit with the power source has occurred in the output circuit of the alarm buzzer
Cause Remedy
1
• Disconnect BZ2 and Is voltage between DPC1 (female) NO
DPC1. (13) - (9)(10) less than1 V?
YES
Defective alarm buzzer Replace
2
• Disconnect fuse BT2-2 Short circuit with power source
and DPC1.
Is voltage between DPC1 (female) NO in wiring harness between Repair or
• Turn starting switch ON. (13) - (9)(10) less than 1 V? DPC1 (female) (13) and BZ2 replace
(female) (2)
YES
HM400-1 20-821
MON-12 When starting switch is turned ON, machine monitor gives no display
★ Nature of failure:
★ Before starting troubleshooting, check that fuse BT2-20, BT2-2, and the fusible link are normal (if any fuse
is blown, there has probably been a surge of current caused by a short circuit, so check the related circuits).
Cause Remedy
1
• Insert T-adapter to DPC1. Is voltage between DPC1 (6)(7) NO
• Turn starting switch ON. – (9)(10) 20 – 30 V?
YES
2
Is voltage between DPC1 (6)(7) NO
• Insert T-adapter to DPC1.
• Turn starting switch ON. and ground 20 – 30 V?
between DPC1 (female) (9)(10) replace
and ground
NO disconnection in wiring harness
• Disconnect fuse BT2-2. Is voltage between fuse BT2-2 between fuse BT2-2 inlet - Repair or
• Turn starting switch ON. inlet and ground 20 - 30 V? starting switch - BT2-20 - battery replace
relay B
and fuse BT2-2 outlet
20-822 HM400-1
MON-13 When starting switch is OFF, machine monitor cannot be operated

★ Nature of failure: Even when the starting switch is turned OFF, the service meter & odometer, turn signal
pilot lamp, and head light beam pilot lamp do not flash (no failure code is displayed).
★ Check that that the monitor does not give a display when any of the switches (machine monitor mode se-
lector switch 1, combination switch, or hazard lamp switch) are operated.
Cause Remedy
1
When starting switch is turned NO Carry out
• Turn starting switch ON. ON, does machine monitor give Defective main power source troubleshoo
normal display? system ting MON-
12.
YES
2
• Insert T-adapter to DPC1. Is voltage between DPC1 (4)(5) – NO
• Turn starting switch OFF. (9)(10) 20 – 30 V?
YES
3
• Disconnect fuse BT2-22. Is voltage between fuse BT2-22 NO disconnection in wiring harness Repair or
• Turn starting switch ON. inlet and ground 20 – 30 V? between fuse BT2-22 inlet and replace
J02 (female) (Y)
and fuse BT2-22 outlet
HM400-1 20-823
MON-14 Alarm buzzer does not sound

★ Nature of failure: When the starting switch is ON, when the emergency stop items are lighted up, or when
the central warning lamp is lighted up, the alarm buzzer does not sound (no failure code is displayed).
Cause Remedy
1
• Disconnect DPC1. Is voltage between DPC1 NO
• Turn starting switch ON. (female) (13) and ground 20 – 30
V?
YES
2
• Disconnect BZ2. Is voltage between BZ2 (female) NO disconnection in wiring harness Repair or
• Turn starting switch ON. (1) and ground 20 – 30 V? between fuse BT2-2 outlet and replace
BZ2 (female) (1)
YES
3
• Turn starting switch OFF. Is resistance between DPC1 Defective contact or
NO disconnection in wiring harness Repair or
• Disconnect DPC1 and (female) (13) and BZ2 (female)
BZ2. (1) less than 1 Ω? between DPC1 (female) (13) replace
and BZ2 (female) (2)
YES
Defective alarm buzzer Replace
20-824 HM400-1
MON-15 Gauges, caution lamps, character display on machine monitor do not give
correct display
★ Nature of failure: The display of the gauges, lamps, and character display is not normal (no failure code is
displayed).
a) Gauge display is different from condition of machine
Cause Remedy
1
Does gauge work normally when NO
• Turn starting switch ON. machine monitor check switch is Defective machine monitor Replace
operated?
YES
2 Carry out
• Turn starting switch ON. When input condition of NO Defective signal system of troubleshoot-
• Operate machine applicable signal is monitored, is applicable sensor ing for signal
monitor. it found to be normal? system
YES
b) Caution lamp display is different from condition of machine
Cause Remedy
1
Do lamp lights up and go off NO
• Turn starting switch ON. when machine monitor check Defective machine monitor Replace
switch is operated?
YES
2 Carry out
When input condition of troubleshoo-
• Turn starting switch ON. NO Defective signal system of ting for
• Operate machine applicable signal is monitored, is applicable sensor signal
monitor. it found to be normal? system
YES
HM400-1 20-825
c) Nothing is displayed on character display, or display is not correct
Cause Remedy
1
When machine monitor monitor NO
• Turn starting switch ON. check switch is operated, does Defective machine monitor Replace
display give normal display?
YES
20-826 HM400-1
MON-16 Actuation check of machine monitor cannot be performed properly

★ Nature of failure: 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.
Cause Remedy
1
DPC2A. Is voltage between DPC2A (10) NO
YES
2
• Turn starting switch OFF. Is resistance between CK1 (male) NO Defective machine monitor Replace
• Disconnect CK1. (3) and (6) as shown in Table 2? check switch
YES
3
• Disconnect CK1. Is voltage between CK1 (female) in wiring harness between fuse Repair or
• Turn starting switch ON. (3) and ground 20 – 30 V? BT2-2 outlet and CK1 (female) (3) replace
DPC2A (female) (10) and CK1
(female) (6)
Table 1 Table 2
Machine monitor Machine monitor

DPC2A Voltage CK1 (male) Resistance value
check switch check switch
Between (10) and Release Max. 1 V Between (3) and Release Min. 1 MΩ
ground Press 20 - 30 V (6) Press Max. 1 Ω
HM400-1 20-827
MON-17 Character display cannot be switched properly

★ Nature of failure: Even when machine monitor mode selection switches 1 or 2 are operated, the display on
the character display does not change (no failure code is displayed).
a) Machine monitor mode selector switch 1 system is not normal
Cause Remedy
1
• Insert T-adapter to Is voltage between DPC2A (8) NO
DPC2A.
YES
2
• Turn starting switch OFF. Is resistance between CH1 (male) NO Defective machine monitor Replace
• Disconnect CH1. (2) and (3) as shown in Table 2? mode selector switch 1
YES
• Disconnect CH1. Is voltage between CH1 (female) NO disconnection in wiring harness Repair or
CH1 (female) (3)
YES short circuit with power source in Repair or
wiring harness between DPC2A replace
(female) (8) and CH1 (female) (2)
4
DPC2A.
YES
5

DPC2A (female) (14) and CH1
(female) (1)
Table 1 Table 2
Machine monitor mode Machine monitor mode Resistance

DPC2A Voltage CH1 (male)
selector switch 1 selector switch 1 value
Between (8) Press [ [] 20 - 30 V Between (2) [
Press [ ] Max. 1 Ω
and ground Neutral Max. 1 V and (3) Neutral Min. 1 MΩ
Between (14) Neutral Max. 1 V Between (1) Neutral Min. 1 MΩ
and ground Press [ ] T 20 - 30 V and (3) T
Press [ ] Max. 1 Ω
20-828 HM400-1
b) Machine monitor mode selector switch 2 system is not normal
Cause Remedy
1
DPC2A.
YES
2
YES
• Disconnect CH2. Is voltage between CH2 (female) NO disconnection in wiring harness Repair or
CH2 (female) (3)
(female) (6) and CH1 (female) (2)
4
DPC2A.
YES
5

DPC2A (female) (15) and CH2
(female) (1)
Table 3 Table 4
Machine monitor mode Machine monitor mode Resistance

DPC2A Voltage CH2 (male)
selector switch 2 selector switch 2 value
Between (6) Press [>] 20 - 30 V Between (2) Press [>] Max. 1 Ω
and ground Press [<] 20 - 30 V and (3) Press [<] Max. 1 Ω
HM400-1 20-829
20-830 HM400-1
MON-18 Power mode selector function does not work properly

★ Nature of failure: Even when the power mode selection switch is operated, the power mode switching func-
tion does not work normally, or the power mode pilot lamp does not light up and go out normally (no failure
code is displayed).
Cause Remedy
1
DPC2A. and ground as shown in Table 1?
YES
2
Is resistance between PWM NO Defective power mode selector
• Turn starting switch OFF. Replace
• Disconnect PWM. (male) (1) and (3) as shown in switch
Table 2?
YES
3
• Disconnect PWM. Is voltage between PWM (female) NO disconnection in wiring harness Repair or
PWM (female) (1)
(female) (13) and PWM (female) (3)
4 Go to
Does condition become normal NO troubleshoot-
• Turn starting switch ON. when machine monitor is Defective control system of
engine controller ing for
replaced? applicable
circuit
YES
Table 1 Table 2
Power mode Power mode

DPC2A Voltage CK1 (male) Resistance value
selector switch selector switch
Between (13) and Up Max. 1 V Between (1) and Up Min. 1 MΩ
ground Down 20 - 30 V (3) Down Max. 1 Ω
HM400-1 20-831
MON-19 AISS function does not work properly

★ Nature of failure: Even when the AISS LOW switch is operated, the AISS function does not work normally
(no failure code is displayed).
Cause Remedy
1
YES
2
Is resistance between AISS NO
(male) (1) and (3) as shown in Defective AISS LOW switch Replace
• Disconnect AISS.
Table 2?
YES
3
• Disconnect AISS. Is voltage between AISS (female) NO disconnection in wiring harness Repair or
AISS (female) (1)
(female) (2) and AISS (female) (3)
4 Go to
engine controller ing for
circuit
YES
Table 1 Table 2
DPC2A AISS LOW switch Voltage AISS (male) AISS LOW switch Resistance value
Between (2) and Up Max. 1 V Between (1) and Up Min. 1 MΩ
ground Down 20 - 30 V (3) Down Max. 1 Ω
20-832 HM400-1
MON-20 Left and right differential lock does not work properly
★ Nature of failure: Even when the left and right differential lock switch and left and right differential lock pedal
are operated, the left and right differential lock does not work normally, or the left and right differential lock
pilot lamp does not light up and go out normally (no failure code is displayed).
a) Troubleshooting procedure 1 (left and right differential lock switch system)
Cause Remedy
1
DPC3A.
YES
2
• Turn starting switch OFF. Is resistance between DFL (male) NO Defective left and right Replace
• Disconnect DFL. (1) and (2) as shown in Table 2? differential lock switch 1
YES
• Disconnect DFL. Is voltage between DFL (female) NO disconnection in wiring harness Repair or
DFL (female) (1)
(female) (2) and DFL (female) (2)
4
• Insert T-adapter to Is voltage between DPC3A (3) and NO
DPC3A.
• Turn starting switch ON. ground as shown in Table 1?
YES
— Go to
troubleshoot-
ing b)
5
• Turn starting switch OFF. Is resistance between DFL (male) NO Defective left and right Replace
• Disconnect DFL. (1) and (3) as shown in Table 2? differential lock switch 1

DPC3A (female) (3) and DFL
(female) (3)
Table 1 Table 2
Left and right differential Left and right differential Resistance

DPC3A Voltage DFL (male)
switch lock switch value
Between (2) Up 20 - 30 V Between (1) Up Max. 1 Ω
and ground Down 20 - 30 V and (3) Down Max. 1 Ω
HM400-1 20-833
1
6
MON-20 a) Related electrical circuit diagram
20-834 HM400-1
1
6
b) Troubleshooting procedure 2 (left and right differential lock pedal system)

Cause Remedy
1
YES
2
Is resistance between DFS NO Defective left and right
(male) (A) and (B) as shown in differential lock pedal
• Disconnect DFS.
Table 4?
YES
3
• Disconnect DFS. Is voltage between DFS (female) NO disconnection in wiring harness Repair or
• Turn starting switch ON. (A) and ground 20 – 30 V? between fuse BT3-18 outlet and replace
DFS (female) (A)
(female) (1) and DFS (female) (A)
4 Go to
retarder controller (q1) ing for
circuit
YES
Table 3 Table 4
Left and right Left and right

DPC3A differential lock Voltage DFS (male) differential lock Resistance value
pedal pedal
Between (1) and Release Max. 1 V Between (A) and Release Min. 1 MΩ
ground Depress 20 - 30 V (B) Depress Max. 1 Ω
MON-20 b) Related electrical circuit diagram
HM400-1 20-835
1
6
MON-21 Inter-axle differential lock does not work properly

★ Nature of failure: Even when the inter-axle differential lock switch is operated, the inter-axle differential lock
does not work normally, or the inter-axle differential lock pilot lamp does not light up and go out normally
(no failure code is displayed).
Cause Remedy
1
YES
2
Is resistance between DEF NO Defective inter-axle differential
(male) (1) and (3) as shown in lock switch
• Disconnect DEF.
Table 2?
YES
3
• Disconnect DEF. Is voltage between DEF (female) NO disconnection in wiring harness Repair or
DEF (female) (1)
(female) (12) and DEF (female) (3)
4 Go to
retarder controller (q1) ing for
circuit
YES
Table 1 Table 2
Inter-axle differential Inter-axle differential

DPC2A Voltage DEF (male) Resistance value
lock switch lock switch
Between (12) Up Max. 1 V Between (1) Up Min. 1 MΩ
and ground Down 20 - 30 V and (3) Down Max. 1 Ω
20-836 HM400-1
1
6
MON-22 Exhaust brake does not work properly (machines equipped with exhaust
brake)
★ Nature of failure: Even when the exhaust brake switch is operated, the exhaust brake does not work nor-
mally, or the exhaust brake pilot lamp does not light up and go out normally (no failure code is displayed).
Cause Remedy
1
YES
2
. Turn starting switch OFF. Is resistance between EXH (male) NO
. Disconnect EXH. (1) and (2) as shown in Table 2? Defective exhaust brake switch Replace
YES
3
• Disconnect EXH. Is voltage between EXH (female) NO disconnection in wiring harness Repair or
• Turn starting switch ON. (1) and ground 20– 30 V? between fuse BT2-2 outlet and replace
EXH (female) (1)
(female) (22) and EXH (female) (2)
4
• Insert T-adapter to Is voltage between DPC2A (3) and NO
DPC2A. ground as shown in Table 1?
YES
5
• Turn starting switch OFF. Is resistance between EXH (male) NO
• Disconnect EXH. (1) and (3) as shown in Table 2?
Defective exhaust brake switch Replace

or short circuit with power source in Repair or
(female) (3) and EXH (female) (3)
6 Go to
troubleshoot-
Does condition become normal NO Defective control system of ing for
• Turn starting switch ON. when machine monitor is replaced? retarder controller (q1) applicable
circuit
YES
HM400-1 20-837
1
6
Table 1 Table 2
DPC2A Exhaust brake switch Voltage Resistance

EXH (male) Exhaust brake switch
value
Between (11) Up 20 - 30 V
and ground Neutral Max. 1 V Between (1) Up Max. 1 Ω
Neutral Max. 1 V and (2) Neutral Min. 1 MΩ
Between (3)
and ground Down 20 - 30 V Between (1) Neutral Min. 1 MΩ
20-838 HM400-1
1
MON-23 Seat belt caution lamp display is not shown properly

★ Nature of failure: Operation of the seat belt and the seat belt caution lamp display are not normal (no failure
code is displayed).
a) Seat belt is fitted, but lamp lights up

Cause Remedy
1
DPC2B. Is voltage between DPC2B (11)
• Turn starting switch ON. and ground 20 – 30 V?
YES
2
• Turn starting switch OFF. Is resistance between SBS (male) NO
(1) and (2) less than 1 Ω? Defective seat belt switch Replace
• Disconnect SBS.
YES
3
• Disconnect SBS. Is voltage between SBS (female) NO disconnection in wiring harness Repair or
• Turn starting switch ON. (1) and ground 20 – 30 V? between fuse BT4-2 and SBS replace
(female) (1)
between DPC2B (female) (11) replace
and SBS (female) (2)
b) Seat belt is not fitted, but lamp does not light up
Cause Remedy
1
• Insert T-adapter to Is voltage between DPC2B (11) NO
DPC2B. and ground less than 1 V?
YES
2
• Turn starting switch OFF. Is resistance between SBS (male) NO
• Disconnect SBS. (1) and (2) more than 1 MΩ? Defective seat belt switch Replace

wiring harness between DPC2B
Repair or
(female) (11) and SBS (female) (2) replace
HM400-1 20-839
MON-24 Turn signal lamp, hazard lamp do not work properly

★ Nature of failure: The turn signal lamp (turn signal lamp) and hazard lamp do not work normally (no failure
code is displayed). * Before starting troubleshooting, check that fuse BT2-24 and BT3-4 are normal (if either
fuse is blown, there has probably been a surge of current caused by a short circuit, so check the related
circuits).
★ The turn signal lamps are divided into front, rear, left, and right from the switch and relay, so if only one of
the lamps does not light up, there is probably a broken bulb, defective wiring harness at the signal end (be-
tween the dividing point and the lamp), or defective wiring harness at the GND end (between the lamp and
ground).
a) Even when turn signal lever and hazard lamp switch are operated, no turn signal lamps light up
Cause Remedy
1
• Turn starting switch ON. when hazard relay 2 (R17) is
YES
Defective hazard relay 2 (R17) Replace
2
• Disconnect FBL. Is voltage between FLB (wiring NO disconnection in wiring harness Repair or
• Turn starting switch ON. harness end) and ground 20 – 30 V? between R17 (female) (3) and replace
FLB
YES
3
• Turn starting switch OFF. Is resistance between FLL (wiring Defective contact or
• Disconnect FLL, CM, harness end) – CM (female) (6),
and R16. R16 (female) (1)(3) less than 1 Ω? between FLL and wiring harness replace
dividing point
YES
Defective flasher Replace
b) When turn signal lever and hazard lamp switch are operated, turn signal lamps light up but do not flash
Cause Remedy
1
• Disconnect FLL, CM, Is voltage between FLL (wiring NO Short circuit with power source in
and R16. harness end) and ground less wiring harness between FLL - CM Repair or
• Turn starting switch ON. than 1 V? (female) (6) - R16 (female) (1)(3) replace
YES
Defective flasher Replace
20-840 HM400-1
c) Even when turn signal lever is operated, turn signal lamps on both sides (left and right), or on one
side only do not flash (they flash normally when hazard lamp switch is operated)
Cause Remedy
1
YES
2
• Turn starting switch ON. (6) and ground 20 – 30 V? between fuse BT1-4 and R17 replace
(female) (6)
YES
3
• Disconnect CM. Is voltage between CM (female) NO disconnection in wiring harness Repair or
• Turn starting switch ON. (6) and ground 20 – 30 V? between CM (female) (6) and replace
wiring harness dividing point
YES
Defective turn signal lever Replace
HM400-1 20-841
d) Even when hazard lamp switch is turned ON, no turn signal lamps flash (they flash normally when
turn signal lever is operated)
Cause Remedy
1
YES Defective hazard relay 1 (R16) Replace
or hazard relay 2 (R17)
2
• Turn starting switch ON. (5) and ground 20 – 30 V? between fuse BT2-24 and R17 replace
(female) (5)
YES
3
• Turn starting switch ON. (1)(3) and ground 20 – 30 V? between FLL and R16 (female) replace
(1)(3)
YES
4
Is voltage between R16 (female) NO
• Disconnect R16 and R17. (5) – ground and between R17
• Turn hazard switch ON.
(female) (1) – ground 20 – 30 V?
YES in wiring harness between R16 Repair or
(female) (6) – ground or between replace
R17 (female) (2) – ground
5
• Turn starting switch OFF. Is resistance between HAZ (male) NO
• Disconnect HAZ. (1) and (3) as shown in Table 1? Defective hazard lamp switch Replace
YES
6
• Turn starting switch OFF. Is voltage between HAZ (female) NO Defective contact or
• Disconnect HAZ. (1) and ground 20 – 30 V? between fuse BT2-24 and HAZ replace
(female) (1)
in wiring harness between HAZ Repair or
(female) (3) –R16 (female) (5) or replace
R17 (female) (1)
Table 1
HAZ (male) Hazard lamp switch Resistance value

Between (1) OFF Min. 1 MΩ
and (3) ON Max. 1 Ω
20-842 HM400-1
e) Even when hazard lamp switch is turned OFF, turn signal lamps flash (they flash normally when turn
signal lever is operated)
Cause Remedy
1
YES
2
• Turn starting switch OFF. Is resistance between HAZ (male) NO
• Disconnect HAZ. (1) and (3) as shown in Table 1 Defective hazard lamp switch Replace

wiring harness between HAZ Repair or
(female) (3) – R16 (female) (5) or replace
R17 (female)
Table 1
HAZ (male) Hazard lamp switch Resistance value

Between (1) OFF Min. 1 MΩ
and (3) ON Max. 1 Ω
f) Turn signal pilot lamp does not flash normally (turn signal lamps flash normally)
Cause Remedy
• Insert T-adapter to Is voltage between DPC2A (7) – NO in wiring harness between DPC2A
DPC2A. ground and between (26) – ground (female) (7) – R14 (female) (4) or Repair or
• Turn starting switch ON. as shown in Table 2? between DPC2A (female) (16) – replace
R14 (female) (2)
YES
Table 2
DPC2A Turn signal lever Voltage Remarks

Right Max. 1 V/20 - 30 V Voltage varies in turn
Between (7) and ground
Neutral Max. 1 V
Neutral Max. 1 V
Between (16) and ground
Left Max. 1 V/20 - 30 V Voltage varies in turn
HM400-1 20-843
20-844 HM400-1
MON-25 Night lighting is not normal

★ Nature of failure: The night lighting of the machine monitor, head lamps, and passing lamps do not work
normally (no failure code is displayed).
★ Before starting troubleshooting, check that fuse BT1-2, BT1-6, BT1-8, BT1-10, and BT1-12 are normal (if
any fuse is blown, there has probably been a surge of current caused by a short circuit, so check the related
circuits).
★ The lamps and night lighting are divided into item of each equipment from the switch and relay, so if only
one item of equipment does not light up, there is probably a broken bulb, defective wiring harness at the
signal end (between the dividing point and the lamp), or defective wiring harness at the GND end (between
the lamp and ground).
a) Even when lamp switch is operated to 1st stage or 2nd stage, none of side lamps, night lighting, or
head lamps light up
Cause Remedy
1
• Disconnect CM. Is voltage between CM (female) NO in wiring harness between fuse Repair or
• Turn starting switch ON. (1) and ground 20 – 30 V? BT1-2 and CM (female) (1) replace
YES
Defective lamp switch Replace
b) When lamp switch is operated to 1st stage, side lamps and night lighting do not light up
Cause Remedy
1
OFF. Is resistance between CM (male) NO Defective lamp switch Replace
• Disconnect CM. (1) and (2) as shown in Table 1?

between CM (female) (2) and replace
c) Lamp switch is turned OFF, but side lamps and night lighting light up
Cause Remedy
1
OFF. Is resistance between CM (male) NO Defective lamp switch Replace
• Disconnect CM. (1) and (2) as shown in Table 1?

wiring harness between CM Repair or
(female) (2) and side lamp, machine replace
monitor, night lighting dimmer switch
HM400-1 20-845
d) Even when night lighting dimmer switch is operated, brightness of night lighting cannot be adjusted
Cause Remedy
1
• Insert T-adapter to LS. Is voltage between LS (1) and NO
• Set lamp switch to 1st stage. (3) 20 – 30 V?
YES
2
• Turn starting switch OFF. Is resistance between LS (female) in wiring harness between LS Repair or
• Disconnect LS. (3) and ground less than 1 Ω? (female) (3) and ground replace
wiring harness between LS (female) Repair or
(1) and wiring harness dividing point replace
3
• Insert T-adapter to LS. NO Defective night lighting dimmer
• Turn starting switch ON. Is voltage between LS (2) and Replace
• Set lamp switch to 1st stage. (3) as shown in Table 2? switch (rheostat)

wiring harness between LS (female) Repair or
(2) and wiring harness dividing point replace
Table 1
LS Switch position Voltage

Between (2) Left end 6 - 10 V
and (3) Right end 18 - 27 V
e) Even when lamp switch is operated to 2nd stage, head lamps do not light up
Cause Remedy
1
•Turn starting switch OFF. Is resistance between CM (male) NO
• Disconnect CM. (1) and (3) as shown in Table 3? Defective lamp switch Replace
YES
2
• Disconnect R31.
Is voltage between R31 (female) NO disconnection in wiring harness Repair or
• Set lamp switch to 2nd stage. (1)(2)(3)(4) and ground 20 – 30 V? between CM (female) (3) and R31 replace
(female) (1)(2)(3)(4)
YES
Defective passing relay Replace
20-846 HM400-1
f) Head lamp Hi beam does not light up (Lo beam lights up)
Cause Remedy
1
• Disconnect R29. Defective contact or
• Turn starting switch ON. Is voltage between R29 (female) NO disconnection in wiring harness Repair or
• Set lamp switch to 2nd stage. (1)(3) and ground 20 – 30 V? between fuse BT1-2 and R29 replace
(female) (1)(3)
YES
2
• Disconnect R29. Is voltage between R29 (female) NO
• Set lamp switch to 2nd stage. (5) and (6) as shown in Table 4?
YES
3
• Turn starting switch OFF. Is resistance between R29 (female) in wiring harness between R29 Repair or
• Disconnect R29. (6) and ground less than 1 Ω? (female) (6) and ground replace
YES
4
• Turn starting switch OFF. Is resistance between CM (male) NO
• Disconnect CM. Defective dimmer switch Replace
(4) and (5) as shown in Table 5?
YES
5
• Insert T-adapter to CM. Is voltage between CM (4) and NO disconnection in wiring harness Repair or
• Turn starting switch ON. ground 20 – 30 V? between CM (female) (4) and replace
in wiring harness between CM Repair or
(female) (5) and R29 (female) (5) replace
6
Does condition become normal Defective contact or
• Turn starting switch ON. when head lamp Hi relay (R29)
is interchanged with other relay? between R29 (female) (2)(4) replace
and head lamp
YES
Defective head lamp Hi relay Replace
Table 4
R29 (female) Dimmer switch Voltage Remarks

Each time switch is oper-
Between (5) and (6) Operate between Hi and Lo Max. 1 V/20 - 30 V
ated, voltage changes
Table 5
CM (male) Dimmer switch Voltage Remarks

Less than 1 Ω/more Each time switch is oper-
Between (4) and (5) Operate between Hi and Lo
than 1 MΩ ated, resistance changes
HM400-1 20-847
g) Head lamp Lo beam does not light up (Hi beam lights up)
Cause Remedy
1
• Disconnect R30. Defective passing relay or defective
• Turn starting switch ON. Is voltage between R30 (female) NO contact or disconnection in wiring Repair or
• Set lamp switch to 2nd stage. (3) and ground 20 – 30 V? harness between fuse R31 (female) replace
(5)(7) and R30 (female) (3)
YES
2
• Disconnect R30. Is voltage between R29 (female) NO
• Set lamp switch to 2nd stage. (1) and (2) as shown in Table 6?
YES
3
• Turn starting switch OFF. Is resistance between R30 (female) in wiring harness between R30 Repair or
• Disconnect R30. (2) and ground less than 1 Ω? (female) (2) and ground replace
YES
4
• Turn starting switch OFF. Is resistance between CM (male) NO
• Disconnect CM. Defective dimmer switch Replace
(4) and (5) as shown in Table 7?
YES
5
• Insert T-adapter to CM. Is voltage between CM (4) and NO disconnection in wiring harness Repair or
• Turn starting switch ON. ground 20 – 30 V? between CM (female) (4) and replace
wiring harness between CM Repair or
(female) (5) and R30 (female) (1) replace
6
Does condition become normal Defective contact or
• Turn starting switch ON. when head lamp Lo relay (R30)
is interchanged with other relay? between R30 (female) (6) and replace
head lamp
YES
Defective head lamp Lo relay Replace
Table 6
R30 (female) Dimmer switch Voltage Remarks

Each time switch is oper-
Between (1) and (2) Operate between Hi and Lo Max. 1 V/20 - 30 V
ated, voltage changes
Table 7
CM (male) Dimmer switch Voltage Remarks

Less than 1 Ω/more Each time switch is oper-
Between (4) and (5) Operate between Hi and Lo
than 1 MΩ ated, resistance changes
20-848 HM400-1
h) W hen h ead lam p is operated to Hi beam , m achine m onitor pilot lam p does no t light up (Hi b eam lights up )
Cause Remedy
1
• Insert T-adapter to DPC2A.
Is voltage between DPC2A (5) NO in wiring harness between DPC2A Repair or
• Set lamp switch to 2nd stage. and ground as shown in Table 8? (female) (5) and wiring harness replace
dividing point
YES
Table 8
DPC2A Dimmer switch Voltage

Between (5) Lo Max. 1 V
and ground Hi 20 - 30 V
HM400-1 20-849
20-850 HM400-1
TROUBLESHOOTING
TROUBLESHOOTING OF
HYDRAULIC, MECHANICAL
SYSTEM (H MODE)
H-1 Machine does not start ................................................................................................................. 20-902
H-2 Machine does not travel smoothly (machine jerks) ...................................................................... 20-903
H-3 Lock-up clutch cannot be disengaged (engine stalls) .................................................................. 20-903
H-4 Excessive shock when starting or shifting .................................................................................... 20-904
H-5 Transmission does not shift up ..................................................................................................... 20-904
H-6 Machine lacks power or speed when traveling ............................................................................. 20-905
H-7 Time lag is excessive when starting or shifting gear .................................................................... 20-908
H-8 Torque converter oil temperature is high ...................................................................................... 20-909
H-9 Torque converter oil pressure is low ............................................................................................. 20-910
H-10 Front brake is ineffective, or effective only on one side ............................................................... 20-911
H-11 Center brake is ineffective, or effective only on one side ............................................................ 20-912
H-12 Rear brake is ineffective, or effective only on one side ............................................................... 20-913
H-13 Steering wheel is heavy ............................................................................................................. 20-914
H-14 Steering wheel does not work .................................................................................................... 20-915
H-15 Steering wheel vibrates .............................................................................................................. 20-916
H-16 Dump body lifting speed is slow, or lacks power ........................................................................ 20-917
H-17 Dump does not work .................................................................................................................. 20-918
H-18 Excessive hydraulic drift of dump body ...................................................................................... 20-919
Remedy symbol Remedy

X Replace
! Repair
A Adjust
C Clean
HM400-1 20-901
1
H-1
TROUBLESHOOTING
H-1 Machine does not start

Ask the operator the following questions Causes
• Did the problem suddenly happen?
a b c d e f g h i j k l m n
Yes = Internal seizure, damage
• When this happened, was there any abnormal
noise?
Yes = Broken part
Drop in set pressure of power train main relief valve
Defective operation of speed clutch ECMV solenoid

Air sucked in at suction side of power train pump
Defective operation of speed clutch ECMV valve

Checks before troubleshooting
Defective power train pump drive system (PT0)
Defective speed clutch piston sealing, groove

• Is the oil level in the transmission case correct?
• Is the torque converter, transmission input shaft
broken? (Monitor with the transmission input shaft
Defective speed clutch shaft seal ring

speed sensor.)
Defective function of speed sensor

Clogged power train pump strainer
Breakage inside torque converter

• Is the drive shaft broken?
• Is there any dragging of the foot brake, retarder
Breakage inside transmission

Defective power train pump
(which is not used in E-SPEC), exhaust brake (ma-
chines equipped with exhaust brake), or parking
Defective speed clutch

brake?
Seized speed clutch

• Is the retarder lever potentiometer returned to the
RELEASE position? (E-SPEC)
• Is any failure code related to the power train dis-
played?
No. Problems Remedy

