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SEN00239-09
ARTICULATED DUMP TRUCK
HM400 -2 SERIAL NUMBERS
2001
and up
SEN00512-09
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
00 Index and foreword
1
Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4
HM400-2
1
SEN00512-09
00 Index and foreword
Composition of shop manual
1
The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: • Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: • File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title
Form Number
Shop Manual, contents binder, binder label and tabs
SEN00239-09
00 Index and foreword Index Foreword and general information
SEN00511-09 SEN00512-09 q SEN00513-04
01 Specification Specification and technical data
SEN00514-01 SEN00515-01
10 Structure, function and maintenance standard Engine and cooling system Power train, Part 1 Power train, Part 2 Steering system Brake system Undercarriage and frame Hydraulic system Cab and its attachments Electrical system, Part 1 Electrical system, Part 2 Electrical system, Part 3 Electrical system, Part 4
SEN00516-04 SEN00517-01 SEN00518-01 SEN00519-02 SEN00520-01 SEN00521-02 SEN00522-02 SEN00523-02 SEN00524-01 SEN00525-01 SEN00526-02 SEN04428-01 SEN00527-02
20 Standard value table Standard service value table
SEN00528-02 SEN00915-02
30 Testing and adjusting Testing and adjusting, Part 1 Testing and adjusting, Part 2 Testing and adjusting, Part 3
SEN00529-04 SEN00916-03 q SEN00917-03 q SEN00918-03 q
40 Troubleshooting General information on troubleshooting Troubleshooting by failure code, General Troubleshooting by failure code, Part 1 Troubleshooting by failure code, Part 2
SEN00530-03 SEN01107-02 q SEN01262-00 SEN01108-00 SEN01109-02 q
2
q q q
q
HM400-2
00 Index and foreword
Troubleshooting by failure code, Part 3 Troubleshooting by failure code, Part 4 Troubleshooting by failure code, Part 5 Troubleshooting by failure code, Part 6 Troubleshooting by failure code, Part 7 Troubleshooting by failure code, Part 8 Troubleshooting for electrical system (E-mode) Troubleshooting of hydraulic and mechanical system (H-mode) Troubleshooting of engine (S-mode)
SEN00512-09
SEN01110-02 SEN01111-02 SEN01112-01 SEN01113-01 SEN01114-00 SEN01115-00 SEN01116-01 SEN01117-00 SEN01118-01
q q q q
q q
50 Disassembly and assembly General information on disassembly and assembly Engine and cooling system Power train, Part 1 Power train, Part 2 Power train, Part 3 Undercarriage and frame Hydraulic system Cab and its attachments Electrical system
SEN00531-03 SEN01442-03 SEN01443-03 SEN01444-03 SEN01445-02 SEN01446-01 SEN01447-02 SEN01448-02 SEN01449-02 SEN01450-02
90 Diagrams and drawings Hydraulic diagrams and drawings Electrical diagrams and drawings
SEN00532-04 SEN00533-02 q SEN00534-04 q
HM400-2
q q q q q q q
3
SEN00512-09
00 Index and foreword
Table of contents
1
00 Index and foreword Index SEN00512-09 Composition of shop manual....................................................................................................... 2 Table of contents ......................................................................................................................... 4 Foreword and general information SEN00513-04 Safety notice................................................................................................................................ 2 How to read the shop manual ..................................................................................................... 7 Explanation of terms for maintenance standard.......................................................................... 9 Handling of electric equipment and hydraulic component........................................................... 11 Handling of connectors newly used for engines.......................................................................... 20 How to read electric wire code .................................................................................................... 23 Precautions when carrying out operation .................................................................................... 26 Method of disassembling and connecting push-pull type coupler ............................................... 29 Standard tightening torque table ................................................................................................. 32 Conversion table ......................................................................................................................... 36 01 Specification Specification and technical data SEN00515-01 Specification drawings................................................................................................................. 2 Specifications .............................................................................................................................. 3 Weight table ................................................................................................................................ 6 Fuel, coolant and lubricants ........................................................................................................ 7 10 Structure, function and maintenance standard Engine and cooling system SEN00517-01 Radiator, oil cooler, aftercooler .................................................................................................... 2 Output shaft................................................................................................................................. 3 Power train, Part 1 SEN00518-01 Power train skeleton.................................................................................................................... 2 Torque converter and transmission hydraulic piping ................................................................... 6 Brake cooling oil control valve (BCV) .......................................................................................... 8 Power train pump ........................................................................................................................ 9 Torque converter ......................................................................................................................... 12 Transmission ............................................................................................................................... 18 Transmission control valve .......................................................................................................... 46 ECMV .......................................................................................................................................... 47 Main relief, torque converter relief valve ..................................................................................... 54 Power train, Part 2 SEN00519-02 Drive shaft ................................................................................................................................... 2 Axle ............................................................................................................................................. 6 Differential ................................................................................................................................... 10 Limited slip differential................................................................................................................. 22 Final drive.................................................................................................................................... 26 Steering system SEN00520-01 Steering column........................................................................................................................... 2 Brake system SEN00521-02 Brake piping ................................................................................................................................ 2 Brake valve.................................................................................................................................. 4 Accumulator charge valve ........................................................................................................... 7 Accumulator ................................................................................................................................ 11 Slack adjuster.............................................................................................................................. 12 Brake ........................................................................................................................................... 14
4
HM400-2
00 Index and foreword
SEN00512-09
Proportional reducing valve......................................................................................................... 19 Brake system tank....................................................................................................................... 20 Parking brake .............................................................................................................................. 22 Parking brake solenoid valve ...................................................................................................... 26 Undercarriage and frame SEN00522-02 Suspension ................................................................................................................................. 2 Suspension cylinder .................................................................................................................... 7 Oscillation hitch ........................................................................................................................... 9 Hydraulic system SEN00523-02 Steering, hoist oil pressure piping diagram ................................................................................. 2 Dump body control ...................................................................................................................... 3 Hydraulic tank and filter............................................................................................................... 4 Flow amp valve ........................................................................................................................... 5 Steering valve.............................................................................................................................. 8 Steering cylinder.......................................................................................................................... 12 Hoist valve................................................................................................................................... 14 Dump control valve (EPC valve) ................................................................................................. 20 Pilot check valve ......................................................................................................................... 24 Hoist cylinder............................................................................................................................... 25 Hydraulic pump ........................................................................................................................... 26 Cab and its attachments SEN00524-01 ROPS cab ................................................................................................................................... 2 Cab tilt ......................................................................................................................................... 3 Air conditioner ............................................................................................................................. 4 Rear view monitor ....................................................................................................................... 12 Controller related......................................................................................................................... 15 Electrical system, Part 1 SEN00525-01 Machine monitor system ............................................................................................................. 2 Electrical system, Part 2 SEN00526-02 Automatic shift control system .................................................................................................... 2 Transmission controller ............................................................................................................... 5 Retarder control system .............................................................................................................. 34 Auto emergency steering system................................................................................................ 46 Battery disconnector switch ........................................................................................................ 48 Dump control lever ...................................................................................................................... 50 Electrical system, Part 3 SEN04228-01 Playload meter (Card type) ......................................................................................................... 2 Electrical system, Part 4 SEN00527-02 Sensors, switches ....................................................................................................................... 2 KOMTRAX terminal system (if equipped) ................................................................................... 12 20 Standard value table Standard service value table SEN00915-02 Standard value table for engine .................................................................................................. 2 Standard value table for chassis ................................................................................................. 3 30 Testing and adjusting Testing and adjusting, Part 1 SEN00916-03 Tools for testing, adjusting, and troubleshooting ......................................................................... 3 Measuring engine speed............................................................................................................. 7 Testing intake air pressure (boost pressure) ............................................................................... 8 Testing exhaust temperature....................................................................................................... 9 Testing exhaust gas color............................................................................................................ 10 Adjusting valve clearance ........................................................................................................... 11 Testing compression pressure .................................................................................................... 12 HM400-2
5
SEN00512-09
00 Index and foreword
Testing blow-by pressure............................................................................................................. 14 Testing engine oil pressure.......................................................................................................... 15 Testing EGR valve and bypass valve drive oil pressure.............................................................. 16 Handling of fuel system devices.................................................................................................. 17 Releasing residual pressure from fuel system ............................................................................ 17 Testing fuel pressure ................................................................................................................... 18 Testing fuel return and leakage amount ...................................................................................... 19 Bleeding air from fuel circuit ........................................................................................................ 22 Testing the fuel circuit for leakage ............................................................................................... 24 Testing and adjusting fan belt tension ......................................................................................... 25 Testing and adjusting alternator belt tension ............................................................................... 26 Testing and adjusting air conditioner compressor belt tension.................................................... 27 Testing and adjusting, Part 2 SEN00917-03 Testing torque converter stall speed............................................................................................ 3 Testing power train oil pressure................................................................................................... 4 Testing and adjusting of differential lock oil pressure (differential lock spec.) ............................. 12 Adjusting transmission speed sensor.......................................................................................... 17 Testing and adjusting brake oil pressure ..................................................................................... 19 Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ............................................................................. 23 Testing brake performance.......................................................................................................... 27 Bleeding air from brake circuit..................................................................................................... 28 Testing wear of wheel brake disc ................................................................................................ 29 Testing the parking brake pad wear ............................................................................................ 30 Emergency release of the parking brake..................................................................................... 31 Testing and adjusting steering circuit oil pressure....................................................................... 32 Testing and adjusting suspension cylinder .................................................................................. 34 Method of tilting cab up ............................................................................................................... 38 Testing and adjusting dump circuit oil pressure........................................................................... 40 Adjusting body positioner sensor ................................................................................................ 42 Adjusting length of spring in body heating spherical joint............................................................ 44 Handling of voltage circuit of engine controller............................................................................ 44 Adjusting transmission controller................................................................................................. 44 Method for emergency escape at electrical system failure ......................................................... 45 Testing and adjusting, Part 3 SEN00918-03 Setting and adjusting various equipments................................................................................... 2 Special function of machine monitor............................................................................................ 11 How to start operation of KOMTRAX terminal............................................................................. 56 Lamp display of KOMTRAX terminal........................................................................................... 61 Pm Clinic check sheet ................................................................................................................. 64 Initial setting of payload meter..................................................................................................... 67 40 Troubleshooting General information on troubleshooting SEN01107-02 Points to remember when troubleshooting.................................................................................. 2 Sequence of events in troubleshooting ....................................................................................... 3 Check before troubleshooting ..................................................................................................... 4 Classification and procedures for troubleshooting ...................................................................... 5 Connection table for connector pin numbers............................................................................... 8 T-branch box and T-branch adapter table ................................................................................... 44 Troubleshooting by failure code, General SEN01262-00 Troubleshooting by failure code, General.................................................................................... 2 Failure codes table .................................................................................................................. 2 Before troubleshooting by failure code .................................................................................... 10 Information in troubleshooting table......................................................................................... 18
6
HM400-2
00 Index and foreword
SEN00512-09
Troubleshooting by failure code, Part 1 SEN01108-00 Troubleshooting by failure code, Part 1....................................................................................... 3 Failure code [1500L0] Double engagement ............................................................................ 3 Failure code [15B0NX] Transmission oil filter: Clogged .......................................................... 4 Failure code [15F0KM] R o F shifting abuse 1 ....................................................................... 6 Failure code [15F0MB] R o F shifting abuse 2 ....................................................................... 6 Failure code [15F7KM] Transmission forward clutch abuse ................................................... 7 Failure code [15G0MW] Trouble in reverse clutch system (Slip)............................................. 8 Failure code [15G7KM] Transmission reverse clutch abuse ................................................... 10 Failure code [15H0MW] Trouble in Hi clutch system (Slip) ..................................................... 12 Failure code [15J0MW] Trouble in Lo clutch system (Slip) ..................................................... 14 Failure code [15K0MW] Trouble in 1st clutch system (Slip) .................................................... 16 Failure code [15L0MW] Trouble in 2nd clutch system (Slip) ................................................... 18 Failure code [15M0MW] Trouble in 3rd clutch system (Slip) ................................................... 20 Failure code [15SBL1] Trouble in reverse clutch pressure control valve .............................. 22 Failure code [15SBMA] Trouble in reverse clutch pressure control valve ........................... 26 Failure code [15SCL1] Trouble in Hi clutch pressure control valve ...................................... 28 Failure code [15SCMA] Trouble in Hi clutch pressure control valve ................................... 32 Failure code [15SDL1] Trouble in Lo clutch pressure control valve ..................................... 34 Failure code [15SDMA] Trouble in Lo clutch pressure control valve ................................... 36 Troubleshooting by failure code, Part 2 SEN01109-02 Failure code [15SEL1] Trouble in 1st clutch pressure control valve ......................................... 3 Failure code [15SEMA] Trouble in 1st clutch pressure control valve ...................................... 6 Failure code [15SFL1] Trouble in 2nd clutch pressure control valve ........................................ 8 Failure code [15SFMA] Trouble in 2nd clutch pressure control valve ..................................... 12 Failure code [15SGL1] Trouble in 3rd clutch pressure control valve ........................................ 14 Failure code [15SGMA] Trouble in 3rd clutch pressure control valve ..................................... 18 Failure code [15SJMA] Trouble in lockup clutch pressure control valve ................................. 20 Failure code [15SKMA] Trouble in interaxle differential lock clutch pressure control valve .... 22 Failure code [2A62L1] Trouble in front wheel differential lock pressure control valve 2 ............. 24 Failure code [2A62LH] Trouble in front wheel differential lock pressure control valve 1............. 26 Failure code [2B62L1] Trouble in rear wheel differential lock pressure control valve 2 .............. 28 Failure code [2B62LH] Trouble in rear wheel differential lock pressure control valve 1.............. 30 Failure code [2C4MNX] Clogging of retarder cooling oil filter ..................................................... 32 Failure code [2F00KM] Dragging of parking brake ..................................................................... 34 Failure code [2G42ZG] Lowering of accumulator oil pressure (front) ......................................... 36 Failure code [2G43ZG] Lowering of accumulator oil pressure (rear) .......................................... 36 Failure code [989A00] Operation of engine overrun prevention system ..................................... 37 Failure code [989D00] Rear section tipping over alarm (Raising operation on slope) ................ 37 Failure code [A570NX] Clogging of engine oil filter..................................................................... 38 Failure code [AA10NX] Clogging of air cleaner........................................................................... 40 Failure code [AB00MA] Trouble in battery charge circuit ............................................................ 42 Failure code [B@BAZG] Lowering of engine oil pressure........................................................... 43 Failure code [B@BAZK] Lowering of engine oil level.................................................................. 44 Failure code [B@BCNS] Overheating of engine ......................................................................... 45 Failure code [B@BCZK] Lowering of coolant level ..................................................................... 46 Failure code [B@BFZK] Lowering of fuel level ........................................................................... 48 Failure code [B@C6NS] Overheating of brake cooling oil (front)................................................ 49 Failure code [B@C7NS] Overheating of brake cooling oil (rear) ................................................ 49 Failure code [B@C8NS] Overheating of brake cooling oil (center)............................................. 50 Failure code [B@CENS] Overheating of torque converter oil ..................................................... 50 Failure code [B@JANS] Overheating of steering oil ................................................................... 51 Troubleshooting by failure code, Part 3 SEN01110-02 Failure code [CA111] Trouble in engine controller ...................................................................... 4 Failure code [CA115] Trouble in engine Ne and Bkup speed sensors........................................ 6 Failure code [CA122] Abnormally high charge pressure............................................................. 8 Failure code [CA123] Abnormally low charge pressure .............................................................. 10
HM400-2
7
SEN00512-09
00 Index and foreword
Failure code [CA131] Abnormally high throttle sensor signal...................................................... 12 Failure code [CA132] Abnormally low throttle sensor signal ....................................................... 14 Failure code [CA135] Abnormally high engine oil pressure ........................................................ 16 Failure code [CA141] Abnormally low engine oil pressure.......................................................... 18 Failure code [CA144] Abnormally high coolant temperature....................................................... 20 Failure code [CA145] Abnormally low coolant temperature ........................................................ 22 Failure code [CA153] Abnormally high charge temperature ....................................................... 24 Failure code [CA154] Abnormally low charge temperature......................................................... 26 Failure code [CA187] Abnormally low voltage in sensor power supply 2.................................... 27 Failure code [CA221] Abnormally high ambient pressure ........................................................... 28 Failure code [CA222] Abnormally low ambient pressure ............................................................ 30 Failure code [CA227] Abnormally high voltage in sensor power supply 2 .................................. 32 Failure code [CA234] Engine overspeed..................................................................................... 34 Failure code [CA238] Trouble in Ne speed sensor power supply ............................................... 36 Failure code [CA263] Abnormally high fuel temperature............................................................. 38 Failure code [CA265] Abnormally low fuel temperature .............................................................. 40 Failure code [CA271] Short circuit in PCV1 ................................................................................ 41 Failure code [CA272] Disconnection in PCV1............................................................................. 42 Failure code [CA273] Short circuit in PCV2 ................................................................................ 43 Failure code [CA274] Disconnection in PCV2............................................................................. 44 Failure code [CA322] Disconnection or short circuit in injector #1 (L #1).................................... 46 Failure code [CA323] Disconnection or short circuit in injector #5 (L #5).................................... 48 Failure code [CA324] Disconnection or short circuit in injector #3 (L #3).................................... 50 Failure code [CA325] Disconnection or short circuit in injector #6 (L #6).................................... 52 Failure code [CA331] Disconnection or short circuit in injector #2 (L #2).................................... 54 Failure code [CA332] Disconnection or short circuit in injector #4 (L #4).................................... 56 Failure code [CA342] Matching error in engine controller data ................................................... 58 Failure code [CA351] Trouble in injector drive circuit .................................................................. 60 Failure code [CA352] Abnormally low voltage in sensor power supply 1.................................... 62 Failure code [CA386] Abnormally high voltage in sensor power supply 1 .................................. 64 Troubleshooting by failure code, Part 4 SEN01111-02 Failure code [CA431] Trouble in idle validation switch ................................................................ 4 Failure code [CA432] Trouble in idle validation process ............................................................. 7 Failure code [CA441] Abnormally low voltage in power supply................................................... 7 Failure code [CA442] Abnormally high voltage in power supply ................................................. 8 Failure code [CA449] Abnormally high common rail pressure 2 ................................................. 8 Failure code [CA451] Abnormally high common rail pressure .................................................... 10 Failure code [CA452] Abnormally low common rail pressure...................................................... 12 Failure code [CA553] Abnormally high common rail pressure 1 ................................................. 12 Failure code [CA554] In-range error in common rail pressure sensor ........................................ 13 Failure code [CA559] Supply pump low pressure 1 .................................................................... 15 Failure code [CA689] Trouble in engine Ne speed sensor.......................................................... 18 Failure code [CA731] Phase error in engine Bkup speed sensor ............................................... 20 Failure code [CA757] Loss of all data in engine controller .......................................................... 20 Failure code [CA778] Trouble in engine Bkup speed sensor ...................................................... 22 Failure code [CA1228] Trouble in EGR valve servo 1................................................................. 24 Failure code [CA1625] Trouble in EGR valve servo 2................................................................. 25 Failure code [CA1626] Short circuit in bypass valve solenoid drive circuit ................................. 26 Failure code [CA1627] Disconnection in bypass valve solenoid drive circuit.............................. 28 Failure code [CA1628] Trouble in bypass valve servo 1 ............................................................. 29 Failure code [CA1629] Trouble in bypass valve servo 2 ............................................................. 30 Failure code [CA1631] Abnormally high signal in bypass valve lift sensor.................................. 32 Failure code [CA1632] Abnormally low signal in bypass valve lift sensor ................................... 34 Failure code [CA1633] Trouble in KOMNET ............................................................................... 36 Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor.............................. 38 Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor ............................ 40 Failure code [CA2185] Abnormally high voltage in throttle sensor power supply ....................... 42 Failure code [CA2186] Abnormally low voltage in throttle sensor power supply ......................... 44
8
HM400-2
00 Index and foreword
SEN00512-09
Failure code [CA2249] Low pressure in supply pump 2.............................................................. 44 Failure code [CA2271] Abnormally high signal voltage in EGR valve lift sensor ........................ 46 Failure code [CA2272] Abnormally low signal voltage in EGR valve lift sensor.......................... 48 Failure code [CA2351] Short circuit in EGR valve solenoid drive circuit ..................................... 50 Failure code [CA2352] Disconnection in EGR valve solenoid drive circuit ................................. 52 Failure code [CA2555] Disconnection in intake air heater relay ................................................. 52 Failure code [CA2556] Short circuit in intake air heater relay ..................................................... 54 Troubleshooting by failure code, Part 5 SEN01112-01 Failure code [DAF9KM] Wrong connection of connector ............................................................ 3 Failure code [DAFRKR] Trouble in CAN communication (machine monitor) .............................. 4 Failure code [DAQ0KK] Lowering of source voltage ................................................................... 6 Failure code [DAQ0KT] Trouble in non-volatile memory............................................................. 8 Failure code [DAQ2KK] Trouble in solenoid power supply system ............................................. 10 Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller)................. 12 Failure code [DAQRKR] Trouble in CAN communication (Transmission controller) ................... 14 Failure code [DAQRMA] Disagreement of option setting (Transmission controller) ................... 16 Failure code [DB10KT] Trouble in non-volatile memory.............................................................. 16 Failure code [DB12KK] Trouble in solenoid power supply system ............................................. 18 Failure code [DB13KK] Lowering of battery direct voltage.......................................................... 20 Failure code [DB19KQ] Disagreement of model selection (Retarder controller)......................... 22 Failure code [DB1QMA] Disagreement of option setting (Retarder controller) ........................... 22 Failure code [DB1RKR] Trouble in CAN communication (Retarder controller) ........................... 24 Failure code [DB2RKR] Trouble in CAN communication (Engine controller).............................. 26 Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal.................... 28 Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve .................................................. 30 Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve................................................... 31 Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve ................................................. 32 Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve ................................................ 33 Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve ................................................ 34 Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve.......................................... 35 Failure code [DF10KA] Input of no lever signals......................................................................... 36 Failure code [DF10KB] Input of multiple lever signals ................................................................ 40 Failure code [DGF1KX] Transmission oil temperature out of range............................................ 44 Failure code [DGR2KZ] Ground fault in brake oil temperature sensor (rear).............................. 46 Failure code [DGR2L8] Disconnection in brake oil temperature sensor (rear) ........................... 48 Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center) .......................... 50 Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center) ........................ 52 Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front) ............................. 54 Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front)........................... 56 Failure code [DGR6KX] Steering oil temperature out of range ................................................... 58 Troubleshooting by failure code, Part 6 SEN01113-01 Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system ........... 4 Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil pressure sensor system .......................................................................................................... 6 Failure code [DHT5L6] Trouble in torque converter oil pressure sensor..................................... 8 Failure code [DHU2KX] Trouble in accumulator oil pressure sensor (front) system ................... 10 Failure code [DHU3KX] Trouble in accumulator oil pressure sensor (rear) system.................... 12 Failure code [DJF1KA] Disconnection in fuel level sensor system ............................................. 14 Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS ............................... 16 Failure code [DK52KX] Trouble in dump lever potentiometer 1 .................................................. 18 Failure code [DK53L8] Trouble in dump lever potentiometer 2................................................... 20 Failure code [DK54KX] Trouble in dump positioner sensor ........................................................ 22 Failure code [DKH0KX] Pitch angle sensor signal out of range.................................................. 24 Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system........... 26 Failure code [DLF1LC] Trouble in transmission input shaft speed sensor.................................. 27 Failure code [DLF2KA] Disconnection in transmission intermediate shaft speed sensor system ..................................................................................................................................... 28
HM400-2
9
SEN00512-09
00 Index and foreword
Failure code [DLF2LC] Disconnection in transmission intermediate shaft speed sensor system ..................................................................................................................................... 29 Failure code [DLF4KA] Disconnection in transmission differential speed sensor system ........... 30 Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system ......... 31 Failure code [DV00KB] Short circuit in buzzer output circuit....................................................... 32 Failure code [DW72KZ] Trouble (Disconnection or ground fault) in kick-out solenoid output system ..................................................................................................................................... 34 Failure code [DW73KZ] Trouble in dump selector valve output system...................................... 36 Failure code [DW78KZ] Trouble in rear wheel BCV command output system............................ 38 Failure code [DW79KZ] Trouble in front wheel BCV command output system ........................... 40 Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1 ..................................................................................................................................... 42 Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid pressure reducing valve........................................................................................................... 44 Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid pressure reducing valve........................................................................................................... 46 Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid pressure reducing valve........................................................................................................... 48 Failure code [DX11MA] Trouble in rear wheel proportional solenoid pressure reducing valve 2 ..................................................................................................................................... 50 Failure code [DX12K4] Trouble in front wheel proportional solenoid pressure reducing valve 1 ..................................................................................................................................... 52 Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid pressure reducing valve........................................................................................................... 54 Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid pressure reducing valve........................................................................................................... 56 Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid pressure reducing valve........................................................................................................... 58 Failure code [DX12MA] Trouble in front wheel proportional solenoid pressure reducing valve 2 ..................................................................................................................................... 60 Troubleshooting by failure code, Part 7 SEN01114-00 Troubleshooting by failure code, Part 7....................................................................................... 4 Failure code [DX13KA] Disconnection in output circuit of dump EPC valve............................ 4 Failure code [DX13KB] Ground fault in output circuit of dump EPC valve .............................. 6 Failure code [DX13KY] Hot short in output circuit of dump EPC valve.................................... 8 Failure code [DX14KZ] Trouble in rear wheel differential lock command output system......... 10 Failure code [DX15KZ] Trouble in front wheel differential lock command output system........ 12 Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch solenoid................................................................................................................................ 14 Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch solenoid................................................................................................................................ 16 Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid.... 18 Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid................... 19 Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid ..................... 20 Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid........................... 22 Failure code [DXH2KA] Disconnection in output circuit of Hi clutch solenoid.......................... 24 Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid valve........ 26 Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid valve............. 28 Failure code [DXH3KA] Disconnection in output circuit of Lo clutch solenoid ......................... 32 Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid valve ....... 34 Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid valve ............ 36 Failure code [DXH4KA] Disconnection in output circuit of 1st clutch solenoid ........................ 40 Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid valve ...... 42 Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid valve ........... 44 Troubleshooting by failure code, Part 8 SEN01115-00 Troubleshooting by failure code, Part 8....................................................................................... 2 Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch solenoid ....................... 2
10
HM400-2
00 Index and foreword
SEN00512-09
Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid valve..... 4 Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid valve .......... 6 Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch solenoid........................ 10 Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid valve...... 12 Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid valve ........... 14 Failure code [DXH7KA] Disconnection in output circuit of reverse clutch solenoid ................. 18 Failure code [DXH7KB] Ground fault in output circuit of reverse clutch ECMV solenoid valve.... 20 Failure code [DXH7KY] Hot short in output circuit of reverse clutch ECMV solenoid valve .... 22 Troubleshooting for electrical system (E-mode) SEN01116-01 Before troubleshooting for electrical system ............................................................................... 3 Information in troubleshooting table ............................................................................................ 9 E-1 Engine does not start (Starting motor does not turn) ............................................................ 10 E-2 Auto preheater does not operate.......................................................................................... 14 E-3 When starting switch is turned ON, machine monitor displays nothing ................................ 18 E-4 When starting switch is turned OFF, machine monitor cannot be operated ......................... 20 E-5 Alarm buzzer does not stop sounding .................................................................................. 22 E-6 Machine monitor does not normally display gauges, caution lamps, and character display section ......................................................................................................................... 23 E-7 Display of character display section cannot be changed...................................................... 24 E-8 Power mode selection function does not operate normally .................................................. 28 E-9 AISS function does not operate normally ............................................................................. 30 E-10 Right and left differential lock function does not operate normally (Differential lock-up specification)............................................................................................ 32 E-11 Interaxle differential lock-up function does not operate normally........................................ 36 E-12 Display of seat belt caution lamp is abnormal .................................................................... 38 E-13 Turn signal lamps and pilot lamps do not operate normally ............................................... 40 E-14 Night lighting is abnormal ................................................................................................... 45 E-15 Backup lamp and backup buzzer operate abnormally........................................................ 51 E-16 Emergency steering system does not operate ................................................................... 55 Troubleshooting of hydraulic and mechanical system (H-mode) SEN01117-00 Troubleshooting of hydraulic and mechanical system (H-mode) ................................................ 3 Information in troubleshooting table ........................................................................................ 3 H-1 Machine does not start ..................................................................................................... 4 H-2 Travel is not smooth (Machine hunts)............................................................................... 6 H-3 Lockup is not reset............................................................................................................ 6 H-4 Start shock and gear shift shock are abnormally large ..................................................... 7 H-5 Gear is not shifted up........................................................................................................ 8 H-6 Travel speed or power is low ............................................................................................ 10 H-7 Start and gearshift time lag is large .................................................................................. 14 H-8 Torque converter oil temperature is high .......................................................................... 16 H-9 Torque converter oil temperature is low............................................................................ 17 H-10 Front brake does not work fully....................................................................................... 18 H-11 Center brake does not work fully .................................................................................... 19 H-12 Rear brake does not work fully ....................................................................................... 20 H-13 Steering wheel is heavy .................................................................................................. 21 H-14 Steering wheel does not move........................................................................................ 22 H-15 Steering wheel waggle.................................................................................................... 23 H-16 Dump body raising speed is low ..................................................................................... 24 H-17 Dump body does not move............................................................................................. 25 H-18 Hydraulic drift of dump body is large .............................................................................. 26 Troubleshooting of engine (S-mode) SEN01118-01 Method of using troubleshooting chart ........................................................................................ 4 S-1 Starting performance of engine is poor................................................................................. 8 S-2 Engine does not start............................................................................................................ 10 S-3 Engine does not pick up smoothly........................................................................................ 14 S-4 Engine stops during operation .............................................................................................. 15 S-5 Engine does not rotate smoothly .......................................................................................... 16 HM400-2
11
SEN00512-09
00 Index and foreword
S-6 Engine lack output (or lacks power)...................................................................................... S-7 Exhaust gas is black (incomplete combustion)..................................................................... S-8 Oil consumption is excessive (or exhaust gas is blue) ......................................................... S-9 Oil becomes dirty quickly ...................................................................................................... S-10 Fuel consumption is excessive ........................................................................................... S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................. S-12 Oil pressure drops .............................................................................................................. S-13 Oil level rises (Entry of coolant or fuel) ............................................................................... S-14 Coolant temperature becomes too high (Overheating)....................................................... S-15 Abnormal noise is made ..................................................................................................... S-16 Vibration is excessive .........................................................................................................
17 18 20 21 22 23 24 26 28 29 30
50 Disassembly and assembly General information on disassembly and assembly SEN01442-03 How to read this manual.............................................................................................................. 2 List of adhesives.......................................................................................................................... 4 Special tool list............................................................................................................................. 7 Sketches of special tools............................................................................................................. 13 Engine and cooling system SEN01443-03 Removal and installation of fuel supply pump ............................................................................. 2 Removal and installation of engine assembly ............................................................................. 5 Removal and installation of cylinder head assembly................................................................... 13 Removal and installation of fuel injector assembly...................................................................... 26 Removal and installation of radiator assembly............................................................................ 32 Removal and installation of cooling assembly............................................................................. 36 Removal and installation of aftercooler ....................................................................................... 40 Removal and installation of engine front seal.............................................................................. 43 Removal and installation of engine rear seal .............................................................................. 45 Power train, Part 1 SEN01444-03 Removal and installation of output shaft assembly ..................................................................... 2 Disassembly and assembly of output shaft assembly ................................................................. 6 Removal and installation of transmission and front differential assembly ................................... 9 Disconnection and coupling of front differential and transmission .............................................. 17 Disassembly and assembly of torque converter assembly ......................................................... 18 Disassembly and assembly of transmission assembly ............................................................... 26 Power train, Part 2 SEN01445-02 Disassembly and assembly of front differential assembly ........................................................... 2 Removal and installation of center differential assembly............................................................. 19 Disassembly and assembly of center differential assembly ........................................................ 22 Removal and installation of rear differential assembly ................................................................ 37 Disassembly and assembly of rear differential assembly............................................................ 39 Power train, Part 3 SEN01446-01 Removal and installation of front final drive and brake assembly ............................................... 2 Disassembly and assembly of front final drive and brake assembly ........................................... 4 Removal and installation of center final drive and brake assembly............................................. 17 Disassembly and assembly of center final drive and plate assembly ......................................... 19 Removal and installation of rear final drive and brake assembly ................................................ 28 Disassembly and assembly of rear final drive and brake assembly............................................ 30 Removal and installation of center axle assembly ...................................................................... 40 Removal and installation of rear axle assembly .......................................................................... 43 Undercarriage and frame SEN01447-02 Removal and installation of front suspension cylinder assembly ................................................ 2 Removal and installation of rear suspension cylinder assembly ................................................. 4 Removal and installation of equalizer bar assembly ................................................................... 5 Removal and installation of front wheel assembly ...................................................................... 7 Removal and installation of rear front wheel assembly ............................................................... 8
12
HM400-2
00 Index and foreword
SEN00512-09
Removal and installation of rear rear wheel assembly................................................................ 8 Removal and installation of hitch frame assembly ...................................................................... 9 Disassembly and assembly of hitch frame.................................................................................. 15 Removal and installation of body assembly ................................................................................ 18 Hydraulic system SEN01448-02 Disassembly and assembly of steering valve ............................................................................. 2 Removal and installation of flow amplifier valve assembly ......................................................... 12 Removal and installation of hoist valve assembly ....................................................................... 14 Disassembly and assembly of hoist valve assembly .................................................................. 16 Disassembly and assembly of steering cylinder assembly ......................................................... 18 Disassembly and assembly of hoist cylinder assembly .............................................................. 24 Cab and its attachments SEN01449-02 Removal and installation of operator's cab ................................................................................. 2 Removal and installation of operator's cab glass (Stuck glass) .................................................. 7 Disassembly and assembly of operator’s seat assembly............................................................ 13 Removal and installation of air conditioner unit assembly .......................................................... 23 Electrical system SEN01450-02 Removal and installation of retarder controller assembly............................................................ 2 Removal and installation of transmission controller assembly .................................................... 4 Removal and installation of engine controller assembly ............................................................. 6 90 Diagrams and drawings Hydraulic diagrams and drawings SEN00533-02 Power train hydraulic circuit diagram .......................................................................................... 3 Steering and hoist hydraulic circuit diagram................................................................................ 5 Brake hydraulic circuit diagram ................................................................................................... 7 Brake cooling hydraulic circuit diagram....................................................................................... 8 Differential lock hydraulic circuit diagram .................................................................................... 9 Electrical diagrams and drawings SEN00534-04 Electrical circuit diagram for inside cab (1/4) .............................................................................. 3 Electrical circuit diagram for inside cab (2/4) Serial No.: 2001 – 2188........................................ 5 Electrical circuit diagram for inside cab (2/4) Serial No.: 2189 and up........................................ 7 Electrical circuit diagram for inside cab (3/4) Serial No.: 2001 – 2188........................................ 9 Electrical circuit diagram for inside cab (3/4) Serial No.: 2189 and up........................................ 11 Electrical circuit diagram for inside cab (4/4) .............................................................................. 13 Electrical circuit diagram for outside cab (1/3) ............................................................................ 15 Electrical circuit diagram for outside cab (2/3) ............................................................................ 17 Electrical circuit diagram for outside cab (3/3) ............................................................................ 19 Electrical circuit diagram for payload meter ................................................................................ 21 Connectors table and arrangement drawing ............................................................................... 23
HM400-2
13
SEN00512-09
00 Index and foreword
HM400-2 Articulated dump truck Form No. SEN00512-09
© 2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (02)
14
HM400-2
SEN00513-04
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
00 Index and foreword
1
Foreword and general information Safety notice ................................................................................................................................................... 2 How to read the shop manual ......................................................................................................................... 7 Explanation of terms for maintenance standard ............................................................................................. 9 Handling of electric equipment and hydraulic component .............................................................................11 Handling of connectors newly used for engines ........................................................................................... 20 How to read electric wire code...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36
HM400-2
1
SEN00513-04
00 Index and foreword
Safety notice
(Rev. 2008/08) 1
Important safety notice Proper service and repair are 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 dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1.
2
General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7)
8) 9)
If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out weld in g wo rk , al way s wear wel din g gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition. Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5
Prohibition of operation and handling by unlicensed workers
6 Safety check before starting work 7
Wearing protective goggles (for cleaning or grinding work)
8
Wearing shielding goggles and protectors (for welding work)
9 Good physical condition and preparation 10
Precautions against work which you are not used to or you are used to too much
HM400-2
00 Index and foreword
2.
3.
SEN00513-04
Preparations for work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
6)
Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
11)
HM400-2
7)
8)
9) 10)
12)
13) 14) 15)
16)
When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 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 and can even start fires. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed. When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul a r ly c a r e fu l t o c he c k t h a t t h e y ar e installed correctly. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tools are correctly assembled. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
3
SEN00513-04
4.
4
Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
00 Index and foreword
8)
When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
HM400-2
00 Index and foreword
If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
SEN00513-04
13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.
q
5.
6.
Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency.
HM400-2
7.
Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.
Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
a
The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
5
SEN00513-04
8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k For the environment, the air conditioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer. However, it does not mean that you may discharge the refrigerant into the atmosphere as it is. Be sure to recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight and your skin may be frozen. Accordingly, put on safety glasses, safety gloves and safety clothes when recovering or adding the refrigerant. Refrigerant gas must be recovered and added by a qualified person. 2)
6
00 Index and foreword a
Example of O-ring (Fitted to every joint of hoses and tubes)
a
For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VA L E O T H E R M A L S Y S T E M S : ZXL100PG (equivalent to PAG46)) to its O-rings.
HM400-2
00 Index and foreword
How to read the shop manual q q q
1.
SEN00513-04
1
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.
2.
Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.
HM400-2
7
SEN00513-04
3.
4.
00 Index and foreword
Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. q
Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 …)
q
Revisions Revised brochures are shown in the shop manual composition table.
Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol
Item
k
Safety
a
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
4
Weight
Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
3
Tightening torque
2
Coat
5
Oil, coolant
6
Drain
Remarks Special safety precautions are necessary when performing work.
Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.
5.
Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
8
HM400-2
00 Index and foreword
SEN00513-04
Explanation of terms for maintenance standard
1
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. 1.
Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. q The tolerance with the symbols of + or – is indicated on the right side of the standard size. q
Example: Standard size 120
Tolerance –0.022 –0.126
a
The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126)
q
Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them
q
Example: Standard size 60
HM400-2
Tolerance Shaft Hole –0.030 +0.046 –0.076 +0
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SEN00513-04
2.
Standard clearance and standard value The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.
00 Index and foreword
5.
q
3.
Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.
4.
Repair limit and allowable value or allowable dimension q The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. q If a part is worn to the repair limit, it must be replaced or repaired. q The performance and function of a product lowers while it is used. A value which the product can be used without causing a problem is called the “allowable value” or “allowable dimension”. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.
10
Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. q
6.
Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q
HM400-2
00 Index and foreword
Handling of electric equipment and hydraulic component
SEN00513-04
1
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 “repairs” 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). Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. 2.
Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2)
Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
HM400-2
11
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12
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 soldering may be damaged, or the wiring may be broken.
4)
High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. 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-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity 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 surface 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 connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a 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 cleaning with compressed air.
00 Index and foreword
HM400-2
00 Index and foreword
3.
SEN00513-04
Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, 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 connectors apart. a Never pull with one hand. 2] q
When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
q
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.
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. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
HM400-2
13
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2)
14
00 Index and foreword
Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a 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 connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 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 position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
HM400-2
00 Index and foreword
3)
Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks
HM400-2
SEN00513-04
q
Disconnection
q
Connection (Example of incomplete setting of (a))
15
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4)
16
00 Index and foreword
Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oi l a nd wa ter fr om t he c om 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. a 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 connector. 3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.
HM400-2
00 Index and foreword
4.
Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
5.
Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a 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. a If there is any change, there is probably defective contact in that circuit.
HM400-2
SEN00513-04
17
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00 Index and foreword
Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure 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 check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.
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 entering. 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 leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.
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 cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
18
HM400-2
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5.
Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (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 hydraulic oil.
6.
Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
7.
Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.
HM400-2
SEN00513-04
19
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00 Index and foreword
Handling of connectors newly used for engines a
1.
Mainly, following engines are object for following connectors. q 95E-5 q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 95 – 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure sensor in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (95, 107, 114 engines) Ne speed sensor of flywheel housing: NE (95 – 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines)
2.
1
Pull lock type (PACKARD-2) 95 – 170, 12V140 engines q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.
q
Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.
20
HM400-2
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3.
SEN00513-04
Push lock type q 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow. q
q
114 engine
q
107, 114 engines Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04)
3)
While pressing lock (D), pull out connector (4) in the direction of the arrow.
107 engine
a
2)
If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
HM400-2
21
SEN00513-04
q
4)
95, 125 – 170, 12V140 engines While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Example) Fuel pressure sensor in common rail: PFUEL etc. (AMP-3)
00 Index and foreword
4.
Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.
q
1)
Disconnect connector (6) according to the following procedure. 1] Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1) becomes heavy to turn. 2] Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.
2)
Connect the connector according to the following procedure. 1] Insert the connector to the end, while setting its groove. 2] Turn housing (H1) in the direction of the arrow until it “clicks”.
Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)
Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.
22
HM400-2
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SEN00513-04
How to read electric wire code a
1
The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX
0.85
L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile
Symbol AV
AVS
Heat-resistant low-voltAEX age wire for automobile
HM400-2
Material Conductor Insulator Conductor
Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance
Insulator
Soft polyvinyl chloride
Conductor
Annealed copper for electric appliance Heat-resistant crosslinked polyethylene
Insulator
Using temperature range (°C)
Example of use General wiring (Nominal No. 5 and above)
–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place
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SEN00513-04
2.
00 Index and foreword
Dimensions
(Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard
8
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7 – 5.5 5.3
4.8 – 7.0 7.0
6.0 – 8.2 8.2
8.0 – 10.8 10.8
8.6 – 11.4 11.4
9.8 – 13.0 13.0
10.4 – 13.6 13.6
12.0 – 16.0 16.0
13.6 – 17.6 17.6
108/0.80 127/0.80 169/0.80 217/0.80
“f” of nominal No. denotes flexible”.
24
HM400-2
00 Index and foreword
3.
SEN00513-04
Color codes table
(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR
Color of wire
Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW
Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red
Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: “GW” means that the background is Green and marking is White. 4.
Types of circuits and color codes
(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit Others
HM400-2
AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch
AEX
–
R B R D Y G L
–
–
WG
–
–
–
–
–
–
–
–
–
– –
–
–
–
–
–
RB YR GW LW BrW LgR
RY YB GR LR BrR LgY
RG YG GY LY BrY LgB
RL YL GB LB BrB LgW
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
YW GL
– –
Gr Br – –
25
SEN00513-04
00 Index and foreword
Precautions when carrying out operation
1
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. q q q q q q q q q q
a
Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit 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 disconnecting 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 and 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 plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2)
26
Sleeve nut (elbow end)
07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234
02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234
Split flange type hoses and tubes Nominal number 04 05
3)
Plug (nut end)
Flange (hose end)
Sleeve head (tube end)
Split flange
07379-00400 07379-00500
07378-10400 07378-10500
07371-30400 07371-30500
If the part is not under hydraulic pressure, the following corks can be used. Nominal number
Part Number
06 08 10 12 14 16 18 20 22 24
07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430
Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30
27
07049-02734
27
22.5
34
HM400-2
00 Index and foreword
2. q q q q q q q q q q q q q
a
a 3.
SEN00513-04
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 and fix them with intermediate clamps, if there are any. 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 idle. 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. Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. q 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. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, “Bleeding air”. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see “Disassembly and assembly”. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.
HM400-2
27
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4)
5)
28
00 Index and foreword
Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness. If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”.
HM400-2
00 Index and foreword
SEN00513-04
Method of disassembling and connecting push-pull type coupler k k
1
Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. 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.
Type 1 1.
Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container.
2.
Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
HM400-2
29
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Type 2 1.
Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)
2.
Connection q Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
30
HM400-2
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SEN00513-04
Type 3 1.
Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2.
Connection q Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
HM400-2
31
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Standard tightening torque table 1.
1
Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a
The following table applies to the bolts in Fig. A.
Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a
Tightening torque Nm 11.8 – 14.7 27 – 34 59 – 74 98 – 123 157 – 196 245 – 309 343 – 427 490 – 608 662 – 829 824 – 1,030 1,180 – 1,470 1,520 – 1,910 1,960 – 2,450 2,450 – 3,040 2,890 – 3,630
kgm 1.2 – 1.5 2.8 – 3.5 6.0 – 7.5 10.0 – 12.5 16 – 20 25 – 31.5 35 – 43.5 50 – 62 67.5 – 84.5 84 – 105 120 – 150 155 – 195 200 – 250 250 – 310 295 – 370
The following table applies to the bolts in Fig. B.
Thread diameter of bolt mm 6 8 10 12 a Fig. A
Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60
Width across flats mm 10 13 14 27
Tightening torque Nm kgm 5.9 – 9.8 0.6 – 1.0 13.7 – 23.5 1.4 – 2.4 34.3 – 46.1 3.5 – 4.7 74.5 – 90.2 7.6 – 9.2 a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are the ones indicated in the table for bolts shown in Fig. B. (Values of tightening torques shown in the table for Fig. A are applied.)
32
HM400-2
00 Index and foreword
2.
Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below.
Thread diameter of bolt mm 10 12 16
3.
Width across flats mm 14 17 22
Tightening torque Nm 59 – 74 98 – 123 235 – 285
kgm 6.0 – 7.5 10.0 – 12.5 23.5 – 29.5
Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Nominal No. 02 03,04 05,06 10,12 14
4.
SEN00513-04
Thread diameter mm 14 20 24 33 42
Width across flats mm
Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0} tor. 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}
Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
HM400-2
Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52
Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –
Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
33
SEN00513-04
5.
00 Index and foreword
Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm}
Nominal No. of hose
Width across flats
02
19
03 04 05 06 (10) (12) (14)
6.
22 24 27 32 36 41 46 55
Range 34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}
Target
44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}
Taper seal Thread size (mm) – 14 – 18 22 24 30 33 36 42
Face seal Nominal No. – Thread Number of diameter (mm) threads, type of (Reference) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –
Table of tightening torques for face seal joints a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines etc. to the torque shown in the following table. a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wetted).
Outer diameter of pipe (mm)
Width across flats (mm)
8 10 12 15 (16) 22 (20)
19 22 24 (27) 30 (32) 36
Tightening torque Nm {kgm} Range
Target
14 – 16 {1.4 – 1.6} 24 – 27 {2.4 – 2.7} 43 – 47 {4.4 – 4.8} 60 – 68 {6.1 – 6.8} 90 – 95 {9.2 – 9.7}
15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}
Face seal Nominal No. – Thread diameter Number of threads, (mm) type of thread (Reference) 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1-14UN 25.4 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification. 7.
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Tightening torque Bolts and nuts
Thread size mm 6 8 10 12 14
34
Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —
kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —
HM400-2
00 Index and foreword
8.
Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14
9.
SEN00513-04
Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5
kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51
Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below.
Material Thread size (inch) 1/16 1/8 1/4 3/8 1/2 3/4
HM400-2
Tightening torque In cast iron or steel In aluminum Nm kgm Nm kgm 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
35
SEN00513-04
00 Index and foreword
Conversion table
1
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), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 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 it 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.
Millimeters to inches
(A)
36
(B)
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811
7 0.276 0.669 1.063 1.457 1.850
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
HM400-2
00 Index and foreword
SEN00513-04
Millimeters to inches
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
5 0.197 0.591 0.984 1.378 1.772
6 0.236 0.630 1.024 1.417 1.811
1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
Kilogram to pound
0 10 20 30 40
0 0 22.05 44.09 66.14 88.18
1 2.20 24.25 46.30 68.34 90.39
2 4.41 26.46 48.50 70.55 92.59
3 6.61 28.66 50.71 72.75 94.80
4 8.82 30.86 51.91 74.96 97.00
5 11.02 33.07 55.12 77.16 99.21
50 60 70 80 90
110.23 132.28 154.32 176.37 198.42
112.44 134.48 156.53 178.57 200.62
114.64 136.69 158.73 180.78 202.83
116.85 138.89 160.94 182.98 205.03
119.05 141.10 163.14 185.19 207.24
121.25 143.30 165.35 187.39 209.44
123.46 145.51 167.55 189.60 211.64
125.66 147.71 169.76 191.80 213.85
127.87 149.91 171.96 194.01 216.05
130.07 152.12 174.17 196.21 218.26
Liters to U.S. Gallons
0 10 20 30 40
0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095
3 0.793 3.434 6.076 8.718 11.359
4 1.057 3.698 6.340 8.982 11.624
1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944
50 60 70 80 90
13.209 15.850 18.492 21.134 23.775
14.001 16.643 19.285 21.926 24.568
14.265 16.907 19.549 22.190 24.832
14.529 17.171 19.813 22.455 25.096
HM400-2
13.473 16.115 18.756 21.398 24.040
13.737 16.379 19.020 21.662 24.304
14.795 17.435 20.077 22.719 25.361
15.058 17.700 20.341 22.983 25.625
15.322 17.964 20.605 23.247 25.889
15.586 18.228 20.870 23.511 26.153
37
SEN00513-04
00 Index and foreword
Liters to U.K. Gallons
0 10 20 30 40
0 0 2.200 4.399 6.599 8.799
1 0.220 2.420 4.619 6.819 9.019
2 0.440 2.640 4.839 7.039 9.239
3 0.660 2.860 5.059 7.259 9.459
4 0.880 3.080 5.279 7.479 9.679
5 1.100 3.300 5.499 7.699 9.899
50 60 70 80 90
10.998 13.198 15.398 17.598 19.797
11.281 13.418 15.618 17.818 20.017
11.438 13.638 15.838 18.037 20.237
11.658 13.858 16.058 18.257 20.457
11.878 14.078 16.278 18.477 20.677
12.098 14.298 16.498 18.697 20.897
1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778 12.318 14.518 16.718 18.917 21.117
12.528 14.738 16.938 19.137 21.337
12.758 14.958 17.158 19.357 21.557
12.978 15.178 17.378 19.577 21.777
kgm to ft.lb
0 10 20 30 40
0 0 72.3 144.7 217.0 289.3
1 7.2 79.6 151.9 224.2 296.6
2 14.5 86.8 159.1 231.5 303.8
3 21.7 94.0 166.4 238.7 311.0
4 28.9 101.3 173.6 245.9 318.3
5 36.2 108.5 180.8 253.2 325.5
6 43.4 115.7 188.1 260.4 332.7
1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4
50 60 70 80 90
361.7 434.0 506.3 578.6 651.0
368.9 441.2 513.5 585.9 658.2
376.1 448.5 520.8 593.1 665.4
383.4 455.7 528.0 600.3 672.7
390.6 462.9 535.2 607.6 679.9
397.8 470.2 542.5 614.8 687.1
405.1 477.4 549.7 622.0 694.4
412.3 484.6 556.9 629.3 701.6
419.5 491.8 564.2 636.5 708.8
426.8 499.1 571.4 643.7 716.1
100 110 120 130 140
723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 160 170 180 190
1084.9 1157.3 1129.6 1301.9 1374.3
38
1092.2 1164.5 1236.8 1309.2 1381.5
1099.4 1171.7 1244.1 1316.4 1388.7
1106.6 1179.0 1251.3 1323.6 1396.0
1113.9 1186.2 1258.5 1330.9 1403.2
1121.1 1193.4 1265.8 1338.1 1410.4
1128.3 1200.7 1273.0 1345.3 1417.7
1135.6 1207.9 1280.1 1352.6 1424.9
1142.8 1215.1 1287.5 1359.8 1432.1
1150.0 1222.4 1294.7 1367.0 1439.4
HM400-2
00 Index and foreword
SEN00513-04
kg/cm2 to lb/in2
0 10 20 30 40
0 0 142.2 284.5 426.7 568.9
1 14.2 156.5 298.7 440.9 583.2
2 28.4 170.7 312.9 455.1 597.4
3 42.7 184.9 327.1 469.4 611.6
4 56.9 199.1 341.4 483.6 625.8
5 71.1 213.4 355.6 497.8 640.1
6 85.3 227.6 369.8 512.0 654.3
1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9
50 60 70 80 90
711.2 853.4 995.6 1,138 1,280
725.4 867.6 1,010 1,152 1,294
739.6 881.8 1,024 1,166 1,309
753.8 896.1 1,038 1,181 1,323
768.1 910.3 1,053 1,195 1,337
782.3 924.5 1,067 1,209 1,351
796.5 938.7 1,081 1,223 1,365
810.7 953.0 1,095 1,237 1,380
825.0 967.2 1,109 1,252 1,394
839.2 981.4 1,124 1,266 1,408
100 110 120 130 140
1,422 1,565 1,707 1,849 1,991
1,437 1,579 1,721 1,863 2,005
1,451 1,593 1,735 1,877 2,020
1,465 1,607 1,749 1,892 2,034
1,479 1,621 1,764 1,906 2,048
1,493 1,636 1,778 1,920 2,062
1,508 1,650 1,792 1,934 2,077
1,522 1,664 1,806 1,949 2,091
1,536 1,678 1,821 1,963 2,105
1,550 1,693 1,835 1,977 2,119
150 160 170 180 190
2,134 2,276 2,418 2,560 2,702
2,148 2,290 2,432 2,574 2,717
2,162 2,304 2,446 2,589 2,731
2,176 2,318 2,460 2,603 2,745
2,190 2,333 2,475 2,617 2,759
2,205 2,347 2,489 2,631 2,773
2,219 2,361 2,503 2,646 2,788
2,233 2,375 2,518 2,660 2,802
2,247 2,389 2,532 2,674 2,816
2,262 2,404 2,546 2,688 2,830
200 210 220 230 240
2,845 2,987 3,129 3,271 3,414
2,859 3,001 3,143 3,286 3,428
2,873 3,015 3,158 3,300 3,442
2,887 3,030 3,172 3,314 3,456
2,901 3,044 3,186 3,328 3,470
2,916 3,058 3,200 3,343 3,485
2,930 3,072 3,214 3,357 3,499
2,944 3,086 3,229 3,371 3,513
2,958 3,101 3,243 3,385 3,527
2,973 3,115 3,257 3,399 3,542
HM400-2
39
SEN00513-04
00 Index and foreword
Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C
°F
°C
°F
°C
°F
°C
1°C = 33.8°F °F
–40.4 –37.2 –34.4 –31.7 –28.9
–40 –35 –30 –25 –20
–40.0 –31.0 –22.0 –13.0 –4.0
–11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
177.8 179.6 181.4 183.2 185.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 60
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
40
HM400-2
00 Index and foreword
HM400-2
SEN00513-04
41
SEN00513-04
00 Index and foreword
HM400-2 Articulated dump truck Form No. SEN00513-04
© 2008 KOMATSU All Rights Reserved Printed in Japan 09-08 (02)
42
HM400-2
SEN00515-01
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
01 Specification
1
Specification and technical data Specification drawings .................................................................................................................................... 2 Specifications .................................................................................................................................................. 3 Weight table .................................................................................................................................................... 6 Fuel, coolant and lubricants ............................................................................................................................ 7
HM400-2
1
SEN00515-01
Specification drawings
2
01 Specification
1
HM400-2
01 Specification
SEN00515-01
Specifications HM400-2
Serial Numbers
2001 and up 32,460
kg kg
37,000 68,960
Unloaded (front wheel)
kg
17,885
(center wheel) (rear wheel)
kg kg
7,401 7,134
Fully loaded (front wheel) (center wheel)
kg kg
19,929 24,688
(rear wheel)
kg
24,412
Struck Heaped (2:1)
m3
16.5 22.3
Weight
kg
Max. payload Overall weight
Dump body capacity Performance
Machine model
Unloaded
Weight
Max. travel speed
3
m
km/h
58.6 0.51
Dumping angle (angle to ground)
mm deg
8,712/4,168 70
Overall length (A) Overall width (B)
mm mm
11,310 3,450
Overall height (C) Body width (D)
mm mm
3,720 3,450
Front over bank (E) Wheelbase (front wheel - center wheel) (F)
mm mm
3,170 4,350
Wheelbase (center wheel - rear wheel) (G) Flexural center - front wheel (H)
mm mm
1,970 1,350
Front tires
mm
2,690
Center tires Rear tires
mm mm
2,690 2,690
Front wheel
mm
3,450
Rear front wheel Rear rear wheel
mm mm
3,450 3,450
Approach angle (L)
deg
25
Front wheel Minimum ground clearRear front wheel ance (M) Rear rear wheel
mm
670
mm mm
625 625
Ground Clearance (N)
mm
605
Minimum ground clearance (dump body lower edge) (P)
mm
720
Dump body loading height (Q)
mm
2,790
Gradeability (tan ) Min turning radius (front wheel/rear wheel) (S)
Tread (J)
Dimensions
1
Entire width of tire (K)
Dump body height (unloaded) (R)
7,130
Rear axis - dump body rear edge (unloaded) (R2) Rear axis - axis pin (R3)
mm
620 1,820
Cab width (T)
mm
1,594
Body length (U)
mm
5,392
HM400-2
3
Engine
SEN00515-01
01 Specification
Machine model
HM400-2
Serial Numbers
2001 and up
Model
Komatsu SAA6D140E-5
Type
4-cycle, water-cooled, in-line 6 cylinder, direct injection, with turbocharger and air-cooled after-cooler
No. of cylinders - Bore x stroke
mm
6 -140 x 165
Piston displacement
l{cc}
15.24 {15,240}
Flywheel horsepower
kW/rpm{HP/rpm}
338/2,000 {453/2,000}
Max. torque
Nm/rpm{kgm/rpm}
2,090/1,400 {213/1,400}
g/kWh{g/HPh}
213 {159}
Fuel consumption (rated) Starting motor
11kW
Alternator
24V 60A
Battery
Power train
Torque converter
Transmission
Travel system
Lock-up clutch
Hydraulically-actuated, wet-type, single-disc clutch
Type
TORQFLOW multiple-axle transmission, fully automatic, electrically-hydraulically actuated, force-feed type pump lubrication type
No. of speeds
Straight bevel gear, splash lubrication
Type
Final drive
Suspension
3-element, 1-stage, 2-phase
Type
F6, R2
Reduction gear
Reduction ratio
3.417
Differential type
Straight bevel gear, splash lubrication
Type
Planetary gear, splash lubrication
Reduction ratio
4.941
Type
Axle type
Suspension method
Tires
Size and no.
Tire inflation pressure
4
12V 160Ah x 2
Fully hydraulic
Front axle
Independent suspension (MacPherson type)
Center axle
Independent suspension (MacPherson type)
Rear axle
Independent suspension (MacPherson type)
Front axle
Hydropneumatic type
Rear axle
Hydropneumatic type
Front tire
29.5 R25 x 2
Center tire
29.5 R25 x 2
Rear tire
29.5 R25 x 2 kPa {kg/cm2}
0.372 {3.8}
HM400-2
01 Specification
Machine model
HM400-2
Serial Numbers
2001 and up
Front wheel
Main brake Brakes
SEN00515-01
Center wheel
Parking brake
Hydraulic pump, motor
Hydraulic system
Independent front and center system brake, sealed, wet- type, multiple disc, hydraulically operated type For steering, hoist Type Discharge amount (l /min) (when engine is at rated speed of 2,000 rpm) For hoist control Type Discharge amount (l /min) (when engine is at rated speed of 2,000 rpm) For transmission, brake cooling Type Discharge amount (l /min) (when engine is at rated speed of 2,000 rpm) For brake cooling Type Discharge amount (l /min) (when engine is at rated speed of 2,000 rpm) For brake Type Discharge amount (l /min) (when engine is at rated speed of 2,000 rpm) For front differential lock-up Type Discharge amount (l /min) (when engine is at rated speed of 2,000 rpm) For differential lock-up motor Type Discharge amount (l /min) (when engine is at rated speed of 2,000 rpm) For center and rear differential lock-up Type Discharge amount (l /min) (when motor is at speed of 1,000 rpm) Hoist cylinder Type
Cylinders
Independent front and center system brake, sealed, wet- type, multiple disc, hydraulically operated type Spring-boosted, caliper disc type
Retarder
HM400-2
Independent front and center system brake, sealed, wet- type, multiple disc, hydraulically operated type
No. - bore (1st-2nd) x stroke Steering cylinder Type No. - bore x stroke
Gear pump 218 + 218
Gear pump 18.5
Gear pump 180
Gear pump 142
Gear pump 56
Gear pump 185
Gear pump 28.1
Gear pump 74 x 2
2-stage piston type (only 2nd stage double-acting) 2-(160mm-120mm) x 3,232mm Piston type, double acting 2-120mm x 525mm
5
SEN00515-01
01 Specification
Weight table
1
This weight table is a guide for use when transporting or handling components. Unit: kg
6
Machine model
HM400-2
Serial Numbers
2001 and up
Engine assembly
1,710
Output shaft assembly
88
Cooling assembly
284
Fuel tank (individual part)
244
Torque converter assembly
282
Transmission assembly
1,450
Drive shaft assembly
295
Front axle assembly
1,505
Differential
428
Final drive
1,077
Center axle assembly
1,898
Differential
397
Final drive
1,060
Rear axle assembly
1,772
Differential
265
Final drive
1,064
Front suspension cylinder
91.5
Rear suspension cylinder
78.9
Oscillation hitch assembly
851
Front frame
1,666
Rear frame
2,094
Cab (interior components)
1,090
Operator’s seat
65
Steering cylinder (one side)
66.8
Hoist cylinder (one side)
254
Flow amp valve
29
Hoist valve
63
Hydraulic tank
244
Hydraulic pump (SDR(30)63 + SA(1)25)
31.4
Hydraulic pump (SDR(30)80 + SB(1)12 + 8)
24.0
Hydraulic pump (SDR(30)100 + 100 + SB(1)8)
42.2
Hydraulic pump (SDR(30)80)
18.7
Body assembly
4,380
HM400-2
01 Specification
SEN00515-01
Fuel, coolant and lubricants
1
a Regarding the details of notes (note 1, note 2, ...), refer to "Operation & Maintenance Manual".