C
1 Abnormal noise comes from between power train pump and filter
2 Machine does not start in any speed range (Item 1 normal)
3 Machine starts normally in certain speed range
4 Machine does not start when torque converter oil temperature rises
5 Measure power Low at every speed range
6 train main relief Becomes lower at certain speed range
7 pressure Oil pressure gauge is unstable and fluctuates excessively
8 When pressure pickup port plug is removed and engine is

cranked, no oil comes out
9 Clutch oil pressure is abnormal
10 Power train main relief pressure is low
Clutch used
Hi Lo 1st 2nd 3rd R
R2
R1
N
Speed range
F1
F2
F3
F4
F5
F6
20-902 HM400-1
6
1
H-2, H-3
TROUBLESHOOTING
H-2 Machine does not travel smoothly (machine jerks)

• There is hunting.
Causes
• Lock-up pilot lamp flashes
a b


played?
Worn speed clutch seal ring

No. Remedy See H-6
Problems
Does not travel smoothly
H-3 Lock-up clutch cannot be disengaged (engine stalls)
• There is hunting. Causes

• Lock-up pilot lamp flashes a b c

Defective operation of lock-up ECMV solenoid
played?
Defective operation of lock-up ECMV valve
Seized lock-up clutch
Remedy C
No. Problems
1 When lock-up clutch pressure is measured, it does not become 0
2 When lock-up clutch pressure is measured, it becomes 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
HM400-1 20-903
1
TROUBLESHOOTING H-4, H-5
H-4 Excessive shock when starting or shifting Causes

Judgement standard a b c
There is some shock, but it is difficult to judge if the
shock is excessive or not, so judge that it is excessive
Defective operation of speed clutch ECMV pressure control valve spool

Defective operation of speed clutch ECMV flow detection valve spool
in the following cases.
• It is clear that the shock has suddenly become ex-
cessive.
• The shock is excessive compared with other ma-
chines of the same class.
Defective operation of speed clutch ECMV solenoid

played?
Remedy C C
No. Problems
Excessive shock when starting or shifting
Causes
H-5 Transmission does not shift up
a b c d

played?
Defective speed clutch piston seal ring, groove
• This is the most probable cause, but for details, see

H-6.
Defective operation of speed clutch ECMV
Clutch used
Slipping or damage of lock-up clutch
Hi Lo 1st 2nd 3rd R

R2
R1
N
Speed range
F1
F2
F3
F4
F5
F6
C
Remedy
No. Problems
Shifts up when traveling downhill ※
Does not shift up, regardless of road surface
20-904 HM400-1
1
TROUBLESHOOTING H-6
H-6 Machine lacks power or speed when traveling

a) Abnormality at all speed ranges
Causes
Checks before troubleshooting a b c d e f g h i j k
• Is there any external oil leakage from the piping or
valve connections (joints)?
Torque converter lock-up does not engage (carry out troubleshooting for H-6b)
Excessive oil leakage inside torque converter (defective seal ring, loose plug)
Defective operation of torque converter relief valve, deteriorated spring

brake?
played?
Defect inside torque converter (turbine rivet broken)

Defective torque converter outlet piping, cooler

Defective torque converter freewheel
Drop in performance of engine
No. Problems Remedy

C
1 Abnormal noise comes from between power train pump and filter
2 Torque converter stall speed is high
3 Torque converter stall speed is low
4 Measure power Low at every speed range (Item 2 normal)
5 train main relief Oil pressure gauge is unstable and fluctuates excessively
6 pressure Becomes low when lock-up is engaged
7 Hydraulic pressure at torque converter inlet port is low (Items 4 - 6 normal)
8 Hydraulic pressure at torque converter outlet port is low (Item 7 normal)
Pieces of iron and aluminium stuck to strainer and drain plug of transmis-
9 sion case
10 Hydraulic pressure at power train pump outlet port is low
11 When carrying out troubleshooting for Item 10, if oil temperature rises, oil pressure drops
HM400-1 20-905
6
1
TROUBLESHOOTING H-6
b) Abnormality at some speed ranges Causes

a b c d e f g h i j k l
brake?
played?
2nd clutch disc worn or seized, seal ring worn

3rd clutch disc worn or seized, seal ring worn
1st clutch disc worn or seized, seal ring worn
Lo clutch disc worn or seized, seal ring worn
Hi clutch disc worn or seized, seal ring worn
R clutch disc worn or seized, seal ring worn
Defective operation of 2nd clutch ECMV

Clutch used
Defective operation of 3rd clutch ECMV

Defective operation of 1st clutch ECMV
Defective operation of Lo clutch ECMV
Defective operation of Hi clutch ECMV
Defective operation of R clutch ECMV

Hi Lo 1st 2nd 3rd R
R2
R1
N
Speed range
F1
F2
F3
F4
F5
F6
No. Problems Remedy
1 F2, F4, and F6 are abnormal, but other speed ranges are normal
2 Same as Item 1, but condition returns to normal when ECMV for Hi
clutch is replaced with ECMV for R clutch
3 F1, F3, and F4 are abnormal, but other speed ranges are normal
4 Same as Item 3, but condition returns to normal when ECMV for Lo
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
7 F3, F4, and R2 are abnormal, but other speed ranges are normal
8 Same as Item 7, but condition returns to normal when ECMV for 2nd
9 F5 and F6 are abnormal, but other speed ranges are normal
Same as Item 9, but condition returns to normal when ECMV for 3rd
10
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
20-906 HM400-1
6
1
TROUBLESHOOTING H-6
c) Torque converter lock-up does not engage Causes

a b c d e f g
Ask the operator the following questions
• Did the problem suddenly happen?
Yes = Internal seizure, damage
• When this happened, was there any abnormal
noise?
Yes = Broken part
Defective operation of lock-up ECMV solenoid spool

Defective operation of lock-up ECMV valve spool

• Is there any external oil leakage from piping or
Worn lock-up clutch piston seal ring

Defective lock-up ECMV solenoid
played?
Cracked lock-up clutch case

Worn lock-up clutch disc
△ △ △ △
No. Problems Remedy × × × × × × ×
1 Power train main relief pressure is low ○
2. With Item 1 normal, lock-up clutch pressure is low or 0 ○ ○ ○
3. With Item 2 abnormal, no disconnection, short circuit, or short circuit with ground is ○
found in lock-up ECMV solenoid
4 With Item 2 abnormal, disconnection, short circuit, or short circuit with
○
ground is found in lock-up ECMV solenoid
5 With Items 1 - 4 normal, lock-up oil pressure is low ○ ○
6 With Items 1 - 4 normal, lock-up oil pressure is normal ○
7 When oil pressure is measured, main relief pressure and lock-up clutch pressure are both low ○
8 Lock-up takes time to engage ○ ○
HM400-1 20-907
1
TROUBLESHOOTING H-7
H-7 Time lag is excessive when starting or shifting gear
Checks before troubleshooting Causes

a b c d e f g h i j k l m n o p q r
• Is there any external oil leakage from the piping
or valve connections (joints)?
• Is operation of control valve normal?
played?
2nd clutch disc worn or defective seal ring, worn seal ring
3rd clutch disc worn or defective seal ring, worn seal ring
1st clutch disc worn or defective seal ring, worn seal ring
Lo clutch disc worn or defective seal ring, worn seal ring
Hi clutch disc worn or defective seal ring, worn seal ring
R clutch disc worn or defective seal ring, worn seal ring

Defective operation of 2nd clutch ECMV

Defective shaft seal ring of speed clutch
Defective operation of 3rd clutch ECMV

Defective operation of 1st clutch ECMV
Defective operation of Lo clutch ECMV
Defective operation of Hi clutch ECMV
Defective operation of R clutch ECMV

Defective oil tightness of speed clutch
Clutch used
Hi Lo 1st 2nd 3rd R

R2
R1
N
Speed range
F1
F2
F3
F4
F5
F6
No. Problems Remedy C
1 Abnormal noise comes from around power train pump

2 There is time lag in any speed range
3 There is time lag when shifting to F2, F4, F6
4 There is time lag when shifting to F1, F3, F4
5 There is time lag when shifting to F1, F2, R1
6 There is time lag when shifting to F3, F4, R2
7 There is time lag when shifting to F5, F6
8 There is 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
20-908 HM400-1
1
TROUBLESHOOTING H-8
H-8 Torque converter oil temperature is high
Ask the operator the following questions Causes

• Does oil temperature go up when torque converter
a b c d e
is stalled and go down when torque converter is
not stalled?
Yes = Normal (but if stalling is frequent, selection of
speed range is incorrect)
Oil leakage inside torque converter (defective seal ring, loose bolt,
• Is oil level in transmission case correct?
played?
Defective operation of torque converter relief valve


Clogged power train filter
crack in pump or turbine)

Remedy
No. Problems C
1 Power train pump makes abnormal noise when oil temperature is low
2 Low idling and high idling speeds are low
3 Torque converter outlet port oil pressure is low
4 Torque converter inlet port oil pressure is low
5 Clutch pressure is low
6 Excessive leakage inside torque converter
★ If the results of all troubleshooting items are normal, this is the probable cause.
HM400-1 20-909
1
TROUBLESHOOTING H-9
H-9 Torque converter oil pressure is low

a b c d e
• Is there any external oil leakage from the piping or
played?
Drop in set pressure of torque converter relief valve

Excessive leakage inside torque converter


No. Problems Remedy C C
1 Abnormal noise comes from power train pump
2 Power train main relief pressure is low
3 Torque converter inlet port pressure is low
4 Torque converter inlet pressure is low (lock-up pressure and clutch pressure are normal)
5 When torque converter relief valve is adjusted, inlet pressure becomes high
20-910 HM400-1
1
TROUBLESHOOTING H-10
H-10 Front brake is ineffective, or effective only on one side

• Is the oil level in the transmission case correct? a b c d e f g h i j k l m n o
• Is the brake pedal play correct?
• Is there any leakage of oil from the brake piping or
deformation of the piping?
Drop in accumulator gas pressure (gas leakage, defective piston seal)

• Is the tire inflation and tread condition normal?
• Is any failure code related to the brakes displayed?
Defective rear brake pressure reducing valve

Air sucked in at suction side of PPC pump
Defective operation of wheel brake piston

Defective PPC pump drive system (PTO)
Defective accumulator charge valve
Defective wheel brake piston seal
Breakage inside wheel brake

Defective brake valve (front)
Defective slack adjuster
Defective retarder lever

Worn wheel brake disc
Defective PPC pump
Air in brake circuit

Improper axle oil
No. Problems Remedy
1 Brake has no effect only when brake pedal is depressed

2 When brake pedal is depressed, it is light
3 When brake pedal is depressed, it is heavy
4 Even when retarder lever is pulled, retarder has no effect
(which is not used in E-SPEC)
5 Extremely large operating effort is needed to obtain
specified braking effect
6 When brakes are applied, abnormal noise is heard from brake portion of axle
7 Hydraulic and steering do not work
8 Abnormal noise is heard from around PTO
9 Abnormal noise is heard from around transmission oil pan
or PPC pump
When oil is drained from inside axle case, large amounts
10
of metal particles are found
11 Accumulator charge pressure is low
12 Brake immediately loses power after engine is stopped
13 There is time lag before brake starts to take effect
14 Brake oil pressure is low
15 Brake disc wear amount is high
16 When air is bled from brake system, air comes out
HM400-1 20-911
6
1
H-11 Center brake is ineffective, or effective only on one side

• Is the oil level in the transmission case correct? a b c d e f g h i j k l m n o

Defective rear brake pressure reducing valve


Defective brake valve (center, rear)

Defective retarder lever

Defective PPC pump

Improper axle oil
No. Problems Remedy
4 Even when retarder lever is pulled, retarder has no effect
(which is not used in E-SPEC)
5 Extremely large operating effort is needed to obtain
specified braking effect
6 When brakes are applied, abnormal noise is heard from
brake portion of axle
9 Abnormal noise is heard from around transmission oil pan
or PPC pump
10 When oil is drained from inside axle case, large amounts
of metal particles are found
20-912 HM400-1
6
1
H-12 Rear brake is ineffective, or effective only on one side

• Is the oil level in the transmission case correct? a b c d e f g h i j k l m


Defective brake valve (center, rear)


Defective PPC pump

Improper axle oil
Remedy
No. Problems
4 Extremely large operating effort is needed to obtain specified
braking effect
5 When brakes are applied, abnormal noise is heard from brake portion of axle
8 Abnormal noise is heard from around transmission oil pan or PPC
pump
9 When oil is drained from inside axle case, large amounts of metal
particles are found
HM400-1 20-913
1
H-13 Steering wheel is heavy

• Is the oil level in the hydraulic tank correct? a b c d e f g h i
• Is there any external oil leakage between the pump
flow amplifier valve steering valve?
• Is the steering wheel play correct?
• Is the differential lock (interaxle differential lock or
Drop in set pressure of flow amplifier valve relief valve or defective oil tightness
differential locks on both sides) operated during
swing operation?
(Do not use the differential lock during swing oper-
ation.)
• Is any failure code related to the steering dis-
played?
Defective operation of flow amplifier valve spool or stuck spool

Air sucked in at suction end of hydraulic and steering pump
Defective hydraulic and steering pump drive system (PTO)
Damaged suction tube of hydraulic and steering pump

Clogged hydraulic and steering pump strainer
Defective hydraulic and steering pump
Defective steering cylinder

A Defective steering valve
Remedy
No. Problems C
1 Dump cylinder also does not work

2 When pressure pickup port plug is removed and engine is cranked, no oil comes out
3 Dump is normal
4 Steering oil pressure is low at end of cylinder stroke
(Item 3 normal)
5 Item 4 is abnormal, relief noise is heard from relief valve
6 Abnormal noise comes from between hydraulic, steering pump - filter
7 Steering wheel works when engine is at low idling
8 When steering cylinder is turned fully to right (left), and hose on opposite side is
disconnected, oil flows out continuously
9 Hydraulic and steering pump discharge amount is too low
10 Excessive play in steering wheel
20-914 HM400-1
6
1
H-14 Steering wheel does not work

• Is the oil level in the hydraulic tank correct?
a b c d e f g h i
flow amplifier valve steering valve?
• Is the steering wheel play correct?
• Is the brake (service brake or retarder brake) oper-
ated?
played?

Damaged suction tube of hydraulic and steering pump

Defective steering cylinder

Defective steering valve
Remedy A
No. Problems C
1 Dump cylinder also does not work

3 Dump is normal
4 Steering oil pressure is low at end of cylinder stroke
(Item 3 normal)
6 Abnormal noise comes from between hydraulic, steering pump - filter
7 Steering wheel works when engine is at low idling
8 When steering cylinder is turned fully to right (left), and hose on opposite side is
disconnected, oil flows out continuously
9 Hydraulic and steering pump discharge amount is too low
10 Excessive play in steering wheel
HM400-1 20-915
6
1
H-15 Steering wheel vibrates

Causes
a b
played?
Leakage of air inside steering cylinder

Air in hydraulic oil
No. Remedy A
Problems
Steering wheel vibrates
20-916 HM400-1
1
H-16 Dump body lifting speed is slow, or lacks power

a b c d e f g h i j k l
- dump valve - dump cylinder?
• Is signal value of dump lever within normal range?
• Is any failure code related to the dump displayed?
Drop in set pressure of dump valve relief valve or defective oil tightness
Air sucked in at suction side of hydraulic and steering pump
Defective operation of check valve of dump valve

Broken hydraulic and steering pump suction tube
Drop in dump EPC valve or defective operation


Defective dump EPC pump
Defective dump cylinder

Defective dump lever
Remedy A A
No. Problems C
1 Steering also does not work normally

2 Steering works normally
3 Steering relief pressure and dump relief pressure is low
5 Dump relief pressure is too high at engine high idling
6 Dump relief pressure is low
8 Dump body does not rise smoothly (moves irregularly)
9 Hydraulic and steering pump discharge amount is low
10 Items 1 - 9 are normal but dump body lifting speed is slow
11 Abnormal noise comes from between hydraulic and steering pump - filter
12 Dump EPC valve oil pressure is low
HM400-1 20-917
6
1
H-17 Dump does not work

a b c d e f g h i j k l m
• Is signal value of dump lever within normal range?
• Is any failure code related to the dump displayed?
• Is the battery charge circuit caution lamp lighting
up?
(If the alternator signal R is not output normally, the
dump controller does not operate.)
Drop in set pressure of dump valve relief valve or defective oil tightness
Broken suction tube of hydraulic and steering pump
Defective operation of check valve of dump valve

Drop in dump EPC valve or defective operation

Defective dump EPC pump
Defective dump cylinder

Defective dump lever
A A
Remedy
No. Problems C
2 Steering also does not work normally
3 Steering works normally
4 Item 2 is abnormal, steering relief pressure and dump relief pressure
is low
6 Dump relief pressure is low
8 Dump relief pressure is low at engine high idling
9 Normal when engine is at low idling
10 Hydraulic and steering pump discharge amount is low
11 When dump body is raised, and hose at head end of dump cylinder is
disconnected, oil flows out
20-918 HM400-1
6
1
H-18 Excessive hydraulic drift of dump body

• Is any failure code related to the dump displayed? a b

Slipping or damage of lock-up clutch
Remedy
No. Problems
1 Raise dump body and disconnect hose at head Oil flows out
2 end of dump cylinder Oil does not flow out
HM400-1 20-919
1
TROUBLESHOOTING 20 TROUBLESHOOTING
TROUBLESHOOTING OF THE ENGINE BODY

(S MODE)
Points to remember when troubleshooting ............................................................................................ 20-1002

Method of using troubleshooting charts ................................................................................................. 20-1003
S-1 Starting performance is poor (starting always takes time) ........................................................... 20-1007
S-2 Engine does not start ................................................................................................................... 20-1008
S-3 Engine does not pick up smoothly (follow-up is poor) .................................................................. 20-1011
S-4 Engine stops during operations .................................................................................................... 20-1012
S-5 Engine does not rotate smoothly (hunting) ................................................................................... 20-1013
S-6 Engine lacks output (or lacks power) ........................................................................................... 20-1014
S-7 Exhaust smoke is black (incomplete combustion) ........................................................................ 20-1015
S-8 Oil consumption is excessive (or exhaust smoke is blue) ............................................................ 20-1016
S-9 Oil becomes contaminated quickly ............................................................................................... 20-1017
S-10 Fuel consumption is excessive ..................................................................................................... 20-1018
S-11 Oil is in cooling water (or water spurts back, or water level goes down) ...................................... 20-1019
S-12 Oil pressure caution lamp lights up (drop in oil pressure) ............................................................ 20-1020
S-13 Oil level rises (water, fuel in oil) .................................................................................................... 20-1021
S-14 Water temperature becomes too high (overheating) .................................................................... 20-1022
S-15 Abnormal noise is made ............................................................................................................... 20-1023
S-16 Vibration is excessive ................................................................................................................... 20-1024
HM400-1 20-1001
(7)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the park-
ing brake is securely applied.
k 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.
k If the radiator cap is removed when the engine is still hot, boiling water may spurt out and cause serious
burns. Always wait for the water temperature to go down before removing the radiator cap.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing a plug or cap from a location which is under pressure from oil, water, 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, and important point is of course to understand
the structure and function. However, a short cut to effective troubleshooting is to ask the operator various ques-
tions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 3. Checks before troubleshooting

hurry to disassemble the components 1) Is there any sign of abnormality in the ma-
If components are disassembled immediately chine or engine?
any failure occurs: 2) Always carry out the Checks before starting.
• Parts that have no connection with the failure 3) Carry out other checks if necessary.
or other unnecessary parts will be disassem- 4) Other maintenance items can be checked
bled. externally, so check any item that is consid-
• It will become impossible to find the cause of ered to be necessary.
the failure. 5) Check for any error display on the controller.
It will also cause a waste of man-hours, parts, or
oil or grease, and at the same time, will also lose 4. Confirming failure
the confidence of the user or operator. Confirm the extent of the failure yourself, and
For this reason, when carrying out troubleshoot- judge whether to handle it as a real failure or as
ing, it is necessary to carry out thorough prior in- a problem with the method of operation, etc.
vestigation and to carry out troubleshooting in a When operating the machine to re-enact the
accordance with the fixed procedure. troubleshooting symptoms, do not carry out
any investigation or measurement that may
2. Points to ask user or operator make the problem worse.
1) Have any other problems occurred apart
from the problem that has been reported? 5. Troubleshooting
2) Was there anything strange about the ma- Use the results of the investigation and inspec-
chine before the failure occurred? tion in Items 2 – 4 to narrow down the causes of
3) Did the failure occur suddenly, or were there failure, then use the troubleshooting matrix or
problems with the machine condition before flowchart to locate the position of the failure ex-
this? actly.
4) Under what conditions did the failure occur? a The basic procedure for troubleshooting is
5) Had any repairs been carried out before the as follows.
failure? When were these repairs carried 1) Start from the simple points.
out? 2) Start from the most likely points.
6) Has the same kind of failure occurred be- 3) Investigate other related parts or informa-
fore? tion.
6. Measures to remove root cause of failure

Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again.
To prevent this, always investigate why the prob-
lem occurred. Then, remove the root cause.
20-1002 HM400-1
(7)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make fi-
nal confirmation.
[Questions]
Sections A + B in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in B are items
that can be obtained from the user, depending
on the user’s level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under C in
the chart on the right correspond to this.
[Causes]
The serviceman narrows down the causes from
information A that he has obtained from the
user and the results of C that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high prob-
ability are marked with w.
Check each of the [Questions] and [Check items]
in turn, and marked the Q or w in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
As a rule, do not use it when calculating the points
for locating the cause, but it can be included if nec-
essary to determine the order for troubleshooting.
Use the E in the Cause column as reference for
[Degree of use (Operated for long period)] in the
[Questions] section as reference.
HM400-1 20-1003
(7)
<Example of troubleshooting> Exhaust smoke is black
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)

General causes why exhaust smoke is black
• Insufficient intake of air
• There is excessive fuel.
• Abnormal fuel injection condition
• Improper selection of fuel
• Engine overheating
a See troubleshooting for [Overheat].
• Controller controlled by delayed mode
(The injection amount (output) is limited be-
cause an error has occurred in the electrical
system.)
20-1004 HM400-1
(7)
HM400-1 20-1005
(7)
TROUBLESHOOTING S-1
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
General causes why starting performance is poor

• Defective electrical system
• Insufficient supply of fuel
a With the common rail fuel injection system, the fuel in-
jection timing is recognized electrically, so even when
the starting operation is carried out, the engine may not
start until the crankshaft has completed two rotations.
However, this does not indicate any abnormality.
HM400-1 20-1007
(7)
TROUBLESHOOTING S-2
S-2 ENGINE DOES NOT START
a) Engine does not turn

General causes why engine does not turn
• Internal parts of engine seized
a See “Engine stops during operations”.
• Defective electrical system
• Failure in power train
a Carry out troubleshooting of the machine.
*1.
*1. Carry out troubleshooting in chassis volume.
20-1008 HM400-1
(7)
TROUBLESHOOTING S-2
b) Engine turns but no exhaust smoke comes out

General causes why engine turns but no exhaust
smoke comes out
• Fuel is not being supplied
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
HM400-1 20-1009
(7)
TROUBLESHOOTING S-2
c) Exhaust smoke comes out but engine does not start

(Fuel is being injected)
General causes why exhaust smoke comes out but en-
gine does not start
• Lack of rotating force due to defective electrical sys-
tem
20-1010 HM400-1
(7)
TROUBLESHOOTING S-3
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
General causes why engine does not pick up smoothly

(The injection amount (output) is limited because an error has
occurred in the electrical system.)
HM400-1 20-1011
(7)
TROUBLESHOOTING S-4
S-4 ENGINE STOPS DURING OPERATIONS
General causes why engine stops

• Internal part of engine seized
• Failure in power train
a Carry out troubleshooting of the machine.
20-1012 HM400-1
(7)
TROUBLESHOOTING S-5
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
General causes why engine does not rotate smoothly

• Air in fuel system
• Speed sensor is not normal
(abnormality not big enough to generate error display)
HM400-1 20-1013
(7)
TROUBLESHOOTING S-6
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
General causes why engine lacks output

(The injection amount (output) is limited because an er-
ror has occurred in the electrical system.)
20-1014 HM400-1
(7)
TROUBLESHOOTING S-7
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
General causes why exhaust smoke is black

• There is excessive fuel.
(The injection amount (output) is limited because an error
has occurred in the electrical system.)
HM400-1 20-1015
(7)
TROUBLESHOOTING S-8
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
General causes why oil consumption is excessive

• Abnormal combustion of oil
• The engine has been run at low or high idling for a long
time continuously (more than 20 minutes continuous op-
eration is not allowed).
• External leakage of oil
• Wear of lubrication system
20-1016 HM400-1
(7)
TROUBLESHOOTING S-9
S-9 OIL BECOMES CONTAMINATED QUICKLY
General causes why oil becomes contaminated quickly

• Entry of exhaust gas into oil due to internal wear
• Clogging of lubrication passage
• Improper fuel used
• Improper oil used
• Operation under excessive load
HM400-1 20-1017
(7)
TROUBLESHOOTING S-10
S-10 FUEL CONSUMPTION IS EXCESSIVE
General causes why fuel consumption is excessive

• Leakage of fuel
• Improper condition of fuel injection (injection pressure, injection timing)
• Excessive injection of fuel
20-1018 HM400-1
(7)
S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)
General causes why oil is in cooling water

• Internal leakage in lubrication system
• Internal leakage in cooling system
*1.
HM400-1 20-1019
(7)
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)
General causes why oil pressure drops

• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
20-1020 HM400-1
(7)
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)
General causes why oil level rises

• Water in oil (cloudy white)
• Fuel in oil (diluted, smells of diesel fuel)
a If there is oil in the cooling water, carry out troubleshooting for “Oil is
in cooling water”.
HM400-1 20-1021
(7)
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
General causes why water temperature becomes too high

• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise in oil temperature in power train
a Carry out troubleshooting for machine.
*1.
20-1022 HM400-1
(7)
S-15 ABNORMAL NOISE IS MADE
General causes why abnormal noise is made

• Abnormality due to defective parts
• Abnormal combustion
• Air sucked in from intake system
a Judge if the noise is an internal noise or an external noise.

a If the engine is not thoroughly warmed up, the engine sound be-
comes slightly louder because it is operated in the low temper-
ature mode, but this is not an abnormality.
a When the engine is accelerated, it enters the acceleration mode
and the engine noise is higher for 3 seconds, but this is not an
abnormality.
HM400-1 20-1023
(7)
S-16 VIBRATION IS EXCESSIVE
General causes why vibration is excessive

• Defective parts (abnormal wear, breakage)
• Improper alignment with machine
• Abnormal combustion
a If there is abnormal noise together with the vibration, carry out trouble-
shooting also for “Abnormal noise is made”.
20-1024 HM400-1
(7)
30 DISASSEMBLY AND ASSEMBLY

HOW TO READ THIS MANUAL REMOVAL OF CENTER DIFFERENTIAL
Removal and installation of assemblies ..30- 3 ASSEMBLY ........................................... 30-126
Disassembly and assembly of INSTALLATION OF CENTER
assemblies .............................................. 30-3-1 DIFFERENTIAL ASSEMBLY ................. 30-128
PRECAUTIONS WHEN CARRYING OUT DISASSEMBLY OF CENTER
OPERATION ..........................................30- 4 DIFFERENTIAL ASSEMBLY ................. 30-129
SECIAL TOOL LIST .....................................30- 6 ASSEMBLY OF CENTER DIFFERENTIAL
SKETCHES OF SPECIAL TOOLS ...............30- 11 ASSEMBLY ........................................... 30-135
REMOVAL OF FUEL SUPPLY PUMP ........ 30-22-1 REMOVAL OF REAR DIFFERENTIAL
INSTALLATION OF FUEL ASSEMBLY ........................................... 30-145
SUPPLY PUMP..................................... 30-22-2 INSTALLATION OF REAR DIFFERENTIAL
REMOVAL OF ENGINE ASSEMBLY ...........30- 23 ASSEMBLY ........................................... 30-146
INSTALLATION OF ENGINE ASSEMBLY ...30- 26 DISASSEMBLY OF REAR DIFFERENTIAL
REMOVAL OF CYLINDER HEAD ASSEMBLY ........................................... 30-147
ASSEMBLY ............................................30- 27 ASSEMBLY OF REAR DIFFERENTIAL
INSTALLATION OF CYLINDER HEAD ........30- 31 ASSEMBLY ........................................... 30-151
REMOVAL AND INSTALLATION OF REMOVAL OF FRONT FINAL DRIVE AND
NOZZLE TIP BRAKE ASSEMBLY .............................. 30-159
Removal ................................................ 30-35-1 INSTALLATION OF FRONT FINAL DRIVE
Installation ............................................. 30-35-2 AND BRAKE ASSEMBLY ..................... 30-160
REMOVAL OF RADIATOR ASSEMBLY ......30- 36 DISASSEMBLY OF FRONT FINAL DRIVE
INSTALLATION OF RADIATOR AND BRAKE ASSEMBLY ..................... 30-161
ASSEMBLY ............................................30- 38 ASSEMBLY OF FRONT FINAL DRIVE AND
REMOVAL OF OUTPUT SHAFT BRAKE ASSEMBLY .............................. 30-167
ASSEMBLY ............................................30- 39 REMOVAL OF CENTER FINAL DRIVE AND
INSTALLATION OF OUTPUT SHAFT BRAKE ASSEMBLY .............................. 30-174
ASSEMBLY ............................................30- 42 INSTALLATION OF CENTER FINAL DRIVE
DISASSEMBLY OF OUTPUT SHAFT AND BRAKE ASSEMBLY ..................... 30-175
ASSEMBLY ............................................30- 43 DISASSEMBLY OF CENTER FINAL DRIVE
ASSEMBLY OF OUTPUT SHAFT AND PLATE ASSEMBLY ...................... 30-176
ASSEMBLY ............................................30- 44 ASSEMBLY OF CENTER FINAL DRIVE
REMOVAL OF TRANSMISSION AND AND BRAKE ASSEMBLY ..................... 30-180
FRONT DIFFERENTIAL ASSEMBLY ....30- 46 REMOVAL OF REAR FINAL DRIVE AND
INSTALLATION OF TRANSMISSION AND BRAKE ASSEMBLY .............................. 30-186
FRONT DIFFERENTIAL ASSEMBLY ....30- 52 INSTALLATION OF REAR FINAL DRIVE
DISCONNECTION OF FRONT DIFFERENTIAL AND BRAKE ASSEMBLY ..................... 30-187
AND TRANSMISSION ...........................30- 54 DISASSEMBLY OF REAR FINAL DRIVE
COUPLING OF FRONT DIFFERENTIAL AND BRAKE ASSEMBLY ..................... 30-187
AND TRANSMISSION ...........................30- 54 ASSEMBLY OF REAR FINAL DRIVE AND
DISASSEMBLY OF TORQUE BRAKE ASSEMBLY .............................. 30-192
CONVERTER ASSEMBLY ....................30- 55 REMOVAL OF CENTER AXLE
ASSEMBLY OF TORQUE CONVERTER ASSEMBLY ........................................... 30-197
ASSEMBLY ............................................30- 59 INSTALLATION OF CENTER AXLE
DISASSEMBLY OF TRANSMISSION ASSEMBLY ........................................... 30-199
ASSEMBLY ............................................30- 63 REMOVAL OF REAR AXLE ASSEMBLY .... 30-200
ASSEMBLY OF TRANSMISSION INSTALLATION OF REAR AXLE
ASSEMBLY ............................................30- 82 ASSEMBLY ........................................... 30-202
DISASSEMBLY OF FRONT REMOVAL OF FRONT SUSPENSION
DIFFERENTIAL ASSEMBLY .................30-108 CYLINDER ASSEMBLY ........................ 30-203
ASSEMBLY OF FRONT DIFFERENTIAL INSTALLATION OF FRONT SUSPENSION
ASSEMBLY ............................................30-115 CYLINDER ASSEMBLY ........................ 30-204
HM400-1 30-1
(12)
2
REMOVAL OF REAR SUSPENSION

CYLINDER ASSEMBLY ........................ 30-204
INSTALLATION OF REAR SUSPENSION
CYLINDER ASSEMBLY ........................ 30-205
REMOVAL OF EQUALIZER BAR
ASSEMBLY ........................................... 30-206
INSTALLATION OF EQUALIZER BAR
ASSEMBLY ........................................... 30-207
REMOVAL OF FRONT WHEEL
ASSEMBLY ........................................... 30-208
INSTALLATION OF FRONT WHEEL
ASSEMBLY ........................................... 30-208
REMOVAL, INSTALLATION OF
REAR WHEEL ASSEMBLY .................. 30-209
REMOVAL OF HITCH FRAME
ASSEMBLY ........................................... 30-210
INSTALLATION OF HITCH FRAME
ASSEMBLY ........................................... 30-214
DISASSEMBLY OF HITCH FRAME ............ 30-216
ASSEMBLY OF HITCH FRAME
ASSEMBLY ........................................... 30-217
STANDARD INTEGRAL ORBIT-ROLL......... 30-220
DISASSEMBLY OF STEERING VALVE....... 30-222
ASSEMBLY OF STEERING VALVE............. 30-224
REMOVAL OF FLOW AMPLIFIER VALVE
ASSEMBLY ........................................... 30-229
INSTALLATION OF FLOW AMPLIFIER
VALVE ASSEMBLY ............................... 30-229
REMOVAL OF HOIST VALVE
ASSEMBLY ........................................... 30-230
INSTALLATION OF HOIST VALVE
ASSEMBLY ........................................... 30-230
DISASSEMBLY OF HOIST VALVE
ASSEMBLY ........................................... 30-231
ASSEMBLY OF HOIST VALVE
ASSEMBLY ........................................... 30-232
DISASSEMBLY OF STEERING CYLINDER
ASSEMBLY ............................................ 30-233
ASSEMBLY OF STEERING CYLINDER
ASSEMBLY ........................................... 30-234
DISASSEMBLY OF HOIST CYLINDER
ASSEMBLY ........................................... 30-236
ASSEMBLY OF HOIST CYLINDER
ASSEMBLY .......................................... 30-238
REMOVAL OF BODY ASSEMBLY .............. 30-241
INSTALLATION OF BODY ASSEMBLY ...... 30-242
DISASSEMBLY AND ASSEMBLY OF
OPERATOR'S SEAT ASSEMBLY ......... 30-243
30-2 HM400-1
(12)
2
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
HOW TO READ THIS MANUAL

REMOVAL AND INSTALLATION OF
ASSEMBLIES
Special tools Installation of parts

• Special tools that are deemed necessary for • Except where otherwise instructed, install parts
removal or installation of parts are listed. is the reverse order of removal.
• List of the special tools contains the following • Instructions and precautions for installing parts
kind of information. are shown with [*1] mark in the INSTALLATION
Section, identifying which step the instructions
1) Necessity
: Special tools which cannot be substi- are intended for.
tuted, should always be used. • Marks shown in the INSTALLATION Section
stand for the following.
¤
z: Special tools which are very useful if
available, can be substituted with com- This mark indicates safety-related pre-
cautions which must be followed when
mercially available tools.
doing the work.
2) Distinction of new and existing special tools ★ This mark gives guidance or precau-
N: Tools with new part numbers, newly tions when doing the procedure.
developed for this model. 2 This mark stands for a specific coating
agent to be used.
3 This mark indicates the specified torque.
R: Tools with upgraded part numbers,
remodeled from already available
5
tools for other models.
Blanks: Tools already available for other This mark indicates an amount of oil or
water to be added.
models, used without any modifica-
tion.
Sketches of special tools
3) Circle mark (c) in sketch column: • Various special tools are illustrated for the con-
A circle mark means that a sketch of the venience of local manufacture.
special tool is presented in the section of
Sketches for Special Tools.
★ Part No. of special tools starting with 79*T
means that they are locally made parts and as
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T---xxx---xxxx.
Removal of parts
• The REMOVAL Section contains procedures,
precautions and the amount of oil or water to be
drained.
• Various symbols used in the REMOVAL Section
are explained and listed below.
¤ This mark indicates safety-related pre-
doing the work.
★ This mark gives guidance or precau-
tions when doing the procedure.
[*1] This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be
drained.
HM400-1 30-3
(12)
2
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL

ASSEMBLIES
Special tools Assembly

• Special tools which are deemed ncessary for • Section titled ASSEMBLY contain procedures,
disassembly and assembly are listed in this sec- precautions and the know-how for the work, as
tion. well as the amount of oil or water to be added.
• List of the special tools contains the following • Various symbols used in the ASSEMBLY Sec-
kind of information. tion are explained and listed below.
1) Neccessity
: Special tools which cannot be substi- cautions which must be followed when
doing the work.
tuted, should always be used.
z: Special tools which are very useful if
2 This mark stands for a specific coating
available, can be substituted with com-
mercially available tools. agent to be used.
2) Distinction of new and existing special tools 3 This mark indicates the specified torque.
5
N: Tools with new part numbers, newly
developed for this model. This mark indicates an amount of oil or
water to be added.
R: Tools with upgraded part numbers,
remodeled from already available
Sketches of special tools
tools for other models.
Blanks: Tools already available for other 1) Various special tools are illustrated for the con-
venience of local manufacture.
models, used without any modifica-
tion.
3) Circle mark (c) in sketch column:
A circle mark means that a sketch of the
special tool is presented in the section of
Sketches for Special Tools.
4) Part No. of special tools starting with 79*T
means that they are locally made parts and
as such not interchangeable with those
made by Komatsu in Japan e.g. 79*T---xxx--
-xxxx.
Disassembly
• The DISASSEMBLY Section contains proce-
dures, precautions and the amount of oil or
water to be drained.
• Various symbols used in the DISASSEMBLY
Section are explained and listed below.
doing the work.
[*1] This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be
drained.
30-3-1 HM400-1
(12)
2
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

• If the coolant contains antifreeze dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number of thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering
after removal.
★ Precautions when handling piping during disassembly

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal
Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
number
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
2) Face seal type hoses and tubes

Nominal
Plug (nut end) Nut (elbow end)
number
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
3) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
30-4 HM400-1
62
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
4) 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
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 - 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idling.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
★ When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment has been removed, always bleed the air from the system after
reassembling the parts.
For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
HM400-1 30-5
6
2
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

★ Tools with part number 79!T-!!!-!!!! cannot be supplied (they are items to be locally
manufactured).
★ Necessity: ": Cannot besubstiuted, should always be installed (used).
#: Extremely useful if available, can be substiuted with commercially availabe part.
★ New/remodel: N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from items already available for other
modes.
★ Blank:Tools already available for other modes, used without any modification.
★ Tools marked ! in the Sketch column are tools introduced in special sketches (See SKETCHES OF
SPECIAL TOOLS).
Necess New/
Component Symbol Part No. Part Name Q’ty Sketch Nature of work, remarks
ity remodel
Wrench Removal, installation of

1 790-331-1110 " 1
cylinder head
795-521-1110 Push tool " 1
790-101-5221 Grip " 1
For front
01010-51225 Bolt " 1
01050-31640 Bolt " 3 Press fitting
2 of crankshaft
795-931-1210 Sleeve " 1 oil seal
795-931-1220 Sleeve " 1
For rear
01050-31625 Bolt " 3
Disassembly,
A 01050-31645 Bolt " 3
assembly of engine
795-471-1320 Plate " 1
01017-32020 Bolt " 1 Removal of Fuel supply

3
01010-81095 Bolt " 2 pump
01643-31032 Washer " 2
792-220-1110 Centering tool " 2 Carrying out shaft of

4 engine assembly and
01050-61225 Bolt " 8 transmission assembly
Removing and installing
5 795T-471-1550 Wrench " 1 ! nozzle tips
790-201-2210 Plate " 1
790-201-2740 Spacer " 1
791-600-1120 Bolt " 1
790-101-2540 Washer " 1 Press fitting of shaft
1
01580-01613 Nut " 1 bearing
Disassembly, 01643-31645 Washer " 2
assembly of output B
shaft 790-101-2102 Puller (30 tons) " 1
790-101-1102 Hydraulic pump " 1
790-101-5401 Push tool kit " 1
790-101-5431 Plate 1 Press fitting of cage oil
2
790-101-5421 Grip 1 seal
01010-51240 Bolt 1
30-6 HM400-1
(9)
2
Neces New/ Ske-

Component Symbol Part No. Part Name Q’ty Nature of work, remarks
790-501-5000 Unit repair stand

T
sity
1
remodel tch
AC100V
Disassembly,
790-501-5200
Unit repair stand T 1
AC110V, assembly of
1
T 220V torque
?
converter
790-901-2110 Bracket
T 1
assembly
792T-413-1110 Plate
792-420-1110 Centering tool
T 1
1
N
792-420-1120 • Flange 2 Centering of engine and

2
792-413-1120 • Collar 1 torque converter
01050-31230 • Bolt 8
3 792-103-5110
Wrench T 1
Removal, installation of pump
Disassembly, bearing locknut
assembly of torque
converter
C
4 790-102-1871
Nut wrench T 1
Removal, installation of PTO
5 790-201-2730 Spacer
T 1
gear bearing set nut
Press fitting of pump bearing
6 793T-623-1170
Push tool T 1 N
? Press fitting of stator shaft
T ? bearing
7 792T-413-1120 Push tool
T 1 N
? Press fitting of gear bearing
8 792T-413-1130 Push tool
790-101-5401 Push tool kit
T 1
1
N Press fitting of coupling cover
790-101-5451 • Plate 1
9 Press fitting of cage oil seal
790-101-5421 • Grip 1
01010-51240 • Bolt
T 1
1
790-201-2750 Spacer
T 1
Press fitting of shaft bearing
790-201-2850
790-101-5401
Spacer
Push tool kit
T 1
1
790-101-5461 • Plate 1
2 Press fitting of cage oil seal
790-101-5421 • Grip 1
3
01010-51240 • Bolt
792T-415-1310 Push tool
T 1
1 N
? Press fitting of coupling cover
4 799-301-1500
Oil leak tester kit T 1
Check of operation of clutch
T ? piston
Disassembly, 5
792T-415-1320 Block
T 2 N Disassembly of 2nd and 3rd
T
01010-81050 Bolt 2 clutch assembly
assembly of D
transmission 790-101-2501 Push puller 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
790-101-2540 • Washer 1
790-101-2560 • Nut 2 Pulling out of FH & 1st clutch
6
790-101-2570 • Plate 4 bearing inner case
790-101-2630 • Leg 2
790-101-2660 • Adapter 2
791-112-1180
790-201-1320
• Nut
• Spacer
T 1
1
HM400-1

30-7
(8)
Neces New/ Ske-

T
sity remodel tch
790-201-2850 Spacer
T 1
Press fitting of bevel pinion
1 790-201-2740 Spacer
T 1
bearing (For R/F differential)
790-201-2750
790-101-5401
Spacer
Push tool kit
T 1
1
790-101-5481 • Plate 1 Press fitting of oil seal to
2
790-101-5421 • Grip 1 cage (For front differential)
01010-51240 • Bolt 1
790-201-2770 Spacer
T 1
For rear
differential
Press fitting of
For front
3
792T-423-1130 Push tool kit
T 1 N
? differential,
output shaft
seal
R/F
T differential
790-201-2740 Spacer
T 1
? Press fitting of shaft bearing
4 792T-423-1110 Push tool
792T-423-1120 Push tool
T 1
1
N
N
? (For front differential, R/F
differential)
5 792T-423-1130
Push tool T 1 N
? Press fitting of cage input
T seal
792-103-0901 Wrench
T 1
Adjustment of preload on
6 792-222-1110 Adapter
T 2
bearing
795-525-1000 Micrometer
T 1
Disassembly,
assembly of axle
H 7
796-751-1500
795-630-1803
Wrench assembly
Torque wrench
T 1
1
Measurement of turning
torque of side gear
8 792T-422-1250
Push tool T 1 N
? Press fitting of pin (for
T differential assembly)
T 1 AC100V
Disassembly,
9
T 1 AC110, 220V assembly of
T ?
790-901-2110 Bracket 1 differential
assembly
793-310-2141 Plate
T 1 R
?
792T-422-1260 Push tool
T 1 N
790-101-5421 Grip
T 1
01010-51240
790-101-5401
Bolt
Push tool kit
T 1
1 Press fitting of differential
10
lock gauge input seal
790-101-5471 • Plate 1
790-101-5421 • Grip 1
01010-51240 • Bolt
T 1
?
792T-423-1140 Push tool
T 1 N
790-101-5421 Grip
T 1
01010-51240
790-101-5401
Bolt
Push tool kit
T 1
1 Press fitting of differential (R/
11
F) gauge input seal
790-101-5451 • Plate 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1

30-8 HM400-1
Neces New/ Ske-

sity remodel tch
792T-422-1210 Fixture ! 3 N " For rear
Removal,
792T-427-1110 Fixture ! 3 N " For front installation of
1
01010-61435 Bolt ! 3 brake
01010-62440 Bolt ! 3 assembly
792T-422-1220 Plate ! 1 N "

2 790-101-5421 Grip ! 1 Press fitting of oil seal
Disassembly, 01010-51240 Bolt ! 1
assembly of final J 3 792T-422-1230 Push tool ! 1 N " Press fitting of bearing to hub
drive and brake
Press fitting of bearing to
4 792T-422-1240 Push tool ! 1 N "
tube
792-520-2110 Installer ! 1 For large
792-530-1600 Push tool ! 1 diameter Fitting of
5
Installer For small floating seal
790-434-1620 ! 1
diameter
6 793-520-1805 Brake tester ! 1 Check for brake oil leakage
Disassembly, 792-620-1001 Tire remover ! 1 Removal of tire from wheel
R 1
assembly of wheel 790-101-1102 Hydraulic pump ! 1 assembly
792T-446-1110 Push tool ! 1 N "
Press fitting of bearing to
1 792T-446-1120 Push tool ! 1 N "
hitch frame
792T-446-1150 Push tool ! 1 N "
790-101-5401 Push tool kit ! 1
Disassembly, 790-101-5461 • Plate 1 Press fitting of oil seal to

2
assembly of hitch 790-101-5421 • Grip 1 frame
frame 01010-51240 • Bolt 1
792T-446-1130 Plate ! 1 N "
792T-446-1140 Plate ! 1 N " Press fitting of oil seal to
3
790-101-5421 Grip ! 1 cage and frame
01010-51240 Bolt ! 1
790-201-1702 Push tool kit ! 1
Q
790-201-1881 • Push tool 1
4 Press fitting of roll bushing
790-201-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1500 Push tool kit ! 1
Disassembly, 790-201-1690 • Plate 1
assembly of 5 Press fitting of dust seal
790-101-5021 • Grip 1
suspension
01010-50816 • Bolt 1
Suspension tool
792-610-1000 ! 1
assembly
Filling with oil and nitrogen
6 792-610-1100 • Pump assembly 1
gas
• Charging tool
792-610-1200 1
assembly
HM400-1 30-9
2
Neces New/ Ske-

sity remodel tch
Disassembly, 790-452-1100 Seal installer set 1
Disassembly, assembly of
assembly of T 1
790-452-1200 Pilot ring tool 1 steering valve
steering valve
Cylinder repair
790-502-1003 1 Disassembly, assembly of
1 stand
hydraulic cylinder
790-101-1102 Hydraulic pump 1
Removal, installation of
2 790-102-3802 Wrench assembly 1
cylinder head
Socket (Width
Removal, installation of nylon
3 790-102-1480 across flats: 80 1
nut (For steering cylinder)
mm)
790-720-1000 Expander 1
796-720-1670 Ring 1 Steering, No.
4 07281-01279 Clamp 1 2 hoist Installation of
796-7201680 Ring 1 For No. 1 piston ring
07281-01289 Clamp 1 hoist cylinder
790-201-1702 Push tool kit 1
Disassembly, 790-101-5021 • Grip 1

assembly of U 01010-50816 • Bolt 1
hydraulic cylinder
For steering Press fitting of
5 790-201-1811 Push tool 1
cylinder roll bushing
For No. 1
790-201-1881 Push tool 1
hoist cylinder
For No. 2
790-201-1841 Push tool 1
hoist cylinder
790-201-1500 Push tool kit 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
For steering Press fitting of
6 790-201-1620 • Plate 1
cylinder dust seal
For No. 1
790-201-1690 • Plate 1
hoist cylinder
For No. 2
790-201-1650 • Plate 1
hoist cylinder
795-471-1700 Remover 1
Disassembly, 795-471-1520 • Block 1 Removal of fuel

V 1
assembly of engine 795-471-1530 • Bolt 1 supply pump
01435-01085 • Bolt 2
799-703-1200 Service tool kit 1
Vacuum pump
799-703-1100 1
(100V)
Air connditioner Vacuum pump Filling with air conditioer
X 799-703-1111 1
assembly (220V) refrigerant (gas)
Vacuum pump
799-703-1121 1
(240V)
799-703-1401 Gas leak detecter 1
30-10 HM400-1
(12)
2
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A5 Wrench
HM400-1 30-11
(9)
2
C1 Plate
C6 Push tool
30-11-1 HM400-1
(9)
C7 Push tool
C8 Push tool
30-12 HM400-1
2
D3 Push tool
D5 Block
HM400-1 30-13
2
H3, H5 Push tool
H4 Push tool
30-14 HM400-1
2
H4 Push tool
H8 Push tool
HM400-1 30-15
2
H9 Plate
H10 Push tool
30-16 HM400-1
2
H4 Push tool
J1 Fixture
HM400-1 30-17
2
J1 Fixture
J2 Push tool
30-18 HM400-1
2
J3 Push tool
J4 Push tool
HM400-1 30-19
2
Q1 Push tool
Q1 Push tool
30-20 HM400-1
2
Q1 Push tool
Q3 Push tool
HM400-1 30-21
2
Q3 Push tool
30-22 HM400-1
2
DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP
REMOVAL OF FUEL SUPPLY

PUMP
1. Align 1.6 TOP stamp line a of damper (2) with

pointer(1).
2. Remove breather tube (3).
3. Remover 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.
6. Remove fuel hose (9),then remove fuel
4. Remove cover (5). Remove gear mounting nut
tube(10)fuel supply tube(11),oil tube (12),and
and washer (6) and (7) with care not to fall them
over flow tube(13).
in the engine.
★ Install masking at the joints and the joint por-
tions of piping to keep dust and debris out.
7. Remove harness connectors (14) and (15).

★ Install masking the connector parts to keep
dust and debris our.
5. Set gear forcing jig A3.

★ Tool bolt A3 must be mounted at the gear
forcing tap hole (2 places).
HM400-1 30-22-1
(9)
DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP
8. Loosen bolts (16) and nuts (17) of the bracket and INSTALLATION OF FUEL
fuel supply mounting bolts (18) (4 places on the
front and rear side). SUPPLY PUMP
9. Clockwise rotate tool bolt (center bolt) A3 to pull
• Carry out installation in the reverse order to re-
out the fuel supply pump drive gear.
moval
★ There is key (19) inside Be careful not to drop it.
• General bolts and nuts conform to KES04.123.1.
• Unspecified joint bolts conform to D07206-
10. Remove bolts (16) and nuts (17) loosened at Step
XXXXX
9, then remove fuel supply pump assembly(20).
3 Plug: 14.7 - 19.6 Nm {1.5 - 2.0 kgm}
3 Nut: 176.5 - 196.1 Nm {18 - 20 kgm}

• Installing the fuel supply pump drive gear
3 joint bolt: 24.5 - 34.3 Nm {2.5 - 3.5 kgm}

• Fuel filter side
• Fuel supply pump tube

★ Place the cap with its slit toward the cylinder
block side.
3 Tube: 39.2 - 49.0 Nm {4 - 5 kgm}

• Supply pump side
3 Tube: 49.0 - 58.8 Nm {5 - 6 kgm}

• Common rail side
3 Mounting bolt upper side:

• Air clamp
4.9 ± 1 Nm {0.5 ± 0.1 kgm} (M6)

3 Mounting bolt lower side:
9.8 - 1.0 Nm {1.0 - 0.1 kgm} (M6)
★ Other clamps conform to KES
30-22-2 HM400-1
(9)
DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY
REMOVAL OF ENGINE 6. Pipes and hoses

ASSEMBLY 2) Disconnect cooling water (engine overflow)
hose (5), radiator overflow hose (6), radiator
Disconnect the cable from the negative (–) ter-
inlet hose (7), and make-up hose (8), then
minal of the battery.
remove aftercooler tube and hose (9) and
(10).
1. Bleed the air conditioner gas.
2. Drain the cooling water. 3) Loosen the clamp of air cleaner tube (11)
3. Engine undercover and shift it to the right of the vehicle body.
Remove the engine undercover.
4. Tilting up operator's cab
Bring the hood down forward (and fix it) and tilt
up operator's cab (1) and support it with the
safety bar.
Check that the operator's cab is supported

securely with the safety bar.
7. Fan guard
Remove fan guard (12).
5. Engine top cover and cooling water reservoir

tank
Remove engine top cover (2) and cooling water
reservoir tank (3).
★ Disconnect the radiator (cooling) water level
connector (CN-B01), too.
8. Fan
Remove fan (13).
★ Bring the fan down toward the radiator.
HM400-1 30-23
2
9. Air conditioner compressor 13.Starting motor wiring harnesses and engine

Remove air conditioner compressor (14). ground wire
★ The air conditioner compressor must be re- Disconnect starting motor wiring harnesses (20)
moved so that the tool (socket joint) can be and (21) and engine ground wire (22).
inserted to remove the front left mounting ★ The starting motor wiring harness (21) is in-
bolt of the engine. stalled from the right side of the engine
10.Water pump inlet hose through the front side to the battery and se-
Remove water pump inlet hose (15). cured with 4 clamps. Remove all of those 4
clamps so that they will not interfere with the
right front mounting bracket when the en-
gine assembly is raised.
11.Fuel hoses
Disconnect fuel supply hose (16) and return
hose (17).
14.Alternator wiring harnesses, heater hoses,
fuel spill tubes, and exhaust brake linkage
Disconnect alternator wiring harnesses (22) (3
places, 4 pieces), heater hoses (23) and (24),
fuel spill tube (25) (2 pieces), and exhaust brake
linkage (34). Remove radiator lower tube and
hose (35).
12.Exhaust pipe
Remove exhaust pipe (18).
30-24 HM400-1
2
15.Engine centralized connector and heater 17.Engine mounting bolts

relay connector Remove engine mounting bolts (32) (4 pieces).
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
1) Disconnect hydraulic hoses (29) (3 pieces)
from the left front side of the vehicle body.
2) Remove guard bracket (30) from the output
shaft cover and disconnect drive shaft (31)
between the engine and transmission from
the engine.
18.Engine assembly
Lift off engine assembly (33).
4 Engine assembly: 1,700 kg
HM400-1 30-25
(9)
2
INSTALLATION OF ENGINE
ASSEMBLY
moval.
Charge the air conditioner with air condition-

er gas (R134a).
• 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
2
the keyway of spider cap fully engage with
Mounting bolts of drive shaft between that of the corresponding yoke, and then
engine and transmission: Adhesive tighten the mounting bolt.
2
(LT-2)
Mounting bolt
3
: Liquid adhesive compound (LT-2)
Mounting bolts of drive shaft between
engine and transmission: 3 Mounting bolt for drive shaft
98 - 123 Nm {10 - 12.5 kgm} between engine and transmission:
[Target: 113 Nm {11.5 kgm}] 98 - 123 Nm {10 - 12.5 kgm}
[Target value: 113 Nm {11.5 kgm}]
★ When measuring dimension "a" between
3 Engine mounting bolt: the flywheel housing and the coupling tip,
662 - 829 Nm {67.5 - 84.5 kgm} while drive shaft (43) between the engine
and transmission is in place, and if this
dimension "a" falls out of the value shown
★ When dismantling the engine assembly, below, make adjustment by shifting the posi-
transmission and torque converter assem- tion of engine assembly mount or transmis-
bly or drive shafts, carry out centering the sion and front differential assembly mount
engine and transmission in the left and right so that the dimension falls within the speci-
direction in the following manner, using tool fied value.
A4. Dimension "a" between flywheel housing
1) Install tool A4 to the coupling on the engine and coupling tip: 210.2 -30 mm
side and the coupling on the torque con-
verter side.
Refilling with water
2) Put scale [1] to the left and right sides of tool • Add water to the water filler of the radiator. Run
A4. the engine to circulate the water through the sys-
3) Measure the clearance between scale [1] tem. Then, check the water level in the reservoir
and tool A4 on the left side "a" and on the tank again.
right side "b".
★ Check that the max. clearance remains
Refilling with oil
below 3 mm both on the left and right
sides. (If both clearances are not in par- • Add engine oil (specified oil: EO30-CD) to the
allel, check that the clearance remains specified level.
less than 3 mm even at the widest point)
★ If the clearance exceeds 3 mm, make
adjustment by shifting the position of
torque converter and transmission
assembly mount.
30-26 HM400-1
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL OF CYLINDER HEAD ASSEMBLY
REMOVAL OF CYLINDER 4. Turbocharger and exhaust manifold assembly

1) Remove heat insulation plate (6) and muffler
HEAD ASSEMBLY pipe (7).
k Disconnect the cable from the negative (-) ter-
2) Remove exhaust brake linkage (8).
1. Tilt up operator's cab (1) and support it with the

safety bar.
k Check that the operator's cab is supported
3) Disconnect turbocharger lubrication tube (9).
2. Remove engine top cover (2) and cooling water

reservoir tank (3).
★ Disconnect the radiator (cooling) water level
connector (CN-B01), too.
4) Sling turbocharger and exhaust manifold assem-

bly (10) temporarily and remove the mounting
bolts, then remove the assembly.
4 Turbocharger and exhaust manifold as-

sembly: 30 kg
3. Remove aftercooler hose (4) and air cleaner

hose (5).
HM400-1 30-27
(9)
2
5. Air intake manifold 3) Disconnect air intake pressure sensor con-

1) Remove corrosion resistor (11), fuel filter (12), nector (17).
and oil filter (13). 4) Remove spill tube (18).
★ Make match marks on the hoses and refer to them

when connecting the hose again.
5) Remove bracket (19).

6) Seeing air intake connector (20) from the
front side of the engine, remove the mount-
2) Remove the wiring harness clamp, each fuel ing bolt at the left lower part.
injector connector, and fuel supply pump con-
nector (14), then move wiring harness (15).
7) Sling exhaust manifold assembly (21) tem-

porarily and remove the mounting bolt, then
★ Insert flat-head screwdriver [1] in the shoul- remove the assembly.
dered part (part "a") of the fuel injector part
(part "a") and move it in the direction X,
pressing the stopper of (16a), and fuel injec-
tor connector (16) is disconnected.
(16b): On fuel injector wiring harness side.
30-28 HM400-1
(9)
2
6. Ribbon heater 9. Head cover

Remove ribbon heater wiring harness (22) to remove Remove head cover (31).
each ribbon heater (23).
10.Rocker arm
7. High-pressure fuel pipe 1) Remove 3 mounting bolts and rocker arm
1) Remove cover (24). (32).
2) Remove clamp (25) and gate-type frame ★ Loosen lock nut (34) and loosen adjustment
(26). screw (35) by 2-3 turns so that an excessive
3) Remove splash guard rubber boot from the force will not be applied to push rod (33)
high-pressure pipe fitting part. when the rocker arm is installed again.
4) Remove each clamp (27) and each high-
pressure pipe (28).
11.Fuel injector assembly

1) Remove 2 nuts (37) of the upper solenoid
8. Aeration tube and water tube valve of fuel injector (36) and pull out spring
Remove aeration tube (29) and water tube (30) clamp (38).
on the exhaust side of the cylinder head. 2) Remove the bolt of clamp (39), 1 mounting
bolt (42) of holder (41) of connector (with O-
ring) (40) and holder (41), then push in
connector (40) to remove it.
HM400-1 30-29
(9)
2
12.Push rod
Remove push rod (46).
3) Loosen the bolt of holder (44) of fuel

injector (36), then remove fuel injector (36).
13.Cylinder head assembly, Cross head

1) Remove cross head (47).
2) Remove mounting bolts (48) and cylinder
head assembly (49).
3) Remove each cylinder head gasket.
4) Insert a small L-bar under connection (45)

of fuel injector (36) carefully.
★ Never hold the solenoid valve on the top of
the injector with priers, etc.
★ Precautions for removing only injector to

replace only injector or only nozzle tip.
Before starting the above work to remove
the injector, loosen the bolts mounting the
injector onto the clamp intake manifold near
the injectors of high-pressure pipe clamps
No.1 - No.6. Remove the sleeve of the high-
pressure pipe on the injector side and pull
out the injector, taking care that its tip will not
touch the concave part of the injector.
30-30 HM400-1
(9)
2
INSTALLATION OF CYLINDER 3. Install the air intake manifold to the cylinder

head.
HEAD ★ Tighten the bolts in the order shown in the
following figure.
• Carry out installation in the reverse order to
removal. 3 Air intake manifold assembly:
59 - 74 Nm {6 - 7.5 kgm}
★ Tighten the bolts in the order shown in the

following figure.
3 Turbocharger mounting bolt:

44.1 - 49.0 Nm {4.5 - 5.0 kgm}
3 Turbocharger and exhaust manifold

assembly:
58.8 - 73.5 Nm {6 - 7.5 kgm}
1) Tighten the all bolts of the 5 high-pressure pipe

clamps by hand, then tighten them permanently.
Then, secure the clamp stays permanently.
2) Tighten the all bolts of the stays and upper and
lower clamps of high-pressure pipe clamps
(25), (52), (53) by hand.
3) Tighten the bolts of the upper and lower clamps
permanently (to bend the rubber before secur-
ing the stay permanently).
3 Spill tube: 8 - 9.8 Nm {0.8 - 1.0 kgm} 3 Clamp bolt:

9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
★ At this time, secure the clamps in the order
1. Fit the gaskets to both sides of ribbon heater of (25), (52) and (53). [If the clamps are se-
(23) and install them to air intake manifold cured in this order, excessive forces are not
assembly. applied to the mounting parts of the supply
2. Install wiring harness (22) to ribbon heater (23) pump (Stress concentration on the mount-
and assemble them with the air intake manifold. ing parts of the supply pump is prevented).]
4) Secure the stays in the order of (25) , (52), and
(53).
5) Install gate frame (26) temporarily. Secure
clamp (on the back side of the gate frame) per-
manently first, then secure gate frame (26) per-
manently with special bolts (4).
3 Clamp bolt:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
HM400-1 30-31
(9)
2
★ When installing the high-pressure pipe,

check it for visible longitudinal slit "b", pit "c",
or level difference (wear) in part "d" (End of
the taper seal: Part of 2 mm from the end)
which is felt with a nail in the taper seal part
of the connecting section (Part "a": 2 mm
from the end). If any of those defects can
cause fuel leakage, replace the high-
pressure pipe.
★ There are 16 rubber caps. All of them have

respective slits, the directions of which are
important.
1) Caps at common rail outlet (50) with their
slits toward the cylinder block.
• Screw sleeve nut (54) by 2 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.
3 Sleeve nut:
22.5 - 24.5 Nm {2.3 - 2.5 kgm}
2) Fit the 6 rubber caps at fuel injector inlet Note2) After finishing the work make sure that
sleeve (51) with their slits down. O-ring is not projected from the sleeve.
★ Secure the rubber caps with metal clips
30-32 HM400-1
(9)
2
★ Make sure that the inside of the injector sleeve
3
is free from dirt.
Water tube: 1) Fit the gasket and O-ring to the fuel injector and
9.8 - 12.7 Nm {1.0 - 1.3 kgm} apply engine oil SAE No. 30 to them.
2) Insert holder (41) in fuel injector (36), then
3
insert them simultaneously with the injector
Head cover: connection directed to the hole for the fuel high-
14.7 - 34.3 Nm {1.5 - 3.5 kgm} pressure pipe.
3) Fit the ball washer and holder (41) to bolt (42),
★ Check that the ball of the adjustment screw then tighten them temporarily. Insert high-
is fitted to the socket of the push rod. pressure pipe sleeve (55) in the hole for the fuel
★ Adjust the valve clearance. For details, see high-pressure pipe and secure it temporarily,
TESTING AND ADJUSTING, Adjusting matching it to injection (56). Secure holder (41)
valve clearance. with bolt (42) permanently.
3
★ Apply engine oil to the spherical surface of
Rocker arm assembly mounting bolt: the ball washer (to fit the ball washer).
3
93 - 103 Nm {9.5 - 10.5 kgm}
3
Holder mounting bolt:
Locknut: 53 - 64.7 Nm {5.4 -6.6 kgm} 58.8-73.5 Nm {6.0-7.5 kgm}
★ After securing the holder, remove the high-
pressure pipe sleeve and install the other
injectors in order according to the above
★ When installing the high-pressure pipe, procedure.
check it for visible longitudinal slit "b", pit "c",
or level difference (wear) in part "d" (End of
the taper seal: Part of 2 mm from the end)
Which is felt with a nail in the taper seal part
of the connecting section (Part "a": 2 mm
from the end). If any of those defects can
cause fuel leakage, replace the high-
pressure pipe.
HM400-1 30-33
(9)
2
★ It is difficult to insert the connector from inside

with the O-ring fitted to it. ★ Adjust the cross head according to the following
4) Remove O-ring (58) from wiring harness procedure.
connector (57). Take wiring harness connector 1) Loosen the locknut and return the adjustment
(57) out of the connector hole and install O-ring screw.
(58) and apply engine oil SAE No. 30 to tem. 2) Holding the top of the cross head (47) lightly,
Install connector holder (41) and push it in and tighten the adjustment screw.
secure it with mounting bolt (59). 3) After the adjustment screw touches the valve
stem, tighten it further by 20°.
4) Tighten the locknut.
3 Locknut: 53-64.7 Nm {5.4-6.6 kgm}.
5) Install wring harness terminal (61) to injector

terminal (60) and tighten 2 nuts (62). Insert
wiring harness holder clamp (63) in the injector
connection and secure wiring harness clamp
(64) with bolt (65).
3
1. Check that the cylinder head mounting face and
Terminal nut: inside of the cylinder are free from foreign
1.8-2.2 Nm {0.18-0.22 kgm} matter, then set cylinder had gasket.
★ Eliminate the slack of the wiring harness ★ When fitting the gasket, check that the
and press it against the body of the injector. grommets are fitted correctly.
2. Before tightening the cylinder head mounting
bolts, check the following item.
★ If a bolt is longer than the following using
limit or has been tightened 5 times (having
5punchi marks denoting the number of
tightening times) or more, replace it.
30-34 HM400-1
(9)
2
1) Measure stem length "a" of every bolt and .