HM400-2
7
SEN00515-01
01 Specification
Reservoir Engine oil pan
Transmission case (Incl. brake oil tank)
Hydraulic tank
Front suspension (each)
Rear suspension (each)
Front differential Case
l
56
270
267
6
4.2
22.5
US gal
14.79
71.33
70.54
1.59
11.09
5.94
l
50
115
180
6
4.2
22.5
US gal
13.21
30.38
47.56
1.59
11.09
5.94
Capacity Specified
Refill
Reservoir
Front final drive case (each)
Center differential Case
Center final drive case (each)
Rear differential Case
Rear final drive case (each)
Fuel tank
Cooling system
l
6.5
39.5
5.5
35
5.5
500
114.5
US gal
1.72
10.44
1.45
9.25
1.45
132.1
30.25
l
6.0
39.5
5.0
35
5.0
–
106.5
US gal
1.59
10.44
1.32
9.25
1.32
–
28.14
Capacity Specified
Refill
8
HM400-2
01 Specification
HM400-2
SEN00515-01
9
SEN00515-01
01 Specification
HM400-2 Articulated dump truck Form No. SEN00515-01
© 2007 KOMATSU All Rights Reserved Printed in Japan 07-07 (02)
10
HM400-2
SEN00517-01
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
10 Structure, function and maintenance standard
1
Engine and cooling system Radiator, oil cooler, aftercooler ....................................................................................................................... 2 Output shaft .................................................................................................................................................... 3
HM400-2
1
SEN00517-01
10 Structure, function and maintenance standard
Radiator, oil cooler, aftercooler
1. 2. 3. 4. 5. 6. 7.
Aftercooler Water filler Reservoir tank Upper tank Lower tank Oil cooler (steering, torque converter) Sub tank
A: B: C: D: E: F: G:
From thermostat To water pump From brake To oil filter From hoist valve To hydraulic tank From water pump
2
1
Specifications Radiator • Core type: CF4-5 • Total heat dissipation area: 90.68m2 Torque converter oil cooler • Core type: PTO-LS • Total heat dissipation area: 4.0655m2 Steering oil cooler • Core type: PTO-OL • Total heat dissipation area: 0.896m2
HM400-2
10 Structure, function and maintenance standard
Output shaft
1. 2. 3. 4. 5. 6. 7.
Rubber cushion Outer body Flange Shaft Coupling Inner body Cover
HM400-2
SEN00517-01
1
Function The output shaft is installed to the engine flywheel,and absorbs the twisting vibration caused by changes in the engine torque.
3
SEN00517-01
10 Structure, function and maintenance standard
Unit: mm No.
1
Check item
Clearance between flywheel and bearing
Tolerance
Remedy
Shaft
Hole
Standard clearance
80
0 -0.013
0 -0.030
-0.030 – 0.013
0.02
Standard size
Clearance limit
2
Clearance between shaft and bearing
40
-0.009 -0.025
0 -0.012
-0.003 – 0.025
0.10
3
Clearance between bearing and cover
120
0 -0.015
-0.006 -0.028
-0.028 – 0.009
–
4
Clearance between bearing and shaft
65
0.012 -0.007
0 -0.015
-0.027 – 0.007
0.025
5
Weaar of oil seal contact surface of coupling
6
Backlash at spline
7
Deformastion of rubber cushion External
4
Criteria
Standard size
Repair limit
95
94.7
Standard backlash
Backlash limit
0.099 – 0.202
0.4
Original dimension : Lo
Replace
Repair or replace
Standard backlash (Dimension Replace at smallest width : L)
75
67 Without cranks
HM400-2
10 Structure, function and maintenance standard
HM400-2
SEN00517-01
5
SEN00517-01
10 Structure, function and maintenance standard
HM400-2 Articulated dump truck Form No. SEN00517-01
© 2007 KOMATSU All Rights Reserved Printed in Japan 07-07 (02)
6
HM400-2
SEN00518-01
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
10 Structure, function and maintenance standard
1
Power train, Part 1 Power train skeleton ....................................................................................................................................... 2 Torque converter and transmission hydraulic piping....................................................................................... 6 Brake cooling oil control valve (BCV).............................................................................................................. 8 Power train pump............................................................................................................................................ 9 Torque converter ........................................................................................................................................... 12 Transmission................................................................................................................................................. 18 Transmission control valve............................................................................................................................ 46 ECMV............................................................................................................................................................ 47 Main relief, torque converter relief valve ....................................................................................................... 54
HM400-2
1
SEN00518-01
Power train skeleton
10 Structure, function and maintenance standard
1
(Machine with differential lock differential)
2
HM400-2
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.
SEN00518-01
Engine Output shaft Front drive shaft Brake cooling and brake system pump (SDR(30)63+SA(1)12) Power train, front brake cooling, differential lock control pump (SDR(30)80+SB(1)12+8) PTO Torque converter Steering, hoist control pump (SDR(30)100+100+SB(1)8) Transmission Center drive shaft Oscillation hitch Drive shaft (hitch) Front differential Front differential lock Front drive shaft Tire Final drive (front) Brake (front) Rear drive shaft (front) Center differential Center differential lock Tire Final drive (center) Brake (center) Rear drive shaft (rear) Rear differential Rear differential lock Tire Final drive (rear) Brake (rear) Interaxle differential lock
HM400-2
3
SEN00518-01
10 Structure, function and maintenance standard
(Machine with limited slip differential)
4
HM400-2
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.
SEN00518-01
Engine Output shaft Front drive shaft Brake cooling and brake system pump (SDR(30)63+SA(1)12) Power train pump (SDR(3)80) PTO Torque converter Steering, hoist control pump (SDR(30)100+100+SB(1)8) Transmission Center drive shaft Oscillation hitch Drive shaft (hitch) Front differential Front limited slip differential Front drive shaft Tire Final drive (front) Brake (front) Rear drive shaft (front) Center differential Center limited slip differential Tire Final drive (center) Brake (center) Rear drive shaft (rear) Rear differential Rear limited slip differential Tire Final drive (rear) Brake (rear) Interaxle differential lock
HM400-2
5
SEN00518-01
10 Structure, function and maintenance standard
Torque converter and transmission hydraulic piping
6
1
HM400-2
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
SEN00518-01
Engine Torque converter Transmission Oil cooler Power train, brake cooling return filter Rear brake cooling and brake system pump (SDR(30)63+SA(1)25) Brake system tank Power train, front brake cooling, differential control pump (SDR(30)80+SB(1)12+8) Transmission oil filter Front brake cooling valve Center brake cooling valve
HM400-2
7
SEN00518-01
Brake cooling oil control valve (BCV)
1. 2. 3. 4.
Pilot relief valve assembly Body Solenoid valve Main valve spool
S: To transmission Q: From transmission R: To oil cooler
8
10 Structure, function and maintenance standard
1
Function • When the retarder is not being used, this valve bypasses part of the brake cooling oil to reduce the power loss when traveling. • The main valve spool is actuated by switching the solenoid vavle ON/OFF. If any abnormal pressure is generated in the hydraulic circuit, the pilot relief valve is actusted, and this actuates the main relief valve, so the brake cooling valve also acts as an unload valve.
HM400-2
10 Structure, function and maintenance standard
SEN00518-01
Power train pump
1
Power train, front brake cooling, differential lock pump (Machine with differential lock differential) SDR(30)80+SB(1)12+8
Unit: mm No.
1
Check item
Side clearance
Criteria Model
Standard clearance
Clearance limit
SDR(30)-80
0.16 – 0.20
0.24
0.10 – 0.15
0.19
SB(1)-12 SB(1)-8
2
Clearance between inside diameter of plain bearing and outside of diameter of gear shaft
4
Depth for knocking in pin
5 6
SDR(30)-80
SDR(30)-80 SB(1)-12 SB(1)-8
Rotating torque of spline shaft
Discharge amount Oil: EO10-CD Oil temperature: 45–55°C
Standard size
Tolerance
Repair limit
10
0 -0.5
–
9.2
±0.3
Replace
10.8 – 21.5 Nm {1.1 – 2.2 kgm} Delivery Standard Rotating pressure delivery speed {MPa amount (rpm) (kg/cm2)} (l/min)
SDR(30)-80 SB(1)-12 SB(1)-8
HM400-2
0.20
0.06 – 0.12
SB(1)-8
Model –
0.06 – 0.13
SB(1)-12 Model
3
Remedy
2,500
20.6 {210}
Delivery amount limit (l/min)
184.5
170.4
26.7
24.5
17.2
15.8
–
9
SEN00518-01
10 Structure, function and maintenance standard
Brake cooling, brake system pump SDR(30)63+SA(1)25
Unit: mm No.
1
2
Check item
Side clearance
Clearance between inside diameter of plain bearing and outside of diameter of gear shaft
Criteria Model
Standard clearance
Clearance limit
SDR(30)-63
0.16 – 0.20
0.24
SA(1)-25
0.10 – 0.15
0.19
SDR(30)-63
0.06 – 0.13
SA(1)-25
0.06 – 0.12
Model 3
Depth for knocking in pin
SDR(30)-63 SA(1)-25
4
–
Rotating torque of spline shaft
Discharge amount Oil: EO10-CD Oil temperature: 45–55°C
0.20
Standard size
Tolerance
Repair limit
10
0 -0.5
–
Replace
8.8 – 16.6 Nm {0.9 – 1.7 kgm}
Model
SDR(30)-63 SA(1)-25
10
Remedy
Delivery Standard Rotating pressure delivery speed {MPa amount (rpm) (kg/cm2)} (l/min) 2,500
20.6 {210}
Delivery amount limit (l/min)
145.8
134.7
56.5
50.8
–
HM400-2
10 Structure, function and maintenance standard
SEN00518-01
Transmission pump (Machine with limited slip differential) SDR(30)80
Unit: mm No.
Check item
1
Side clearance
2
Clearance between inside diameter of plain bearing and outside of diameter of gear shaft
3
Insertion depth of pin
4
Rotating torque of spline shaft
–
Discharge amount Oil: EO10-CD Oil temperature: 45–55°C
HM400-2
Criteria
Remedy
Standard clearance
Clearance limit
0.16 – 0.20
0.24
0.06 – 0.13
0.20
Replace
Standard size
Tolerance
Repair limit
10
0 -0.5
–
Rotating speed (rpm)
Delivery pressure {MPa (kg/cm2)}
Standard delivery amount (l/min)
Delivery amount limit (l/min)
2,500
20.6 {210}
184.5
170.4
–
11
SEN00518-01
10 Structure, function and maintenance standard
Torque converter
1
Unit: mm No.
1
2
Check item
Clearance between PTO gear and bearing
Clearance between bearing and case
Criteria Tolerance Shaft
Hole
Standard clearance
50
+0.018 +0.002
0 -0.012
-0.030 – -0.002
—
90
0 -0.015
+0.004 -0.018
-0.018 – 0.019
—
Standard size
3. Power train, front brake cooling, differential lock control pump installation port 4. Steering, hoist control pump installation port 5. Brake cooling, brake system pump installation port 6. PTO gear (number of teeth: 91)
12
Remedy Clearance limit Replace
Specifications Type:
3-element, 1-stage, 2-phase with modulation and lockup clutch Lockup clutch: wet type single-disc clutch hydraulic control (with modulation valve) Stall torque ratio: 2.63
HM400-2
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8. 9.
Coupling Input shaft (number of teeth: 108) Case Drive case Turbine Outer race Pump Retainer Stator shaft
HM400-2
SEN00518-01
10. 11. 12. 13. 14. 15. 16. 17.
Sleeve Inner race Free wheel Stator Lockup clutch disc Lockup clutch piston Lockup clutch housing Retainer
13
SEN00518-01
14
10 Structure, function and maintenance standard
HM400-2
10 Structure, function and maintenance standard
SEN00518-01
Unit: mm No.
Check item
Criteria
1
Outer diameter of the oil seal contact surface of the coupling
2
Remedy
Standard size
Tolerance
Repair limit
95
0 -0.087
94.8
Inner diameter of the seal ring contact surface of the input shaft
35
+0.025 0
35.5
3
Inner diameter of the seal ring contact surface of the clutch housing
420
+0.097 0
420.5
4
Inner diameter of the seal ring contact surface of the clutch piston
295
+0.081 0
295.1
5
Inner diameter of the seal ring contact surface of the retainer
135
+0.040 0
135.5
6
Inner diameter of the seal ring contact surface of the sleeve
70
+0.030 0
70.5
7
Wear of the clutch housing seal ring
Width
5
-0.01 -0.04
4.5
Thickness
7
±0.15
6.85
8
Inner diameter of race free wheel transmission surface
127.844
±0.013
127.874
9
Outer diameter of stator shaft free wheel transmission surface
108.883
±0.013
108.853
10
Inner diameter of sliding portion of bushing
109
+0.015 0
109.08
11
Thickness of sliding portion of bushing
5
0 -0.1
4.5
5.4
±0.1
4.9
12 Thickness of the clutch disc 13
Backlash between input shaft and PTO gear
HM400-2
Replace
0.17 - 0.45
15
SEN00518-01
10 Structure, function and maintenance standard
Power transmission route When lockup clutch is “disengaged“
When lockup clutch is “engaged“
Drive case (4) is disconnected from boss (7) and turbine (6) and lockup torque converter works as an ordinary torque converter.
Drive case (4) is connected to boss (7) and turbine (6) and lockup torque converter is locked up.
The power from engine O Drive shaft O Coupling (1) O Input shaft (2), clutch housing (3), drive case (4) and pump (5) rotate together O Oil is used as medium O Turbine (6) and boss (7) O Transmission input shaft (8) •
16
The power transmitted to input shaft (2) is also used as power for driving the pump after being transmitted through PTO gear.
The power from engine O Drive shaft O Coupling (1) O Input shaft (2), clutch housing (3), drive case (4) and pump (5) rotate together O Lockup clutch is engaged O Turbine (6) and boss (7) O Transmission input shaft (8) •
The power transmitted to input shaft (2) is also used as power for driving the pump after being transmitted through PTO gear.
HM400-2
10 Structure, function and maintenance standard
SEN00518-01
Oil flow
•
• •
The oil flows through the main relief valve and its pressure is reduced to below the set pressure by the torque converter relief valve. It then flows into inlet port (A), goes through the oil passages of stator shaft (1), and flows into pump (2). The oil is given centrifugal force by pump (2) and flows into turbine (3) to transfer its energy to turbine (3). The oil from turbine (3) is sent to stator (4) and flows into pump (2) again. However, part of the oil passes between turbine (3) and stator (4) and is sent from outlet port (B) to the oil cooler to be cooled. It is then used to lubricate the transmission.
HM400-2
17
SEN00518-01
Transmission
18
10 Structure, function and maintenance standard
1
HM400-2
10 Structure, function and maintenance standard
A: To front brake B: From return filter C: To power train, front brake cooling, differential lock control pump D: To brake cooling, brake system pump 1. 2. 3. 4. 5. 6. 7. 8.
Transmission case (front) Transmission case (rear) Transmission intermediate shaft speed sensor Differential input speed sensor Oil filler tube mounting port Power train, lubricating oil temperature sensor Drain plug Drain valve
SEN00518-01
Outline • The transmission adopted is a “forward 6-gear speed and reverse 2-gear speed“ transmission which consists of the counter-shaft type, constant mesh spur gear mechanisms and the disc clutches. • The transmission selects one rotation direction and rotation speed by fixing the counter-shaft type, constant mesh spur gear mechanisms and 2 out of 6 sets disc clutch with the oil pressure by ECMV operation. • The transmission transfers the power received by the transmission input shaft to the output shaft while changing the gear speed (forward 1st-6th or reverse 1st-2nd) by any combination of the FL, FH, R clutches and 3 speed clutches. • The gear is automatically shifted with automatic transmission based on the engine speed changes. Number of plates and disks used Clutch No.
Number of plates
Number of discs
FL clutch
12
11
R clutch
12
11
FH clutch
10
9
1st clutch
12
11
3rd clutch
8
7
2nd clutch
14
13
Combinations of clutches at respective gear speeds and reduction ratio
HM400-2
Gear speed
Operated clutches
Reduction ratio
Forward 1st
FL x 1st
6.061
Forward 2nd
FH x 1st
3.957
Forward 3rd
FL x 2nd
2.574
Forward 4th
FH x 2nd
1.680
Forward 5th
FL x 3rd
1.094
Forward 6th
FH x 3rd
0.714
Neutral
—
—
Reverse 1st
R x 1st
5.851
Reverse 2nd
R x 2nd
2.484
19
SEN00518-01
10 Structure, function and maintenance standard
Unit: mm No.
1
2
3. 4. 5. 6. 7. 8. 9. 10.
Check item
Clearance between bearing and case
Clearance between R idler gear and bearing
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
70
+0.032 +0.002
0 -0.015
-0.047 – -0.002
—
125
0 -0.018
-0.036 -0.061
-0.061 – -0.018
—
Replace
Transmission input shaft speed sensor Torque converter outlet oil temperature sensor Transmission control valve Main relief, torque converter relief valve Torque converter intermediate oil pressure sensor R idler gear (Number of teeth: 35) Strainer Lubricating oil relief valve
A: From transmission oil filter
20
HM400-2
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7.
R clutch 1st clutch 2nd clutch Differential lock clutch Rear output shaft Rear coupling Front output shaft
HM400-2
SEN00518-01
8. 9. 10. 11. 12. 13. 14.
Lower shaft 3rd clutch Upper shaft FH clutch Input shaft FL clutch Torque converter
21
SEN00518-01
22
10 Structure, function and maintenance standard
HM400-2
10 Structure, function and maintenance standard
SEN00518-01
Unit: mm No.
1
Check item
Clearance between FL, R clutch bearing and case (front)
Criteria Tolerance
Remedy
Shaft
Hole
Standard clearance
160
0 -0.025
0 -0.040
-0.040 – 0.025
—
Standard size
Clearance limit
2
Clearance between FL, R clutch bearing and case (rear)
160
0 -0.025
0 -0.040
-0.040 – 0.025
—
3
Clearance between FH, 1st clutch bearing and case (front)
160
0 -0.025
0 -0.040
-0.040 – 0.025
—
4
Clearance between FH, 1st clutch bearing and case (rear)
160
0 -0.025
0 -0.040
-0.040 – 0.025
—
5
Clearance between 2nd, 3rd clutch bearing and case (front)
160
0 -0.025
-0.012 -0.052
-0.052 – 0.013
—
6
Clearance between 2nd, 3rd clutch bearing and cage (rear)
160
0 -0.025
-0.017 -0.052
-0.052 – 0.008
—
7
Clearance between differential lock clutch bearing and case (front)
230
0 -0.030
-0.014 -0.060
-0.060 – 0.016
—
8
Clearance between differential lock clutch bearing and cage (rear)
230
0 -0.030
-0.014 -0.060
-0.060 – 0.016
—
9
Clearance between front output bearing and cage
140
0 -0.018
+0.018 -0.007
-0.007 – 0.036
—
10
Clearance between front output bearing and spacer
90
+0.045 +0.023
0 -0.020
-0.065 – -0.023
—
11
Width of the input shaft seal ring groove
12
Standard size
Tolerance
Repair limit
2.5
+0.18 +0.10
2.7
Width of the input shaft seal ring groove
3.2
+0.076 0
3.5
Inner diameter of seal ring contact surface of input, upper and lower shafts (rear)
50
+0.050 0
50.1
Width of seal ring grooves of input, upper and lower shafts (rear)
3.2
+0.076 0
3.5
Inner diameter of the seal ring contact surface of the sleeve
140
+0.040 0
140.1
Width of the sleeve seal ring groove
4.5
+0.15 +0.10
5.0
Inner diameter of the seal ring contact surface of the front 15 output shaft
85
+0.035 0
85.1
Width of the front output shaft seal ring groove
3.0
+0.15 +0.10
3.3
Outer diameter of the oil seal 16 contact surface of the rear coupling
120
0 -0.087
119.8
13
14
HM400-2
Replace
23
SEN00518-01
10 Structure, function and maintenance standard
FL, R clutch
A: R clutch oil port B: FL clutch oil port
C: Lubrication oil port D: Lockup clutch oil port
1. 2. 3. 4.
5. FL, R cylinder 6. R clutch 7. R clutch gear (Number of teeth: 25)
Input shaft Input gear (Number of teeth: 43) FL clutch gear (Number of teeth: 33) FL clutch
Unit: mm No.
8
9
Check item
Criteria
Clearance between FL, R shaft and bearing (front)
Clearance between FL, R shaft and bearing (rear)
10 Clutch plate
11 Clutch disc
Tolerance
Standard size
Remedy
Shaft
Hole
Standard clearance
Clearance limit
75
+0.071 +0.061
0 -0.015
-0.086 – -0.061
—
75
+0.071 +0.061
0 -0.015
-0.086 – -0.061
—
Standard size
Tolerance
Repair limit
Thickness
2.0
±0.05
1.8
Strain
—
0.05
0.15
Thickness
3.2
±0.08
2.75
Strain
—
0.10
0.25
1,270 N {130 kg}
115 N {11.7 kg}
1,090 N {111 kg}
12
Wave spring load [Test height: 3.8 mm]
13
Thickness of thrust washer (FL clutch)
4
±0.2
3.7
14
Thickness of thrust washer (R clutch)
4
±0.2
3.7
24
Replace
HM400-2
10 Structure, function and maintenance standard
SEN00518-01
FH, 1st clutch
A: 1st clutch oil port B: FH clutch oil port
C: Lubrication oil port
1. 2. 3. 4.
5. 1st clutch gear (Number of teeth: 30) 6. Upper gear (Number of teeth: 49) 7. Upper shaft
FH clutch gear (Number of teeth: 57) FH clutch FH, 1st cylinder (Number of teeth: 67) 1st clutch
Unit: mm No.
8
9
Check item
Criteria
Clearance between FH, 1st shaft and bearing (front)
Clearance between FH, 1st shaft and bearing (rear)
10 Clutch plate
11 Clutch disc
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
75
+0.071 +0.051
0 -0.015
-0.086 – -0.051
—
75
+0.071 +0.051
0 -0.015
-0.086 – -0.051
—
Standard size
Standard size
Tolerance
Repair limit
Thickness
2.0
±0.05
1.8
Strain
—
0.05
0.15
Thickness
3.2
±0.08
2.75
Strain
—
0.10
0.25
1,270 N {130 kg}
115 N {11.7 kg}
1,090 N {111 kg}
12
Wave spring load [Test height: 3.8 mm]
13
Thickness of thrust washer (FH clutch)
4
±0.2
3.7
14
Thickness of thrust washer (1st clutch)
4
±0.2
3.7
HM400-2
Replace
25
SEN00518-01
10 Structure, function and maintenance standard
2nd, 3rd clutch
A: 3rd clutch oil port B: 2nd clutch oil port
C: Lubrication oil port
1. 2. 3. 4.
5. 2nd clutch gear (Number of teeth: 43) 6: Lower gear (Number of teeth: 54) 7. Lower shaft
3rd clutch gear (Number of teeth: 25) 3rd clutch 2nd, 3rd cylinder (Number of teeth: 62) 2nd clutch
Unit: mm No.
8
9
Check item
Criteria
Clearance between 2nd, 3rd shaft and bearing (front) Clearance between 2nd, 3rd shaft and bearing (rear)
10 Clutch plate
11 Clutch disc
Tolerance
Standard size
Remedy
Shaft
Hole
Standard clearance
Clearance limit
75
+0.071 +0.051
0 -0.015
-0.086 – -0.051
—
75
+0.071 +0.051
0 -0.015
-0.086 – -0.051
—
Standard size
Tolerance
Repair limit
Thickness
2.0
±0.05
1.8
Strain
—
0.05
0.15
Thickness
3.2
±0.08
2.75
Strain
—
0.10
0.25
1,270 N {130 kg}
115 N {11.7 kg}
1,090 N {111 kg}
12
Wave spring load [Test height: 3.8 mm]
13
Thickness of thrust washer (3rd clutch)
4
±0.2
3.7
14
Thickness of thrust washer (2nd clutch)
4
±0.2
3.7
26
Replace
HM400-2
10 Structure, function and maintenance standard
HM400-2
SEN00518-01
27
SEN00518-01
10 Structure, function and maintenance standard
Differential lock clutch
A: Lubrication oil port 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
28
Front output shaft Clutch hub Housing Differential lock clutch Sun gear (Number of teeth: 40) Planetary gear (Number of teeth: 20) Ring gear (Number of teeth: 80) Carrier Output gear (Number of teeth: 78) Rear output shaft
HM400-2
10 Structure, function and maintenance standard
SEN00518-01
Unit: mm No.
Check item
Criteria Tolerance
Standard size
Clearance between 11 housing and bearing
Remedy
Shaft
Hole
Standard clearance
Clearance limit
170
+0.052 +0.027
0 -0.025
-0.077 – -0.027
—
12
Clearance between output gear and bearing
170
+0.065 +0.040
0 -0.025
-0.090 – -0.040
—
13
Clearance between housing and bearing
130
0 -0.018
-0.012 -0.052
-0.052 – 0.006
—
14
Clearance between front output shaft and bearing
75
+0.012 -0.007
0 -0.015
-0.027 – 0.007
—
15
Clearance between output gear and bearing (front)
150
0 -0.015
-0.050 -0.090
-0.090 – -0.035
—
16
Clearance between output gear and bearing (rear)
150
0 -0.015
-0.028 -0.068
-0.068 – -0.013
—
17
Clearance between rear output shaft and bearing
100
+0.028 +0.013
0 -0.015
-0.043 – -0.013
—
Replace
Standard size
Tolerance
Repair limit
Thickness
2.0
±0.05
1.8
Strain
—
0.05
0.15
Thickness
3.2
±0.10
2.75
Strain
—
0.20
0.25
1,480 N {151 kg}
440 N {45 kg}
1,260 N {128 kg}
Inner diameter of the seal ring contact surface 21 of the carrier
70
+0.030 0
70.1
Width of the front output shaft seal ring groove
2.1
±0.05
2.3
18 Clutch plate
19 Clutch disc 20
Wave spring load [Test height: 3.2 mm]
HM400-2
29
SEN00518-01
10 Structure, function and maintenance standard
Operation of the disc clutch When clutch is “engaged“ (fixed)
Clutch “disengaged“ (released)
•
•
• • •
30
The oil sent from the ECMV flows through the oil passage of shaft (1), is pressure-fed to the back side of piston (2), and pushes piston (2) to the right. Piston (2) compresses plates (3) and discs (4) and the rotation of discs (4) is stopped by the frictional force. As the internal teeth of disc (4) are meshed with the clutch gear (5), shaft (1) and cluch gear (5) transfer the power as a unit. The oil is drained from oil drain hole (6), but the drain amount is less than the amount of oil supplied, so there is no influence on the actuation of the clutch.
• • •
When the oil sent from the ECMV is shut off, pressure of the oil acting on the back face of piston (2) goes down. Piston (2) is pushed back to the left by the tension of wave spring (7). The friction force between plates (3) and discs (4) is eliminated and shaft (1) and clutch gear (5) are released. When the clutch is released, the oil in the back side of piston is drained by the centrifugal force through oil drain hole (6) to prevent the clutch from being partially applied.
a Oil drain hole (6) forms part of the structure of only the 2nd, 3rd and differential lock clutches.
HM400-2
10 Structure, function and maintenance standard
HM400-2
SEN00518-01
31
SEN00518-01
10 Structure, function and maintenance standard
Forward 1st speed
32
HM400-2
10 Structure, function and maintenance standard
SEN00518-01
FL clutch (4) and 1st clutch (12) are fixed hydraulically. The power from the torque converter O Input shaft (1) O FL and R cylinders (2) O FL clutch (4) O FL clutch gear (6) O FH and 1st cylinders (9) O 1st clutch (12) O 1st clutch gear (13) O 2nd and 3rd cylinders (15) O Lower gear (20) O Output gear (21) (The operation when differential lock is turned "OFF" is explained below) O Carrier (22) O Planetary gear (26) O Sun gear (27) O Front output shaft (29)
Ring gear (28) O Rear output shaft (30)
a If the differential lock is "on", see Forward 2nd speed.
HM400-2
33
SEN00518-01
10 Structure, function and maintenance standard
Forward 2nd speed
34
HM400-2
10 Structure, function and maintenance standard
SEN00518-01
FH clutch (11) and 1st clutch (12) are fixed hydraulically. The power from the torque converter O Input shaft (1) O Input gear (3) O FH clutch gear (10) O FH clutch (11) O FH and 1st cylinders (9) O 1st clutch (12) O 1st clutch gear (13) O 2nd and 3rd cylinders (15) O Lower gear (20) O Output gear (21) (The operation when differential lock is turned "ON" is explained below) O Carrier (22) O Front housing (23) O Differential lock clutch (24) O Clutch hub (25) O Front output shaft (29)
Planetary gear (26) O Ring gear (28) O Rear output shaft (30)
a If the differential lock is "off", see Forward 1st speed.
HM400-2
35
SEN00518-01
10 Structure, function and maintenance standard
Forward 3rd speed
36
HM400-2
10 Structure, function and maintenance standard
SEN00518-01
FL clutch (4) and 2nd clutch (18) are fixed hydraulically. The power from the torque converter O Input shaft (1) O FL and R cylinders (2) O FL clutch (4) O FL clutch gear (6) O FH and 1st cylinders (9) O Upper gear (14) O 2nd clutch gear (16) O 2nd clutch (18) O 2nd and 3rd cylinders (15) O Lower gear (20) O Output gear (21) (The operation when differential lock is turned "OFF" is explained below) O Carrier (22) O Planetary gear (26) O Sun gear (27) O Front output shaft (29)
Ring gear (28) O Rear output shaft (30)
a If the differential lock is "on", see Forward 2nd speed.
HM400-2
37
SEN00518-01
10 Structure, function and maintenance standard
Forward 4th speed
38
HM400-2
10 Structure, function and maintenance standard
SEN00518-01
FH clutch (11) and 2nd clutch (18) are fixed hydraulically. The power from the torque converter O Input shaft (1) O Input gear (3) O FH clutch gear (10) O FH clutch (11) O FH and 1st cylinders (9) O Upper gear (14) O 2nd clutch gear (16) O 2nd clutch (18) O 2nd and 3rd cylinders (15) O Lower gear (20) O Output gear (21) (The operation when differential lock is turned "ON" is explained below) O Carrier (22) O Front housing (23) O Differential lock clutch (24) O Clutch hub (25) O Front output shaft (29)
Planetary gear (26) O Ring gear (28) O Rear output shaft (30)
a If the differential lock is "off", see Forward 1st speed.
HM400-2
39
SEN00518-01
10 Structure, function and maintenance standard
Forward 5th speed
40
HM400-2
10 Structure, function and maintenance standard
SEN00518-01
FL clutch (4) and 3rd clutch (19) are fixed hydraulically. The power from the torque converter O Input shaft (1) O FL and R cylinders (2) O FL clutch (4) O FL clutch gear (6) O FH and 1st cylinders (9) O 3rd clutch gear (17) O 3rd clutch (19) O 2nd and 3rd cylinders (15) O Lower gear (20) O Output gear (21) (The operation when differential lock is turned "OFF" is explained below) O Carrier (22) O Planetary gear (26) O Sun gear (27) O Front output shaft (29)
Ring gear (28) O Rear output shaft (30)
a If the differential lock is "on", see Forward 2nd speed.
HM400-2
41
SEN00518-01
10 Structure, function and maintenance standard
Forward 6th speed
42
HM400-2
10 Structure, function and maintenance standard
SEN00518-01
FH clutch (11) and 3rd clutch (19) are fixed hydraulically. The power from the torque converter O Input shaft (1) O Input gear (3) O FH clutch gear (10) O FH clutch (11) O FH and 1st cylinders (9) O 3rd clutch gear (17) O 3rd clutch (19) O 2nd and 3rd cylinders (15) O Lower gear (20) O Output gear (21) (The operation when differential lock is turned "ON" is explained below) O Carrier (22) O Front housing (23) O Differential lock clutch (24) O Clutch hub (25) O Front output shaft (29)
Planetary gear (26) O Ring gear (28) O Rear output shaft (30)
a If the differential lock is "off", see Forward 1st speed.
HM400-2
43
SEN00518-01
10 Structure, function and maintenance standard
Reverse 1st speed
44
HM400-2
10 Structure, function and maintenance standard
SEN00518-01
R clutch (5) and 1st clutch (12) are fixed hydraulically. The power from the torque converter O Input shaft (1) O FL and R cylinders (2) O R clutch (5) O R clutch gear (7) O R idler gear (8) (Output rotation is reversed through R idler gear (8).) O Upper gear (14) O FH and 1st cylinders (9) O 1st clutch (12) O 1st clutch gear (13) O 2nd and 3rd cylinders (15) O Lower gear (20) O Output gear (21) (The operation when differential lock is turned "OFF" is explained below) O Carrier (22) O Planetary gear (26) O Sun gear (27) Ring gear (28) O O Front output shaft (29) Rear output shaft (30) a If the differential lock is "on", see Forward 2nd speed.
HM400-2
45
SEN00518-01
Transmission control valve
10 Structure, function and maintenance standard
1
A: B: C: D: E: F: G: H:
Lockup clutch oil pressure pickup port 2nd clutch oil pressure pickup port 3rd clutch oil pressure pickup port R clutch oil pressure pickup port FL clutch oil pressure pickup port 1st clutch oil pressure pickup port FH clutch oil pressure pickup port Differential lock clutch oil pressure pickup port
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Lockup clutch ECMV 2nd clutch ECMV 3rd clutch ECMV R clutch ECMV FL clutch ECMV Breather 1st clutch ECMV FH clutch ECMV Differential lock clutch ECMV Seat Last chance filter
46
Operation table of ECMV ECMV sgear FL FH R 1st speed F1 Q Q F2 Q Q F3 Q F4 Q F5 Q F6 Q R1 Q Q R2 Q N L/U: lockup clutch ECMV D/L: differential lock clutch ECMV
2nd
3rd
L/U
D/L Q Q Q
Q Q
Q Q Q Q Q Q
Q Q
Q
Q Q Q
Outline • Lockup clutch ECMV operates when traveling forward at the speed higher than the set speed of transmission controller. • Differential lock clutch ECMV operates in the 3rd or lower gear speeds. HM400-2
10 Structure, function and maintenance standard
ECMV
SEN00518-01
1
a ECMV: Abbreviation for Electronic Control Modulation Valve For FL, FH, R, 1st, 2nd, 3rd clutches a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch P: From pump T: Drain Dr: Drain P1: Clutch oil pressure pickup port 1. 2. 3. 4. 5. 6. 7.
*1: Operated clutches
Stamp of the nameplates
FL,FH,R,1st
A*******
2nd,3rd
E*******
Fill switch connector Proportional solenoid connector Pressure detection valve Fill switch Proportional solenoid Pressure control valve Nameplate (*1)
HM400-2
47
SEN00518-01
Outline of ECMV • The ECMV consists of 1 pressure control valve and 1 fill switch. • Pressure control valve This valve receives the current sent from the transmission controller with a proportional solenoid, and then converts it into oil pressure. • Fill switch This switch is detects that the clutch is filled with oil and has the following functions. 1. Outputs a signal (a fill signal) to the controller to notify that filling is completed when the clutch is filled with oil. 2. Keeps outputting signals (fill signals) to the controller to notify whether oil pressure is applied or not while oil pressure is applied to the clutch.
10 Structure, function and maintenance standard
ECMV and proportional solenoid • For each ECMV, 1 proportional solenoid is installed. The proportional solenoid generates thrust shown below according to the command current from the controller. The thrust generated by the proportional solenoid is applied to the pressure control valve spool to generate oil pressure as shown in the figure below. Accordingly, the thrust is changed by controlling the command current to operate the pressure control valve to control the flow and pressure of the oil. Current - propulsion force characteristics of proportional solenoid
Propulsion force - hydraulic pressure characteristics of proportional solenoid
Range A: Before shifting gear (When draining) Range B: During filling Range C: Pressure regulation Range D: During filling (During triggering) Point E: Start of filling Point F: Finish of filling
ECMV and fill switch • For each ECMV, 1 fill switch is installed. If the clutch is filled with oil, the fill switch is turned “on“ by the pressure of the clutch. The oil pressure is build up according to this signal.
a The logic is so made that the controller will not recognize completion of filling even if the fill switch is turned “on“ during triggering (Range D).
48
HM400-2
10 Structure, function and maintenance standard
Operation of ECMV • ECMV is controlled with the command current sent from the controller to the proportional solenoid and the fill switch output signal. The relationship between the proportional solenoid command current of ECMV, clutch input pressure, and fill switch output signal is shown below.
SEN00518-01
Before shifting gear (when draining) (Range A in chart)
•
Range A: Before shifting gear (When draining) Range B: During filling Range C: Pressure regulation Range D: During filling (During triggering) Point E: Start of filling Point F: Finish of filling
Under the condition where any current is not sent to the proportional solenoid (1), pressure control valve (3) drains the oil from clutch port (A) through drain port (T). Also at this time, fill switch (5) is turned “off“ because oil pressure is not applied to pressure detection valve (4).
a The logic is so made that the controller will not recognize completion of filling even if the fill switch is turned “on“ during triggering (Range D).
HM400-2
49
SEN00518-01
10 Structure, function and maintenance standard
During filling (Range B in chart)
Pressure regulation (Range C in chart)
•
•
50
If current is applied to proportional solenoid (1) with no oil in the clutch, the oil pressure force balanced with the solenoid force is applied to chamber (B) and pushes pressure control valve (3) to the left.This opens pump port (P) and clutch port (A) to feed oil in the clutch. When the clutch is filled with oil, pressure detection valve (4) actuates to turn “on“ fill switch (5).
If current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current. This thrust of the solenoid is balanced with the sum of the thrust generated by the oil pressure in clutch port and the tension of pressure control valve spring (2), and then the pressure is settled.
HM400-2
10 Structure, function and maintenance standard
SEN00518-01
For lockup, differential lock clutch a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch P: From pump T: Drain Dr: Drain P1: Clutch oil pressure pickup port 1. 2. 3. 4. 5.
*1: Operated clutches Lockup, differential lock
Stamp of the nameplates K*******
Proportional solenoid connector Sleeve Proportional solenoid Pressure control valve Nameplate (*1)
HM400-2
51
SEN00518-01
Outline ECMV for lockup clutch • This valve acts to set the lockup clutch oil pressure to the set pressure, and also to switch the lockup clutch. It forms a modulation wave pattern, so the lockup clutch is engaged smoothly to reduce the shock when shifting gear. In addition, it prevents generation of peak torque in the power train. As a result, it provides a comfortable ride for the operator and greatly increases the durability of the power train. Torque converter travel o direct travel
10 Structure, function and maintenance standard
ECMV for differential lock clutch • For each ECMV, 1 proportional solenoid is installed. The proportional solenoid generates thrust shown below according to the command current from the controller. The thrust generated by the proportional solenoid is applied to the pressure control valve spool to generate oil pressure as shown in the figure below. Accordingly, the thrust is changed by controlling the command current to operate the pressure control valve to control the flow and pressure of the oil. Current - propulsion force characteristics of proportional solenoid
When shifting gear (direct travel) Propulsion force - hydraulic pressure characteristics of proportional solenoid
52
HM400-2
10 Structure, function and maintenance standard
SEN00518-01
Operation Clutch “disengaged“ (released)
When clutch is “engaged“ (fixed)
•
•
Under the condition where any current is not sent to the proportional solenoid (1), pressure control valve (3) drains the oil from clutch port (A) through drain port (T).
•
HM400-2
If current is applied to proportional solenoid (1), the oil pressure force balanced with the solenoid force is applied to chamber (B) and pushes pressure control valve (3) to the left. As a result, the circuit between pump port (P) and clutch port (A) opens, and oil starts to fill the clutch. When the clutch is filled with oil, the propulsion force of the solenoid, the propulsion force generated by the oil pressure in the clutch port, and the tension of pressure control valve spring (2) come into balance, and the pressure is adjusted.
53
SEN00518-01
10 Structure, function and maintenance standard
Main relief, torque converter relief valve
1
Unit: mm No.
1
2
Check item
Clearance between the main relief valve and the valve body
Clearance between the torque converter relief valve and the valve body
Criteria Tolerance Shaft
Hole
Standard clearance
Clearance limit
28
-0.035 -0.045
+0.013 0
0.035 – 0.058
0.078
22
-0.035 -0.045
+0.013 0
0.035 – 0.058
0.078
Standard size
Standard size 3
Main relief valve spring (outside)
Remedy
Repair limit
Free length
Installed length
Installed load
Free length
Installed load
108
79.5
275 N {28.0 kg}
104.8
261 N {26.6 kg}
4
Main relief valve spring (inside)
108
79.5
326 N {33.2 kg}
104.8
309 N {31.5 kg}
5
Torque converter relief valve spring
50
41
173 N {17.6 kg}
48.5
164 N {16.7 kg}
6. 7. 8. 9. 10.
54
Body Piston Torque converter relief valve Piston Main relief valve
A: B: C: D: E: P1: P2:
Replace
Drain (Torque converter relief) Drain From pump Drain To torque converter Main relief oil pressure pickup port Torque converter relief oil pressure pickup port HM400-2
10 Structure, function and maintenance standard
Outline
SEN00518-01
Operation of main relief valve
Torque converter relief valve The torque converter relief valve maintains the oil pressure in the torque converter inlet circuit always below the set pressure in order to protect the torque converter from abnormally high pressure. Set pressure: 0.91 MPa {9.31 kg/cm2} (Cracking pressure) Main relief valve The main relief valve is keeping each oil pressure of the transmission and the brake below the set pressure. Set pressure: 2.60 MPa {26.5 kg/cm2} (Engine at rated rotation)
•
The oil from the hydraulic pump flows through the filter, port (C) of the relief valve, and orifice (a) of main relief valve (1) to chamber (F).
•
When the oil pressure in the circuit exceeds the set pressure, the oil in chamber (F) pushes piston (2), the reaction force of which moves spool (1) to the left to open port (C) and port(E). Then the oil from the pump flows through port (E) into the torque converter.
Operation Operation of torque converter relief valve
•
•
The oil from the main relief valve flows through port (E) to the torque converter, and at the same time, also flows through orifice (b) of torque converter relief valve (3) to chamber (G). When the oil pressure on the torque converter exceeds the set pressure, the oil in chamber (G) pushes piston (4), the reaction force of which moves torque converter relief valve (3) to the right to open port (E) and port (A). Then the oil in port (E) is drained from port (A) to the oil tank.
HM400-2
55
SEN00518-01
10 Structure, function and maintenance standard
HM400-2 Articulated dump truck Form No. SEN00518-01
© 2007 KOMATSU All Rights Reserved Printed in Japan 07-07 (02)
56
HM400-2
SEN00519-02
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
10 Structure, function and maintenance standard
1
Power train, Part 2 Drive shaft....................................................................................................................................................... 2 Axle ................................................................................................................................................................. 6 Differential ..................................................................................................................................................... 10 Limited slip differential .................................................................................................................................. 22 Final drive ..................................................................................................................................................... 26
HM400-2
1
SEN00519-02
10 Structure, function and maintenance standard
Drive shaft
1. Drive shaft (right) 2. Front drive shaft 3. Drive shaft (left) k
Precautions for tightening torque of spider mounting bolts
1. There are 2 types (new and old types) of the spider mounting bolts which have the same part No. a Different tightening torques are specified for the new bolt and old bolt. 2. Since the new and old bolts cannot be distinguished from each other by appearances, the existing spider mounting bolts cannot be reused. a The specified torque for the new bolt is lower than that for the old bolt. Accordingly, if the new bolt is tightened to the torque for the old bolt, it may be broken during operation and the machine may not able to travel.
2
1
4. Center drive shaft 5. Rear drive shaft (front) 6. Rear drive shaft (rear) 3. For the above reason, when "retightening", "removing" or "installing", be sure to replace the existing bolts with new bolts and tighten them to the torque specified for them. a A new part No. is set for the new bolt. For the new part No., see the parts book. 3 * Spider mounting bolts (A, C, J): 107 – 127 Nm {10.9 – 13 kgm} 3 Shaft mounting bolts (B, D, K): 98 – 123 Nm {10 – 12.5 kgm} 3 * Spider mounting bolts (E, G): 215 – 255 Nm {21.9 – 26 kgm} 3 Shaft mounting bolts (F, H): 157 – 196 Nm {16 – 20 kgm} * Bolts of new tightening torque (New bolt values).
HM400-2
10 Structure, function and maintenance standard
SEN00519-02
Front drive shaft
Left and right drive shaft
HM400-2
3
SEN00519-02
10 Structure, function and maintenance standard
Center drive shaft
Rear drive shaft (front)
4
HM400-2
10 Structure, function and maintenance standard
SEN00519-02
Rear drive shaft (rear)
Outline • The power from the engine goes from the output shaft through front drive shaft (2), the transmission, and the front axle, and is transmitted by left and right drive shafts (1) and (3). 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.
HM400-2
5
SEN00519-02
Axle
10 Structure, function and maintenance standard
1
Front
1. 2. 3. 4.
6
Drive shaft Front differential Brake Final drive
HM400-2
10 Structure, function and maintenance standard
SEN00519-02
Center
1. 2. 3. 4. 5. 6.
Center axle Center differential Brake Final drive Oil filler port / level plug Drain plug
HM400-2
7
SEN00519-02
10 Structure, function and maintenance standard
Rear
1. 2. 3. 4. 5. 6.
8
Drain plug Rear axle Oil filler port / level plug Rear differential Brake Final drive
HM400-2
10 Structure, function and maintenance standard
HM400-2
SEN00519-02
9
SEN00519-02
10 Structure, function and maintenance standard
Differential
1
Front
1. 2. 3. 4.
10
Bevel gear (No. of teeth: 41) Bevel pinion (No. of teeth: 12) Differential case Side gear (No. of teeth: 24)
5. 6. 7. 8.
Pinion gear (No. of teeth: 14) Shaft Plate Disc
HM400-2
10 Structure, function and maintenance standard
SEN00519-02
Unit: mm No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
95
0 -0.087
94.9
9
Wear of coupling oil seal contact surface
10
Wear of coupling oil seal contact surface
110
0 -0.087
109.9
11
Thickness of side gear thrust washer
4
± 0.05
3.5
12
Thickness of disc
3.5
± 0.1
3.1
13
Thickness of plate
2.1
± 0.1
1.9
14
Backlash between bevel gear and pinion
HM400-2
0.42 – 0.65 (in circumferential direction at bevel gear outside diameter)
Repair or replace
Replace
Adjust
11
SEN00519-02
10 Structure, function and maintenance standard
Center
1. 2. 3. 4.
12
Disc Plate Pinion gear (No. of teeth: 14) Differential case
5. 6. 7. 8.
Shaft Side gear (No. of teeth: 24) Bevel gear (No. of teeth: 41) Bevel pinion (No. of teeth: 12) HM400-2
10 Structure, function and maintenance standard
SEN00519-02
Unit: mm No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
95
0 -0.087
94.9
4
± 0.05
3.5
9
Wear of coupling oil seal contact surface
10
Thickness of side gear thrust washer
11
Thickness of disc
3.5
± 0.1
3.1
12
Thickness of plate
2.1
± 0.1
1.9
13
Backlash between bevel gear and pinion
HM400-2
0.42 – 0.65 (in circumferential direction at bevel gear outside diameter)
Repair or replace
Replace
Adjust
13
SEN00519-02
10 Structure, function and maintenance standard
Rear
1. 2. 3. 4. 5. 6. 7. 8.
14
Pinion gear (No. of teeth: 14) Shaft Differential case Plate Disc Side gear (No. of teeth: 24) Bevel gear (No. of teeth: 41) Bevel pinion (No. of teeth: 12)
HM400-2
10 Structure, function and maintenance standard
SEN00519-02
Unit: mm No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
90
0 -0.087
89.9
4
± 0.05
3.5
9
Wear of coupling oil seal contact surface
10
Thickness of side gear thrust washer
11
Thickness of disc
3.5
± 0.1
3.1
12
Thickness of plate
2.1
± 0.1
1.9
13
Backlash between bevel gear and pinion
HM400-2
0.42 – 0.65 (in circumferential direction at bevel gear outside diameter)
Repair or replace
Replace
Adjust
15
SEN00519-02
10 Structure, function and maintenance standard
(Machine with limited slip differential) Front
1. 2. 3. 4. 5.
16
Bevel gear (No. of teeth: 41) Bevel pinion (No. of teeth: 12) Limited slip differential Side gear (No. of teeth: 24) Pinion gear (No. of teeth: 14)
6. 7. 8. 9.
Shaft Shaft Disc Plate
HM400-2
10 Structure, function and maintenance standard
SEN00519-02
Unit: mm No.
Check item
10
Wear of coupling oil seal contact surface
11
Wear of coupling oil seal contact surface
12
Backlash between bevel gear and pinion
HM400-2
Criteria
Remedy
Standard size
Tolerance
Repair limit
95
0 -0.087
94.9
110
0 -0.087
109.9
0.42 – 0.65 (in circumferential direction at bevel gear outside diameter)
Repair or replace
Adjust
17
SEN00519-02
10 Structure, function and maintenance standard
Center
1. 2. 3. 4.
18
Bevel pinion (No. of teeth: 13) Disc Plate Pinion gear (No. of teeth: 14)
5. 6. 7. 8.
Limited slip differential Bevel gear (No. of teeth: 42) Side gear (No. of teeth: 24) Shaft
HM400-2
10 Structure, function and maintenance standard
SEN00519-02
Unit: mm No.
Check item
9
Wear of coupling oil seal contact surface
10
Backlash between bevel gear and pinion
HM400-2
Criteria
Remedy
Standard size
Tolerance
Repair limit
95
0 -0.087
94.9
0.42 – 0.65 (in circumferential direction at bevel gear outside diameter)
Repair or replace Adjust
19
SEN00519-02
10 Structure, function and maintenance standard
Rear
1. 2. 3. 4. 5. 6. 7. 8.
20
Bevel pinion (No. of teeth: 12) Plate Disc Bevel gear (No. of teeth: 41) Shaft Limited slip differential Pinion gear (No. of teeth: 14) Side gear (No. of teeth: 24)
HM400-2
10 Structure, function and maintenance standard
SEN00519-02
Unit: mm No.
Check item
9
Wear of coupling oil seal contact surface
10
Backlash between bevel gear and pinion
Criteria Standard size
Tolerance
Repair limit
90
0 -0.087
89.9
0.42 – 0.65 (in circumferential direction at bevel gear outside diameter)
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 90f, 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 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.
HM400-2
Remedy Repair or replace Adjust
When turning • When the machine is turned, the speed that the wheels turn on the left and right sides is different, so pinion gear (6) and side gear (3) inside the differential rotate according to the difference in the turning speed on the left and right sides, and transmit the power of differential case (2) to the left and right shafts.
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 resistance 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).
21
SEN00519-02
Limited slip differential
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
22
10 Structure, function and maintenance standard
1
Washer Disc Plate Bevel gear Pressure ring Side gear Pinion gear Shaft Case Cover Shaft
HM400-2
10 Structure, function and maintenance standard
SEN00519-02
Unit: mm No.
Check item
Criteria Standard size
1
Plate thickness
3.4 3.5
Tolerance
Repair limit
±0.03
3.3
+0.04 –0.03
3.55
2
Disc thickness
3
Clearance between disc and plate (Total on both sides)
4
Washer thickness
5
End play of side gear in axial direction (Each side)
0.2 – 0.4
6
Backlash between case and plate
0 – 0.4
7
Backlash between side gear and disc
0.13 – 0.36
HM400-2
3.6
Remedy
0.2 – 0.75 4 4.1
Replace ±0.05
3.8
23
SEN00519-02
10 Structure, function and maintenance standard
Operation of limited slip differential The power transmitted from the transmission goes from bevel gear (4) to case (9), pressure ring (5), shaft (8), pinion gear (7), side gear (6), and is then divided and sent to left and right shafts (11). A brake mechanism consisting of disc (2) and plate (3) is assembled at the rear face of side gear (6), and the brake torque is generated in proportion to the torque transmitted from pressure ring (5) to shaft (8). In order for this brake torque to act to suppress the 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 suppressed.
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.
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 uniformly to the left and right by the limited slip differential. Under these conditions, the limit for wheel slip for the left and right wheels is the same, so even if the power from the transmission exceeds the wheel slip limit, the wheels on both sides slip and the differential is not actuated. No load is applied to the brake at the rear surface of the side gear.
24
HM400-2
10 Structure, function and maintenance standard
SEN00519-02
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 surface.
•
The power from the transmission is divided uniformly 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 supplied 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 actuated.
Difference in wheel drive force for each type of differential when wheel on one side is slipping
Wheel drive force (taken as 1 for wheel that is slipping) Slipping wheel
Locked wheel
Total (proportional)
Limited slip differential
1
2.64
3.64 (1.82)
Normal differential
1
1
2 (1)
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.
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.
HM400-2
25
SEN00519-02
Final drive
10 Structure, function and maintenance standard
1
Front
1. 2. 3. 4. 5. 6. 7.
26
Axle shaft Ring gear (No. of teeth: 67) Planet gear (No. of teeth: 24) Planet carrier Sun gear (No. of teeth: 17) Drain plug Brake
HM400-2
10 Structure, function and maintenance standard
SEN00519-02
Unit: mm No.
Check item
Criteria
8
Backlash between planet gear and sun gear
0.19 – 0.43
9
Backlash between planet gear and ring gear
0.19 – 0.53
10
Curvature of drive shaft
11
Thickness of spacer
12
13
14
Remedy
Replace
Repair limit: 0.7TIR
Repair or replace
Standard size
Tolerance
Repair limit
12
± 0.1
11.5
Wear of outside diameter of portion of ring gear hab inserted into bearing
180
+0.040 +0.015
180.0
Wear of outside diameter of portion of axle tube inserted into bearing
170
Clearance between shaft (outside diameter) and bushing
Correct
Standard size 65
HM400-2
Replace
-0.030 -0.055 Tolerance
169.83
Shaft
Hole
Standard clearance
Clearance limit
0 -0.019
+0.39 +0.32
0.409 – 0.32
0.4
Replace
27
SEN00519-02
10 Structure, function and maintenance standard
Center, rear
1. 2. 3. 4.
5. Sun gear (No. of teeth: 17) 6. Drain plug 7. Brake
Axle shaft Ring gear (No. of teeth: 67) Planet gear (No. of teeth: 24) Planet carrier
Unit: mm No.
Check item
Criteria
8
Backlash between planet gear and sun gear
0.19 – 0.43
9
Backlash between planet gear and ring gear
0.19 – 0.53
10
Curvature of drive shaft
11
Thickness of spacer
12
13
28
Remedy
Replace
Repair limit: 1.5TIR
Repair or replace
Standard size
Tolerance
Repair limit
26
± 0.1
11.5
Wear of outside diameter of portion of ring gear hab inserted into bearing
180
+0.040 +0.015
180.0
Wear of outside diameter of portion of axle tube inserted into bearing
170
Replace
Correct -0.030 -0.055
169.83
HM400-2
10 Structure, function and maintenance standard
SEN00519-02
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.
HM400-2
29
SEN00519-02
10 Structure, function and maintenance standard
HM400-2 Articulated dump truck Form No. SEN00519-02
© 2008 KOMATSU All Rights Reserved Printed in Japan 01-08 (02)
30
HM400-2
SEN00520-01
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
10 Structure, function and maintenance standard
1
Steering system Steering column .............................................................................................................................................. 2
HM400-2
1
SEN00520-01
Steering column
1. 2. 3. 4. 5. 6.
2
10 Structure, function and maintenance standard
1
Steering shaft Steering column Lock lever Yoke Join shaft Steering valve
HM400-2
10 Structure, function and maintenance standard
HM400-2
SEN00520-01
3
SEN00520-01
10 Structure, function and maintenance standard
HM400-2 Articulated dump truck Form No. SEN00520-01
© 2007 KOMATSU All Rights Reserved Printed in Japan 07-07 (02)
4
HM400-2
SEN00521-02
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
10 Structure, function and maintenance standard
1
Brake system Brake piping .................................................................................................................................................... 2 Brake valve ..................................................................................................................................................... 4 Accumulator charge valve............................................................................................................................... 7 Accumulator ...................................................................................................................................................11 Slack adjuster ............................................................................................................................................... 12 Brake............................................................................................................................................................. 14 Proportional reducing valve .......................................................................................................................... 19 Brake system tank ........................................................................................................................................ 20 Parking brake................................................................................................................................................ 22 Parking brake solenoid valve ........................................................................................................................ 26
HM400-2
1
SEN00521-02
Brake piping
2
10 Structure, function and maintenance standard
1
HM400-2
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
SEN00521-02
Accumulator charge valve Shuttle valve Slack adjuster Brake filter Brake valve Brake system tank Accumulator (for front) Accumulator (for rear) Accumulator (for parking) Proportional reducing valve Parking brake solenoid valve
HM400-2
3
SEN00521-02
10 Structure, function and maintenance standard
Brake valve
1. 2. 3. 4. 5. 6.
4
Pilot piston Rod Lower cylinder Spool Upper cylinder Spool
1
A: To center brake B: To front brake T: To brake system tank PA: From center, rear accumulator PB: From front accumulator
HM400-2
10 Structure, function and maintenance standard
Operation Upper portion • When brake pedal (1) is depressed, the operating force is transmitted to spool (3) through rod (2) and spring (4). When spool (3) goes down, drain port a is closed, and the oil from the pump and accumulator flows from port (PA) to port (A) and actuates the center brake cylinder.
SEN00521-02
Applying brake when upper valve fails • Even if there is leakage of oil in the upper piping, spool (5) is moved down mechanically when pedal (1) is depressed, and the lower portion is actuated normally. The upper portion brake is not actuated. Applying brake when lower valve fails • 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 operating 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 (PB) to port (B) and actuates the front brake cylinders.
When actuation is balanced Upper portion • When oil fills the center brake cylinders and the pressure between port (PA) and port (A) becomes high, the oil entering port (H) from orifice (e) of spool (3) pushes against spring (4). It pushes up spool (3) and shuts off the circuit between port (PA) and port (A). When this happens, drain port (a) stays closed, so the oil entering the brake cylinder is held and the brake remains applied.
HM400-2
5
SEN00521-02
Lower portion • When spool (3) in the upper portion moves up and the circuit between port (PA) and port (A) is shut off, oil also fills the front brake cylinder at the same time, so the pressure in the circuit between port (PB) and port (B) rises. The oil entering port (J) from orifice (f) of spool (5) pushes up spool (5) by the same amount that spool (3) moves, and shuts off port (PB) and port (B). Drain port (b) is closed, so the oil entering the brake cylinder is held, and the brake is applied. • The pressure in the space in the upper portion is balanced with the operating force of the pedal, and the pressure in the space in the lower portion is balanced with the pressure in the space in the upper portion. When spools (3) and (5) move to the end of their stroke, the circuits between ports (PA) and (A) and between ports (PB) and (B) are fully opened, so the pressure in the space in the upper and lower portions and the pressure in the left and right brake cylinders is the same as the pressure from the pump. Therefore, up to the point where the piston moves to the end of its stroke, the effect of the brake can be adjusted by the amount that the pedal is depressed.
6
10 Structure, function and maintenance standard
Brake released Upper portion • When pedal (1) is released and the operating force is removed from the top of the spool, the back pressure from the brake cylinder and the force of the spool return spring move spool (3) up. Drain port (a) is opened and the oil from the brake cylinder flows to the brake system tank return circuit to release the center and rear brakes. Lower portion • When the pedal is released, spool (3) in the upper portion moves up. At the same time, the back pressure from the brake cylinder and the force of the spool return spring move spool (5) up. Drain port (b) is opened and the oil from the brake cylinder flows to the brake system tank return circuit to release the front brake.
HM400-2
10 Structure, function and maintenance standard
Accumulator charge valve
ACC: P: PP: T:
To accumulator From hydraulic pump To accumulator (pirot pressure) To brake tank
HM400-2
SEN00521-02
1
Function • The accumulator charge valve is actuated to maintain the oil pressure from the pump at the specified pressure and to store it in the accumulator. • 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.
7
SEN00521-02
1. Main relief valve (R3) 2. Valve body 3. Relief valve (R1)
8
10 Structure, function and maintenance standard
4. Relief valve (H1) 5. Filter 6. Filter
HM400-2
10 Structure, function and maintenance standard
Operation 1. When no oil is being supplied to accumulator (cut-out condition) • The pressure at port (B) is higher than the set pressure of the relief valve (R1), so piston (8) is forcibly pushed up by the oil pressure at port (B). Poppet (6) is opened, so port (C) and port (T) are short 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 oil tank pressure. The oil from the pump enters port (P), pushes spool (15) to the right at a low pressure equivalent to the load on spring (14). It also passes through orifices (17), (18) and (16), and flows to the oil tank.