make sure that it is less than the using limit.
2) Using limit length of bolt
Short bolt: 170.8 mm
Long bolt: 205.8 mm
• When not using tool A1

Make marks on the bolts and head
with paint, then tighten the bolts by
90° +30°
0 in the order of (1) - (6).
★ After tightening bolts (1) - (6), tighten bolt (7)
3. Install cylinder head assembly and tighten to 66.6 ±7.4 Nm {6.8±0.8 kgm}.
mounting bolts.
2 Mounting bolt:
Lubricant containing molybdenum
disulfide (LM-P)
★ A special socket to tighten the head bolts is
necessary.
3 Mounting bolt:
1st time: 137-157 Nm {14-16 kgm}
2nd time: 284-294 Nm {29.0-30.0 kgm}
3rd time 1) When using tool A1
Using the angle tightening wrench
(tool A1), 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 {6.8±0.8 kgm}.
HM400-1 30-35
(9)
2
DISASSEMBLY AND ASSEMBLY NOZZLE TIP
REMOVAL AND INSTALLATION OF NOZZLE TIP

★ [EPA regulations] 3. Loosen rerating nut (4) with 19 mm deep socket
For countries subject to EPA regulations, the en- [3].
tire nozzle assembly of the common rail engine
shall be replaced if any of its components needs
to be replaced. For other conutries, the following
procedure may be applied for replacing the noz-
zle tip.
★ The 125 Engine Series are used as examples in
all of the following photos. The procedures for
removing and installing the nozzle chip shown in
these photos are applicable to the other
engines, however.
REMOVAL
1. Fix tool A5 in vice [1].
4. Remove rerating nut (4) from injector assembly
★ Do not pinch the injectior directly in the vice.
(3).
5. Lift nozzle assembly (5) perpendicularly upward
to remove it.
★ Do not remove tip guide (6). (Disassembling
the portion after the tip guide is not allowed.)
★ Be careful not to get the assembly dirty.
2. Set injector assembly (3) on tool A5.
30-35-1 HM400-1
(9)
DISASSEMBLY AND ASSEMBLY NOZZLE TIP
INSTALLATION 5. Mount nozzle assembly (3) and manually tighten

retaining nut (2).
1. Fix tool A5 in vice [1].
★ Do not pinch the injector directly in the vice.
6. Set 19-mm deep socket (2) in the torque wrench,

then tighten the retaining nut by following the
2. Set injector assembly (1) on tool A5. steps below.
3. Comletely clean the lower body and screw sec- ★ Apply rust prevention oil on the nozzle body.
tions of retaining nut (2) with parts cleaner, and 1) Tighten with torque of 88.3 Nm {9.0 kgm}.
apply air blow. 2) Attach identification mark (6) to retainig nut
(2) and lower body (5).
3) Tighten at an angle of 45º (angle tightening)
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.
HM400-1 30-35-2
(9)
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
REMOVAL OF RADIATOR
ASSEMBLY 5. Pipes and hoses under radiator
1) Disconnect heater hose (14) and remove
1. Drain the cooling water.
radiator lower tube and hose (15).
2. Radiator undercover
Remove the radiator undercover.
safety bar.

2) Disconnect power train and brake circuit

cooling hoses (16) and (17) and steering
and hoist circuit cooling hoses (18) and
(19).
4. Pipes and hoses above radiator

2) Disconnect cooling water (engine overflow)
hose (5) , radiator overflow hose (6),
radiator inlet hose (7), and make-up hose
(8), then remove aftercooler tube and hose
(9) and (10).
3) Loosen the clamp of air cleaner tube (11)
and shift it to the right of the vehicle body.
30-36 HM400-1
2
6. Fan guard 9. Stays

Remove fan guard (12). Remove stays (22) from both sides.
★ Measure the installed dimensions.
7. Fan
Remove fan (13). 10.Radiator assembly
★ Bring the fan down toward the radiator. 1) Sling radiator assembly (23) (including the
fan) temporarily and remove mounting bolts
(24).
8. Air conditioner condenser and front covers

1) Remove air conditioner condenser (20) and
shift it forward and fix it (by binding with
strings).
2) Remove front covers (21) (2 pieces).
HM400-1 30-37
2
INSTALLATION OF RADIATOR
1) Lift off radiator assembly (23) (including the ASSEMBLY
fan).
Radiator assembly (including fan): moval.
340 kg.
Install the radiator assembly so that clear-
ance "a" between it and front guard will be
13 - 15 mm.

• Add water to the water filler of the radiator. Run
the engine to circulate the water through the sys-
tem. Then, check the water level in the reservoir
tank again.
30-38 HM400-1
2
DISASSEMBLY AND ASSEMBLY REMOVAL OF OUTPUT SHAFT ASSEMBLY
REMOVAL OF OUTPUT 3. Hoist and steering pump

1) Disconnect suction pipes (3) and (4) and
SHAFT ASSEMBLY hoses (5), (6), and (7).
Disconnect the cable from the negative (-) ter-

safety bar.

2) Lift off hoist and steering pump assembly

(9).
Hoist and steering pump assembly:

45 kg
2. Vertical member
Remove vertical member (2).
Vertical member: 45 kg
4. Brake cooling and differential lock (machine with

differential lock differential) pump
1) Disconnect suction pipe and hose (10) and
(11) and discharge hoses (12) and (13).
HM400-1 30-39
(7)
2
2) Lift off brake cooling and differential lock 6. Coupling and oil seal cage
pump assembly (14). Remove coupling (17) and oil seal cage (18).
Brake cooling and differential lock pump

assembly:
30 kg (Machine with differential lock differential)
20 kg (Machine with limited slip differential)
7. Output shaft cover

Remove snap ring (19), then remove cover (20)
by using forcing screw 1 and guide bolt 2.
5. Drive shaft between engine and transmission
1) Remove guard bracket (15) from the output
between the engine and transmission.
Drive shaft between engine and

transmission: 55 kg
8. Output shaft
Using forcing screw 1 and guide bolt 2, remove
output shaft (21).
30-40 HM400-1
(7)
2
9. Bearing
Remove bearing (22).
HM400-1 30-41
62
DISASSEMBLY AND ASSEMBLY INSTALLATION OF OUTPUT SHAFT ASSEMBLY
INSTALLATION OF OUTPUT
SHAFT ASSEMBLY
removal. Raise the cover and set to the output shaft, use
tool B1 to press fit the inner bearing, then install
cover (20).
★ Using tool C2, align the engine and torque con-
verter with each other.
Output shaft mounting bolt:

Thread tightener (LT-2)
Mounting bolts of drive shaft between Bearing cover mounting bolt:

engine and transmission: 98-123 Nm {10.0-12.5 kgm}
Adhesive (LT-2)
Bearing: Coat whole surface of bearing inside diam-
Mounting bolts of drive shaft between eter and shaft outside diameter with ENS
engine and transmission: grease.
98 - 123 Nm {10 - 12.5 kgm}
[Target: 113 Nm {11.5 kgm}]
• For details of filling with ENS grease, see DIS-

ASSEMBLY, ASSEMBLY OF OUTPUT SHAFT
ASSEMBLY.
Spline: ENS grease
★ Before using ENS grease, remove all other

grease completely. Do not mix ENS grease
with other grease. (Use different grease
guns for each type of grease.)
ENS grease Part No.:
427-12-11871 (2kg can)
Bearing cover mounting bolt:

Bearing cover mounting bolt:
98-123 Nm {10.0-12.5 kgm}
30-42 HM400-1
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY
DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY
1. Oil cage assembly

Remove oil seal (1) from cage (2).
2. Cover assembly
Remove nearing (3) from cover (4).
3. Damper assembly (5)

1) To keep the balance when reassembling, mark
the set positions of flange (6), body assembly (7),
and outer body (9) before disassembling.
2) Remove body assembly (7) and rubber (8) from
outer body (9).
3) Remove bearing (10) from flywheel.
HM400-1 30-43
(11)
2
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF OUTPUT SHAFT ASSEMBLY
ASSEMBLY OF OUTPUT
SHAFT ASSEMBLY
1. Using push tool, press fit bearing (10) in flywheel. 5. Install cover assembly to flywheel
Flywheel hole portion, inside of bear- 4 Cover assembly: 35kg

ing: ENS grease
2. Assembly of damper assembly.

1) Coat mating surface of outer body (9) and
one side of flange (6) with adhesive, then
assemble.
Mating surface of flange:
Adhesive (LG-4)
Mounting bolt:
3 Mounting bolt: 6. Assemble oil seal (1) in (2).

66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
Oil seal: ENS grease
2) Install body assembly (7).
3) Assemble rubber (8). 7. Install cage assembly to cover assembly.
★ Before assembling, coat with grease.
Mounting bolt: Thread tightener (LT-2)
3
Outer body, body assembly, rubber:
Grease (G2-L1) Mounting bolt:
4) Install flange (6). 110.3 ± 12.3 {11.25 ± 1.25 kgm}
Mating surface of flange:

Adhesive (LG-4) • Procedure for filling with ENS grease
1) ENS grease Part No.: 427-12-11871
Mounting bolt:Thread tightener (LT-2) 2) Places to fill with grease, amount of ENS-
3 Mounting bolt:
grease (total amount: approx. 225g), and
places to coat with grease.
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
★ Align the marking position of the outer body, in-
ner body, and flange, ten assembly.
3. Install damper assembly (5) to flywheel.
Shaft spline of body assembly:

ENS grease
Mounting bolt: Thread tightener (LT-2)
3 Mounting bolt:
110.3 ± 12.3 {11.25 ± 1.25 kgm}
4. Press fit bearing (3) in cover (4).

Bearing: ENS grease
30-44 HM400-1
(11)
2
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF OUTPUT SHAFT ASSEMBLY
a: 60% pack (30g) g: Fill between grease lip and dust lip
b: Coat all surfaces of bearing inner dia. and shaft h: 50% pack (30g)
outer dia. i: Full pack (20g)
c: Fill 3 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)
HM400-1 30-45
2
REMOVAL OF TRANSMISSION AND FRONT
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL ASSEMBLY
REMOVAL OF TRANSMIS-
SION AND FRONT DIFFEREN- 10.Operator's cab lift cylinder
TIAL ASSEMBLY Remove the connecting pin on the cab side and
disconnect operator's cab lift cylinder (62).
1. Discharging the air conditioner gas.

2. Drain the cooling water.
3. Drain the hydraulic oil and transmission oil.
4. Lower the transmission undercover. (Do not dis-
connect it from the hinge.)
safety bar.

11.Operator's cab assembly
Pull mounting pins (6) on both sides of the rear
section outward and lift off operator's cab
assembly (7).
★ Loosen the muffler cover mounting bolts
and shift the muffler cover so that the mount-
ing pin will not interfere with it.
★ Do not remove the pins, but just move them
outward.
Operator's cab assembly: 1,300 kg
6. Joint connectors between cab and vehicle

body
Disconnect joint connectors (2) (10 places)
between the cab and vehicle body.
★ Before disconnecting, make match marks.
7. Brake hoses (on brake valve side)

Disconnect brake hoses (3) (5 pieces) (on the
brake valve side).
★ Before removing the clamps, check the po-
sitions of the hoses.
8. Steering hoses
Disconnect steering hoses (5) (5 pieces).
9. Heater hoses
Disconnect heater hoses (4) (5 pieces).
30-46 HM400-1
6
2
12.Transmission rear brake hoses (Section above transmission)

1) Disconnect right rear brake hoses (8) 13.Vertical member
(Upper s ide: 4 pieces, Lower side: 2 Remove vertical member (13).
pieces).
Vertical member: 45 kg.
2) Disconnect right rear brake hoses (9) and

(10). 14.Frame and hose assembly
Remove frame and hose assembly (14).
3) Disconnect left rear brake hoses (11) and

(12).
HM400-1 30-47
62
15.Centralized connectors between vehicle 18.Intermediate connectors, torque converter oil

body and engine pressure sensor connector, exhaust brake
Remove top cover (15) and disconnect central- hoses, and brake oil drain hose
ized connectors (16) and (17) between the vehi- 1) Disconnect intermediate connectors (CN-
cle body and engine. DT1) (25), (CN-DT2) (26), and (CN-TD3)
(27).
16.Steering pipes and hoses 2) Disconnect torque converter oil pressure

Disconnect steering hoses (18) - (22) and sensor connector (28), exhaust brake
remove orifice (23). hoses (29) (2 pieces), and brake oil drain
hose (30).
17.Centralized oil pressure pickup hoses

Disconnect centralized oil pressure pickup hoses
(24) (5 pieces) (Section above front of transmission)
19.Hoist and steering pump
1) Disconnect suction pipes (31) and (32) and
hoses (33), (34), and (35).
30-48 HM400-1
6
2
2) Lift off hoist and steering pump assembly 21.Drive shaft between engine and transmission
(37). 1) Remove guard bracket (43) from the output
Hoist and steering pump assembly: between the engine and transmission.
45 kg
Drive shaft between engine and

transmission: 55 kg..
20.Brake cooling and differential lock (machine

with differential lock differential) pump
1) Disconnect suction pipe and hose (38) and
(39) and discharge hoses (40) and (41).
2) Lift off brake cooling and differential lock

(machine with differential lock differential)
pump assembly (42). (Section under front of transmission)
22.Torque converter and transmission charge
Brake cooling and differential lock pump
pump hoses, differential lock hoses, brake
assembly:
hoses, and brake cooling hoses
30 kg (Machine with differential lock differential)
1) Disconnect torque converter and
20 kg (Machine with limited slip differential)
transmission charge pump hoses (45) and
(46), differential lock hoses (47) - (49) (only
machine with differential lock differential),
and brake cooling hose (50).
2) Disconnect brake hoses (51) and (52).
HM400-1 30-49
(7)
62
(Section under left rear of transmission)

23.Subtank (Tank for brake) pipe
Disconnect subtank (tank for the brake) pipe
(55).
★ Remove the pipe coupling.
24.Transmission rear mount grease tube

Disconnect rear mount grease tube (56) from the
rear mount.
3) Disconnect brake cooling hoses (53) and

(54).
30-50 HM400-1
6
2
25.Drive shaft between transmission and hitch

frame
Disconnect the guard and drive shaft (57)
between the transmission and hitch frame from
the transmission.
26.Drive shafts on both sides (between front dif-

ferential and front final drive)
Disconnect drive shafts (58) on both sides
(between front differential and front final drive)
from the front differential.
27.Transmission and front differential assembly

Remove mounting bolts (59) (Front side: 4
pieces) and (60) (Rear side: 8 pieces) and lift off
transmission and front differential assembly (61).
Transmission and front differential as-

sembly: 2,100 kg
HM400-1 30-51
62
INSTALLATION OF TRANSMISSION AND
DISASSEMBLY AND ASSEMBLY FRONT DIFFERENTIAL ASSEMBLY
INSTALLATION OF TRANS-
MISSION AND FRONT DIF- • When installing the drive shaft, check that the
FERENTIAL ASSEMBLY key way of the spider cap is matched to that of
moval. Mounting bolts of drive shaft between
transmission and hitch frame:
Adhesive (LT-2)
• Add refrigerant (R134a). Mounting bolts of drive shaft between
157 - 198 Nm {16 - 20 kgm}
• Standard clearance "a" for operator's cab [Target: 177 Nm {18 kgm}]
mounting pin: 0.2 mm (on each side)

Mounting bolts of drive shafts on both

sides (between front differential and
front final drive): Adhesive (LT-2)
Mounting bolts of drive shafts on both

sides (between front differential and
front final drive):
98 - 123 Nm {10 - 12.5 kgm}
• When installing the drive shaft, check that the • Standard shim thickness "b" for front mounting
key way of the spider cap is matched to that of bolt: 1 mm
the mating yoke and tighten the bolts. • Standard shim thickness "c" for rear mounting
★ Using tool C2, align the engine and torque con- bolt: 2 mm.
verter with each other.

engine and transmission:
Adhesive (LT-2)

engine and transmission:
98 - 123 Nm {10 - 12.5 kgm}
30-52 HM400-1
6
2
TRANSMISSION AND FRONT DIFFERENTIAL
DISASSEMBLY AND ASSEMBLY ASSEMBLY
Front mounting bolt:

1,150 - 1,440 Nm {118 - 147 kgm}
Rear mounting bolt:
171.5 - 214.5 Nm {17.5 - 21.5 kgm}
After installing, bleed air from the brake circuit.

Bleeding air from brake circuit.

• Add water to the water filler of the radiator. Run
the engine to circulate the water through the sys-
tem. Then, check the water level in the reservoir
tank again.
Refilling with oil

• Add engine oil (specified oil) to the specified lev-
el.
• Add transmission oil (specified oil) to the speci-
fied level.
• Supply the front differential case with specified
oil to the specified level.
HM400-1 30-53
2
DISCONNECTION OF FRONT FINAL DRIVE
DISASSEMBLY AND ASSEMBLY AND TRANSMISSION
DISCONNECTION OF FRONT
DIFFERENTIAL AND TRANS-
MISSION
1. Piping
Remove hose and piping (1).
2. Torque converter and transmission assembly and
brake pump
Remove the torque converter and transmission
assembly and brake pump (2).
4. Front differential assembly

Lift off front differential assembly (5).
Front differential assembly: 450 kg
COUPLING OF FRONT DIF-

FERENTIAL AND TRANSMIS-
SION
3. Front output shaft speed sensor of transmission
Remove cover (3) and speed sensor (4).
Adjust the speed sensor. For details, see TESTING
AND ADJUSTING.
Front differential mounting bolt:

Adhesive (LT2)
Front differential mounting bolt:

490 - 608 Nm {50 - 62 kgm}
30-54 HM400-1
(7)
2
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
DISASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
1. P.T.O. assembly 3. Turbine and clutch assembly
Using eyebolt 1, tighten forcing screw 2 to 1) Set torque converter assembly (4) to tool
remove P.T.O. assembly (1). C1.
2. Torque converter assembly 2) Remove mounting bolts (5) on the pump

1) Loosen all mounting bolts (2) and remove side.
them, leaving 3 of them.
3) Using eyebolt 5, remove turbine and clutch

2) Place torque converter housing (3) on block assembly (6).
3 with the pump side down. ★ For further disassembly, see "7. Disassem-
3) Remove mounting bolts (2) left in step 1) bly of turbine and clutch assembly".
above. Using eyebolt 4, remove torque
converter assembly (4).
HM400-1 30-55
(11)
2
4. Stator assembly 3) Remove the mounting bolts, retainer (11),

Lift up and remove stator assembly (7). and guide (12).
★ For further disassembly, see "8. Disassem-
bly of stator assembly".
4) Using push tool 7, remove bearing (13)

from guide (12).
5. Pump assembly
1) Using tool C3, remove nut (8).
6. Stator shaft
1) Remove the plug. Using a bar, remove
2) Using puller 6, remove inner race (9) and inner race (15) from stator shaft (14).
pump assembly (10). ★ When installing the plug again, do not apply
adhesive (LT-2).
2) Remove bushing (16).
3) Remove seal ring (17).
30-56 HM400-1
2
7. Disassembly of turbine and clutch assembly 5) Remove the mounting bolts and lift off
1) Using forcing screw 8, remove input shaft housing assembly (23).
(18). 6) Remove piston (24) and seal ring (25) from
2) Using puller 9, remove bearing (19). the housing assembly.
3) Remove snap ring (20) and plate (21). 7) Using push tool A, remove bearing (26)
from the housing.
8) Remove seal ring (27).
9) Remove pin (28).
4) Using forcing screw 0, remove turbine (22).
10) Remove disc (30) from case (29).
HM400-1 30-57
2
8. Disassembly of stator assembly

1) Remove the mounting bolts and stator (31).
2) Remove bushings (33) and (34) from race

(32).
3) Remove race (35) and free wheel (36) from
race (32).
30-58 HM400-1
2
ASSEMBLY OF TORQUE 2. Assembly of turbine clutch assembly

1) Set turbine (22) and case (29) to push tool
CONVERTER ASSEMBLY B.
★ Use a block to prevent case (29) from
1. Assembly of stator assembly
touching turbine (22).
1) Install free wheel (36) and race (35) to race
(32).
★ Install the free wheel with the arrow of
the gauge end on the input side.
★ Apply engine oil EO30-CD or EO10-CD
to the sliding surfaces of the races.
2) Install bushings (34) and (33) to race (32).
★ Install the bushings by expansion fit.
to the sliding surfaces.
★ Put in the ball without fail.
2) Install disc (30).

to the sliding surfaces.
3) Install stator (31) to race (32).
Mounting bolt: Adhesive (LT-2)
Mounting bolt:
58.8 - 73.5 Nm {6 - 7.5 kgm}
★ Check the rotating direction of the stator

View from input sideClockwise: Free
Counterclockwise:
Locked
HM400-1 30-59
2
3) Install pin (28). 7) Using push tool C, press fit bearing (26).
★ Install pin (28) to the housing by expan-
sion fit.
4) Install the seal rings (27) and (25) to piston
(24) and housing (23).
Seal ring: Grease (G2-LI)

5) Install the piston to housing assembly (23).
to the sliding surfaces of the piston.
★ When installing the piston take care that
the seal rings will not be caught.
8) Install plate (21) and snap ring (20).
6) Sling housing assembly (23) and install it to

case (29).

9) Using the push tool, press fit bearing (19) to
Mounting bolt:
input shaft (18).
98.1 - 122.6 Nm {10 - 12.5 kgm}
10) Install input shaft (18) to the housing.
Mounting bolt:
269.7 - 308.9 Nm {27.5 - 31.5 kgm}
30-60 HM400-1
2
3. Stator shaft 4. Pump assembly

• The following is the assembly procedure for 1) Using push tool D, press fit bearing (13) to
the torque converter. guide (12).
1) Set stator shaft (14) to tool C1 and turn it
over.
2) Using the push tool, install bushing (16) by
expansion fit.
★ Press fit the bushing with the chamfered
end directed to the stator shaft.
2) Set guide (12) and retainer (11) and tighten

the mounting bolts.
3 Mounting bolt:
58.8 - 73.5 Nm {6 - 7.5 kgm}
3) Install the seal ring (17).
Seal ring: Grease (G2-LI)
4) Using the push tool, press fit inner race
(15).
3) Set pump assembly (10) and inner race (9).

★ Drop 10 cc of engine oil EO30-CD or
EO10-CD onto the bearing and rotate
the bearing by 10 turns.
HM400-1 30-61
(11)
2
4) Using push tool E, press fit inner race (9).
7. Torque converter assembly

5) Using tool C3, tighten nut (8). Using eyebolt 4, set torque converter assembly
Nut: Adhesive (LT-2) (4) to torque converter housing (3) and tighten
3 Nut: 441.3 - 490.3 Nm {45 - 50 kgm} the mounting bolts.
3 Mounting bolt:
98.1 - 122.6 Nm {10 - 12.5 kgm}
5. Stator assembly
Install stator assembly (7).
• For further assembly, see "1. Assembly of
stator assembly".
8. P.T.O. assembly
Fit the O-ring and install P.T.O. assembly (1),
using eyebolt 1.
6. Turbine and clutch assembly

Using eyebolt 5, set turbine and clutch
assembly (6) to the pump and tighten the
mounting bolts.
3 Mounting bolt:
49.0 - 58.8 Nm {5 - 6 kgm}
30-62 HM400-1
(11)
2
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DISASSEMBLY OF
TRANSMISSION ASSEMBLY
1. Piping
Remove hoses and piping (1).
2. Wiring harness assembly
Remove wiring harness assembly (2).
3. Torque converter and transmission assembly and
charge pump (3)
Remove torque converter and transmission
assembly and charge pump (3).
4. Transmission speed sensor
Remove transmission input shaft speed sensor
(4), intermediate shaft speed sensor (5)
(installed inside the cover), and rear output
shaft speed sensor (6).
★ For the front output shaft speed sensor, see
"Disconnection of front differential and
transmission".
5. Torque converter oil temperature sensors
Remove torque converter oil temperature
sensors (7) and (8).
6. Torque converter oil pressure sensor
Remove torque converter oil pressure sensor
(230).
7. Strainer
Remove strainer (9).
8. Mounting bracket and trunnion
Remove trunnion (10) (on the rear side) and
mounting bracket (11) (on the front differential
side)
Disconnect the front differential assembly. For
details, see "Disconnection of front differential
and transmission".
10. Transmission control valve, main relief valve, valve
seat and tube.
Remove transmission control valve assembly
(12), main relief valve assembly (13), valve seat
(14) and tube (225).
HM400-1 30-63
(7)
11. Coupling
1) Remove rear coupling (15).
13. Covers
Remove covers (18) (on the 1st clutch side) and
2) Remove input coupling (27). (19) (on the 2nd clutch side).
★ Check the thickness and quantity of the
shims on the cover (19) side.
12. Front output shaft snap ring

Remove snap ring (16).
14. Bearing cage
1) Using forcing screw 1, remove bearing
case (20).
shims.
30-64 HM400-1
2
2) Remove bearing outer race (38o), dust seal 16. Shroud

(67), and oil seal (68) from bearing cage Remove shroud (90).
(66).
★ For bearing inner race, see "Disassembly of
differential lock clutch assembly".
17. Differential lock clutch assembly

Remove differential lock clutch assembly (22).
★ For further disassembly of the differential
15. Transmission case assembly (on opposite side of lock clutch assembly, see "step 23".
torque converter)
Place the transmission with the torque converter
side down and remove the transmission case
assembly (21) (on the opposite side of the
torque converter).
If the transmission is not placed with the
torque converter side down, it cannot be
disassembled. Be sure to set it with the
torque converter side down.
★ If the transmission is disassembled with the

torque converter side up, its inside will be
broken. Accordingly, be sure to
disassemble the transmission with the 18. FH and 1st clutch assembly and 2nd and 3rd clutch
torque converter side down. assembly
Lift off FH and 1st clutch assembly (23) and 2nd
★ For further disassembly of the transmission
and 3rd clutch assembly (24) simultaneously.
case, see "step 27".
★ 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".
HM400-1 30-65
(7)
19. R and FL clutch assembly i) Remove snap ring (201), then remove
Remove R and FL clutch assembly (25). bear ing and spacer and snap ring
★ For further disassembly of the R and FL assembly (202).
clutch assembly, see "step 26".
ii) Remove snap ring (203) from bearing

20. Cage assembly and spacer and snap ring assembly
1) Using forcing screw 2, remove cage (202), then remove bearing (205) from
assembly (26). spacer (204).
2) Disassemble the cage assembly according iii) Remove bearing outer race (380) from
to the following procedure. cage (211).
30-66 HM400-1
2
21. P.T.O. assembly 2) Disassemble the gear and shaft and ring
Remove P.T.O. assembly (28). gear assembly according to the following
★ For further disassembly of the P.T.O. as- procedure.
sembly, see "step 28". i) Using push tool E, remove shaft and
ring gear assembly (31).
22. Torque converter assembly

Remove the bolts (12 pieces) used to install the ii) Remove shaft and snap ring assembly
torque converter assembly (29) to the transmis- (32), ring gear assembly (33), and
sion, then remove torque converter assembly bearing (34) (Inner races: 34-1i, 34-2i,
(29). Spacer: 34-3).
★ For disassembly of the torque converter as- ★ Bearing (34) (Inner races: 34-1, 34-
sembly, see Disassembly of torque convert- 2, 34-3) is the assembly No.
er assembly. ★ For bearing outer race (34-1o, 2o),
see iv) below.
23. Disassembly of differential lock clutch assembly

1) Using forcing screw 3, remove gear and
shaft and ring gear assembly (30).
HM400-1 30-67
2
iii) Remove snap rings (36) and (68) from 4) Remove snap ring (41).
shaft (35).
★ Snap ring (68) is for the oil sump.
5) Remove the mounting bolts (12 pieces) and

carrier assembly (42).
iv) Remove gear (37), bearing (34) (Outer
races: 34-1o, 34-2o), and bearing inner
race (38).
6) Disassemble the carrier assembly accord-

ing to the following procedure.
i) Remove ring (43).
3) Remove snap ring (39) and sun gear (40). ii) Drive out shaft (44) toward ball (45) and
remove shaft (44), gear (46), ball (45),
bearing (47) (2 pieces), and thrust
washers (48) (2 pieces).
30-68 HM400-1
2
7) Remove front shaft and hub assembly (49). 9) Remove end plate (55), discs (56) (7 pieces),
plate (57) (7 pieces), and wave springs (58) (7
pieces) from the differential clutch.
8) 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).
ii) Remove seal rings (53) and (54).
10) Using the hanging tap, remove piston

assembly (59).
HM400-1 30-69
2
11) Remove seal ring (61) from piston (60). 24. Disassembly of 2nd and 3rd clutch assembly
(2nd clutch side)
1) Remove seal rings (71) (3 pieces).
12) Disassemble the housing assembly

according to the following procedure.
i) Remove seal ring (63), bearing outer 2) Using puller (4), remove spacer (226) and
race (64o), and bearing inner race (65i) bearing inner race (73i) together. After
from housing (62). removing spacer (227) (2-piece type),
★ For bearing outer race (65o), see remove gear (72).
Disassembly of transmission case
assembly on torque converter side.
3) Remove spacer (74) (2-piece type) and

thrust washer (75).
30-70 HM400-1
(7)
4) Remove gear and needle roller bearing 7) Remove end plate (80), plates (81) (14
assembly (76). pieces), discs (82) (13 pieces), and wave
springs (83) (13 pieces) from the 2nd
clutch.
5) Remove needle roller bearing (78) from

gear (77).
8) Using the hanging tap, remove thrust washers

6) Using a C-clamp, jig 5, etc., compress the (84) and piston assembly (86).
clutch spring and remove snap ring (79).
★ The 2nd clutch has a screw hole for
eyebolt on the gear. The clutch spring
may be compressed by inserting a
spacer of proper thickness on the clutch
side and utilizing that screw hole.
HM400-1 30-71
(7)
11) Remove snap ring (102) and thrust washer

(103).
9) Remove seal rings (88) and (89) from

piston (87).
12) Remove gear and needle roller bearing
assembly (104).
(3rd clutch side)

10) Using push puller 6, remove bearing inner 13) Remove needle roller bearing (106) from
race (100i) and spacer (101). gear (105).
★ For bearing outer race (100o), see
30-72 HM400-1
(7)
14) Using C-clamp 7, etc., compress the clutch

spring and remove snap ring (107).
★ 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.)
16) Remove thrust washer (112) and piston

assembly (113).

piston (114).
15) Remove end plate (108), plates (109) (8

pieces), discs (110) (7 pieces), and wave
springs (111) (7 pieces) from the 3rd clutch.
HM400-1 30-73
2
25. Disassembly of 1st and FH clutch assembly 4) Remove gear and needle roller bearing assembly
(1st clutch side) (126).
5) Remove needle roller bearing (128) (2 pieces)

2) Using puller 4, remove gear (122) and from gear (127).
bearing inner race (123i) together.
assembly on opposite side of torque
converter.

3) Remove snap ring (124) and thrust washer (For example, put a bar to the screw
(125). hole of the shaft and press down the
end plate with the spacer.).
30-74 HM400-1
(7)
. 8) Using the hanging tap, remove thrust washers

(134) and piston assembly (136).

spring (133) (12 pieces) from the 1st clutch.

piston (137).
HM400-1 30-75
(7)
(FH clutch side) 12) Using C-clamp 9, etc., compress the clutch
10) Using push puller 8, remove gear and spring and remove snap ring (146).
needle roller bearing assembly (140), ★ The clutch spring may be compressed
bearing inner race (141i), spacer (142), and by holding the end plate without using
thrust washer (143) together. the C-clamp similarly to the 2nd clutch.
★ For bearing outer race (141o), see (For example, put a bar to the screw
Disassembly of transmission case hole of the shaft and press down the
assembly on torque converter side. end plate with the spacer.).
11) Remove needle roller bearing (145) from 13) Remove end plate (147), plates (148) (10
gear (144). pieces), discs (149) (9 pieces), and wave
springs (150) (9 pieces) from the FH clutch.
30-76 HM400-1
(7)
. 26. Disassembly of R and FL clutch assembly

(R clutch side)
14) Using the hanging tap, remove thrust

washer (151) and piston assembly (152).
2) Using push puller 0, remove gear and

needle roller bearing assembly (162),
bearing inner race (163i), spacer (164), and
thrust washer (165) together.
converter.

piston (153).

from gear (166).
HM400-1 30-77
(7)
4) Using C-clamp A, etc., compress the clutch .


assembly (174).

piston (175).

springs (172) (11 pieces) from the R clutch.
30-78 HM400-1
(7)
(FL clutch side) 11) Using C-clamp A, etc., compress the clutch
8) Using push puller 4, remove gear (178) spring and remove snap ring (185).
and bearing inner race (179i) together. ★ The clutch spring may be compressed
9) Remove spacer (180) (2 piece type) and

thrust washer (181), then remove gear and
needle roller bearing (182) assembly.

from gear (183). 12) Remove end plate (186), plates (187) (12
springs (189) (11 pieces) from the FL
clutch.
HM400-1 30-79
(7)
27. Disassembly of transmission case assembly (on

opposite side of torque converter)
1) Remove holder (213), gear (214), bearings
(215) and (216), snap ring (217), and collar
(218).

assembly (191).
2) Remove bearing outer races (73o), (123o),

and (163o).

piston (192).
28. Disassembly of transmission case assembly (on

torque converter side)
Remove bearing outer races (64o), (100o), and
(141o) from the case.
30-80 HM400-1
2
29. Disassembly of P.T.O. case assembly

Disassemble the 3 idle gear according to the fol-
lowing procedure.
1) Remove nut (219) and P.T.O. gear and
bearing inner race assembly (220).
2) Remove bearing inner race (222ir) from

P.T.O. gear and bearing inner race assem-
bly (221).
3) Remove snap ring (223), plate (224), bear-

ing (222l), spacer (222c), and bearing outer
race (222or).
HM400-1 30-81
2
ASSEMBLY OF TRANSMIS-
SION ASSEMBLY
• Precautions for assembly 2) Set bearing inner race (222il) in position
★ Clean the all parts and check them for dirt or and install P.T.O. gear (221) and press fit it
damage before installing. by tightening nut (219).
★ Coat the sliding surfaces of the all parts with Bolt: Adhesive (LT-2)
3
engine oil before installing.
Bolt: 313.8 - 392.3 Nm {32 - 40 kgm}
★ Dip the discs in clean engine oil (EO-30CD)
for at least 2 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.
2. Assembly of transmission case assembly (on

torque converter side)
Install bearing outer races (64o), (100o), and
(141o) to the case.
1. Assembly of P.T.O. case assembly
1) Install bearing outer race (222or), spacer
(222c), and bearing (222ol), then fix them
with plate (224) and snap ring (223).
3. Assembly of transmission case assembly (on

opposite side of torque converter)
1) Install bearing outer races (73o), (123o),
and (163o).
30-82 HM400-1
(11)
(7)
2) Fit collar (218) and install bearings (215) 2) Install piston assembly (191) and thrust
and (216) to gear (214) by expansion fit. washer (190).
★ Take care of the installing direction. Apply engine oil (EO-30CD) to the
3) Install snap ring (217). periphery and contact surfaces of the
4) Install gear assembly (214) by shrink fit. seal rings.
★ Shrink fit temperature: Approx. 120°C
for 30 minutes
5) Install holder (213) and tighten the bolts
Bolt: Adhesive (LT-2)
Bolt: 245 - 309 Nm {25 - 31.9 kgm}
3) Install plates (187) (12 pieces), discs (188)

(11 pieces), wave springs (189) (11 pieces),
and end plate (186) to the FL clutch.
4. Assembly of R and FL clutch assembly
(FL clutch side)
1) Install seal rings (193) and (194) to piston
(192).
★ Install the seal rings with the pressure
receiving side directed to the housing.
HM400-1 30-83
(7)
4) Install needle roller bearing (184) (2 pieces) ..

to gear (183).
5) Install gear and needle roller bearing assembly

(182) temporarily and match the grooves of the
discs.
★ Pressing down the assembly, turn it to
the right and left and push it in gradually
so that it will not collide with the crests of
the discs.

(182), thrust washer (181), and spacer (180)
(2-piece type).
★ If the gear and needle roller bearing
assembly (182) is difficult to install,
repeat the procedure from step 5).
★ The gear and needle roller bearing
assembly (182) may be installed first.
Then, compress the clutch spring with
C-clamp (11) and install snap ring (184).
6) Remove the gear and needle roller bearing
assembly (182).
7) Using C-clamp A, etc., compress the clutch
spring and install snap ring (185).
30-84 HM400-1
(7)
9) Install gear (178), then install bearing inner 11) Install piston assembly (174) and thrust
race (179i) by shrink fit. washer (173).
★ Shrink fit temperature: Approx. 120°C Apply engine oil (EO-30CD) to the pe-
for 30 minutes riphery and contact surfaces of the seal
★ For bearing outer race (179o), see Dis- rings.
assembly of transmission case assem-
bly on opposite side of torque converter.

and end plate (169) to the R clutch.
(R clutch side)
★ Dip the discs in clean engine oil (EO-
30CD) for at least 2 minutes before in-
(175).
stalling.
HM400-1 30-85
2
13) Install needle roller bearing (167) (2 pieces) 16) Using C-clamp, jig A, etc., compress the
to gear (166). clutch spring and install snap ring (168).

discs.
the discs.

assembly (162).
30-86 HM400-1
(7)
17) Install gear and needle roller bearing assembly ★ Install the seal rings with the pressure
(162), thrust washer (165), and spacer (164). receiving side directed to the housing.
★ If gear and needle roller bearing assembly
(162) is difficult to install, repeat the
procedure from step 14).
18) Install bearing inner race (163i) by shrink fit.
for 30 minutes.
assembly of transmission case
converter.
2) Install piston assembly (152) and thrust

washer (151).
★ Using the hanging tap, install piston
assembly (152), taking extreme care
that the seal rings will not be caught.
Apply engine oil (EO-30CD) to the
periphery and contact surfaces of the
seal rings.
19) Install seal rings (161) (3 pieces).

and end plate (147) to the FH clutch.
5. Assembly of 1st and FH clutch assembly
(FH clutch side)
(153).
HM400-1 30-87
(7)

assembly (140).
4) Install needle roller bearing (145) to gear

(144).
5) Install gear and needle roller bearing

assembly (140) temporarily and match the
grooves of the discs.
the discs.
assembly (140), thrust washer (143), and
spacer (142).
assembly (140) is difficult to install,
repeat the procedure from step 5).
30-88 HM400-1
2
11) Install piston assembly (136) and thrust washer

(134).
assembly (136), taking extreme care
that the seal rings will not be caught.
seal rings.

for 30 minutes
converter.
(1st clutch side) 12) Install plates (131) (12 pieces), discs (132)
10) Install seal rings (138) and (139) to piston (11 pieces), wave springs (133) (11 pieces),
(137). and end plate (130) to the 1st clutch.
★ Install the seal rings with the pressure ★ Dip the discs in clean engine oil (EO-30CD)
receiving side directed to the housing. for at least 2 minutes before installing.
HM400-1 30-89
(7)

assembly (126).
16) Using C-clamp, jig 8, etc., compress the
clutch spring and install snap ring (129).
13) Install needle roller bearing (128) (2 pieces)

to gear (127).

assembly (126) temporarily and match the
grooves of the discs.
the discs.
assembly (126).
assembly is difficult to install, repeat the
procedure from step 13)
30-90 HM400-1
(7)
18) Install thrust washer (125) and snap ring

(124). 6. Assembly of 2nd and 3rd clutch assembly
(3rd clutch side)
(114).
19) Install gear (127).

for 30 minutes
converter.
HM400-1 30-91
(7)
2) Install piston assembly (113) and thrust 4) Install needle roller bearing (106) to gear (105).
washer (112).
seal rings.

discs.
3) Install plates (109) (8 pieces), discs (110) (7
pieces), wave springs (111) (7 pieces), and
the discs.
end plate (108) to the 3rd clutch.
6) Remove gear and needle roller bearing assembly
★ Dip the discs in clean engine oil (EO-
(104) again.
30CD) for at least 2 minutes before
installing.

30-92 HM400-1
(7)
(2nd clutch side)

(87).

(104).
★ If it is difficult to install the gear and
needle roller bearing assembly, repeat
the procedure from 5).
9) Install thrust washer (103) and snap ring 12) Install piston assembly (86) and thrust washer
(102). (84).
assembly (86), taking extreme care that
seal rings.
10) Install spacer (101), then install bearing

inner race (100i) by shrink fit.
for 30 minutes
HM400-1 30-93
(7)
14) Install needle roller bearing (78) to gear

(77).

end plate (80) to the 2nd clutch. 15) Install gear and needle roller bearing
★ Dip the discs in clean engine oil (EO- assembly (76) temporarily and match the
30CD) for at least 2 minutes before grooves of the discs.
installing. ★ Pressing down the assembly, turn it to
the discs.

assembly (76).
17) Using C-clamp, jig 5, etc., compress the
clutch spring and install snap ring (79).
★ The 2nd clutch has a screw hole for
eyebolt on the gear. The clutch spring
may be compressed by inserting a
spacer of proper thickness on the clutch
side and utilizing that screw hole.
30-94 HM400-1
(7)
19) Install gear (73), spacer (227) (2-piece type),

and spacer (226) (having a spline).

for 30 minutes

assembly (76).
assembly is difficult to install, repeat the
procedure from step 13).
HM400-1 30-95
(7)
7. Assembly of differential clutch assembly 2) Install seal ring (61) to piston (60).
1) Assemble the housing assembly according Apply grease (G2-LI) to the seal ring.
★ Install the seal ring with the pressure
i) Using push tool B, press fit bearing
inner race (65i) to housing (62).
3) Install piston assembly (59).

assembly (59), taking extreme care that
ii) Using push tool C, press fit bearing
outer race (64o) to housing (62).
iii) Install seal ring (63).

★ Install the seal ring with the pressure
receiving side directed to the
housing.
30-96 HM400-1
(7)
2
4) Assemble front shaft and hub assembly 5) Install front shaft and hub assembly (49).
(49) according to the following procedure.
i) Using push tool D, press fit bearing
inner race (64i) to shaft (51).

end plate (55) to the differential clutch.
ii) Install hub (52) to shaft (51), then install ★ Dip the discs in clean engine oil (EO-
snap ring (50). 30CD) for at least 2 minutes before
iii) Install seal rings (53) and (54). installing.
Apply grease (G2-LI) to the seal rings.
HM400-1 30-97
(7)
2
7) Assemble the carrier assembly according to 8) Install carrier assembly (42).

the following procedure. Mounting bolt: Adhesive (LT-2)
i) Set gear (46), bearings (47) (2 pieces)
Mounting bolt:
and thrust washers (48) (2 pieces) in
position and drive in shaft (44) halfway 98 - 122.5 Nm {10 - 12.5 kgm}
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.
ii) Install ring (43).
9) Install snap ring (41).
10) Install sun gear (40) and snap ring (39).
30-98 HM400-1
(7)
11) Assemble the gear and shaft and ring gear iv) Install shaft and snap ring assembly
a s s e m bl y ac c o r d i ng t o th e fol l ow in g (32) to ring gear (33).
procedure.
i) Install snap rings (68) and (36) to shaft
(35).
★ Snap ring (68) is for the oil sump.
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,
ii) Press fit bearing inner race (38i) to gear using push tool G.
(37).
★ For bearing outer race (38o), see the
section of bearing cage.
iii) Using push tool F, press fit bearing

outer race (34-2o) to gear (37).
★ Bearing (34) (Inner races: 34-1, 34-2,
34-3) is the assembly No.
HM400-1 30-99
2
vi) Install spacer (34-3) to shaft and ring 8. Torque converter assembly
gear assembly (69). Install torque converter assembly (29).
Mounting bolt:
98.1 - 122.6 Nm {10 - 12.5 kgm}
★ For assembly of the torque converter, see
Assembly of torque converter assembly.
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 H.
9. P.T.O. assembly
Install the O-ring and P.T.O. assembly (28).
O-ring on mating face: Grease (G2-LI)
Mounting bolt:
98.1 - 122.6 Nm {10 - 12.5 kgm}
★ For assembly of the P.T.O. assembly, see
Assembly of P.T.O. assembly.
12) Install gear and shaft and ring gear

assembly (30).
30-100 HM400-1
2
10. Cage assembly iii) Install bearing and spacer and snap
1) Assemble the cage assembly according to ring assembly (202), then install snap
the following procedure. ring (201).
i) Install bearing outer race (380) to cage
(211).
ii) Using push tool I, press fit bearing

(205) to spacer (204) and install snap
ring (203).
2) Install cage assembly (26).

O-ring on mating face: Grease (G2-LI)
HM400-1 30-101
2
11. R and FL clutch assembly 13. Differential lock clutch assembly

Install R and FL clutch assembly (25). Install differential lock clutch assembly (22).
★ For assembly of R and FL clutch assembly, ★ For assembly of the differential lock clutch
see 4. assembly, see 7.
Apply grease (G2-LI) to the seal rings
(3 places) before installing transmis-
sion case assembly (21) (on the oppo-
site side of the torque converter).
★ Check that the cuts of the seal rings (3
places) are not opened.
14. Shroud
Install shroud (90).
★ Press the shroud lightly against the housing,
then separate it from the housing by 1 mm
and install it.
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 5. For assembly of the 2nd
and 3rd clutch assembly, see 6.
Apply grease (G2-LI) to the seal rings (6
places) before installing transmission
case assembly (21) (on the opposite
side of the torque converter).
★ Check that the cuts of the seal rings (6
places) are not opened.
30-102 HM400-1
(7)
15. Transmission case assembly (on opposite side of 3) Using push tool J, press fit oil seal (67) to
torque converter) bearing cage (66).
Install transmission case assembly (21) (on the ★ Adjust distance "g" from the cage end to
opposite side of the torque converter). 13.5 ± 0.2 mm.
Mounting bolt:
98.1 - 122.6 Nm {10 - 12.5 kgm}
★ For assembly of the transmission case (on the
opposite side of the torque converter), see 3.
4) Install bearing outer race (38o).
16. Bearing cage

1) Bearing cage (2nd side)
Install outer race (129) to bearing cage (128).
17. Procedure for installing bearing cage and adjust-

ing preload on tapered roller bearing
1) Engage the differential lock clutch with air.
★ Keep the differential lock clutch engaged
until the following adjustment of the shim
is completed.
2) Install bearing cages (19) and (20) without
2) Bearing cage (Rear output side)
shims.
Using push tool (20), press fit oil seal (68)
to bearing cage (66). Mounting bolt:
★ Adjust distance "f" from the cage end to 9.8 ± 1.0 Nm {1 ± 0.1 kg}
28.5 ± 0.2 mm.
HM400-1 30-103
(7)
3) Rotate the output shaft 20 turns. 11) Subtract the following value from the
4) Check that the tightening torque of the average of clearance "f" obtained in 10)
mounting bolt has not changed. If it has above. Insert shims of the thickness
changed, repeat steps 2) and 3). equivalent to the result of this calculation.
5) Loosen the mounting bolts of bearing cage ★ Reduction of thickness:
(19) and measure the rotating torque of the 0.05 - 0.10 mm
output shaft. ★ Allowable range of shim thickness
★ Rotating torque: (Reference):
14.7 - 25.5 Nm {1.5 - 2.6 kgm} 1.50 - 3.15 mm
6) Measure clearance "f" between bearing 12) Rotating the output shaft, tighten the mounting
cage (19) and rear transmission case at 3 bolts of bearing cage (20) to the following
places (equally spaced on the periphery) torque.
and obtain the average. Mounting bolt:
7) Subtract the following value from the 98 - 122 Nm {10 - 12.5 kgm}
average of clearance "a" obtained in vi) 13) Measure the rotating torque of the output
above. Insert shims of the thickness shaft and check that its increase from the
equivalent to the result of this calculation. value obtained in step 9) is in the following
★ Reduction of thickness: range.
0.10 - 0.15 mm ★ Increase of rotating torque:
★ Allowable range of shim thickness 2.94 - 9.81 Nm {0.3 - 1.0 kgm}
(Reference): 1.7 - 3.0 mm
8) Rotating the output shaft, tighten the
mounting bolts of bearing cage (19) to the
following torque.
Mounting bolt:
98 - 122 Nm {10 - 12.5 kgm}
9) Measure the rotating torque of the output
shaft and check that its increase from the
value obtained in step 5) is in the following
range.
2.94 - 9.81 Nm {0.3 - 1.0 kgm}
10) Measure clearance "a" between bearing

cage (20) and the rear transmission case at
3 places (equally spaced on the periphery)
and obtain the average.
★ If the dispersion of the measured values
at the 3 places exceeds 0.15 mm, check
the bearing and other parts for
abnormality. Correct any abnormal part
and measure clearance "a" again.
30-104 HM400-1
(7)
14) Install cover (18) (1st clutch side).
18. Snap ring of front output shaft 2) Install input coupling (27).
Install snap ring (16). Fitting part of O-ring: Grease (G2-LI)
Mounting bolt:
245.2 - 308.9 Nm {25 - 31.5 kgm}
19. Coupling
1) Install the O-ring, holder, and rear coupling
(15).
Mounting bolt:
824 - 1,030 Nm {84 - 105 kgm}
HM400-1 30-105
(7)
20. Transmission control valve, torque converter 22. Mounting bracket and trunnion
valve, valve seat and tube Install mounting bracket (11) (on the front
1) Install transmission case upper tube (130). differential side) and trunnion (10) (on the rear
★ Take care not to mistake the direction of side).
the tube. Mounting bolt of mounting bracket (11)
2) Install the O-ring, valve seat (14), transmission (on front differential side):
control valve assembly (12), and main relief
Adhesive (LT-2)
valve assembly (13).
Mounting bolt of mounting bracket (11)
Mounting bolt marked * (2 pieces)
(on front differential side):
(Others must conform to KES):
455 - 566 Nm {46.5 - 58.5 kgm}
34 - 44 Nm {3.5 - 4.5 kgm}
23. Strainer
Install strainer (9).
24. Torque converter oil pressure (pickup) sensor
Install torque converter oil pressure (pickup)
sensor (230).
Threaded parts of oil pressure sensor:
Gasket sealant (LG-5)
25. Torque converter oil temperature sensors
Install torque converter oil temperature sensors
(6) and (7).
Threaded parts: Gasket sealant (LG-5)
Threaded parts:
15.7 - 19.2 Nm {1.6 - 2.0 kgm}
26. Transmission speed sensors
Install transmission input shaft speed sensor
(4), intermediate shaft speed sensor (5), and
rear output shaft speed sensor (6).
★ For adjustment method and tightening
torque, see TESTING AND ADJUSTING.
★ For the front output shaft speed sensor, see
Separation of front differential and
transmission.
27. Torque converter and transmission charge pump
Install the torque converter and transmission
charge pump (3).
28. Wiring harness assembly
Install wiring harness assembly (2).

Couple the front differential assembly. For
details, see Coupling front differential with
transmission.
30-106 HM400-1
(7)
29. Piping
Install piping (1)
HM400-1 30-107
(7)
DISASSEMBLY AND ASSEMBLY FRONT DIFFERENTIAL
DISASSEMBLY OF FRONT
DIFFERENTIAL ASSEMBLY
1. Speed sensor and top cover
Remove speed sensor (1) and top cover (2).
2) Disassemble pinion and case assembly (9)

i) Remove case assembly (10) from
pinion assembly (11).
2. Bevel gear supporting bolt
Remove bevel gear supporting bolt (4).
3. Pinion and case assembly

1) Using forcing screw 1, remove pinion and
case assembly (9).
shims.
30-108 HM400-1
2
ii) Remove spacer (12) and bearing inner 5. Right and left output shaft couplings
race (13i). Remove couplings (17) and (18) on both sides.
shims.
iii) Remove seals (14) and (15), bearing

(16), and bearing outer race (13o) from
case (11). 6. Side carrier and shaft assembly
1) Sling the differential gear case with wires
and remove side carrier and shaft assembly
(19) on the bevel gear side by using forcing
screw 1.
shims.
4. Input shaft coupling and holder

Remove holder (5) and coupling and gear
assembly (6).
HM400-1 30-109
2
2) Under the above condition, remove side

carrier and shaft assembly (20) on the
opposite side by using forcing screw 2.
shims and the position of the side
carrier.
2) Disassemble the differential gear and

differential lock assembly according to the
i) Using pullers 3 (10 t) and 4, remove
retainer (23) and bearing inner race
(24i).
★ For disassembly of side carrier and shaft

assembly, see 8.
7. Differential gear and differential lock assembly
1) Remove the mounting bolts (21) (3 pieces)
from the retainer of the differential gear
case, then remove differential gear and
differential lock assembly (22).
30-110 HM400-1
2
ii) Remove seal ring (25). v) Remove seal ring (29) from piston (28).
★ Check the direction of the seal ring.
iii) Remove case and piston assembly

(26). vi) Remove seal ring (30) and thrust
washer (68) from case (27).
iv) Remove piston (28) from case (27).

★ Piston (28) may be left below (on the vii) Remove plate (31), disc (32), and pin
differential case side). In that case, (33).
remove the piston separately.
HM400-1 30-111
2
viii) Bevel gear assembly ix) Remove washer (41) and differential
1 Turn over the assembly and remove side gear (42).
mounting bolts (36) (12 pieces) of
bevel gear assembly (35) of case
(34), then remove bevel gear
assembly (35).
★ Check the match marks on the
bevel gear and case before
removing the bevel gear
assembly (on the tooth surface
side of the bevel gear).
2 Using puller 5, remove bearing

inner race (38i) from bevel gear and
case assembly (37).
3 Remove case (39) from bevel gear
(40). x) Remove pinion gear assembly (43) and
cross shaft (44) in 1 unit.
30-112 HM400-1
2
8. Disassembly of side carrier and shaft assembly

1) Disassemble the side carrier and shaft
assembly on the bevel gear side according
i) Remove seal (49).
xi) Remove washer (45), pinion gear (46),

and bushing (sleeve) (47).
ii) Shaft and bearing inner race assembly

1 Remove shaft and bearing inner
race assembly (50)
xii) Remove side gear (48).
2 Using push tool 6, remove bearing

inner race (51i).
HM400-1 30-113
2
iii) Remove bearing (53) and bearing outer 2 Using push tool 7, remove bearing
races (38o) and (51o) from case (52). inner race (56i).
★ Bearing (53) is divided into the inner
race and outer race when the shaft is
removed (pulled out).
iii) Remove bearing (58) and bearing outer

races (24o) and (56o) from case (57).
★ Bearing (58) is divided into the inner
2) Disassemble the side carrier and shaft race and outer race when the shaft is
assembly on the opposite side of the bevel removed (pulled out).
gear according to the following procedure.
i) Remove seal (54).

1 Remove shaft and bearing inner
race assembly (55).
30-114 HM400-1
2
ASSEMBLY OF FRONT 2 Set the standard shims (having the

thickness and quantity checked
DIFFERENTIAL ASSEMBLY when disassembled) and install
coupling (17). Using push tool 7,
★ When installing a seal to another part
press holder (60) to press fit case
(particularly when installing it to the input shaft),
assembly (61) to shaft and bearing
use a push tool matched to the diameter of that
inner race assembly (50).
seal, even if use of the push tool is not described
in this manual.
1. Assembly of side carrier and shaft assembly
1) Assemble the side carrier and shaft
assembly on the bevel gear side according
i) Install bearing outer races (38o), (51o),
and (53o) to case (52).
3 Adjust the shims for the bearing

a) Measure the starting tangential
force in the tangential direction of
the bolt hole (φ234) of the case.
★ Standard tangential force:
Max. 21.5 N {2.2 kg}
b) If the starting tangential force is
too large, increase the shims. If
1 Using tool H4, press fit bearing inner
the former is too little, decrease
race (51i) to shaft (59).
the latter. Then, measure the
starting tangential force again.
★ If the starting tangential force
is tool large, disassemble
shaft and bearing inner race
as s e mb l y ( 5 0 ) a n d c a s e
assembly (61) and increase
the shims, then execute 2
above.
HM400-1 30-115
2
. ii) Shaft and bearing inner race assembly

1 Using tool H4, press fit bearing inner
race (56i) to shaft (63)..
iii) Using tool H3, press fit seal (49)..
2 Set the standard shims (having the

thickness and quantity checked
when disassembled) and install
coupling (18). Using push tool 7,
press holder (65) to press fit case
assembly (66) to shaft and bearing
inner race assembly (55).
2) Assemble the side carrier and shaft

assembly on the opposite side of the bevel
gear according to the following procedure.
i) Install bearing outer races (24o), (56o),
and (58o) to case (57).
30-116 HM400-1
2
3 Adjust the shims for the bearing ★ The procedure for installing both side carrier and
according to the following procedure, shaft assemblies to the body is explained in 3
similarly to the side carrier on the below.
bevel gear side. 2. Differential gear and differential lock assembly
a) Measure the starting tangential 1) Assemble the differential gear and
force in the tangential direction of differential lock assembly according to the
the bolt hole (φ208) of the case. following procedure.
★ Standard tangential force: i) Install side gear (48).
Max. 24.5 N {2.5 kg}
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 tool large, disassemble
shaft and bearing inner race
as s em b l y ( 5 5 ) a n d c a s e
assembly (65) and increase
the shims, then execute 2
above.
iii) Using tool H3, press fit seal (54).
ii) Install bushing (sleeve) (47), pinion

gear (46), and washer (45).
HM400-1 30-117
2
iii) Install pinion gear assembly (43) and 2 Install bearing inner race (38i) to
cross shaft (44) in 1 unit. bevel gear and case assembly (37)
by shrink fit.
★ Shrink fit temperature:
120°C for 30 minutes
iv) Install differential side gear (42) and

washer (41).
3 Install bevel gear assembly (35) to

case (34).
★ Match the match marks to each
other.
vi) Install pin (33), plate (31), and disc (32).