HM400-2
SEN00521-02
2. When oil supplied to accumulator 1) Cut-in condition • When the pressure at port B is lower than the set pressure of the relief valve (R1), piston (8) is pushed back down by spring (5). Valve seat (7) and poppet (6) are brought into tight contact, and port (C) and port (T) are shut off. • The spring chamber at the right end of spool (15) is also shut off from port (T), so the pressure rises, and the pressure at port (P) also rises in the same way. • When the pressure at port (P) goes above the pressure at port (B) (accumulator pressure), the supply of oil to the accumulator starts immediately. In this case, it is decided by the size (area) of orifice (17) and the pressure difference (equivalent to the load on spring (14)) generated on both sides of the orifice. A fixed amount is supplied regardless of the engine speed.
9
SEN00521-02
2) When cut-out pressure is reached • When the pressure at port (B) (accumulator pressure) reaches the set pressure of the relief valve (R1), poppet (6) separates from valve seat (7), so an oil flow is generated and the circuit is relieved. • When the circuit is relieved, a pressure difference is generated above and below piston (8), so piston (8) moves up, poppet (6) is forcibly opened, and port (C) and port (T) are short circuited. • The spring chamber at the right end of spool (15) is connected to port (C) of the relief valve (R1), so the pressure becomes the brake oil tank pressure. • The pressure at port (P) drops in the same way to a pressure equivalent to the load on spring (14), so the supply of oil to port (B) is stopped.
10
10 Structure, function and maintenance standard
3. Main relief valve (R3) • If the pressure at port (P) (pump pressure) goes above the set pressure of the relief valve (R3), the oil from the pump pushes spring (3). Ball (11) is pushed up and the oil flows to the brake oil tank circuit, so this set the maximum pressure in the brake circuit and protects the circuit.
HM400-2
10 Structure, function and maintenance standard
Accumulator
1. 2. 3. 4.
SEN00521-02
1
Valve Top cover Cylinder Piston
Function • The accumulator is installed between the accumulator 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 Gas capacity: 4,000 cc Charging pressure: 4.4 ± 0.15MPa {45 ± 1.5kg/cm2} (at 20 °C ± 5 °C)
HM400-2
11
SEN00521-02
10 Structure, function and maintenance standard
Slack adjuster
1. 2. 3. 4. 5.
1
Breather Cylinder Check valve Spring Piston
A: Inlet port B: Outlet port Unit: mm No.
6
Check item
Clearance between body and piston
Front
Center
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
55
-0.030 -0.076
+0.074 0
0.030 – 0.150
0.25
55
-0.030 -0.076
+0.074 0
0.030 – 0.150
0.25
Standard size
7
Slack adjuster spring
Front
Center
12
Replace
Repair limit
Free length
Installed length
Installed load
Free length
Installed load
230
88
118 N {12 kg}
–
–
198
60
39.2 N {4.0 kg}
–
–
HM400-2
10 Structure, function and maintenance standard
Specifications Piston actuation oil pressure: 9.8 +9.8 kPa {0.1 +0.1 kg/cm2} +0 +0 Check valve cracking pressure: 1.74 ± 0.05 MPa {17.8 ± 0.5 kg/cm2} Check valve closing pressure: 1.09 ± 0.05 MPa {11.1 ± 0.5 kg/cm2}
SEN00521-02
•
If the brake pedal is depressed further, and the oil pressure discharged from the brake valve goes above to set pressure, check valve (3) opens and the pressure is applied to port (C) to act as the braking force. Therefore, when the brake is applied, the time lag is a fixed valve.
Function • The slack adjuster is installed in the brake oil line from the brake valve to the brake piston. It acts to keep a constant time lag when the brake is operated. Operation 1. When brake pedal is depressed • Before the brake is depressed, piston (4) is returned by the distance of stroke (S) (full stroke). When the brake pedal is depressed, the oil discharged from the brake valve flows from port (P) of the slack adjuster and is divided to left and right cylinders (2), where it moves piston (4) by stroke (S) to the left and right.
•
2. When brake pedal is released • When the brake is released, piston (4) returns because of lowering of the brake oil pressure by an amount equivalant to the oil for stroke (S), and the brake is released again. 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.
As a result, brake piston (7) moves by an amount equal to stroke (S). When this happens, the relationship between the brake piston and disc is simply that the clearance becomes 0. No braking force is generated.
HM400-2
13
SEN00521-02
Brake
10 Structure, function and maintenance standard
1
Front
1. 2. 3. 4. 5. 6. 7.
14
Stud bolt Cylinder Brake piston Disc Plate Hub gear (No. of teeth: 112) Outer gear (No. of teeth: 164)
HM400-2
10 Structure, function and maintenance standard
SEN00521-02
Unit: mm No.
Check item
Criteria
Remedy
Standard size
Repair limit
0.52 – 0.90
1.5
0.52 – 0.90
1.5
Standard size
Repair limit
2.4
2.15
Thickness of disc
5.1
4.6
5
Thickness of damper
6.9
5.1
6
Warping of disc friction surface
Standard warping
Repair limit
Max 0.45
0.7
7
Warping of plate and damper friction surface
Max 0.50
0.7
8
Assemble thickness of plate, disc and damper
Standard warping
Repair limit
56.4
51.4
1
Backlash between outer gear and plate
2
Backlash between hub gear and plate
3
Thickness of plate
4
HM400-2
Replace
15
SEN00521-02
10 Structure, function and maintenance standard
Center, rear
1. 2. 3. 4. 5. 6. 7.
16
Bolt Cylinder Brake piston Disc Plate Hub gear (No. of teeth: 112) Outer gear (No. of teeth: 164)
HM400-2
10 Structure, function and maintenance standard
SEN00521-02
Unit: mm No.
Check item
Criteria
Remedy
Standard size
Repair limit
0.52 – 0.90
1.5
0.52 – 0.90
1.5
Standard size
Repair limit
2.4
2.15
Thickness of disc
5.1
4.6
5
Thickness of damper
6.9
5.1
6
Warping of disc friction surface
Standard warping
Repair limit
Max 0.45
0.7
7
Warping of plate and damper friction surface
Max 0.50
0.7
8
Assemble thickness of plate, disc and damper
Standard warping
Repair limit
56.4
51.4
1
Backlash between outer gear and plate
2
Backlash between hub gear and plate
3
Thickness of plate
4
HM400-2
Replace
17
SEN00521-02
10 Structure, function and maintenance standard
Function • There are wet-type multiple disc brakes installed to all of the six wheels. Operations • When the brake pedal is depressed, pressure oil from the brake valve moves brake piston (3) to the right in the direction of the arrow. This presses disc (7) and plate (6) together and generates friction between the disc and plate. The wheel is rotating together with the disc, so this friction reduces the travel speed and stops the machine.
•
18
When the brake pedal is released, the pressure at the back face of brake piston (3) is released, so the piston is moved to the left in the direction of the arrow by the internal pressure, and this releases the brake.
HM400-2
10 Structure, function and maintenance standard
Proportional reducing valve
1. Filter 2. Connector 3. Solenoid assembly A: To slack adjuster P: From accumulator T: To brake system tank
HM400-2
SEN00521-02
1
Function • The proportional reducing valve is a valve used for retarder control. It is installed between the brake valve and the system tank in the brake circuit. It varies the discharge pressure of the pressure oil in accordance with the turning angle of the retarder control lever, so the retarder control can be carried out as desired.
19
SEN00521-02
Brake system tank
1. 2. 3. 4.
10 Structure, function and maintenance standard
1
Inlet tube Outlet tube Oil gauge Valve
A: From accumulator charge valve and brake valve B: To transmission C: To hydraulic pump
20
HM400-2
10 Structure, function and maintenance standard
HM400-2
SEN00521-02
21
SEN00521-02
Parking brake
1. Spring cylinder 2. Parking brake disc 3. Parking brake caliper
22
10 Structure, function and maintenance standard
1
Function • The parking brake is a disc type and is installed to the oscillation hitch. • 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 oscillation hitch. The disc is installed to the oscillation hitch shaft output coupling and rotates together with the coupling.
HM400-2
10 Structure, function and maintenance standard
SEN00521-02
Unit: mm No. 4
5
Check item Face runout of disc
Criteria
Remedy
Standard backlash
Repair limit
0.4
0.8
Thickness of disc
Repair or replace Rebuid (Thickness of disc must not be under 20 mm)
Min. 20
25
Max. 20 6
7
Thickness of pad (including thickness of plate)
Clearance between blade and brake assembly
21.5 Standard dimension of blade
Tolerance
22.3
0 -0.3
Standard dimension of brake assembly 22.3
HM400-2
Replace
11.5
Tolerance
Standard clearance
1.0 ± 0.4
Allowable clearance
1.5
Correct or replace
+0.4 -0.1
23
SEN00521-02
10 Structure, function and maintenance standard
Parking brake caliper
1. 2. 3. 4. 5.
24
Adjuster Piston Piston shaft Pad Caliper
Outline • A piston guide is installed to caliper (5). Piston (2) and piston shaft (3) are inserted, and the rotation of piston shaft (3) moves piston (2) in the axial direction to bring pad (4) into tight contact. • The adjuster (1) is joined by a spline to the spline side of piston shaft (3). Pad (4) is inserted together with caliper (5) into the caliper mounting plate and is held in position.
HM400-2
10 Structure, function and maintenance standard
SEN00521-02
Spring cylinder
1. 2. 3. 4. 5. 6.
Outer spring Inner spring Piston Cylinder Boot Rod
HM400-2
Outline • The oil pressure from the parking brake solenoid valve pushes the spring and releases the parking brake. When the engine is stopped, the parking brake is applied by springs (1) and (2), so the machine is prevented from moving.
25
SEN00521-02
Parking brake solenoid valve
1. Solenoid valve assembly 2. Relief valve 3. Block A: Outlet port P: Inlet port T: Drain port
26
10 Structure, function and maintenance standard
1
Function • The parking brake solenoid valve is installed between the secondary brake valve and parking brake. If the parking brake switch is set to "Travel", the solenoid valve is energized and the brake oil pressure is sent to the parking brake spring cylinder to release the parking brake. If the parking brake switch is set to "Park", the solenoid valve is de-energized and the brake oil pressure is relieved from the parking brake spring cylinder to operate the parking brake.
HM400-2
10 Structure, function and maintenance standard
HM400-2
SEN00521-02
27
SEN00521-02
10 Structure, function and maintenance standard
HM400-2 Articulated dump truck Form No. SEN00521-02
© 2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (02)
28
HM400-2
SEN00522-02
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
10 Structure, function and maintenance standard
1
Undercarriage and frame Suspension ..................................................................................................................................................... 2 Suspension cylinder........................................................................................................................................ 7 Oscillation hitch............................................................................................................................................... 9
HM400-2
1
SEN00522-02
Suspension
10 Structure, function and maintenance standard
1
Front
2
HM400-2
10 Structure, function and maintenance standard
1. 2. 3. 4.
SEN00522-02
Front suspension cylinder Arm Lateral rod Dust cover Unit: mm
No.
5
6
Check item
Clearance between pin and bushing
Clearance between pin and bushing
HM400-2
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
60
-0.030 -0.076
+0.046 0
0.030 – 0.122
0.3
60
-0.030 -0.076
+0.046 0
0.030 – 0.122
0.3
Replace
3
SEN00522-02
10 Structure, function and maintenance standard
Rear
4
HM400-2
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6.
SEN00522-02
Arm Equalizer bar Lateral rod (center) Spring Rear suspension Lateral rod (rear)
HM400-2
5
SEN00522-02
10 Structure, function and maintenance standard
Unit: mm No.
Check item
Criteria Tolerance Shaft
Hole
Standard clearance
Clearance limit
60
-0.030 -0.076
+0.046 0
0.030 – 0.122
0.3
8
Clearance between pin and bushing
60
-0.030 -0.076
+0.046 0
0.030 – 0.122
0.3
9
Clearance between pin and bushing
60
-0.030 -0.076
+0.046 0
0.030 – 0.122
0.3
7
Clearance between pin and bushing
Standard size
Remedy
Outline • The suspension supports the weight of the machine. It also reduces any impact caused by unevenness in the road surface and provides a comfortable ride for the operator. By ensuring that all the tires are always in contact with the road surface, it maintains the stability of the machine, and also fulfills the operating performance by ensuring that the machine can carry out acceleration, braking, and turning. • 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.
Replace
2. Center, rear suspension The center axle and rear axle are both fixed to arms. The center axle is joined to the equalizer bar through a spring, and the rear axle is joined through the rear suspension cylinder. The arm and equalizer bar oscillate in accordance with the condition of the road surface to keep the wheels in contact with the road surface. The main frame and arm are connected by a lateral rod and receive the lateral load.
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.
6
HM400-2
10 Structure, function and maintenance standard
Suspension cylinder
1. 2. 3. 4. 5. 6.
SEN00522-02
1
Oil level valve Feed valve Retainer Rod Flange Cylinder
HM400-2
7
SEN00522-02
10 Structure, function and maintenance standard
Unit: mm No.
Check item
Criteria Tolerance Shaft
Hole
Standard clearance
Clearance limit
140
-0.043 -0.106
+0.277 +0.061
0.104 – 0.383
0.4
8
Clearance between piston rod and bushing
140
-0.043 -0.106
+0.277 +0.061
0.104 – 0.383
0.7
9
Clearance between cylinder and wear ring
180
0 -0.21
+0.010 0
0 – 0.22
0.8
7
Clearance between piston rod and bushing
Standard size
Remedy
Replace
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 ball (6), and is sent to chamber (1) through only orifice (5), so the flow of oil passing through the orifice is controlled so that it is less than during retraction. In this way, the amount of oil returning to chamber (1) is restricted to provide a shock absorbing effect.
8
a 1. 2. 3. 4. 5. 6.
This drawing shows rear suspension cylinder. Oil chamber Nitrogen gas chamber Cavity Orifice Orifice Check ball
HM400-2
10 Structure, function and maintenance standard
SEN00522-02
Oscillation hitch
1. 2. 3. 4. 5. 6.
Steering cylinder Front frame Center drive shaft Rear frame Rear drive shaft (front) Pin
HM400-2
1
7. 8. 9. 10. 11. 12.
Hitch frame Disc Coupling Shaft Coupling Pin
9
SEN00522-02
10
10 Structure, function and maintenance standard
HM400-2
10 Structure, function and maintenance standard
SEN00522-02
Unit: mm No.
1
Check item
Standard shim thickness
Criteria Standard size
Tolerance Shaft
Hole
Remedy Standard clearance
Clearance limit
2 2
Standard shim thickness
1.5
3
Clearance between bushing and front frame
115
-0.036 -0.090
+0.054 0
0.036 – 0.144
–
4
Clearance between shaft and bushing
85
-0.036 -0.058
+0.054 0
0.036 – 0.112
–
5
Clearance between shaft and bearing
85
-0.036 -0.058
0 -0.020
0.016 – 0.058
–
6
Clearance between shaft and bushing
85
-0.036 -0.058
+0.054 0
0.036 – 0.112
–
7
Clearance between front frame and shaft
85
-0.036 -0.058
+0.054 0
0.036 – 0.112
–
8
Standard shim thickness
9
Clearance between front frame and pin
85
-0.036 -0.058
+0.054 0
0.036 – 0.112
–
10
Clearance between pin and bearing
85
-0.036 -0.058
0 -0.020
0.016 – 0.058
–
11
Clearance between front frame and pin
85
-0.036 -0.058
+0.054 0
0.036 – 0.112
–
12
Clearance between hitch frame and bearing
150
0 -0.018
0 -0.040
-0.040 – 0.018
–
13
Clearance between hitch frame and bearing
340
0 -0.057
0 -0.040
-0.040 – 0.057
–
14
Clearance between rear frame and bearing
460
0 -0.045
-0.017 -0.080
-0.080 – 0.028
–
15
Clearance between rear frame and bearing
435
-0.020 -0.083
+0.063 0
0.020 – 0.146
–
16
Clearance between rear frame and bearing
420
0 -0.045
-0.017 -0.080
-0.080 – 0.028
–
17
Clearance between bearing and hitch frame
300
-0.056 -0.108
0 -0.035
0.021 – 0.108
–
18
Standard shim thickness
2
Outline • The front frame and the rear frame are connected by the oscillation hitch. • Front frame (2) is connected with bearings and pins (6) and (12); rear frame (4) is connected with a spacer, retainer, and bearing. This makes it possible for the front and rear frames to articulate and oscillate.
HM400-2
Replace
3
•
In addition, the output from the transmission is transmitted from center drive shaft (3) to coupling (9). It is then transmitted from coupling (11) through the rear drive shaft (5) to the rear axle.
11
SEN00522-02
10 Structure, function and maintenance standard
HM400-2 Articulated dump truck Form No. SEN00522-02
© 2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (02)
12
HM400-2
SEN00523-02
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
10 Structure, function and maintenance standard
1
Hydraulic system Steering, hoist oil pressure piping diagram ..................................................................................................... 2 Dump body control.......................................................................................................................................... 3 Hydraulic tank and filter .................................................................................................................................. 4 Flow amp valve ............................................................................................................................................... 5 Steering valve ................................................................................................................................................. 8 Steering cylinder ........................................................................................................................................... 12 Hoist valve .................................................................................................................................................... 14 Dump control valve (EPC valve) ................................................................................................................... 20 Pilot check valve ........................................................................................................................................... 24 Hoist cylinder ................................................................................................................................................ 25 Hydraulic pump ............................................................................................................................................. 26
HM400-2
1
SEN00523-02
10 Structure, function and maintenance standard
Steering, hoist oil pressure piping diagram
1
1. Steering, hoist control pump (SDR(30)100+100+SB(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
2
HM400-2
10 Structure, function and maintenance standard
Dump body control
1. 2. 3. 4.
Dump control lever EPC valve Hoist valve Steering, hoist control pump (SDR(30)100+100+SB(1)8) 5. Body positioner sensor
HM400-2
SEN00523-02
1
Function • This control is carried out by the body position sensors. The body position sensor senses the position of the dump body and the retarder controller controls it. • The signal from the dump control lever is controlled by the retarder controller 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.
3
SEN00523-02
Hydraulic tank and filter
1. 2. 3. 4. 5. 6. 7.
4
10 Structure, function and maintenance standard
1
Hydraulic oil filter Breather Oil level gauge Drain plug Bypass valve Element Strainer
HM400-2
10 Structure, function and maintenance standard
Flow amp valve
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Valve Relief Valve Orifice Spring Pin Valve Valve Plug Valve Spool Valve body Stopper
HM400-2
CL: To steering cylinder L: To steering valve P: To steering valve PP: From steering valve HP: From hydraulic pump LS: From steering valve HT: From hoist valve T: To steering valve EF: To hoist valve R: From steering valve CR:To steering cylinder
SEN00523-02
1
Outline • The flow amp valve consists of the directional valve, amplifying stage, priority valve, relief valve, pressure control valve, and suction valve. • It amplifies the oil flow sent from ports (L) and (R) of the steering unit by the specified ratio. The amplified oil then goes from ports (CL) and (CR) of the flow amp valve and flows to the steering cylinder. The amplified oil flow is proportional to the amount the steering wheel is turned.
5
SEN00523-02
10 Structure, function and maintenance standard
Operation
Operation 1. At neutral • Port (P) of steering unit (7) is closed and the flow amp valve is closed at chamber M of pressure control valve (3). • Ports (L), (R), and (T) of steering unit (7) are connected to each other, so the oil passes through port (T) of the flow amp valve and is drained to the hydraulic tank. By connecting in this way, directional valve (6) is always held at the neutral position by the springs on both sides. For this reason, at the neutral position, the reaction or impact from the steering cylinder is not transmitted to steering unit (7).
6
•
•
For priority valve (2) also, the oil is drained from relief valve (1). Before starting, priority valve (2) is pushed strongly to the left by the spring, so in reality, port (EF) of the flow amp valve is almost closed. At the same time as the engine starts, oil flows to port (HP) of the flow amp valve and then flows to port (P) of steering unit (7). At the same time, the pilot pressure that is connected to port (PP) suddenly rises. As a result of balancing with the spring and moving to the right, port (EF) opens and the oil flows to the hoist piping.
HM400-2
10 Structure, function and maintenance standard
2. When turning • When steering unit (7) is actuated, the oil sent from port (P) of priority valve (2) passes through ports (P) and (L) of steering unit (7) and enters port (L) of directional valve (6). At the same time, oil from priority valve (2) also enters chamber (M) of pressure control valve (3). • When the oil entering directional valve (6) rises to a pressure greater than the force of the spring, it pushes the spool to the right, and enters chamber (C) of pressure control valve (3). When it rises to a pressure greater than the force of the spring in chamber (C) also, it pushes 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 steering unit (7). It then flows from port (P), goes out from port (CL) of directional valve (6), and flows from suction valve (5) to the bottom end of the steering cylinder. HM400-2
SEN00523-02
•
•
The oil at the steering cylinder head end goes out from suction valve (5). It then goes from port (CR) of directional valve (6) through check valve (4) and is drained to the hydraulic tank from port (HT) of the flow amp valve. If there are rocks on the road or the the road surface is uneven, and any abnormal external force is applied to the tires and steering cylinder, relief valves (8) and (9) of suction valve (5) open at a pressure of 29.1 MPa {285.5 kg/cm2}, so the oil passes through directional valve (6) and is drained to the hydraulic tank.
7
SEN00523-02
10 Structure, function and maintenance standard
Steering valve
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
8
Cover Drive shaft Valve body Center pin Bearing Spool Centering spring Sleeve Stator Rotor Lower cover
1
L: LS: P: R: T:
To flow amp valve To flow amp valve From flow amp valve To flow amp valve To flow amp valve
HM400-2
10 Structure, function and maintenance standard
Outline • The orbit-roll valve is connected directly to the steering wheel shaft. If the steering wheel is operated, the orbit-roll valve operates the steering valve by using the oil from the PPC pump as the pilot pressure. Then, the oil from the steering pump is sent to the right or left steering cylinder through the steering valve to change the travel direction of the machine. • The orbit-roll valve, broadly speaking, consists of the following components: rotary type spool (9) and sleeve (8), which have the function of selecting the direction, and the Girotor set (a combination of rotor (5) and stator (10)), which acts as hydraulic motor during normal steering operations, and as a hand pump (in fact, the operating force of the steering wheel is too high, so it cannot be operated) when the steering pump or engine have failed and the supply of oil is stopped.
HM400-2
SEN00523-02
Structure • Spool (9) is connected to the drive shaft of the steering wheel, and is connected to sleeve (8) by center pin (7) (this is not touching the spool when the steering wheel is at the neutral position) and centering spring (2). • Drive shaft (3) is meshed at the top with center pin (7) and forms one unit with sleeve (8). The bottom is meshed with the spline of rotor (5) of the Gerotor set. • Valve body (4) has five ports. These are connected to the pump circuit, tank circuit, steering cylinder head end, bottom end, and flow amp valve pilot end. In addition, the port at the pump end and the port at the tank end are connected by the check valve inside the body. If there is any failure in the pump or engine, this check valve acts to suck in oil directly from the tank.
9
SEN00523-02
10 Structure, function and maintenance standard
Connection between hand pump and sleeve
• •
10
The diagrams above show the connections with the sleeve ports used to connect the suction and 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 diagram above left, ports (1), (2) and (3) are the discharge ports of the Girotor set. They are connected to ports (l), (b) and (d) so the oil is sent to the cylinder. Ports (5), (6) and (7) are connected and the oil flows in from the pump. If the steering wheel is turned 90°, the condition changes to the condition shown in diagram above right. In this case, ports (1), (2) and (3) are the suction ports, and are connected to ports (i), (k) and (c). Ports (5), (6) and (7) are discharge ports, and are connected to ports (d), (f) and (h).
Suctiion / discharge port
SBW00727
•
•
In this way, the ports of the Girotor acting as delivery ports are connected to ports which are connected to the end of the steering cylinder. The ports acting as suction ports are connected to the pump circuit. Adjusting delivery in accordance with angle of steering wheel: For every 1/7 turn of the steering wheel, the inner teeth of the Girotor gear advance one position so the oil flow from the pump 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.
HM400-2
10 Structure, function and maintenance standard
SEN00523-02
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 cylinder. 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 pressure rises. To prevent this, when the turning of the steering wheel is stopped, the action of the centering spring only allows it to turn by an amount equal to the difference in angle of rotation (angle variation (a) of the sleeve and spool, so the steering wheel returns to the NEUTRAL position.
HM400-2
11
SEN00523-02
10 Structure, function and maintenance standard
Steering cylinder
1
Unit: mm No.
1
Check item
Clearance between piston rod and bushing
Criteria
Shaft
Hole
Standard clearance
70
-0.030 -0.104
+0.271 +0.075
0.105 – 0.375
0.475
0 -0.074
+0.174 +0.100
0.100 – 0.248
1.0
0 -0.074
+0.174 +0.100
0.100 – 0.248
1.0
2
Clearance between piston rod support shaft and bushing
65
3
Clearance between cylinder bottom support shaft and bushing
65
4
Cylinder bore
12
Tolerance
Standard size
Remedy Clearance limit
Replace
Standard size
Tolerance
Repair limit
120
+0.15 0
–
HM400-2
10 Structure, function and maintenance standard
HM400-2
SEN00523-02
13
SEN00523-02
10 Structure, function and maintenance standard
Hoist valve
a
14
1
ADT: Set pressure is increased or decreased by 19.6 MPa {200 kg/cm2} per turn.
HM400-2
10 Structure, function and maintenance standard
SEN00523-02
A: To hoist cylinder head B: To hoist cylinder bottom P: From steering control valve PA: From EPC valve (LOWER, FLOAT) PB: From EPC valve (RAISE) T: To tank T2: To tank 1. 2. 3. 4. 5.
Valve body Hoist spool Check valve Housing Relief valve Unit: mm
No.
Check item
Criteria
Remedy
Standard size
6
Spool return spring
Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
63.4 x 61
61
308 N {31.4 kg}
–
246 N {25.1 kg}
7
Spool return spring
47 x 36
45
340 N {34.7 kg}
–
8
Spool return spring
47.51 x 41
45.2
308 N {31.4 kg}
–
9
Spool return spring
87.63 x 52
60
1,370 N {140 kg}
–
1,100 N {112 kg}
10 Spool return spring
97.8 x 35
86
823 N {83.9 kg}
–
658 N {67.1 kg}
84.7 x 26.6
47.5
12.7 N {1.3 kg}
–
10.2 N {1.04 kg}
11 Check valve return spring
HM400-2
273 N {27.8 kg} If damaged or deformed, 246 N replace spring. {25.1 kg}
15
SEN00523-02
10 Structure, function and maintenance standard
Operation 1. When hoist valve is in "HOLD" position
•
16
The pressurized oil from the steering control valve flows in chamber (C). Since the passage to the hoist cylinder is blocked by hoist spool (2), the pressurized oil flows through chamber (D) to the tank.
•
Since the port to the hoist cylinder is blocked on both bottom side and head side, the hoist cylinder is held in the current position.
HM400-2
10 Structure, function and maintenance standard
SEN00523-02
2. When hoist valve is in "RAISE" position
• • •
If the dump control lever in the cab is set in the "RAISE" position, the pressurized oil from the EPC valve moves hoist spool (2) to the left. Accordingly, the pressurized oil flows through chamber (C), opens check valve (3), and enters chamber (A). The pressurized oil flows through chamber (A) to the bottom side of the hoist cylinder to extend the hoist cylinder and raise the body.
HM400-2
•
The pressurized oil returning from the head side flows through chambers (B) and (D) to the tank.
17
SEN00523-02
10 Structure, function and maintenance standard
3. When hoist valve is in "FLOAT" position
•
18
If the dump control lever in the cab is set in the "FLOAT" position, the pressurized oil from the EPC valve moves hoist spool (2) to the right. Then, chamber (C) is connected to chamber (D), and chambers (B) and (H) are connected to chamber (D).
•
•
The pressurized oil from the steering control valve flows through chambers (C) and (B) to the hoist cylinder. A part of it flows through chambers (C) and (D) to the steering oil cooler, too. Since the bottom side and head side of the hoist cylinder are connected by the hoist valve, the hoist cylinder is free.
HM400-2
10 Structure, function and maintenance standard
SEN00523-02
4. When hoist valve is in "LOWER" position
•
•
If the dump control lever in the cab is moved from the "FLOAT" position to the "LOWER" position, the pressurized oil from the EPC valve moves hoist spool (2) to the right further from the "FLOAT" position. Accordingly, the pressurized oil flows through chamber (C), opens check valve (3), and enters chamber (B). The pressurized oil flows through chamber (B) to the head side of the hoist cylinder to retract the hoist cylinder and lower the body.
HM400-2
• •
The pressurized oil returning from the head side of the hoist cylinder flows through chamber (A) to chamber (H). When the dump body is lowered, the output pressure of the EPC valve rises and becomes greater than the cracking pressure of the pilot check valve. As a result, the return oil from chamber (H) returns to the tank through two lines: one from chamber (D) to the tank, and the other from chamber (E) to the tank.
19
SEN00523-02
Dump control valve (EPC valve)
10 Structure, function and maintenance standard
1
Serial No.: 2001 – 2603
1. 2. 3. 4.
Manual operation button Solenoid assembly (Solenoid a) Relief valve (R) Solenoid assembly (Solenoid b)
A: To hoist valve (RAISE side) B: To hoist valve (LOWER side) P1: From hydraulic pump P2: Pick up port T1: To hydraulic tank T2: To hydraulic tank
20
Function • With the EPC valve, the oil from the hydraulic pump is controlled by the retarder controller. It is then sent to the spool of the hoist valve, and switches the pilot pressure to control the hoist valve.
HM400-2
10 Structure, function and maintenance standard
HM400-2
SEN00523-02
21
SEN00523-02
10 Structure, function and maintenance standard
Serial No.: 2604 and up
22
HM400-2
10 Structure, function and maintenance standard
1. 2. 3. 4. 5.
Manual operation button Solenoid assembly (Solenoid a) Relief valve (R) Solenoid assembly (Solenoid b) Strainer
A: B: P1: P2: T1: T2:
To hoist valve (RAISE side) To hoist valve (LOWER side) From hydraulic tank Pick up port To hydraulic tank To hydraulic tank
SEN00523-02
Function •
The EPC valve sends the oil from the hydraulic pump to the hoist valve spool to change the pilot pressure and control the hoist valve.
HM400-2
23
SEN00523-02
10 Structure, function and maintenance standard
Pilot check valve
1. 2. 3. 4. 5.
1
A: From hoist valve B: To hydraulic tank P.P: From EPC valve
Body Check valve Retainer Spring Cover
Unit: mm No.
Check item
Criteria
Remedy
Standard size 6
24
Spring
Repair limit
Free length x O.D.
Installed length
Installed load
Free length
Installed load
198.5 x 53
70
821.2 N {83.7 kg}
–
739 N {75.4 kg}
Replace spring if damaged or deformed
HM400-2
10 Structure, function and maintenance standard
SEN00523-02
Hoist cylinder
1
Unit: mm No.
1
Check item
Clearance between cylinder and bushing
Criteria Tolerance
Remedy
Shaft
Hole
Standard clearance
140
-0.043 -0.143
+0.277 +0.061
0.104 – 0.420
0.720
Standard size
Clearance limit
2
Clearance between piston rod and bushing
90
-0.036 -0.123
+0.270 +0.061
0.097 – 0.393
0.693
3
Clearance between piston rod support pin and bearing
60
–
+0.004 -0.019
–
1.0
4
Clearance between cylinder support pin and bushing
60
–
+0.004 -0.019
–
1.0
HM400-2
Replace
25
SEN00523-02
10 Structure, function and maintenance standard
Hydraulic pump
1
Steering, hoist control pump SDR(30)100+100+SB(1)8
Unit: mm No.
Check item
Criteria Model
1
Side clearance
Standard clearance
Clearance limit
0.16 – 0.20
0.24
0.10 – 0.15
0.19
0.06 – 0.13
0.20
0.06 – 0.12
0.20
SDR(30)-100 SDR(30)-100 SB(1)-8
2
Clearance between inside diameter of plain bearing and outside of diameter of gear shaft
SDR(30)-100 SDR(30)-100 SB(1)-8 Model
3
Depth for knocking in pin
SDR(30)-100 SDR(30)-100 SB(1)-8
4
–
Rotating torque of spline shaft
Discharge amount Oil: EO10-CD Oil temperature: 45–55°C
Standard size
Tolerance
Repair limit
10
0 -0.5
–
9.2
±0.3
Replace
8.7 – 20.7 Nm {0.9 – 2.1 kgm} Model
Delivery Standard Rotating pressure delivery speed {MPa amount (rpm) (kg/cm2)} (l/min)
SDR(30)-100 SDR(30)-100 SB(1)-8
26
Remedy
2,500
20.6 {210}
Delivery amount limit (l/min)
231
213.4
17.2
15.8
–
HM400-2
10 Structure, function and maintenance standard
SEN00523-02
Emergency steering pump SBL(1)21
Unit: mm No.
Check item
1
Side clearance
2
Clearance between inside diameter of plain bearing and outside of diameter of gear shaft
3
Depth for knocking in pin
4
Rotating torque of spline shaft
–
Discharge amount Oil: EO10-CD Oil temperature: 45–55°C
HM400-2
Criteria
Remedy
Standard clearance
Clearance limit
0.10 – 0.15
0.19
0.060 – 0.119
0.20
Replace
Standard size
Tolerance
Repair limit
10
0 -0.5
–
2.0 – 4.9 Nm {0.2 – 0.5 kgm} Rotating speed (rpm)
Delivery pressure {MPa (kg/cm2)}
Standard delivery amount (l/min)
Delivery amount limit (l/min)
3,500
20.6 {210}
67.6
62.4
–
27
SEN00523-02
10 Structure, function and maintenance standard
Differential lock pump (Machine with differential lock differential) SBR(1)8+8
Unit: mm No.
Check item
1
Side clearance
2
Clearance between inside diameter of plain bearing and outside of diameter of gear shaft
–
28
Discharge amount Oil: EO10-CD Oil temperature: 45–55°C
Criteria
Remedy
Standard clearance
Clearance limit
0.10 – 0.15
0.19 Replace
0.060 – 0.119
0.20
Rotating speed (rpm)
Delivery pressure {MPa (kg/cm2)}
Standard delivery amount (l/min)
Delivery amount limit (l/min)
3,500
20.6 {210}
25.2
23.7
–
HM400-2
10 Structure, function and maintenance standard
HM400-2
SEN00523-02
29
SEN00523-02
10 Structure, function and maintenance standard
HM400-2 Articulated dump truck Form No. SEN00523-02
© 2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (02)
30
HM400-2
SEN00524-01
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
10 Structure, function and maintenance standard
1
Cab and its attachments ROPS cab ....................................................................................................................................................... 2 Cab tilt............................................................................................................................................................. 3 Air conditioner ................................................................................................................................................. 4 Rear view monitor ......................................................................................................................................... 12 Controller related .......................................................................................................................................... 15
HM400-2
1
SEN00524-01
ROPS cab
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
2
10 Structure, function and maintenance standard
1
Front glass Front wiper Washer tank Front working lamp Door (left) Radio antenna KOMTRAX GPS antenna (if equipped) Rear glass Rear wiper Air conditioner fresh air filter Door (right)
HM400-2
10 Structure, function and maintenance standard
Cab tilt
1. 2. 3. 4. 5.
SEN00524-01
1
Tilt stopper bar Tilt cylinder Breather Adapter Pin
HM400-2
3
SEN00524-01
10 Structure, function and maintenance standard
Air conditioner
1. 2. 3. 4. 5. 6. A: B: C: D:
4
Air conditioner unit Fresh filter Control panel Compressor Receiver dryer Condenser To compressor From receiver dryer To heater (engine coolant) From heater (engine coolant)
1
Function • The air conditioner makes a pleasant operating environment for the operator and acts to reduce fatigue. Specifications Refrigerant used Refrigerant refilling level (g)
HFC134a (R134a) 1,200 ± 50
HM400-2
10 Structure, function and maintenance standard
SEN00524-01
Refrigerant flow system
Table of tightening torque for refrigerant piping adapter No.
Check item
Criteria
A
• Condenser refrigerant outlet side • Connecting part to cab (Between receiver drier and air conditioner unit)
12 – 15 Nm {1.2 – 1.5 kgm} (Screw size: M16 x 1.5)
B
• Condenser refrigerant inlet side
20 – 25 Nm {2.0 – 2.5 kgm} (Screw size: M22 x 1.5)
C
• Connecting part to cab (Between air conditioner unit and compressor)
30 – 35 Nm {3.0 – 3.5 kgm} (Screw size: M24 x 1.5)
D
• Receiver refrigerant piping lock bolt
E
• Compressor refrigerant piping lock bolt
F
• Air conditioner unit refrigerant piping lock bolt
HM400-2
Remedy
Retighten
8 – 12 Nm {0.8 – 1.2 kgm} (Screw size: M6 bolt of receiver) 20 – 25 Nm {2.0 – 2.5 kgm} (Screw size: M8 bolt of compressor) 8 – 12 Nm {0.8 – 1.2 kgm} (Screw size: M6 bolt of air conditioner unit)
5
SEN00524-01
10 Structure, function and maintenance standard
Air conditioner unit
1. 2. 3. 4. 5. 6. 7.
Face outlet port Face outlet port Ambient air inlet port Hot and cool box duct connecting port Internal air inlet port Foot outlet port Defroster output port
A: B: C: D: E:
Refrigerant gas inlet side Refrigerant gas outlet side Hot water outlet port Hot water inlet port Drain port
Outline • The vertical air conditioner unit on which evaporator and heater core is synchronized with the blower and intake unit to generate cool and hot air. • The temperature adjusting switch on the air conditioner panel controls air mix dampers and to adjust the spurting out temperature. Cooler • The cooler circulates refrigerant through evaporator to cause heat exchange (dehumidification and cooling). • Air taken in by the blower and intake unit is cooled with evaporator and then blown out from the grille through the duct. Heater • The heater circulates engine coolant in heater core to cause heat exchange (heating). • Air taken in by the blower and intake unit is heated with heater core and then blown out from the grille through the duct.
6
HM400-2
10 Structure, function and maintenance standard
SEN00524-01
Receiver dryer
1. Pressure switch 2. Label A: Refrigerant gas inlet port B: Refrigerant gas outlet port
Function • It is used to store liquefied high-pressure, hightemperature misty refrigerant from the condenser. It is capable of completely liquefying the refrigerant even when bubbles are contained in refrigerant due to the condenser condition in heat dissipation. • It eliminates foreign substances in the circulation circuit and water content in the refrigerant by use of the built-in filter and desiccating agent. • Sight glass allows inspecting flow of the refrigerant. Specifications
HM400-2
Effective cubic capacity (cm3)
578
Mass of desiccating agent (g)
300
7
SEN00524-01
10 Structure, function and maintenance standard
Condenser
1. Fin 2. Tube A: Refrigerant gas inlet port B: Refrigerant gas outlet port
Function • The condenser cools and liquefies the highpressure and high-temperature refrigerant gas compressed by the compressor. a If the fin crushes or is clogged with dusts, heat exchange efficiency is degraded and complete liquefaction of refrigerant becomes unavailable. As the result, pressure in the refrigerant circulation circuit will be increased, applying extra load to the engine or degrading the cooling effect. Thus, care must be used in its handling and daily inspection. Specifications Fin pitch (mm)
1.5
Total heat dissipation surface (m ) 2
Max. pressure used (MPa {kg/cm }) 2
8
6.55 3.6 {3.6}
HM400-2
10 Structure, function and maintenance standard
SEN00524-01
Compressor
1. Case 2. Clutch A: Suction service valve B: Discharge service valve
Function • Other than circulating the refrigerant, it compresses the refrigerant gas from the evaporator to high-pressure, high-temperature gas so that it may be easily regenerated (liguefied) at normal temperature. • Its built-in magnet clutch turns on or off depending on the evaporator temperature and refrigerant pressure. Specifications Number of cylinder – Bore x Stroke (mm) 5 – 35 x 28.6 Piston capacity (cc/rev) Allowable maximum speed (rpm)
HM400-2
138 4,000
9
SEN00524-01
10 Structure, function and maintenance standard
Air conditioner panel
Display section No. Display type Display item
Display range
Display method
Outlet air temperature
See above figure
All segments of current level and below light up (Display in 8 levels).
2
Air flow rate
See above figure
All segments of current level and below light up (Display in 4 levels).
3
RECIRC and FRESH air
RECIRC or FRESH air
RECIRC or FRESH is displayed according to RECIRC/FRESH selector switch position.
4
Air conditioner
Turning "ON" of air conditioner switch
When air conditioner switch is turned "ON", lamp lights up.
5
DEF air flow
Turning "ON" of DEF switch
When DEF switch is turned "ON", lamp lights up.
6
Mode
FACE, FACE/ FOOT of FOOT mode
FACE, FACE/FOOT or FOOT air outlet is displayed according to mode selector switch position.
1 Gauges
Pilot
10
Display color
Black
Remarks
LCD
HM400-2
10 Structure, function and maintenance standard
SEN00524-01
Switch section No.
Name
Function
Operation RECIRC I O FRESH
7
RECIRC/FRESH switch
Switch to select RECIRC or FRESH air (Pilot display on display section changes according to setting)
8
Air conditioner switch
Switch to turn ON and OFF air-conditioning function.
OFF io ON
9
ON/OFF switch
Switch to turn ON and OFF main power supply for air conditioner ON: Setting in "OFF" state is displayed on display section. OFF: Display section is turned OFF and fan is stopped.
OFF io ON
10 Fan switch
Switch to control air flow from fan (Control in 4 levels [LO, M1, M2, HI])
11 Temperature control switch
Switch to control outlet air temperature (Control in 8 levels)
12 DEF switch
Switch to turn ON and OFF defroster
13 Mode selector switch
Switch to change air outlet position (3 modes [FACE, FACE/FOOT, FOOT]) If pressed in DEF mode, setting before DEF mode is selected.
LO io HI Low temperature I O High temperature OFF io ON FACE O FACE/FOOT O FOOT
Outline • CPU (central processing unit) installed on the panel processes input signals from respective sensors and operation signals of the panel switches to display and output them. • The self-diagnosis function of CPU makes the troubleshooting easier. Input and output signals JAE IL-AG5-14P Pin Signal name No. 1 GND 2 Sensor ground air changeover damper ac3 Internal/external tuator limiter 4 NC 5 Evaporator temperature sensor 6 NC 7 Starting switch (ON) 8 Night lamp signal 9 NC 10 NC 11 NC 12 NC 13 NC 14 NC
HM400-2
JAE IL-AG5-22P Input/output signals — — Input — Input — Input Input — — — — — —
Pin Signal name No. 1 NC 2 NC 3 Blower motor relay Internal/external air changeover damper 4 actuator output 1 Internal/external air changeover damper 5 actuator output 2 6 Mode selector actuator output 2 7 Mode selector actuator output 1 8 Air mix damper actuator output 2 9 Air mix damper actuator output 1 10 Actuator potentiometer power supply (5V) 11 NC 12 NC 13 NC 14 NC 15 Magnet clutch 16 Air mix damper actuator limiter 17 Mode selector actuator limiter 18 Air mix damper actuator potentiometer 19 Mode selector actuator potentiometer 20 Blower gate 21 Blower feedback 22 Actuator potentiometer ground
Input/output signals — — Input Output Output Output Output Output Output — — — — — Input Input Input Input Input Input Input —
11
SEN00524-01
Rear view monitor
10 Structure, function and maintenance standard
1
(If equipped)
1. 2. 3.
12
Monitor Camera Cable
HM400-2
10 Structure, function and maintenance standard
SEN00524-01
Monitor
1. 2. 3. 4. 5. 6. 7.
Auto switch Manual switch Zoom/Iris switch (Reverse light compensation switch) Bright/Dim light selector switch Mark switch Contrast adjustment knob Brightness adjustment knob
HM400-2
Specifications TV signal method: As per Japanese standard TV method Scanning method: 2:1 Interlace method CRT: 4.5 inch, black and white, 90-deg. deflection Resolution: Horizontal 400 lines and vertical 300 lines Power supply voltage: DC 24/12 V
13
SEN00524-01
10 Structure, function and maintenance standard
Camera
1. 2.
14
Camera Connector
Specifications TV signal method: As per Japanese standard TV method Scanning method: 2:1 Interlace method Image sensor: 1/4 inch color CCD with 250,000 pixels Lens: 1.7 mm, 1:2.8 Angle of view: Horizontal; Approx. 118 deg., Vertical; Approx. 97.6 deg. Electronic zoom: Approx. 1.4 power Using luminance range: Min. luminance of object; 3 lux Power supply voltage: DC 5.5 V – 99.5 V for main unit (supplied by monitor) Power consumption: Max. 120 mA
HM400-2
10 Structure, function and maintenance standard
Controller related
SEN00524-01
1
Controller layout
1. 2. 3. 4.
Engine controller Transmission controller Retarder controller KOMTRAX controller (if equipped)
HM400-2
15
SEN00524-01
10 Structure, function and maintenance standard
HM400-2 Articulated dump truck Form No. SEN00524-01
© 2007 KOMATSU All Rights Reserved Printed in Japan 07-07 (02)
16
HM400-2
SEN00525-01
ARTICULATED DUMP TRUCK HM400-2
Machine model
Serial number
HM400-2
2001 and up
10 Structure, function and maintenance standard Electrical system, Part 1 Machine monitor system ................................................................................................................................. 2
HM400-2
1
SEN00525-01
10 Structure, function and maintenance standard
Machine monitor system
Network data 1. From machine monitor to each controller • Switch sensor data • Option setting data • Model selection data 2. From each controller to machine monitor • Display data related to each controller • Service mode data • Troubleshooting data
2
HM400-2
10 Structure, function and maintenance standard
Outline The machine monitor system is comprised of controllers and a machine monitor. The controllers on the network use the data from the sensors installed to all parts of the machine to observe and control the condition of the vehicle and transmit those data as network data to the machine monitor. The machine monitor, in return, displays these data and inform the operator of the condition of the machine. • There are two types of display on the machine monitor: the normal mode and the service mode. • The items that are always displayed for the operator are the normal mode items. Their main content is as follows. 1. Normal display items • Meters (speedometer, tachometer) • Gauges (engine coolant temperature, torque converter oil temperature, retarder oil temperature, fuel level) • Pilot display • Service meter, odometer (character display) 2. Items displayed when there is abnormality Caution, action code display (while an action code is being displayed, press machine monitor mode selector switch (>). A failure code (6-digit) is then displayed.) 3. Maintenance monitor function When the filter, oil replacement interval is reached, the item needing replacement is displayed in the character display. 4. Others In combination with the character display and the machine monitor mode selector switch, which is used to operate the character display, the following items can be displayed, set, and adjusted. 1) Dozing counter (option) 2) Display reverse travel distance measurement value 3) Reset filter oil replacement interval 4) Input telephone number 5) Select language •
To make it easier to carry out troubleshooting of the controllers on the network (including the monitor panel itself), a service mode function is provided. Its main content is as follows.
HM400-2
SEN00525-01
1. Displaying trouble history data for electrical components • Displays electrical component failure occurrence data from each controller that is saved in machine monitor • Deletes data from memory 2. Displaying trouble history data for machine Displays machine failure occurrence data from each controller that is saved in machine monitor. 3. Real-time monitor Takes input, output signal, and calculation values recognized by each controller on network and displays them in real time 4. Reduced cylinder mode This function is used to stop the supply of fuel sprayed from the fuel injector to each of the cylinders. This function is used for the purpose of, for example, determining the cylinder where there is defective combustion. 5. No injection cranking This function is used to lubricate an engine without starting the engine to drive a vehicle after a long-term storage. 6. Adjusting function This function is used to correct installation errors of sensors, solenoid valves, and compensate production tolerances of parts and components. This function is also used to change control characteristic data in response to user's request. 7. Maintenance monitor This function is used to change filter oil replacement interval and stop the function. 8. Operation information display function This function is used to display fuel consumption amount per operation hour. 9. Option selection function This function is used to select controller information and optional equipment to be operated. 10. Model selection function Input model information to be mounted. 11. Initialize This function is used to set the machine monitor when the machine is shipped from the factory.
3
SEN00525-01
10 Structure, function and maintenance standard
Machine monitor
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
4
Speedometer Engine tachometer Retarder oil temperature gauge Torque converter oil temperature gauge Engine coolant temperature gauge Fuel gauge Character display Turn signal pilot lamp (R.H.) Turn signal pilot lamp (L.H.) Front lamp high beam pilot lamp Gearshift lever position pilot lamp Shift indicator Lock-up pilot lamp Shift hold pilot lamp Power mode pilot lamp (power mode) Power mode pilot lamp (economy mode) Central warning lamp Maintenance caution lamp Battery charge circuit caution lamp Steering oil temperature caution lamp
21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39.
Engine oil pressure caution lamp Brake oil pressure caution lamp Machine monitor, option system caution lamp Engine system caution lamp Transmission system caution lamp Retarder system caution lamp Tilt caution lamp Seat belt caution lamp Parking brake pilot lamp Retarder pilot lamp Inter-axle differential lock pilot lamp Left and right differential lock pilot lamp (if equipped) Dump body pilot lamp Emergency steering pilot lamp Preheating pilot lamp Retarder oil temperature caution lamp Torque converter oil temperature caution lamp Engine coolant temperature caution lamp Fuel level caution lamp
HM400-2
10 Structure, function and maintenance standard
40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50.
SEN00525-01
Rotary switch [SW1] Rotary switch [SW2] Rotary switch [SW3] Dipswitch [SW5-4] Dipswitch [SW5-3] Dipswitch [SW5-2] SI Spec, Non-SI Spec selection switch [SW5-1] Dipswitch [SW6-4] Dipswitch [SW6-3] Dipswitch [SW6-2] Dipswitch [SW6-1]
HM400-2
5
SEN00525-01
10 Structure, function and maintenance standard
Machine monitor normal display functions Q : Lights up E: Sounds intermittently A: Q shows that all lamps light up for approx. 2 seconds after starting o all off for 1 second A Immediately after Alarm starting buzzer switch is turned ON
Related actuation No.
1
Display item
Display category
Device
Meter
Movement
Backlight
LED
Travel speed
Meter 2
Engine speed Backlight
Gauge Brake 3 cooling oil 36 temperature
Torque converter oil temperature
7
6
Fuel level gauge
When side lamps light up
Scale: 0 - 3400 rpm (red White, red Movement Background zone: More than 2500 rpm) color: Black LED
Amber
When side lamps light up
Scale: 50 - 150°C White, red (red zone: Movement Background More than 120°C) color: Black
—
—
—
Lights up when actuated
—
—
Q
Analog display
Q
E
—
Lights up when actuated
—
—
Q
Analog display
—
—
—
Red
When temperature is more than 120°C
Lights up when abnormal
Q
E
Q
Backlight
LED
Amber
When side lamps light up
Lights up when actuated
—
—
Q
Analog display
—
—
—
Scale: 50 - 135°C White, red Movement Background (red zone: More than 120°C) color: Black
Caution
LED
Red
When temperature is more than 120°C
Lights up when abnormal
Q
E
Q
Backlight
LED
Amber
When side lamps light up
Lights up when actuated
—
—
Q
Analog display
—
—
—
Scale: 50 - 135°C White, red (red zone: More than Movement Background 102°C) color: Black
Caution
LED
Red
When temperature is more than 102°C
Lights up when abnormal
Q
E
Q
Backlight
LED
Amber
When side lamps light up
Lights up when actuated
—
—
Q
EMPTY-FULL
Analog display
—
—
—
Gauge
6 39
Amber
Analog display
LED
Gauge Engine 5 coolant 38 temperature
Scale: 0 - 80 km/h or 0 - 50 White mph Background (mph display is only color: Black when non-SI is used)
Method of Central display warning lamp
Caution
Gauge 4 37
Color
Display range/ conditions
Scale: White Movement Background color: Black
Remarks
Caution
LED
Red
When below specified level (amount of fuel remaining in tank is less than 75 l)
Lights up when actuated
—
—
Q
Backlight
LED
Amber
When side lamps light up
Lights up when actuated
—
—
Q
0 - 65535.0h * Displayed on top line of character display
Actuated when engine is running Ratio of movement to time 1:1
—
—
When time exceeds 65535.0h, stops at 65535.0h
0 - 999999.9km * Displayed on bottom line of character display
Actuated when traveling
—
—
When distance exceeds 999999.9km, stops at 999999.9km
Service meter (normal display items)
Service meter
Odometer (normal display items)
Odometer
LED
Display letters: Black Background color: Green
HM400-2
10 Structure, function and maintenance standard
No
Display item
Action code
Failure code
Display category
Device
Color
Action code
Failure code
Reverse travel distance meter, filter, oil Other displays replacemen t time reset, telephone No. setting, language selection Backlight
Related actuation Immediately after Method of display Central starting Alarm warning buzzer switch is lamp turned ON When abnormality or failure occurs on machine, top line shows action code; bottom line displays remedy or nature of failure
—
—
Top line displays failure code (6 digit) and When there is controller that abnormality or failure, press mode switch ">". detected problem; bottom line * Displayed on top displays system and bottom lines of that is abnormal or character display nature of abnormality
—
—
When abnormality or failure occurs on machine * Displayed on top and bottom lines of character display
7
Night lighting
Display range/ conditions
SEN00525-01
Note
Remarks
Note: Top line displays "KOMATSU", bottom displays "SYSTEM CHECK"
See Operation & Maintenance Manual for details of failure display
Operate machine monitor mode Press machine monitor mode selector switch selector switch ">" or "] switch or []: To proceed to next monitoring system and function q [], [ ]: Number at the cursor increases. q [ < ]: Number at the cursor decreases q [U]: Number at the cursor is determined q [t ]: Cursor moves to the left end / To return to the monitoring system and function selection screen. q Monitoring code: 32500 and 38922 a Indicate the transmission oil temperature in the upper row (32500) and study condition of clutch trigger in the lower row (38922) (0: not learned yet, 1: already learned).
12) Set AISS LOW switch to LOW. 13) Start the engine, keep the gear shift lever at N position for 10 seconds at the low idle, then operate the gear shift lever as follows. a Gear shift lever operation: N o R1 o N 14) Confirm the trigger learning display of R clutch in the monitoring display. a Proceed to the next step if the display is "1". a If the display is "0", repeat procedure 13) until it becomes "1". a The * marked clutch display can be either "0" or "1".
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18) In the monitoring display, confirm finally the trigger learning display of lower line. a If displayed as drawing, the initial learning has completed normally. a The * marked clutch display can be either "0" or "1".
15) Set the shift lever to the D position, travel pressing the accelerator pedal, then shift up from F2 – F4. a Shift up: F2 o F3 o F4 a Be careful not to shift up to F5. When shifted up to F5, redo from F2. 16) Release the accelerator pedal after traveling for 10 seconds at F4, then shift down from F4 – F2 at coasting traveling. a Shift down: F4 o F3 o F2 a Do not operate the break during the coasting travel. 17) In the monitoring display, confirm the trigger learning display of Lo clutch and 1st clutch. a Learning operation is completed, if the display is "1". a If the display is "0", repeat procedure 15) - 16) until it becomes "1". a The * marked clutch display can be either "0" or "1".
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19) Press [t] switch several times and complete service menu. q [t]: To return to the previous screen
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[15] Filter and oil replacement time setting function (MAINTENANCE MONITOR) Machine monitor can set the maintenance intervals for various filters and oil which become the base of replacement time display for filter and oil. Also the machine monitor can activate or deactivate the display function. 1. Selection of the service menu Select the filter and oil replacement time setting function (MAINTENANCE MONITOR) in the service menu selection screen.
2.
a No.
If [>] switch or []: To proceed to next maintenance item and function. q [] switch or the [], [ ]: Number at the cursor increases. q [ < ]: Number at the cursor decreases. q [U]: Number at the cursor is determined. q [ t]: To return to the service menu selection screen. a The time must always be input with 4 digits. For the time with less than 4 digits, input 0s in place of the vacant number.
5.
Set the function activation or deactivation by maintenance item (items No.1 – 14). 1) With the item selected on the maintenance item and function selection screen (ex: FUEL P FILT) to change the activation or deactivation of the function, press the [U]switch to display the interval input screen. q [U]: Implement the function to change maintenance item.
2)
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When the interval time is completely determined, the screen to confirm the changes is displayed. Then, operate each of the switches [] and [t]. q [ ]: Select NO (move cursor) q [t]: Execute YES or NO
After displaying the screen to input intervals, press the [>] switch or the []: Switch the setting screen. q [ ]: Select NO (move cursor) q [t]: Execute YES or NO
a
a a
6.
50
If the timer which has been OFF is turned ON, the interval is set to the value before it was turned OFF and the rest of set time of the timer is reset. The number of resetting times is set to the value before it was turned OFF.
Setting default values of interval time for all items (function of No.15) 1) With all item default value setting (INITIALIZE) selected on the maintenance item and function selection screen, press
a a 7.
If the intervals for all the items are changed in an item, all the items are set to their respective default values, regardless of the ON or OFF state of each item. The rest of the set time of the timer is set to the [default value/elapsed time after the previous replacement]. The number of resetting times is kept at the value before the default was set. Each item is set turned ON.
Setting the function activation or deactivation for all the items (function No.16) 1) With the activation or deactivation setting for all items selected (ALL ITEMS) on the maintenance item and function selection screen, press the [U] switch to display the all items activation or deactivation setting screen.
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q
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[U]: Implement the function to set activation or deactivation of all the items.
4) 2)
After the all items activation or deactivation setting screen is displayed, press the [>] switch or the []: Switch the setting screen. q [] switch or the []: To display the next information screen. q [] switch or the [] switch or the []: Switch the displayed screen q [], [ ]: To switch the cursor symbol (+/-) / Number increases. q [ < ]: To switch the cursor symbol (+/-) / Number decreases. q [U]: Sign/number at the cursor is determined. q [t ]: Return to the fuel correction screen a The correction value at the plant before shipment is [+/-00.0%] (In case of inputting 00.0, +/- does not matter.) a The compensation value can be input within the range of [-50.0% – +50.0%].
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[17] Option selection function (OPTIONAL SELECTION) Machine monitor can set and adjust various optional devices which have been installed or removed. a The operating method of this function refers to the item of "Setting and adjusting various equipment".
[18] Model selection function (MACHINE) Machine monitor is common among many models, and if the machine monitor is replaced, select the same model as the one currently installed. a The operating method of this function refers to the item of "Setting and adjusting various equipment".
[19] Initializing function (INITIALIZE) a This function is exclusive for the plant, and is not used for service.
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How to start operation of KOMTRAX terminal
30 Testing and adjusting
3)
When about 3 to 5 seconds elapsed after the starting switch was set to ACC, make sure that the 7-segment indicator lamp changes to hyphen “–” on the KOMTRAX terminal.
4)
Disconnect inspection connector 1, and wait for about 3 to 5 seconds as it is. a Ensure that the connector is disconnected. Reconnect inspection connector 1, and wait for about 3 to 5 seconds as it is. a If the KOMTRAX terminal detects that the connector was disconnected and connected, the dot on the 7-segment indicator lamp blinks a few times.
1
In the case where the KOMTRAX terminal has been installed at the plant before shipment: a Implement the following procedure in the case where the KOMTRAX terminal has already been installed at the plant before shipment (as standard equipment). q Domestic (Japan): The setting work has already completed. q Other than Japan: Execute "3. Request of opening station of ORBCOMM terminal". In the case where KOMTRAX terminal is retrofitted on machine after shipment: a Implement the following procedure in the case where the KOMTRAX terminal is retrofitted after shipment of the machine (retrofitted machine). q Domestic (Japan): Execute "1. Opening station inspection of machine side" and "2. Application of start of use". q Other than domestic (Japan): Execute "1. Opening station inspection of machine side" and "2. Application of start of use" and "3. Opening station request of ORBCOMM terminal". How to start operation 1. Station opening check in machine side a Complete steps 3) to 5) within 60 seconds. If 60 seconds or above elapsed, begin with step 1) again. 1) Turn OFF the starting switch and then, a ft e r m a k i n g s u r e 5 s e c o n d s h a v e elapsed, proceed to the next step. 2) Visually check that check connectors 1 and 2 are connected. q Check connector 1: CHK1 q Check connector 2: CHK2
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5)
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6)
Make sure that the 7-segment indicator lamp is indicated normally on the KOMTRAX terminal. a If so, the 7-segment indicator lamp will indicate characters “d”, “0”, and “–” repeatedly for 30 seconds after step 5) was ended. a Those characters, even if displayed normally, will change to a character other than hyphen “–”after 30 seconds or above elapsed. The display may change to a character other than “0” even within 30 seconds.
a a
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As [Normal] is indicated, proceed to the next step. If “–” remains displayed, execute steps 1) to 5) again.
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7) Turn the starting switch to START position for about 3 to 5 seconds, and make sure that the engine does not start. a If the engine starts, re-execute the procedure above from step 1). a Do not return the starting switch to OFF position. 8) Turn the starting switch from ACC position to START position again, and make sure that the engine starts. 9) Make sure that the KOMTRAX terminal's indicator lamps are normally turned on. a Move on to the next step if you can check that the display is [Normal]. (It takes from 90 seconds to 15 minutes before the display turns normal.) a If [GPS position data detection trouble] is indicated, check if there is any abnormality on the GPS antenna or cable. If there is any abnormality, repair it and start from procedure 1) again. a If [Reception trouble] is indicated, check if there is any abnormality on the appearance of the communication antenna or cable. If there is any abnormality, repair it then repeat from procedure 1) again. a If [GPS position data detection trouble and reception trouble] is indicated, check if there is any abnormality on the GPS antenna/ cable or communication antenna/ cable. If there is any abnormality, repair it and start from procedure 1) again. a If [Network trouble] is indicated, check the display of [LED-C4] referring to “Lamp display of KOMTRAX terminal”. If the CAN is not recognized, check the CAN harness of the KOMTRAX terminal, and then if there is any abnormality, repair it and start from procedure 1) again.