★ Apply engine oil (EO-30) to the
surfaces of the disc and plate.
v) Bevel gear assembly

1 Install case (39) to bevel gear (40).
Mounting bolt:
Adhesive (LT-2)
Mounting bolt:
245 - 309 Nm {25 - 31.5 kgm}
30-118 HM400-1
2
vii) Install seal ring (30) and thrust washer x) Install case and piston assembly (26).
(68) to piston case (27). Mounting bolt:
★ When installing the seal ring, take
157 - 196 Nm {16 - 20 kgm}
care of its direction.
xi) Install seal ring (25).

viii) Install seal ring (29) to piston (28).
xii) Using push tool 9, press fit bearing

ix) Install piston (28) to case (27).
inner race (24i) and retainer (23) in 1
unit.
HM400-1 30-119
2
2) Sling differential gear and differential lock 2) Under the above condition, set the standard
assembly (22) and install it to differential shim (having the thickness and quantity
gear case (67) and tighten the retainer checked when disassembled) and install
mounting bolts (21) (3 pieces). side carrier and shaft assembly (20) on the
opposite side.
3 Mounting bolt:
157 - 196 Nm {16 - 20 kgm}
3) Adjusting preload on side bearing

i) Measure the initial rotating force of the
periphery of the bevel gear in the tan-
gential direction.
★ Initial rotating force:
6.86 - 25.0 N {0.7 - 2.55 kg}
ii) If the rotating force is larger than the
standard level, increase the thickness/
quantity of the shims. If the former is in
3. Side carrier and shaft assembly the standard range, it is normal.
1) Sling the differential gear case and set the ★ After adjusting the tooth contact and
standard shims (having the thickness and backlash, the shims on both sides
quantity checked when disassembled) and may be exchanged with each other.
install side carrier and shaft assembly (19) Do not change the total quantity and
on the bevel gear side. thickness of the shims on both sides,
3
however.
Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
4) After adjusting the preload, be sure to

tighten the mounting bolts to the specified
torque in 1).
30-120 HM400-1
(11)
2
4. Right and left output shaft couplings iii) Using tool H1, press fit bearing inner
Install couplings (17) and (18) on both sides. race (13i) to pinion (10).
Mounting bolt: Adhesive (LT-2) iv) Install spacer (12).
Mounting bolt:
490 - 608 Nm {50 - 62 kgm}
2) Using tool H1, press fit case assembly (11)

to pinion (10).
★ Never push the case assembly with a
5. Pinion and case assembly press.
1) Assemble pinion and case assembly (9) ★ Press fit bearing inner race (16i) with
according to the following procedure. tool H1.
i) Using push tool 0, install bearing outer ★ Press fitting force:
race (13o) to case (11). 0 - 8134 N {0 - 830 kg}
ii) Using push tool A, install bearing outer ★ Press fit case assembly (11), turning it.
race (16o) to case (11).
HM400-1 30-121
2
i) Using push tool B, press fit seal (15) to 3) Set the standard shim (having the thickness
case (11). and quantity checked when disassembled)
Apply Sealend 242 to the pe- and install pinion and case assembly (9).
riphery of the seal. ★ Tighten 3 mounting bolts first.
★ After adjusting the tooth contact, tighten
★ Taking care of the direction of the
the all mounting bolts.
3
seal, press fit it until it is flush with the
case as shown in the figure. Mounting bolt:
★ Press fit the seal so that standard di- 245 - 309 Nm {25 - 31.5 kgm}
mension "a" will be 110 mm.
ii) Using tool H2, press fit seal (14) to
case (11).
Apply Sealend 242 to the pe-
riphery of the seal.
★ Taking care of the direction of the
seal, press fit it until it is flush with the
case as shown in the figure.
6. Input shaft coupling and holder

1) Using push tool C, press fit speed detec-
tion gear (8) to coupling (7).
★ Press fit the gear until it is flush with the
coupling.
30-122 HM400-1
(11)
2
2) Install coupling and gear assembly (6) and ii) Apply dial gauge C perpendicularly to
holder (5). the reversing tooth surface at the outer
Holder end (Face to be in contact with end of the bevel gear. Adjust the
bearing at bottom): Adhesive (LMP) backlash so that the gauge will indicate
0.3 - 0.4mm.
Holder mounting bolt: Adhesive (LT-2)
★ Adjust the backlash at 3 - 4 places
Holder mounting bolt: and measure it with the pinion fixed.
824 - 1,030 Nm {84 - 105 kgm} Do not change the total quantity and
thickness of the shims on both sides
so that the given preload will not
change.
7. Adjusting tooth contact and backlash

Adjust the backlash and tooth contact
simultaneously.
1) Adjust the backlash according to the 2) Adjust the tooth contact according to the
following procedure. following procedure.
i) Move the bevel gear with the shims i) Adjust the projection of the bevel pinion
(69) and (70) of both carrier with shim (71) between the differential
assemblies. At this time, do not change case and bearing case.
the total quantity and thickness of the
shims on both sides so that the preload
on the bearing will not change.
ii) Adjusting tooth contact

★ See Adjusting tooth contact in iii)
below.
HM400-1 30-123
2
iii) Adjusting tooth contact of bevel gear Adjusting

and bevel pinion If the tooth contact pattern is not proper, adjust it
Testing i) If the bevel pinion is too far from the center
i) Apply red lead thinly to the tooth surfaces of line of the bevel gear, the contact is at the
the bevel pinion and turn the bevel gear in small end of the bevel gear tooth surfaces
the forward and reverse directions, then curved outward and at the large end of the
check the tooth contact pattern on the bevel bevel gear tooth surfaces curved inward.
gear. • In this case, adjust the tooth contact
ii) The center of the tooth contact must be at according to the following procedure.
the middle of the tooth height and about Adjust the thickness of the shims on the
33% (b) of tooth depth from the small end. bevel pinion side to move the bevel pinion in
The width of the tooth contact must be 30 - direction A. Adjust the thickness of the
60% (a) of the tooth depth. Check that shims of both carrier assemblies to move
there is not a strong contact at the tips or the bevel gear in direction B, then check the
bottoms of the teeth of both small end and tooth contact pattern and backlash again.
large end. ii) If the bevel pinion is too close to the center
★ If the bevel gear and bevel pinion are line of the bevel gear, contact is at the large
adjusted in this way, their teeth come in end of the bevel gear tooth faces curved
contact with each other correctly when outward and the small end of the bevel gear
they are loaded. tooth faces curved inward.
• In this case, adjust the tooth contact
similarly to i) above. Reverse directions A
and B, however.
★ If the shim on the 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.
30-124 HM400-1
2
★ After adjusting the tooth contact, refer to the

sections of the mounting bolts of both bevel
gear side c arr iers , both output shaft
couplings, pinion and case assembly, and
input shaft and observe the application of
adhesive and tightening torque.
Install bevel gear supporting bolt (4).
★ Bring the bolt end in contact with the back of
the gear, then return it by a half turn and
secure it with the locknut.
Bolt: Gasket sealant (LG-5)
Locknut: 196 - 245 Nm {20 - 25kgm}
9. Speed sensor and top cover

Install speed sensor (1) and top cover (2).
Top cover: Gasket sealant (LT-515)
Top cover mounting bolt:
157 - 196 Nm {16 - 20 kgm}
HM400-1 30-125
2
DISASSEMBLY AND ASSEMBLY CENTER DIFFERENTIAL
REMOVAL OF CENTER DIF- 4. Drive shaft between center differential and rear
differential
FERENTIAL ASSEMBLY Remove the guard and disconnect only the
center differential end of drive shaft (3) between
center differential and rear differential.
Raise the dump body and insert the safety pin.
1. Draining oil
Drain oil from the center differential case and
center final drive case.
2. Sun gear and drive shaft
Remove the center final drive cover and pull out
sun gear and drive shaft (1) (from both sides).
5. Coupling on rear differential side

Remove the holder, coupling (4) on the rear dif-
ferential side, and cover (5).
3. Drive shaft between hitch frame and center differ-

ential
Remove the guard and disconnect only the
hitch frame and center differential.
Drive shaft between hitch frame and

center differential (Only center differen-
tial end): 35 kg
★ Make match marks so that the spline will not 6. Rear differential drive shaft and bearing cage
shift in the circumferential direction. assembly
Using forcing screw 1, remove rear differential
drive shaft (7) and bearing cage assembly (6) in
1 unit.
30-126 HM400-1
2
7. Piping and wiring harness

Disconnect differential lock hoses (8) - (10),
brake hose (11), brake cooling hoses (12) (3
pieces), and rear retarder oil temperature sen-
sor connector (CN-T14) (13), then remove
brake cooling tube (14).
8. Center differential assembly

Sling center differential (15) temporarily. Using
forcing screws (M14 x 2), pull out the center dif-
ferential. After pulling out the differential half-
way, change the slinging position (increase the
number of slings) and remove the differential.
Center differential assembly: 380 kg
HM400-1 30-127
2
INSTALLATION OF CENTER
DIFFERENTIAL ASSEMBLY Center differential mounting bolt:
• Carry out installation in the reverse order to re- 157 - 198 Nm {16 - 20 kgm}
moval. [Target: 177 Nm {18 kgm}]

★ When installing the drive shaft, check that the For details, see TESTING AND ADJUSTING,
key way of the spider cap is matched to that of Bleeding air from brake circuit.
Refilling with oil
Mounting bolt of drive shaft between • Pour the specified oil in the center differential
hitch frame and center differential: Ad- case and final drive case to the specified level.
hesive (LT-2) • Check the oil level in the transmission case and
Mounting bolt of drive shaft between add the specified oil to the specified level if nec-
hitch frame and center differential: essary.
• Check the oil level in the hydraulic tank and add
157 - 198 Nm {16 - 20 kgm} the specified oil to the specified level if neces-
[Target: 177 Nm {18 kgm}]] sary.
★ When installing the drive shaft, check that the
Mounting bolt of drive shaft between

center differential and rear differential:
Adhesive (LT-2)

98 - 123 Nm {10 - 12.5 kgm}
★ When installing a seal to a cover, use a push tool

matched to the diameter of that seal.
Seal lip: Grease (G2-LI)
Cover mounting bolt:

98 - 123 Nm {10 - 12.5 kgm}
★ Install the rear (output) coupling so that the

phase difference between it and the front (input)
coupling will be 6° or less.
Coupling holder mounting bolt:

Adhesive (LT-2)
Coupling holder mounting bolt:

490 - 608 Nm {50 - 62 kgm}
[Target: 550 Nm {56 kgm}]
30-128 HM400-1
2
DISASSEMBLY OF CENTER 4. Cage

1) Using forcing screw 1, remove cage
DIFFERENTIAL ASSEMBLY assembly (4).
1. Set the center differential gear assembly to
shims.
tool H9.
2) Remove side seal (5), oil seal (6), and bear-

2. Cover
ing outer race (7o) from cage (12).
Remove cover (1).
5. Transfer input shaft and gear assembly

3. Transfer input coupling and holder
1) Remove transfer input shaft and gear
Remove holder (2) and coupling (3). assembly (8).
HM400-1 30-129
2
2) Disassemble transfer input shaft and gear 7. Transfer case

assembly (8) according to the following pro- 1) Using forcing screw 2, remove transfer
cedure. case assembly (16).
• Remove bearing inner race (7i), spacer
(11), and gear (12) from transfer input
shaft (9).
6. Input shaft holder

★ Place a wood block, etc. so that the bevel
pinion will not fall.
1) Remove holder (13).
shims.
2) Remove bearing outer race (10o) and bear-

ing (18) from transfer case (17).
2) Remove holder (14) and key (15).
30-130 HM400-1
2
8. Input gear and spacer 10. Pinion assembly

Remove spacer (19) and input gear (20). 1) Remove pinion assembly (24).
★ Check the identification mark (A - J) of the
spacer.
2) Disassemble pinion assembly (24) accord-

9. Cage assembly Remove bearing inner race (21i) from pin-
1) Using forcing screw 3, remove cage ion (25).
assembly (21).
shims.
2) Remove bearing outer race (23o) from cage

(22).
HM400-1 30-131
2
11. Differential gear and differential lock assembly ii) Remove washer (37) and pin (38).
★ Sling the differential case in advance. iii) Remove piston (39).
1) Remove locks (26) and (27). • Remove seal ring (40) from piston
2) Using tool H6, loosen adjustment nuts (28) (39).
and (29) to the degree that you can turn iv) Using a bearing puller, remove bearing
them with fingers. inner race (41i).
3) Loosen bolts (30) (4 pieces). v) Remove sleeve (42).
4) Sling the differential gear case assembly
with wires and remove bearing caps (31)
and (32) and nuts (28) and (29), then
remove the differential gear case assembly.
★ Take care not to drop the bearing outer
race.
vi) Remove plate (43) and disc (44).

vii) Remove pins (45) (4 pieces).
5) Disassemble the differential gear case

assembly according to the following proce-
dure.
i) Gear case
1 Set the gear case to a block (Height:
Approx. 200 mm).
2 Remove mounting bolts (33) (20
pieces).
3 Lift off case (34) with wires.
4 Remove seal rings (35) and (36)
from case (34).
30-132 HM400-1
2
(46), then remove bevel gear assem-
bly (47).
bevel gear and case before re-
moving the bevel gear assembly
(on the tooth surface side of the
bevel gear).
2 Using puller 4, remove bearing in-

ner race (50i) from bevel gear and
case assembly (49).
HM400-1 30-133
2

30-134 HM400-1
2
ASSEMBLY OF CENTER DIF- iii) Install pinion gear assembly (55) and
FERENTIAL ASSEMBLY
★ When installing a seal to another part (particular-

ly when installing it to the input shaft), use a
push tool matched to the diameter of that seal,
even if use of the push tool is not described in
this manual.
1. Differential gear and differential lock assem-

bly
1) Assemble the differential gear and differen-
tial lock assembly according to the following
procedure.
i) Install side gear (60). iv) Install differential side gear (54) and
washer (53).

gear (58), and washer (57). v) Bevel gear assembly
Mounting bolt:
Adhesive (LT-2)
Mounting bolt:
245 - 309 Nm {25 - 31.5 kgm}
HM400-1 30-135
2
(2) Install bearing inner race (50i) to vii) Install seal ring (40) to piston (39).
bevel gear and case assembly (49) ★ Take care of the direction of the seal
by shrink fit. ring.
★ Shrink fit temperature: 120°C for viii) Install seal rings (35) to case (34).
30 minutes ★ Take care of the direction of the seal
rings.
ix) Install pin (38) and washer (37).
x) Install piston (39) to case (34).
xi) Install the case and piston assembly,
matching it to the position of pin (45).
3 Case mounting bolt:
157 - 196 Nm {16 - 20 kgm}
xii) Install seal ring (36) to case (34).
★ Take care of the direction of the seal
rings.
xiii) Install sleeve (42), taking care not to
damage seal ring (36).
xiv) Install bearing (41) to case (34) by
(3) Install bevel gear assembly (47) to shrink fit.
case (46). ★ Shrink fit temperature: 120°C for 30
★ Match the match marks to each minutes
other.
vi) Turn over the case and install pin (45),

disc (44), and plate (43).
★ Apply engine oil (EO-30) to the sur-
faces of the disc and plate.
30-136 HM400-1
(11)
2
2. Assembly of differential 4. Bearing

1) Differential gear assembly 1) Rotate the adjustment rings (28) and (29)
i) Install nuts (28) and (29), matching with bar H6 until the ring gear reaches the
them to the grooves of differential case pinion gear and the backlash is eliminated.
(61). ★ Rotate the bearing sufficiently so that it
ii) Sling gear case (62) and install the will come in contact with the other con-
outer race to the bearing, then install tact surfaces and hit the ring gear with a
them to differential case (61). copper hammer, etc.
★ Apply sufficient amount of oil to the
bearing.
★ If you loosened either adjustment ring
by 1 turn, tighten the other one by 1 turn.
2) 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 {1.03 - 1.98 kg}
3. Caps
1) Install caps (31) and (32) and tighten bolt
(30) temporarily.
2) Using tools 5 and 6, tighten bolt (30).
3 Bolt: 824 - 1,040 Nm {84 - 105 kgm}
HM400-1 30-137
(11)
2
5. Assembly of transfer input shaft 7. Assembly of transfer case

1) Assemble transfer input shaft assembly (8) Install bearing outer race (10o) and bearing
according to the following procedure. outer race (18o).
• Install gear (12) and spacer (11) to
transfer input shaft (9). Using push
tools 7 and 8, press fit bearing inner
race (7i).
6. Assembly of cage of transfer input shaft

1) Assemble cage assembly (4) according to
the following procedure.
i) Install bearing outer race (7o).
ii) Using push tool 9, install oil seal (6).
iii) Using push tool 0, install side seal (5).
30-138 HM400-1
2
8. Adjusting preload on bearing of transfer input 9. Assembly of bevel pinion assembly

shaft Assemble bevel pinion assembly (8) according
1) Install input shaft and gear assembly (8) to to the following procedure.
transfer case (17) without inser ting any • Using push tool B, press fit bearing inner
shim. Install cage assembly (4) and tighten race (21i) to pinion (25).
mounting bolts (64) (8 pieces) to 113.0 Nm
{11.5 kgm}.
★ At this time, tighten mounting bolts (64)
repeatedly, rotating the bearing, until ro-
tation is stabilized.
2) Sling the coupling with a crane and meas-
ure the end play after adjustment with dial
gauge A. Determine the thickness of the
shims so that end play will be 0 - 0.05 mm.
3) After checking the thickness of the shims,
remove input shaft and gear assembly (8)
and cage assembly (4).
10. Adjustment of preload on bevel pinion support

bearing
1) Install pinion assembly (24).
2) Cage assembly
i) Install bearing outer race (23o) to cage
(22).
HM400-1 30-139
2
ii) Install cage assembly (21). 5) Bearing inner race

Using push tool C, press fit bearing inner
race (18i).
3) Input gear and spacer

Install input gear (20) and spacer (19).
★ Install the spacer checked when disas-
sembled.
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
6) Input shaft holder

i) Install holder (14) and key (15).
4) Transfer case
Install transfer case assembly (16).
★ Check that the bearing of the pinion is
fitted accurately.
30-140 HM400-1
2
ii) Set the standard shim (having the thick- 11. Adjusting tooth contact and backlash
ness and quantity checked when disas- Adjust the backlash and tooth contact simulta-
sembled) and install holder (13). neously.
Mounting bolt: 1) Adjust the backlash according to the follow-
ing procedure.
824 - 1,040 Nm {84 - 105 kgm}
i) Move the bevel gear with the adjust-
★ Execute "11. Measurement of tooth
ment nuts (28) and (29). At this time,
contact and backlash", then
rotate the nuts on both sides by the
determine the quantity and thickness
same turns in the same direction so
of the shims.
that the preload on the bearing will not
change.
7) Measurement of turning torque

Measure the star ting tangential force
ii) Apply dial gauge A perpendicularly to
(torque) of the input shaft with push-pull
the reversing tooth surface at the outer
scale D and check that the result is as fol-
end of the bevel gear. Rotate the
lows.
adjustment nuts until the dial gauge
★ Starting tangential force (torque)
indicates 0.3 - 0.4mm.
Starting torque:
514.5 - 1543.5 Ncm {52.5 - 157.5 kgcm}
and measure it with the pinion fixed.
(Measure this torque by putting a
wrench to the shaft end bolt.)
HM400-1 30-141
2
2) Adjust the tooth contact according to the fol- ★ If the bevel gear and bevel pinion are
lowing procedure. adjusted in this way, their teeth come in
i) Adjust the projection of the bevel pinion contact with each other correctly when
with shim (65) between differential case they are loaded.
(64) and transfer case (17).
ii) Adjusting tooth contact
★ See Adjusting tooth contact in 3) be-
low
3) Adjusting tooth contact of bevel gear and

bevel pinion
Testing
i) 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.
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.
30-142 HM400-1
2
Adjusting 12. Transfer input shaft and gear assembly

If the tooth contact pattern is not proper, adjust it ac- Install transfer input shaft and gear assembly
cording to the following procedure. (8).
i) 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 accord-
Adjust the thickness of the shims on the bev-
el pinion side to move the bevel pinion in di-
rection 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.
ii) If the bevel pinion is too close to the center 13. Cage
line of the bevel gear, contact is at the large
1) Install bearing outer race (7o) to cage (10).
end of the bevel gear tooth faces curved
Using tool H11, press fit oil seal (6).
outward and the small end of the bevel gear
★ Press fit oil seal (6) so that clearance "c"
tooth faces curved inward.
between the periphery of oil seal (6) and
• In this case, adjust the tooth contact similar-
cage (10) will be 10 ± 0.5 mm.
ly to i) above. Reverse directions A and B,
however.
change.
2) 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 po-
sitioned accurately.
HM400-1 30-143
2
3) Set the standard shims and install cage 15. Cover

assembly (4). Install cover (1).
14. Transfer input coupling and holder 16. Bevel gear supporting bolt
Install coupling (3) and holder (2). Install bevel gear supporting bolt (66).
End of bearing (Part A): ★ Bring the bolt end in contact with the back of
Grease (G2-LI) the gear, then return it by a half turn and se-
cure it with the locknut.
End of side seal (Part B):
Grease (G2-LI) Bolt: Gasket sealant (LG-5)
Holder mounting bolt: Adhesive (LT-2) Locknut: 196 - 245 Nm {20 - 25kgm}
824 - 1,040 Nm {84 - 105 kgm}
★ For disassembly and assembly of the output

section of the center axle transfer, see Removal,
installation of center differential assembly.
30-144 HM400-1
2
DISASSEMBLY AND ASSEMBLY REAR DIFFERENTIAL
REMOVAL OF REAR DIFFER-

ENTIAL ASSEMBLY
1. Draining oil
Drain oil from the rear differential case and rear
final drive case.
Remove the rear final drive cover and pull out
sun gear and drive shaft (1) (from both sides).
5. Rear differential assembly

Sling rear differential (10) temporarily. Using
forcing screws (M14 x 2), pull out the rear differ-
ential. 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 under-

side, too, with transmission jack 1, etc.
★ Since the rear side of the rear differential is
a little low, it does not come out easily. Ac-
cordingly, use guide bolt 2, etc. to pull out
3. Drive shaft between center differential and rear the rear differential forward carefully.
differential
Rear differential assembly: 280 kg
Remove the guard and disconnect only the
center differential and rear differential.
4. Piping and wiring harness

Disconnect differential lock hoses (3) - (5),
brake hose (6), brake cooling hoses (7) (3
pieces), and rear brake oil temperature sensor
connector (CN-T13) (8), then remove brake
cooling tube (9).
HM400-1 30-145
2
INSTALLATION OF REAR DIF-

FERENTIAL ASSEMBLY
moval.

Adhesive (LT-2)
98 - 123 Nm {10 - 12.5 kgm}
Rear differential mounting bolt:

157 - 198 Nm {16 - 20 kgm}

Refilling with oil

• Pour the specified oil in the rear differential case
and rear 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 nec-
essary.
the specified oil to the specified level if neces-
sary.
30-146 HM400-1
2
DISASSEMBLY OF REAR DIF- 2) Remove side seal (6) and oil seal (7) from
pinion and cage assembly (5).
FERENTIAL ASSEMBLY
1. Set the rear differential gear assembly to tool
H9.
2. Input coupling and holder
Remove holder (1) and coupling (2).
3) Remove pinion assembly (8) from cage

assembly (9).
3. Pinion and cage assembly

1) Using forcing screw 1, remove pinion and
cage assembly (3).
shims.
4) Disassembly of pinion assembly

Remove spacer (11) and bearing inner race
(12i) from pinion (10).
5) Disassembly of cage assembly

Remove bearing (14) and bearing outer
race (12o) from cage (13).
★ The inner race of bearing (14) was re-
moved in 3) above.
HM400-1 30-147
2
5) Disassemble the differential gear case

assembly according to the following proce-
dure.
i) Gear case
1 Set the gear case to a block (Height:
Approx. 200 mm).
2 Remove mounting bolts (33) (20
pieces).
3 Lift off case (34) with wires.
from case (34).
ii) Remove washer (37) and pin (38).
iii) Remove piston (39).
• Remove seal ring (40) from piston
4. Differential gear and differential lock assembly
(39).
★ Sling the differential case in advance. iv) Using a bearing puller, remove bearing
1) Remove locks (26) and (27). inner race (41i).
2) Using tool H6, loosen adjustment nuts (28) v) Remove sleeve (42).
and (29) to the degree that you can turn
them with fingers.
3) Loosen bolts (30) (4 pieces).
4) Sling the differential gear case assembly
with wires and remove bearing caps (31)
and (32) and nuts (28) and (29), then
remove the differential gear case assembly.
★ Take care not to drop the bearing outer
race.
vi) Remove plate (43) and disc (44).

vii) Remove pins (45) (4 pieces).
30-148 HM400-1
2
(46), then remove bevel gear assem-
bly (47).
bevel gear and case before re-
moving the bevel gear assembly
(on the tooth surface side of the
bevel gear).
2 Using puller 4, remove bearing in-

ner race (50i) from bevel gear and
case assembly (49).
HM400-1 30-149
2

30-150 HM400-1
2
ASSEMBLY OF REAR DIF- iii) Install pinion gear assembly (55) and
FERENTIAL ASSEMBLY
★ When installing a seal to another part (particular-

ly when installing it to the input shaft), use a
push tool matched to the diameter of that seal,
even if use of the push tool is not described in
this manual.
1. Differential gear and differential lock assem-

bly
1) Assemble the differential gear and differen-
tial lock assembly according to the following
procedure.
i) Install side gear (60). iv) Install differential side gear (54) and
washer (53).

gear (58), and washer (57). v) Bevel gear assembly
Mounting bolt:
Adhesive (LT-2)
Mounting bolt:
245 - 309 Nm {25 - 31.5 kgm}
HM400-1 30-151
2
2 Install bearing inner race (50i) to vii) Install seal ring (40) to piston (39).
bevel gear and case assembly (49) ★ Take care of the direction of the seal
by shrink fit. ring.
★ Shrink fit temperature: 120°C for viii) Install seal rings (35) to case (34).
30 minutes ★ Take care of the direction of the seal
rings.
ix) Install pin (38) and washer (37).
x) Install piston (39) to case (34).
xi) Install the case and piston assembly,
matching it to the position of pin (45).
Case mounting bolt:
157 - 196 Nm {16 - 20 kgm}
xii) Install seal ring (36) to case (34).
xiii) Install sleeve (42), taking care not to
damage seal ring (36).
xiv) Install bearing (41i) to case (34) by
shrink fit.
★ Shrink fit temperature: 120°C for 30
3 Install bevel gear assembly (47) to minutes
case (46).
★ Match the match marks to each
other.
vi) Turn over the case and install pin (45),

disc (44), and plate (43).
★ Apply engine oil (EO-30) to the sur-
faces of the disc and plate.
30-152 HM400-1
2
2. Assembly of differential 4. Bearing

1) Differential gear assembly 1) Rotate the adjustment rings (28) and (29)
i) Install nuts (28) and (29), matching with bar H6 until the ring gear reaches the
them to the grooves of differential case pinion gear and the backlash is eliminated.
(61). ★ Rotate the bearing sufficiently so that it
ii) Sling gear case (62) and install the will come in contact with the other con-
outer race to the bearing, then install tact surfaces and hit the ring gear with a
them to differential case (63). copper hammer, etc.
★ Apply sufficient amount of oil to the
bearing.
★ If you loosened either adjustment ring
by 1 turn, tighten the other one by 1 turn.
2) 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 {1.03 - 1.98 kg}
3. Caps
1) Install caps (31) and (32) and tighten bolt
(30) temporarily.
2) Using tools 5 and 6, tighten bolt (21).
Bolt: 824 - 1,040 Nm {84 - 105 kgm}
HM400-1 30-153
2
5. Assembly of pinion and cage assembly 3) Erect pinion assembly (8) and insert spacer
Assemble pinion and cage assembly (8) accord- (11) and install cage assembly (9).
1) Assembly of cage assembly
Install bearing outer races (12o) and (14o)
to cage (13).
2) 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 7.
4) Using push tool 8 and turning cage assem-

bly (9), install bearing inner race (14i).
★ Never push bearing inner race (14i) with
a press.
★ Apply oil to bearing inner race (14i).
30-154 HM400-1
2
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 "8. Measurement of tooth contact
and backlash", then determine the quantity
and thickness of the shims.
5) Using tool H11, press fit oil seal (7).

★ Press fit oil seal (7) so that clearance "c"
between the periphery of oil seal (7) and
cage (13) will be 10 ± 0.5 mm.
6) Using tool H5, press fit side seal (5).

★ Press fit side seal (5) so that its periph-
ery will be flush with cage (13).
HM400-1 30-155
2
7. Input coupling and holder

Install coupling (2) and holder (1).
End of bearing (Part A):
Grease (G2-LI)
End of side seal (Part B):
Grease (G2-LI)
Holder mounting bolt: Adhesive (LT-2)
824 - 1,030 Nm {84 - 105 kgm}
ii) Apply dial gauge A perpendicularly to

the reversing tooth surface at the outer
end of the bevel gear. Rotate the
adjustment nuts until the dial gauge
indicates 0.3 - 0.4mm.
and measure it with the pinion fixed.
2) Adjust the tooth contact according to the fol-

lowing procedure.
8. Adjusting tooth contact and backlash
i) Adjust the projection of the bevel pinion
• Adjust the backlash and tooth contact simul- with shim (65) between differential case
taneously. (64) and transfer case (17).
1) Adjust the backlash according to the follow- ii) Adjusting tooth contact
ing procedure. ★ See Adjusting tooth contact in 3) be-
i) Move the bevel gear with the adjust- low
ment 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 bearing will not
change.
30-156 HM400-1
2
3) Adjusting tooth contact of bevel gear and Adjusting

bevel pinion If the tooth contact pattern is not proper, adjust it ac-
cording to the following procedure.
Testing i) If the bevel pinion is too far from the center
i) Apply red lead thinly to the tooth surfaces of line of the bevel gear, the contact is at the
the bevel pinion and turn the bevel gear in small end of the bevel gear tooth surfaces
the forward and reverse directions, then curved outward and at the large end of the
check the tooth contact pattern on the bevel bevel gear tooth surfaces curved inward.
gear. • In this case, adjust the tooth contact accord-
ii) The center of the tooth contact must be at ing to the following procedure.
the middle of the tooth height and about Adjust the thickness of the shims on the bev-
33% (b) of tooth depth from the small end. el pinion side to move the bevel pinion in di-
The width of the tooth contact must be 30 - rection A. Adjust the thickness of the shims
60% (a) of the tooth depth. Check that of both carrier assemblies to move the bevel
there is not a strong contact at the tips or gear in direction B, then check the tooth
bottoms of the teeth of both small end and contact pattern and backlash again.
large end. ii) If the bevel pinion is too close to the center
★ If the bevel gear and bevel pinion are line of the bevel gear, contact is at the large
adjusted in this way, their teeth come in end of the bevel gear tooth faces curved
contact with each other correctly when outward and the small end of the bevel gear
they are loaded. tooth faces curved inward.
• In this case, adjust the tooth contact similar-
ly to i) above. Reverse directions A and B,
however.
change.
HM400-1 30-157
2

Install bevel gear supporting bolt (66).
★ Bring the bolt end in contact with the back of
the gear, then return it by a half turn and se-
cure it with the locknut.
Bolt: Gasket sealant (LG-5)
Locknut: 196 - 245 Nm {20 - 25kgm}
30-158 HM400-1
2
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
REMOVAL OF FRONT FINAL

DRIVE AND BRAKE
ASSEMBLY
1. Draining oil from front final drive case
Drain oil from the front final drive case.
2. Jacking up
1) Jack up the front (sub) frame and support it
on stand 1, etc.
2) Jack up the front axle support section with
jack 2, etc.
5. Drive shaft between front differential and

front final drive
Disconnect the front differential end of drive
shaft (3) between front differential and front final
drive.
3. Left fender
Lift of left fender (1).
4. Front wheels
Sling the front wheels (2) temporarily, then
remove the mounting bolts and front wheels (2).

Front wheel assembly: 800 kg
HM400-1 30-159
2
6. Brake cooling tubes and brake drive hose INSTALLATION OF FRONT

Disconnect brake cooing tubes (4) (2 pieces)
and brake drive hose (5). FINAL DRIVE AND BRAKE
ASSEMBLY
removal.
Front wheel mounting bolt:

824 - 1,030 Nm {84 - 105 kgm}

front differential and front final drive:
Adhesive (LT-2)

front differential and front final drive:
98 - 123 Nm {10 - 12.5 kgm}

7. Front final drive and brake and side drive Bleeding air from brake circuit.
shaft assembly
Lift off front final drive and brake and side drive Refilling with oil
shaft assembly (6). • Pour the specified oil in the final drive case to the
★ When removing, take extreme care that the specified level.
spline at the center of the side drive shaft will • Check the oil level in the transmission case and
not come out. add the specified oil to the specified level if
necessary.
Front final drive and brake and side • Check the oil level in the hydraulic tank and add
drive shaft assembly: 610 kg. the specified oil to the specified level if
necessary.
30-160 HM400-1
2
DISASSEMBLY OF FRONT
FINAL DRIVE AND BRAKE .
ASSEMBLY
1. Drive shaft (1)
Remove drive shaft (1).
★ When removing the drive shaft, take care
that its cap (yoke) will not come off.
3. Place the assembly with the brake side down.
4. Sun gear
Remove sun gear (5).
2. Cover and shaft

Remove cover (2) and snap ring (3), then
remove shaft (4) toward the opposite side.
★ Drain the remaining oil from the case.
★ When removing snap ring (3), take extreme
care not to expand it too wide. If the inside
diameter of the removed snap ring is larger
than 51 .4 mm or its l ev el di ffere nce
measured on a level place is larger than 0.3
mm, do not use it again.
5. Carrier assembly
1) Remove carrier assembly (6).
HM400-1 30-161
2
2) Disassemble the carrier assembly 7. Plate

according to the following procedure. Using forcing screw 1, remove plate (12).
i) Remove shaft (7).
★ Take care not to lose ball (8).
ii) Remove planetary gear (9) and bearing
(10).
8. Retainer and shim

1) Using tools J1 (Install them to 3 places on
the periphery, equally spaced), secure inner
gear (13) and outer gear (14).
★ Be sure to install tool J1 to protect the
floating seal before removing retainer
(15).
★ Install tools J1 to 3 places on the
periphery, equally spaced.
2) Remove the mounting bolts, retainer (15),
and shim.
6. Thrust washer
Remove thrust washer (11).
9. Ring gear
1) Remove ring gear (16).
30-162 HM400-1
2
2) Disassemble the ring gear according to the .

i) Remove mounting bolts (17) and holder
(18).
ii) Remove inner hub (20) from ring gear
(19).
11.Place the assembly with the brake side up.
12.Brake assembly
1) Remove brake assembly (24) from shaft
(23).
10.Floating seal cage and floating seal ★ Make match marks in advance.
Remove floating seal cage (21) [including a half
part of floating seal (22a)].
★ Use a forcing screw of M10 (long size) to
remove the floating seal cage.
2) Disassemble the brake assembly according

i) Remove tools J1.
HM400-1 30-163
2
ii) Remove cylinder assembly (25).
iii) Disconnect the cylinder assembly 3) Remove damper (end plate) (30), plate
according to the following procedure. (31), and disc (32).
1 Remove piston (27) from cylinder ★ Check the cut of the plate.
(26).

from cylinder (26) and piston (27).
30-164 HM400-1
2
13.Hub (Inner gear) and outer gear 3) Remove floating seal (37a) from floating
1) Remove outer gear (34) from hub (inner seal and cage assembly (36).
gear) (33).
4) Remove cover (39) from outer gear (38),

2) Remove floating seal and cage assembly then remove seal (40).
(36) and floating seal (22b) from hub (inner
gear) (35).Check the cut of the plate.
5) Remove floating seal (37b) from outer gear

(38).
HM400-1 30-165
2
14.Shaft (Tube) assembly

Remove bearing inner race (42), retainer (43),
seal (44), and bushing (45) from shaft (tube)
(41).
30-166 HM400-1
2
ASSEMBLY OF FRONT FINAL 2. Hub (Inner gear) and outer gear

1) Using tool J5, install floating seal (37o) to
DRIVE AND BRAKE outer gear (38).
ASSEMBLY
in this manual.
1. Shaft (Tube) assembly
1) Install retainer (43) to shaft (tube) (41), then
install bearing inner race (42).
2) Using tool J2, install seal (40) to outer gear

(38).
2) Install bushing (45) and seal (44) to shaft

(tube) (41)
★ Dimension "c" between shaft (tube) end
and seal end: 29 ± 0.2 mm
★ Dimension "b" between shaft (tube)
mounting part and bushing end:
3) Install cover (39) to outer gear (38).
5 ± 0.2 mm.
4) Using tool J5, install floating seal (37a) to

cage (46).
★ Measure height A of the seal above the
gear, hub, and ratainer (at 4 places on
the periphery) and c hec k that its
dispersion is less than 1 mm.
HM400-1 30-167
2
5) Using tool J5, install floating seal (22b) to 3. Brake assembly

hub (inner gear) (35). 1) Install disc (32), plate (31), and damper
(end plate) (30).
★ When installing the plate, match the 6
cuts on its per.
6) Install floating seal and cage assembly (36)

to hub (internal gear) (35).
7) Install outer gear (34) to hub (inner gear)

(33).
★ Take extreme care that the floating seal
will not be damaged or rolled up.
30-168 HM400-1
(11)
2
2) Assemble the brake assembly according to .

i) Assemble the cylinder assembly
1 Install seal rings (28) and (29) to
cylinder (26) and piston (27).
iii) Install tools J1.
3) Install brake assembly (24) to shaft (23).
2 Install piston (27) to cylinder (26).

5. Floating seal cage and floating seal
ii) Install cylinder assembly (25). cage (21).
Cylinder mounting bolt: ★ Measure height A of the seal above the
157 - 196 Nm {16 - 20 kgm} gear, hub, and ratainer (at 4 places on
HM400-1 30-169
2
. 6. Ring gear
1) Assemble the ring gear according to the
i) Using tool J3, press fit bearing inner
race (46) to inner hub (20).
2) Install floating seal cage (21) {including a

half part of floating seal (22a)}.
ii) Install holder (18) and tighten mounting

bolts (17).

27.5 - 34 Nm {2.8 - 3.5 kgm}
2) Install ring gear (16).
30-170 HM400-1
2
7. Retainer and shim .

1) Adjust the preload on the bearing according
i) Install retainer (15) with the bolts
temporarily without inserting any shim.
ii) Remove tools J1 (from 3 places) and
tighten the bolts.
2) 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.
Threaded parts of retainer

iii) Secure the assembly to forklift 1, etc. mounting bolt:
Rotating the inner gear (13) by 20 - 30 Adhesive (LT-2)
turns, evenly tighten every other bolt, 4
in total, to 78.5 ± 4.9 Nm {8 ± 0.5 kgm}. Retainer mounting bolt:
★ If the bolts are tightened without 157 - 196 Nm {16 - 20 kgm}
rotating the inner gear (13), the ★ After tightening the mounting bolts, turn in-
bearing does not fit and proper ner gear (13) and check that it rotates nor-
preload is not applied to it. mally.
iv) Using depth micrometer 2, measure

distance "c" between the ends of the
shaft and retainer (15).
★ Measure the distance at 2 places
v) Remove retainer (15) and measure its
thickness "a". Obtain difference "b" (= c
- a) and add 0.3 mm to it and use the
result as the thickness of the shim.
HM400-1 30-171
2
8. Shaft 10.Thrust wawher

Install shaft (4). Install thrust washer (11).
11.Carrier assembly
1) Assemble the carrier assembly according to
i) Install bearing (10) and planetary gear
(9).
ii) Install shaft (7).
9. Plate
Install plate (12).
30-172 HM400-1
2
2) Install carrier assembly (6). 14.Drive shaft

Install drive shaft (1).
Threaded parts of retainer mounting

bolt:
Adhesive (LT-2)
Drive shaft mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}.
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).
Cover mounting bolt:

98 - 123 Nm {10 - 12.5 kgm}
HM400-1 30-173
2
REMOVAL OF CENTER FINAL .
DRIVE AND BRAKE

ASSEMBLY
1. Draining oil from center final drive case
Drain oil from the center final drive case.
2. Jacking up center axle

Jack up the center axle.
3. Rear (Front) wheel

Sling the rear (front) wheels (1) temporarily and
remove the mounting bolts to remove rear (front)
wheels (1).
Remove the center final drive cover and sun
gear and drive shaft (4).
Rear (Front) wheel assembly: 800 kg.
6. Center final drive assembly

4. Brake cooling tubes and brake drive hose Lift off center final drive assembly (5).
Disconnect brake cooing tubes (2) (2 pieces)
and brake drive hose (3). Center final drive assembly: 500 kg.
30-174 HM400-1
2
FINAL DRIVE AND BRAKE
ASSEMBLY
removal.
Rear wheel mounting bolt:

824 - 1,030 Nm {84 - 105 kgm}

Refilling with oil

• Pour the specified oil in the final drive case to the
specified level.
add the specified oil to the specified level if
necessary.
the specified oil to the specified level if
necessary.
HM400-1 30-175
2
DISASSEMBLY OF CENTER 3. Retainer and shim

1) Using tools J1 (Install them to 3 places on
FINAL DRIVE AND PLATE the periphery, equally spaced), secure inner
ASSEMBLY gear (6) and outer gear (7).
★ Be sure to install tool J1 to protect the
★ The sun gear was removed when the final drive floating seal before removing retainer
and brake assembly was removed. (8).
1. Place the assembly with the brake side down. periphery, equally spaced.
2. Carrier assembly and shim.
1) Remove carrier assembly (1).
4. Ring gear
2) Disassemble the carrier assembly Remove ring gear (9).
(5).
30-176 HM400-1
2
1) Disassemble the ring gear according to the .

i) Remove mounting bolts (10) and holder
(11).
ii) Remove inner hub (13) from ring gear
(12).
6. Place the assembly with the brake side up.
7. Brake assembly.
1) Remove brake assembly (17) from shaft
(16).
5. Floating seal cage and floating seal ★ Make match marks in advance.

i) Remove tools J1.
HM400-1 30-177
2
iii) Disconnect the cylinder assembly 3) Remove damper (end plate) (23), plate
according to the following procedure. (24), and disc (25).
1 Remove piston (20) from cylinder ★ Check the cut of the plate.
(19).

30-178 HM400-1
2
8. Hub (Inner gear) and outer gear 3) Remove floating seal (30a) from floating
1) Remove outer gear (27) from hub (inner seal and cage assembly (29).
gear) (26).

2) Remove floating seal and cage assembly then remove seal (33).
gear) (28).

(31).
HM400-1 30-179
2
ASSEMBLY OF CENTER FINAL

9. Shaft (Tube) assembly DRIVE AND BRAKE ASSEMBLY
Remove bearing inner race (35) and retainer
(36) from shaft (tube) (34).
in this manual.

2. Hub (Inner gear) and outer gear

1) Using tool J5, install floating seal (30b) to
outer gear (31).
30-180 HM400-1
2
2) Using tool J2, install seal (33) to outer gear 5) Using tool J5, install floating seal (15b) to
(31). hub (inner gear) (28).
3) Install cover (32) to outer gear (31). 6) Install floating seal and cage assembly (29)

cage (36). 7) Install outer gear (26) to hub (inner gear)
★ Measure height A of the seal above the (27).
gear, hub, and ratainer (at 4 places on ★ Take extreme care that the floating seal
the periphery) and c hec k that its will not be damaged or rolled up.
HM400-1 30-181
2
3. Brake assembly 2) Assemble the brake assembly according to

1) Install disc (25), plate (24), and damper the following procedure.
(end plate) (23). i) Assemble the cylinder assembly
★ When installing the plate, match the 6 according to the following procedure.
cuts on its periphery. 1 Install seal rings (21) and (22) to
30-182 HM400-1
2
ii) Install cylinder assembly (18). 4. Place the assembly with the brake side down.
Cylinder mounting bolt: 5. Floating seal cage and floating seal

157 - 196 Nm {16 - 20 kgm} 1) Using tool J5, install floating seal (15a) to
cage (14).
iii) Install tools J1. 2) Install floating seal cage (14) [including a
half part of floating seal (15a)].
HM400-1 30-183
2

6. Ring gear to the following procedure.
1) Assemble the ring gear according to the i) Install retainer (8) with the bolts
following procedure. temporarily without inserting any shim.
i) Using tool J3, press fit bearing inner ii) Remove tools J1 (from 3 places) and
race (39) to inner hub (13). tighten the bolts.
iii) Rotating the inner gear (6) by 20 - 30
in total, to 73.5 ± 0.98 Nm {7.5 ± 0.1
kgm}.
★ If the bolts are tightened without
rotating the inner gear (6), the
bearing does not fit and proper
preload is not applied to it.

bolts (10).
27.5 - 34 Nm {2.8 - 3.5 kgm}.
30-184 HM400-1
2
iv) Using depth micrometer 1, measure .

shaft and retainer (8).

mounting bolt evenly until the tightening
2) Install carrier assembly (1).
Threaded parts of retainer
mounting bolt:
Adhesive (LT-2)
Retainer mounting bolt:
157 - 196 Nm {16 - 20 kgm}
★ After tightening the mounting bolts,
rotate inner gear (6) and check that it
rotates normally.
8. Carrier assembly
i) Install bearing (5) and planetary gear
(4). ★ Install the sun gear when installing the final drive
ii) Install shaft (2). and brake assembly.
HM400-1 30-185
2
REMOVAL OF REAR FINAL

DRIVE AND BRAKE
ASSEMBLY
1. Remove the body assembly. For details, see
Removal of body assembly.
2. Draining oil from rear final drive case

Drain oil from the rear final drive case.
3. Jacking up rear axle

Jack up the rear axle.
4. Rear wheel
Sling the rear wheels (1) temporarily and remove 6. Sun gear and drive shaft
the mounting bolts to remove rear wheels (1). Remove the rear final drive cover and sun gear
and drive shaft (4).
Rear wheel assembly: 800 kg
7. Center final drive and brake assembly

Lift off the center final drive and brake assembly.
5. Brake cooling tubes and brake drive hose Rear final drive and brake assembly:
Disconnect brake cooing tubes (2) (2 pieces) 500 kg
and brake drive hose (3).
30-186 HM400-1
2
INSTALLATION OF REAR DISASSEMBLY OF REAR

FINAL DRIVE AND BRAKE FINAL DRIVE AND BRAKE
ASSEMBLY ASSEMBLY
• Carry out installation in the reverse order to ★ The sun gear was removed when the final drive
removal. and brake assembly was removed.
2. Carrier assembly
Rear wheel mounting bolt: 1) Remove carrier assembly (1).
824 - 1,030 Nm {84 - 105 kgm}

Refilling with oil

• Pour the specified oil in the final drive case to the
specified level.
2) Disassemble the carrier assembly
necessary.
necessary.
(5).
HM400-1 30-187
2
FINAL DRIVE
3. Retainer and shim 2) Disassemble the ring gear according to the

1) Using tools J1 (Install them to 3 places on following procedure.
the periphery, equally spaced), secure inner i) Remove mounting bolts (10) and holder
gear (6) and outer gear (7). (11).
★ Be sure to install tools J1 to protect the ii) Remove inner hub (13) from ring gear
floating seal before removing retainer (12).
(8).
periphery, equally spaced.
and shim.

4. Ring gear
1) Remove ring gear (9).
30-188 HM400-1
2
6. Place the assembly with the brake side up. iii) Disconnect the cylinder assembly
7. Brake assembly 1 Remove piston (20) from cylinder
1) Remove brake assembly (17) from shaft (19).
(16).
★ Make match marks in advance.

to the following procedure
i) Remove tools J1.
HM400-1 30-189
2

1) Remove outer gear (27) from hub (inner
gear) (26).
3) Remove damper (end plate) (23), plate

(24), and disc (25).
★ Check the cut of the plate.
2) Remove floating seal and cage assembly
gear) (28).
30-190 HM400-1
2
3) Remove floating seal (30a) from floating 9. Shaft (Tube) assembly

seal and cage assembly (29). Remove bearing inner race (35), retainer (36),
seal (37), and bushing (38) from shaft (tube)
(34).

then remove seal (33).

(31).
HM400-1 30-191
2
ASSEMBLY OF REAR FINAL 3) Install cover (32) to outer gear (31).
DRIVE AND BRAKE ASSEMBLY

in this manual.


cage (36).

outer gear (31).

hub (inner gear) (28).
2) Using tool J2, install seal (33) to outer gear

(31).
30-192 HM400-1
2
6) Install floating seal and cage assembly (29)

2) Assemble the brake assembly according to

7) Install outer gear (26) to hub (inner gear) the following procedure.
(27). i) Assemble the cylinder assembly
★ Take extreme care that the floating seal according to the following procedure.
will not be damaged or rolled up. 1 Install seal rings (21) and (22) to
3. Brake assembly
1) Install disc (25), plate (24), and damper
(end plate) (23).
★ When installing the plate, match the 6
cuts on its periphery.
HM400-1 30-193
2
ii) Install cylinder assembly (18). 4. Place the assembly with the brake side down.
Cylinder mounting bolt: 1) Using tool J5, install floating seal (15a) to
157 - 196 Nm {16 - 20 kgm} cage (14).
.
2) Install floating seal cage (14) {including a

iii) Install tools J1. half part of floating seal (15a)}.
30-194 HM400-1
2
6. Ring gear
1) Assemble the ring gear according to the
i) Using tool J3, press fit bearing inner
race (39) to inner hub (13).
i) Install retainer (8) with the bolts
temporarily without inserting any shim.
ii) Remove tools J1 (from 3 places) and
tighten the bolts.
iii) Rotating the inner gear (6) by 20 - 30
in total, to 73.5 ± 0.98 Nm {7.5 ± 0.1
kgm}.
★ If the bolts are tightened without rotating
the inner gear (6), the bearing does not
fit and proper preload is not applied to it.

bolts (10).

27.5 - 34 Nm {2.8 - 3.5 kgm}
HM400-1 30-195
2
iv) Using depth micrometer 1, measure .

shaft and retainer (8)
.

mounting bolt evenly until the tightening 2) Install carrier assembly (1).
Threaded parts of retainer mount-

ing bolt: Adhesive (LT-2)
Retainer mounting bolt:
157 - 196 Nm {16 - 20 kgm}
★ After tightening the mounting bolts,
rotate inner gear (6) and check that it
rotates normally.
8. Carrier assembly
i) Install bearing (5) and planetary gear ★ Install the sun gear when installing the final drive
(4). and brake assembly.
ii) Install shaft (2).
30-196 HM400-1
2
REMOVAL OF CENTER AXLE

ASSEMBLY
Disconnect the cable from the negative (-)
terminal of the battery.

2. Jacking up frame
1) Jack up the rear frame and support it on
stand 1, etc.
2) Jack up the center axle and rear axle with
jacks 2 and 3.
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.
3. Center wheels
Sling both center wheels temporarily, then
remove the mounting bolts and center wheels
(1).
Center wheel assembly: 800kg

6. Drive shaft between hitch frame and center
differential
Remove the guard and disconnect the center
differential end of drive shaft (9) between the
hitch frame and center differential and fix it to the
rear frame.

center differential: 85 kg
4. Piping and harnesses

Disconnect differential lock hoses (2) - (4), brake
hose (5), brake cooling hoses (6) (3 pieces), and
rear retarder oil temperature sensor connector
(CN-T13) (7).

HM400-1 30-197
2
2) Remove holder plate (13) of the center axle

arm support, then remove center axle and
arm assembly (12) down.
Center axle and arm assembl 2,200kg
7. Lateral rod
Remove lateral rod (10).
Lateral rod: 60 kg
8. Equalizer bar spring

Remove equalizer bar spring (11).
9. Center axle and arm assembly

1) Sling center axle and arm assembly (12)
temporarily.
30-198 HM400-1
2
AXLE ASSEMBLY ★ Install the center axle and arm assembly so that
• Carry out installation in the reverse order to distance (y) between the rear frame top and
removal. 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
Center wheel mounting bolt: mm at this time).
824 - 1,030 Nm {84 - 105 kgm}

Adhesive (LT-2)

98 - 123 Nm {10 - 12.5 kgm} After installing, bleed air from the brake circuit.
[Target: 113 Nm {11.5 kgm}] For details, see TESTING AND ADJUSTING,
★ Adjust the suspension cylinder length. For

★ When installing the lateral rod, match tap hole
details, see TESTING AND ADJUSTING,
(a) to the center line of bearing (15) as shown in
Testing and adjusting suspension cylinder.
Fig. 1.
Refilling with oil
necessary.
necessary.
HM400-1 30-199
2
REMOVAL OF REAR AXLE

ASSEMBLY

2. Jacking up frame
1) Jack up the rear frame and support it on
stand 1, etc.
2) Jack up the center axle and rear axle with
jacks 2 and 3.
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.
3. Rear wheels
Sling both rear wheels temporarily, then remove
the mounting bolts and rear wheels (1).
Rear wheel assembly: 800 kg

6. Lateral rod
Remove lateral rod (9).
Lateral rod: 60 kg
4. Piping and harnesses

Disconnect differential lock hoses (2) - (4), brake
hose (5), brake cooling hoses (6) (2 pieces), and
rear brake oil temperature sensor connector
(CN-T13) (7).

30-200 HM400-1
2
7. Bracket (left) 3) Pull out lower pin (14) of rear suspension

Remove bracket (left) (10). cylinder (13) and remove rear axle and arm
assembly (11) down.
Rear axle and arm assembly:

2, 200 kg
8. Rear axle and arm assembly

1) Sling rear axle and arm assembly (11)
temporarily.
2) Remove holder plate (12) of the rear axle

arm support pin.
HM400-1 30-201
2
INSTALLATION OF REAR
AXLE ASSEMBLY ★ Install the rear axle and arm assembly so that
• Carry out installation in the reverse order to distance (y) between the rear frame top and
removal. equalizer bar spring top will be 201 mm when
Rear wheel mounting bolt: mm at this time).
824 - 1,030 Nm {84 - 105 kgm}

Adhesive (LT-2)

98 - 123 Nm {10 - 12.5 kgm} After installing, bleed air from the brake circuit.
[Target: 113 Nm {11.5 kgm}] For details, see TESTING AND ADJUSTING,

Fig. 1.
Refilling with oil
necessary.
necessary.
30-202 HM400-1
2
REMOVAL OF FRONT
SUSPENSION CYLINDER
ASSEMBLY
★ Release nitrogen gas from the front suspension
cylinder. For details, see TESTING AND
ADJUSTING, Testing and adjusting suspension
cylinder.
1. Jacking up
on stand 1, etc.
jack 2, etc.
4. Front suspension cylinder
1) Remove the cover and disconnect grease
tube (3).
2) Remove upper and lower pins (4) and (5)
and front suspension cylinder assembly (6)
.
2. Left fender
3. Front wheels
Front wheel assembly:

800 kg
HM400-1 30-203
2
INSTALLATION OF FRONT 2. Bracket

Remove bracket (2).
SUSPENSION CYLINDER
ASSEMBLY
removal.
Front wheel mounting bolt:

824 - 1,030 Nm {84 - 105 kgm}
★ Adjust the suspension cylinder length. For 3. Rear suspension cylinder

details, see TESTING AND ADJUSTING, Using balancing rod (3), etc., remove upper and
Testing and adjusting suspension cylinder. lower pins (3) and (4) and rear suspension
cylinder assembly (5).
REMOVAL OF REAR
SUSPENSION CYLINDER
ASSEMBLY
★ Release nitrogen gas from the rear suspension
cylinder. For details, see TESTING AND
ADJUSTING, Testing and adjusting suspension
cylinder.
1. Jacking up and lateral rod

1) Jack up the rear frame and rear axle with
jacks 1 and 2.
2) Lower lateral rod (1) and pull it out toward
you.
Since the lateral rod cannot be slung,

secure it (with a rope, etc.) and remove
it, watching your steps carefully.
Lateral rod: 60 kg
30-204 HM400-1
2
INSTALLATION OF REAR
SUSPENSION CYLINDER
ASSEMBLY
removal.

Fig. 1.

HM400-1 30-205
2
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR
REMOVAL OF EQUALIZER
BAR ASSEMBLY 4. Remove the rear wheels (front and rear) on the
side from which the equalizer bar will be
Stop the engine and operate the hoist cylinder
removed. For details, see Removal of rear wheel
control lever 2 - 3 times to release the remaining
assembly.
pressure.
5. Remove bottom pin (5) of the rear suspension
Loosen the oil filler cap to release the remaining
cylinder and bring cylinder (6) down toward the
pressure from the hydraulic tank.
rear of the vehicle body.
1. Release the nitrogen gas.
• Release nitrogen gas from the rear
suspension cylinder. For details, see
TESTING AND ADJUSTING, Testing and
adjusting suspension cylinder.
3. Remove the hoist cylinder.
1) Disconnect hoses (1) and (2)
★ Plug the hoses to prevent the oil from
flowing out.
6. Remove 4 mounting bolts (8) of the equalizer bar

above cushion (7).
2) Sling the hoist cylinder temporarily and

bring it down at a right angle to vehicle
body.
Pull the hoist cylinder toward inside of
the vehicle body in advance. (If the rod
pin is removed, the hoist cylinder falls. 7. Sling the equalizer bar temporarily.
Accordingly, be sure to pull the cylinder 8. Remove mounting bolts (10) of plate (9) at the
toward inside of the vehicle body in center of the equalizer bar.
advance.)
3) Remove rod pin (3) and hoist cylinder (4).
9. Using forcing screw 1, remove bushing (11)..
Hoist cylinder: 270 kg.
30-206 HM400-1
2
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR
10.Lift off equalizer bar (12). INSTALLATION OF

Equalizer bar: 250 kg. EQUALIZER BAR ASSEMBLY
removal.
Refill the rear suspension cylinder with nitrogen gas.

For details, see Testing and adjusting suspension
cylinder.
Rod pin: 157 - 196 Nm {16 - 20 kgm}
★ 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.
Plate (Diameter of thread: 24 mm):
824 - 1,030 Nm {84 - 105 kgm}
(Diameter of thread: 14 mm):

157 - 196 Nm {16 - 20 kgm}
★ 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
mm at this time).
Refilling with oil

★ Pour the specified oil in the final drive case to the
specified level.
★ Add engine oil (EO10-CD) to spcified.
HM400-1 30-207
2
DISASSEMBLY AND ASSEMBLY FRONT WHEEL
REMOVAL OF FRONT WHEEL INSTALLATION OF FRONT

ASSEMBLY WHEEL ASSEMBLY
1. Jacking up removal.
on stand 1, etc.
jack 2, etc. Front wheel mounting bolt:
824 - 1,030 Nm {84 - 105 kgm}
2. Left fender
3. Front wheels
Front wheel assembly: 800 kg
30-208 HM400-1
2
DISASSEMBLY AND ASSEMBLY REAR WHEEL
REMOVAL, INSTALLATION Removal of rear (rear) wheel assembly

OF REAR WHEEL ASSEMBLY 1. Remove the body assembly. For details, see
Removal of rear (front) wheel assembly
★ If the rear (rear) wheel assembly is removed
with a forklift, etc., step 1 above is not
1. Draining oil from center final drive case
necessary.
Drain oil from the center final drive case.
2. Jacking up rear axle
2. Jacking up center axle
Jack up the rear axle.
Jack up the center axle.
3. Rear (rear) wheel
3. Rear (front) wheel
Sling rear wheels (1) temporarily and remove the
Sling the rear (front) wheels (1) temporarily and
remove the mounting bolts to remove rear (front) mounting bolts to remove rear wheels (1).
wheels (1). Rear wheel assembly: 800 kg
Rear (front) wheel assembly: 800 kg
Installation of rear (front) wheel

Installation of rear (front) wheel assembly
• Installation of rear (rear) wheel assembly
assembly
removal.
Rear (rear) wheel mounting bolt:
824 - 1,030 Nm {84 - 105 kgm}
Rear (front) wheel mounting bolt:
824 - 1,030 Nm {84 - 105 kgm}
HM400-1 30-209
2
DISASSEMBLY AND ASSEMBLY HITCH FRAME
REMOVAL OF HITCH FRAME .
ASSEMBLY
1. Piping, hoses, and wiring harnesses

1) Disconnect hoist cylinder hoses (1) and (2),
brake hoses (3) - (6), brake cooling hoses
(7) and (8), and parking brake hose (9).
2) Disconnect joint connectors (CN-J015) (10)

and (CN-J013) (11) and differential lock
connector (CN-B36).
3. Drive shaft between hitch frame and center

differential
Remove the guard and drive shaft (15) between
the hitch frame and center differential.

center differential: 85 kg
2. Parking brake assembly

1) Release the parking brake.
2) Remove pad expansion spring bracket (12).
3) Remove the mounting bolts of plate (13)

and parking brake and cylinder assembly 4. Parking brake disc and coupling assembly
(14). Remove the coupling holder, then remove
parking brake disc and coupling assembly (16)
Parking brake and coupling assembly:

55 kg
30-210 HM400-1
2
. 7. Steering cylinder
Remove head pin (19) and disconnect steering
cylinders (20) (on both sides).
5. Parking brake bracket.

Remove parking brake bracket (17).
Parking brake bracket 55 kg 8. Jacking up vehicle body

1) [Front operator’s cab side]
i) Sling the front part with a crane [chain
1]
ii) Place a stand under the rear frame for
safety.
6. Drive shaft between transmission and hitch

frame
Remove the guard and disconnect the
transmission end of drive shaft (18) between the
transmission and hitch frame.
2) [Rear dump body side]
Drive shaft between transmission and i) Support the rear dump body end on
hitch frame. 55 kg block 2.
ii) Support the front frame with a jack, etc.
for safety.
HM400-1 30-211
2
9. Hinge pins .
1) Move the rear frame of the front operator’s
cab section and the front frame of the rear
dump body section up and down with jacks
3 and 4 to center the hinge pins.
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
2) Remove plate (21) and pull down out upper forward to disconnect from the rear dump body
hinge pin (22). section.
3) Pull up out lower hinge pin (23) with a jack. Keep the level of the front and rear parts
around the pins until the rear frame of the
front operator’s cab section is separated
from the hitch frame
Check that there are clearances "a" and "b"
between the r ear fr ame of the fr ont
operator’s cab section and the hitch frame,
then disconnect the front operator’s cab
section from the rear dump body.
Move the rear frame of the front operator’s
cab section forward together with a stand
under it until it is separated from the hitch
frame so that it will be supported on the
stand at any time.
30-212 HM400-1
2
11.Hitch frame assembly.

1) Remove rear seal and retainer (large)
assembly (24). .
2) Using forcing screw 5, remove end retainer

(25). .
3) 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 hitc h frame is pul led 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.
HM400-1 30-213
2
INSTALLATION OF HITCH
FRAME ASSEMBLY key way of the spider cap is matched to that of
• Carry out installation in the reverse order to the mating yoke and tighten the bolts.
removal
Adhesive (LT-2)
★ Bleed air from the brake circuit. For details,
see TESTING AND ADJUSTING, Bleeding Mounting bolt of drive shaft between
air from brake circuit. transmission and hitch frame:
157 - 198 Nm {16 - 20 kgm}
★ Test the wear of the brake pad and adjust

the brake pad clearance. For details, see
TESTING AND ADJUSTING, Testing wear ★ When installing rear seal (27) to rear retainer
of parking brake pad. (28), use push tool 6 matched to the diameter
of the seal.
★ 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.

hitch frame and center differential:
Adhesive (LT-2)
hitch frame and center differential:
157 - 198 Nm {16 - 20 kgm}
Coupling spline: LM-P
Coupling bolt: Adhesive (LT-2)

Coupling bolt:
824 - 1,030 Nm {84.0 - 105.0 kgm}
30-214 HM400-1
2
★ Procedure for adjusting bearing of oscillation

section
1) Measure thickness "t" of end retainer (25)
at 2 places (equally spaced on the
periphery).
2) Tighten mounting bolts (30) (3 pieces) to
the following torque without inserting shim
(29).
Mounting bolt: 68.6 Nm {7 kgm}
3) Under this condition, measure dimension

"d" with a micrometer.
4) Rotate hitch frame (31) by 5 - 6 turns, then
repeat steps 2) and 3) above.
★ Repeat steps 2) - 4) above until
dimension "d" is stabilized.
5) Combine shims so that difference "e" of the
measured values (e = d - 5) will be 0 - 0.15
mm.
6) After finishing the above adjustment,
tighten all mounting bolts (30) to the
following torque.
Mounting bolt:
385 Nm (Target) {39.25 kgm} (Target)
HM400-1 30-215
2
DISASSEMBLY OF HITCH 3. Center shaft

1) Remove center shaft and bearing assembly
FRAME (8) from hitch frame (7).
1. Coupling
Remove coupling holder (1) and coupling (2).
2) Remove rear bearing (10) and front bearing

inner race (11i) from center shaft (9).
2. Rear retainer
1) Using forcing screw 1, remove retainer
assembly (3).
4. Disassembly of hitch frame

1) Remove front cage assembly (13), ring
(14), front bearing outer race (11o), and
rings (15) and (16) from hitch frame (12).
2) Remove ring (5), dust seal (6), grease
2) Remove dust seal (18) from front cage (17).
fitting (19), and nipple (20) from rear
retainer (4).
★ Grease fitting (19) and nipple (20) are
installed to serial No. 1104 and up.
30-216 HM400-1
(11)
2
ASSEMBLY OF HITCH FRAME .
ASSEMBLY
★ When installing a seal, use a push tool matched
to the diameter of that seal, even if use of the
push tool is not described in this manual.
1. Center shaft
Using the push tool, press fit rear bearing (10)
and bearing inner race (11i) to center shaft (9).
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 (23 g)].
★ Select grease for the above parts from
2. Assembly of hitch frame Table 1. (For part J, see 2 above.)
Install ring (15) and front bearing outer race Table 1
(11o) to the front side of hitch frame (12). Install
ring (16) to the rear side of the hitch frame (12). No Manufacturer Grease brand
Fill the inside space of ring (15) with 1 Nippon Oil Hirex
grease [Part A: 60% pack (76 g), Part 2 Shell Oil Super Duty Grease 2
B: 60% pack (88g)].
3 Esso Oil RONEX MP
Fill the inside space of front bearing outer 4 BP Energrease LS-EP2
race (11o) with grease [Part I: 40% pack
(27 g)]. .
Fill the inside space of rear bearing (10)
with grease [Part J: 40% pack (23 g)].
★ Select grease for the above parts from
Table 1.
Table 1
No Manufacturer Grease brand

1 Nippon Oil Hirex
2 Shell Oil Super Duty Grease 2
3 Esso Oil RONEX MP
4 BP Energrease LS-EP2
HM400-1 30-217
2
4. Ring and front cage assembly 6. Rear retainer

1) Install ring (14) to hitch frame (12). 1) Press fit dust seal (6) to rear retainer (4).
2 Lip: Grease (G2-L1)

2) Install dust seal (18) and O-ring to front
cage (17), then install front cage (13) to
hitch frame (12). 2) Install ring (5) and O-ring to rear retainer
2
(4).
Apply grease to the lip of dust seal ★ Fill the groove of the ring with grease of
(18). about 88 g.
2 Fill the inside space of dust seal (18) 2 Groove of ring: Grease (G2-L1)
with grease [Part K: Full pack (25 g), 3) Install nipple (20) and grease fitting (19) to
Part C: 60% pack (74g)]. rear retainer (4).
★ Select grease for the above parts from ★ Install nipple (20) and grease fitting (19)
Table 1. to serial No. 1104 and up.
Table 1
No Manufacturer Grease brand
1 Nippon Oil Hirex
2 Shell Oil Super Duty Grease 2
3 Esso Oil RONEX MP
4 BP Energrease LS-EP2
4) Install rear retainer assembly (3).