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[A]: Normal [B]: GPS position data detection trouble [C]: Reception trouble [D]: GPS position data detection trouble and reception trouble [E]: Network trouble
12) When station opening check ended norm a l l y, a c o m m u n i c a t i o n w i t h t h e KOMTRAX server starts automatically, and settings are stored in KOMTRAX. (This requires about 25 minutes to 4 hours.) a During this time, you may turn the starting switch off and start the engine. a During the communication and check above, you should park the machine outside to enable a frequent communication with the ORBCOMM satellite. The station opening check may not be completed in doors that cause radio waves from the satellite to be intercepted.
10) Turn the starting switch OFF. 11) Make sure that the 7-segment indicator lamp is displayed normally after 5 seconds elapsed. a When [Normal] appears, station opening check is completed. a If [Abnormal] appears, station opening check does not end normally, so you should perform the procedure above from step 1) again. a If station opening check ends normally, it should not be rechecked.
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2.
Application for the start of use a Application for the start of use is made only after the sign-up test on the machine side is finished. 1) Notify to the KOMTRAX operations administrator the following information concerning the machine whose sign-up test on the machine is completed. (1) Information on the machine whose sign-up test on the machine system is completed (model, model number and serial number). (2) Part number and serial number of the KOMTRAX terminal (3) Reading of the service meter when the KOMTRAX terminal is installed (0.1 h unit)
2)
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3.
Opening station request of ORBCOMM terminal Fill in the necessary matters in the paper of "opening request of ORBCOMM terminal" and send KOMTRAX service hotline by fax or mail.
The KOMTRAX operations administrator registers the body using a KOMTRAX client personal computer. a For the procedure, see the following; In Japan: "KOMTRAX instruction manual for responsible person for operation" Out of Japan: "Global KOMTRAX Web Reference Manual" (For key person)
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Lamp display of KOMTRAX terminal
CPU LED 1. LED-C1 (R signal, ACC signal) 2. LED-C2 (Starting output status) 3. LED-C3 (S-NET, C signal status) 4. LED-C4 (Condition of CAN communication) 5. LED-C5 (downloading and writing status) 6. LED-C6 (downloading and writing status)
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7 segments and dot for CPU 7. 7 segments (number of mails not yet sent) 8. Dot (GPS positioning status)
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In the KOMTRAX system, various information and processing details are displayed on the LEDs on the upper surface of the KOMTRAX terminal. Therefore, if a detect is suspected in the system, perform the following checks. q Check of antennas q Check of terminal LED displays Application for the start of use and sign-up test on the vehicle bodies should be completed before using KOMTRAX system. Check of antennas a Before checking the LED displays, check that there is no abnormality around the communication antenna and GPS antenna. q The communication antenna should not be disconnected or damaged. q The communication antenna cable should not be broken and be connected normally with the KOMTRAX terminal. q The GPS antenna should not be disconnected or damaged. q The GPS antenna cable should not be broken and normally be connected to the KOMTRAX terminal. Check of terminal LED displays 1. Display contents of LED for CPU a The LED displays should be checked with the starting switch ON, starting switch START, or with the engine started. No.
1
LED
Name and function
Starting switch ACC LED-C1 signal and alternator R signal Engine control signal status
2
LED-C2
3
S-NET connection LED-C3 status and starting switch C signal status
4
LED-C4 CAN status
Display (refer to *1) Lighting on
Starting switch ACC signal: ON, alternator R signal: ON
Fast blinking
Starting switch ACC signal: OFF, alternator R signal: ON
Slow blinking
Starting switch ACC signal: ON, alternator R signal: OFF
Lighting off
Starting switch ACC signal: OFF, alternator R signal: OFF
Lighting on
Engine control signal: ON
Lighting off
Engine control signal: OFF
Lighting on
S-NET: connected, starting switch C signal: OFF
Fast blinking
Starting switch C signal: ON
Slow blinking
(Not used)
Lighting off
S-NET: disconnected, starting switch C signal: OFF
Lighting on
CAN: active (fuel sensor: inactive)
Fast blinking
CAN: active (fuel sensor: active)
Slow blinking
CAN: inactive (fuel sensor: active)
Lighting off 5 6
LED-C5 Downloading and writing status LED-C6
Display contents
One side is ON
CAN: inactive (fuel sensor: inactive) Downloading and writing status (special function for system administrator)
Both lighting off Normal operation mode
* 1: Blinking type and time Fast blinking: blinking on an approximately 1 second cycle Slow blinking: blinking on an approximately 4 second cycle
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2.
No.
7
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Display contents of 7-segment and dot for CPU a LED displays should be checked with the starting switch ON. LED
7 segments
Dot
Name and function
Number of mails not yet sent and waiting status acquiring satellite
GPS positioning status
Display (refer to *2)
Display contents
0–9 lighting on
Number means number of mails not yet sent (9 is displayed even if there are more than 9 mails). Lighting on indicates status acquiring satellite.
0–9 fast blinking
Number means number of mails not yet sent (9 is displayed even if there are more than 9 mails). Fast blinking means waiting status acquiring satellite.
Lighting on
GPS positioning has been completed. (Position has been recognized. Refer to *3.)
Lighting off
GPS positioning has not been completed. (Position has not been recognized. Refer to *3.)
* 2: Blinking type and time Fast blinking: blinking on an approximately 1 second cycle Slow blinking: blinking on an approximately 4 second cycle * 3: Supplementary explanation of GPS positioning status It may take more than 1 minute from turning on the starting switch to the completion of positioning even in an outdoor place where radio wave can reach. Positioning is impossible in areas with extremely weak radio waves or areas beyond the reach of radio waves.
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Pm Clinic check sheet
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1
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Initial setting of payload meter
1
In the following cases, perform "setting of option selection of machine monitor" and "setting with VHMS initialization manual (tool)" according to Table 1. 1. When the payload meter in the VHMS or card-type payload meter (PLM ) is installed for the first time 2. When the payload meter in the VHMS or card-type payload meter (PLM ) is removed 3. When the VHMS controller or transmission controller is replaced 4. When setting of VHMS controller (PLM ) is changed Table 1 Setting with VHMS initial setting manual (tool) (*1) VHMS controller
PLM function in VHMS controller
Card-type payload meter (PLM- )
Payload meter (PLM) function
Installed
Not installed
Not installed
Not installed
Installed
Not installed
Installed
Installed
Installed
Installed
Not installed
Installed
Model
Type
Variation code
Date Time Time difference (GMT) Summer time
ST HD465 HD605
– 7E0
P2
Set properly
PV
(*1) For setting of the model, type, variation code, etc., see the VHMS initial setting manual (Tool) When there is not a problem in installation and wiring of the payload meter but there are the following problems, check the above setting again. 1. Items related to the payload meter are not displayed on the machine monitor. "The payload is not displayed when the machine is loaded and stopped", "There are not the manus related to the payload meter on the match marks", etc. a In the following cases, perform "setting of option selection of machine monitor" and "setting with VHMS initialization manual (tool)" according to Table 1. 2. While the payload meter in the VHMS is not set, there are the menus related to the payload meter on the machine monitor. a In the following cases, perform "setting of option selection of machine monitor" and "setting with VHMS initialization manual (tool)" according to Table 1. 3. While the payload meter in the VHMS is set, the payload does not match to the lighting condition of the red lamp of the outside indicator lamps. a Wrong setting of the model and serial No. with the VHMS initial setting tool. 4. The storage place of the data file made by the download software is not found. a Wrong setting of the model and serial No. with the VHMS initial setting tool. 5. Data cannot be downloaded. a Wrong setting of the model, serial No., and variation code with the VHMS initial setting tool. 6. Date and time of the downloaded data are wrong. a Wrong setting of the date and time with the VHMS initial setting tool.
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HM400-2 Articulated dump truck Form No. SEN00918-03
© 2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (02)
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ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
40 Troubleshooting
1
General information on troubleshooting Points to remember when troubleshooting ..................................................................................................... 2 Sequence of events in troubleshooting........................................................................................................... 3 Check before troubleshooting ......................................................................................................................... 4 Classification and procedures for troubleshooting .......................................................................................... 5 Connection table for connector pin numbers .................................................................................................. 8 T-branch box and T-branch adapter table ..................................................................................................... 44
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40 Troubleshooting
Points to remember when troubleshooting k k k k k k
1
Stop the machine in a level ground, and check that the lock 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 coolant 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.
2.
3.
2
When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: q Parts that have no connection with the failure or other unnecessary parts will be disassembled. q It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before?
4)
Other maintenance items can be checked externally, so check any item that is considered to be necessary.
4.
Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse.
5.
Troubleshooting Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1] Start from the simple points. 2] Start from the most likely points. 3] Investigate other related parts or information.
6.
Measures to remove root cause of failure 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 problem occurred. Then, remove the root cause.
Check before troubleshooting 1) Is there any sign of irregularities of the machine? 2) Make checks before starting day's work. 3) Make checks of other items.
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Sequence of events in troubleshooting
1
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40 Troubleshooting
Check before troubleshooting Item 1. Check of level and type of fuel 2. Check of fuel for foreign matter
Add fuel Add coolant
4. Check of dust indicator for clogging
Other than red
Clean or replace
5. Check of oil level in engine oil pan
Between H – L
Add oil
6. Check of engine oil filter 7. Check of oil level in transmission case 8. Check of transmission oil filter
—
Replace
Between H – L
Add oil
—
Replace
Between H – L
Add oil
10. Check of hydraulic oil strainer
—
Clean
11. Check of hydraulic oil filter
—
Replace
12. Check of oil level in final drive case
—
Add oil
13. Check of oil level in differential case
—
Add oil
1. Check for abnormal sound and smell
—
Repair
2. Check for oil leakage
—
Repair
3. Execution of air bleeder operation
—
Bleed air
1. Check of battery terminal wiring for looseness and corrosion
—
Retighten or replace
2. Check of alternator terminal wiring for looseness and corrosion
—
Retighten or replace
3. Check of starting motor terminal wiring for looseness and corrosion
—
Retighten or replace
20 – 30 V
Charge or replace
Between H – L
Add or replace
6. Check of wiring for discoloration, burn, and peeling of cover
—
Repair or replace
7. Check for removal of wire clamp and sag of wire
—
Repair
8. Check of wiring for wetness (Check connectors and terminals in particular)
—
Dray
9. Check for trip of circuit breaker and breakage and corrosion of fuse
—
Replace
5. Check of electrolyte level
4
—
Clean and drain
4. Check of battery voltage (with engine stopped) Electrical components and parts
Remedy
—
9. Check of oil level in hydraulic tank
Hydraulic and mechanical components
Criterion
Between FULL – LOW
3. Check of coolant level
Lubricating oil and coolant
1
10. Check of alternator voltage (with engine speed at 27.5 – 29.5 V after operamedium or higher) tion of several minutes
Replace
11. Check of operating sound of battery relay (when starting switch is turned ON or OFF)
Replace
—
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Classification and procedures for troubleshooting
1
Classification for troubleshooting Type Display of code
Contents Troubleshooting by failure code
E mode
Troubleshooting for electrical system
H mode
Troubleshooting for hydraulic and mechanical system
S mode
Troubleshooting for engine
Procedure for troubleshooting If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according to the following procedure, and then go to the corresponding troubleshooting section. 1.
Procedure for troubleshooting to be taken when action code and failure code are displayed on machine monitor: If a action code and a failure code are displayed on the machine monitor, carry out the troubleshooting for the corresponding "Display of code" according to the displayed failure code.
2.
When electrical system failure code or mechanical system failure code is recorded in fault history: If a action code and a failure code are not displayed on the machine monitor, check for a mechanical system failure code and an electrical system failure code with the fault history function of the machine monitor. If a failure code is recorded, carry out troubleshooting for the corresponding "Display of code" according to that code. a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then see if the trouble is still detected. a A failure code of the mechanical system cannot be deleted.
3.
When action code or failure code is not displayed and no failure code is recorded in fault history: If a action code or a failure code is not displayed on the machine monitor and no failure code is recorded in the fault history, a trouble that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical system. In this case, check the phenomenon looking like a trouble again and select the same phenomenon from the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out troubleshooting corresponding to that phenomenon in the "E mode", "H mode", or "S mode".
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40 Troubleshooting
Phenomena looking like troubles and troubleshooting Nos. Troubleshooting No.
Phenomenon looking like trouble
Display of code
E mode
H mode
S mode
Action code/Failure code 1 Action code and failure code are displayed on machine monitor 2
When fault history is checked, failure code is displayed in mechanical system fault history
3
When fault history is checked, failure code is displayed in electrical system fault history
According to failure code
Phenomena related to engine 4 Starting performance is poor
S-1
5 Engine does not start
E-1
S-2
6 Engine does not pick up smoothly
S-3
7 Engine stops during operations
S-4
8 Engine does not rotate smoothly
S-5
9 Engine lacks output (or lacks power)
S-6
10 Exhaust smoke is black (incomplete combustion)
S-7
11 Oil consumption is excessive (or exhaust smoke is blue)
S-8
12 Oil becomes contaminated quickly
S-9
13 Fuel consumption is excessive
S-10
14 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-11
15 Oil pressure drops
S-12
16 Oil level rises (Entry of coolant/fuel)
S-13
17 Coolant temperature becomes too high (overheating)
S-14
18 Abnormal noise is made
S-15
19 Vibration is excessive
S-16
20 Preheater does not operate
E-2 Phenomena related to power train
21 Machine does not start
H-1
22 Travel is not smooth
H-2
23 Lockup is not reset
H-3
24 Start shock and gear shift shock are abnormally large
H-4
25 Gear is not shifted up
H-5
26 Travel speed or power is low
H-6
27 Start and gearshift time lag is large
H-7
28 Torque converter oil temperature is high
H-8
29 Torque converter oil temperature is low
H-9 Phenomena related to brake
30 Front brake does not work fully
H-10
31 Center brake does not work fully
H-11
32 Rear brake does not work fully
H-12 Phenomena related to steering system
33 Steering wheel is heavy
H-13
34 Steering wheel does not move
H-14
35 Steering wheel waggle
H-15
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Troubleshooting No.
Phenomenon looking like trouble
Display of code
E mode
H mode
S mode
Phenomena related to dump body 36 Dump body raising speed is low
H-16
37 Dump body does not move
H-17
38 Hydraulic drift of dump body is large
H-18
Phenomena related to machine monitor/panel switch 39 When starting switch is turned ON, machine monitor displays nothing 40
When starting switch is turned OFF, machine monitor cannot be operated
41 Alarm buzzer does not stop sounding 42
Machine monitor does not normally display gauges, caution lamps, and character display section
E-3 E-4 E-5 E-6
43 Display of character display section cannot be changed
E-7
44 Power mode selection function does not operate normally
E-8
45 AISS function does not operate normally
E-9
46
Right and left differential lock function does not operate normally (Differential lock-up specification)
E-10
47 Interaxle differential lock-up function does not operate normally
E-11
48 Display of seat belt caution lamp is abnormal
E-12
49 Turn signal lamps and pilot lamps do not operate normally
E-13
50 Night lighting is abnormal
E-14
51 Backup lamp and backup buzzer operate abnormally
E-15
52 Emergency steering system does not operate
E-16
HM400-2
7
SEN01107-02
Connection table for connector pin numbers
40 Troubleshooting
(Rev. 2008.09) 1
a
The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing.
8
HM400-2
40 Troubleshooting
HM400-2
SEN01107-02
9
SEN01107-02
10
40 Troubleshooting
HM400-2
40 Troubleshooting
HM400-2
SEN01107-02
11
SEN01107-02
12
40 Troubleshooting
HM400-2
40 Troubleshooting
HM400-2
SEN01107-02
13
SEN01107-02
14
40 Troubleshooting
HM400-2
40 Troubleshooting
HM400-2
SEN01107-02
15
SEN01107-02
16
40 Troubleshooting
HM400-2
40 Troubleshooting
HM400-2
SEN01107-02
17
SEN01107-02
18
40 Troubleshooting
HM400-2
40 Troubleshooting
HM400-2
SEN01107-02
19
SEN01107-02
20
40 Troubleshooting
HM400-2
40 Troubleshooting
HM400-2
SEN01107-02
21
SEN01107-02
22
40 Troubleshooting
HM400-2
40 Troubleshooting
HM400-2
SEN01107-02
23
SEN01107-02
24
40 Troubleshooting
HM400-2
40 Troubleshooting
HM400-2
SEN01107-02
25
SEN01107-02
26
40 Troubleshooting
HM400-2
40 Troubleshooting
HM400-2
SEN01107-02
27
SEN01107-02
28
40 Troubleshooting
HM400-2
40 Troubleshooting
HM400-2
SEN01107-02
29
SEN01107-02
30
40 Troubleshooting
HM400-2
40 Troubleshooting
HM400-2
SEN01107-02
31
SEN01107-02
32
40 Troubleshooting
HM400-2
40 Troubleshooting
HM400-2
SEN01107-02
33
SEN01107-02
34
40 Troubleshooting
HM400-2
40 Troubleshooting
HM400-2
SEN01107-02
35
SEN01107-02
36
40 Troubleshooting
HM400-2
40 Troubleshooting
HM400-2
SEN01107-02
37
SEN01107-02
38
40 Troubleshooting
HM400-2
40 Troubleshooting
HM400-2
SEN01107-02
39
SEN01107-02
40
40 Troubleshooting
HM400-2
40 Troubleshooting
HM400-2
SEN01107-02
41
SEN01107-02
42
40 Troubleshooting
HM400-2
40 Troubleshooting
HM400-2
SEN01107-02
43
SEN01107-02
40 Troubleshooting
T-branch box and T-branch adapter table a
(Rev. 2008.02) 1
q
q
q q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification symbol
799-601-2700
Part name
T-adapter kit 799-601-2500
Part No.
Number of pins
The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly.
q
799-601-2600 T-box (for ECONO)
21
799-601-3100 T-box (for MS)
37
q
799-601-3200 T-box (for MS)
37
q q
799-601-3380 Plate for MS (14-pin) 799-601-3410 Adapter for BENDIX (MS)
24
MS-24P
q
799-601-3420 Adapter for BENDIX (MS)
24
MS-24P
q
799-601-3430 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3440 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3450 Adapter for BENDIX (MS)
5
MS-5P
q
799-601-3460 Adapter for BENDIX (MS)
10
MS-10P
q
799-601-3510 Adapter for BENDIX (MS)
5
MS-5S
q
799-601-3520 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3530 Adapter for BENDIX (MS)
19
MS-19P
q
799-601-2910 Adapter for BENDIX (MS)
14
MS-14P
q
799-601-2710 Adapter for MIC
5
MIC-5P
q q
799-601-2720 Adapter for MIC
13
MIC-13P
q q
799-601-2730 Adapter for MIC
17
MIC-17P
q q q
799-601-2740 Adapter for MIC
21
MIC-21P
q q q
799-601-2950 Adapter for MIC
9
MIC-9P
799-601-2750 Adapter for ECONO
2
ECONO2P
q q
799-601-2760 Adapter for ECONO
3
ECONO3P
q q
799-601-2770 Adapter for ECONO
4
ECONO4P
q q
799-601-2780 Adapter for ECONO
8
ECONO8P
q q
799-601-2790 Adapter for ECONO
12 ECONO12P q q
q
799-601-3470 Case
799-601-2810 Adapter for DLI
8
DLI-8P
q q
799-601-2820 Adapter for DLI
12
DLI-12P
q q
799-601-2830 Adapter for DLI
16
DLI-16P
q q
799-601-2840 Extension cable (ECONO type)
12 ECONO12P q q
q q q
q
q q
q
q q q
q
q
q
799-601-2850 Case 799-601-4350 T-box (for DRC60, ECONO)
q
q
60
q
799-601-4360 Case q
q
X2P
q q q
q
3
X3P
q q q
q
4
X4P
q q q
q
799-601-7050 Adapter for SWP
6
SW6P
q q q
799-601-7060 Adapter for SWP
8
SW8P
q q q
799-601-7310 Adapter for SWP
12
SW12P
799-601-7070 Adapter for SWP
14
SW14P
799-601-7320 Adapter for SWP
16
SW16P
799-601-7010 Adapter for X (T-adapter)
1
799-601-7020 Adapter for X
2
799-601-7030 Adapter for X 799-601-7040 Adapter for X
q q
q q
799-601-7080 Adapter for M (T-adapter)
1
—
q
q
799-601-7090 Adapter for M
2
M2P
q q q
q
799-601-7110 Adapter for M
3
M3P
q q q
q
44
HM400-2
40 Troubleshooting
SEN01107-02
q q q
q q
Out of kit
S8P
799-601-4201
8
799-601-4101
799-601-7140 Adapter for S
799-601-9300
q
799-601-9200
q q q
M8P
799-601-9100
M6P
8
799-601-9000
6
799-601-7340 Adapter for M
799-601-8000
799-601-7130 Adapter for M
799-601-7500
q
799-601-7400
q q q
799-601-7100
M4P
799-601-7000
4
799-601-2800
799-601-7120 Adapter for M
Part name
799-601-2700
Identification symbol
Part No.
799-601-2500
Number of pins
T-adapter kit
q
799-601-7150 Adapter for S (White)
10
S10P
q q q
799-601-7160 Adapter for S (Blue)
12
S12P
q q q q q q
q
799-601-7170 Adapter for S (Blue)
16
S16P
799-601-7330 Adapter for S (White)
16
S16PW
799-601-7350 Adapter for S (White)
12
S12PW
799-601-7180 Adapter for AMP040
8
A8P
q
799-601-7190 Adapter for AMP040
12
A12P
q
q
799-601-7210 Adapter for AMP040
16
A16P
q q q
q
799-601-7220 Adapter for AMP040
20
A20P
q q q
q
799-601-7230 Short connector for X
2
—
q q q
q
q q
q q
799-601-7240 Case
q
799-601-7270 Case 799-601-7510 Adapter for 070
10
07-10
q
799-601-7520 Adapter for 070
12
07-12
q
799-601-7530 Adapter for 070
14
07-14
q
799-601-7540 Adapter for 070
18
07-18
q
799-601-7550 Adapter for 070
20
07-20
q
799-601-7360 Adapter for relay
5
REL-5P
q
799-601-7370 Adapter for relay
6
REL-6P
q
799-601-7380 Adapter for JFC
2
—
q
799-601-9010 Adapter for DTM
2
DTM2
q
q
799-601-9020 Adapter for DT
2
DT2
q
q
799-601-9030 Adapter for DT
3
DT3
q
q
799-601-9040 Adapter for DT
4
DT4
q
q
799-601-9050 Adapter for DT
6
DT6
q
q
799-601-9060 Adapter for DT (Gray)
8
DT8GR
q
q
799-601-9070 Adapter for DT (Black)
8
DT8B
q
q
799-601-9080 Adapter for DT (Green)
8
DT8G
q
q
799-601-9090 Adapter for DT (Brown)
8
DT8BR
q
q
799-601-9110 Adapter for DT (Gray)
12
DT12GR
q
q
799-601-9120 Adapter for DT (Black)
12
DT12B
q
q
799-601-9130 Adapter for DT (Green)
12
DT12G
q
q
799-601-9140 Adapter for DT (Brown)
12
DT12BR
q
q
799-601-9210 Adapter for HD30-18
8
D18-8
q q
799-601-9220 Adapter for HD30-18
14
D18-14
q q
799-601-9230 Adapter for HD30-18
20
D18-20
q q
799-601-9240 Adapter for HD30-18
21
D18-21
q q
799-601-9250 Adapter for HD30-24
9
D24-9
q q
799-601-9260 Adapter for HD30-24
16
D24-16
q q
799-601-9270 Adapter for HD30-24
21
D24-21
q q
799-601-9280 Adapter for HD30-24
23
D24-23
q q
799-601-9290 Adapter for HD30-24
31
D24-31
q q
799-601-9310 Plate for HD30 (24-pin)
HM400-2
q q
q q q q
q
45
799-601-9320 T-box (for ECONO)
q q
24
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification symbol
799-601-2700
Part name
T-adapter kit 799-601-2500
Part No.
40 Troubleshooting
Number of pins
SEN01107-02
q
q
799-601-9330 Case
q
799-601-9340 Case 799-601-9350 Adapter for DRC
40
DRC-40
q q
799-601-9360 Adapter for DRC
24
DRC-24
799-601-9410* Socket for engine (CRI-T2)
2
G
Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Adapter for oil pressure
3
A3
q q
2
P
q q
799-601-9440* Socket for engine (CRI-T2)
3
1,2,3
q
795-799-5520* Socket for engine (HPI-T2)
2
S
q
Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor
2
C
q q
2
A
q q
795-799-5460 Cable for engine (HPI-T2)
3
—
q
795-799-5470 Cable for engine (HPI-T2)
3
—
q
795-799-5480 Cable for engine (HPI-T2)
3
—
q
799-601-9430*
795-799-5540*
Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV
Socket for engine (HPI-T2) Socket for engine (CRI-T3) TIM
q
799-601-4110 Adapter for engine (140-T3) PIM
4
ITT3N
q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM
3
FCIN
q q
Adapter for engine (CRI-T3) 799-601-4140 Atmosphere pressure
3
FCIG
q q
799-601-4150 Adapter for engine (CRI-T3) POIL
3
FCIB
q q
Adapter for engine (CRI-T3) 799-601-4160 Oil pressure switch
2
4160
q q
799-601-4180 Adapter for engine (CRI-T3) PEVA
3
4180
q q
Socket for engine (CRI-T3) 799-601-4190* Commonrail pressure
3
1,2,3L
q q
4
1,2,3,4C
q q
799-601-4240* Socket for engine (CRI-T3) PAMB
3
1,2,3A
q q
799-601-4250* Socket for engine (CRI-T3) PIM
3
1,2,3B
q q
799-601-4330* Socket for engine (CRI-T3) G
3
1,2,3,G
q q
Socket for engine (CRI-T3) 799-601-4340* Pump actuator
2
2,PA
q q
4
1,2,3,4T
799-601-4230*
799-601-4380*
Socket for engine (CRI-T3) Air intake pressure/temperature
Socket for engine (CRI-T3)(95) Air intake pressure/temperature
q q q
799-601-4260 Adapter for controller (ENG)
4
DTP4
799-601-4211 Adapter for controller (ENG)
50
DRC50
q q
799-601-4220 Adapter for controller (ENG)
60
DRC60
799-601-4390* Socket for controller (95 ENG)
60
—
q
799-601-4280 Box for controller (PUMP)
121
—
q
799-601-9720 Adapter for controller (HST)
16
HST16A
q
799-601-9710 Adapter for controller (HST)
16
HST16B
q
799-601-9730 Adapter for controller (HST)
26
HST26A
q
799-601-9890 Multi-adapter for DT2-4 and DTM2
2, 3, 4
—
q
“*” Shows not T-adapter but socket.
46
HM400-2
40 Troubleshooting
HM400-2
SEN01107-02
47
SEN01107-02
40 Troubleshooting
HM400-2 Articulated dump truck Form No. SEN01107-02
© 2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (02)
48
HM400-2
SEN01262-00
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
40 Troubleshooting
1
Troubleshooting by failure code, General Troubleshooting by failure code, General ....................................................................................................... 2 Failure codes table............................................................................................................................... 2 Before troubleshooting by failure code............................................................................................... 10 Information in troubleshooting table ................................................................................................... 18
HM400-2
1
SEN01262-00
40 Troubleshooting
Troubleshooting by failure code, General
1
Failure codes table
1
Failure codes
Failure contents
Applicable equipments
Action code
1500L0
Detecting dual engagement
TM
E03
15B0NX
T/M oil filter clogging
TM
E01
15F0KM
R o F gear shift abuse 1
TM
–
15F0MB
R o F gear shift abuse 2
TM
–
15F7KM
T/M forward clutch abuse
TM
–
15G0MW
R clutch system failure (Slip is detected)
TM
E03
15G7KM
T/M reverse clutch abuse
TM
–
15H0MW
Hi clutch system failure (Slip is detected.)
TM
E03
15J0MW
Lo clutch system failure (Slip is detected.)
TM
E03
15K0MW
1st clutch system failure (Slip is detected.)
TM
E03
15L0MW
2nd clutch system failure (Slip is detected.)
TM
E03
15M0MW
3rd clutch system failure (Slip is detected.)
TM
E03
15SBL1
R clutch pressure control valve failure
TM
E03
15SBMA
R clutch pressure control valve failure
TM
E03
15SCL1
Hi clutch pressure control valve failure
TM
E03
15SCMA
Hi clutch pressure control valve failure
TM
E03
15SDL1
Lo clutch pressure control valve failure
TM
E03
15SDMA
Lo clutch pressure control valve failure
TM
E03
15SEL1
1st clutch pressure control valve failure
TM
E03
15SEMA
1st clutch pressure control valve failure
TM
E03
15SFL1
2nd clutch pressure control valve failure
TM
E03
15SFMA
2nd clutch pressure control valve failure
TM
E03
15SGL1
3rd clutch pressure control valve failure
TM
E03
15SGMA
3rd clutch pressure control valve failure
TM
E03
15SJMA
L/U clutch pressure control valve failure
TM
E03
TM
E01
BK
E01
BK
E01
BK
E01
15SKMA 2A62L1 2A62LH 2B62L1
2
Inter axle differential lock-up clutch pressure control valve failure Front wheels differential lockup control valve system failure Front wheels differential lockup control valve system failure Rear wheels differential lockup control valve system failure
History classification Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
Reference manual
Troubleshooting by failure code, Part 1 SEN01108-00
Troubleshooting by failure code, Part 2 SEN01109-00
HM400-2
40 Troubleshooting
Failure codes
SEN01262-00
Failure contents
Applicable equipments
Action code
2B62LH
Rear wheels differential lockup control valve system failure
BK
E01
2C4MNX
Retarder cooling filter clogging
MON
E01
2F00KM
Dragging of parking brake
TM
–
2G42ZG
Decrease of accumulator oil pressure (Front)
BK
E03
2G43ZG
Decrease of accumulator oil pressure (Rear)
BK
E03
(989A00)
Engine over run prevention activated
MON
E02
A570NX
Engine oil filter clogging
TM
E01
AA10NX
Clogged air cleaner
MON
E01
AB00MA
Failure of battery charge circuit
TM
E03
B@BAZG
Engine oil pressure is too low.
ENG
E03
B@BAZK
Engine oil level is too low.
TM
E01
B@BCNS
Engine overheat
ENG
E02
B@BCZK
Coolant level is too low.
MON
E01
B@C6NS
Overheat of brake cooling oil temperature (Front)
MON
E02
B@C7NS
Overheat of brake cooling oil temperature (Rear)
MON
E02
B@C8NS
Overheat of brake cooling oil temperature (Center)
MON
E02
B@CENS
Overheat of T/C fluid temperature
MON
E02
B@JANS
Overheat of steering oil temperature
TM
E02
CA111
Abnormality in engine controller
ENG
E03
CA115
Abnormal engine Ne and Bkup speed sensors
ENG
E03
CA122
Charge pressure sensor too high
ENG
E03
CA123
Charge pressure sensor too low
ENG
E03
CA131
Throttle sensor tool high
ENG
E03
CA132
Throttle sensor too low
ENG
E03
CA135
Engine oil pressure sensor too high
ENG
E01
CA141
Engine oil pressure sensor too low
ENG
E01
CA144
Coolant temperature sensor too high
ENG
E01
CA145
Coolant temperature sensor too low
ENG
E01
CA153
Charge temperature sensor too high
ENG
E01
CA154
Charge temperature sensor too low
ENG
E01
CA187
Sensor power source 2 too low
ENG
E03
HM400-2
History classification Electrical system Mechanical system Mechanical system Mechanical system Mechanical system – Mechanical system Mechanical system Electrical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
Reference manual
Troubleshooting by failure code, Part 2 SEN01109-00
Troubleshooting by failure code, Part 3 SEN01110-00
3
SEN01262-00
Failure codes
40 Troubleshooting
Failure contents
Applicable equipments
Action code
CA221
Atmospheric pressure sensor too high
ENG
E01
CA222
Atmospheric pressure sensor too low
ENG
E01
CA227
Sensor power source 2 too high
ENG
E03
CA234
Engine overspeed
ENG
E02
CA238
Abnormal power source for Ne speed sensor
ENG
E03
CA263
Fuel temperature sensor too high
ENG
E01
CA265
Fuel temperature sensor too low
ENG
E01
CA271
PCV1 short circuit
ENG
E03
CA272
PCV1 disconnection
ENG
E03
CA273
PCV2 short circuit
ENG
E03
CA274
PCV2 disconnection
ENG
E03
CA322
Disconnection or short circuit in injector No.1(L No.1)
ENG
E03
CA323
ENG
E03
ENG
E03
ENG
E03
ENG
E03
CA332
Disconnection or short circuit in injector No.5 (L No.5) Disconnection or short circuit in injector No.3 (L No.3) Disconnection or short circuit in injector No.6 (L No.6) Disconnection or short circuit in injector No.2 (L No.2) Disconnection or short circuit in injector No.4 (L No.4)
ENG
E03
CA342
Abnormal engine controller data consistency
ENG
E03
CA351
Abnormal injector drive circuit
ENG
E03
CA352
Sensor power source 1 too low
ENG
E03
CA386
Sensor power source 1 too high
ENG
E03
CA431
Abnormal idle validation switch
ENG
E01
CA432
Abnormal process with idle validation
ENG
E03
CA441
Power source voltage too low
ENG
E03
CA442
Power source voltage too high
ENG
E03
CA449
Common rail pressure too high 2
ENG
E03
CA451
Common rail pressure sensor too high
ENG
E03
CA452
Common rail pressure sensor too low
ENG
E03
CA553
Common rail pressure too high 1
ENG
E03
CA554
Common rail pressure sensor: in range error
ENG
E03
CA559
Loss of pressure feed from supply pump 1
ENG
E03
CA324 CA325 CA331
4
History classification Electrical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
Reference manual
Troubleshooting by failure code, Part 3 SEN01110-00
Troubleshooting by failure code, Part 4 SEN01111-00
HM400-2
40 Troubleshooting
Failure codes
SEN01262-00
Failure contents
Applicable equipments
Action code
CA689
Abnormal engine Ne speed sensor
ENG
E03
CA731
Abnormal engine Bkup speed sensor phase
ENG
E03
CA757
Loss of all engine controller data
ENG
E03
CA778
Abnormal engine Bkup speed sensor
ENG
E03
CA1228
Abnormal EGR valve servo 1
ENG
E03
CA1625
Abnormal EGR valve servo 2
ENG
E03
CA1626
Short circuit of bypass valve solenoid drive
ENG
E03
CA1627
Disconnection in bypass valve solenoid drive
ENG
E03
CA1628
Abnormal bypass valve servo 1
ENG
E03
CA1629
Abnormal bypass valve servo 2
ENG
E03
CA1631
Bypass valve lift sensor too high
ENG
E03
CA1632
Bypass valve lift sensor too low
ENG
E03
CA1633
Abnormal KOMNET
ENG
E03
CA1642
EGR inlet pressure sensor too low
ENG
E01
CA1653
EGR inlet pressure sensor too high
ENG
E01
CA2185
Throttle sensor power source too high
ENG
E03
CA2186
Throttle sensor power source too low
ENG
E03
CA2249
Loss of pressure feed from supply pump 2
ENG
E03
CA2271
EGR valve lift sensor too high
ENG
E03
CA2272
EGR valve lift sensor too low
ENG
E03
CA2351
EGR valve solenoid drive short circuit
ENG
E03
CA2352
EGR valve solenoid drive disconnection
ENG
E03
CA2555
Disconnection in intake air heater relay
ENG
E01
CA2556
Short circuit in intake air heater relay
ENG
E01
DAF9KM
Wrong connection of connector
MON
E03
DAFRKR
Abnormal CAN communication (machine monitor)
TM
E03
DAQ0KK
Power source voltage too low
TM
E03
DAQ0KT
Abnormal non volatile memory
TM
E01
DAQ2KK
Solenoid power supply system failure
TM
E03
(DAQ9KQ) Inconsistent model selection (T/M controller)
MON
E03
DAQRKR
MON
E03
MON
E03
Abnormal CAN communication (T/M controller)
(DAQRMA) Inconsistent option setting (T/M controller)
HM400-2
History classification Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system – Electrical system –
Reference manual
Troubleshooting by failure code, Part 4 SEN01111-00
Troubleshooting by failure code, Part 5 SEN01112-00
5
SEN01262-00
Failure codes
40 Troubleshooting
Failure contents
Applicable equipments
Action code
DB10KT
Abnormal non volatile memory
BK
E03
DB12KK
Solenoid power supply system failure
BK
E03
DB13KK
Battery direct power supply too low
BK
E03
MON MON
E03 E03
(DB19KQ) Inconsistent model selection (T/M controller) (DB1QMA) Inconsistent option setting (T/M controller) DB1RKR
Abnormal CAN communication (T/M controller)
TM
E03
DB2RKR
Abnormal CAN communication (engine controller)
TM
E03
DD1ML4
Inconsistent signal of axle connected retarder switch
TM
E01
DDTHKA
Failure of flow detection valve for Hi clutch
TM
E03
DDTJKA
Failure of flow detection valve for Lo clutch
TM
E03
DDTKKA
Failure of flow detection valve for 1st clutch
TM
E03
DDTLKA
Failure of flow detection valve for 2nd clutch
TM
E03
DDTMKA
Failure of flow detection valve for 3rd clutch
TM
E03
DDTNKA
Failure of flow detection valve for R clutch
TM
E03
DF10KA
No lever signal input
TM
E03
DF10KB
Multiple lever signal input
TM
E03
DGF1KX
T/M oil temperature out of range
TM
E03
DGR2KZ
MON
E01
MON
E01
MON
E01
MON
E01
MON
E01
DGR4L8
Ground fault of brake oil temperature sensor (rear) system Disconnection of brake oil temperature sensor (rear) system Ground fault of brake oil temperature sensor (center) system Disconnection of brake oil temperature sensor (center) system Ground fault of brake oil temperature sensor (front) system Disconnection of brake oil temperature sensor (front) system
MON
E01
DGR6KX
Steering oil temperature signal out of range
TM
E01
DGT1KX
Short circuit of T/C oil temperature sensor system
TM
E01
DHT5KX
Disconnection, ground fault, and short circuit of T/C fluid pressure sensor system
TM
E01
DHT5L6
T/C fluid pressure sensor failure
TM
E01
BK
E01
BK
E01
MON
E01
BK
E03
DGR2L8 DGR3KZ DGR3L8 DGR4KZ
DHU3KX
Accumulator fluid pressure sensor (front) system failure Accumulator fluid pressure sensor (rear) system failure
DJF1KA
Disconnection of fuel level sensor system
DK51L5
Manual retarder potentiometer and RVS failure
DHU2KX
6
History classification Electrical system Electrical system Electrical system – – Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
Reference manual
Troubleshooting by failure code, Part 5 SEN01112-00
Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
Troubleshooting by failure code, Part 6 SEN01113-00
HM400-2
40 Troubleshooting
Failure codes
SEN01262-00
Failure contents
Applicable equipments
Action code
DK52KX
Dump lever potentiometer failure 1
TM
E03
DK53L8
Dump lever potentiometer failure 2
TM
E03
DK54KX
Body positioner sensor failure
TM
E03
DKH0KX
Pitch angle sensor signal out of range
TM
E01
DLF1KA
Disconnection of T/M input shaft speed sensor system
TM
E03
DLF1LC
T/M input shaft speed sensor failure
TM
E03
DLF2KA
Disconnection of T/M intermediate shaft speed sensor system
TM
E03
DLF2LC
T/M intermediate shaft speed sensor failure
TM
E03
TM
E01
TM
E03
MON
E01
History classification Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
DLT3KA
Disconnection of T/M differential speed sensor system Disconnection of T/M output shaft speed sensor system
DV00KB
Short circuit of buzzer output
DW72KZ
Kick out solenoid output system failure (disconnection or ground fault)
TM
E01
DW73KZ
Dump selector valve output system failure
TM
E03
DW78KZ
Rear wheel BCV command output system failure
BK
E01
DW79KZ
Front wheel BCV command output system failure
BK
E01
BK
E03
BK
E03
Electrical system
BK
E03
Electrical system
BK
E03
BK
E03
BK
E03
BK
E03
Electrical system
BK
E03
Electrical system
BK
E03
BK
E03
Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
DLF4KA
DX11K4 DX11KA DX11KB DX11KY DX11MA DX12K4 DX12KA DX12KB DX12KY DX12MA
Rear wheels electromagnetic proportional pressure reducing valve failure 1 Disconnection of rear wheels electromagnetic proportional pressure reducing valve output system Ground fault of rear wheels electromagnetic proportional pressure reducing valve output circuit Hot short of rear wheels electromagnetic proportional pressure reducing valve output circuit Rear wheels electromagnetic proportional pressure reducing valve failure 2 Front wheels electromagnetic proportional pressure reducing valve failure 1 Disconnection of rear wheels electromagnetic proportional pressure reducing valve output circuit Ground fault of front wheels electromagnetic proportional pressure reducing valve output circuit Hot short circuit of front wheels electromagnetic proportional pressure reducing valve output circuit Front wheels electromagnetic proportional pressure reducing valve failure 2
DX13KA
Disconnection of Dump EPC valve output circuit
TM
E03
DX13KB
Ground fault of Dump EPC valve output circuit
TM
E03
DX13KY
Hot short circuit of Dump EPC valve output circuit
TM
E03
DX14KZ
Rear wheels differential lock-up command output system failure
BK
E03
HM400-2
Reference manual
Troubleshooting by failure code, Part 6 SEN01113-00
Electrical system Electrical system Electrical system
Troubleshooting by failure code, Part 7 SEN01114-00
7
SEN01262-00
Failure codes
40 Troubleshooting
Failure contents
Applicable equipments
Action code
BK
E03
TM
E01
TM
E01
DXH0KY
Front wheels differential lock-up command output system failure Disconnection of inter axle differential lock-up clutch solenoid output circuit Ground fault of inter axle differential lock-up clutch solenoid output circuit Hot short circuit of inter axle differential lock-up clutch solenoid output circuit
TM
E03
DXH1KA
Disconnection of L/U clutch solenoid output circuit
TM
E03
DXH1KB
Ground fault of lock-up clutch solenoid output circuit
TM
E03
DXH1KY
Hot short circuit of lock-up clutch solenoid output circuit
TM
E03
DXH2KA
Disconnection of Hi clutch solenoid output circuit
TM
E03
DXH2KB
Ground fault of Hi clutch solenoid output circuit
TM
E03
DXH2KY
Hot short circuit of Hi clutch solenoid output circuit
TM
E03
DXH3KA
Disconnection of Lo clutch solenoid output circuit
TM
E03
DXH3KB
Ground fault of Lo clutch solenoid output circuit
TM
E03
DXH3KY
Hot short circuit of Lo clutch solenoid output circuit
TM
E03
DXH4KA
Disconnection of 1st clutch solenoid output circuit
TM
E03
DXH4KB
Ground fault of 1st clutch solenoid output circuit
TM
E03
DXH4KY
Hot short circuit of 1st clutch solenoid output circuit
TM
E03
DXH5KA
Disconnection of 2nd clutch solenoid output circuit
TM
E03
DXH5KB
Ground fault of 2nd clutch solenoid output circuit
TM
E03
DXH5KY
Hot short circuit of 2nd clutch solenoid output circuit
TM
E03
DXH6KA
Disconnection of 3rd clutch solenoid output circuit
TM
E03
DXH6KB
Ground fault of 3rd clutch solenoid output circuit
TM
E03
DXH6KY
Hot short circuit of 3rd clutch solenoid output circuit
TM
E03
DXH7KA
Disconnection of R clutch solenoid output circuit
TM
E03
DXH7KB
Ground fault of R clutch solenoid output circuit
TM
E03
DXH7KY
Hot short circuit of R clutch solenoid output circuit
TM
E03
DX15KZ DXH0KA DXH0KB
8
History classification Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
Reference manual
Troubleshooting by failure code, Part 7 SEN01114-00
Troubleshooting by failure code, Part 8 SEN01115-00
HM400-2
40 Troubleshooting a
a
a a
SEN01262-00
Failure codes: The failure code table is written in alphabetical order and also starting from small number. The failure code in parentheses is not recorded in the failure history for both electrical system and mechanical system. Applicable equipment: Applicable equipment indicates in which controller system the failure has occurred. MON : Machine monitor system ENG : Engine controller system TM : Transmission controller system BK : Retarder controller system Action codes: Action codes indicate what is displayed in the operator mode when a failure is detected. History classification: History classification indicates in which system, either electrical system or mechanical system in the failure history display function, a failure has been recorded.
HM400-2
9
SEN01262-00
40 Troubleshooting
Before troubleshooting by failure code
1
a This connection table shows the devices to which each power supply of the circuit breakers and fuse box supplies power (An accessory power supply is a device which supplies power while the starting switch is in the ON position and an unswitched power supply is a device which supplies power while the starting switch is in the OFF and ON positions). a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers and fuses to see if the power is supplied normally. Locations and connections of circuit breakers (30 A and 80 A)
Type of power supply Unswitched power supply
Accessory power supply
Circuit breaker Circuit breaker No. capacity
Destination of power Fuse box (BT2)
1
30A
2
30A
Fuse box (BT3)
3
80A
Fuse box (BT3)
Fuse box (BT4)
Fuse box (BT1) 4
80A
Fuse box (BT2) Fuse box (BT3) Fuse box (BT4)
10
HM400-2
40 Troubleshooting
SEN01262-00
Location and connection of fuse box (BT1)
Type of power supply
Fuse No.
Fuse capacity
Destination of power Lamp switch circuit (including brightness control switch) BT1-No. 3 power supply (through relay)
1
20A
BT1-No. 4 power supply (through relay) BT1-No. 5 power supply (through switch) BT1-No. 6 power supply (through switch)
Accessory power supply
HM400-2
2
10A
Flasher
3
20A
Headlamp (High beam)
4
10A
Headlamp (Low beam)
5
10A
Small lamp (Right)
6
10A
Small lamp (Left)
7
10A
Stop lamp (Right and left)
8
20A
9
20A
Front working lamp (Right and left)
10
20A
Service power supply connector
Backup lamp (Right and left) Backup buzzer
11
SEN01262-00
40 Troubleshooting
Location and connection of fuse box (BT2)
Type of power supply
Accessory power supply
Unswitched power supply
12
Fuse No.
Fuse capacity
11
10A
Engine controller (Starting switch ACC signal)
Destination of power
12
10A
KOMTRAX terminal
13
10A
Machine monitor
14
10A
Parking brake solenoid valve
15
10A
Rear view monitor
16
20A
Front wiper motor
17
20A
Rear wiper motor
18
10A
19
10A
Retarder controller
20
20A
Starting switch (Terminal B power supply)
Machine monitor KOMTRAX
21
10A
Transmission controller
22
20A
Hazard lamp (Front, rear, right, and left)
23
10A
Emergency steering relay (motor circuit) and timer
24
10A
25
20A
Room lamp Car radio or car stereo Service power supply connector
HM400-2
40 Troubleshooting
SEN01262-00
Location and connection of fuse box (BT3)
Type of power supply
Accessory power supply
Unswitched power supply
HM400-2
Fuse No.
Fuse capacity
26
20A
Fog lamp (Right and left)
Destination of power
27
20A
Air conditioner unit
28
10A
Heater
29
10A
Heater
30
10A
31
10A
32
10A
33
10A
Emergency steering relay (signal circuit) and timer
34
20A
Power window motor (Right)
35
20A
Power window motor (Left)
36
—
(Spare)
37
—
(Spare)
38
—
(Spare)
39
30A
Rear glass heater
40
30A
Engine controller
Machine monitor Alarm buzzer Retarder controller Transmission controller Shift lever
13
SEN01262-00
40 Troubleshooting
Location and connection of fuse box (BT4)
Type of power supply
Accessory power supply
Unswitched power supply Accessory power supply
14
Fuse No.
Fuse capacity
41
10A
Room lamp 2
Destination of power
42
10A
Car radio or car stereo
43
10A
Yellow rotary lamp
44
20A
Side lamp (Right and left)
45
10A
Intake air heater relay
46
10A
Horn (Right and left)
47
10A
Tachograph
48
10A
Cigarette lighter
49
10A
Air suspension seat
50
10A
Air conditioner unit
HM400-2
40 Troubleshooting
SEN01262-00
Location and connection of fuse (V)
Type of power supply
Fuse No.
Fuse capacity
Accessory power supply
V
300A
HM400-2
Destination of power Intake air heater
15
SEN01262-00
40 Troubleshooting
Fuse box (BT4)
Type of power supply
Accessory power supply
Unswitched power supply Accessory power supply
16
Fuse No.
Fuse capacity
41
10A
Room lamp 2
Destination of power
42
10A
Car radio or car stereo
43
10A
Yellow rotary lamp
44
20A
Side lamp (Right and left)
45
10A
Intake air heater relay
46
10A
Horn (Right and left)
47
10A
Tachograph
48
10A
Cigarette lighter
49
10A
Air suspension seat
50
10A
Air conditioner unit
HM400-2
SEN01262-00
40 Troubleshooting
Information in troubleshooting table
1
a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Action code
Failure code
Display on Display on machine machine monimonitor tor Contents of trouble
Trouble
Trouble name displayed in fault history of machine monitor
Contents of trouble detected by machine monitor or controller
Action of Action taken by machine monitor or controller to protect system or devices when they detect machine monitrouble tor or controller Problem that appears on machine
Problem that appears on machine as result of action taken by machine monitor or controller (shown above)
Related information
Information related to detected trouble or troubleshooting
Cause
Standard value in normal state/Remarks on troubleshooting
• Standard value in normal state to judge possible causes • Remarks on judgment
1
2 Possible causes and standard value in normal state
18
• Disconnection Connector is connected defectively or wiring harness is broken. • Ground fault Wiring harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. • Hot short Wiring harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit. • Short circuit Independent wiring harnesses are in contact with each other abnormally.
Possible causes of trouble (Given numbers are refer ence numbers, which do not (1) Method of indicating connector No. and handling of Tindicate priority) adapter Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. • If connector No. has no marks of "male" and "female", 3 disconnect connector and insert T-adapters in both male side and female side. • If connector No. has marks of "male" and "female", disconnect connector and connect T-adapter to only male side or female side. (2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting, unless otherwise specified. 4 • Connect positive (+) lead to pin No. or wiring harness entered on front side. • Connect negative (–) lead to pin No. or harness entered on rear side.
HM400-2
40 Troubleshooting
SEN01262-00
Related circuit diagram
This drawing is a part of the electric circuit diagram related to troubleshooting. • Connector No.: Indicates (Model – Number of pins) and (Color). • "Connector No. and pin No." from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. • Arrow (i o): Roughly shows the location on the machine.
HM400-2
19
SEN01262-00
40 Troubleshooting
HM400-2 Articulated dump truck Form No. SEN01262-00
© 2006 KOMATSU All Rights Reserved Printed in Japan 05-06 (02)
20
HM400-2
SEN01108-00
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
40 Troubleshooting
1
Troubleshooting by failure code, Part 1 Troubleshooting by failure code, Part 1 .......................................................................................................... 3 Failure code [1500L0] Double engagement ......................................................................................... 3 Failure code [15B0NX] Transmission oil filter: Clogged ....................................................................... 4 Failure code [15F0KM] R o F shifting abuse 1.................................................................................... 6 Failure code [15F0MB] R o F shifting abuse 2.................................................................................... 6 Failure code [15F7KM] Transmission forward clutch abuse ............................................................... 7 Failure code [15G0MW] Trouble in reverse clutch system (Slip) ......................................................... 8 Failure code [15G7KM] Transmission reverse clutch abuse.............................................................. 10 Failure code [15H0MW] Trouble in Hi clutch system (Slip) ................................................................ 12 Failure code [15J0MW] Trouble in Lo clutch system (Slip) ............................................................... 14 Failure code [15K0MW] Trouble in 1st clutch system (Slip)............................................................... 16 Failure code [15L0MW] Trouble in 2nd clutch system (Slip) .............................................................. 18 Failure code [15M0MW] Trouble in 3rd clutch system (Slip).............................................................. 20 Failure code [15SBL1] Trouble in reverse clutch pressure control valve ........................................ 22 Failure code [15SBMA] Trouble in reverse clutch pressure control valve ..................................... 26 Failure code [15SCL1] Trouble in Hi clutch pressure control valve ................................................. 28
HM400-2
1
SEN01108-00
40 Troubleshooting
Failure code [15SCMA] Trouble in Hi clutch pressure control valve .............................................. 32 Failure code [15SDL1] Trouble in Lo clutch pressure control valve ............................................... 34 Failure code [15SDMA] Trouble in Lo clutch pressure control valve ............................................. 36
1
2
HM400-2
40 Troubleshooting
SEN01108-00
Troubleshooting by failure code, Part 1
1
Failure code [1500L0] Double engagement
1
Action code
Failure code
E03
1500L0
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
• Fill switch signals of 2 clutches of wrong combination were inputted. • Turns transmission cut-off relay OFF. • Sets gear speed in neutral. • Gear speed is set in neutral suddenly during travel and machine cannot restart. • Method of reproducing failure code: Start engine + Travel.
Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
Clutch ECMV solenoid valve may be defective. Carry out troubleDefective clutch ECMV sole- shooting for other displayed failure code(s). 1 noid valve (Internal defect) • Failure codes that can be displayed together with this code: [15SBL1], [15SCL1], [15SDL1], [15SEL1], [15SFL1], [15SGL1] Defective hydraulic and Clutch ECMV solenoid valve may be defective. Carry out trouble2 mechanical systems of shooting for hydraulic and mechanical systems. clutch ECMV solenoid valve 3
HM400-2
Double engagement (Transmission controller system)
Defective transmission controller
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
3
SEN01108-00
40 Troubleshooting
Failure code [15B0NX] Transmission oil filter: Clogged Action code
Failure code
E01 Contents of trouble Action of controller Problem that appears on machine Related information
15B0NX
Trouble
1
Transmission oil filter: Clogged (Transmission controller system)
• When torque converter oil temperature is above 50°C, signal circuit of transmission oil filter clogging switch is open (disconnected from ground). • None in particular. • If machine is used as it is, transmission may be broken. • After taking remedy and checking that system is repaired, initialize transmission controller, referring to Testing and adjusting, Setting and adjusting each device. • Method of reproducing failure code: Start engine. Cause
Standard value in normal state/Remarks on troubleshooting
Clogged transmission oil fil1 Transmission oil filter may be clogged. Clean or replace it. ter (When system is normal) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. T03 (male)
Defective transmission oil fil2 ter clogging switch (Internal defect)
Possible causes and standard value in normal state
Between (1) – (2)
Transmission oil filter
Resistance
When normal (Reference: Differential pressure is below 275 ± 19.6 kPa {2.8 ± 0.2 kg/cm2})
Max. 1 z
When clogged (Reference: Differential pressure is above 275 ± 19.6 kPa {2.8 ± 0.2 kg/cm2})
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC2 (female) (37) Resis3 Max. 1 z or defective contact in con- – T03 (female) (1) tance nector) Wiring harness between T03 (female) (2) – ResisMax. 1 z ground T1 tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ATC2 (female)
4
4
Defective transmission controller
Transmission oil filter
When normal (Reference: Differential pressure is below 275 ± 19.6 kPa {2.8 ± 2 Between (37) – chas- 0.2 kg/cm }) sis ground When clogged (Reference: Differential pressure is above 275 ± 19.6 kPa {2.8 ± 0.2 kg/cm2})
Voltage
Max. 1 V
20 – 30 V
HM400-2
40 Troubleshooting
SEN01108-00
Circuit diagram related to transmission oil filter clogging switch
HM400-2
5
SEN01108-00
40 Troubleshooting
Failure code [15F0KM] R o F shifting abuse 1 Action code
Failure code
— Contents of trouble Action of controller Problem that appears on machine Related information
15F0KM
Trouble
R o F shifting abuse 1 (Transmission controller system)
• Shifting from reverse to forward was detected 10 times in total while output shaft speed was 200 300 rpm (approx. 4 – 6 km/h). • None in particular. • If machine is used as it is, it may be broken. • Output shaft speed can be checked with monitoring function. (Monitoring code: TRANSMISSION - TRANSMISSION SPEED: OUT - 31400) Cause
Possible causes and standard value in normal state
1
Standard value in normal state/Remarks on troubleshooting
Gearshift lever may have been operated wrongly (Transmission Wrong operation of gearshift may have been set in forward during reverse travel). Teach opera1 lever tor correct operation. (Travel direction must be changed after machine is stopped completely.) 2
Defective transmission controller
If cause 1 is not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Failure code [15F0MB] R o F shifting abuse 2 Action code
Failure code
— Contents of trouble Action of controller Problem that appears on machine Related information
15F0MB
Trouble
• None in particular. • If machine is used as it is, it may be broken. • Output shaft speed can be checked with monitoring function. (Monitoring code: TRANSMISSION - TRANSMISSION SPEED: OUT - 31400) Standard value in normal state/Remarks on troubleshooting
Gearshift lever may have been operated wrongly (Transmission Wrong operation of gearshift may have been set in forward during reverse travel). Teach opera1 lever tor correct operation. (Travel direction must be changed after machine is stopped completely.) 2
6
R o F shifting abuse 2 (Transmission controller system)
• Shifting from reverse to forward was detected 5 times in total while output shaft speed was above 300 rpm (approx. 6 km/h).
Cause Possible causes and standard value in normal state
1
Defective transmission controller
If cause 1 is not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
HM400-2
40 Troubleshooting
SEN01108-00
Failure code [15F7KM] Transmission forward clutch abuse Action code
Failure code
— Contents of trouble Action of controller Problem that appears on machine
15F7KM
Trouble
1
Transmission forward clutch abuse (Transmission controller system)
• Shifting from neutral or reverse to forward was detected 10 times in total while engine speed was above 1,800 rpm. • None in particular. • If machine is used as it is, it may be broken.
Related information Cause Possible causes and standard value in normal state
Gearshift lever may have been operated wrongly (Transmission Wrong operation of gearshift may have been set in forward while engine was running higher 1 lever than set speed). Teach operator correct operation. (Transmission must be set to forward while engine is running at low idle.) 2
HM400-2
Standard value in normal state/Remarks on troubleshooting
Defective transmission controller
If cause 1 is not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
7
SEN01108-00
40 Troubleshooting
Failure code [15G0MW] Trouble in reverse clutch system (Slip) Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine Related information
15G0MW
Trouble
1
Trouble in reverse clutch system (Slip) (Transmission controller system)
• When signal is output to reverse clutch ECMV solenoid valve, value calculated from signals of transmission input shaft speed sensor, intermediate shaft speed sensor, and output shaft reverse speed sensor is abnormal. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • Machine cannot travel in reverse. • Output current to reverse clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV R DIR - 31606) • Method of reproducing failure code: Start engine + Travel at R1 Cause Defective reverse clutch 1 ECMV solenoid valve (Internal defect)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CN8 (male)
Resistance
Between (1) – (2)
5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (13) 2 or defective contact in con- – CN8 (female) (2) nector) Wiring harness between ATC3 (female) (25) – CN8 (female) (1)
Max. 1 z
Resistance
Max. 1 z
Defective transmission controller
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Defective hydraulic and mechanical systems of 4 reverse clutch or reverse clutch ECMV solenoid valve
If causes 1 – 3 are not detected, reverse clutch or reverse clutch ECMV solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
3
8
Resistance
HM400-2
40 Troubleshooting
SEN01108-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to reverse clutch ECMV solenoid valve
HM400-2
9
SEN01108-00
40 Troubleshooting
Failure code [15G7KM] Transmission reverse clutch abuse Action code
Failure code
— Contents of trouble Action of controller Problem that appears on machine
15G7KM
Trouble
1
Transmission reverse clutch abuse (Transmission controller system)
• Shifting from neutral or forward to reverse was detected 10 times in total while engine speed was above 1,800 rpm. • None in particular. • If machine is used as it is, it may be broken.
Related information Cause Possible causes and standard value in normal state
Gearshift lever may have been operated wrongly (Transmission Wrong operation of gearshift may have been set in reverse while engine was running higher 1 lever than set speed). Teach operator correct operation. (Transmission must be set to reverse while engine is running at low idle.) 2
10
Standard value in normal state/Remarks on troubleshooting
Defective transmission controller
If cause 1 is not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
HM400-2
SEN01108-00
40 Troubleshooting
Failure code [15H0MW] Trouble in Hi clutch system (Slip) Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine Related information
15H0MW
Trouble
1
Trouble in Hi clutch system (Slip) (Transmission controller system)
• When signal is output to Hi clutch ECMV solenoid valve, value calculated from signals of transmission input shaft speed sensor, intermediate shaft speed sensor, and output shaft reverse speed sensor is abnormal. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • Machine travels at gear speeds which do not use Hi clutch. • Output current to Hi clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV H DIR - 31600) • Method of reproducing failure code: Start engine + Travel at F2. Cause Defective Hi clutch ECMV 1 solenoid valve (Internal defect)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CN10 (male)
Resistance
Between (1) – (2)
5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (13) 2 or defective contact in con- – CN10 (female) (2) nector) Wiring harness between ATC3 (female) (26) – CN10 (female) (1) 3
Defective transmission controller
Defective hydraulic and mechanical systems of Hi 4 clutch or Hi clutch ECMV solenoid valve
12
Resistance
Max. 1 z
Resistance
Max. 1 z
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 – 3 are not detected, Hi clutch or Hi clutch ECMV solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
HM400-2
40 Troubleshooting
SEN01108-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to Hi clutch ECMV solenoid valve
HM400-2
13
SEN01108-00
40 Troubleshooting
Failure code [15J0MW] Trouble in Lo clutch system (Slip) Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine Related information
15J0MW
Trouble
1
Trouble in Lo clutch system (Slip) (Transmission controller system)
• When signal is output to Lo clutch ECMV solenoid valve, value calculated from signals of transmission input shaft speed sensor, intermediate shaft speed sensor, and output shaft reverse speed sensor is abnormal. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • Machine travels at gear speeds which do not use Lo clutch. • Output current to Lo clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV L DIR - 31601) • & Method of reproducing failure code: Start engine + Travel at F1. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective Lo clutch ECMV 1 solenoid valve (Internal defect)
Possible causes and standard value in normal state
Resistance 5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (3) Resis2 Max. 1 z or defective contact in con- – CN6 (female) (2) tance nector) Wiring harness between ATC3 (female) (6) ResisMax. 1 z – CN6 (female) (1) tance 3
Defective transmission controller
Defective hydraulic and mechanical systems of Lo 4 clutch or Lo clutch ECMV solenoid valve
14
CN6 (male) Between (1) – (2)
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 – 3 are not detected, Lo clutch or Lo clutch ECMV solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
HM400-2
40 Troubleshooting
SEN01108-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to Lo clutch ECMV solenoid valve
HM400-2
15
SEN01108-00
40 Troubleshooting
Failure code [15K0MW] Trouble in 1st clutch system (Slip) Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine Related information
15K0MW
Trouble
1
Trouble in 1st clutch system (Slip) (Transmission controller system)
• When signal is output to 1st clutch ECMV solenoid valve, value calculated from signals of transmission input shaft speed sensor, intermediate shaft speed sensor, and output shaft reverse speed sensor is abnormal. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • If gearshift lever is set in neutral, machine cannot start. (For emergency escape method, see Testing and adjusting, "Emergency escape method when electrical system has trouble".) • Output current to 1st clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV 1 DIR - 31602) • Method of reproducing failure code: Start engine + Travel at F1. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective 1st clutch ECMV 1 solenoid valve (Internal defect)
Possible causes and standard value in normal state
Resistance 5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (13) Resis2 Max. 1 z or defective contact in con- – CN12 (female) (2) tance nector) Wiring harness between ATC3 (female) (36) ResisMax. 1 z – CN12 (female) (1) tance 3
Defective transmission controller
Defective hydraulic and mechanical systems of 1st 4 clutch or 1st clutch ECMV solenoid valve
16
CN12 (male) Between (1) – (2)
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 – 3 are not detected, 1st clutch or 1st clutch ECMV solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
HM400-2
40 Troubleshooting
SEN01108-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to 1st clutch ECMV solenoid valve
HM400-2
17
SEN01108-00
40 Troubleshooting
Failure code [15L0MW] Trouble in 2nd clutch system (Slip) Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine Related information
15L0MW
Trouble
1
Trouble in 2nd clutch system (Slip) (Transmission controller system)
• When signal is output to 2nd clutch ECMV solenoid valve, value calculated from signals of transmission input shaft speed sensor, intermediate shaft speed sensor, and output shaft reverse speed sensor is abnormal. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • If gearshift lever is set in neutral, machine cannot start. (For emergency escape method, see Testing and adjusting, "Emergency escape method when electrical system has trouble".) • Output current to 2nd clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV 2 DIR - 31603) • Method of reproducing failure code: Start engine + Travel at F3. Cause Defective 2nd clutch ECMV 1 solenoid valve (Internal defect)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CN14 (male)
Resistance
Between (1) – (2)
5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (3) 2 or defective contact in con- – CN14 (female) (2) nector) Wiring harness between ATC3 (female) (6) – CN14 (female) (1)
Max. 1 z
Resistance
Max. 1 z
Defective transmission controller
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Defective hydraulic and mechanical systems of 2nd 4 clutch or 2nd clutch ECMV solenoid valve
If causes 1 – 3 are not detected, 2nd clutch or 2nd clutch ECMV solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
3
18
Resistance
HM400-2
40 Troubleshooting
SEN01108-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to 2nd clutch ECMV solenoid valve
HM400-2
19
SEN01108-00
40 Troubleshooting
Failure code [15M0MW] Trouble in 3rd clutch system (Slip) Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine Related information
15M0MW
Trouble
1
Trouble in 3rd clutch system (Slip) (Transmission controller system)
• When signal is output to 3rd clutch ECMV solenoid valve, value calculated from signals of transmission input shaft speed sensor, intermediate shaft speed sensor, and output shaft reverse speed sensor is abnormal. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • If gearshift lever is set in neutral, machine cannot start. (For emergency escape method, see Testing and adjusting, "Emergency escape method when electrical system has trouble".) • Output current to 3rd clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV 3 DIR - 31604) • Method of reproducing failure code: Start engine + Travel at F5. Cause Defective 3rd clutch ECMV 1 solenoid valve (Internal defect)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CN16 (male)
Resistance
Between (1) – (2)
5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (15) 2 or defective contact in con- – CN16 (female) (1) nector) Wiring harness between ATC3 (female) (23) – CN14 (female) (2) 3
Defective transmission controller
Defective hydraulic and mechanical systems of 3rd 4 clutch or 3rd clutch ECMV solenoid valve
20
Resistance
Max. 1 z
Resistance
Max. 1 z
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 – 3 are not detected, 3rd clutch or 3rd clutch ECMV solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
HM400-2
40 Troubleshooting
SEN01108-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to 3rd clutch ECMV solenoid valve
HM400-2
21
SEN01108-00
40 Troubleshooting
Failure code [15SBL1] Trouble in reverse clutch pressure control valve 1 Action code
Failure code
E03
15SBL1
Contents of trouble Action of controller Problem that appears on machine
Related information
Trouble
• When signal to reverse clutch ECMV solenoid valve is turned OFF, signal from fill switch is kept ON. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 2". • Turns lockup system OFF. • Machine cannot travel forward. • Output current to reverse clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV R DIR - 31606) • Input signal to reverse clutch ECMV fill switch can be checked with monitoring function. (Monitoring code: TRANSMISSION - D-IN--8-----15 - 40906) • When machine is checked for cause 1, its travel speed at R1 gear speed reaches about 7 km/h. Take care of safety around machine extremely. • Method of reproducing failure code: Start engine. Cause Defective reverse clutch 1 ECMV fill switch (Internal defect)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. CN9 (male)
Gear speed
Resistance
Between (1) – chassis ground
N
Min. 1 Mz
R1
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between ATC3 (female) (29) Resiscircuit) Min. 1 Mz – CN9 (female) (1) tance Defective transmission controller
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Defective hydraulic and mechanical systems of 4 reverse clutch or reverse clutch ECMV solenoid valve
If causes 1 – 3 are not detected, reverse clutch or reverse clutch ECMV solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
3
22
Trouble in reverse clutch pressure control valve (Transmission controller system)
HM400-2
40 Troubleshooting
SEN01108-00
Table 2 Gear speed before trouble
F6
F5
F4
F3
F2
F1
R3
R2
R1
N
HM400-2
3rd Hi
3rd Lo
2nd Hi
2nd Lo
1st Hi
1st Lo
3rd Reverse
2nd Reverse
1st Reverse
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
3H
F6
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
3L
F5
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
2H
F4
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
2L
F3
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
1H
F2
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
2nd
2R
R2
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
ANY
NONE
No reaction
—
23
SEN01108-00
40 Troubleshooting
Circuit diagram related to reverse clutch ECMV fill switch
24
HM400-2
SEN01108-00
40 Troubleshooting
Failure code [15SBMA] Trouble in reverse clutch pressure control valve Action code
Failure code
E03
15SBMA
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Trouble in reverse clutch pressure control valve (Transmission controller system)
• When signal is output to reverse clutch ECMV solenoid valve, signal from fill switch is kept OFF and clutch is not engaged. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • Machine cannot travel in reverse. • Output current to reverse clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV R DIR - 31606) • Method of reproducing failure code: Start engine + Travel at R1. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective reverse clutch 1 ECMV solenoid valve (Internal defect)
Possible causes and standard value in normal state
Resistance
Between (1) – (2)
5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (13) 2 or defective contact in con- – CN8 (female) (2) nector) Wiring harness between ATC3 (female) (25) – CN8 (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
Defective transmission controller
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Defective hydraulic and mechanical systems of 4 reverse clutch or reverse clutch ECMV solenoid valve
If causes 1 – 3 are not detected, reverse clutch or reverse clutch ECMV solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
3
26
CN8 (male)
HM400-2
40 Troubleshooting
SEN01108-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to reverse clutch ECMV solenoid valve
HM400-2
27
SEN01108-00
40 Troubleshooting
Failure code [15SCL1] Trouble in Hi clutch pressure control valve Action code
Failure code
E03
15SCL1
Contents of trouble Action of controller Problem that appears on machine
Related information
Trouble
• Shifts up and keeps gear speed according to gear speed before trouble and "Table 2". • Turns lockup system OFF. • Machine travels at gear speeds which use Hi clutch. • Machine cannot travel in reverse. • Output current to Hi clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV H DIR - 31600) • Input signal to Hi clutch ECMV fill switch can be checked with monitoring function. (Monitoring code: TRANSMISSION - D-IN--8-----15 - 40906) • When machine is checked for cause 1, its travel speed at F2 gear speed reaches about 11 km/h. Take care of safety around machine extremely. • Method of reproducing failure code: Start engine.
1
Defective Hi clutch ECMV fill switch (Internal defect)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine with gearshift lever at position 2 and gear speed at F2 and carry out troubleshooting. CN11 (male)
Gear speed
Resistance
Between (1) – chassis ground
N
Min. 1 Mz
F2
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between ATC3 (female) (30) Resiscircuit) Min. 1 Mz – CN11 (female) (1) tance 3
Defective transmission controller
Defective hydraulic and mechanical systems of Hi 4 clutch or Hi clutch ECMV solenoid valve
28
Trouble in Hi clutch pressure control valve (Transmission controller system)
• When signal to Hi clutch ECMV solenoid valve is turned OFF, signal from fill switch is kept ON.
Cause
Possible causes and standard value in normal state
1
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 – 3 are not detected, Hi clutch or Hi clutch ECMV solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
HM400-2
40 Troubleshooting
SEN01108-00
Table 2 Gear speed before trouble
F6
F5
F4
F3
F2
F1
R3
R2
R1
N
HM400-2
3rd Hi
3rd Lo
2nd Hi
2nd Lo
1st Hi
1st Lo
3rd Reverse
2nd Reverse
1st Reverse
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
3H
F6
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
3L
F5
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
2H
F4
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
2L
F3
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
1H
F2
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
2nd
2R
R2
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
ANY
NONE
No reaction
—
29
SEN01108-00
40 Troubleshooting
Circuit diagram related to Hi clutch ECMV fill switch
30
HM400-2
SEN01108-00
40 Troubleshooting
Failure code [15SCMA] Trouble in Hi clutch pressure control valve Action code
Failure code
E03
15SCMA
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Trouble in Hi clutch pressure control valve (Transmission controller system)
• When signal is output to Hi clutch ECMV solenoid valve, signal from fill switch is kept OFF and clutch is not engaged. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • Machine travels at gear speeds which do not use Hi clutch. • Output current to Hi clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV H DIR - 31600) • Method of reproducing failure code: Start engine + Travel at F2. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective Hi clutch ECMV 1 solenoid valve (Internal defect)
Possible causes and standard value in normal state
Resistance
Between (1) – (2)
5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (13) 2 or defective contact in con- – CN10 (female) (2) nector) Wiring harness between ATC3 (female) (26) – CN10 (female) (1) 3
Defective transmission controller
Defective hydraulic and mechanical systems of Hi 4 clutch or Hi clutch ECMV solenoid valve
32
CN10 (male)
Resistance
Max. 1 z
Resistance
Max. 1 z
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 – 3 are not detected, Hi clutch or Hi clutch ECMV solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
HM400-2
40 Troubleshooting
SEN01108-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to Hi clutch ECMV solenoid valve
HM400-2
33
SEN01108-00
40 Troubleshooting
Failure code [15SDL1] Trouble in Lo clutch pressure control valve Action code
Failure code
E03
15SDL1
Contents of trouble Action of controller Problem that appears on machine
Related information
Trouble
1
Trouble in Lo clutch pressure control valve (Transmission controller system)
• When signal to Lo clutch ECMV solenoid valve is turned OFF, signal from fill switch is kept ON. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • Machine travels at gear speeds which do not use Lo clutch. • Machine cannot travel in reverse. • Output current to Lo clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV L DIR - 31601) • Input signal to Lo clutch ECMV fill switch can be checked with monitoring function. (Monitoring code: TRANSMISSION - D-IN--8-----15 - 40906) • When machine is checked for cause 1, its travel speed at F1 gear speed reaches about 7 km/h. Take care of safety around machine extremely. • Method of reproducing failure code: Start engine. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
1
Possible causes and standard value in normal state
Defective Lo clutch ECMV fill switch (Internal defect)
Gear speed
Resistance
Between (1) – chassis ground
N
Min. 1 Mz
F1
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between ATC3 (female) (20) Resiscircuit) Min. 1 Mz – CN7 (female) (1) tance 3
Defective transmission controller
Defective hydraulic and mechanical systems of Lo 4 clutch or Lo clutch ECMV solenoid valve
34
CN7 (male)
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 – 3 are not detected, Lo clutch or Lo clutch ECMV solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
HM400-2
40 Troubleshooting
SEN01108-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to Lo clutch ECMV fill switch
HM400-2
35
SEN01108-00
40 Troubleshooting
Failure code [15SDMA] Trouble in Lo clutch pressure control valve Action code
Failure code
E03
15SDMA
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Trouble in Lo clutch pressure control valve (Transmission controller system)
• When signal is output to Lo clutch ECMV solenoid valve, signal from fill switch is kept OFF and clutch is not engaged. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 2". • Turns lockup system OFF. • Gear speed is set in neutral suddenly during travel. • Once machine stops, it can restart. • Output current to Lo clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV L DIR - 31601) • Method of reproducing failure code: Start engine + Travel at F1. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective Lo clutch ECMV 1 solenoid valve (Internal defect)
Possible causes and standard value in normal state
Resistance
Between (1) – (2)
5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (3) 2 or defective contact in con- – CN10 (female) (2) nector) Wiring harness between ATC3 (female) (16) – CN10 (female) (1) 3
Defective transmission controller
Defective hydraulic and mechanical systems of Lo 4 clutch or Lo clutch ECMV solenoid valve
36
CN6 (male)
Resistance
Max. 1 z
Resistance
Max. 1 z
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 – 3 are not detected, Lo clutch or Lo clutch ECMV solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
HM400-2
40 Troubleshooting
SEN01108-00
Table 2 Gear speed before trouble
F6
F5
F4
F3
F2
F1
R3
R2
R1
N
HM400-2
3rd Hi
3rd Lo
2nd Hi
2nd Lo
1st Hi
1st Lo
3rd Reverse
2nd Reverse
1st Reverse
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
3H
F6
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
3L
F5
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
2H
F4
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
2L
F3
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
1H
F2
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
2nd
2R
R2
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
ANY
NONE
No reaction
—
37
SEN01108-00
40 Troubleshooting
Circuit diagram related to Lo clutch ECMV solenoid valve
38
HM400-2
SEN01108-00
40 Troubleshooting
HM400-2 Articulated dump truck Form No. SEN01108-00
© 2006 KOMATSU All Rights Reserved Printed in Japan 05-06 (02)
40
HM400-2
SEN01109-02
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
40 Troubleshooting
1
Troubleshooting by failure code, Part 2 Failure code [15SEL1] Trouble in 1st clutch pressure control valve ............................................................. 3 Failure code [15SEMA] Trouble in 1st clutch pressure control valve .......................................................... 6 Failure code [15SFL1] Trouble in 2nd clutch pressure control valve ............................................................ 8 Failure code [15SFMA] Trouble in 2nd clutch pressure control valve ....................................................... 12 Failure code [15SGL1] Trouble in 3rd clutch pressure control valve .......................................................... 14 Failure code [15SGMA] Trouble in 3rd clutch pressure control valve ........................................................ 18 Failure code [15SJMA] Trouble in lockup clutch pressure control valve ................................................... 20 Failure code [15SKMA] Trouble in interaxle differential lock clutch pressure control valve ....................... 22 Failure code [2A62L1] Trouble in front wheel differential lock pressure control valve 2 ............................... 24 Failure code [2A62LH] Trouble in front wheel differential lock pressure control valve 1............................... 26 Failure code [2B62L1] Trouble in rear wheel differential lock pressure control valve 2 ................................ 28 Failure code [2B62LH] Trouble in rear wheel differential lock pressure control valve 1 ............................... 30 Failure code [2C4MNX] Clogging of retarder cooling oil filter ....................................................................... 32 Failure code [2F00KM] Dragging of parking brake ....................................................................................... 34 Failure code [2G42ZG] Lowering of accumulator oil pressure (front) ........................................................... 36 Failure code [2G43ZG] Lowering of accumulator oil pressure (rear)............................................................ 36
HM400-2
1
SEN01109-02
40 Troubleshooting
Failure code [989A00] Operation of engine overrun prevention system ....................................................... 37 Failure code [989D00] Rear section tipping over alarm (Raising operation on slope) .................................. 37 Failure code [A570NX] Clogging of engine oil filter....................................................................................... 38 Failure code [AA10NX] Clogging of air cleaner............................................................................................. 40 Failure code [AB00MA] Trouble in battery charge circuit .............................................................................. 42 Failure code [B@BAZG] Lowering of engine oil pressure............................................................................. 43 Failure code [B@BAZK] Lowering of engine oil level.................................................................................... 44 Failure code [B@BCNS] Overheating of engine ........................................................................................... 45 Failure code [B@BCZK] Lowering of coolant level ....................................................................................... 46 Failure code [B@BFZK] Lowering of fuel level ............................................................................................. 48 Failure code [B@C6NS] Overheating of brake cooling oil (front).................................................................. 49 Failure code [B@C7NS] Overheating of brake cooling oil (rear) .................................................................. 49 Failure code [B@C8NS] Overheating of brake cooling oil (center)............................................................... 50 Failure code [B@CENS] Overheating of torque converter oil ....................................................................... 50 Failure code [B@JANS] Overheating of steering oil ..................................................................................... 51
2
HM400-2
40 Troubleshooting
SEN01109-02
Failure code [15SEL1] Trouble in 1st clutch pressure control valve Action code
Failure code
E03
15SEL1
Contents of trouble Action of controller Problem that appears on machine
Related information
Trouble
1
Trouble in 1st clutch pressure control valve (Transmission controller system)
• When signal to 1st clutch ECMV solenoid valve is turned OFF, signal from fill switch is kept ON. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 2". • Turns lockup system OFF. • Machine travels at gear speeds which use 1st clutch. • Output current to 1st clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV 1 DIR - 31602) • Input signal to 1st clutch ECMV fill switch can be checked with monitoring function. (Monitoring code: TRANSMISSION - D-IN--8-----15 - 40906) • When machine is checked for cause 1, its travel speed at F1 gear speed reaches about 7 km/h. Take care of safety around machine extremely. • Method of reproducing failure code: Start engine. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
1
Possible causes and standard value in normal state
Defective 1st clutch ECMV fill switch (Internal defect)
Gear speed
Resistance
Between (1) – chassis ground
N
Min. 1 Mz
F1
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between ATC3 (female) (40) Resiscircuit) Min. 1 Mz – CN13 (female) (1) tance 3
Defective transmission controller
Defective hydraulic and mechanical systems of 1st 4 clutch or 1st clutch ECMV solenoid valve
HM400-2
CN13 (male)
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 – 3 are not detected, 1st clutch or 1st clutch ECMV solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
3
SEN01109-02
40 Troubleshooting
Table 2 Gear speed before trouble
F6
F5
F4
F3
F2
F1
R3
R2
R1
N
4
3rd Hi
3rd Lo
2nd Hi
2nd Lo
1st Hi
1st Lo
3rd Reverse
2nd Reverse
1st Reverse
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
3H
F6
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
3L
F5
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
2H
F4
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
2L
F3
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
1H
F2
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
2nd
2R
R2
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
ANY
NONE
No reaction
—
HM400-2
40 Troubleshooting
SEN01109-02
Circuit diagram related to 1st clutch ECMV fill switch
HM400-2
5
SEN01109-02
40 Troubleshooting
Failure code [15SEMA] Trouble in 1st clutch pressure control valve Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine Related information
15SEMA
Trouble
1
Trouble in 1st clutch pressure control valve (Transmission controller system)
• When signal is output to 1st clutch ECMV solenoid valve, signal from fill switch is kept OFF and clutch is not engaged. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • Machine travels at gear speeds which do not use 1st clutch. • Output current to 1st clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV 1 DIR - 31602) • Method of reproducing failure code: Start engine + Travel at F1. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective 1st clutch ECMV 1 solenoid valve (Internal defect)
Possible causes and standard value in normal state
Resistance
Between (1) – (2)
5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (13) 2 or defective contact in con- – CN12 (female) (2) nector) Wiring harness between ATC3 (female) (36) – CN12 (female) (1) 3
Defective transmission controller
Defective hydraulic and mechanical systems of 1st 4 clutch or 1st clutch ECMV solenoid valve
6
CN12 (male)
Resistance
Max. 1 z
Resistance
Max. 1 z
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 – 3 are not detected, 1st clutch or 1st clutch ECMV solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
HM400-2
40 Troubleshooting
SEN01109-02
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to 1st clutch ECMV solenoid valve
HM400-2
7
SEN01109-02
40 Troubleshooting
Failure code [15SFL1] Trouble in 2nd clutch pressure control valve Action code
Failure code
E03
15SFL1
Contents of trouble Action of controller Problem that appears on machine
Related information
Trouble
1
Trouble in 2nd clutch pressure control valve (Transmission controller system)
• When signal to 2nd clutch ECMV solenoid valve is turned OFF, signal from fill switch is kept ON. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 2". • Turns lockup system OFF. • Machine travels at gear speeds which use 2nd clutch. • Output current to 2nd clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV 2 DIR - 31603) • Input signal to 2nd clutch ECMV fill switch can be checked with monitoring function. (Monitoring code: TRANSMISSION - D-IN--8-----15 - 40906) • When machine is checked for cause 1, its travel speed at F3 gear speed reaches about 16 km/h. Take care of safety around machine extremely. • Method of reproducing failure code: Start engine. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
1
Possible causes and standard value in normal state
CN15 (male)
Gear speed
Resistance
Between (1) – chassis ground
N
Min. 1 Mz
F3
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between ATC3 (female) (9) Resiscircuit) Min. 1 Mz – CN15 (female) (1) tance Defective transmission controller
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Defective hydraulic and mechanical systems of 2nd 4 clutch or 2nd clutch ECMV solenoid valve
If causes 1 – 3 are not detected, 2nd clutch or 2nd clutch ECMV solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
3
8
Defective 2nd clutch ECMV fill switch (Internal defect)
HM400-2
40 Troubleshooting
SEN01109-02
Table 2 Gear speed before trouble
F6
F5
F4
F3
F2
F1
R3
R2
R1
N
HM400-2
3rd Hi
3rd Lo
2nd Hi
2nd Lo
1st Hi
1st Lo
3rd Reverse
2nd Reverse
1st Reverse
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
3H
F6
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
3L
F5
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
2H
F4
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
2L
F3
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
1H
F2
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
2nd
2R
R2
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
ANY
NONE
No reaction
—
9
SEN01109-02
40 Troubleshooting
Circuit diagram related to 2nd clutch ECMV fill switch
10
HM400-2
40 Troubleshooting
HM400-2
SEN01109-02
11
SEN01109-02
40 Troubleshooting
Failure code [15SFMA] Trouble in 2nd clutch pressure control valve Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine Related information
15SFMA
Trouble
1
Trouble in 2nd clutch pressure control valve (Transmission controller system)
• When signal is output to 2nd clutch ECMV solenoid valve, signal from fill switch is kept OFF and clutch is not engaged. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • Machine travels at gear speeds which do not use 2nd clutch. • Output current to 2nd clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV 2 DIR - 31603) • Method of reproducing failure code: Start engine + Travel at F3. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective 2nd clutch ECMV 1 solenoid valve (Internal defect)
Possible causes and standard value in normal state
Resistance
Between (1) – (2)
5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (3) 2 or defective contact in con- – CN14 (female) (2) nector) Wiring harness between ATC3 (female) (5) – CN14 (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
Defective transmission controller
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Defective hydraulic and mechanical systems of 2nd 4 clutch or 2nd clutch ECMV solenoid valve
If causes 1 – 3 are not detected, 2nd clutch or 2nd clutch ECMV solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
3
12
CN14 (male)
HM400-2
40 Troubleshooting
SEN01109-02
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to 2nd clutch ECMV solenoid valve
HM400-2
13
SEN01109-02
40 Troubleshooting
Failure code [15SGL1] Trouble in 3rd clutch pressure control valve Action code
Failure code
E03
15SGL1
Contents of trouble Action of controller Problem that appears on machine
Related information
Trouble
1
Trouble in 3rd clutch pressure control valve (Transmission controller system)
• When signal to 3rd clutch ECMV solenoid valve is turned OFF, signal from fill switch is kept ON. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 2". • Turns lockup system OFF. • Machine travels at gear speeds which use 3rd clutch. • Output current to 3rd clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV 3 DIR - 31604) • Input signal to 3rd clutch ECMV fill switch can be checked with monitoring function. (Monitoring code: TRANSMISSION - D-IN--8-----15 - 40906) • When machine is checked for cause 1, its travel speed at F5 gear speed reaches about 38 km/h. Take care of safety around machine extremely. • Method of reproducing failure code: Start engine. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
1
Possible causes and standard value in normal state
Defective 3rd clutch ECMV fill switch (Internal defect)
Gear speed
Resistance
Between (1) – chassis ground
N
Min. 1 Mz
F5
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between ATC3 (female) (19) Resiscircuit) Min. 1 Mz – CN17 (female) (1) tance 3
Defective transmission controller
Defective hydraulic and mechanical systems of 3rd 4 clutch or 3rd clutch ECMV solenoid valve
14
CN17 (male)
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 – 3 are not detected, 3rd clutch or 3rd clutch ECMV solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
HM400-2
40 Troubleshooting
SEN01109-02
Table 2 Gear speed before trouble
F6
F5
F4
F3
F2
F1
R3
R2
R1
N
HM400-2
3rd Hi
3rd Lo
2nd Hi
2nd Lo
1st Hi
1st Lo
3rd Reverse
2nd Reverse
1st Reverse
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
3H
F6
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
3L
F5
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
2H
F4
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
2L
F3
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
1H
F2
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
2nd
2R
R2
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
ANY
NONE
No reaction
—
15
SEN01109-02
40 Troubleshooting
Circuit diagram related to 3rd clutch ECMV fill switch
16
HM400-2
40 Troubleshooting
HM400-2
SEN01109-02
17
SEN01109-02
40 Troubleshooting
Failure code [15SGMA] Trouble in 3rd clutch pressure control valve Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine Related information
15SGMA
Trouble
1
Trouble in 3rd clutch pressure control valve (Transmission controller system)
• When signal is output to 3rd clutch ECMV solenoid valve, signal from fill switch is kept OFF and clutch is not engaged. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • Machine travels at gear speeds which do not use 3rd clutch. • Output current to 3rd clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV 3 DIR - 31604) • Method of reproducing failure code: Start engine + Travel at F5. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective 3rd clutch ECMV 1 solenoid valve (Internal defect)
Possible causes and standard value in normal state
Resistance
Between (1) – (2)
5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (15) 2 or defective contact in con- – CN16 (female) (1) nector) Wiring harness between ATC3 (female) (23) – CN16 (female) (2) 3
Defective transmission controller
Defective hydraulic and mechanical systems of 3rd 4 clutch or 3rd clutch ECMV solenoid valve
18
CN16 (male)
Resistance
Max. 1 z
Resistance
Max. 1 z
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 – 3 are not detected, 3rd clutch or 3rd clutch ECMV solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
HM400-2
40 Troubleshooting
SEN01109-02
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to 3rd clutch ECMV solenoid valve
HM400-2
19
SEN01109-02
40 Troubleshooting
Failure code [15SJMA] Trouble in lockup clutch pressure control valve Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine Related information
15SJMA
Trouble
1
Trouble in lockup clutch pressure control valve (Transmission controller system)
• When signal is output to lockup clutch ECMV solenoid valve, signal from fill switch is kept OFF and clutch is not engaged. • Keeps current gear speed and turns lockup system OFF. • Keeps gear speed at neutral after gearshift lever is set to "N". • Lockup system is reset and gear speed cannot be changed. • If gearshift lever is set to "N", machine cannot restart until it stops. • Output current to lockup clutch solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV LU DIR - 31609) • Method of reproducing failure code: Start engine + Travel at F1 + Turn lockup pilot lamp. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Possible causes and standard value in normal state
Defective lockup clutch solenoid valve (Internal defect)
Resistance
Between (1) – (2)
5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (6) 2 or defective contact in con- – CN18 (female) (1) nector) Wiring harness between ATC3 (female) (23) – CN18 (female) (2) 3
Defective transmission controller
Defective hydraulic and mechanical systems of 4 lockup clutch or lockup clutch ECMV solenoid valve
20
CN18 (male)
Resistance
Max. 1 z
Resistance
Max. 1 z
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 – 3 are not detected, lockup clutch or lockup clutch ECMV solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
HM400-2
40 Troubleshooting
SEN01109-02
Circuit diagram related to lockup clutch ECMV fill switch
HM400-2
21
SEN01109-02
40 Troubleshooting
Failure code [15SKMA] Trouble in interaxle differential lock clutch pressure control valve Action code
Failure code
E01
15SKMA
Contents of trouble Action of controller Problem that appears on machine
Related information
Trouble
1
Trouble in interaxle differential lock clutch pressure control valve (Transmission controller system)
• When signal is output to interaxle differential lock clutch solenoid valve, signal from fill switch is kept OFF and clutch is not engaged. • Turns interaxle differential lock command OFF. • Interaxle differential lock does not operate. • Output current to interaxle differential lock clutch solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV D DIR - 31607) • Slip of clutch can be checked by displaying following simultaneously with monitoring function. (Monitoring code: TRANSMISSION - TRANSMISSION SPEED: OUT - 31400) (Monitoring code: TRANSMISSION - TRANSMISSION DIFF OUT - 31402) • Method of reproducing failure code: Turn starting switch ON + Operate interaxle switch (manual). Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective interaxle differen1 tial lock clutch solenoid valve (Internal defect)
Possible causes and standard value in normal state
Resistance
Between (1) – (2)
5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (23) 2 or defective contact in con- – CN20 (female) (2) nector) Wiring harness between ATC3 (female) (35) – CN20 (female) (1) 3
Defective transmission controller
Defective hydraulic and mechanical systems of inter4 axle differential lock clutch or interaxle differential lock clutch solenoid
22
CN20 (male)
Resistance
Max. 1 z
Resistance
Max. 1 z
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 – 3 are not detected, interaxle differential lock clutch or interaxle differential lock clutch solenoid may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
HM400-2
40 Troubleshooting
SEN01109-02
Circuit diagram related to interaxle differential lock clutch ECMV fill switch
HM400-2
23
SEN01109-02
40 Troubleshooting
Failure code [2A62L1] Trouble in front wheel differential lock pressure control valve 2 1 Action code
Failure code
E01
2A62L1
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Trouble in front wheel differential lock pressure control valve 2 (Retarder controller system)
• When signal to front differential lock clutch solenoid valve circuit is turned OFF, signal from differential lock oil pressure switch (front) is kept ON. • None in particular. • There is no particular effect on machine. • Method of reproducing failure code: Turn starting switch ON + Set right and left differential lock switches to neutral position. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine, press right and left differential lock pedals, and carry out troubleshooting.
Defective differential lock oil 1 pressure switch (front) (Internal defect)
B39 (male) Between (1) – (2)
Possible causes and standard value in normal state
24
Right and left differential lock switches
Resistance
Upper position
Min. 1 Mz
Lower position
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND ResisWiring harness between BRC3 (female) circuit) Min. 1 Mz (10) – chassis ground tance 3 Defective retarder controller
If causes 1 – 2 are not detected, retarder controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Defective hydraulic and mechanical systems of front 4 differential lock clutch or front differential lock clutch solenoid valve
If causes 1 – 3 are not detected, front differential lock clutch or front differential lock clutch solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
HM400-2
40 Troubleshooting
SEN01109-02
Circuit diagram related to differential lock oil pressure switch (front)
HM400-2
25
SEN01109-02
40 Troubleshooting
Failure code [2A62LH] Trouble in front wheel differential lock pressure control valve 1 1 Action code
Failure code
E01
2A62LH
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Trouble in front wheel differential lock pressure control valve 1 (Retarder controller system)
• When signal is output to front differential lock solenoid circuit 30 seconds or more after engine is started, signal from differential lock oil pressure switch (front) is kept OFF. • None in particular. • There is no particular effect on machine. • Method of reproducing failure code: Turn starting switch ON + Set right and left differential lock switches to lower position + Press right and left differential lock pedals. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine, press right and left differential lock pedals, and carry out troubleshooting.
Defective differential lock oil 1 pressure switch (front) (Internal defect)
B39 (male) Between (1) – (2)
Possible causes and standard value in normal state
Right and left differential lock switches
Resistance
Upper position
Min. 1 Mz
Lower position
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between BRC3 (female) Resis2 Max. 1 z or defective contact in con- (10) – B39 (female) (1) tance nector) Wiring harness between B39 (female) (2) – ResisMin. 1 Mz chassis ground (ER) tance 3 Defective retarder controller
If causes 1 – 2 are not detected, retarder controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Defective hydraulic and mechanical systems of front 4 differential lock clutch or front differential lock clutch solenoid valve
If causes 1 – 3 are not detected, front differential lock clutch or front differential lock clutch solenoid valve may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
Note: This troubleshooting code is not applied to the following serial number # 2038 – 2452.
26
HM400-2
40 Troubleshooting
SEN01109-02
Circuit diagram related to differential lock oil pressure switch (front)
HM400-2
27
SEN01109-02
40 Troubleshooting
Failure code [2B62L1] Trouble in rear wheel differential lock pressure control valve 2 1 Action code
Failure code
E01
2B62L1
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Trouble in rear wheel differential lock pressure control valve 2 (Retarder controller system)
• When signal to rear differential lock clutch solenoid valve circuit is turned OFF, signal from differential lock oil pressure switch (center) (rear) is kept ON. • None in particular. • There is no particular effect on machine. • Method of reproducing failure code: Turn starting switch ON + Set right and left differential lock switches to upper or lower position + Press right and left differential lock pedals Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. B40 (male)
Defective differential lock oil 1 pressure switch (center) (Internal defect) Between (1) – (2)
Right and left differential lock switches and differential lock pedals
Resistance
Right and left differential lock switches: Neutral position Right and left differential lock pedals: Released
Min. 1 Mz
Right and left differential lock switches: Upper position Right and left differential lock pedals: Pressed
Max. 1 z
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. B41 (male) Possible causes and standard value in normal state
Defective differential lock oil 2 pressure switch (rear) (Internal defect) Between (1) – (2)
Right and left differential lock switches and differential lock pedals
Resistance
Right and left differential lock switches: Neutral position Right and left differential lock pedals: Released
Min. 1 Mz
Right and left differential lock switches: Upper position Right and left differential lock pedals: Pressed
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between BRC3 (female) (20) – chassis ground ER circuit) Wiring harness between B40 (female) (2) – chassis ground ER
28
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
4 Defective retarder controller
If causes 1 – 3 are not detected, retarder controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Defective hydraulic and mechanical systems of rear 5 differential lock clutch or rear differential lock clutch solenoid
If causes 1 – 4 are not detected, rear differential lock clutch or rear differential lock clutch solenoid may have trouble in its hydraulic and mechanical systems. Carry out troubleshooting for hydraulic and mechanical systems.
HM400-2
40 Troubleshooting
SEN01109-02
Circuit diagram related to differential lock oil pressure switches (center and rear)
HM400-2
29
SEN01109-02
40 Troubleshooting
Failure code [2B62LH] Trouble in rear wheel differential lock pressure control valve 1 1 Action code
Failure code
E01
2B62LH
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Trouble in rear wheel differential lock pressure control valve 1 (Retarder controller system)
• When signal is output to rear differential lock solenoid circuit 30 seconds or more after engine is started, signal from differential lock oil pressure switch is kept OFF. • None in particular. • There is no particular effect on machine. • Method of reproducing failure code: Turn starting switch ON + Set right and left differential lock switches to upper or lower position + Press right and left differential lock pedals Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. B40 (male)
Defective differential lock oil 1 pressure switch (center) (Internal defect) Between (1) – (2)
Right and left differential lock switches and differential lock pedals
Resistance
Right and left differential lock switches: Neutral position Right and left differential lock pedals: Released
Min. 1 Mz
Right and left differential lock switches: Upper position Right and left differential lock pedals: Pressed
Max. 1 z
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Possible causes and standard value in normal state
B41 (male)
Defective differential lock oil 2 pressure switch (rear) (Internal defect) Between (1) – (2)
Right and left differential lock switches and differential lock pedals
Resistance
Right and left differential lock switches: Neutral position Right and left differential lock pedals: Released
Min. 1 Mz
Right and left differential lock switches: Upper position Right and left differential lock pedals: Pressed
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harResis3 ness (Disconnection in wiring Wiring harness between BRC3 (female) Max. 1 z or defective contact in con- (20) – B40 (1) (female) tance nector) Wiring harness between BRC3 (female) Resis- Min. 1 Mz (21), (31), (32), (33) – B41 (2) (female) tance
30
4 Defective retarder controller
If causes 1 – 3 are not detected, retarder controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
5 Defective hydraulic and mechanical systems
If causes 1 – 4 are not detected, carry out troubleshooting for hydraulic and mechanical systems.
Note:This troubleshooting code is not applied to the following serial number # 2038 – 2452. HM400-2
40 Troubleshooting
SEN01109-02
Circuit diagram related to differential lock oil pressure switches (center and rear)
HM400-2
31
SEN01109-02
40 Troubleshooting
Failure code [2C4MNX] Clogging of retarder cooling oil filter Action code
Failure code
E01 Contents of trouble
2C4MNX
Trouble
1
Clogging of retarder cooling oil filter (Machine monitor system)
• When brake oil temperature is above 50°C while engine is running, signal circuit of retarder oil filter clogging switch is open (disconnected from chassis ground).
Action of • None in particular. machine monitor Problem that appears on machine Related information
• If machine is used as it is, foreign matter may be sent to retarder cooling circuit. • This failure code is used for only machines having retarder oil filter clogging switches. • Method of reproducing failure code: Start engine. Cause 1
Clogged retarder oil filter (When system is normal)
Standard value in normal state/Remarks on troubleshooting Check filter. If it is clogged, clean or replace. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. M08 (male)
Defective retarder oil filter 2 clogging switch (Internal defect)
Possible causes and standard value in normal state
Between (1) – (2)
Retarder oil filter
Resistance
When normal (Reference: Differential pressure is below 98.1 ± 19.6 kPa {1.0 ± 0.2 kg/cm2})
Max. 1 z
When clogged (Reference: Differential pressure is above 98.1 ± 19.6 kPa {1.0 ± 0.2 kg/cm2})
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between DPC2B (female) 3 or defective contact in con- (6) – M08 (female) (2) nector) Wiring harness between DPC2B (female) (7) – M08 (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. DPC2B
4 Defective machine monitor Between (6) – (7)
32
Retarder oil filter
Voltage
When normal (Reference: Differential pressure is below 98.1 ± 19.6 kPa {1.0 ± 0.2 kg/cm2})
Max. 1 V
When clogged (Reference: Differential pressure is above 98.1 ± 19.6 kPa {1.0 ± 0.2 kg/cm2})
20 – 30 V
HM400-2
40 Troubleshooting
SEN01109-02
Circuit diagram related to retarder oil filter clogging switch
HM400-2
33
SEN01109-02
40 Troubleshooting
Failure code [2F00KM] Dragging of parking brake Action code
Failure code
–
2F00KM
Contents of trouble Action of controller Problem that appears on machine
Trouble
1
Dragging of parking brake (Transmission controller system)
• While signal circuit of parking brake was ON, operator performed travel operation. • None in particular. • If machine is used as it is, parking brake may be damaged.
Related information Cause Wrong operation of parking 1 brake switch (When system is normal)
Standard value in normal state/Remarks on troubleshooting Parking brake switch may have been operated wrongly. Teach operator correct operation. (Travel must be started after parking brake switch is turned OFF.)
2 Defective fuse (BT3-No. 33) If fuse is broken, circuit probably has ground fault. (See cause 6.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
Defective parking brake relay Replace parking brake relay (R02) with another relay and perform (R02) (Internal defect) reproducing operation. If blinking failure code lights up at this time, relay is defective.
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective parking brake oil 4 pressure switch (Internal defect)
B17 (male) Between (1) – (2)
Possible causes and standard value in normal state
Parking brake oil pressure switch
Resistance
ON
Max. 1 z
OFF
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 5 or defective contact in connector)
Wiring harness between R02 (female) (2), (6) – chassis ground
Resistance
Max. 1 z
Wiring harness between fuse BT3-No. 33 (16) – B17 (female) (1)
Resistance
Max. 1 z
Wiring harness between R02 (female) (1) – B17 (female) (2)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 6 ness (Short circuit with GND Wiring harness between BRC3 (female) (9) Resiscircuit) Max. 1 z – R02 (female) (3) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 7
34
Defective transmission controller
BRC3
Parking brake switch
Voltage
Between (9) – chassis ground
Parking
20 – 30 V
Travel
Max. 1 V
HM400-2
40 Troubleshooting
SEN01109-02
Circuit diagram related to parking brake switch
HM400-2
35
SEN01109-02
40 Troubleshooting
Failure code [2G42ZG] Lowering of accumulator oil pressure (front) Action code E03 Contents of trouble Action of controller Problem that appears on machine Related information
Failure code 2G42ZG
Trouble
Lowering of accumulator oil pressure (front) (Retarder controller system)
• While engine is running, signal of accumulator oil pressure sensor (front) lowered below 6.86 MPa {70 kg/cm2}. • None in particular. • If machine is used as it is, front brake may not work. • Front accumulator pressure can be checked with monitoring function. (Monitoring code: BRAKE - ACC OIL PRE F - 35500) • Method of reproducing failure code: Start engine. Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
Lowering of front accumula1 tor oil pressure (When system is normal)
Oil pressure in front accumulator may be lowered. Check and repair.
2 Defective retarder controller
If cause 1 is not detected, retarder controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Failure code [2G43ZG] Lowering of accumulator oil pressure (rear) Action code
Failure code
E03
2G43ZG
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
36
1
Lowering of accumulator oil pressure (rear) (Retarder controller system)
• While engine is running, signal of accumulator oil pressure sensor (rear) lowered below 6.86 MPa {70 kg/cm2}. • None in particular. • If machine is used as it is, rear brake may not work. • Accumulator pressure can be checked with monitoring function. (Monitoring code: BRAKE - ACC OIL PRE R - 35501) • Method of reproducing failure code: Start engine. Cause
Possible causes and standard value in normal state
1
Standard value in normal state/Remarks on troubleshooting
Lowering of rear accumulator Oil pressure in rear accumulator may be lowered. Check and 1 oil pressure (When system is repair. normal) 2 Defective retarder controller
If cause 1 is not detected, retarder controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
HM400-2
40 Troubleshooting
SEN01109-02
Failure code [989A00] Operation of engine overrun prevention system 1 Action code
Failure code
E02
989A00
Contents of trouble
Trouble
Operation of engine overrun prevention system (Machine monitor system)
• While gear speed is not neutral, transmission input shaft speed is above 2,450 rpm.
Action of • Outputs command signal to retarder controller to operate brake (retarder). machine monitor Problem that appears on machine Related information
• Brake (Retarder) operates to lower travel speed. • Input shaft speed can be checked with monitoring function. (Monitoring code: TRANSMISSION - TRANSMISSION SPEED:IN - 31200) • Overrun signal is received from transmission controller through network. Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
Overrun of engine (When 1 system is normal)
Engine may have overrun. Teach operator correct operation. (Engine speed must be kept below 2,450 rpm.)
Defective transmission controller
If cause 1 is not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
3 Defective retarder controller
If causes 1 – 2 are not detected, retarder controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
2
Failure code [989D00] Rear section tipping over alarm (Raising operation on slope) 1 Action code
Failure code
–
989D00
Contents of trouble
Trouble
Rear section tipping over alarm (Raising operation on slope) (Machine monitor system)
• While machine is slanting more than 15°, dump body is raised.
Action of • Turns pitch angle caution lamp ON and sounds alarm buzzer. machine monitor Problem that appears on machine Related information
• If dump body is raised as it is, machine may tip over. • Pitch angle and pitch angle signal can be checked with monitoring function. (Monitoring code: TRANSMISSION - ANGLE SENSOR - 32900) • Information of operation of rear section tipping over alarm is received from transmission controller through network. Cause
Possible causes and standard value in normal state
HM400-2
Standard value in normal state/Remarks on troubleshooting
1
Wrong dumping operation (When system is normal)
Dump body may have been raised on slope sharper than 15°. Teach operator correct operation. (Dump body must not be raised on slope sharper than 15°.)
2
Defective transmission controller
If cause 1 is not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
3 Defective retarder controller
If causes 1 – 2 are not detected, retarder controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
37
SEN01109-02
40 Troubleshooting
Failure code [A570NX] Clogging of engine oil filter Action code
Failure code
E01
A570NX
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Clogging of engine oil filter (Transmission controller system)
• While engine is running, engine oil filter clogging signal is detected. • None in particular. • If machine is used as it is, engine may be damaged. • Operation of engine oil filter clogging switch can be checked with monitoring function. (Monitoring code: TRANSMISSION - D-IN-24-----31 - 40908) • Method of reproducing failure code: Start engine. Cause Clogged engine oil filter 1 (When system is normal)
Standard value in normal state/Remarks on troubleshooting Engine oil filter may be clogged. Check it, then replace if necessary. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 0F (male)
Defective engine oil filter 2 clogging switch (Internal defect)
Possible causes and standard value in normal state
Engine oil filter
When normal (Reference: Differential pressure is below 147.1 – 186.3 kPa {1.5 – 1.9 kg/cm2}) Between 0F – chassis ground When clogged (Reference: Differential pressure is above 147.1 – 186.3 kPa {1.5 – 1.9 kg/cm2})
Resistance
Max. 1 z
Min. 1 Mz
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 3 or defective contact in con- Wiring harness between ATC2 (female) (3) ResisMax. 1 z nector) – 0F (male) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ATC2 (female)
4
38
Defective transmission controller
Engine oil filter
When normal (Reference: Differential pressure is below 147.1 – 186.3 kPa {1.5 – 1.9 kg/cm2}) Between (3) – chassis ground When clogged (Reference: Differential pressure is above 147.1 – 186.3 kPa {1.5 – 1.9 kg/cm2})
Voltage
Max. 1 V
20 – 30 V
HM400-2
40 Troubleshooting
SEN01109-02
Circuit diagram related to engine oil filter clogging switch
HM400-2
39
SEN01109-02
40 Troubleshooting
Failure code [AA10NX] Clogging of air cleaner Action code
Failure code
E01 Contents of trouble
AA10NX
Trouble
1
Clogging of air cleaner (Machine monitor system)
• While engine is running, air cleaner clogging signal circuit is kept open (disconnected from chassis ground) for 2 seconds.
Action of • None in particular. machine monitor Problem that appears on machine Related information
• If machine is used as it is, engine output may be lowered. • Method of reproducing failure code: Start engine.
Cause 1
Clogged air cleaner (When system is normal)
Standard value in normal state/Remarks on troubleshooting Air cleaner may be clogged. Check it, then clean or replace if necessary.
2 Defective fuse (BT3-No. 30) If fuse is broken, circuit probably has ground fault. (See cause 6.)
3
Defective air cleaner clogging sensor (Internal defect)
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. M11 (male)
Voltage
Between (1) – (2)
20 – 30 V
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Replace dust indicator relay (R03) with another relay and perform reproducing operation. If blinking failure code lights up at this time, Defective dust indicator relay relay is defective. 4 (R03) (Internal defect) a Prepare with starting switch OFF, then check relay unit. Possible causes and standard value in normal state
R03 (male)
Resistance
Between (1) – (2)
200 – 400 z
Between (3) – (6)
Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 5 or defective contact in con- Wiring harness between DPC2B (female) ResisMax. 1 z nector) (2) – DPC2B (female) (6) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between R03 (female) (2) – 6 ness (Short circuit with GND DPC2B (female) (2) circuit) Wiring harness between DPC2B (female) (6) – M11 (female) (2)
7 Defective machine monitor
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. a Check monitoring code: 40902 "MONITOR PANEL D-IN-18" with real-time function. DPC2B (2) – (6)
40
Resistance
Voltage
Real-time display
20 – 30 V
0
Max. 1 V
1
HM400-2
40 Troubleshooting
SEN01109-02
Circuit diagram related to air cleaner clogging sensor
HM400-2
41
SEN01109-02
40 Troubleshooting
Failure code [AB00MA] Trouble in battery charge circuit Action code
Failure code
E03
AB00MA
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Trouble in battery charge circuit (Transmission controller system)
• While engine is running, generation signal is not input from alternator. • Turns battery charge circuit caution lamp ON and sounds alarm buzzer. • If machine is used as it is, battery voltage lowers and machine may not able to continue travel. • Battery voltage can be checked with monitoring function. (Monitoring code: TRANSMISSION - ALTERNATOR R - 04301) • Method of reproducing failure code: Start engine. Cause
Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then run engine (at medium speed) and carry out troubleshooting. Defective charge by alterna1 tor (When system is normal) R, E Engine speed Voltage Between R – E Possible causes and standard value in normal state
Medium or higher
27.6 – 29.5 V
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between ATC1 (female) ResisMax. 1 z nector) alternator R tance
3
Defective transmission controller
a Prepare with starting switch OFF, then run engine (at medium speed) and carry out troubleshooting. ATC1
Engine speed
Voltage
Between (15) – chassis ground
Medium or higher
27.6 – 29.5 V
Circuit diagram related to battery charge circuit
42
HM400-2
40 Troubleshooting
SEN01109-02
Failure code [B@BAZG] Lowering of engine oil pressure Action code
Failure code
– Contents of trouble Action of controller Problem that appears on machine Related information
B@BAZG
Trouble
HM400-2
Lowering of engine oil pressure (Engine controller system)
• While engine was running, engine oil pressure sensor signal circuit detected abnormal lowering of engine oil pressure. • Operates with normal control system. • Turns engine oil pressure caution lamp ON and sounds alarm buzzer. • If machine is used as it is, engine may be seized. • Engine oil pressure can be checked with monitoring function. (Monitoring code: ENGINE - ENGINE OIL PRESS - 37200) • Method of reproducing failure code: Start engine. Cause
Possible causes and standard value in normal state
1
Lowering of engine oil pres1 sure (When system is normal) 2
Standard value in normal state/Remarks on troubleshooting Engine oil pressure may be low. Check it and remove cause, if necessary.
If cause 1 is not detected, engine oil pressure sensor system may Defective engine oil pressure be defective. Carry out troubleshooting for failure codes [CA135] sensor system and [CA141].
43
SEN01109-02
40 Troubleshooting
Failure code [B@BAZK] Lowering of engine oil level Action code
Failure code
E01
B@BAZK
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Lowering of engine oil level (Transmission controller system)
• Engine oil level switch signal circuit is open (disconnected from chassis ground). • Operates with normal control system. • If machine is used as it is, engine may be seized. • Operation of engine oil level switch can be checked with monitoring function. (Monitoring code: TRANSMISSION - D-IN-24-----31 - 40908) • Method of reproducing failure code: Turn starting switch ON. Cause 1
Lowering of engine oil level (When system is normal)
Standard value in normal state/Remarks on troubleshooting Check engine oil level and add new oil if necessary. a If engine oil level is low, check around engine for oil leakage before adding oil. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2 Possible causes and standard value in normal state
Defective engine oil level switch (Internal defect)
0L (male)
Engine oil level
Between (1) – chas- Between H – L levels sis ground L level
Resistance Max. 1 z Min. 1 Mz
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 3 or defective contact in con- Wiring harness between ATC2 (female) (13) ResisMax. 1 z nector) – 0L (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4
Defective transmission controller
ATC2
Engine oil level
Between (13) – chas- Between H – L levels sis ground L level
Voltage Max. 1 V 20 – 30 V
Circuit diagram related to engine oil level switch
44
HM400-2
40 Troubleshooting
SEN01109-02
Failure code [B@BCNS] Overheating of engine Action code
Failure code
E02 Contents of trouble Action of controller Problem that appears on machine Related information
B@BCNS
Trouble
Overheating of engine (Engine controller system)
• While engine was running, engine coolant temperature sensor signal circuit detected overheating of engine coolant. • Limits fuel injection until coolant temperature lowers to operating range. • Turns engine oil pressure caution lamp ON and sounds alarm buzzer. • Engine output lowers. • Engine coolant temperature can be checked with monitoring function. (Monitoring code: ENGINE - COOLANT TEMP - 04104) Cause
Possible causes and standard value in normal state
1
Standard value in normal state/Remarks on troubleshooting
1
Overheating of engine cool- Engine coolant may be overheating. Check it and remove cause, if ant (When system is normal) necessary.
2
Defective engine coolant temperature gauge system
If cause 1 is not detected, engine coolant temperature gauge system may be defective. Carry out troubleshooting for failure codes [CA144] and [CA145].
Circuit diagram related to engine coolant temperature sensor
HM400-2
45
SEN01109-02
40 Troubleshooting
Failure code [B@BCZK] Lowering of coolant level Action code
Failure code
E01 Contents of trouble
B@BCZK
Trouble
1
Lowering of coolant level (Machine monitor system)
• Signal circuit of radiator coolant level switch is kept open (disconnected from chassis ground) for 30 seconds.
Action of • None in particular. machine monitor Problem that appears on machine Related information
• If machine is used as it is, engine may overheat. • Operation of radiator coolant level switch can be checked with monitoring function. (Monitoring code: MONITOR PANEL - D-IN-16-----23 - 40902) • Method of reproducing failure code: Turn starting switch ON. Cause Lowering of radiator coolant 1 level (When system is normal)
Standard value in normal state/Remarks on troubleshooting Coolant level in radiator sub tank may be low. Check it and add coolant if necessary. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2
Defective radiator coolant level switch (Internal defect)
M01 (male) Between (1) – (2)
Possible causes and standard value in normal state
Resistance
Normal
Max. 1 z
Low
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between DPC2B (female) 3 or defective contact in con- (4) – M01 (female) (1) nector) Wiring harness between DPC2B (female) (6) – M01 (female) (2) 4 Defective machine monitor
5 Defective machine monitor
Resistance
Max. 1 z
Resistance
Max. 1 z
If causes 1 – 3 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) a Prepare with starting switch OFF, then start engine and carry out troubleshooting. a Check monitoring code: 40902 "MONITOR PANEL D-IN-22" with real-time function. DPC2B (4) – (6)
46
Radiator coolant level
Voltage
Real-time display
20 – 30 V
0
Max. 1 V
1
HM400-2
40 Troubleshooting
SEN01109-02
Circuit diagram related to radiator coolant level switch
HM400-2
47
SEN01109-02
40 Troubleshooting
Failure code [B@BFZK] Lowering of fuel level Action code
Failure code
–
B@BFZK
Contents of trouble
Trouble
1
Lowering of fuel level (Machine monitor system)
• Fuel level sensor signal indicates lowering of fuel level (Resistance of 70 z or higher is detected).
Action of • Does not display this failure code, if DJF1KA is detected. machine monitor • Turns fuel level caution lamp ON. Problem that appears on machine Related information
• None in particular. • When fuel level is below LOW and fuel is added, if failure code disappears, fuel was insufficient. • Signal from fuel level sensor can be checked with monitoring function. (Monitoring code: MONITOR PANEL - FUEL SENSOR - 04200/04201) • Method of reproducing failure code: Turn starting switch ON. Cause 1
Lack of fuel (When system is Fuel may be insufficient. Check and add fuel, if necessary. normal)
Defective fuel level sensor 2 (Internal disconnection or short circuit) Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
M06 (male) Between (1) – (2)
Fuel level
Resistance
When full
Approx. 10 z
When empty
Approx. 80 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between DPC3B (female) 3 or defective contact in con- (3) – M06 (female) (1) nector) Wiring harness between DPC3B (female) (6) – M06 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective machine monitor
DPC3B (female) Between (3) – (6)
Fuel level
Resistance
When full
Approx. 10 z
When empty
Approx. 80 z
Circuit diagram related to fuel level sensor
48
HM400-2
40 Troubleshooting
SEN01109-02
Failure code [B@C6NS] Overheating of brake cooling oil (front) Action code
Failure code
E02
B@C6NS
Contents of trouble
Trouble
1
Overheating of brake cooling oil (front) (Machine monitor system)
• Front brake cooling oil is overheating.
Action of • Turns retarder oil temperature caution lamp ON and sounds alarm buzzer. machine monitor Problem that appears on machine Related information
Possible causes and standard value in normal state
• If machine is used as it is, front brake may be broken. • Brake oil temperature can be checked with monitoring function. (Monitoring code: MONITOR PANEL - BRAKE OIL T F - 30201) (Monitoring code: MONITOR PANEL - BRAKE OIL T F - 30204) Cause
Standard value in normal state/Remarks on troubleshooting
Overheating of front brake 1 cooling oil (When system is normal)
Front brake cooling oil may be overheating. Check for cause and repair.
2
If cause 1 is not detected, brake oil temperature sensor (front) sysDefective brake oil temperatem may be defective. Carry out troubleshooting for failure code ture sensor (front) system [DGR4KZ].
Failure code [B@C7NS] Overheating of brake cooling oil (rear) Action code
Failure code
E02
B@C7NS
Contents of trouble
Trouble
1
Overheating of brake cooling oil (rear) (Machine monitor system)
• Rear brake cooling oil is overheating.
Action of • Turns retarder oil temperature caution lamp ON and sounds alarm buzzer. machine monitor Problem that appears on machine Related information
• If machine is used as it is, rear brake may be broken. • Brake oil temperature can be checked with monitoring function. (Monitoring code: MONITOR PANEL - BRAKE OIL T R - 30202) (Monitoring code: MONITOR PANEL - BRAKE OIL T R - 30205) Cause
Possible causes and standard value in normal state
HM400-2
Overheating of rear brake 1 cooling oil (When system is normal) 2
Standard value in normal state/Remarks on troubleshooting Rear brake cooling oil may be overheating. Check for cause and repair.
If cause 1 is not detected, brake oil temperature sensor (rear) sysDefective brake oil temperatem may be defective. Carry out troubleshooting for failure code ture sensor (rear) system [DGR2KZ].
49
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40 Troubleshooting
Failure code [B@C8NS] Overheating of brake cooling oil (center) Action code
Failure code
E02
B@C8NS
Contents of trouble
Trouble
1
Overheating of brake cooling oil (center) (Machine monitor system)
• Center brake cooling oil is overheating.
Action of • Turns retarder oil temperature caution lamp ON and sounds alarm buzzer. machine monitor Problem that appears on machine Related information
• If machine is used as it is, center brake may be broken. • Brake oil temperature can be checked with monitoring function. (Monitoring code: MONITOR PANEL - BRAKE OIL T M - 30203) (Monitoring code: MONITOR PANEL - BRAKE OIL T M - 30206) Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
Overheating of center brake Center brake cooling oil may be overheating. Check for cause and 1 cooling oil (When system is repair. normal) 2
If cause 1 is not detected, brake oil temperature sensor (center) Defective brake oil temperasystem may be defective. Carry out troubleshooting for failure ture sensor (center) system code [DGR3KZ].
Failure code [B@CENS] Overheating of torque converter oil Action code
Failure code
E02
B@CENS
Contents of trouble
Trouble
1
Overheating of torque converter oil (Machine monitor system)
• Torque converter oil is overheating.
Action of • Turns torque converter oil temperature caution lamp ON and sounds alarm buzzer. machine monitor Problem that appears on machine Related information
• If machine is used as it is, torque converter may be broken. • Signal of torque converter oil temperature sensor is input to transmission controller and then its information is transmitted to machine monitor through communication system. • Power train oil temperature can be checked with monitoring function. (Monitoring code: TRANSMISSION - T/C OIL TEMP - 30100) Cause
Possible causes and standard value in normal state
50
Standard value in normal state/Remarks on troubleshooting
Overheating of torque con1 verter oil (When system is normal)
Torque converter oil may be overheating. Check for cause and repair.
Defective torque converter 2 oil temperature sensor system
If cause 1 is not detected, torque converter oil temperature sensor system may be defective. Carry out troubleshooting for failure code [DGT1KX].