★ Supply grease of 200 g to the retainer
through the grease fitting of serial No.
1104 and up.
2 Inside of retainer: Grease (G2-L1)
5. Coupling
Install coupling (2) and coupling holder (1).
2 Coupling spline: LM-P.

3 Coupling bolt: 824 - 1,030 Nm
{84.0 - 105.0 kgm}
.
30-218 HM400-1
(11)
2
DISASSEMBLY AND ASSEMBLY STANDARD INTEGRAL ORBIT-ROLL
STANDARD INTEGRAL ORBIT-ROLL
Tools needed for disassmbluy and assembly

(1) Torque wrench (torque capacity: 5 kgfm) (7) Plastic hammer
(2) 5/12 in - 12 point socket (8) Small amount of grease
(3) Flat-headed screwdriver (large) (9) Vice
(4) Flat-headed screwdriver (small) (10)Oil-based felt pen
(5) Spring insertion tool (P/N: 600057) (11)Tweezers
(6) 3/16 in hexagonal wrench
30-220 HM400-1
2
DISASSEMBLY AND ASSEMBLY STANDARD INTEGRAL ORBIT-ROLL
Part No. Part name Q‘ty Remarks

1 Screw 6
2 Retainer screw assembly 1
3 End cap 1
4 Gerotor 1
5 Spacer 1
6 Spacer (1)
7 Spacer plate 1
8 Drive 1
9 Housing 1
10 Sleeve 1
11 Spool 1
12 Pin 1
13 Centering spring 6 For standard input torque specification
Centering spring 4 For low input torque specification
14 Flat spring (2) Only for low input torque specification
15 Race bearing 1
16 Thrust needle 1
17 O-ring 1
18 Oil seal 1 X-ring or Teflon seal
19 Dust seal 1
20 Retaining ring 1
21 Seal gland bushing 1
22 O-ring 2 Part No.: 5776
23 O-ring 1 Part No.: BA0098A
24 Inlet check valve sub assembly 1 (Cannot be disassembled)
25 Valve seat 1 (Cannot be disassembled)
26 Poppet 1
27 Spring 1
28 Plug 1
29 O-ring 1
30 Retainer plug 2
31 Spring 2
32 Ball 2
33 Valve seat 2 (Cannot be disassembled)
34 Ball 2
35 Ball holder 2
36 Spring 2
37 Plug 2
38 O-ring 2
39 Adapter screw 1
40 Ball 1
41 Name plate 1
42 Rivet 2
Seal kit (X-ring) Part No.: BA0271A

Seal kit (Teflon seal) Part No.: BA0273A
HM400-1 30-221
2
DISASSEMBLY AND ASSEMBLY STEERING VALVE
DISASSEMBLY OF STEER-
ING VALVE
★ When disassenbling the valve, cleanliness 3. Remove spacer (5) inside spline on inside of star
is extremely important. Carry out the work in of Gerotor (4).
a clean place. Remove Gerotor (4). Be careful not to drop star
★ In the following explanation diagrams, it is from ring of outer cicumference of Gerotor.
not absolutely necessary to hold the unit in Remove O-ring (22) from Gerotor.
a vice, but it is recommended to use a vice
as far as possible.
★ Before removing the piping, remove all dirt
and dust from around the ports and joints on
the outside circumferences of the motor.
Be extremely careful not to injure yourself
on the edges of sleeves, spool, housing,
and other machined parts.
1. Put end cap (3) at the top, fit side face of hous-
ing between copper sheets in vice 8, and be
careful not to tighten vice too strongly.
4. Remove drive (8), then remove spacer plate (7).

Remove O-ring (23) from housing.
2. Remove 6 screws (1) and 1 retainer screw (2),

then remove end cap (3). Remove O-ring (22)
from end cap (3).
5. Using flat-headed screwdriver, remove adapter
screw (39). Remove housing from vice, set
upside down, then remove ball (40).
★ Be careful not to drop or lose the ball.
30-222 HM400-1
2
6. Set housing updise down, remove 2 springs 9. Remove 2 race bearings (15) and thrust needle
(31), 2 retainer lugs (30), and 2 balls (32). (16).
★ Be careful not to drop or lose the parts.
10.Push spline portion inside spool with thumb and

7. Set on clean cloth with flange surface of housing remove spool and sleeve assembly from oppo-
facing up to prevent damage to finished surface. site side of housing flange. When doing this, be
Use flat-headed screwdriver to raise tip of careful not to let outside diameter of sleeve get
retaining ring (20), then remove from housing. caught in inside diameter of housing.
The retaining ring may fly out from the hous- ★ Depending on the assembly of sleeve and
ing, so always wear protective glasses. 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)
The retaining ring may fly out from the
housing, so always wear protective glasses
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 11.Push out spool inside sleeve slightly, and remove
bushing. centering spring (13) carefully by hand from
★ When remove the seal, be careful not to spool.
damage the seal gland bushing.
HM400-1 30-223
2
12.Rotate spool slowly and pull out spool (11) from ASSEMBLY OF STEERING
sleeve (10). Remove O-ring from housing.
VALVE
★ Check all the joining parts.
Parts with gouges or burrs will cause
leakage of oil, so replace them with new
parts.
Wash all metal parts with clean solvent and
blow dry with compressed air. If they are
wiped with rags or paper, pieces of cloth or
paper will stick to the parts or get inside the
valves. This will cause the hydraulic system
to become dirty, so do not wipe with cloth or
paper.
Do not polish parts with sandpaper or
DISASSEMBLY OF STEERING RELIEF VALVE modify with a file.
• Using hexagonal wrench (width across flats: Be extremely careful not to injure yourself
3/16 inch), remove plug (28). Remove O- on the edges of sleeves, spools, housing,
ring (29) from plug. Using tweezers, remove and other machined parts.
spring (27) and poppet (26). ★ As a basic rule, assemble new O-rings and
★ The valve seat is stuck to the housing and seal after disassembling. Coat the O-rings
cannot be removed. with a small amount of clean grease before
assembling.
★ The O-rings in front of or behind the spacer
plate are of very similar sizes, so check the
part number before opening the seal kit, and
be extremely careful not to mix them.
1. Turn spool (11) and insert slowly into sleeve
(10). Grip spline portion of spool and check that
spool rotates smoothly inside sleeve. Align mark
made when disassembling.
DISASSEMBLY OF OVERLORD RELIEF VALVE

• Using hexagonal wrench (width across flats: 3/
16 inch), remove plug (37)(2 places). Remove
O-ring (38) from plug. Using tweezers, remove
2 springs (36), 2 ball holders (35), and 2 balls
(34).
★ The valve seat is stuck to the housing and
cannot be removed.
30-224 HM400-1
2
2. Align 2 spring grooves st 180° in spool and 4. Place housing on clean flat surface, then assem-
sleeve, then stand on a horizontal plate. Insert ble O-ring (17).
spring insertion tool (Part No.: 60057) in spring Assemble 2 race bearings (15) and thrust needle
groove, then fit centering spring to insertion tool (16). Always insert thrust needle between race
so that notched portions at both ends are at bearings.
bottom.When doing this, it is easier to insert if
spool is lifed up slightly from sleeve. Hold
centering 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
The centering spring may fly out from the spool, so

always wear protective glasses.
★ 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.
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
postion, 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 diagram below is the standard seal
the housing. If it is inserted further, the pin
specification drawing.
will fall inside the housing, so stop inserting
when the end face is level.
HM400-1 30-225
2
6. After assembling seals, rotate seal gland ASSEMBLY OF OVERLOAD RELIEF VALVE
bushing (21) and insert to spool. Tap with plastic • Assemble O-ring (38) to plug (37), Fit grease to
hammer to insert to specified position. ball holder (35) and install ball (34). Using twee-
Assemble retaining ring (20) to housing. zers, assemble ball holder (35) and spring (36)
★ Push open with a flat-headed screwdriver so to housing. Using hexagonal wrench (width
that the whole circumference of the retaining across flats: 3/16 inch), assemble plug (37) to
ring fits securely in the groove in the housing. housing.
The retaining ring may fly out from the hous- ★ The size of the overload valve ball and the
ing, so always wear protective glasses. anti-cavitation check valve ball is different,
so be careful not to mix them.
★ Seal assembly drawing

Screwdriver 9, dust seal (19), retaining ring ASSEMBLY OF ANTI-CAVITATION CHECK
(20), seal gland bushing (21), oil seal (18), O- VALVE
ring (17) . • 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 7 bolt holes in the end face of the housing,
insert 1 each of spring (31), retainer plug (30),
and ball (32) in the 2 holes shown in the drawing.
★ Be careful not to drop or lose the ball. Be
careful of the assembly direction of the re-
tainer plug.
ASSEMBLY OF STEERING RELIEF VALVE

• Assemble O-ring (29) to plug (28).
Using tweezers, assemble spring (27) and
poppet (26) to housing. Using hexagonal
wrench (width across flats: 3/16 inch),
assemble plug (28) to housing.
30-226 HM400-1
2
ASSEMBLY OF GEROTOR END • Turn spool and sleeve assemblly and set pin
• Grip the port surface and side surface of the (12) and port surface (46) of housing in parallel.
housing lightly in a vice. (45): 25 mm. Fit copper Insert drive (8) into portion (47), then mate drive
sheets in the vice, and be careful not to tighten yoke and pin (12). To carry out positioning ex-
the vice too strongly. actly, use a felt pen to draw line on end face of
drive (8) parallel to pin.
• Of the 7 bolt holes in the end face of the housing,

insert ball (40) in the holes shown in the drawing. • Assemble O-ring (22) to Gerotor (4).
Assemble adapter screw (39) in holes in same
drawing.
• Assemble O-ring (23) to housing.

Set spacer plate (7) on top and align position of
bolt holes.
★ The pitch diameter of the bolt holes and oil
holes is different.
HM400-1 30-227
2
• Set O-ring at end face of Gerotor (4) at spacer • Order for tightening end cap mounting screws is
plate (7) side, align concave portions (48) of as shown in diagram below.
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 parallel as shown in diagram be-
low.
★ Turn Gerotor ring to align bolt holes. Do not
remove mating of drive and Gerotor star.
★ The above procedure is important for align-
ing the valve timing.
★ After tightening to torque given below, install

handle to spool and check that spool ro-
tates.
Screw tightening torque
Discharge capacity Tightening torque

cc/rev (N.m{kgm}
51 - 230 22.6 {2.3}

• Assemble spacer (5) to spline Gerotor star.
★ Do not assemble spacers to 51 cc/rev and 277 23.5 {2.4}
69 cc/rev discharge capacity Orbit-rolls.
369 - 737 28.4 {2.9}
Asseble 2 spacers to 184 cc/rev discharge
capacity orbit-roll.
Assemble O-ring (22) to end cap (3), set on List of capacities and spacers
top of Gerotor, then align bolt holes. Coat 6 Discharge Discharge
screws (1) and thread of retainer screw as- Spacer
capacity capacity
sembly (2) with oil, then assemble to end thickness (mm)
symbol (cc/rev)
cap.
Install retainer screw assemblies to bolt A 51
holes where adapter screws have already
B 69
been assembled. 14.7 N {1.5 kgm}, then
tighten in order to following torque. 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
30-228 HM400-1
2
DISASSEMBLY AND ASSEMBLY FLOW AMPLIFIER VALVE
REMOVAL OF FLOW 3) Remove the mounting bolts of pipe (7) of

priority circuit (EF) (the circuit to the port P
AMPLIFIER VALVE of the hoist valve) and keep pipe (7) away
ASSEMBLY from the steering valve.
★ Loosen the mounting bolts of port P of
1. Tilting up operator’s cab the hoist valve.
up operator’s cab (1) and support it with the
safety bar.
Check that the operator’s cab is supported
4) Disconnect pump circuit (HP) hose (8) and

remove tank circuit (HT) piping (9).
5) Disconnect steering cylinder circuit pipes
(CL) (10) and (CR) (11) and keep them
away from the steering valve.
2. Steering valve 6) Remove steering valve (12).
1) Remove left side cover (2) of the operator’s
cab and steering valve side cover. Steering valve: 35 kg
2) Remove the wire harness clamp and dis-
connect the steering hose and R, P, T, L,
and LS circuit hoses (3) - (6).
INSTALLATION OF FLOW
AMPLIFIER VALVE
ASSEMBLY
removal.
HM400-1 30-229
2
DISASSEMBLY AND ASSEMBLY HOIST VALVE
REMOVAL OF HOIST VALVE

ASSEMBLY
1. Drain the hydraulic oil.
2. Left fender
Lift off left fender (1).
5. Hoist valve
Remove hoist valve assembly (12).
Hoist valve assembly: 65 kg
3. Steering valve
Remove the steering valve assembly. For
details, see Removal of steering valve assembly.
4. Hose and piping
1) Remove the tube of port P of the loosened
hoist valve and disconnect tank circuit
hoses (2), (3), (4).
2) Remove bracket (5) and tank circuit tube
(6).
★ Remove the throttle between tube (6)
and hoist valve, too.
INSTALLATION OF HOIST
VALVE ASSEMBLY
removal.
Check valve mounting bolt (Hexagon

socket head bolt):
14.7 - 34.3 Nm (Target: 24.5 Nm)
{1.5 - 3.5 kgm} (Target: 2.5 kgm)
3) Disconnect hoses (7) and (8) of pilot ports
(PA) and (PB). Refilling with oil
4) Remove check valve (9). • Add specified oil to the specified level.
5) 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.
30-230 HM400-1
2
DISASSEMBLY OF HOIST VALVE ASSEMBLY
1. Housing assembly 3. Body assembly

1) Remove housing (2) from body (1). 1) Remove spool (27) and plug (28) from body
2) Loosen nut (3). (1).
3) Remove screw (4), nut (5), retainer (6), 2) Remove seat (29), spring (30), and valve
spring (7), and poppet (8). (31) from body (1).
4) Remove holder (9) and seat (10).
5) Loosen sleeve (11) and remove spring (12),
valve (13), and retainer (14).
2. Spring case assembly

1) Remove spring case (15) from body (1),
then remove springs (16) and (17) and
retainer (18).
2) Remove spring case (19) from body (1),
then remove retainer (20).
3) Remove plug (21).
4) Remove flange (22) from spring case (19),
then remove springs (23) and (24), retainer
(25), and spring (26).
HM400-1 30-231
2
ASSEMBLY OF HOIST VALVE ASSEMBLY
• Clean the all parts carefully and remove burrs.

• Apply engine oil to the sliding parts before
installing.
1. Body assembly 3. Housing assembly

1) Install valve (31), spring (30), and seat (29) 1) Install retainer (14), valve (13), and spring
to body (1). (12) to housing (2) and tighten sleeve (11).
2) Install plug (28) and spool (27) to body (1). 2) Install seat (10) and holder (9) and tighten
nut (3).
2. Spring case assembly 3) Install poppet (8), spring (7), and retainer
1) Install spring (26), retainer (25), and springs (6) and tighten nut (5) and screw (4).
(24) and (23) to spring case (19), then 4) Install body (1) to housing (2).
install flange (22).
2) Install plug (21). Mating faces of housing and body:
3) Install retainer (20) to body (1), then install Sealant (LOCTITE #752 or 575 or
spring case (19). Sealend #242)
4) Install retainer (18) and springs (17) and Housing (Diameter of thread: 12 mm):
(16) to body (1), then install spring case 110.3 ± 12.6 Nm {11.25 ± 1.25 kgm}
(15). (Diameter of thread: 14 mm):
176.5 ± 29.6 Nm {18 ± 2 kgm}
30-232 HM400-1
2
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
DISASSEMBLY OF STEERING CYLINDER ASSEMBLY

1. Set cylinder assembly (1) in tool U1 3) Remove piston assembly (6) and cylinder
2. Raise lock of cylinder head nut,and using tool head assembly (7) from rod(8).
U2, remove cylinder head assembly (2).
6. Disassembly of piston assembly

3. Pull out cylinder head and piston rod assembly 1) Remove wear ring (9) from piston (10).
(3) from cylinder (4) and remove. 2) Remove wear ring (11) from piston (10).
★ When the piston rod assembly is pulled out
from the cylinder, oil will come out, so catch
it in a container.
4. Remove cylinder (4) from tool U1.
7. Disassembly of cylinder head assembly

1) Remove snap ring (12), then remove dust
seal (13).
2) Remove rod packing (14).
5. Disassembly of piston rod assembly 3) Remove bushing (15) from cylinder head
1) Set piston rod assembly (3) in tool U1. (16)
2) Using tool U3, remove nut (5). 4) Remove O-ring (17) and backup ring (18).
HM400-1 30-233
2
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
ASSEMBLY OF STEERING 4) Using tool U6, install dust seal (13) to

cylinder head (16).
CYLINDER ASSEMBLY
★ Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
oil before installing
1. Assembly of cylinder head assembly

1) Using tool U5, press fit bushing (15) to cylinder
head (16).
★ Take care not to deform bushing (15) when
press fitting it.
5) Install snap ring (12).
2) Install rod packing (14).

★ Take care of installing direction.
3) Install backup ring (18) and O-ring (17) in
order
★ Do not insert the backup ring forcibly,
but heat it in water at about 50 - 60°C, 2. Assembly piston assembly
then insert it. 1) Using tool U4, expand piston ring (11).
★ Set piston ring (11) to the tool and rotate
the handle by 8 - 10 turns to expand the
ring.
2) Remove piston rod (11) from tool U4 and
install it to piston (10).
30-234 HM400-1
2
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF STEERING CYLINDER ASSEMBLY
3) Using tool U4, shrink the piston ring. 3) Remove piston rod assembly (3) from tool
U1.
4) Install wear ring (9).

4. Set cylinder (4) in toll U1.
5. Assemble cylinder head and piston rod assem-
bly (3) in cylinder (4).
3. Assembly of piston rod assembly

1) Assemble cylinder head assembly (7) and piston
assembly (6) to piston rod (8).
6. Using tool U2, tighten cylinder head assembly
(2).
Cylinder head nut:

981 ± 98 Nm {100 ± 10 kgm}
2) Using tool U4, tighten nuts (5).
Nut: Thread tightener (LT-2)
Nut:
3.97 ± 0.4 kNm {4.05 ± 40.5 kgm}
HM400-1 30-235
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF HOIST CYLINDER ASSEMBLY
DISASSEMBLY OF HOIST 5. Remove cylinder head assembly (6) from cylin-

der II (4).
CYLINDER ASSEMBLY 6. Remove wear ring (7) and collar (8).
• Be careful not to damage the rod packing, dust
seal, piston ring, and wear ring.
1. Set cylinder assembly to tool U1.

2. Using tool U2, remove crown (1) from cylinder I
(2).
★ After loosening the crown, remove the grease
nipple from the rod head, then pull put the crown.
.
7. Disassembly of cylinder head assembly.

1) Remove O-ring, then remove dust seal (9)
and rod packing (10).
2) Remove bushing (11).
3. Remove cylinder II and rod assembly from cylin-

der I (2).
8. Remove snap ring (12) from cylinder II (4), then

remove piston assembly (13).
4. Remove bolt (3), then lift off rod (5) from cylinder
II (4).
30-236 HM400-1
6
2
DISASSEMBLY AND ASSEMBLY HOIST CYLINDER
9. Disassembly of piston assembly

Remove piston ring (14) and wear ring (15) from
piston assembly.
10.Remove snap ring (16) from cylinder II (4), then

remove dust seal (17), rod packing (18), and
bushing (19).
HM400-1 30-237
2
DISASSEMBLY AND ASSEMBLY HOIST CYLINDER
ASSEMBLY OF HOIST 4. Assembly of piston assembly

1) Using tool U4, expand piston ring (14), and
CYLINDER ASSEMBLY assemble to piston (13).
★ Set the piston ring on tool, and turn the
★ Clean all parts, and check for dirt or damage.
handle 8 - 10 times to expand the ring.
Coat the sliding surfaces of all parts with engine
2) Set tools U4 in position, and compress pis-
oil befor installing.
ton ring (14).
3) Install wear ring (14)
1. Using tool U5, press fit bushing (19) to cylinder II
(4).
2. Install rod packing (18).

★ Check the direction of assembly for the rod
packing when installing.
3. Using tool U6 fit dust seal (17) and install snap ring
(16).
5. Assembly piston assembly (13) to cylinder II (4),

and install snap (12).
30-238 HM400-1
2
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF HOIST CYLINDER ASSEMBLY
6. Install wear ring (7) to cylinder II (4). 3) Using tool U6 install dust seal (9).
7. Assembly of cylinder head assembly. 8. Assemble cylinder head (6) to cylinder II (4).
1) Using tool U5, press fit bushing (11).
9. Sling rod (5) and assemble to cylinder II (4).

2) Assemble rod packing (10) to cylinder head ★ Align the stud bolt at the tip of the rod with
(6). the bolt hole in the piston assembly.
★ Check the direction of assembly for the
rod packing when installing.
HM400-1 30-239
2
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF HOIST CYLINDER ASSEMBLY
10.Tihten mounting nut (3) of piston assembly.
Mounting bolt:
Thread tightener (Loctie #262)
Mounting bolt:
274.6 ± 27.5 Nm {28 ± 2.8 kgm}
★ Remove all oil and grease from the assem-
bly portion of the nuts and blots.
11.Assemble cylinder II and rod assembly to cylin-

der I (2).
12.Using tool U2 install crown (1) to cylinder I (2),

and fit grease nipple.
Crown:
1,270 ± 130 Nm {130 ± 13 kgm}.
30-240 HM400-1
6
2
DISASSEMBLY AND ASSEMBLY BODY ASSEMBLY
REMOVAL OF BODY 5. Remove body hinge pins (3) on both sides.
ASSEMBLY
1. Remove both hoist cylinder rod pins (1).
★ Sling the bottom of the hoist cylinder

temporarily.
★ After removing pin (1) from each cylinder
rod, install lever block 1 between the
vehicle body and hoist cylinder and tense it
to prevent the hoist cylinder from falling
down.
If rod pin (1) is removed, the hoist cylinder
falls outward. Accordingly, be sure to pull
the cylinder toward inside of the vehicle
body in advance.
6. Lift off body assembly (4).
Body assembly: 4450 kg.
2. Loosening lever block 1, lower the crane to

place the bottom of the hoist cylinder on the tire.
★ Place block (2) between the bottom of the
hoist cylinder and tire.
★ Install lever block 1 between the vehicle
body and hoist cylinder and tense it to
prevent the hoist cylinder from falling down.
3. Sling the body temporarily.
4. Disconnect body potentiometer linkage (2) from

the body.
HM400-1 30-241
2
DISASSEMBLY AND ASSEMBLY BODY ASSEMBLY
INSTALLATION OF BODY .
ASSEMBLY
removal.
Aligning the pin holes slowly with the engine

at low speed. Never insert your fingers in
the pin holes.
Bottom pin (Diameter of thread: 14 mm):

157 - 196 Nm {16 - 20 kgm}
★ When installing the body hinge pin, check the

thickness and quantity of the shims.
Body hinge pin:

157 - 196 Nm {16 - 20 kgm}
• Adjustment of body mount shims

1) Install spacer (5) 58 mm high to the end of 3) Calculate the thickness of the shims to be
body (4). (1 place on each side) installed to each part.
2) Measure clearance "a" between the center ★ Thickness of shims = (a - 26) mm
of the mounting part of bottom mount (6) 4) Insert shims of the calculated thickness.
and frame top (7). ★ Standard thickness of shims: 4 mm
★ Measure at A, B, and C on both side, 6 5) Lower the body and check that all of the 6
places in total. parts of the bottom mount are in contact
with the frame top.
30-242 HM400-1
2
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF OPERATOR’S SEAT

ASSEMBLY
a The procedure for disassembling and assembling the operator's seat assembly [with air suspension (man-
ufactured by ISRING HAUSEN)] is shown below.
A: Headrest E : Left-hand armrest

B: Seatback F : Suspension cover
C: Seat cushion G : Sliderails
D: Right-hand armrest
DISASSEMBLY
1. Headrest
1) Referring to the figure, check the positions of
the 2 clips (2) of headrest stay (1) on both
sides.
HM400-1 30-243
(7)
2) Apply force b to part a of each clip (2) in the 2. Seatback

direction of the arrow to turn the clip. Re- 1) Disconnect 3 air hoses (5) from the rear left
lease headrest stay (1) from part d of the clip of seatback (4).
and pull out up headrest (3). a Before disconnecting the air hoses,
check their types.
2) Remove seatback hinge mounting bolt (6)

(M8 bolt).
a Pushing in both clips (2) simultaneously,

remove headrest (3).
3) Bring seatback (4) down forward.
30-244 HM400-1
(7)
4) Apply force E to the right side of seatback (4) 2) Push cushion stopper wire (9) down with
in the direction of the arrow. screwdriver [1], etc.
5) Applying the force to seatback (4), pull its 3) Pull out seat cushion (8) forward and remove
right side up. it.
6) Slide seatback (4) sideway and remove it.
4. Armrest
3. Seat cushion • The procedure for disassembling right-hand
1) Push cushion adjuster lever (7) inward and armrest (10) is shown below.
slide seat cushion (8) to the front end. (Disassemble left-hand armrest (11) similar-
ly.)
HM400-1 30-245
(7)
1) Remove plastic cap (12) from the armrest 6) Remove right-hand armrest (10).
hinge. a There are 2 position adjustment washers
a Use a flat-head screwdriver, etc. to re- (16) installed to each bolt between the
move the cap. armrest and seatback. Take care not
2) Loosen armrest hinge mounting bolt (13). lose them.
3) Remove plastic cap (14), and then remove 5. Suspension cover

lower mounting bolt (15A) (M8 bolt) of right- 1) Remove right-hand hinge cover (17).
hand armrest (10). 2) Remove plastic plate (18) from the rear with
screwdriver [1], etc.
a Take care not to damage the plastic plate
by prying it off forcibly with a screwdriver,
etc.
4) Turn right-hand armrest (10) up by 180 de-

grees.
a If the armrest is not turned, you cannot
apply the tool to upper mounting bolt
(15B).
5) Remove plastic cap (14) and upper mount-
ing bolt (15B).
30-246 HM400-1
(7)
3) Remove 4 suspension cover fixing rings 6) Remove 6 plastic suspension cover clips
(19). (small) (25) and 2 plastic suspension cover
clips (large) (26).
a Clips (small) (25):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
7) Remove suspension cover (27).
a If you remove the suspension cover with-
out performing the work in steps 5) and
6), the suspension cover may be broken.
4) Remove 4 mounting bolts (20), cushion rear

fixing plate (21), 2 cushion rails (22), and 4
bushings (23).
6. Rails
1) Turn over the seat assembly to set rails (28)
on the upside.
5) Remove 3 metallic suspension cover clips

(24).
HM400-1 30-247
(7)
2) Slide rails (28) to the rear end. ASSEMBLY

3) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the front part of 1. Rails
each rail. q6 1) Put height adjustment washers (31) between
rails (28) and suspension, and then set rails
(28) in position.
4) Slide rails (28) to the front end.

5) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the rear part of 2) Set rails (28) to the front end and install 1
each rail, and then remove rails (28). q 7 lock washer (30) and 1 hexagon socket head
3 Hexagon socket head bolt:

bolt (29) to each rail.
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
a Take care not to lose height adjustment

washers (31) between the rails and sus-
pension.
30-248 HM400-1
(7)
3) Set rails (28) to the rear end and install 1 lock 2) Install 3 metallic suspension cover clips (24).
washer (30) and 1 hexagon socket head bolt
3 Hexagon socket head bolt:

(29) to each rail.
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
3) Set 4 bushings (23) and 2 cushion rails (22),

and then install cushion rear fixing plate (21),
3 Cushion rail mounting bolt:

and 4 mounting bolts (20).
2. Suspension cover 21.4 – 27.6 Nm {2.18 – 2.82 kgm}

1) Set suspension cover (27) in position and in-
stall 6 plastic suspension cover clips (small)
(25) and 2 plastic suspension cover clips
(large) (26).
a Clips (small) (25):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
4) Install 4 suspension cover fixing rings (19).
HM400-1 30-249
(7)
5) Install plastic plate (18) to the rear. 2) Tighten lower mounting bolt (15A) lightly and
6) Install right-hand hinge cover (17). turn armrest (10) by 180 degrees.
3) Tighten upper mounting bolt (15B) lightly.
4) Tighten lower mounting bolt (15A) and upper
3 Upper and lower armrest mounting

mounting bolt (15A) permanently.
bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
5) Install 2 plastic caps (14).
3. Armrest
• The procedure for assembling right-hand
armrest (10) is shown below.
(Assemble left-hand armrest (11) similarly.)
6) Tighten armrest hinge mounting bolt (13).

a Tighten the bolt so that the arm will move
smoothly.
• Operating effort at armrest end:
49 – 78.4 N {5 – 8 kg}
7) Install plastic cap (12).
1) Install 2 position adjustment washers (16) for

each bolt and set right-hand armrest (10) in
position.
30-250 HM400-1
(7)
4. Seat cushion 5. Seatback

1) Slide in the seat cushion from the front of the 1) Insert the left side of seatback (4), and then
fitting position. lower and set the right side.
a If seat cushion (8) is slid to the rear, it is
locked by cushion stopper wire (9).
2) Install seatback hinge mounting bolt (6) (M8
3 Seatback hinge mounting bolt:

bolt).
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
HM400-1 30-251
(7)
3) Connect 3 air hoses (5) to the rear left of the

seatback (4).
6. Headrest
1) Insert headrest (3) in seatback (4).
a Check that 2 clips (2) on both sides are
locked securely.
30-252 HM400-1
(7)
OTHERS
90 OTHERS
Power train hydraulic circuit diagram............................................................................................................. 90-2

Steering and hoist hydraulic circuit diagram.................................................................................................. 90-3
Differential lock hydraulic circuit diagram ...................................................................................................... 90-4
Brake hydraulic circuit diagram ..................................................................................................................... 90-5
Diagram for electrical circuit air conditioner................................................................................................... 90-6
Diagram for electrical circuit inside cab (1/4)................................................................................................. 90-7
Diagram for electrical circuit inside cab (2/4)................................................................................................. 90-9
Diagram for electrical circuit inside cab (3/4)............................................................................................... 90-11
Diagram for electrical circuit inside cab (4/4)............................................................................................... 90-13
Diagram for electrical circuit outside cab (1/3) ............................................................................................ 90-15
Payload meter electrical circuit.................................................................................................................... 90-21
HM400-1 90-1
(10)
OTHERS POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
90-2 HM400-1
4
"
OTHERS STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM
HM400-1 90-3
OTHERS DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM
DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM
90-4 HM400-1
OTHERS BRAKE HYDRAULIC CIRCUIT DIAGRAM
BRAKE HYDRAULIC CIRCUIT DIAGRAM
HM400-1 90-5
OTHERS DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER
DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER
90-6 HM400-1
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/4)
HM400-1 90-7
(7)
HM400-1 90-9
(7)
HM400-1 90-11
(7)
HM400-1 90-13
(7)
OTHERS DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (5/7)
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/3)
HM400-1 90-15

OTHERS AGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (6/7)
HM400-1 90-17

OTHERS DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (7/7)
HM400-1 90-19

HM400-1 90-21
(10)

HM400-1 2nd Edition SEBM023012

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

HM400-1 2nd Edition SEBM023012

Uploaded by

Copyright:

Available Formats

SEBM023012

Machine model Serial number

HM400-1 1001 and up

• HM400-1 mount the SAA6D140E-3 engine.

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD .......10-1

20 TESTING AND ADJUSTMENT..........................................................20-1

30 DISASSEMBLY AND ASSEMBLY ....................................................30-1

( ) Page to be deleted Discard

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

Revision Revision Revision Revision Revision

z 00- 1 (12) 10- 9 (6) 10-52 10- 89 10-133 (7)

10-181-5 (6) 20- 12 (1) 20-150 (1) (20-207) 20-401 (9)

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rubber

• Used as lubricant for sliding portion (to

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

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

CLASSIFICATION BY COLOR AND CODE

METHOD OF USING THE CONVERSION TABLE

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354