HM400-2
40 Troubleshooting
SEN01109-02
Failure code [B@JANS] Overheating of steering oil Action code
Failure code
E02
B@JANS
Contents of trouble
Trouble
1
Overheating of steering oil (Machine monitor system)
• Signal circuit of steering oil temperature switch is open (disconnected from chassis ground).
Action of • Turns steering oil temperature caution lamp ON and sounds alarm buzzer. machine monitor Problem that appears on machine Related information
• If machine is used as it is, oil may leak. • Steering oil temperature can be checked with monitoring function. (Monitoring code: TRANSMISSION - STRG OIL TEMP - 32701) Cause
Possible causes and standard value in normal state
HM400-2
Standard value in normal state/Remarks on troubleshooting
1
Overheating of steering oil (When system is normal)
Steering oil may be overheating. Check for cause and repair.
2
Defective steering oil temperature sensor system
If cause 1 is not detected, steering oil temperature sensor system may be defective. Carry out troubleshooting for failure code [DGR6KX].
51
SEN01109-02
40 Troubleshooting
HM400-2 Articulated dump truck Form No. SEN01109-02
© 2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (02)
52
HM400-2
SEN01110-02
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
40 Troubleshooting
1
Troubleshooting by failure code, Part 3 Failure code [CA111] Trouble in engine controller .......................................................................................... 4 Failure code [CA115] Trouble in engine Ne and Bkup speed sensors............................................................ 6 Failure code [CA122] Abnormally high charge pressure ................................................................................ 8 Failure code [CA123] Abnormally low charge pressure................................................................................ 10 Failure code [CA131] Abnormally high throttle sensor signal ....................................................................... 12 Failure code [CA132] Abnormally low throttle sensor signal......................................................................... 14 Failure code [CA135] Abnormally high engine oil pressure .......................................................................... 16 Failure code [CA141] Abnormally low engine oil pressure ........................................................................... 18 Failure code [CA144] Abnormally high coolant temperature ........................................................................ 20 Failure code [CA145] Abnormally low coolant temperature.......................................................................... 22 Failure code [CA153] Abnormally high charge temperature ......................................................................... 24 Failure code [CA154] Abnormally low charge temperature .......................................................................... 26 Failure code [CA187] Abnormally low voltage in sensor power supply 2 ..................................................... 27 Failure code [CA221] Abnormally high ambient pressure............................................................................. 28 Failure code [CA222] Abnormally low ambient pressure .............................................................................. 30 Failure code [CA227] Abnormally high voltage in sensor power supply 2 .................................................... 32
HM400-2
1
SEN01110-02
40 Troubleshooting
Failure code [CA234] Engine overspeed ...................................................................................................... 34 Failure code [CA238] Trouble in Ne speed sensor power supply ................................................................. 36 Failure code [CA263] Abnormally high fuel temperature .............................................................................. 38 Failure code [CA265] Abnormally low fuel temperature................................................................................ 40 Failure code [CA271] Short circuit in PCV1 .................................................................................................. 41 Failure code [CA272] Disconnection in PCV1............................................................................................... 42 Failure code [CA273] Short circuit in PCV2 .................................................................................................. 43 Failure code [CA274] Disconnection in PCV2............................................................................................... 44 Failure code [CA322] Disconnection or short circuit in injector #1 (L #1) ..................................................... 46 Failure code [CA323] Disconnection or short circuit in injector #5 (L #5) ..................................................... 48 Failure code [CA324] Disconnection or short circuit in injector #3 (L #3) ..................................................... 50 Failure code [CA325] Disconnection or short circuit in injector #6 (L #6) ..................................................... 52 Failure code [CA331] Disconnection or short circuit in injector #2 (L #2) ..................................................... 54 Failure code [CA332] Disconnection or short circuit in injector #4 (L #4) ..................................................... 56 Failure code [CA342] Matching error in engine controller data..................................................................... 58 Failure code [CA351] Trouble in injector drive circuit.................................................................................... 60 Failure code [CA352] Abnormally low voltage in sensor power supply 1...................................................... 62 Failure code [CA386] Abnormally high voltage in sensor power supply 1 .................................................... 64
2
HM400-2
40 Troubleshooting
HM400-2
SEN01110-02
3
SEN01110-02
40 Troubleshooting
Failure code [CA111] Trouble in engine controller Action code
Failure code
E03
CA111
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Trouble in engine controller (Engine controller system)
• Engine controller has trouble in it. • None in particular. • Machine continues operation normally but may stop suddenly or may not able to restart. • Source voltage of engine controller can be checked with monitoring function. (Monitoring code: ENGINE - POWER SUPPLY - 03200) Cause 1 Trip of circuit breaker (30 A)
Standard value in normal state/Remarks on troubleshooting If circuit breaker has tripped, circuit probably has ground fault. (See cause 4.)
2 Defective fuse (BT3-No. 40) If fuse is broken, circuit probably has ground fault. (See cause 4.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between J3P (female) (3), (4) – fuse BT3-No. 40 (30)
Resistance
Max. 1 z
Wiring harness between fuse BT3-No. 40 (29) – circuit breaker 83 terminal
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between battery relay 66 – battery (+) terminal
Resistance
Max. 1 z
Wiring harness between J3P (female) (1), (2) – chassis ground GS
Resistance
Max. 1 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between circuit breaker 81 3 or defective contact in con- terminal – circuit breaker 82 terminal nector) Wiring harness between circuit breaker 82 terminal – battery relay 66 terminal
Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between J3P (female) (3), (4) – fuse BT3-No. 40 (30)
Resistance
Max. 1 z
Wiring harness between fuse BT3-No. 40 (29) – circuit breaker 83 terminal
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between battery relay 66 – battery (+) terminal
Resistance
Max. 1 z
Wiring harness between J3P (female) (1), (2) – chassis ground GS
Resistance
Max. 1 z
Ground fault in wiring harWiring harness between circuit breaker 81 4 ness (Short circuit with GND terminal – circuit breaker 82 terminal circuit) Wiring harness between circuit breaker 82 terminal – battery relay 66 terminal
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller
4
J3P
Starting switch
Voltage
Between (3), (4) – (1), (2)
ON
20 – 30 V
HM400-2
40 Troubleshooting
SEN01110-02
Circuit diagram related to engine controller power supply
HM400-2
5
SEN01110-02
40 Troubleshooting
Failure code [CA115] Trouble in engine Ne and Bkup speed sensors Action code
Failure code
E03
CA115
Contents of trouble Action of controller Problem that appears on machine
Trouble
1
Trouble in engine Ne and Bkup speed sensors (Engine controller system)
• Both engine Ne and Bkup speed sensor circuits have troubles in them. • None in particular. • Engine cannot be started (if it has been stopped). • Engine stops (if it has been running).
Related information Cause
Possible causes and standard value in normal state
1
Defective Ne speed sensor system
Ne speed sensor system may be defective. Carry out troubleshooting for failure code [CA689].
2
Defective Bkup speed sensor system
Bkup speed sensor system may be defective. Carry out troubleshooting for failure code [CA778].
3
Defective installation of Ne speed sensor
Installation of Ne speed sensor may be defective. Check it directly (for defective installation, internal defect of flywheel, etc.)
4
Installation of Bkup speed sensor may be defective. Check it Defective installation of Bkup directly (for defective installation, internal defect of supply pump, speed sensor etc.)
5
Defective connection of sen- Ne speed sensor and Bkup speed sensor may be connected sor (Wrong connection) defectively (wrongly). Check them directly.
6 Defective engine controller
6
Standard value in normal state/Remarks on troubleshooting
If causes 1 – 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
HM400-2
40 Troubleshooting
HM400-2
SEN01110-02
7
SEN01110-02
40 Troubleshooting
Failure code [CA122] Abnormally high charge pressure Action code
Failure code
E03
CA122
Contents of trouble Action of controller Problem that appears on machine
Trouble
1
Abnormally high charge pressure (Engine controller system)
• Charge pressure sensor circuit detected abnormally high pressure. • Fixes charge pressure to 400 kPa {4.08 kg/cm2} and continues operation. • Acceleration performance of engine lowers. • More black smoke is produced during acceleration.
Related information Cause
Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA187] or [CA227] is displayed, carry out trouble1 ply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 2
Defective charge pressure sensor (Internal defect)
PIM Between (1) – (2)
Voltage Power supply
4.75 – 5.25 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector)
Possible causes and standard value in normal state
Wiring harness between ENG (female) (37) – PIM (female) (1)
Resistance
Max. 1 z
Wiring harness between ENG (female) (47) – PIM (female) (2)
Resistance
Max. 1 z
Wiring harness between ENG (female) (44) – PIM (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) Ground fault in wiring har– PIM (female) (1) 4 ness (Short circuit with GND Wiring harness between ENG (female) (47) circuit) – PIM (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (44) – PIM (female) (3)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Short circuit in wiring har5 ness (with another wiring harness)
Wiring harness between ENG (female) (37) – PIM (female) (1) and between ENG (female) (47) – PIM (female) (2)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (37) – PIM (female) (1) and between ENG (female) (44) – PIM (female) (3)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (47) – PIM (female) (2) and between ENG (female) (44) – PIM (female) (3)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller
ENG Between (37) – (47)
8
Voltage Power supply
4.75 – 5.25 V
HM400-2
40 Troubleshooting
SEN01110-02
Circuit diagram related to charge pressure sensor
HM400-2
9
SEN01110-02
40 Troubleshooting
Failure code [CA123] Abnormally low charge pressure Action code
Failure code
E03
CA123
Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state
10
Trouble
1
Abnormally low charge pressure (Engine controller system)
• Charge pressure sensor circuit detected abnormally low pressure. • Fixes charge pressure to 400 kPa {4.08 kg/cm2} and continues operation. • Acceleration performance of engine lowers. • More black smoke is produced during acceleration. • Condition of charge pressure sensor signal can be checked with monitoring function. (Monitoring code: ENGINE - CHG PRESS-A - 36500/36501) Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA122].
HM400-2
40 Troubleshooting
HM400-2
SEN01110-02
11
SEN01110-02
40 Troubleshooting
Failure code [CA131] Abnormally high throttle sensor signal Action code
Failure code
E03
CA131
Contents of trouble Action of controller Problem that appears on machine
Trouble
1
Abnormally high throttle sensor signal (Engine controller system)
• Signal voltage of throttle sensor is above 4.5 V. • Throttle is set to low idle while pedal is released and set to medium speed while pedal is pressed according to idle validation switch • Turns caution lamp ON and sounds alarm buzzer. • When accelerator pedal is pressed, engine speed does not rise above medium.
Related information Cause
Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA2185] or [CA2186] is displayed, carry out trou1 ply system bleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2
Defective accelerator pedal (Internal defect)
AS1
Accelerator pedal
Voltage
Between (1) – (3)
All range (Power supply)
4.75 – 5.25 V
Released
(13 ± 2 % of source voltage)
Pressed
(77 ± 2 % of source voltage)
Between (2) – (3)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector)
Wiring harness between J2P (female) (22) – AS1 (female) (1)
Resistance
Max. 1 z
Wiring harness between J2P (female) (9) – AS1 (female) (2)
Resistance
Max. 1 z
Wiring harness between J2P (female) (23) – AS1 (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between J2P (female) (22) – Ground fault in wiring harAS1 (female) (1) 4 ness (Short circuit with GND Wiring harness between J2P (female) (9) – circuit) AS1 (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between J2P (female) (23) – AS1 (female) (3)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
5 Defective engine controller
J2P
Accelerator pedal
Voltage
Between (22) – (23)
All range (Power supply)
4.75 – 5.25 V
Released
(13 ± 2 % of source voltage)
Pressed
(77 ± 2 % of source voltage)
Between (9) – (23)
12
HM400-2
40 Troubleshooting
SEN01110-02
Circuit diagram related to accelerator pedal signal Applied serial number: – 2188
Applied serial number: 2189 and up
HM400-2
13
SEN01110-02
40 Troubleshooting
Failure code [CA132] Abnormally low throttle sensor signal Action code
Failure code
E03
CA132
Contents of trouble Action of controller
Trouble
1
Abnormally low throttle sensor signal (Engine controller system)
• Signal voltage of throttle sensor is abnormally low. • Sets throttle position with signals other than throttle sensor signal and continues operation.
Problem that appears on machine Related information Possible causes and standard value in normal state
14
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA131].
HM400-2
40 Troubleshooting
HM400-2
SEN01110-02
15
SEN01110-02
40 Troubleshooting
Failure code [CA135] Abnormally high engine oil pressure Action code
Failure code
E01
CA135
Contents of trouble Action of controller
Trouble
1
Abnormally high engine oil pressure (Engine controller system)
• Engine oil pressure sensor circuit detected abnormally high pressure. • Fixes engine oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Problem that appears on machine Related information
• Condition of engine oil pressure sensor signal can be checked with monitoring function. (Monitoring code: ENGINE - ENGINE OIL PRESS - 37201) Cause
Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA187] or [CA227] is displayed, carry out trouble1 ply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 2
Defective engine oil pressure sensor (Internal defect)
POIL Between (1) – (2)
Voltage Power supply
4.75 – 5.25 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector)
Possible causes and standard value in normal state
Wiring harness between ENG (female) (37) – POIL (female) (1)
Resistance
Max. 1 z
Wiring harness between ENG (female) (47) – POIL (female) (2)
Resistance
Max. 1 z
Wiring harness between ENG (female) (13) – POIL (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 4 or defective contact in connector)
Wiring harness between ENG (female) (37) – POIL (female) (1)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (47) – POIL (female) (2)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (13) – POIL (female) (3)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Short circuit in wiring har5 ness (with another wiring harness)
Wiring harness between ENG (female) (37) – POIL (female) (1) and between ENG (female) (47) – POIL (female) (2)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (37) – POIL (female) (1) and between ENG (female) (13) – POIL (female) (3)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (47) – POIL (female) (2) and between ENG (female) (13) – POIL (female) (3)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller
ENG Between (37) – (47)
16
Voltage Power supply
4.75 – 5.25 V
HM400-2
40 Troubleshooting
SEN01110-02
Circuit diagram related to engine oil pressure sensor
HM400-2
17
SEN01110-02
40 Troubleshooting
Failure code [CA141] Abnormally low engine oil pressure Action code
Failure code
E01
CA141
Contents of trouble Action of controller
Trouble
1
Abnormally low engine oil pressure (Engine controller system)
• Engine oil pressure sensor circuit detected abnormally low pressure. • Fixes engine oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Problem that appears on machine Related information Possible causes and standard value in normal state
18
• Condition of engine oil pressure sensor signal can be checked with monitoring function. (Monitoring code: ENGINE - OIL PRESS - 37201) Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA135].
HM400-2
40 Troubleshooting
HM400-2
SEN01110-02
19
SEN01110-02
40 Troubleshooting
Failure code [CA144] Abnormally high coolant temperature Action code
Failure code
E01
CA144
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Abnormally high coolant temperature (Engine controller system)
• Engine coolant temperature sensor circuit detected abnormally high temperature. • Fixes engine coolant temperature to 90°C and continues operation. • Engine does not start easily at low temperature. • Condition of engine coolant temperature sensor signal can be checked with monitoring function. (Monitoring code: ENGINE - COOLANT TEMP - 04105) Cause Defective engine coolant 1 temperature sensor (Internal defect)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TWTR (male)
Coolant temperature
Resistance
Between (A) – (B)
10 – 100°C
0.6 – 20 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (15) 2 or defective contact in con- – TWTR (female) (A) nector) Wiring harness between ENG (female) (38) – TWTR (female) (B)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between ENG (female) (15) Resiscircuit) Min. 1 Mz – TWTR (female) (A) tance
4 Defective engine controller
20
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female)
Coolant temperature
Resistance
Between (15) – (38)
10 – 100°C
0.6 – 20 kz
HM400-2
40 Troubleshooting
SEN01110-02
Circuit diagram related to engine coolant temperature sensor
HM400-2
21
SEN01110-02
40 Troubleshooting
Failure code [CA145] Abnormally low coolant temperature Action code
Failure code
E01
CA145
Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state
22
Trouble
1
Abnormally low coolant temperature (Engine controller system)
• Engine coolant temperature sensor circuit detected abnormally low temperature. • Fixes engine coolant temperature to 90°C and continues operation. • Engine does not start easily at low temperature. • Condition of engine coolant temperature sensor signal can be checked with monitoring function. (Monitoring code: ENGINE - COOLANT TEMP - 04105) Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA144].
HM400-2
40 Troubleshooting
HM400-2
SEN01110-02
23
SEN01110-02
40 Troubleshooting
Failure code [CA153] Abnormally high charge temperature Action code
Failure code
E01
CA153
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Abnormally high charge temperature (Engine controller system)
• Charge temperature sensor circuit detected abnormally high temperature. • Fixes charge temperature (intake air temperature) to 70°C and continues operation. • Engine does not start easily at low temperature. • Condition of charge temperature sensor signal can be checked with monitoring function. (Monitoring code: ENGINE - CHG TEMP - 18501) Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Possible causes and standard value in normal state
Defective charge temperature sensor (Internal defect)
TIM (male)
Charge temperature
Resistance
Between (A) – (B)
10 – 100°C
0.5 – 20 kz
Between (A) – chassis ground
All range
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (23) 2 or defective contact in con- – TIM (female) (A) nector) Wiring harness between ENG (female) (47) – TIM (female) (B)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between ENG (female) (23) Resiscircuit) Min. 1 Mz – TIM (female) (A) tance
4 Defective engine controller
24
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female)
Charge temperature
Resistance
Between (23) – (47)
10 – 100°C
0.5 – 20 kz
HM400-2
40 Troubleshooting
SEN01110-02
Circuit diagram related to charge temperature sensor
HM400-2
25
SEN01110-02
40 Troubleshooting
Failure code [CA154] Abnormally low charge temperature Action code
Failure code
E01
CA154
Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state
26
Trouble
1
Abnormally low charge temperature (Engine controller system)
• Charge temperature sensor circuit detected abnormally low temperature. • Fixes charge temperature (intake air temperature) to 70°C and continues operation. • Engine does not start easily at low temperature. • Condition of charge temperature sensor signal can be checked with monitoring function. (Monitoring code: ENGINE - CHG TEMP - 18501) Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA153].
HM400-2
40 Troubleshooting
SEN01110-02
Failure code [CA187] Abnormally low voltage in sensor power supply 21 Action code
Failure code
E03
CA187
Contents of trouble
Action of controller
Problem that appears on machine
Trouble
Abnormally low voltage in sensor power supply 2 (Engine controller system)
• Voltage in sensor power supply 2 (5V) circuit of engine controller is abnormally low. • Bkup speed sensor operates with Ne speed sensor signal. • Oil pressure sensor fixes oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation. • Ambient pressure sensor fixes ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. • Charge pressure sensor fixes charge pressure to 400 kPa {4.08 kg/cm2} and continues operation. • EGR inlet pressure sensor fixes EGR inlet pressure to default value (102 kPa {1.05 kg/cm2}) and limits output and continues operation. • EGR valve lift sensor limits output and closes EGR valve and bypass valve. • Bypass valve lift sensor limits output and closes EGR valve and bypass valve. • Engine output lowers.
Related information Possible causes and standard value in normal state
HM400-2
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA227].
27
SEN01110-02
40 Troubleshooting
Failure code [CA221] Abnormally high ambient pressure Action code
Failure code
E01
CA221
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Abnormally high ambient pressure (Engine controller system)
• Ambient pressure sensor circuit detected abnormally high pressure. • Fixes ambient pressure to default value (52.44 kPa {0.53 kg/cm2} and continues operation. • Engine output lowers. • Condition of ambient pressure sensor signal can be checked with monitoring function. (Monitoring code: ENGINE - AMBIENT PRESS - 37401) Cause
Standard value in normal state/Remarks on troubleshooting
1 Defective sensor power sup- If failure code [CA187] or [CA227] is displayed, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PAMB Defective ambient pressure 2 sensor (Internal defect)
Voltage
Between (1) – (2)
Power supply
Between (3) – (2)
Signal
4.75 – 5.25 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector)
Possible causes and standard value in normal state
Wiring harness between ENG (female) (37) – PAMB (female) (1)
Resistance
Max. 1 z
Wiring harness between ENG (female) (38) – PAMB (female) (2)
Resistance
Max. 1 z
Wiring harness between ENG (female) (3) – PAMB (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) Ground fault in wiring har– PAMB (female) (1) 4 ness (Short circuit with GND Wiring harness between ENG (female) (38) circuit) – PAMB (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (3) – PAMB (female) (3)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Short circuit in wiring har5 ness (with another wiring harness)
Wiring harness between ENG (female) (37) – PAMB (female) (1) and between ENG (female) (38) – PAMB (female) (2)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (37) – PAMB (female) (1) and between ENG (female) (13) – PAMB (female) (3)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (38) – PAMB (female) (2) and between ENG (female) (13) – PAMB (female) (3)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller
ENG
Voltage
Between (37) – (38)
4.75 – 5.25 V
Between (3) – (38)
28
HM400-2
40 Troubleshooting
SEN01110-02
Circuit diagram related to ambient pressure sensor
HM400-2
29
SEN01110-02
40 Troubleshooting
Failure code [CA222] Abnormally low ambient pressure Action code
Failure code
E01
CA222
Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state
30
Trouble
1
Abnormally low ambient pressure (Engine controller system)
• Ambient pressure sensor circuit detected abnormally low pressure. • Fixes ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. • Engine output lowers. • Condition of ambient pressure sensor signal can be checked with monitoring function. (Monitoring code: ENGINE - AMBIENT PRESS - 37401) Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA221].
HM400-2
40 Troubleshooting
HM400-2
SEN01110-02
31
SEN01110-02
40 Troubleshooting
Failure code [CA227] Abnormally high voltage in sensor power supply 21 Action code
Failure code
E03
CA227
Contents of trouble
Action of controller
Problem that appears on machine
Trouble
Abnormally high voltage in sensor power supply 2 (Engine controller system)
• Voltage in sensor power supply 2 (5V) circuit of engine controller is abnormally high. • Bkup speed sensor operates with Ne speed sensor signal. • Oil pressure sensor fixes oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation. • Ambient pressure sensor fixes ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. • Charge pressure sensor fixes charge pressure to 400 kPa {4.08 kg/cm2} and continues operation. • EGR inlet pressure sensor fixes EGR inlet pressure to default value (102 kPa {1.05 kg/cm2}) and limits output and continues operation. • EGR valve lift sensor limits output and closes EGR valve and bypass valve. • Bypass valve lift sensor limits output and closes EGR valve and bypass valve. • Engine output lowers.
Related information Cause 1 Defective related system
Standard value in normal state/Remarks on troubleshooting If another failure code is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
2 Defective sensor (Internal defect)
Possible causes and standard value in normal state
Disconnect devices at right in order. If mark E of failure code disappears when a device is disconnected, that device has defect in it.
Bkup speed sensor
Connector G
Oil pressure sensor
Connector POIL
Ambient pressure sensor
Connector PAMB
Charge pressure sensor
Connector PIM
EGR inlet pressure sensor
Connector PEVA
EGR valve lift sensor
Connector SEGR
Bypass valve lift sensor
Connector SBP
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (37) 3 or defective contact in con- – each sensor (female) nector) Wiring harness between ENG (female) (47) – each sensor (female)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between ENG (female) (37) 4 ness (Short circuit with GND – each sensor (female) circuit) Wiring harness between ENG (female) (47) – each sensor (female) Short circuit in wiring har5 ness (with another wiring harness)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) – each sensor (female) and between ENG (female) (47) – each sensor (female)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6 Defective engine controller
32
ENG
Voltage
Between (37) – (47)
4.75 – 5.25 V
HM400-2
40 Troubleshooting
SEN01110-02
Circuit diagram related to engine controller sensor power supply (5 V)
HM400-2
33
SEN01110-02
40 Troubleshooting
Failure code [CA234] Engine overspeed Action code
Failure code
E02
CA234
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
34
Engine overspeed (Engine controller system)
• Engine speed is higher than operating range. • Limits fuel injection until engine speed lowers to operating range. • Engine speed fluctuates. • Engine speed can be checked with monitoring function. (Monitoring code: ENGINE - ENGINE SPEED - 01002) Cause
Possible causes and standard value in normal state
1
Standard value in normal state/Remarks on troubleshooting
1 Defective related system
If another failure code is displayed, carry out troubleshooting for it first.
2 Improper use
Machine may be used improperly. Teach operator correct operation.
3 Defective engine controller
If causes 1 – 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
HM400-2
40 Troubleshooting
HM400-2
SEN01110-02
35
SEN01110-02
40 Troubleshooting
Failure code [CA238] Trouble in Ne speed sensor power supply Action code
Failure code
E03
CA238
Contents of trouble Action of controller Problem that appears on machine
Trouble
1
Trouble in Ne speed sensor power supply (Engine controller system)
• Engine Ne speed sensor power supply (5V) has trouble in it. • Controls with signal of engine Bkup speed sensor. • Engine stops it has been running (when Bkup speed sensor also has trouble). • Engine cannot be started it has been stopped (when Ne speed sensor also has trouble).
Related information Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Defective engine Ne speed 1 sensor (Internal defect)
Possible causes and standard value in normal state
Engine Ne speed sensor
Connector NE
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (16) Resis2 Max. 1 z or defective contact in con- – NE (female) (1) tance nector) Wiring harness between ENG (female) (48) ResisMax. 1 z – NE (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (16) 3 ness (Short circuit with GND – NE (female) (1) circuit) Wiring harness between ENG (female) (48) – NE (female) (2) Short circuit in wiring har4 ness (with another wiring harness)
5 Defective engine controller
36
When device at right is disconnected, if mark E of failure code disappears, that device has defect in it.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (16) – NE (female) (1) and between ENG (female) (48) – NE (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ENG
Voltage
Between (16) – (48)
4.75 – 5.25 V
HM400-2
40 Troubleshooting
SEN01110-02
Circuit diagram related to engine Ne speed sensor
HM400-2
37
SEN01110-02
40 Troubleshooting
Failure code [CA263] Abnormally high fuel temperature Action code
Failure code
E01
CA263
Contents of trouble Action of controller
Trouble
1
Abnormally high fuel temperature (Engine controller system)
• Fuel temperature sensor circuit detected abnormally high temperature. • Fixes fuel temperature to 90°C and continues operation.
Problem that appears on machine Related information
• Condition of fuel temperature sensor signal can be checked with monitoring function. (Monitoring code: ENGINE - FUEL TEMP - 04205) Cause Defective fuel temperature 1 sensor (Internal defect)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TFUEL (male)
Fuel temperature
Resistance
Between (A) – (B)
10 – 100°C
0.6 – 20 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (30) Resis2 Max. 1 z or defective contact in con- – TFUEL (female) (A) tance nector) Wiring harness between ENG (female) (47) ResisMax. 1 z – TFUEL (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between ENG (female) (30) Resiscircuit) Min. 1 Mz – TFUEL (female) (A) tance
4 Defective engine controller
38
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female)
Fuel temperature
Resistance
Between (30) – (47)
10 – 100°C
0.6 – 20 kz
HM400-2
40 Troubleshooting
SEN01110-02
Circuit diagram related to fuel temperature sensor
HM400-2
39
SEN01110-02
40 Troubleshooting
Failure code [CA265] Abnormally low fuel temperature Action code
Failure code
E01
CA265
Contents of trouble Action of controller
Trouble
1
Abnormally low fuel temperature (Engine controller system)
• Fuel temperature sensor circuit detected abnormally low temperature. • Fixes fuel temperature to 90°C and continues operation.
Problem that appears on machine Related information Possible causes and standard value in normal state
40
• Condition of fuel temperature sensor signal can be checked with monitoring function. (Monitoring code: ENGINE - FUEL TEMP - 04205) Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting failure code [CA263].
HM400-2
40 Troubleshooting
SEN01110-02
Failure code [CA271] Short circuit in PCV1 Action code
Failure code
E03
CA271
Contents of trouble Action of controller
Trouble
1
Short circuit in PCV1 (Engine controller system)
• There is short circuit in PCV1 circuit of supply pump. • None in particular.
Problem that appears on machine Related information Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective supply pump PCV1 (Internal short circuit)
PCV1 (male)
Resistance
Between (1) – (2)
2.3 – 5.3 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Ground fault in wiring harWiring harness between ENG (female) (4) – 2 ness (Short circuit with GND PCV1 (female) (1) circuit) Wiring harness between ENG (female) (5) – PCV1 (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3
Hot short (Short circuit with Wiring harness between ENG (female) (4) – 24V circuit) in wiring harness PCV1 (female) (1)
Voltage
Max. 1 V
Wiring harness between ENG (female) (5) – PCV1 (female) (2)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller
EGN (female)
Resistance
Between (4) – (5)
2.3 – 5.3 z
Between (4), (5) – chassis ground
Min. 1 Mz
Circuit diagram related to supply pump PCV1
HM400-2
41
SEN01110-02
40 Troubleshooting
Failure code [CA272] Disconnection in PCV1 Action code
Failure code
E03
CA272
Contents of trouble Action of controller
Trouble
1
Disconnection in PCV1 (Engine controller system)
• There is disconnection in PCV1 circuit of supply pump. • None in particular.
Problem that appears on machine Related information Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective supply pump 1 PCV1 (Internal disconnection)
PCV1 (male)
Resistance
Between (1) – (2)
2.3 – 5.3 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (4) – 2 or defective contact in con- PCV1 (female) (1) nector) Wiring harness between ENG (female) (5) – PCV1 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (4) – 3 ness (Short circuit with GND PCV1 (female) (1) circuit) Wiring harness between ENG (female) (5) – PCV1 (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller
EGN (female)
Resistance
Between (4) – (5)
2.3 – 5.3 z
Between (4), (5) – chassis ground
Min. 1 Mz
Circuit diagram related to supply pump PCV1
42
HM400-2
40 Troubleshooting
SEN01110-02
Failure code [CA273] Short circuit in PCV2 Action code
Failure code
E03
CA273
Contents of trouble Action of controller
Trouble
1
Short circuit in PCV2 (Engine controller system)
• There is short circuit in PCV2 circuit of supply pump. • None in particular.
Problem that appears on machine Related information Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective supply pump PCV2 (Internal short circuit)
PCV2 (male)
Resistance
Between (1) – (2)
2.3 – 5.3 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Ground fault in wiring harWiring harness between ENG (female) (9) – 2 ness (Short circuit with GND PCV2 (female) (1) circuit) Wiring harness between ENG (female) (10) – PCV2 (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3
Hot short (Short circuit with Wiring harness between ENG (female) (9) – 24V circuit) in wiring harness PCV2 (female) (1)
Voltage
Max. 1 V
Wiring harness between ENG (female) (10) – PCV2 (female) (2)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller
EGN (female)
Resistance
Between (9) – (10)
2.3 – 5.3 z
Between (9), (10) – chassis ground
Min. 1 Mz
Circuit diagram related to supply pump PCV2
HM400-2
43
SEN01110-02
40 Troubleshooting
Failure code [CA274] Disconnection in PCV2 Action code
Failure code
E03
CA274
Contents of trouble Action of controller
Trouble
1
Disconnection in PCV2 (Engine controller system)
• There is disconnection in PCV2 circuit of supply pump. • None in particular.
Problem that appears on machine Related information Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective supply pump 1 PCV2 (Internal disconnection)
PCV2 (male)
Resistance
Between (1) – (2)
2.3 – 5.3 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (9) – 2 or defective contact in con- PCV2 (female) (1) nector) Wiring harness between ENG (female) (10) – PCV2 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (9) – 3 ness (Short circuit with GND PCV2 (female) (1) circuit) Wiring harness between ENG (female) (10) – PCV2 (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller
EGN (female)
Resistance
Between (9) – (10)
2.3 – 5.3 z
Between (9), (10) – chassis ground
Min. 1 Mz
Circuit diagram related to supply pump PCV2
44
HM400-2
40 Troubleshooting
HM400-2
SEN01110-02
45
SEN01110-02
40 Troubleshooting
Failure code [CA322] Disconnection or short circuit in injector #1 (L #1) 1 Action code
Failure code
E03
CA322
Contents of trouble Action of controller Problem that appears on machine
Trouble
Disconnection or short circuit in injector #1 (L #1) (Engine controller system)
• There is disconnection or short circuit in injector #1 circuit. • None in particular. • Output is reduced. • Rotation is unstable.
Related information Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective injector #1 (Internal defect)
CN1 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (45) 2 or defective contact in con- – CN1 (female) (1) nector) Wiring harness between ENG (female) (53) – CN1 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (45) 3 ness (Short circuit with GND – CN1 (female) (1) circuit) Wiring harness between ENG (female) (53) – CN1 (female) (2) 4
Defective another cylinder injector or wiring harness
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
If multiple failure codes are displayed for injector malfunction, carry out troubleshooting for them, too. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Defective engine controller
46
ENG (female)
Resistance
Between (45) – (53)
0.4 – 1.1 z
Between (45), (53) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01110-02
Circuit diagram related to injector #1
HM400-2
47
SEN01110-02
40 Troubleshooting
Failure code [CA323] Disconnection or short circuit in injector #5 (L #5) 1 Action code
Failure code
E03
CA323
Contents of trouble Action of controller Problem that appears on machine
Trouble
Disconnection or short circuit in injector #5 (L #5) (Engine controller system)
• There is disconnection or short circuit in injector #5 circuit. • None in particular. • Output is reduced. • Rotation is unstable.
Related information Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective injector #5 (Internal defect)
CN5 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (46) 2 or defective contact in con- – CN5 (female) (1) nector) Wiring harness between ENG (female) (60) – CN5 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (46) 3 ness (Short circuit with GND – CN5 (female) (1) circuit) Wiring harness between ENG (female) (60) – CN5 (female) (2) 4
Defective another cylinder injector or wiring harness
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
If multiple failure codes are displayed for injector malfunction, carry out troubleshooting for them, too. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Defective engine controller
48
ENG (female)
Resistance
Between (46) – (60)
0.4 – 1.1 z
Between (46), (60) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01110-02
Circuit diagram related to injector #5
HM400-2
49
SEN01110-02
40 Troubleshooting
Failure code [CA324] Disconnection or short circuit in injector #3 (L #3) 1 Action code
Failure code
E03
CA324
Contents of trouble Action of controller Problem that appears on machine
Trouble
Disconnection or short circuit in injector #3 (L #3) (Engine controller system)
• There is disconnection or short circuit in injector #3 circuit. • None in particular. • Output is reduced. • Rotation is unstable.
Related information Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective injector #3 (Internal defect)
CN3 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (55) 2 or defective contact in con- – CN3 (female) (1) nector) Wiring harness between ENG (female) (52) – CN3 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (55) 3 ness (Short circuit with GND – CN3 (female) (1) circuit) Wiring harness between ENG (female) (52) – CN3 (female) (2) 4
Defective another cylinder injector or wiring harness
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
If multiple failure codes are displayed for injector malfunction, carry out troubleshooting for them, too. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Defective engine controller
50
ENG (female)
Resistance
Between (55) – (52)
0.4 – 1.1 z
Between (55), (52) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01110-02
Circuit diagram related to injector #3
HM400-2
51
SEN01110-02
40 Troubleshooting
Failure code [CA325] Disconnection or short circuit in injector #6 (L #6) 1 Action code
Failure code
E03
CA325
Contents of trouble Action of controller Problem that appears on machine
Trouble
Disconnection or short circuit in injector #6 (L #6) (Engine controller system)
• There is disconnection or short circuit in injector #6 circuit. • None in particular. • Output is reduced. • Rotation is unstable.
Related information Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective injector #6 (Internal defect)
CN6 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (57) 2 or defective contact in con- – CN6 (female) (1) nector) Wiring harness between ENG (female) (59) – CN6 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (57) 3 ness (Short circuit with GND – CN6 (female) (1) circuit) Wiring harness between ENG (female) (59) – CN6 (female) (2) 4
Defective another cylinder injector or wiring harness
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
If multiple failure codes are displayed for injector malfunction, carry out troubleshooting for them, too. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Defective engine controller
52
ENG (female)
Resistance
Between (57) – (59)
0.4 – 1.1 z
Between (57), (59) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01110-02
Circuit diagram related to injector #6
HM400-2
53
SEN01110-02
40 Troubleshooting
Failure code [CA331] Disconnection or short circuit in injector #2 (L #2) 1 Action code
Failure code
E03
CA331
Contents of trouble Action of controller Problem that appears on machine
Trouble
Disconnection or short circuit in injector #2 (L #2) (Engine controller system)
• There is disconnection or short circuit in injector #2 circuit. • None in particular. • Output is reduced. • Rotation is unstable.
Related information Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective injector #2 (Internal defect)
CN2 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (54) 2 or defective contact in con- – CN2 (female) (1) nector) Wiring harness between ENG (female) (51) – CN2 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (54) 3 ness (Short circuit with GND – CN2 (female) (1) circuit) Wiring harness between ENG (female) (51) – CN2 (female) (2) 4
Defective another cylinder injector or wiring harness
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
If multiple failure codes are displayed for injector malfunction, carry out troubleshooting for them, too. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Defective engine controller
54
ENG (female)
Resistance
Between (54) – (51)
0.4 – 1.1 z
Between (54), (51) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01110-02
Circuit diagram related to injector #2
HM400-2
55
SEN01110-02
40 Troubleshooting
Failure code [CA332] Disconnection or short circuit in injector #4 (L #4) 1 Action code
Failure code
E03
CA332
Contents of trouble Action of controller Problem that appears on machine
Trouble
Disconnection or short circuit in injector #4 (L #4) (Engine controller system)
• There is disconnection or short circuit in injector #4 circuit. • None in particular. • Output is reduced. • Rotation is unstable.
Related information Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective injector #4 (Internal defect)
CN4 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (56) 2 or defective contact in con- – CN4 (female) (1) nector) Wiring harness between ENG (female) (58) – CN4 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (56) 3 ness (Short circuit with GND – CN4 (female) (1) circuit) Wiring harness between ENG (female) (58) – CN4 (female) (2) 4
Defective another cylinder injector or wiring harness
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
If multiple failure codes are displayed for injector malfunction, carry out troubleshooting for them, too. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Defective engine controller
56
ENG (female)
Resistance
Between (56) – (58)
0.4 – 1.1 z
Between (56), (58) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01110-02
Circuit diagram related to injector #4
HM400-2
57
SEN01110-02
40 Troubleshooting
Failure code [CA342] Matching error in engine controller data Action code
Failure code
E03
CA342
Contents of trouble Action of controller Problem that appears on machine
Trouble
1
Matching error in engine controller data (Engine controller system)
• There is matching error in engine controller. • None in particular. • Engine operates normally but may stop or may not be able to restart.
Related information Possible causes and standard value in normal state
58
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA111].
HM400-2
40 Troubleshooting
HM400-2
SEN01110-02
59
SEN01110-02
40 Troubleshooting
Failure code [CA351] Trouble in injector drive circuit Action code
Failure code
E03
CA351
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Trouble in injector drive circuit (Engine controller system)
• Injector drive circuit has trouble in it. • Limits engine output and continues operation (Limits common rail pressure). • Engine output lowers. • Source voltage of engine controller can be checked with monitoring function. (Monitoring code: ENGINE - POWER SUPPLY - 03200) Cause
Standard value in normal state/Remarks on troubleshooting
1 Defective related system
If another failure code (failure code of trouble in injector system) is displayed, carry out troubleshooting for it first.
2 Trip of circuit breaker (30 A)
If circuit breaker has tripped, circuit probably has ground fault. (See cause 5.)
3 Defective fuse (BT3-No. 40) If fuse is broken, circuit probably has ground fault. (See cause 5.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between J3P (female) (3), (4) – fuse BT3-No. 40 (30)
Resistance
Max. 1 z
Wiring harness between fuse BT3-No. 40 (29) – circuit breaker 83 terminal
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between battery relay 66 – battery (+) terminal
Resistance
Max. 1 z
Wiring harness between J3P (female) (1), (2) – chassis ground GS
Resistance
Max. 1 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between circuit breaker 81 4 or defective contact in con- terminal – circuit breaker 82 terminal nector) Wiring harness between circuit breaker 82 terminal – battery relay 66 terminal
Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between J3P (female) (3), (4) – fuse BT3-No. 40 (30)
Resistance
Max. 1 z
Wiring harness between fuse BT3-No. 40 (29) – circuit breaker 83 terminal
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between battery relay 66 – battery (+) terminal
Resistance
Max. 1 z
Wiring harness between J3P (female) (1), (2) – chassis ground GS
Resistance
Max. 1 z
Ground fault in wiring harWiring harness between circuit breaker 81 5 ness (Short circuit with GND terminal – circuit breaker 82 terminal circuit) Wiring harness between circuit breaker 82 terminal – battery relay 66 terminal
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6 Defective engine controller
60
J3P
Starting switch
Voltage
Between (3), (4) – (1), (2)
ON
20 – 30 V
HM400-2
40 Troubleshooting
SEN01110-02
Circuit diagram related to engine controller power supply
HM400-2
61
SEN01110-02
40 Troubleshooting
Failure code [CA352] Abnormally low voltage in sensor power supply 11 Action code
Failure code
E03
CA352
Contents of trouble Action of controller Problem that appears on machine
Trouble
Abnormally low voltage in sensor power supply 1 (Engine controller system)
• Voltage in sensor power supply 1 (5V) circuit of engine controller is abnormally low. • Common rail pressure sensor limits output and continues operation (limits common rail pressure). • Engine output lowers.
Related information Possible causes and standard value in normal state
62
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA386].
HM400-2
40 Troubleshooting
HM400-2
SEN01110-02
63
SEN01110-02
40 Troubleshooting
Failure code [CA386] Abnormally high voltage in sensor power supply 11 Action code
Failure code
E03
CA386
Contents of trouble Action of controller Problem that appears on machine
Trouble
Abnormally high voltage in sensor power supply 1 (Engine controller system)
• Voltage in sensor power supply 1 (5V) circuit of engine controller is abnormally high. • Common rail pressure sensor limits output and continues operation (limits common rail pressure). • Engine output lowers.
Related information Cause 1 Defective related system
Standard value in normal state/Remarks on troubleshooting If another failure code is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
2
Defective sensor (Internal defect)
When device at right is disconnected, if mark E of failure code disappears, that device has defect in it.
Common rail pressure sensor
Connector PFUEL
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (33) 3 or defective contact in con- – PFUEL (female) (1) nector) Wiring harness between ENG (female) (47) – PFUEL (female) (3)
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (33) 4 ness (Short circuit with GND – PFUEL (female) (1) circuit) Wiring harness between ENG (female) (47) – PFUEL (female) (3) Short circuit in wiring har5 ness (with another wiring harness)
6 Defective engine controller
64
Resistance
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (33) – PFUEL (female) (1) and between ENG (female) (47) – PFUEL (female) (3)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ENG
Voltage
Between (33) – (47)
4.75 – 5.25 V
HM400-2
40 Troubleshooting
SEN01110-02
Circuit diagram related to engine controller sensor power supply 1 (5 V)
HM400-2
65
SEN01110-02
40 Troubleshooting
HM400-2 Articulated dump truck Form No. SEN01110-02
© 2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (02)
66
HM400-2
SEN01111-02
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
40 Troubleshooting
1
Troubleshooting by failure code, Part 4 Failure code [CA431] Trouble in idle validation switch.................................................................................... 4 Failure code [CA432] Trouble in idle validation process ................................................................................. 7 Failure code [CA441] Abnormally low voltage in power supply ...................................................................... 7 Failure code [CA442] Abnormally high voltage in power supply ..................................................................... 8 Failure code [CA449] Abnormally high common rail pressure 2..................................................................... 8 Failure code [CA451] Abnormally high common rail pressure...................................................................... 10 Failure code [CA452] Abnormally low common rail pressure ....................................................................... 12 Failure code [CA553] Abnormally high common rail pressure 1................................................................... 12 Failure code [CA554] In-range error in common rail pressure sensor .......................................................... 13 Failure code [CA559] Supply pump low pressure 1...................................................................................... 15 Failure code [CA689] Trouble in engine Ne speed sensor ........................................................................... 18 Failure code [CA731] Phase error in engine Bkup speed sensor ................................................................. 20 Failure code [CA757] Loss of all data in engine controller............................................................................ 20 Failure code [CA778] Trouble in engine Bkup speed sensor........................................................................ 22 Failure code [CA1228] Trouble in EGR valve servo 1 .................................................................................. 24 Failure code [CA1625] Trouble in EGR valve servo 2 .................................................................................. 25
HM400-2
1
SEN01111-02
40 Troubleshooting
Failure code [CA1626] Short circuit in bypass valve solenoid drive circuit ................................................... 26 Failure code [CA1627] Disconnection in bypass valve solenoid drive circuit................................................ 28 Failure code [CA1628] Trouble in bypass valve servo 1 ............................................................................... 29 Failure code [CA1629] Trouble in bypass valve servo 2 ............................................................................... 30 Failure code [CA1631] Abnormally high signal in bypass valve lift sensor ................................................... 32 Failure code [CA1632] Abnormally low signal in bypass valve lift sensor..................................................... 34 Failure code [CA1633] Trouble in KOMNET ................................................................................................. 36 Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor................................................ 38 Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor .............................................. 40 Failure code [CA2185] Abnormally high voltage in throttle sensor power supply ......................................... 42 Failure code [CA2186] Abnormally low voltage in throttle sensor power supply........................................... 44 Failure code [CA2249] Low pressure in supply pump 2................................................................................ 44 Failure code [CA2271] Abnormally high signal voltage in EGR valve lift sensor .......................................... 46 Failure code [CA2272] Abnormally low signal voltage in EGR valve lift sensor............................................ 48 Failure code [CA2351] Short circuit in EGR valve solenoid drive circuit....................................................... 50 Failure code [CA2352] Disconnection in EGR valve solenoid drive circuit ................................................... 52 Failure code [CA2555] Disconnection in intake air heater relay ................................................................... 52 Failure code [CA2556] Short circuit in intake air heater relay ....................................................................... 54
2
HM400-2
40 Troubleshooting
HM400-2
SEN01111-02
3
SEN01111-02
40 Troubleshooting
Failure code [CA431] Trouble in idle validation switch Action code
Failure code
E01
CA431
Contents of trouble Action of controller Problem that appears on machine
Trouble
1
Trouble in idle validation switch (Engine controller system)
• Both of signals 1 and 2 of idle validation switch are open or there is trouble in ground circuit. • Operates normally according to throttle sensor (E01 Testing and maintenance) • None in particular.
Related information Applied serial number: – 2188 Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
1
Defective accelerator pedal (Internal defect)
AS1
Signal name
Between (5) – (4)
Signal 1
Between (6) – (4)
Signal 2
Voltage See Fig. 1
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector)
Possible causes and standard value in normal state
Wiring harness between J2P (female) (32) – AS1 (female) (4)
Resistance
Max. 1 z
Wiring harness between J2P (female) (11) – AS1 (female) (5)
Resistance
Max. 1 z
Wiring harness between J2P (female) (1) – AS1 (female) (6)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between J2P (female) (32) – Ground fault in wiring harAS1 (female) (4) 3 ness (Short circuit with GND Wiring harness between J2P (female) (11) – circuit) AS1 (female) (5)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between J2P (female) (1) – AS1 (female) (6)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between J2P (female) (32) – Hot short (Short circuit with AS1 (female) (4) 4 24V circuit) in wiring harness Wiring harness between J2P (female) (11) – AS1 (female) (5) Wiring harness between J2P (female) (1) – AS1 (female) (6)
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller
4
J2P
Signal name
Between (11) – (32)
Signal 1
Between (1) – (32)
Signal 2
Voltage See Fig. 1
HM400-2
40 Troubleshooting
SEN01111-02
Applied serial number: 2189 and up Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
1
Defective accelerator pedal (Internal defect)
AS1
Signal name
Between (5) – (4)
Signal 1
Between (6) – (4)
Signal 2
Voltage See Fig. 1
Between AS (1) – (2)
5V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector)
Possible causes and standard value in normal state
Wiring harness between J2P (female) (32) – AS1 (female) (4)
Resistance
Max. 1 z
Wiring harness between J2P (female) (11) – AS1 (female) (5)
Resistance
Max. 1 z
Wiring harness between J2P (female) (1) – AS1 (female) (6)
Resistance
Max. 1 z
Wiring harness between ATC1 (female) (4) – AS2 (female) (2)
Resistance
Min.1 Mz
Wiring harness between ATC3 (female) (34) – AS2 (female) (1)
Resistance
Min.1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between J2P (female) (32) – Ground fault in wiring harAS1 (female) (4) 3 ness (Short circuit with GND Wiring harness between J2P (female) (11) – circuit) AS1 (female) (5)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between J2P (female) (1) – AS1 (female) (6)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between J2P (female) (32) – Hot short (Short circuit with AS1 (female) (4) 4 24V circuit) in wiring harness Wiring harness between J2P (female) (11) – AS1 (female) (5) Wiring harness between J2P (female) (1) – AS1 (female) (6)
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. J2P
Signal name
Between (11) – (32)
Signal 1
Between (1) – (32)
Signal 2
5 Defective engine controller
6
Defective transmisson controller
1) 2) 3) 4) 5)
See Fig. 1
Turn starting switch OFF Disconnect AS2 connector Disconnect ATC3,ATC1 connector Connect T-adapter to ATC3, ATC1 connector Turn starting switch ON and carry out troubleshooting
Between ATC3 (34) – ATC1 (4)
HM400-2
Voltage
Voltage
5V
5
SEN01111-02
40 Troubleshooting
Circuit diagram related to idle validation switch
Fig. 1
Pedal: Stroke of accelerator pedal Output voltage: Output voltage (%) Sig1: Signal voltage of throttle sensor Sig2: Signal voltage of idle validation switch 1 Sig3: Signal voltage of idle validation switch 2 Lo: Switch circuit is closed Hi: Switch circuit is open Switch gap: Overlap between signals of switch 1 and switch 2
6
HM400-2
40 Troubleshooting
SEN01111-02
Failure code [CA432] Trouble in idle validation process Action code E03 Contents of trouble
Failure code CA432
Trouble
1
Trouble in idle validation process (Engine controller system)
• Throttle potentiometer signal of accelerator pedal is different from idle validation switch signals 1 and 2.
Action of controller
• Turns caution lamp ON and sounds alarm buzzer. • When throttle is fixed to low idle or pedal is released, engine speed is set to low idle. When pedal is pressed, engine speed is set to medium speed.
Problem that appears on machine
• When accelerator pedal is pressed, engine speed does not rise from low idle or does not rise above medium speed.
Related information Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA431].
Failure code [CA441] Abnormally low voltage in power supply Action code
Failure code
E03
CA441
Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state
HM400-2
Trouble
1
Abnormally low voltage in power supply (Engine controller system)
• Voltage in power supply circuit of engine controller is abnormally low. • None in particular. • Machine continues operation normally but may stop suddenly or may not able to restart. • Source voltage of engine controller can be checked with monitoring function. (Monitoring code: ENGINE - POWER SUPPLY - 03200) Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA111].
7
SEN01111-02
40 Troubleshooting
Failure code [CA442] Abnormally high voltage in power supply Action code
Failure code
E03
CA442
Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state
Trouble
1
Abnormally high voltage in power supply (Engine controller system)
• Voltage in power supply circuit of engine controller is abnormally high. • None in particular. • Machine continues operation normally but may stop suddenly or may not able to restart. • Source voltage of engine controller can be checked with monitoring function. (Monitoring code: ENGINE - POWER SUPPLY - 03200) Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA111].
Failure code [CA449] Abnormally high common rail pressure 2 Action code
Failure code
E03
CA449
Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state
8
Trouble
1
Abnormally high common rail pressure 2 (Engine controller system)
• Common rail pressure sensor circuit detected abnormally high pressure (level 2). • Limits engine output and continues operation (Limits common rail pressure). • Engine output lowers. • Common rail pressure can be checked with monitoring function. (Monitoring code: ENGINE - RAIL PRESS - 36400) Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA553].
HM400-2
40 Troubleshooting
HM400-2
SEN01111-02
9
SEN01111-02
40 Troubleshooting
Failure code [CA451] Abnormally high common rail pressure Action code
Failure code
E03
CA451
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Abnormally high common rail pressure (Engine controller system)
• Common rail pressure sensor circuit detected abnormally high pressure. • Limits engine output and continues operation (Limits common rail pressure). • Engine output lowers. • Condition of common rail pressure sensor signal can be checked with monitoring function. (Monitoring code: ENGINE - RAIL PRESS - 36401) Cause 1
Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA352] or [CA386] is displayed, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. PFUEL
Defective common rail pres2 sure sensor (Internal defect)
Voltage
Between (1) – (3)
Power supply
4.75 – 5.25 V
Between (2) – (3)
Signal
0.25 – 4.6 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Possible causes and standard value in normal state
Wiring harness between ENG (female) (33) – PFUEL (female) (1)
Resistance
Max. 1 z
Wiring harness between ENG (female) (25) – PFUEL (female) (2)
Resistance
Max. 1 z
Wiring harness between ENG (female) (47) – PFUEL (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (33) Ground fault in wiring har– PFUEL (female) (1) 4 ness (Short circuit with GND Wiring harness between ENG (female) (25) circuit) – PFUEL (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (47) – PFUEL (female) (3)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Short circuit in wiring har5 ness (with another wiring harness)
10
Wiring harness between ENG (female) (33) – PFUEL (female) (1) and between ENG (female) (25) – PFUEL (female) (2)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (33) – PFUEL (female) (1) and between ENG (female) (47) – PFUEL (female) (3)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (25) – PFUEL (female) (2) and between ENG (female) (47) – PFUEL (female) (3)
Resistance
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01111-02
Cause Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. ENG
Voltage
Between (33) – (47)
4.75 – 5.25 V
Between (25) – (47)
0.25 – 4.6 V
6 Defective engine controller
Circuit diagram related to common rail pressure sensor
HM400-2
11
SEN01111-02
40 Troubleshooting
Failure code [CA452] Abnormally low common rail pressure Action code
Failure code
E03
CA452
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Abnormally low common rail pressure (Engine controller system)
• Common rail pressure sensor circuit detected abnormally low pressure. • Limits engine output and continues operation (Limits common rail pressure). • Engine output lowers. • Condition of common rail pressure sensor signal can be checked with monitoring function. (Monitoring code: ENGINE - RAIL PRESS - 36401)
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA451].
Failure code [CA553] Abnormally high common rail pressure 1 Action code
Failure code
E03
CA553
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
• None in particular. • Engine output lowers. • Common rail pressure can be checked with monitoring function. (Monitoring code: ENGINE - RAIL PRESS - 36400) Standard value in normal state/Remarks on troubleshooting
1 Defective related system
If another failure code is displayed, carry out troubleshooting for it first.
2 Use of improper fuel
Improper fuel may be used. Check used fuel directly (for high viscosity).
3
Defective electrical system of Electrical system of common rail pressure sensor may be defeccommon rail pressure sensor tive. Carry out troubleshooting for failure code [CA451].
Defective mechanical system Mechanical system of common rail pressure sensor may be defec4 of common rail pressure sentive. Check it directly. sor 5 Defective overflow valve 6
Clogged overflow valve piping
7 Defective pressure limiter
12
Abnormally high common rail pressure 1 (Engine controller system)
• Common rail pressure sensor circuit detected abnormally high pressure (level 1).
Cause
Possible causes and standard value in normal state
1
Check overflow valve for breakage of spring, wear of seat, and sticking of ball. Overflow valve piping may be clogged. Check it directly. Pressure limiter may have mechanical trouble. Check it directly.
HM400-2
40 Troubleshooting
SEN01111-02
Failure code [CA554] In-range error in common rail pressure sensor Action code
Failure code
E03
CA554
Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state
HM400-2
Trouble
1
In-range error in common rail pressure sensor (Engine controller system)
• Common rail pressure sensor circuit has in-range error in it. • Limits engine output and continues operation (Limits common rail pressure). • Engine output lowers. • Condition of common rail pressure sensor signal can be checked with monitoring function. (Monitoring code: ENGINE - RAIL PRESS - 36401) Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA451].
13
SEN01111-02
14
40 Troubleshooting
HM400-2
40 Troubleshooting
SEN01111-02
Failure code [CA559] Supply pump low pressure 1 Action code
Failure code
E03
CA559
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Supply pump low pressure 1 (Engine controller system)
• Low pressure (level 1) is detected in supply pump. • Limits common rail pressure. • Engine output lowers. • Common rail pressure can be checked with monitoring function. (Monitoring code: ENGINE - RAIL PRESS - 36400) Cause
Standard value in normal state/Remarks on troubleshooting
1 Defective related system
If another failure code is displayed, carry out troubleshooting for it first.
2 Use of improper fuel
Improper fuel may be used. Check used fuel directly.
3
Defective low-pressure circuit device
4 Clogged filter or strainer
Possible causes and standard value in normal state
1
a For contents of troubleshooting, see Note 1. For measurement of pressure in fuel low-pressure circuit, see Testing and adjusting, Measuring fuel pressure. Pressure in fuel low-pressure circuit (High idle)
Min. 0.15 MPa {Min. 1.5 kg/cm2}
a For contents of troubleshooting, see Note 2.
5
Supply pump PCV may have electrical defect. Carry out troubleDefective electrical system of shooting for failure codes [CA271], [CA272], [CA273], and supply pump PCV [CA274].
6
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring harsure sensor ness for damage. a For measurement of leakage from pressure limiter, see Testing and adjusting, Measuring fuel return rate and fuel leakage.
7 Defective pressure limiter
Leakage from pressure limiter (Operation equivalent to rating (stall load))
Max. 10 cc/min
a For measurement of limit of return (spill) from injector, see Testing and adjusting, Measuring fuel return rate and fuel leakage. Speed at operation equivalent to Limit of return (spill) from injector rating (stall load) 8 Defective injector
9 Defective supply pump
1,600 rpm
960 cc/min
1,700 rpm
1,020 cc/min
1,800 rpm
1,080 cc/min
1,900 rpm
1,140 cc/min
2,000 rpm
1,200 cc/min
If causes 1 – 8 are not detected, supply pump may be defective.
Carry out the above troubleshooting and take a record of the contents of the attached "Check sheet for rail pressure low error".
HM400-2
15
SEN01111-02
40 Troubleshooting
Check sheet for rail pressure low error Model Machine serial No.
HM400-2 #
Date of check
Engine Engine serial No.
Work No.
SAA6D140E-5
/
/
Service meter
#
h
Worker's name
Good NG
A. Visual check 1 Fuel leakage to outside 2 Clogging of fuel tank breather
B. Check with machine monitor (02 Fault history, 01 monitoring, and 09 reduced cylinder mode operation) Good NG 3 Check of failure code
/
/
/
/
Check of monitoring information Code
Displayed item
01002 Engine speed
31706
4
Final accelerator position
Final fuel injection 18600 rate command (by weight)
ISO unit
Standard value (Reference value)
Low idle
r/min
700 – 750
High idle
r/min
2,200 – 2,250
Torque converter stall
r/min
2,000
Checking condition
Measured value
Good NG
Low idle
%
0
High idle
%
100
mg/st
—
—
—
Torque converter stall
36200
Final common rail Torque converter stall pressure command
MPa
—
—
—
36400
Common rail pressure
MPa
—
—
—
Low idle
CA
—
—
—
High idle
CA
—
—
—
Torque converter stall
CA
—
—
—
Torque converter stall
Final injection tim36300 ing command 36500 Boost pressure
Torque converter stall
kPa
—
—
—
Engine coolant tem04107 Low idle perature
°C
—
—
—
14200 Fuel temperature
°C
—
—
—
ISO unit
Standard value (Reference value)
Low idle
Check of reduced cylinder mode operation (Engine speed) Setting
5
16
Reduced cylinder
Checking condition
Measured value
Good NG
No. 1 cylinder
Low idle
r/min
—
—
—
No. 2 cylinder Reduce No. 3 cylinder each cylinder No. 4 cylinder No. 5 cylinder
Low idle
r/min
—
—
—
Low idle
r/min
—
—
—
Low idle
r/min
—
—
—
Low idle
r/min
—
—
—
No. 6 cylinder
Low idle
r/min
—
—
—
HM400-2
40 Troubleshooting
C. Check of fuel circuit pressure 6
Fuel low-pressure circuit pressure
SEN01111-02
Checking condition High idle or load equivalent to rating (at stall)
Unit
Standard value (Reference value)
MPa {kg/cm2}
Min. 0.15 {Min. 1.5}
Measured value
D. Check of strainers and filters
Good NG
Good NG
7 Visual check of strainers 8 Visual check of gauze filter 9 Visual check of fuel filter 10 Visual check of bypass valve
E. Check of leakage and return rate 11
Leakage through pressure limiter
12 Return rate from injector
HM400-2
Unit
Standard value (Reference value)
Torque converter stall
cc/min
Max. 10
Torque converter stall 1,600 rpm
cc/min
960
Torque converter stall 1,700 rpm
cc/min
1,020
Torque converter stall 1,800 rpm
cc/min
1,080
Torque converter stall 1,900 rpm
cc/min
1,140
Torque converter stall 2,000 rpm
cc/min
1,200
Checking condition
Measured value
Good NG
Speed: Leakage
17
SEN01111-02
40 Troubleshooting
Failure code [CA689] Trouble in engine Ne speed sensor Action code
Failure code
E03
CA689
Contents of trouble Action of controller Problem that appears on machine
Trouble
1
Trouble in engine Ne speed sensor (Engine controller system)
• Engine Ne speed sensor circuit has trouble in it. • Operates with signal of Bkup speed sensor. • Engine stops if it has been running (when Bkup speed sensor also has trouble). • Engine cannot be started if it has been stopped (when Ne speed sensor also has trouble).
Related information Cause 1
Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA238] is indicated, carry out troubleshooting for it ply system first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector)
Wiring harness between ENG (female) (16) – NE (female) (1)
Resistance
Max. 1 z
Wiring harness between ENG (female) (48) – NE (female) (2)
Resistance
Max. 1 z
Wiring harness between ENG (female) (27) – NE (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (16) Ground fault in wiring har– NE (female) (1) 3 ness (Short circuit with GND Wiring harness between ENG (female) (48) circuit) – NE (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (27) – NE (female) (3)
Resistance
Min. 1 Mz
Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Short circuit in wiring har4 ness (with another wiring harness)
Wiring harness between ENG (female) (16) – NE (female) (1) and between ENG (female) (48) – NE (female) (2)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (16) – NE (female) (1) and between ENG (female) (48) – NE (female) (3)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (48) – NE (female) (2) and between ENG (female) (27) – NE (female) (3)
Resistance
Min. 1 Mz
Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective 5 defective rotation sensing clearance) or check rotation sensing part (flywheel) directly for part defect. Defective engine Ne speed sensor
If causes 1 – 5 are not detected, engine Ne speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
7 Defective engine controller
If causes 1 – 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
6
18
HM400-2
40 Troubleshooting
SEN01111-02
Circuit diagram related to engine Ne speed sensor
HM400-2
19
SEN01111-02
40 Troubleshooting
Failure code [CA731] Phase error in engine Bkup speed sensor Action code
Failure code
E03
CA731
Contents of trouble Action of controller Problem that appears on machine
Trouble
1
Phase error in engine Bkup speed sensor (Engine controller system)
• Engine Bkup sensor circuit detected abnormality in phase. • Controls with signal of engine Ne speed sensor. • Engine stops if it has been running (when Bkup speed sensor also has trouble). • Engine cannot be started if it has been stopped (when Ne speed sensor also has trouble).
Related information
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
1
Defective engine Ne speed sensor system
Engine Ne speed sensor may be defective. Carry out troubleshooting for failure code [CA689].
2
Defective engine Bkup speed sensor system
Engine Bkup speed sensor may be defective. Carry out troubleshooting for failure code [CA778].
Failure code [CA757] Loss of all data in engine controller Action code
Failure code
E03
CA757
Contents of trouble Action of controller Problem that appears on machine
Trouble
1
Loss of all data in engine controller (Engine controller system)
• All data in engine controller are lost. • None in particular. • Engine operates normally but may stop or may not be able to restart.
Related information Possible causes and standard value in normal state
20
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA111].
HM400-2
40 Troubleshooting
HM400-2
SEN01111-02
21
SEN01111-02
40 Troubleshooting
Failure code [CA778] Trouble in engine Bkup speed sensor Action code
Failure code
E03
CA778
Contents of trouble Action of controller Problem that appears on machine
Trouble
1
Trouble in engine Bkup speed sensor (Engine controller system)
• Engine Bkup speed sensor circuit has trouble in it. • Operates with signal of Ne speed sensor. • Engine stops if it has been running (when Bkup speed sensor also has trouble). • Engine cannot be started if it has been stopped (when Ne speed sensor also has trouble).
Related information Cause 1
Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA187] or [CA227] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector)
Wiring harness between ENG (female) (37) – G (female) (1)
Resistance
Max. 1 z
Wiring harness between ENG (female) (47) – G (female) (2)
Resistance
Max. 1 z
Wiring harness between ENG (female) (26) – G (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) Ground fault in wiring har– G (female) (1) 3 ness (Short circuit with GND Wiring harness between ENG (female) (47) circuit) – G (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (26) – G (female) (3)
Resistance
Min. 1 Mz
Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Short circuit in wiring har4 ness (with another wiring harness)
Wiring harness between ENG (female) (37) – G (female) (1) and between ENG (female) (47) – G (female) (2)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (37) – G (female) (1) and between ENG (female) (26) – G (female) (3)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (47) – G (female) (2) and between ENG (female) (29) – G (female) (3)
Resistance
Min. 1 Mz
Defective mount of sensor or Check Bkup speed sensor directly for defective mount (defective 5 defective rotation sensing clearance) or check rotation sensing part (in supply pump) directly part for defect. 6
Defective engine Bkup speed sensor
7 Defective engine controller
22
If causes 1 – 5 are not detected, engine Bkup speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 – 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
HM400-2
40 Troubleshooting
SEN01111-02
Circuit diagram related to engine Bkup speed sensor
HM400-2
23
SEN01111-02
40 Troubleshooting
Failure code [CA1228] Trouble in EGR valve servo 1 Action code
Failure code
E03
CA1228
Contents of trouble Action of controller
Trouble
1
Trouble in EGR valve servo 1 (Engine controller system)
• EGR valve servo has trouble (level 1) in it. • Performs open control.
Problem that appears on machine Related information
• Operating condition of EGR valve can be checked with monitoring function. (Monitoring code: ENGINE - EGR VALVE POS - 18100) Cause 1 Defective related system
Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it first. a For check of engine oil pressure, see TESTING AND ADJUSTING, Measuring engine oil pressure.
Defective engine oil pressure 2 system (main circuit) Possible causes and standard value in normal state
24
Engine
Engine oil pressure
Low idle
0.08 MPa {0.8 kg/cm2}
High idle
0.21 MPa {2.1 kg/cm2}
If engine oil pressure is abnormal, carry out troubleshooting for "S12 Oil pressure lowers" in S mode. 3
Defective oil pump for EGR valve
Pump and relief valve for EGR valve circuit may be defective. Check it directly.
4
Defective oil feed piping for EGR valve
Oil feed piping for EGR valve circuit may be defective. Check it directly.
5
Defective oil return piping for Oil return piping for EGR valve circuit may be defective. Check it EGR valve directly.
6 Defective EGR valve
Mechanical section of EGR valve may be defective. Check it directly.
7 Defective engine controller
If causes 1 – 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
HM400-2
40 Troubleshooting
SEN01111-02
Failure code [CA1625] Trouble in EGR valve servo 2 Action code
Failure code
E03
CA1625
Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state
HM400-2
Trouble
1
Trouble in EGR valve servo 2 (Engine controller system)
• EGR valve servo has trouble (level 2) in it. • Limits engine output and continues operation. • Closes EGR valve and bypass valve. • Engine output lowers. • Operating condition of EGR valve can be checked with monitoring function. (Monitoring code: ENGINE - EGR VALVE POS - 18100) Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA1228].
25
SEN01111-02
40 Troubleshooting
Failure code [CA1626] Short circuit in bypass valve solenoid drive circuit Action code
Failure code
E03
CA1626
Contents of trouble Action of controller Problem that appears on machine
Trouble
1
Short circuit in bypass valve solenoid drive circuit (Engine controller system)
• There is short circuit in drive circuit of bypass valve solenoid. • Limits engine output and continues operation. • Closes EGR valve and bypass valve. • Engine output lowers.
Related information Cause
Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective bypass valve sole1 noid (Internal defect) BP (male) Resistance Between (1) – (2)
10 – 21 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (31) 2 or defective contact in con- – BP (female) (1) nector) Wiring harness between ENG (female) (11) – BP (female) (2) Possible causes and standard value in normal state
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (31) 3 ness (Short circuit with GND – BP (female) (1) circuit) Wiring harness between ENG (female) (11) – BP (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4
Hot short (Short circuit with Wiring harness between ENG (female) (31) 24V circuit) in wiring harness – BP (female) (1)
Voltage
Max. 1 V
Wiring harness between ENG (female) (11) – BP (female) (2)
Voltage
Max. 1 V
5 Defective engine controller
26
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female)
Resistance
Between (31) – (11)
10 – 21 z
HM400-2
40 Troubleshooting
SEN01111-02
Circuit diagram related to bypass valve solenoid and lift sensor
HM400-2
27
SEN01111-02
40 Troubleshooting
Failure code [CA1627] Disconnection in bypass valve solenoid drive circuit1 Action code
Failure code
E03
CA1627
Contents of trouble Action of controller Problem that appears on machine
Trouble
Disconnection in bypass valve solenoid drive circuit (Engine controller system)
• There is disconnection in drive circuit of bypass valve solenoid. • Limits engine output and continues operation. • Closes EGR valve and bypass valve. • Engine output lowers.
Related information Possible causes and standard value in normal state
28
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA1626].
HM400-2
40 Troubleshooting
SEN01111-02
Failure code [CA1628] Trouble in bypass valve servo 1 Action code
Failure code
E03
CA1628
Contents of trouble Action of controller
Trouble
1
Trouble in bypass valve servo 1 (Engine controller system)
• Bypass valve servo has trouble (level 1) in it. • Performs open control.
Problem that appears on machine Related information
• Operating condition of bypass valve can be checked with monitoring function. (Monitoring code: ENGINE - BPS VALVE POS - 18200) Cause 1 Defective related system
Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it first. a For check of engine oil pressure, see TESTING AND ADJUSTING, Measuring engine oil pressure.
2
Possible causes and standard value in normal state
HM400-2
Defective engine oil pressure system (main circuit)
Engine
Engine oil pressure
Low idle
0.08 MPa {0.8 kg/cm2}
High idle
0.21 MPa {2.1 kg/cm2}
If engine oil pressure is abnormal, carry out troubleshooting for "S12 Oil pressure lowers" in S mode. 3
Defective oil pump for bypass valve
Oil pump and relief valve for bypass valve circuit may be defective. Check it directly.
4
Defective oil feed piping for bypass valve
Oil feed piping for bypass valve circuit may be defective. Check it directly.
5
Defective oil return piping for Oil return piping for bypass valve circuit may be defective. Check it bypass valve directly.
6 Defective bypass valve
Mechanical section of bypass valve may be defective. Check it directly.
7 Defective engine controller
If causes 1 – 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
29
SEN01111-02
40 Troubleshooting
Failure code [CA1629] Trouble in bypass valve servo 2 Action code
Failure code
E03
CA1629
Trouble
Trouble in bypass valve servo 2 (Engine controller system)
Contents of trouble
• Bypass valve servo has trouble (level 2) in it.
Action of controller
• Limits engine output and continues operation. • Closes EGR valve and bypass valve.
Problem that appears on machine Related information Possible causes and standard value in normal state
30
1
• Engine output lowers. • Operating condition of bypass valve can be checked with monitoring function. (Monitoring code: ENGINE-BPS VALVE POS-18200) Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA1628].
HM400-2
40 Troubleshooting
HM400-2
SEN01111-02
31
SEN01111-02
40 Troubleshooting
Failure code [CA1631] Abnormally high signal in bypass valve lift sensor Action code
Failure code
E03
CA1631
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Abnormally high signal in bypass valve lift sensor (Engine controller system)
• Signal voltage in bypass valve lift sensor circuit is abnormally high. • Limits engine output and continues operation. • Closes EGR valve and bypass valve. • Engine output lowers. • Condition of bypass valve lift sensor signal can be checked with monitoring function. (Monitoring code: ENGINE - BPS VALVE POS - 18201) Cause 1
Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA187] or [CA227] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting.
2
Defective bypass valve lift sensor (Internal defect)
SBP Between (1) – (2)
Voltage Power supply
4.75 – 5.25V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Possible causes and standard value in normal state
Wiring harness between ENG (female) (37) – SBP (female) (1)
Resistance
Max. 1 z
Wiring harness between ENG (female) (38) – SBP (female) (2)
Resistance
Max. 1 z
Wiring harness between ENG (female) (29) – SBP (female) (3), (4)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) Ground fault in wiring har– SBP (female) (1) 4 ness (Short circuit with GND Wiring harness between ENG (female) (38) circuit) – SBP (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (29) – SBP (female) (3), (4)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Short circuit in wiring har5 ness (with another wiring harness)
32
Wiring harness between ENG (female) (37) – SBP (female) (1) and between ENG (female) (38) – SBP (female) (2)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (37) – SBP (female) (1) and between ENG (female) (29) – SBP (female) (3), (4)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (38) – SBP (female) (2) and between ENG (female) (29) – SBP (female) (3), (4)
Resistance
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01111-02
Cause Possible causes and standard value in normal state
6 Defective engine controller
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. ENG
Voltage
Between (37) – (38)
4.75 – 5.25 V
Circuit diagram related to bypass valve lift sensor
HM400-2
33
SEN01111-02
40 Troubleshooting
Failure code [CA1632] Abnormally low signal in bypass valve lift sensor Action code
Failure code
E03
CA1632
Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state
34
Trouble
1
Abnormally low signal in bypass valve lift sensor (Engine controller system)
• Signal voltage in bypass valve lift sensor circuit is abnormally low. • Limits engine output and continues operation. • Closes EGR valve and bypass valve. • Engine output lowers. • Condition of bypass valve lift sensor signal can be checked with monitoring function. (Monitoring code: ENGINE - BPS VALVE POS - 18201) Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA1631].
HM400-2
40 Troubleshooting
HM400-2
SEN01111-02
35
SEN01111-02
40 Troubleshooting
Failure code [CA1633] Trouble in KOMNET Action code E03 Contents of trouble Action of controller
Failure code CA1633
Trouble
1
Trouble in KOMNET (Engine controller system)
• Trouble occurred in KOMNET (CAN) communication circuit between engine controller, machine monitor, transmission controller, and retarder controller. • Operates in default mode or maintains condition when abnormality occurs.
Problem that appears on machine Related information Cause Defective CAN terminal 1 resistor (Internal defect)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CAN1 (male), CAN2 (male)
Resistance
Between (A) – (B)
Approx. 120 ± 12 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector)
Possible causes and standard value in normal state
Wiring harness between DPC4 (female) (3) – J2P (female) (47) or ATC2 (female) (22) – BRC2 (female) (22)
Resistance
Max. 1 z
Wiring harness between DPC4 (female) (8) – J2P (female) (46) or ATC2 (female) (32) – BRC2 (female) (32)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between DPC4 (female) (3) Ground fault in wiring har– J2P (female) (47) or ATC2 (female) (22) – 3 ness (Short circuit with GND BRC2 (female) (22) or circuit branch end circuit) Wiring harness between DPC4 (female) (8) – J2P (female) (46) or ATC2 (female) (32) – BRC2 (female) (32) or related circuit
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between DPC4 (female) (3) Hot short (Short circuit with – J2P (female) (47) or ATC2 (female) (22) – 4 24V circuit) in wiring harness BRC2 (female) (22) or related circuit
Voltage
Max. 1 V
Wiring harness between DPC4 (female) (8) – J2P (female) (46) or ATC2 (female) (32) – BRC2 (female) (32) or related circuit
Voltage
Max. 1 V
Defective engine controller, machine monitor, transmis5 sion controller, or retarder controller
36
If causes 1 – 4 are not detected, engine controller, machine monitor, transmission controller, or retarder controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
HM400-2
40 Troubleshooting
SEN01111-02
Circuit diagram related to CAN communication
HM400-2
37
SEN01111-02
40 Troubleshooting
Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor1 Action code
Failure code
E01
CA1642
Contents of trouble Action of controller Problem that appears on machine
Trouble
Abnormally low signal in EGR inlet pressure sensor (Engine controller system)
• Signal voltage in EGR valve inlet pressure sensor circuit is abnormally low. • Sets EGR valve inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation. • Limits engine output and continues operation. • Engine output lowers.
Related information Possible causes and standard value in normal state
38
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA1653].
HM400-2
40 Troubleshooting
HM400-2
SEN01111-02
39
SEN01111-02
40 Troubleshooting
Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor Action code
Failure code
E01
CA1653
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Abnormally high signal in EGR inlet pressure sensor (Engine controller system)
• Signal voltage in EGR valve inlet pressure sensor circuit is abnormally high. • Sets EGR valve inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation. • Limits engine output and continues operation. • Engine output lowers. • Condition of EGR valve inlet pressure sensor signal can be checked with monitoring function. (Monitoring code: ENGINE - EGR IN PRESS-A - 18001) Cause 1
Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA187] or [CA227] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting.
Defective EGR valve inlet 2 pressure sensor (Internal defect)
PEVA Between (1) – (2)
Voltage Power supply
4.75 –5.25 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Possible causes and standard value in normal state
Wiring harness between ENG (female) (37) – PEVA (female) (1)
Resistance
Max. 1 z
Wiring harness between ENG (female) (47) – PEVA (female) (2)
Resistance
Max. 1 z
Wiring harness between ENG (female) (20) – PEVA (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) Ground fault in wiring har– PEVA (female) (1) 4 ness (Short circuit with GND Wiring harness between ENG (female) (47) circuit) – PEVA (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (20) – PEVA (female) (3)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Short circuit in wiring har5 ness (with another wiring harness)
40
Wiring harness between ENG (female) (37) – PEVA (female) (1) and between ENG (female) (47) – PEVA (female) (2)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (37) – PEVA (female) (1) and between ENG (female) (20) – PEVA (female) (3)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (47) – PEVA (female) (2) and between ENG (female) (20) – PEVA (female) (3)
Resistance
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01111-02
Cause Possible causes and standard value in normal state
6 Defective engine controller
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. ENG
Voltage
Between (37) – (47)
4.75 – 5.25 V
Circuit diagram related to EGR valve inlet pressure sensor
HM400-2
41
SEN01111-02
40 Troubleshooting
Failure code [CA2185] Abnormally high voltage in throttle sensor power supply1 Action code
Failure code
E03
CA2185
Contents of trouble Action of controller
Trouble
Abnormally high voltage in throttle sensor power supply (Engine controller system)
• Voltage in throttle sensor power supply (5V) circuit is abnormally high. • Sets throttle position with signals other than throttle sensor signal and continues operation.
Problem that appears on machine Related information Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Defective accelerator pedal 1 (Internal defect)
Possible causes and standard value in normal state
Accelerator pedal
Connector AS1
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between J2P (female) (22) – Resis2 Max. 1 z or defective contact in con- AS1 (female) (1) tance nector) Wiring harness between J2P (female) (23) – ResisMax. 1 z AS1 (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between J2P (female) (22) – 3 ness (Short circuit with GND AS1 (female) (1) circuit) Wiring harness between J2P (female) (23) – AS1 (female) (3) Short circuit in wiring har4 ness (with another wiring harness)
5 Defective engine controller
42
When device at right is disconnected, if mark E of failure code disappears, that device has defect in it.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between J2P (female) (22) – AS1 (female) (1) and between J2P (female) (23) – AS1 (female) (3)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. J2P
Voltage
Between (22) – (23)
4.75 – 5.25 V
HM400-2
40 Troubleshooting
SEN01111-02
Circuit diagram related to throttle sensor power supply of engine controller
HM400-2
43
SEN01111-02
40 Troubleshooting
Failure code [CA2186] Abnormally low voltage in throttle sensor power supply1 Action code
Failure code
E03
CA2186
Contents of trouble Action of controller
Trouble
Abnormally low voltage in throttle sensor power supply (Engine controller system)
• Voltage in throttle sensor power supply (5V) circuit of engine controller is abnormally low. • Sets throttle position with signals other than throttle sensor signal and continues operation.
Problem that appears on machine Related information Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA2185].
Failure code [CA2249] Low pressure in supply pump 2 Action code
Failure code
E03
CA2249
Contents of trouble Action of controller Problem that appears on machine
Trouble
1
Low pressure in supply pump 2 (Engine controller system)
• Very low pressure (level 2) is detected in supply pump. • Limits common rail pressure. • Engine output lowers.
Related information Possible causes and standard value in normal state
44
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA559].
HM400-2
40 Troubleshooting
HM400-2
SEN01111-02
45
SEN01111-02
40 Troubleshooting
Failure code [CA2271] Abnormally high signal voltage in EGR valve lift sensor Action code
Failure code
E03
CA2271
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Abnormally high signal voltage in EGR valve lift sensor (Engine controller system)
• Signal voltage in EGR valve lift sensor circuit is abnormally high. • Limits engine output and continues operation. • Closes EGR valve and bypass valve. • Engine output lowers. • Condition of EGR valve lift sensor signal can be checked with monitoring function. (Monitoring code: ENGINE - EGR VALVE POS - 18101) Cause 1
Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA187] or [CA227] is indicated, carry out troubleply shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting.
2
Defective EGR valve lift sensor (Internal defect)
SEGR Between (1) – (2)
Voltage Power supply
4.75 – 5.25 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Possible causes and standard value in normal state
Wiring harness between ENG (female) (37) – SEGR (female) (1)
Resistance
Max. 1 z
Wiring harness between ENG (female) (47) – SEGR (female) (2)
Resistance
Max. 1 z
Wiring harness between ENG (female) (19) – SEGR (female) (3), (4)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) Ground fault in wiring har– SEGR (female) (1) 4 ness (Short circuit with GND Wiring harness between ENG (female) (47) circuit) – SEGR (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (19) – SEGR (female) (3), (4)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Short circuit in wiring har5 ness (with another wiring harness)
46
Wiring harness between ENG (female) (37) – SEGR (female) (1) and between ENG (female) (47) – SEGR (female) (2)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (37) – SEGR (female) (1) and between ENG (female) (19) – SEGR (female) (3), (4)
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (47) – SEGR (female) (2) and between ENG (female) (19) – SEGR (female) (3), (4)
Resistance
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01111-02
Cause Possible causes and standard value in normal state
6 Defective engine controller
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. ENG
Voltage
Between (37) – (47)
4.75 – 5.25 V
Circuit diagram related to EGR valve solenoid & lift sensor
HM400-2
47
SEN01111-02
40 Troubleshooting
Failure code [CA2272] Abnormally low signal voltage in EGR valve lift sensor 1 Action code
Failure code
E03
CA2272
Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state
48
Trouble
Abnormally low signal voltage in EGR valve lift sensor (Engine controller system)
• Signal voltage in EGR valve lift sensor circuit is abnormally low. • Limits engine output and continues operation. • Closes EGR valve and bypass valve. • Engine output lowers. • Condition of EGR valve lift sensor signal can be checked with monitoring function. (Monitoring code: ENGINE - EGR VALVE POS - 18101) Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA2271].
HM400-2
40 Troubleshooting
HM400-2
SEN01111-02
49
SEN01111-02
40 Troubleshooting
Failure code [CA2351] Short circuit in EGR valve solenoid drive circuit1 Action code
Failure code
E03
CA2351
Contents of trouble Action of controller Problem that appears on machine
Trouble
Short circuit in EGR valve solenoid drive circuit (Engine controller system)
• There is short circuit in EGR valve solenoid drive circuit. • Limits engine output and continues operation. • Closes EGR valve and bypass valve. • Engine output lowers.
Related information Cause Defective EGR valve sole1 noid (Internal defect)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. EGR (male)
Resistance
Between (1) – (2)
10 – 21 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (22) Resis2 Max. 1 z or defective contact in con- – EGR (female) (1) tance nector) Wiring harness between ENG (female) (11) ResisMax. 1 z – EGR (female) (2) tance Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (22) 3 ness (Short circuit with GND – EGR (female) (1) circuit) Wiring harness between ENG (female) (11) – EGR (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4
Hot short (Short circuit with Wiring harness between ENG (female) (22) 24V circuit) in wiring harness – EGR (female) (1)
Voltage
Max. 1 V
Wiring harness between ENG (female) (11) – EGR (female) (2)
Voltage
Max. 1 V
5 Defective engine controller
50
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female)
Resistance
Between (22) – (11)
10 – 21 z
HM400-2
40 Troubleshooting
SEN01111-02
Circuit diagram related to EGR valve solenoid and lift sensor
HM400-2
51
SEN01111-02
40 Troubleshooting
Failure code [CA2352] Disconnection in EGR valve solenoid drive circuit1 Action code
Failure code
E03
CA2352
Contents of trouble Action of controller Problem that appears on machine
Trouble
Disconnection in EGR valve solenoid drive circuit (Engine controller system)
• There is disconnection in EGR valve solenoid drive circuit. • Limits engine output and continues operation. • Closes EGR valve and bypass valve. • Engine output lowers.
Related information Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting failure code [CA2351].
Failure code [CA2555] Disconnection in intake air heater relay Action code
Failure code
E01
CA2555
Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state
52
Trouble
1
Disconnection in intake air heater relay (Engine controller system)
• There is disconnection in intake air heater relay circuit. • None in particular. • Engine does not start easily at low temperature. • Engine coolant temperature can be checked with monitoring function. (Monitoring code: ENGINE - COOLANT - TEMP - 04104) Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting failure code [CA2556].
HM400-2
40 Troubleshooting
HM400-2
SEN01111-02
53
SEN01111-02
40 Troubleshooting
Failure code [CA2556] Short circuit in intake air heater relay Action code
Failure code
E01
CA2556
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Short circuit in intake air heater relay (Engine controller system)
• There is short circuit in intake air heater relay. • None in particular. • Engine does not start easily at low temperature. • Engine controller has automatic preheating function, which is turned ON when engine coolant temperature is below -5°C (for up to 30 seconds). • Engine coolant temperature can be checked with monitoring function. (Monitoring code: ENGINE - COOLANT TEMP - 04104) Cause
1
Defective intake air heater relay (Internal trouble)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. R07 (male)
Resistance
Between (1) – (2)
200 – 400 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between J2P (female) (40) – 2 or defective contact in con- R07 (female) (1) nector) Wiring harness between R07 (female) (42) – R07 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between J2P (female) (40) – 3 ness (Contact with GND cirR07 (female) (1) cuit) Wiring harness between J2P (female) (42) – R07 (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective engine controller
54
J2P
Coolant temperature
Voltage
Between (40) – chassis ground
Above -5 °C
Max. 1 V
Below -5 °C
20 – 30 V
HM400-2
40 Troubleshooting
SEN01111-02
Circuit diagram related to preheating/starting/charging of engine
HM400-2
55
SEN01111-02
40 Troubleshooting
HM400-2 Articulated dump truck Form No. SEN01111-02
© 2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (02)
56
HM400-2
SEN01112-01
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
40 Troubleshooting
1
Troubleshooting by failure code, Part 5 Failure code [DAF9KM] Wrong connection of connector ................................................................................ 3 Failure code [DAFRKR] Trouble in CAN communication (machine monitor).................................................. 4 Failure code [DAQ0KK] Lowering of source voltage....................................................................................... 6 Failure code [DAQ0KT] Trouble in non-volatile memory................................................................................. 8 Failure code [DAQ2KK] Trouble in solenoid power supply system............................................................... 10 Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller) .................................. 12 Failure code [DAQRKR] Trouble in CAN communication (Transmission controller)..................................... 14 Failure code [DAQRMA] Disagreement of option setting (Transmission controller) ..................................... 16 Failure code [DB10KT] Trouble in non-volatile memory ............................................................................... 16 Failure code [DB12KK] Trouble in solenoid power supply system ............................................................... 18 Failure code [DB13KK] Lowering of battery direct voltage ........................................................................... 20 Failure code [DB19KQ] Disagreement of model selection (Retarder controller)........................................... 22 Failure code [DB1QMA] Disagreement of option setting (Retarder controller) ............................................. 22 Failure code [DB1RKR] Trouble in CAN communication (Retarder controller)............................................. 24 Failure code [DB2RKR] Trouble in CAN communication (Engine controller)................................................ 26 Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal ..................................... 28
HM400-2
1
SEN01112-01
40 Troubleshooting
Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve .................................................................... 30 Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve..................................................................... 31 Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve ................................................................... 32 Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve .................................................................. 33 Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve .................................................................. 34 Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve............................................................ 35 Failure code [DF10KA] Input of no lever signals........................................................................................... 36 Failure code [DF10KB] Input of multiple lever signals .................................................................................. 40 Failure code [DGF1KX] Transmission oil temperature out of range.............................................................. 44 Failure code [DGR2KZ] Ground fault in brake oil temperature sensor (rear)................................................ 46 Failure code [DGR2L8] Disconnection in brake oil temperature sensor (rear) ............................................. 48 Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center) ............................................ 50 Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center).......................................... 52 Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front)............................................... 54 Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front)............................................. 56 Failure code [DGR6KX] Steering oil temperature out of range ..................................................................... 58
2
HM400-2
40 Troubleshooting
SEN01112-01
Failure code [DAF9KM] Wrong connection of connector Action code
Failure code
E03
DAF9KM
Contents of trouble
Trouble
1
Wrong connection of connector (Machine monitor system)
• Check signal of connector is different from internal setting of machine monitor.
Action of • Detects only at start. machine monitor • Keeps trouble condition until starting switch is turned OFF. Problem that appears on machine Related information
• Machine monitor mode selector switch cannot be selected. • Headlamp high beam pilot lamp, turn signal pilot lamp, and output mode pilot lamp do not operate. • Method of reproducing failure code: Turn starting switch ON.
Cause 1 Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
Wrong connection of connec- Connector DPC2A (female) may be connected to DPC3A (male) tor by mistake. Check and connect it correctly, if connected wrongly.
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between DPC2A (female) ResisMax. 1 z nector) (5) – fuse BT3-No. 30 (10) tance
3 Defective machine monitor
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. DPC2A
Voltage
Between (5) – chassis ground
20 – 30 V
Circuit diagram related to connector check signal a Display panel is the same as machine monitor.
HM400-2
3
SEN01112-01
40 Troubleshooting
Failure code [DAFRKR] Trouble in CAN communication (machine monitor) 1 Action code
Failure code
E03
DAFRKR
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Trouble in CAN communication (machine monitor) (Transmission controller system)
• Transmission stops updating of data received from machine monitor. • Keeps information collected when trouble occurred. • If network has trouble, data which machine monitor obtains from each controller cannot be displayed normally. • Method of reproducing failure code: Turn starting switch ON.
Cause Defective CAN terminal 1 resister (Internal defect)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CAN1 (male), CAN2 (male)
Resistance
Between (A) – (B)
Approx. 120 ± 12 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector)
Wiring harness between J2P (female) (46) – CAN1 (female) (A), CAN2 (female) (A), DPC4 (female) (3), ATC2 (32), BRC2 (32) or DL (female) (3)
Resistance
Max. 1 z
Wiring harness between J2P (female) (47) – CAN1 (female) (B), CAN2 (female) (B), DPC4 (female) (8), ATC2 (22), BRC2 (22) or DL (female) (10)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
Wiring harness between J2P (female) (46) – CAN1 (female) (A), CAN2 (female) (A), Ground fault in wiring harDPC4 (female) (3), ATC2 (32), BRC2 (32) or 3 ness (Short circuit with GND DL (female) (3) circuit) Wiring harness between J2P (female) (47) – CAN1 (female) (B), CAN2 (female) (B), DPC4 (female) (8), ATC2 (22), BRC2 (22) or DL (female) (10)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between J2P (female) (46) – CAN1 (female) (A), CAN2 (female) (A), Hot short (Short circuit with DPC4 (female) (3), ATC2 (32), BRC2 (32) or 4 24V circuit) in wiring harness DL (female) (3)
Voltage
Max. 1 V
Wiring harness between J2P (female) (47) – CAN1 (female) (B), CAN2 (female) (B), DPC4 (female) (8), ATC2 (22), BRC2 (22) or DL (female) (10)
Voltage
Max. 1 V
Defective machine monitor, engine controller, transmis5 sion controller or retarder controller
4
If causes 1 – 4 are not detected, machine monitor, engine controller, transmission controller, or retarder controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
HM400-2
40 Troubleshooting
SEN01112-01
Circuit diagram related to CAN communication
HM400-2
5
SEN01112-01
40 Troubleshooting
Failure code [DAQ0KK] Lowering of source voltage Action code E03 Contents of trouble Action of controller Problem that appears on machine Related information
Failure code DAQ0KK
Trouble
1
Lowering of source voltage (Transmission controller system)
• While engine is running, voltages of both main power supply circuit and direct power supply circuit are below 18 V. • Sets gear speed in neutral. • Machine is set in neutral suddenly during travel and cannot restart. • If failure code [AB00MA] (defective alternator function) is also displayed, carry out troubleshooting for it first. • Method of reproducing failure code: Start engine. Cause 1 Defective battery 2 Trip of circuit breaker (80 A)
Standard value in normal state/Remarks on troubleshooting Battery voltage
Min. 24 V
Electrolyte specific gravity
Min. 1.26
If circuit breaker has tripped, circuit probably has ground fault. (See cause 5.)
3 Defective fuse (BT2-No. 21) If fuse is broken, circuit probably has ground fault. (See cause 5.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Wiring harness between ATC3 (female) (21), (31), (32), (33) – ground ER
Resistance
Max. 1 z
Wiring harness between ATC3 (1), (11) – fuse BT2-No. 21 (22)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between battery relay 66 terminal – battery (+) terminal
Resistance
Max. 1 z
Wiring harness between ATC3 (14), (24) – starting switch ACC
Resistance
Max. 1 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between fuse BT2-No. 21 4 or defective contact in con- (21) – circuit breaker 84 terminal nector) Wiring harness between circuit breaker 82 terminal – battery relay 66 terminal
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ATC3 (female) (21), (31), (32), (33) – ground ER
Resistance
Max. 1 z
Wiring harness between ATC3 (1), (11) – fuse BT2-No. 21 (22)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between battery relay 66 terminal – battery (+) terminal
Resistance
Max. 1 z
Wiring harness between ATC3 (14), (24) – starting switch ACC
Resistance
Max. 1 z
Ground fault in wiring harWiring harness between fuse BT2-No. 21 5 ness (Short circuit with GND (21) – circuit breaker 84 terminal circuit) Wiring harness between circuit breaker 82 terminal – battery relay 66 terminal
6
HM400-2
40 Troubleshooting
SEN01112-01
Cause Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
6
Defective transmission controller
ATC3
Voltage
Between (1), (11) – (21), (31), (32), (33)
20 – 30 V
Between (14), (24) – (21), (31), (32), (33)
20 – 30 V
Circuit diagram related to transmission controller power supply
HM400-2
7
SEN01112-01
40 Troubleshooting
Failure code [DAQ0KT] Trouble in non-volatile memory Action code
Failure code
E01 Contents of trouble Action of controller
Trouble in non-volatile memory (Transmission controller system)
• Non-volatile memory in transmission controller has trouble in it. • When starting switch was turned OFF, finishing process was not carried out normally. • Controls model selection and option setting with default values.
Problem that appears on machine
• Control parameters of machine may change and gearshift shock of transmission and seating shock of hoist may increase.
Related information
• Perform initial setting and adjustment of transmission controller to be performed after replacement (See Testing and adjusting, Setting and adjusting each device). • Method of reproducing failure code: Turn the starting switch ON.
Possible causes and standard value in normal state
8
DAQ0KT
Trouble
1
Cause 1
Defective transmission controller
Standard value in normal state/Remarks on troubleshooting Troubleshooting cannot be carried out since the trouble is in the controller. (If there is not any visible trouble in the machine, the controller may be used as it is.)
HM400-2
40 Troubleshooting
HM400-2
SEN01112-01
9
SEN01112-01
40 Troubleshooting
Failure code [DAQ2KK] Trouble in solenoid power supply system Action code
Failure code
E03
DAQ2KK
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Trouble in solenoid power supply system (Transmission controller system)
• While controller power supply circuit is normal, voltage in solenoid power supply circuit is below 18 V. • Turns transmission cut-off relay OFF. • Sets gear speed in neutral. • Machine is set in neutral suddenly during travel and cannot restart. • Dump body cannot be operated. • Method of reproducing failure code: Turn starting switch ON.
Cause 1 Trip of circuit breaker (80 A)
Standard value in normal state/Remarks on troubleshooting If circuit breaker has tripped, circuit probably has ground fault. (See cause 4.)
2 Defective fuse (BT3-No. 32) If fuse is broken, circuit probably has ground fault. (See cause 4.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ATC3 (2), (12), (22) – fuse BT3-No. 32 (14)
Disconnection in wiring harness (Disconnection in wiring Wiring harness between fuse BT3-No. 32 3 or defective contact in con- (13) – circuit breaker 64 terminal nector) Wiring harness between circuit breaker 65 terminal – battery relay 69 terminal
Battery relay 66 terminal – battery (+) terminal
Possible causes and standard value in normal state
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ATC3 (2), (12), (22) – fuse BT3-No. 32 (14)
Ground fault in wiring harWiring harness between fuse BT3-No. 32 4 ness (Short circuit with GND (13) – circuit breaker 64 terminal circuit) Wiring harness between circuit breaker 65 terminal – battery relay 69 terminal
Battery relay 66 terminal – battery (+) terminal
5
10
Resistance
Defective transmission controller
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ATC3
Voltage
Between (2), (12), (22) – (21), (31), (32), (33)
20 – 30 V
HM400-2
40 Troubleshooting
SEN01112-01
Circuit diagram related to solenoid power supply system
HM400-2
11
SEN01112-01
40 Troubleshooting
Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller) 1 Action code
Failure code
E03
DAQ9KQ
Contents of trouble
Trouble
Disagreement of model selection (Transmission controller) (Machine monitor system)
• Transmission controller detected disagreement of model selection.
Action of • None in particular. machine monitor Problem that appears on machine Related information
• If machine travels at it is, transmission may be damaged. • Method of reproducing failure code: Turn starting switch ON.
Cause
Possible causes and standard value in normal state
12
Standard value in normal state/Remarks on troubleshooting
1
Wrong setting of model by machine monitor
Wrong model may be set by machine monitor. After replacing machine monitor or transmission controller, set it correctly according to Testing and adjusting.
2
Installation of wrong transmission controller
Wrong transmission controller may be installed. Check its part No. and replace it with correct one, if necessary.
3 Defective machine monitor
If causes 1 – 2 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
HM400-2
40 Troubleshooting
HM400-2
SEN01112-01
13
SEN01112-01
40 Troubleshooting
Failure code [DAQRKR] Trouble in CAN communication (Transmission controller) 1 Action code
Failure code
E03
DAQRKR
Contents of trouble
Trouble
Trouble in CAN communication (Transmission controller) (Machine monitor system)
• Machine monitor cannot receive information from transmission controller.
Action of • Keeps information collected when trouble occurred. machine monitor Problem that appears on machine Related information
• Information obtained from transmission controller and special functions cannot be operated or displayed. • Method of reproducing failure code: Turn starting switch ON.
Cause
1
Defective CAN terminal resister (Internal defect)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CAN1 (male), CAN2 (male)
Resistance
Between (A) – (B)
Approx. 120 ± 12 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector)
Wiring harness between J2P (female) (46) – CAN1 (female) (A), CAN2 (female) (A), DPC4 (female) (3), ATC2 (32), BRC2 (32) or DL (female) (3)
Resistance
Max. 1 z
Wiring harness between J2P (female) (47) – CAN1 (female) (B), CAN2 (female) (B), DPC4 (female) (8), ATC2 (22), BRC2 (22) or DL (female) (10)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
Wiring harness between J2P (female) (46) – CAN1 (female) (A), CAN2 (female) (A), Ground fault in wiring harDPC4 (female) (3), ATC2 (32), BRC2 (32) or 3 ness (Short circuit with GND DL (female) (3) circuit) Wiring harness between J2P (female) (47) – CAN1 (female) (B), CAN2 (female) (B), DPC4 (female) (8), ATC2 (22), BRC2 (22) or DL (female) (10)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between J2P (female) (46) – CAN1 (female) (A), CAN2 (female) (A), Hot short (Short circuit with DPC4 (female) (3), ATC2 (32), BRC2 (32) or 4 24V circuit) in wiring harness DL (female) (3)
Voltage
Max. 1 V
Wiring harness between J2P (female) (47) – CAN1 (female) (B), CAN2 (female) (B), DPC4 (female) (8), ATC2 (22), BRC2 (22) or DL (female) (10)
Voltage
Max. 1 V
Defective machine monitor, engine controller, transmis5 sion controller or retarder controller
14
If causes 1 – 4 are not detected, machine monitor, engine controller, transmission controller, or retarder controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
HM400-2
40 Troubleshooting
SEN01112-01
Circuit diagram related to CAN communication
HM400-2
15
SEN01112-01
40 Troubleshooting
Failure code [DAQRMA] Disagreement of option setting (Transmission controller) 1 Action code
Failure code
E03
DAQRMA
Contents of trouble
Trouble
Disagreement of option setting (Transmission controller) (Machine monitor system)
• Information of option setting sent from machine monitor when starting switch is turned ON is different from option setting saved in controller.
• Keeps gear speed in neutral. Action of • Controls with option setting saved in controller. machine monitor • Turns machine monitor and option system caution lamp ON and sounds alarm buzzer. Problem that appears on machine Related information
Possible causes and standard value in normal state
• Machine is set in neutral and cannot restart. • Option setting signal is obtained from transmission controller through network. • Method of reproducing failure code: Turn starting switch ON. Cause 1
Standard value in normal state/Remarks on troubleshooting
Wrong option setting in machine monitor
2 Defective machine monitor
Option may be set wrongly in machine monitor. Set it correctly according to Testing and adjusting. If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Failure code [DB10KT] Trouble in non-volatile memory Action code
Failure code
E01
DB10KT
Contents of trouble Action of controller Problem that appears on machine Related information
Possible causes and standard value in normal state
16
Trouble
1
Trouble in non-volatile memory (Retarder controller system)
• Non-volatile memory in transmission controller has trouble in it. • Controls model selection and option setting with default values. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. • Control parameters of machine may change and power may increase or decrease. • Perform initial setting and adjustment of retarder controller to be performed after replacement (See Testing and adjusting, Setting and adjusting each device). • Method of reproducing failure code: Turn the starting switch ON. Cause 1 Defective retarder controller
Standard value in normal state/Remarks on troubleshooting Troubleshooting cannot be carried out since the trouble is in the controller.
HM400-2
40 Troubleshooting
HM400-2
SEN01112-01
17
SEN01112-01
40 Troubleshooting
Failure code [DB12KK] Trouble in solenoid power supply system Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Failure code DB12KK
Trouble
1
Trouble in solenoid power supply system (Retarder controller system)
• While retarder controller power supply circuit is normal, voltage in solenoid power supply circuit is below 18 V. • Turns all output circuits OFF. • Turns 24V power supply for sensors OFF. • No systems of retarder controller operate (Retarder and brake cooling valve). • Failure codes [DHU2KX] and [DHU3KX] are also displayed. • If failure code [DAQ0KK] or [DAQ2KK] (transmission controller power supply) is also displayed, carry out troubleshooting for it first. • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting
If circuit breaker has tripped, circuit probably has ground fault. 1 Trip of circuit breaker (80 A) (See cause 4.) 2 Defective fuse (BT3-No. 32) If fuse is broken, circuit probably has ground fault. (See cause 4.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between BRC3 (2), (12), (22) – fuse BT3-No. 32 (12)
Disconnection in wiring harness (Disconnection in wiring Wiring harness between fuse BT3-No. 32 3 or defective contact in con- (11) – circuit breaker 64 terminal nector) Wiring harness between circuit breaker 65 terminal – battery relay 69 terminal Battery relay 66 terminal – battery (+) terminal
Possible causes and standard value in normal state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between BRC3 (2), (12), (22) – fuse BT3-No. 32 (12)
Ground fault in wiring harWiring harness between fuse BT3-No. 32 4 ness (Short circuit with GND (11) – circuit breaker 64 terminal circuit) Wiring harness between circuit breaker 65 terminal – battery relay 69 terminal Battery relay 66 terminal – battery (+) terminal
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective retarder controller
18
BRC3
Voltage
Between (2), (12), (22) – (21), (31), (32), (33)
20 – 30 V
HM400-2
40 Troubleshooting
SEN01112-01
Circuit diagram related to retarder controller solenoid power supply system
HM400-2
19
SEN01112-01
40 Troubleshooting
Failure code [DB13KK] Lowering of battery direct voltage Action code
Failure code
E03
DB13KK
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Lowering of battery direct voltage (Transmission controller system)
• Voltage in power supply circuit of retarder controller is below 18 V. • Turns all outputs OFF. • Retarder does not operate. • If failure code [DAQ0KK] or [DAQ2KK] (transmission controller power supply) is also displayed, carry out troubleshooting for it first. • Method of reproducing failure code: Turn starting switch ON. Cause 1 Defective battery 2 Trip of circuit breaker (30 A)
Standard value in normal state/Remarks on troubleshooting Battery voltage
Min. 24 V
Electrolyte specific gravity
Min. 1.26
If circuit breaker has tripped, circuit probably has ground fault. (See cause 5.)
3 Defective fuse (BT2-No. 19) If fuse is broken, circuit probably has ground fault. (See cause 5.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Wiring harness between BRC3 (female) (21), (31), (32), (33) – ground ER
Resistance
Max. 1 z
Wiring harness between BRC3 (1), (11) – fuse BT2-No. 19 (18)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between battery relay 66 terminal – battery (+) terminal
Resistance
Max. 1 z
Wiring harness between ATC3 (14), (24) – starting switch ACC
Resistance
Max. 1 z
Wiring harness between BRC3 (1), (11) – fuse BT2-No. 19 (18)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between fuse BT2-No. 19 4 or defective contact in con- (17) – circuit breaker 84 terminal nector) Wiring harness between circuit breaker 82 terminal – battery relay 66 terminal
Wiring harness between fuse BT2-No. 19 Ground fault in wiring har(17) – circuit breaker 84 terminal 5 ness (Short circuit with GND Wiring harness between circuit breaker 82 circuit) terminal – battery relay 66 terminal Wiring harness between battery relay 66 terminal – battery (+) terminal
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6 Defective retarder controller
20
BRC3
Voltage
Between (1), (11) – (21), (31), (32), (33)
20 – 30 V
HM400-2
40 Troubleshooting
SEN01112-01
Circuit diagram related to retarder controller power supply
HM400-2
21
SEN01112-01
40 Troubleshooting
Failure code [DB19KQ] Disagreement of model selection (Retarder controller) Action code
Failure code
E03
DB19KQ
Contents of trouble
Trouble
1
Disagreement of model selection (Retarder controller) (Machine monitor system)
• Information of model selection input from machine monitor when starting switch is turned ON is different from model selection saved in retarder controller.
Action of • Turns all outputs OFF. machine monitor Problem that appears on machine Related information
Possible causes and standard value in normal state
• When starting operation is performed, machine does not start. • Perform initial setting and adjustment of retarder controller to be performed after replacement. • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting
1
Wrong model selection in machine monitor
Model may be set wrongly in machine monitor. When machine monitor or retarder controller is replaced, set it correctly according to Testing and adjusting.
2
Defective transmission controller
Wrong transmission controller may be installed. Check its part No. and install correct transmission controller.
Failure code [DB1QMA] Disagreement of option setting (Retarder controller) Action code
Failure code
E03
DB1QMA
Contents of trouble
Trouble
1
Disagreement of option setting (Retarder controller) (Machine monitor system)
• Information of option setting sent from machine monitor when starting switch is turned ON is different from option setting saved in retarder controller.
• Turns machine monitor and option system caution lamp ON and sounds alarm buzzer. Action of • Controls with option setting saved in controller. machine monitor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Problem that appears on machine Related information
• Perform initial setting and adjustment of retarder controller to be performed after replacement. • Method of reproducing failure code: Turn starting switch ON. Cause
Possible causes and standard value in normal state
22
Standard value in normal state/Remarks on troubleshooting
Wrong option setting in machine monitor
Option may be set wrongly in machine monitor. When machine monitor or retarder controller is replaced, set it correctly according to Testing and adjusting.
2 Defective machine monitor
If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
1
HM400-2
40 Troubleshooting
HM400-2
SEN01112-01
23
SEN01112-01
40 Troubleshooting
Failure code [DB1RKR] Trouble in CAN communication (Retarder controller) Action code
Failure code
E03
DB1RKR
Contents of trouble Action of controller
Trouble
1
Trouble in CAN communication (Retarder controller) (Transmission controller system)
• Updating of date received from retarder controller is stopped. • Fixes AISS to Lo or Hi (Controls with data received last). • Keeps information collected when trouble occurred.
Problem that appears on machine
• Information obtained from retarder controller is not displayed. • Special functions do not operate.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
1
Defective CAN terminal resister (Internal defect)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CAN1 (male), CAN2 (male)
Resistance
Between (A) – (B)
Approx. 120 ± 12 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector)
Wiring harness between J2P (female) (46) – CAN1 (female) (A), CAN2 (female) (A), DPC4 (female) (3), ATC2 (32), BRC2 (32) or DL (female) (3)
Resistance
Max. 1 z
Wiring harness between J2P (female) (47) – CAN1 (female) (B), CAN2 (female) (B), DPC4 (female) (8), ATC2 (22), BRC2 (22) or DL (female) (10)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
Wiring harness between J2P (female) (46) – CAN1 (female) (A), CAN2 (female) (A), Ground fault in wiring harDPC4 (female) (3), ATC2 (32), BRC2 (32) or 3 ness (Short circuit with GND DL (female) (3) circuit) Wiring harness between J2P (female) (47) – CAN1 (female) (B), CAN2 (female) (B), DPC4 (female) (8), ATC2 (22), BRC2 (22) or DL (female) (10)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between J2P (female) (46) – CAN1 (female) (A), CAN2 (female) (A), Hot short (Short circuit with DPC4 (female) (3), ATC2 (32), BRC2 (32) or 4 24V circuit) in wiring harness DL (female) (3)
Voltage
Max. 1 V
Wiring harness between J2P (female) (47) – CAN1 (female) (B), CAN2 (female) (B), DPC4 (female) (8), ATC2 (22), BRC2 (22) or DL (female) (10)
Voltage
Max. 1 V
Defective machine monitor, engine controller, transmis5 sion controller or retarder controller
24
If causes 1 – 4 are not detected, machine monitor, engine controller, transmission controller, or retarder controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
HM400-2
40 Troubleshooting
SEN01112-01
Circuit diagram related to CAN communication
HM400-2
25
SEN01112-01
40 Troubleshooting
Failure code [DB2RKR] Trouble in CAN communication (Engine controller) 1 Action code
Failure code
E03
DB2RKR
Contents of trouble Action of controller
Trouble
Trouble in CAN communication (Engine controller) (Transmission controller system)
• Updating of date received from engine controller is stopped. • Keeps gear speed. • Keeps gearshift lever in N position.
Problem that appears on machine
• Information obtained from engine controller is not displayed. • Special functions do not operate.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
1
Defective CAN terminal resister (Internal defect)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CAN1 (male), CAN2 (male)
Resistance
Between (A) – (B)
Approx. 120 ± 12 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector)
Wiring harness between J2P (female) (46) – CAN1 (female) (A), CAN2 (female) (A), DPC4 (female) (3), ATC2 (32), BRC2 (32) or DL (female) (3)
Resistance
Max. 1 z
Wiring harness between J2P (female) (47) – CAN1 (female) (B), CAN2 (female) (B), DPC4 (female) (8), ATC2 (22), BRC2 (22) or DL (female) (10)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
Wiring harness between J2P (female) (46) – CAN1 (female) (A), CAN2 (female) (A), Ground fault in wiring harDPC4 (female) (3), ATC2 (32), BRC2 (32) or 3 ness (Short circuit with GND DL (female) (3) circuit) Wiring harness between J2P (female) (47) – CAN1 (female) (B), CAN2 (female) (B), DPC4 (female) (8), ATC2 (22), BRC2 (22) or DL (female) (10)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between J2P (female) (46) – CAN1 (female) (A), CAN2 (female) (A), Hot short (Short circuit with DPC4 (female) (3), ATC2 (32), BRC2 (32) or 4 24V circuit) in wiring harness DL (female) (3)
Voltage
Max. 1 V
Wiring harness between J2P (female) (47) – CAN1 (female) (B), CAN2 (female) (B), DPC4 (female) (8), ATC2 (22), BRC2 (22) or DL (female) (10)
Voltage
Max. 1 V
5
Defective engine controller power supply
Defective machine monitor, engine controller, transmis6 sion controller or retarder controller
26
Engine controller power supply may be defective. Carry out troubleshooting for "Failure code CA111". If causes 1 – 4 are not detected, machine monitor, engine controller, transmission controller, or retarder controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
HM400-2
40 Troubleshooting
SEN01112-01
Circuit diagram related to CAN communication
HM400-2
27
SEN01112-01
40 Troubleshooting
Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal Action code
Failure code
E01
DD1ML4
Contents of trouble
Trouble
1
Disagreement of accelerator-linked retarder switch signal (Transmission controller system)
• Switch 1 signal and switch 2 signal of accelerator-linked retarder switch are turned ON simultaneously. • Switch 1 signal and switch 2 signal of accelerator-linked retarder switch are turned OFF simultaneously.
Action of • Stops operation of accelerator-linked retarder. machine monitor Problem that appears on machine
Related information
• Accelerator-linked retarder does not operate. • Signal of accelerator-linked retarder switch is input to machine monitor and then its information is transmitted to transmission controller through communication system. • Operation of accelerator-linked retarder switch can be checked with monitoring function. (Monitoring code: MONITOR PANEL - D-IN---0------7 - 40900) (Monitoring code: MONITOR PANEL - D-IN-24-----31 - 40903) • Method of reproducing failure code: Turn starting switch ON. Cause 1 Trip of circuit breaker (30 A)
Standard value in normal state/Remarks on troubleshooting If circuit breaker has tripped, circuit probably has ground fault. (See cause 5.)
2 Defective fuse (BT3-No. 30) If fuse is broken, circuit probably has ground fault. (See cause 5.) ACC (female) Defective accelerator-linked 3 retarder switch (Internal defect)
Between (1) – (2) Between (1) – (3)
Accelerator-linked retarder switch
Resistance
Upper
Min. 1 Mz
Lower
Max. 1 z
Upper
Max. 1 z
Lower
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring 4 or defective contact in connector)
Wiring harness between DPC2A (female) (10) – ACC (female) (3)
Resistance
Max. 1 z
Wiring harness between DPC3A (female) (11) – ACC (female) (2)
Resistance
Max. 1 z
Wiring harness between AAC (male) (1) – fuse BT3-No. 30 (10)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between DPC2A (female) Ground fault in wiring har(10) – ACC (female) (3) 5 ness (Short circuit with GND Wiring harness between DPC3A (female) circuit) (11) – ACC (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between AAC (male) (1) – fuse BT3-No. 30 (10)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6
28
Hot short (Short circuit with Wiring harness between DPC2A (female) 24V circuit) in wiring harness (10) – ACC (female) (3)
Voltage
Max. 1 V
Wiring harness between DPC3A (female) (11) – ACC (female) (2)
Voltage
Max. 1 V
HM400-2
40 Troubleshooting
SEN01112-01
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Accelerator-linked retarder switch
Voltage
Between DPC2A (10) – chassis ground
Upper
20 – 30 V
Lower
Max. 1 V
Between DPC3A (11) – chassis ground
Upper
Max. 1 V
Lower
20 – 30 V
DPC2A, DPC3A Possible causes and standard value in normal state
7 Defective machine monitor
8
Defective transmission controller
If causes 1 – 7 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Circuit diagram related to accelerator-linked retarder switch a Display panel is the same as machine monitor.
HM400-2
29
SEN01112-01
40 Troubleshooting
Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine
Related information
DDTHKA
Trouble
1
Trouble in Hi clutch flow sensor valve (Transmission controller system)
• When output to Hi clutch ECMV solenoid valve is turned ON, clutch is engaged but signal from fill switch is not turned ON. • Keeps current gear speed. • If gearshift lever is set in "N", gear speed is kept in neutral. • • • •
Gear cannot be shifted. If gearshift lever is set in "N", machine cannot restart until it stops. Machine can travel in gear speeds which use Hi clutch. Machine cannot travel in reverse.
• Input of Hi clutch ECMV fill signal can be checked with monitoring function. (Monitoring code: TRANSMISSION - D-IN--8-----15 - 40906) • When machine is checked for cause 1, its travel speed at F2 gear speed reaches about 11 km/h. Take care of safety around machine extremely. • Method of reproducing failure code: Start engine + travel at F2. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
1
Possible causes and standard value in normal state
Defective Hi clutch ECMV fill switch (Internal defect)
CN11 (male)
Gear speed
Resistance
Between (1) – chassis ground
N
Min. 1 Mz
F2
Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between ATC3 (female) (30) ResisMax. 1 z nector) – CN11 (female) (1) tance a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3
Defective transmission controller
ATC3
Gear speed
Voltage
Between (30) – chassis ground
N
20 – 30 V
F2
Max. 1 V
Circuit diagram related to Hi clutch ECMV fill switch
30
HM400-2
40 Troubleshooting
SEN01112-01
Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine
Related information
DDTJKA
Trouble
1
Trouble in Lo clutch flow sensor valve (Transmission controller system)
• When output to Lo clutch ECMV solenoid valve is turned ON, clutch is engaged but signal from fill switch is not turned ON. • Keeps current gear speed. • If gearshift lever is set in "N", gear speed is kept in neutral. • • • •
Gear cannot be shifted. If gearshift lever is set in "N", machine cannot restart until it stops. Machine can travel in gear speeds which use Lo clutch. Machine cannot travel in reverse.
• Input of Lo clutch ECMV fill signal can be checked with monitoring function. (Monitoring code: TRANSMISSION - D-IN--8-----15 - 40906) • When machine is checked for cause 1, its travel speed at F1 gear speed reaches about 7 km/h. Take care of safety around machine extremely. • Method of reproducing failure code: Start engine + travel at F1. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
1
Possible causes and standard value in normal state
Defective Lo clutch ECMV fill switch (Internal defect)
CN7 (male)
Gear speed
Resistance
Between (1) – chassis ground
N
Min. 1 Mz
F1
Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between ATC3 (female) (20) ResisMax. 1 z nector) – CN7 (female) (1) tance a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3
Defective transmission controller
ATC3 (female)
Gear speed
Voltage
Between (20) – chassis ground
N
20 – 30 V
F1
Max. 1 V
Circuit diagram related to Lo clutch ECMV fill switch
HM400-2
31
SEN01112-01
40 Troubleshooting
Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine Related information
DDTKKA
Trouble
1
Trouble in 1st clutch flow sensor valve (Transmission controller system)
• When output to 1st clutch ECMV solenoid valve is turned ON, clutch is engaged but signal from fill switch is not turned ON. • Keeps current gear speed. • If gearshift lever is set in "N", gear speed is kept in neutral. • Gear cannot be shifted. • If gearshift lever is set in "N", machine cannot restart until it stops. • Machine can travel in gear speeds which use 1st clutch. • Input of 1st clutch ECMV fill signal can be checked with monitoring function. (Monitoring code: TRANSMISSION - D-IN--8-----15 - 40906) • When machine is checked for cause 1, its travel speed at F1 gear speed reaches about 7 km/h. Take care of safety around machine extremely. • Method of reproducing failure code: Start engine + travel at F1. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
1
Possible causes and standard value in normal state
Defective 1st clutch ECMV fill switch (Internal defect)
CN13 (male)
Gear speed
Resistance
Between (1) – chassis ground
N
Min. 1 Mz
F1
Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between ATC3 (female) (40) ResisMax. 1 z nector) – CN13 (female) (1) tance a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3
Defective transmission controller
ATC3 (female)
Gear speed
Voltage
Between (40) – chassis ground
N
20 – 30 V
F1
Max. 1 V
Circuit diagram related to 1st clutch ECMV fill switch
32
HM400-2
40 Troubleshooting
SEN01112-01
Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine Related information
DDTLKA
Trouble
1
Trouble in 2nd clutch flow sensor valve (Transmission controller system)
• When output to 2nd clutch ECMV solenoid valve is turned ON, clutch is engaged but signal from fill switch is not turned ON. • Keeps current gear speed. • If gearshift lever is set in "N", gear speed is kept in neutral. • Gear cannot be shifted. • If gearshift lever is set in "N", machine cannot restart until it stops. • Machine can travel in gear speeds which use 2nd clutch. • Input of 2nd clutch ECMV fill signal can be checked with monitoring function. (Monitoring code: TRANSMISSION - D-IN--8-----15 - 40906) • When machine is checked for cause 1, its travel speed at F3 gear speed reaches about 16 km/h. Take care of safety around machine extremely. • Method of reproducing failure code: Start engine + travel at F3. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
1
Possible causes and standard value in normal state
Defective 2nd clutch ECMV fill switch (Internal defect)
CN15 (male)
Gear speed
Resistance
Between (1) – chassis ground
N
Min. 1 Mz
F3
Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between ATC3 (female) (9) ResisMax. 1 z nector) – CN15 (female) (1) tance a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3
Defective transmission controller
ATC3 (female)
Gear speed
Voltage
Between (9) – chassis ground
N
20 – 30 V
F3
Max. 1 V
Circuit diagram related to 2nd clutch ECMV fill switch
HM400-2
33
SEN01112-01
40 Troubleshooting
Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine Related information
DDTMKA
Trouble
1
Trouble in 3rd clutch flow sensor valve (Transmission controller system)
• When output to 3rd clutch ECMV solenoid valve is turned ON, clutch is engaged but signal from fill switch is not turned ON. • Keeps current gear speed. • If gearshift lever is set in "N", gear speed is kept in neutral. • Gear cannot be shifted. • If gearshift lever is set in "N", machine cannot restart until it stops. • Machine can travel in gear speeds which use 3rd clutch. • Input of 3rd clutch ECMV fill signal can be checked with monitoring function. (Monitoring code: TRANSMISSION - D-IN--8-----15 - 40906) • When machine is checked for cause 1, its travel speed at F5 gear speed reaches about 38 km/h. Take care of safety around machine extremely. • Method of reproducing failure code: Start engine + travel at F5. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
1
Possible causes and standard value in normal state
Defective 3rd clutch ECMV fill switch (Internal defect)
CN17 (male)
Gear speed
Resistance
Between (1) – chassis ground
N
Min. 1 Mz
F5
Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between ATC3 (female) (19) ResisMax. 1 z nector) – CN15 (female) (1) tance a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3
Defective transmission controller
ATC3 (female)
Gear speed
Voltage
Between (19) – chassis ground
N
20 – 30 V
F5
Max. 1 V
Circuit diagram related to 3rd clutch ECMV fill switch
34
HM400-2
40 Troubleshooting
SEN01112-01
Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine
Related information
DDTNKA
Trouble
Trouble in reverse clutch flow sensor valve (Transmission controller system)
• When output to reverse clutch ECMV solenoid valve is turned ON, clutch is engaged but signal from fill switch is not turned ON. • Keeps current gear speed. • If gearshift lever is set in "N", gear speed is kept in neutral. • • • •
Gear cannot be shifted. If gearshift lever is set in "N", machine cannot restart until it stops. Machine can travel in gear speeds which use reverse clutch. Machine cannot travel forward.
• Input of reverse clutch ECMV fill signal can be checked with monitoring function. (Monitoring code: TRANSMISSION - D-IN--8-----15 - 40906) • When machine is checked for cause 1, its travel speed at R1 gear speed reaches about 7 km/h. Take care of safety around machine extremely. • Method of reproducing failure code: Start engine + travel at R1. Cause Defective reverse clutch 1 ECMV fill switch (Internal defect)
Possible causes and standard value in normal state
1
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. CN9 (male)
Gear speed
Resistance
Between (1) – chassis ground
N
Min. 1 Mz
R1
Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between ATC3 (female) (29) ResisMax. 1 z nector) – CN9 (female) (1) tance a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3
Defective transmission controller
ATC3 (female)
Gear speed
Voltage
Between (29) – chassis ground
N
20 – 30 V
R1
Max. 1 V
Circuit diagram related to reverse clutch ECMV fill switch
HM400-2
35
SEN01112-01
40 Troubleshooting
Failure code [DF10KA] Input of no lever signals Action code
Failure code
E03
DF10KA
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Input of no lever signals (Transmission controller system)
• No lever signals are input. • Controls with lever information before trouble. • • • •
Gear is shifted up above gear speed set with gearshift lever. Gear is kept in neutral and machine cannot start. Travel direction cannot be changed. All of gearshift lever position lamps are turned OFF.
• N position of gearshift lever can be checked with monitoring function. (Monitoring code: TRANSMISSION - D-IN--0------7 - 40905) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting
Gearshift lever may have been pressed by some force other than Wrong operation of gearshift gearing shifting effort. Check its condition. 1 lever Gearshift lever may be stopped at intermediate point between normal positions. Checks its condition. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. SF1
Shift range
Voltage
Between (3) – chassis ground
R2
20 – 30 V
Other than above
Max. 1 V
R1
20 – 30 V
Between (4) – chassis ground Between (5) – chassis ground Between (6) – chassis ground
Possible causes and standard value in normal state 2
Defective gearshift lever (Internal defect)
Between (7) – chassis ground Between (8) – chassis ground Between (9) – chassis ground Between (10) – chassis ground Between (11) – chassis ground
Other than above
Max. 1 V
N
20 – 30 V
Other than above
Max. 1 V
D
20 – 30 V
Other than above
Max. 1 V
5
20 – 30 V
Other than above
Max. 1 V
4
20 – 30 V
Other than above
Max. 1 V
3
20 – 30 V
Other than above
Max. 1 V
2
20 – 30 V
Other than above
Max. 1 V
1
20 – 30 V
Other than above
Max. 1 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
36
SF1
HOLD switch
Voltage
Between (12) – chassis ground
ON
20 – 30 V
OFF
Max. 1 V
HM400-2
40 Troubleshooting
SEN01112-01
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector)
Possible causes and standard value in normal state
Wiring harness between BT3 (14) – SF1 (female) (1)
Resistance
Max. 1 z
Wiring harness between ATC2 (female) (35) – SF1 (female) (3)
Resistance
Max. 1 z
Wiring harness between ATC2 (female) (25) – SF1 (female) (4)
Resistance
Max. 1 z
Wiring harness between ATC1 (female) (6) – SF1 (female) (5)
Resistance
Max. 1 z
Wiring harness between ATC2 (female) (15) – SF1 (female) (6)
Resistance
Max. 1 z
Wiring harness between ATC2 (female) (5) – SF1 (female) (7)
Resistance
Max. 1 z
Wiring harness between ATC2 (female) (36) – SF1 (female) (8)
Resistance
Max. 1 z
Wiring harness between ATC2 (female) (26) – SF1 (female) (9)
Resistance
Max. 1 z
Wiring harness between ATC2 (female) (16) – SF1 (female) (10)
Resistance
Max. 1 z
Wiring harness between ATC2 (female) (6) – SF1 (female) (11)
Resistance
Max. 1 z
Wiring harness between ATC1 (female) (12) – SF1 (female) (12)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ATC2 (female) (35) – SF1 (female) (3)
Resistance
Max. 1 z
Wiring harness between ATC2 (female) (25) – SF1 (female) (4)
Resistance
Max. 1 z
Wiring harness between ATC1 (female) (6) – SF1 (female) (5)
Resistance
Max. 1 z
Wiring harness between ATC2 (female) (15) – SF1 (female) (6)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between ATC2 (female) (26) – SF1 (female) (9)
Resistance
Max. 1 z
Wiring harness between ATC2 (female) (16) – SF1 (female) (10)
Resistance
Max. 1 z
Wiring harness between ATC2 (female) (6) – SF1 (female) (11)
Resistance
Max. 1 z
Wiring harness between ATC1 (female) (12) – SF1 (female) (12)
Resistance
Max. 1 z
Ground fault in wiring harWiring harness between ATC2 (female) (5) 4 ness (Short circuit with GND – SF1 (female) (7) circuit) Wiring harness between ATC2 (female) (36) – SF1 (female) (8)
HM400-2
37
SEN01112-01
40 Troubleshooting
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ATC1, ATC2
Shift range
Voltage
Between ATC2 (35) – chassis ground
R2
20 – 30 V
Between ATC2 (25) – chassis ground Between ATC1 (6) – chassis ground Possible causes and standard value in normal state
Between ATC2 (15) – chassis ground Defective transmission con5 troller
Between ATC2 (5) – chassis ground Between ATC2 (36) – chassis ground Between ATC2 (26) – chassis ground Between ATC2 (16) – chassis ground Between ATC2 (6) – chassis ground Between ATC2 (12) – chassis ground
38
Other than above
Max. 1 V
R1
20 – 30 V
Other than above
Max. 1 V
N
20 – 30 V
Other than above
Max. 1 V
D
20 – 30 V
Other than above
Max. 1 V
5
20 – 30 V
Other than above
Max. 1 V
4
20 – 30 V
Other than above
Max. 1 V
3
20 – 30 V
Other than above
Max. 1 V
2
20 – 30 V
Other than above
Max. 1 V
1
20 – 30 V
Other than above
Max. 1 V
HOLD
20 – 30 V
Other than above
Max. 1 V
HM400-2
40 Troubleshooting
SEN01112-01
Circuit diagram related to gearshift lever signal
HM400-2
39
SEN01112-01
40 Troubleshooting
Failure code [DF10KB] Input of multiple lever signals Action code
Failure code
E03
DF10KB
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Input of multiple lever signals (Transmission controller system)
• Multiple lever signals are input simultaneously. • Controls with signal of higher priority. (1): N > D > 5 > 4 > 3 > 2 > 1 (2): N > R2 > R1 • If signals of (1) and (2) above are input simultaneously, gear is set in neutral. • Gear may be shifted up above gear speed set with gearshift lever. • Gear is kept in neutral and machine cannot start. • All of gearshift lever position lamps are turned OFF. • N position of gearshift lever can be checked with monitoring function. (Monitoring code: TRANSMISSION - D-IN--0------7 - 40905) • Method of reproducing failure code: Turn starting switch ON + operate gearshift lever. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Possible causes and standard value in normal state
1
Defective gearshift lever (Internal defect)
SF1
Shift range
Voltage
Between (3) – chassis ground
R2
20 – 30 V
Other than above
Max. 1 V
Between (4) – chassis ground
R1
20 – 30 V
Other than above
Max. 1 V
Between (5) – chassis ground
N
20 – 30 V
Other than above
Max. 1 V
Between (6) – chassis ground
D
20 – 30 V
Other than above
Max. 1 V
Between (7) – chassis ground
5
20 – 30 V
Other than above
Max. 1 V
Between (8) – chassis ground
4
20 – 30 V
Other than above
Max. 1 V
Between (9) – chassis ground
3
20 – 30 V
Other than above
Max. 1 V
Between (10) – chassis ground
2
20 – 30 V
Other than above
Max. 1 V
1
20 – 30 V
Other than above
Max. 1 V
Between (11) – chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
40
SF1
HOLD switch
Voltage
Between (12) – chassis ground
ON
20 – 30 V
OFF
Max. 1 V
HM400-2
40 Troubleshooting
SEN01112-01
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
2
Wiring harness between ATC2 (female) (35) – SF1 (female) (3)
Voltage
Max. 1 V
Wiring harness between ATC2 (female) (25) – SF1 (female) (4)
Voltage
Max. 1 V
Wiring harness between ATC1 (female) (6) – SF1 (female) (5)
Voltage
Max. 1 V
Wiring harness between ATC2 (female) (15) – SF1 (female) (6)
Voltage
Max. 1 V
Voltage
Max. 1 V
Wiring harness between ATC2 (female) (36) – SF1 (female) (8)
Voltage
Max. 1 V
Wiring harness between ATC2 (female) (26) – SF1 (female) (9)
Voltage
Max. 1 V
Wiring harness between ATC2 (female) (16) – SF1 (female) (10)
Voltage
Max. 1 V
Wiring harness between ATC2 (female) (6) – SF1 (female) (11)
Voltage
Max. 1 V
Wiring harness between ATC1 (female) (12) – SF1 (female) (12)
Voltage
Max. 1 V
Hot short (Short circuit with Wiring harness between ATC2 (female) (5) 24V circuit) in wiring harness – SF1 (female) (7)
Possible causes and standard value in normal state
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ATC1, ATC2
Shift range
Voltage
Between ATC2 (35) – chassis ground
R2
20 – 30 V
Other than above
Max. 1 V
R1
20 – 30 V
Between ATC2 (25) – chassis ground Between ATC1 (6) – chassis ground Between ATC2 (15) – chassis ground Defective transmission con3 troller
Between ATC2 (5) – chassis ground Between ATC2 (36) – chassis ground Between ATC2 (26) – chassis ground Between ATC2 (16) – chassis ground Between ATC2 (6) – chassis ground Between ATC2 (12) – chassis ground
HM400-2
Other than above
Max. 1 V
N
20 – 30 V
Other than above
Max. 1 V
D
20 – 30 V
Other than above
Max. 1 V
5
20 – 30 V
Other than above
Max. 1 V
4
20 – 30 V
Other than above
Max. 1 V
3
20 – 30 V
Other than above
Max. 1 V
2
20 – 30 V
Other than above
Max. 1 V
1
20 – 30 V
Other than above
Max. 1 V
HOLD
20 – 30 V
Other than above
Max. 1 V
41
SEN01112-01
40 Troubleshooting
Circuit diagram related to gearshift lever signal
42
HM400-2
40 Troubleshooting
HM400-2
SEN01112-01
43
SEN01112-01
40 Troubleshooting
Failure code [DGF1KX] Transmission oil temperature out of range Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine Related information
DGF1KX
Trouble
Transmission oil temperature out of range (Transmission controller system)
• Voltage in transmission oil temperature sensor signal circuit is below 0.97 V (above150°C). • While torque converter oil temperature sensor voltage is below 3.75 V (above 55°C), voltage in transmission oil temperature sensor signal circuit is above 4.56 V (below 15°C). • Controls clutch oil pressure with oil temperature before trouble. • Gear shifting shock is increased. • Signal input from oil temperature sensor can be checked with monitoring function. (Monitoring code: TRANSMISSION - TRANSMISSION OIL TEMP - 32500) (Monitoring code: TRANSMISSION - TRANSMISSION OIL TEMP - 32501) • Method of reproducing failure code: Turn starting switch ON or start engine. Cause Defective transmission oil 1 temperature sensor (Internal defect)
Possible causes and standard value in normal state
1
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CN24 (male) Between (1) – (2)
Brake oil temperature
Resistance
25°C
37 – 50 kz
100°C
3.5 – 4.0 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC1 (female) (3) Resis2 Max. 1 z or defective contact in con- – CN24 (female) (1) tance nector) Wiring harness between ATC1 (female) (21) ResisMax. 1 z – CN24 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between ATC1 (female) (3) Resiscircuit) Min. 1 Mz – CN24 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between ATC1 (female) (3) Voltage Max. 1 V – CN24 (female) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5
Defective transmission controller
ATC1 (female) Between (3) – (21)
44
Brake oil temperature
Resistance
25°C
37 – 50 kz
100°C
3.5 – 4.0 kz
HM400-2
40 Troubleshooting
SEN01112-01
Circuit diagram related to transmission oil temperature sensor
HM400-2
45
SEN01112-01
40 Troubleshooting
Failure code [DGR2KZ] Ground fault in brake oil temperature sensor (rear) Action code
Failure code
E01
DGR2KZ
Contents of trouble
Trouble
1
Ground fault in brake oil temperature sensor (rear) (Machine monitor system)
• Voltage in signal circuit of brake oil temperature sensor (rear) is below 0.96 V.
Action of • None in particular. machine monitor Problem that appears on machine Related information
• Oil temperature gauge does not move in failure mode of sensor. • Signal input from brake oil temperature sensor (rear) can be checked with monitoring function. (Monitoring code: MONITOR PANEL - BRAKE OIL T R - 30202) (Monitoring code: MONITOR PANEL - BRAKE OIL T R - 30205) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. M05 (male)
Defective brake oil tempera1 ture sensor (rear) (Internal defect)
Possible causes and standard value in normal state
Brake oil temperature
Resistance
25°C
Approx. 42.7 kz
30°C
Approx. 35.1 kz
80°C
Approx. 6.6 kz
90°C
Approx. 4.9 kz
100°C
Approx. 3.8 kz
Between (1) – (2)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between DCP3B (female) Resis2 Max. 1 z or defective contact in con- (8) – M05 (female) (1) tance nector) Wiring harness between DCP3B (female) ResisMax. 1 z (6) – M05 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between DCP3B (female) Resiscircuit) Min. 1 Mz (8) – M05 (female) (1) tance Short circuit in wiring har4 ness (with another wiring harness)
5 Defective machine monitor
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between DCP3B (female) (8) – M05 (female) (1) and between DCP3B (female) (6) – M05 (female) (2)
Min. 1 Mz
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. a Read monitoring code: 30202 (MONITOR PANEL - BRAKE OIL T R) with rear-time function. Displayed temperature
46
Resistance
True oil temperature
HM400-2
40 Troubleshooting
SEN01112-01
Circuit diagram related to brake oil temperature sensor (rear) a Display panel is the same as machine monitor.
HM400-2
47
SEN01112-01
40 Troubleshooting
Failure code [DGR2L8] Disconnection in brake oil temperature sensor (rear) 1 Action code
Failure code
E01
DGR2L8
Contents of trouble
Trouble
Disconnection in brake oil temperature sensor (rear) (Machine monitor system)
• While brake oil temperature sensor (front) signal and brake oil temperature sensor (center) signal are above 60°C, brake oil temperature sensor (rear) signal is below 10°C.
Action of • None in particular. machine monitor Problem that appears on machine Related information
• Retarder oil temperature gauge is not displayed normally. • If machine is used as it is, braking effect may lower. • Signal input from brake oil temperature sensor (rear) can be checked with monitoring function. (Monitoring code: MONITOR PANEL - BRAKE OIL T R - 30202) (Monitoring code: MONITOR PANEL - BRAKE OIL T R - 30205) • Method of reproducing failure code: Start engine. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. M05 (male)
Defective brake oil tempera1 ture sensor (rear) (Internal defect)
Possible causes and standard value in normal state
Brake oil temperature
Resistance
25°C
Approx. 42.7 kz
30°C
Approx. 35.1 kz
80°C
Approx. 6.6 kz
90°C
Approx. 4.9 kz
100°C
Approx. 3.8 kz
Between (1) – (2)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between DCP3B (female) Resis2 Max. 1 z or defective contact in con- (8) – M05 (female) (1) tance nector) Wiring harness between DCP3B (female) ResisMax. 1 z (6) – M05 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Hot short (Short circuit with 3 24V circuit) in wiring harness Wiring harness between DCP3B (female) Voltage Max. 1 V (8) – M05 (female) (1)
4 Defective machine monitor
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. a Read monitoring code: 30202 (MONITOR PANEL - BRAKE OIL T R) with rear-time function. Displayed temperature
48
True oil temperature
HM400-2
40 Troubleshooting
SEN01112-01
Circuit diagram related to brake oil temperature sensor (rear) a Display panel is the same as machine monitor.
HM400-2
49
SEN01112-01
40 Troubleshooting
Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center) Action code
Failure code
E01
DGR3KZ
Contents of trouble
Trouble
1
Ground fault in brake oil temperature sensor (center) (Machine monitor system)
• Voltage in signal circuit of brake oil temperature sensor (center) is below 0.96 V.
Action of • None in particular. machine monitor Problem that appears on machine Related information
• Oil temperature gauge does not move in failure mode of sensor. • Signal input from brake oil temperature sensor (center) can be checked with monitoring function. (Monitoring code: MONITOR PANEL - BRAKE OIL T M - 30203) (Monitoring code: MONITOR PANEL - BRAKE OIL T M - 30206) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. M04 (male)
Defective brake oil tempera1 ture sensor (center) (Internal defect)
Possible causes and standard value in normal state
Brake oil temperature
Resistance
25°C
Approx. 42.7 kz
30°C
Approx. 35.1 kz
80°C
Approx. 6.6 kz
90°C
Approx. 4.9 kz
100°C
Approx. 3.8 kz
Between (1) – (2)
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between DCP3B (female) Resiscircuit) Min. 1 Mz (2) – M04 (female) (1) tance Short circuit in wiring har3 ness (with another wiring harness)
4 Defective machine monitor
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between DCP3B (female) (2) – M04 (female) (1) and between DCP3B (female) (6) – M04 (female) (2)
Min. 1 Mz
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. a Read monitoring code: 30203 (MONITOR PANEL - BRAKE OIL T M) with rear-time function. Displayed temperature
50
Resistance
True oil temperature
HM400-2
40 Troubleshooting
SEN01112-01
Circuit diagram related to brake oil temperature sensor (center) a Display panel is the same as machine monitor.
HM400-2
51
SEN01112-01
40 Troubleshooting
Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center) 1 Action code
Failure code
E01
DGR3L8
Contents of trouble
Trouble
Disconnection in brake oil temperature sensor (center) (Machine monitor system)
• While brake oil temperature sensor (front) signal and brake oil temperature sensor (rear) signal are above 60°C, brake oil temperature sensor (center) signal is below 10°C.
Action of • None in particular. machine monitor Problem that appears on machine Related information
• Retarder oil temperature gauge is not displayed normally. • If machine is used as it is, braking effect may lower. • Signal input from brake oil temperature sensor (center) can be checked with monitoring function. (Monitoring code: MONITOR PANEL - BRAKE OIL T M - 30203) (Monitoring code: MONITOR PANEL - BRAKE OIL T M - 30206) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. M04 (male)
Defective brake oil tempera1 ture sensor (center) (Internal defect)
Possible causes and standard value in normal state
Brake oil temperature
Resistance
25°C
Approx. 42.7 kz
30°C
Approx. 35.1 kz
80°C
Approx. 6.6 kz
90°C
Approx. 4.9 kz
100°C
Approx. 3.8 kz
Between (1) – (2)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between DCP3B (female) Resis2 Max. 1 z or defective contact in con- (2) – M04 (female) (1) tance nector) Wiring harness between DCP3B (female) ResisMax. 1 z (6) – M04 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Hot short (Short circuit with 3 24V circuit) in wiring harness Wiring harness between DCP3B (female) Voltage Max. 1 V (2) – M04 (female) (1)
4 Defective machine monitor
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. a Read monitoring code: 30203 (MONITOR PANEL - BRAKE OIL T M) with rear-time function. Displayed temperature
52
True oil temperature
HM400-2
40 Troubleshooting
SEN01112-01
Circuit diagram related to brake oil temperature sensor (center) a Display panel is the same as machine monitor.
HM400-2
53
SEN01112-01
40 Troubleshooting
Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front) Action code
Failure code
E01
DGR4KZ
Contents of trouble
Trouble
1
Ground fault in brake oil temperature sensor (front) (Machine monitor system)
• Voltage in signal circuit of brake oil temperature sensor (front) is below 0.96 V.
Action of • None in particular. machine monitor Problem that appears on machine Related information
• Oil temperature gauge does not move in failure mode of sensor. • Signal input from brake oil temperature sensor (front) can be checked with monitoring function. (Monitoring code: MONITOR PANEL - BRAKE OIL T F - 30201) (Monitoring code: MONITOR PANEL - BRAKE OIL T F - 30204) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. M07 (male)
Defective brake oil tempera1 ture sensor (front) (Internal defect)
Possible causes and standard value in normal state
Brake oil temperature
Resistance
25°C
Approx. 42.7 kz
30°C
Approx. 35.1 kz
80°C
Approx. 6.6 kz
90°C
Approx. 4.9 kz
100°C
Approx. 3.8 kz
Between (1) – (2)
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between DCP3B (female) Resiscircuit) Min. 1 Mz (7) – M07 (female) (1) tance Short circuit in wiring har3 ness (with another wiring harness)
4 Defective machine monitor
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between DCP3B (female) (7) – M07 (female) (1) and between DCP3B (female) (6) – M07 (female) (2)
Min. 1 Mz
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. a Read monitoring code: 30201 (MONITOR PANEL - BRAKE OIL T F) with rear-time function. Displayed temperature
54
Resistance
True oil temperature
HM400-2
40 Troubleshooting
SEN01112-01
Circuit diagram related to brake oil temperature sensor (front)
HM400-2
55
SEN01112-01
40 Troubleshooting
Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front) 1 Action code
Failure code
E01
DGR4L8
Contents of trouble
Trouble
Disconnection in brake oil temperature sensor (front) (Machine monitor system)
• While brake oil temperature sensor (center) signal and brake oil temperature sensor (rear) signal are above 60°C, brake oil temperature sensor (front) signal is below 10°C.
Action of • None in particular. machine monitor Problem that appears on machine Related information
• Retarder oil temperature gauge is not displayed normally. • If machine is used as it is, braking effect may lower. • Signal input from brake oil temperature sensor (front) can be checked with monitoring function. (Monitoring code: MONITOR PANEL - BRAKE OIL T F - 30201) (Monitoring code: MONITOR PANEL - BRAKE OIL T F - 30204) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. M07 (male)
Defective brake oil tempera1 ture sensor (front) (Internal defect)
Possible causes and standard value in normal state
Brake oil temperature
Resistance
25°C
Approx. 42.7 kz
30°C
Approx. 35.1 kz
80°C
Approx. 6.6 kz
90°C
Approx. 4.9 kz
100°C
Approx. 3.8 kz
Between (1) – (2)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between DCP3B (female) Resis2 Max. 1 z or defective contact in con- (7) – M07 (female) (1) tance nector) Wiring harness between DCP3B (female) ResisMax. 1 z (6) – M07 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between DCP3B (female) circuit) Voltage Max. 1 V (7) – M07 (female) (1)
4 Defective machine monitor
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. a Read monitoring code: 30201 (MONITOR PANEL - BRAKE OIL T F) with rear-time function. Displayed temperature
56
True oil temperature
HM400-2
40 Troubleshooting
SEN01112-01
Circuit diagram related to brake oil temperature sensor (front) a Display panel is the same as machine monitor.
HM400-2
57
SEN01112-01
40 Troubleshooting
Failure code [DGR6KX] Steering oil temperature out of range Action code
Failure code
E01 Contents of trouble Action of controller Problem that appears on machine Related information
DGR6KX
Trouble
1
Steering oil temperature out of range (Transmission controller system)
• Voltage in steering oil temperature sensor signal circuit is below 0.97 V (above 150°C). • While voltage in torque converter oil temperature sensor and brake oil temperature sensor is below 3.75 V (above 55°C), voltage in transmission oil temperature sensor signal circuit is above 4.56 V (below 15°C). • None in particular. • Steering oil temperature gauge is not displayed normally. • Signal input from steering oil temperature sensor can be checked with monitoring function. (Monitoring code: TRANSMISSION - STRG OIL TEMP - 32701) (Monitoring code: TRANSMISSION - STRG OIL TEMP - 32702) • Method of reproducing failure code: Turn starting switch ON or start engine. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective steering oil tem1 perature sensor (Internal defect)
T04 (male) Between (1) – (2)
Steering oil temperature
Resistance
25°C
37 – 50 kz
100°C
3.5 – 4.0 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC1 (female) (14) 2 or defective contact in con- – T04 (female) (1) nector) Wiring harness between ATC1 (female) (21) – T04 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between ATC1 (female) (14) Resiscircuit) Min. 1 Mz – T04 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between ATC1 (female) (14) Voltage Max. 5 V – T04 (female) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5
Defective transmission controller
ATC1 (female) Between (14) – (21)
58
Steering oil temperature
Resistance
25°C
37 – 50 kz
100°C
3.5 – 4.0 kz
HM400-2
40 Troubleshooting
SEN01112-01
Circuit diagram related to steering oil temperature sensor
HM400-2
59
SEN01112-01
40 Troubleshooting
HM400-2 Articulated dump truck Form No. SEN01112-01
© 2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (02)
60
HM400-2
SEN01113-01
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
40 Troubleshooting
1
Troubleshooting by failure code, Part 6 Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system ............................... 4 Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil pressure sensor system............................................................................................................................................ 6 Failure code [DHT5L6] Trouble in torque converter oil pressure sensor ........................................................ 8 Failure code [DHU2KX] Trouble in accumulator oil pressure sensor (front) system..................................... 10 Failure code [DHU3KX] Trouble in accumulator oil pressure sensor (rear) system...................................... 12 Failure code [DJF1KA] Disconnection in fuel level sensor system ............................................................... 14 Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS................................................. 16 Failure code [DK52KX] Trouble in dump lever potentiometer 1.................................................................... 18 Failure code [DK53L8] Trouble in dump lever potentiometer 2..................................................................... 20 Failure code [DK54KX] Trouble in dump positioner sensor .......................................................................... 22 Failure code [DKH0KX] Pitch angle sensor signal out of range.................................................................... 24 Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system............................. 26 Failure code [DLF1LC] Trouble in transmission input shaft speed sensor.................................................... 27 Failure code [DLF2KA] Disconnection in transmission intermediate shaft speed sensor system................. 28 Failure code [DLF2LC] Disconnection in transmission intermediate shaft speed sensor system................. 29
HM400-2
1
SEN01113-01
40 Troubleshooting
Failure code [DLF4KA] Disconnection in transmission differential speed sensor system............................. 30 Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system........................... 31 Failure code [DV00KB] Short circuit in buzzer output circuit......................................................................... 32 Failure code [DW72KZ] Trouble (Disconnection or ground fault) in kick-out solenoid output system........... 34 Failure code [DW73KZ] Trouble in dump selector valve output system........................................................ 36 Failure code [DW78KZ] Trouble in rear wheel BCV command output system.............................................. 38 Failure code [DW79KZ] Trouble in front wheel BCV command output system............................................. 40 Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1 ................... 42 Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid pressure reducing valve .......................................................................................................................................... 44 Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid pressure reducing valve .......................................................................................................................................... 46 Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid pressure reducing valve .......................................................................................................................................... 48 Failure code [DX11MA] Trouble in rear wheel proportional solenoid pressure reducing valve 2 .................. 50 Failure code [DX12K4] Trouble in front wheel proportional solenoid pressure reducing valve 1 .................. 52 Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid pressure reducing valve .......................................................................................................................................... 54 Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid pressure reducing valve .......................................................................................................................................... 56 Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid pressure reducing valve .......................................................................................................................................... 58 Failure code [DX12MA] Trouble in front wheel proportional solenoid pressure reducing valve 2 ................. 60
2
HM400-2
40 Troubleshooting
HM400-2
SEN01113-01
3
SEN01113-01
40 Troubleshooting
Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system 1 Action code
Failure code
E01
DGT1KX
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Short circuit in torque converter oil temperature sensor system (Transmission controller system)
• Voltage in torque converter oil temperature sensor signal circuit is below 0.97 V (above 150°C). • While voltage in transmission oil temperature sensor is below 0.37 V (above 55°C), voltage in torque converter oil temperature sensor signal circuit is above 4.56 V (below 15°C). • Fixes torque converter oil temperature. • Torque converter oil temperature gauge is not displayed normally. • Signal input from torque converter oil temperature sensor can be checked with monitoring function. (Monitoring code: TRANSMISSION - T/C OIL TEMP - 30100) (Monitoring code: TRANSMISSION - T/C OIL TEMP - 30101) • Method of reproducing failure code: Turn starting switch ON or start engine. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective torque converter 1 oil temperature sensor (Internal defect)
CN23 (male) Between (1) – (2)
Torque converter oil temperature
Resistance
25°C
37 – 50 kz
100°C
3.5 – 4.0 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC1 (female) (9) 2 or defective contact in con- – CN23 (female) (1) nector) Wiring harness between ATC1 (female) (21) – CN23 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between ATC1 (female) (9) Resiscircuit) Min. 1 Mz – CN23 (female) (1) tance Hot short (Short circuit with 4 24 V circuit) in wiring harness
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between ATC1 (female) (9) – CN23 (female) (1)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5
Defective transmission controller
ATC1 (female) Between (9) – (21)
4
Torque converter oil temperature
Resistance
25°C
37 – 50 kz
100°C
3.5 – 4.0 kz
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to torque converter oil temperature sensor
HM400-2
5
SEN01113-01
40 Troubleshooting
Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil pressure sensor system 1 Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Failure code DHT5KX
Trouble
Disconnection, ground fault, or short circuit in torque converter oil pressure sensor system (Transmission controller system)
• Voltage in torque converter oil pressure sensor signal circuit is below 0.5 V or above 4.5 V. • Fixes torque converter oil pressure to oil pressure set in controller and continues control. • Large shock is made when lockup system operates. • Signal input from torque converter oil pressure sensor can be checked with monitoring function. (Monitoring code: TRANSMISSION - T/C OIL PRESS - 32600) (Monitoring code: TRANSMISSION - T/C OIL PERSS - 32605) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Defective torque converter 1 oil pressure sensor (Internal defect)
CN22 (male)
Voltage
Between (2) – (1)
Power source
20 – 30 V
Between (3) – (1)
Signal
0.8 – 2.0 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector) Possible causes and standard value in normal state
Wiring harness between ATC1 (female) (19) – CN22 (female) (3)
Resistance
Max. 1 z
Wiring harness between ATC1 (female) (21) – CN22 (female) (1)
Resistance
Max. 1 z
Wiring harness between ATC1 (female) (8) – CN22 (female) (2)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ATC1 (female) (19) 3 ness (Short circuit with GND – CN22 (female) (3) circuit) Wiring harness between ATC1 (female) (8) – CN22 (female) (2) Hot short (Short circuit with 4 24 V circuit) in wiring harness
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between ATC1 (female) (19) – CN22 (female) (3)
Voltage 0.8 – 2.0 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission con5 troller
6
ATC1, ATC3
Voltage
Between ATC3 (8) – ATC1 (21)
Power source
20 – 30 V
Between ATC1 (19) – (21)
Signal
0.8 – 2.0 V
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to torque converter oil pressure sensor
HM400-2
7
SEN01113-01
40 Troubleshooting
Failure code [DHT5L6] Trouble in torque converter oil pressure sensor 1 Action code
Failure code
E01 Contents of trouble Action of controller Problem that appears on machine Related information
DHT5L6
Trouble
Trouble in torque converter oil pressure sensor (Transmission controller system)
• While engine is stopped, signal circuit of torque converter oil pressure sensor inputted oil pressure signal. • Fixes torque converter oil pressure to oil pressure set in controller and continues control after engine is started. • Large shock is made when lockup system operates. • Signal input from torque converter oil pressure sensor can be checked with monitoring function. (Monitoring code: TRANSMISSION - T/C OIL PRESS - 32600) (Monitoring code: TRANSMISSION - T/C OIL PERSS - 32605) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Defective torque converter 1 oil pressure sensor (Internal defect)
Possible causes and standard value in normal state
CN22
Voltage
Between (2) – (1)
Power source
20 – 30 V
Between (3) – (1)
Signal
0.8 – 2.0 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. Hot short (Short circuit with 2 24 V circuit) in wiring harness
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between ATC1 (female) (19) – CN22 (female) (3)
Voltage 0.8 – 2.0 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3
8
Defective transmission controller
ATC1, ATC3
Voltage
Between ATC3 (8) – ATC1 (21)
Power source
20 – 30 V
Between ATC1 (19) – (21)
Signal
0.8 – 2.0 V
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to torque converter oil pressure sensor
HM400-2
9
SEN01113-01
40 Troubleshooting
Failure code [DHU2KX] Trouble in accumulator oil pressure sensor (front) system Action code
Failure code
E01
DHU2KX
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Trouble in accumulator oil pressure sensor (front) system (Retarder controller system)
• Voltage in accumulator oil pressure sensor (front) signal circuit is below 0.5 V or above 4.5 V. • None in particular. • There is no particular effect on machine. • Signal input from pressure sensor can be checked with monitoring function. (Monitoring code: BRAKE - ACC OIL PRE F - 35500) (Monitoring code: BRAKE - ACC OIL PER F - 35506) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. B25 (male)
Between (B) – (A) Defective accumulator oil 1 pressure sensor (front) (Internal defect)
Brake oil pressure
Resistance
Below 4.9 MPa {50 kg/cm²}
Min. 1 Mz
Above 4.9 MPa {50 kg/cm²}
Max. 1 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. B25
Voltage
Between (B) – (A)
Power source
20 – 30 V
Between (C) – (A)
Signal
1.8 – 3.5 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector)
Wiring harness between BRC1 (female) (7) – B25 (female) (C)
Resistance
Max. 1 z
Wiring harness between BRC1 (female) (21) – B25 (female) (A)
Resistance
Max. 1 z
Wiring harness between BRC1 (female) (16) – B25 (female) (B)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between BRC1 (female) (7) 3 ness (Short circuit with GND – B25 (female) (C) circuit) Wiring harness between BRC1 (female) (16) – B25 (female) (B) Hot short (Short circuit with 4 24 V circuit) in wiring harness
10
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between BRC1 (female) (7) – B25 (female) (C)
Voltage
Max. 1 V
HM400-2
40 Troubleshooting
SEN01113-01
Cause Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
5 Defective retarder controller
BRC1
Voltage
Between (16) – (21)
Power source
20 – 30 V
Between (7) – (21)
Signal
0.5 – 4.5 V
Circuit diagram related to accumulator oil pressure sensor (front)
HM400-2
11
SEN01113-01
40 Troubleshooting
Failure code [DHU3KX] Trouble in accumulator oil pressure sensor (rear) system Action code
Failure code
E01
DHU3KX
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Trouble in accumulator oil pressure sensor (rear) system (Retarder controller system)
• Voltage in accumulator oil pressure sensor (rear) signal circuit is below 0.5 V or above 4.5 V. • None in particular. • There is no particular effect on machine. • Signal input from pressure sensor can be checked with monitoring function. (Monitoring code: BRAKE - ACC OIL PRE R - 35501) (Monitoring code: BRAKE - ACC OIL PER R - 35507) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. B24 (male)
Between (B) – (A)
Brake oil pressure
Resistance
Below 4.9 MPa {50 kg/cm²}
Min. 1 Mz
Above 4.9 MPa {50 kg/cm²}
Max. 1 z Defective accumulator oil 1 pressure sensor (rear) (Inter- a Prepare with starting switch OFF, then turn starting switch ON nal defect) and carry out troubleshooting. B24
Voltage
Between (B) – (A)
Power source
20 – 30 V
Between (C) – (A)
Signal
1.8 – 3.5 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector)
Wiring harness between BRC1 (female) (7) – B24 (female) (C)
Resistance
Max. 1 z
Wiring harness between BRC1 (female) (21) – B24 (female) (A)
Resistance
Max. 1 z
Wiring harness between BRC1 (female) (16) – B24 (female) (B)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between BRC1 (female) (1) 3 ness (Short circuit with GND – B24 (female) (C) circuit) Wiring harness between BRC1 (female) (16) – B24 (female) (B) Hot short (Short circuit with 4 24 V circuit) in wiring harness
12
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between BRC1 (female) (1) – B24 (female) (C)
Voltage
Max. 1 V
HM400-2
40 Troubleshooting
SEN01113-01
Cause Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
5 Defective retarder controller
BRC1
Voltage
Between (16) – (21)
Power source
20 – 30 V
Between (1) – (21)
Signal
0.5 – 4.5 V
Circuit diagram related to accumulator oil pressure sensor (rear)
HM400-2
13
SEN01113-01
40 Troubleshooting
Failure code [DJF1KA] Disconnection in fuel level sensor system Action code
Failure code
E01
DJF1KA
Contents of trouble
Trouble
1
Disconnection in fuel level sensor system (Machine monitor system)
• Voltage in fuel level sensor signal circuit is above 4.0 V.
Action of • None in particular. machine monitor Problem that appears on machine Related information
• Fuel level gauge is not displayed normally. • Signal input from fuel level sensor can be checked with monitoring function. (Monitoring code: MONITOR PANEL - FUEL SENSOR - 04200) (Monitoring code: MONITOR PANEL - FUEL SENSOR - 04201) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective fuel level sensor (Internal defect)
M06 (male) Between (1) – (2)
Fuel level
Resistance
Full
Approx. 10 z
Empty
Approx. 80 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between DPC3B (female) 2 or defective contact in con- (3) – M06 (female) (1) nector) Wiring harness between DPC3B (female) (6) – M06 (female) (2) Hot short (Short circuit with 3 24 V circuit) in wiring harness
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between DPC3B (female) (3) – M06 (female) (1)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective machine monitor
DPC3B (female) Between (3) – (6)
14
Fuel level
Resistance
Full
Approx. 10 z
Empty
Approx. 80 z
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to fuel level sensor a Display panel is the same as machine monitor.
HM400-2
15
SEN01113-01
40 Troubleshooting
Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS1 Action code
Failure code
E03
DK51L5
Contents of trouble
Trouble
Trouble in manual retarder potentiometer and RVS (Retarder controller system)
• Signal voltage in retarder control lever circuit potentiometer is below 0.3 V or above 4.7 V.
Action of controller
Takes following measures, depending on condition of trouble. • Controls with potentiometer signal. • Limits output to solenoid to 70 %. • Turns output to solenoid OFF.
Problem that appears on machine
Following occur, depending on remedy. • There is no particular effect on machine. • Retarder cannot be controlled finely. • Retarder does not operate (Food brake operates, however).
Related information
• Signal from retarder control lever can be checked with monitoring function. (Monitoring code: BRAKE - RETARD LEVER - 33900) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective body positioner 1 sensor potentiometer (Internal defect)
RTL (male) Between (4) – (6) Between (5) – (6)
2 Defective resistor (RE1)
Lever position
Resistance
Release
Max. 1 z
Apply
Min. 1 Mz
Release
Min. 1 Mz
Apply
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between RE1 (1) – (2)
Resistance
250 ± 5 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector)
Wiring harness between BRC1 (female) (22) – RE1 (female) (2)
Resistance
Max. 1 z
Wiring harness between RE1 (female) (1) – BTL (female) (1)
Resistance
Max. 1 z
Wiring harness between BRC1 (female) (21) – RTL (female) (3)
Resistance
Max. 1 z
Wiring harness between BRC1 (female) (14) – BTL (female) (2)
Resistance
Max. 1 z
Wiring harness between BRC1 (female) (24) – RTL (female) (4)
Resistance
Max. 1 z
Wiring harness between BRC1 (female) (18) – RTL (female) (5)
Resistance
Max. 1 z
Wiring harness between BRC1 (female) (21) – RTL (female) (6)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between BRC1 (female) Ground fault in wiring har(22) – RE1 (female) (2) 4 ness (Short circuit with GND Wiring harness between RE1 (female) (1) – circuit) BTL (female) (1) Wiring harness between BRC1 (female) (14) – BTL (female) (2)
16
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01113-01
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Hot short (Short circuit with 5 24 V circuit) in wiring harness
Wiring harness between BRC1 (female) (22) – RE1 (female) (2)
Voltage
Max. 1 V
Wiring harness between RE1 (female) (1) – BTL (female) (1)
Voltage
Max. 1 V
Wiring harness between BRC1 (female) (14) – BTL (female) (2)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Possible causes and standard value in normal state
6 Defective retarder controller
BRC1
Voltage
Between (22) – (21)
4.1 – 4.8 V
Between (14) – (21)
0.3 – 4.7 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. BRC1 (female)
Lever position
Resistance
Between (24) – chassis ground
Release
Max. 1 z
Apply
Min. 1 Mz
Between (18) – chassis ground
Release
Min. 1 Mz
Apply
Max. 1 z
Circuit diagram related to body positioner
HM400-2
17
SEN01113-01
40 Troubleshooting
Failure code [DK52KX] Trouble in dump lever potentiometer 1 Action code
Failure code
E03
DK52KX
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Trouble in dump lever potentiometer 1 (Transmission controller system)
• Signal voltage in signal circuit of dump lever potentiometer 1 or 2 is below 0.3 V or above 4.7 V. • Operates normally with signal of normal potentiometer (A). • Recognizes that dump lever is in HOLD position (B). • There is no particular effect on machine in case of (A) above. • Dump body does not operate in case of (B) above. • Signal from dump lever can be checked with monitoring function. (Monitoring code: TRANSMISSION - DUMP LEVER 1 - 34506) (Monitoring code: TRANSMISSION - DUMP LEVER 2 - 34507) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. HSL
1
Defective dump lever (Internal defect)
Voltage
Between (4) – (1)
Power source
4.6 – 5.4 V
Between (2) – (1)
Signal 1
0.3 – 4.7 V
Between (3) – (1)
Signal 2
0.3 – 4.7 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ATC1 (female) (22) – HSL (female) (4)
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC1 (female) (1) 2 or defective contact in con- – HSL (female) (2) nector) Wiring harness between ATC1 (female) (7) – HSL (female) (3)
Wiring harness between ATC1 (female) (21) – HSL (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ATC1 (female) (22) Ground fault in wiring har– HSL (female) (4) 3 ness (Short circuit with GND Wiring harness between ATC1 (female) (1) circuit) – HSL (female) (2) Wiring harness between ATC1 (female) (7) – HSL (female) (3)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24 V circuit) in wiring harness
18
Wiring harness between ATC1 (female) (22) – HSL (female) (4)
Voltage
Max. 1 V
Wiring harness between ATC1 (female) (1) – HSL (female) (2)
Voltage
Max. 1 V
Wiring harness between ATC1 (female) (7) – HSL (female) (3)
Voltage
Max. 1 V
HM400-2
40 Troubleshooting
SEN01113-01
Cause Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
5
Defective transmission controller
ATC1
Voltage
Between (22) – (21)
Power source
4.6 – 5.4 V
Between (1) – (21)
Signal 1
0.3 – 4.7 V
Between (7) – (21)
Signal 2
0.3 – 4.7 V
Circuit diagram related to dump lever potentiometer
HM400-2
19
SEN01113-01
40 Troubleshooting
Failure code [DK53L8] Trouble in dump lever potentiometer 2 Action code
Failure code
E03
DK53L8
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Trouble in dump lever potentiometer 2 (Transmission controller system)
• Total voltage in signal circuit of dump lever potentiometer 1 or 2 is below 4.4 V or above 5.6 V. • Recognizes that dump lever is in HOLD position. • Dump body does not operate. • Signal from dump lever can be checked with monitoring function. (Monitoring code: TRANSMISSION - DUMP LEVER 1 - 34506) (Monitoring code: TRANSMISSION - DUMP LEVER 2 - 34507) • If failure code [DK52KX] is displayed, carry out troubleshooting for it. • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Possible causes and standard value in normal state
1
2
20
Defective dump lever (Internal defect)
Defective transmission controller
HSL
Voltage
Between (4) – (1)
Power source
4.6 – 5.4 V
Between (2) – (1)
Signal 1
0.3 – 4.7 V
Between (3) – (1)
Signal 2
0.3 – 4.7 V
If cause 1 is not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to dump lever potentiometer
HM400-2
21
SEN01113-01
40 Troubleshooting
Failure code [DK54KX] Trouble in dump positioner sensor Action code
Failure code
E03
DK54KX
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Trouble in dump positioner sensor (Transmission controller system)
• Voltage in dump positioner sensor is below 0.3 V or above 4.7 V. • Controls dump body according to signal of dump lever. • Recognizes that dump body is not seated. • • • •
Seating shock of dump body increases. Dump lever positioner does not function. Highest gear speed is limited. Machine cannot travel in reverse when dump lever is not in FLOAT position.
• Signal from body positioner sensor can be checked with monitoring function. (Monitoring code: TRANSMISSION - BODY POSITION - 34603) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. T14
Defective body positioner 1 sensor (Internal defect)
Voltage
Between (C) – (A)
Power source
4.6 – 5.4 V
Between (B) – (A)
Signal
0.3 – 4.7 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector) Possible causes and standard value in normal state
Wiring harness between ATC1 (female) (22) – T14 (female) (C)
Resistance
Max. 1 z
Wiring harness between ATC1 (female) (2) – T14 (female) (B)
Resistance
Max. 1 z
Wiring harness between ATC1 (female) (21) – T14 (female) (A)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ATC1 (female) (22) 3 ness (Short circuit with GND – T14 (female) (C) circuit) Wiring harness between ATC1 (female) (2) – T14 (female) (B)
Hot short (Short circuit with 4 24 V circuit) in wiring harness
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between ATC1 (female) (22) – T14 (female) (C)
Voltage
Max. 1 V
Wiring harness between ATC1 (female) (2) – T14 (female) (B)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5
22
Defective transmission controller
ATC1
Voltage
Between (22) – (21)
Power source
4.6 – 5.4 V
Between (2) – (21)
Signal
0.3 – 4.7 V
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to body positioner sensor
HM400-2
23
SEN01113-01
40 Troubleshooting
Failure code [DKH0KX] Pitch angle sensor signal out of range Action code
Failure code
E01
DKH0KX
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Pitch angle sensor signal out of range (Transmission controller system)
• Voltage in pitch angle sensor is below 0.5 V or above 4.5 V. • None in particular. • Pitch angle cannot be sensed. • Signal from pitch angle sensor can be checked with monitoring function. (Monitoring code: TRANSMISSION - ANGLE SENSOR - 32900) (Monitoring code: TRANSMISSION - ANGLE SENSOR - 32902) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. T10
Defective pitch angle sensor 1 (Internal defect)
Voltage
Between (C) – (A)
Power source
20 – 30 V
Between (B) – (A)
Signal
0.5 – 4.5 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector)
Wiring harness between ATC1 (female) (13) – T10 (female) (B)
Resistance
Max. 1 z
Wiring harness between ATC1 (female) (16) – T10 (female) (C)
Resistance
Max. 1 z
Wiring harness between ATC1 (female) (21) – T10 (female) (A)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ATC1 (female) (13) 3 ness (Short circuit with GND – T10 (female) (B) circuit) Wiring harness between ATC1 (female) (16) – T10 (female) (C) Hot short (Short circuit with 4 24 V circuit) in wiring harness
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between ATC1 (female) (13) – T10 (female) (B)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5
24
Defective transmission controller
ATC1
Voltage
Between (16) – (21)
Power source
20 – 30 V
Between (13) – (21)
Signal
0.5 – 4.5 V
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to pitch angle sensor
HM400-2
25
SEN01113-01
40 Troubleshooting
Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system 1 Action code
Failure code
E03
DLF1KA
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Disconnection in transmission input shaft speed sensor system (Transmission controller system)
• There is disconnection in transmission input shaft speed sensor signal circuit and signal is not input. • Keeps current gear speed and turns lockup system OFF. • If gearshift lever is set in N, gear speed is kept in neutral. • Lockup system is reset and gear cannot be shifted. • If gearshift lever is set in N, machine cannot restart until it stops. • Signal from transmission input shaft speed sensor can be checked with monitoring function. (Monitoring code: TRANSMISSION - TRANSMISSION SPEED: IN - 31200) • Method of reproducing failure code: Start engine. Cause Defective adjustment of 1 transmission input shaft speed sensor
Standard value in normal state/Remarks on troubleshooting Transmission input shaft speed sensor may be adjusted defectively. Adjust it correctly, referring to Testing and adjusting, Adjusting transmission speed sensor. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2 Possible causes and standard value in normal state
Defective transmission input shaft speed sensor
CN3 (male)
Resistance
Between (1) – (2)
500 – 1,000 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC2 (female) (40) Resis3 Max. 1 z or defective contact in con- – CN3 (female) (1) tance nector) Wiring harness between ATC2 (female) (39) ResisMax. 1 z – CN3 (female) (2) tance
4
Defective transmission controller
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ATC2 (female)
Resistance
Between (40) – (39)
500 – 1,000 z
Circuit diagram related to transmission input shaft speed sensor
26
HM400-2
40 Troubleshooting
SEN01113-01
Failure code [DLF1LC] Trouble in transmission input shaft speed sensor Action code
Failure code
E03
DLF1LC
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Trouble in transmission input shaft speed sensor (Transmission controller system)
• Speed calculated from engine speed sensor signal, transmission intermediate shaft speed sensor signal, and transmission output shaft speed sensor signal is different from signal speed of transmission input shaft speed sensor. • Keeps current gear speed and turns lockup system OFF. • If gearshift lever is set in N, gear speed is kept in neutral. • Lockup system is reset and gear cannot be shifted. • If gearshift lever is set in N, machine cannot restart until it stops. • Signal from transmission input shaft speed sensor can be checked with monitoring function. (Monitoring code: TRANSMISSION - TRANSMISSION SPEED: IN - 31200) • Method of reproducing failure code: Start engine. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Possible causes and standard value in normal state
Defective transmission input shaft speed sensor
CN3 (male)
Resistance
Between (1) – (2)
500 – 1,000 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between ATC2 (female) (40) Resiscircuit) Min. 1 Mz – CN3 (female) (1) tance Hot short (Short circuit with 3 24 V circuit) in wiring harness
4
Defective transmission controller
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between ATC2 (female) (40) – CN3 (female) (1)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ATC2 (female)
Resistance
Between (40) – (39)
500 – 1,000 z
Circuit diagram related to transmission input shaft speed sensor
HM400-2
27
SEN01113-01
40 Troubleshooting
Failure code [DLF2KA] Disconnection in transmission intermediate shaft speed sensor system Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine Related information
DLF2KA
Trouble
1
Disconnection in transmission intermediate shaft speed sensor system (Transmission controller system)
• There is disconnection in transmission intermediate shaft speed sensor signal circuit and signal is not input. • Keeps current gear speed. • If gearshift lever is set in "N", gear speed is kept in neutral. • Gear cannot be shifted. • If gearshift lever is set in "N", machine cannot restart until it stops. • Signal from input shaft speed sensor can be checked with monitoring function. (Monitoring code: TRANSMISSION - TRANSMISSION SPEED: MID - 31300) • Method of reproducing failure code: Start engine + travel. Cause Defective adjustment of 1 transmission intermediate shaft speed sensor
Standard value in normal state/Remarks on troubleshooting Transmission intermediate shaft speed sensor may be adjusted defectively. Adjust it correctly, referring to Testing and adjusting, Adjusting transmission speed sensor. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2 Possible causes and standard value in normal state
Defective transmission input shaft speed sensor
CN4 (male)
Resistance
Between (1) – (2)
500 – 1,000 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC2 (female) (20) 3 or defective contact in con- – CN4 (female) (1) nector) Wiring harness between ATC2 (female) (39) – CN4 (female) (2)
4
Defective transmission controller
Voltage
Max. 1 z
Voltage
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ATC2 (female)
Resistance
Between (20) – (39)
500 – 1,000 z
Circuit diagram related to transmission intermediate shaft speed sensor
28
HM400-2
40 Troubleshooting
SEN01113-01
Failure code [DLF2LC] Disconnection in transmission intermediate shaft speed sensor system Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine Related information
DLF2LC
Trouble
1
Disconnection in transmission intermediate shaft speed sensor system (Transmission controller system)
• Speed calculated from engine speed sensor signal, transmission input shaft speed sensor signal, and transmission output shaft speed sensor signal is different from signal speed of transmission intermediate shaft speed sensor. • Keeps current gear speed. • If gearshift lever is set in "N", gear speed is kept in neutral. • Gear cannot be shifted. • If gearshift lever is set in "N", machine cannot restart until it stops. • Signal from intermediate shaft speed sensor can be checked with monitoring function. (Monitoring code: TRANSMISSION - TRANSMISSION SPEED: MID - 31300) • Method of reproducing failure code: Start engine + travel. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Possible causes and standard value in normal state
Defective transmission intermediate shaft speed sensor
CN4 (male)
Resistance
Between (1) – (2)
500 – 1,000 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between ATC2 (female) (20) Resiscircuit) Min. 1 Mz – CN4 (female) (1) tance Hot short (Short circuit with 3 24 V circuit) in wiring harness
4
Defective transmission controller
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between ATC2 (female) (20) – CN4 (female) (1)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ATC2 (female)
Resistance
Between (20) – (39)
500 – 1,000 z
Circuit diagram related to transmission intermediate shaft speed sensor
HM400-2
29
SEN01113-01
40 Troubleshooting
Failure code [DLF4KA] Disconnection in transmission differential speed sensor system 1 Action code
Failure code
E01
DLF4KA
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Disconnection in transmission differential speed sensor system (Transmission controller system)
• There is disconnection in transmission differential speed sensor signal circuit and signal is not input. • Keeps interaxle differential lock OFF. • Does not output neutral signal. • Interaxle differential lock does not operate. • Signal from transmission differential speed sensor can be checked with monitoring function. (Monitoring code: TRANSMISSION - TRANSMISSION DIFF OUT - 31402) • Method of reproducing failure code: Start engine + Set interaxle differential lock switch to upper position + travel. Cause Defective adjustment of 1 transmission differential speed sensor
Standard value in normal state/Remarks on troubleshooting Transmission differential speed sensor may be adjusted defectively. Adjust it correctly, referring to Testing and adjusting, Adjusting transmission speed sensor. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2 Possible causes and standard value in normal state
Defective transmission input shaft speed sensor
FE1 (male)
Resistance
Between (1) – (2)
500 – 1,000 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC2 (female) (10) 3 or defective contact in con- – FE1 (female) (1) nector) Wiring harness between ATC2 (female) (29) – FE1 (female) (2)
4
Defective transmission controller
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ATC2 (female)
Resistance
Between (10) – (29)
500 – 1,000 z
Circuit diagram related to transmission differential speed sensor
30
HM400-2
40 Troubleshooting
SEN01113-01
Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system Action code
Failure code
E03
DLT3KA
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Disconnection in transmission output shaft speed sensor system (Transmission controller system)
• There is disconnection in transmission output shaft speed sensor signal circuit and signal is not input. • Keeps current gear speed and turns lockup system OFF. • If gearshift lever is set in N, gear speed is kept in neutral. • Lockup system is reset and gear cannot be shifted. • If gearshift lever is set in N, gear is set in neutral. (For emergency escape method, see Testing and adjusting, Emergency escape method when electrical system has trouble. • Signal from output shaft speed sensor can be checked with monitoring function. (Monitoring code: TRANSMISSION - TRANSMISSION DIFF OUT - 31402) • Method of reproducing failure code: Start engine + travel. Cause Defective adjustment of 1 transmission output shaft speed sensor
Standard value in normal state/Remarks on troubleshooting Transmission output shaft speed sensor may be adjusted defectively. Adjust it correctly, referring to Testing and adjusting, Adjusting transmission speed sensor. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2 Possible causes and standard value in normal state
Defective transmission output shaft speed sensor
CN5 (male)
Resistance
Between (1) – (2)
500 – 1,000 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC2 (female) (30) Resis3 Max. 1 z or defective contact in con- – CN5 (female) (1) tance nector) Wiring harness between ATC2 (female) (29) ResisMax. 1 z – CN5 (female) (2) tance
4
Defective transmission controller
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ATC2 (female)
Resistance
Between (30) – (29)
500 – 1,000 z
Circuit diagram related to transmission output shaft speed sensor
HM400-2
31
SEN01113-01
40 Troubleshooting
Failure code [DV00KB] Short circuit in buzzer output circuit Action code
Failure code
E01
DV00KB
Contents of trouble
Trouble
1
Short circuit in buzzer output circuit (Machine monitor system)
• There is short circuit in alarm buzzer output circuit.
Action of • Turns buzzer output circuit OFF. machine monitor Problem that appears on machine Related information
• Alarm buzzer does not sound. • Buzzer operation signal can be checked with monitoring function. (Monitoring code: MONITOR PANEL - D-OUT-0--3 - 40925) • Method of reproducing failure code: Turn starting switch ON. Cause Hot short (Short circuit with 1 24 V circuit) in wiring harness
Possible causes and standard value in normal state
Wiring harness between DPC1 (female) (13) – BZ2 (female) (2)
Voltage
Max. 5 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2 Defective machine monitor
3
32
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting (Carry out troubleshooting when buzzer stops).
Defective alarm buzzer (Internal defect)
DPC1
Buzzer
Voltage
Between (13) – (9), (10)
ON
Max. 1 V
OFF
20 – 30 V
If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to alarm buzzer a Display panel is the same as machine monitor.
HM400-2
33
SEN01113-01
40 Troubleshooting
Failure code [DW72KZ] Trouble (Disconnection or ground fault) in kick-out solenoid output system Action code
Failure code
E01 Contents of trouble Action of controller Problem that appears on machine Related information
DW72KZ
Trouble
1
Trouble (Disconnection or ground fault) in kick-out solenoid output system (Transmission controller system)
• When output to dump lever kick-out solenoid circuit is turned ON, more current flows. • When output to dump lever kick-out solenoid circuit is turned ON, no current flows. • When output to dump lever kick-out solenoid circuit is turned OFF, some current flows. • Turns output to dump lever kick-out solenoid OFF. • Dump lever detent lock does not work. • Operation signal of dump lever kick-out solenoid can be checked with monitoring function. (Monitoring code: TRANSMISSION - D-OUT-0------7 - 40949) • Method of reproducing failure code: Start engine + Operate dump lever to raise body. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective dump lever kickout solenoid (Internal defect)
LK0 (male)
Resistance
Between (1) – (2)
39 z ± 5 %
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC (female) (3) – 2 or defective contact in con- LK0 (female) (2) nector) Wiring harness between ATC3 (female) (38) – LK0 (female) (1)
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ATC (female) (3) – 3 ness (Short circuit with GND LK0 (female) (2) circuit) Wiring harness between ATC3 (female) (38) – LK0 (female) (1)
Hot short (Short circuit with 4 24 V circuit) in wiring harness
5
34
Resistance
Defective transmission controller
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between ATC (female) (3) – LK0 (female) (2)
Voltage
Max. 1 V
Wiring harness between ATC3 (female) (38) – LK0 (female) (1)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ATC3 (female)
Resistance
Between (38) – chassis ground
39 z ± 5 %
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to dump lever kick-out solenoid
HM400-2
35
SEN01113-01
40 Troubleshooting
Failure code [DW73KZ] Trouble in dump selector valve output system 1 Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine Related information
DW73KZ
Trouble
Trouble in dump selector valve output system (Transmission controller system)
• When output to dump selector valve circuit is turned ON, more current flows. • When output to dump selector valve circuit is turned ON, no current flows. • When output to dump selector valve circuit is turned OFF, some current flows. • Turns output to dump selector valve OFF. • Turns output to dump EPC valve OFF. • Dump body does not move. • Operation signal of dump selector valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - D-OUT-0------7 - 40949) • Method of reproducing failure code: Start engine + Operate dump lever to lower body. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Possible causes and standard value in normal state
Defective dump selector valve (Internal defect)
Resistance 15 – 35 z
Between (A), (B) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC (female) (3) – Resis2 Max. 1 z or defective contact in con- T01 (female) (B) tance nector) Wiring harness between ATC3 (female) (17) ResisMax. 1 z – T01 (female) (A) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ATC (female) (17) 3 ness (Short circuit with GND – T01 (female) (A) circuit) Wiring harness between ATC3 (female) (13) – T01 (female) (B)
Hot short (Short circuit with 4 24 V circuit) in wiring harness
5
36
T01 (male) Between (A) – (B)
Defective transmission controller
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between ATC (female) (17) – T01 (female) (A)
Voltage
Max. 1 V
Wiring harness between ATC3 (female) (13) – T01 (female) (B)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ATC3 (female)
Resistance
Between (17) – (3)
15 – 35 z
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to dump selector valve
HM400-2
37
SEN01113-01
40 Troubleshooting
Failure code [DW78KZ] Trouble in rear wheel BCV command output system Action code
Failure code
E01
DW78KZ
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Trouble in rear wheel BCV command output system (Retarder controller system)
• No current or excessive current flows in solenoid of brake cooling oil control valve (rear). • Continues control. • Retarder may overheat since cooling capacity lowers. • Method of reproducing failure code: Start engine + operate retarder control lever.
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective solenoid of brake 1 cooling oil control valve (rear) (Internal defect)
B06 (male)
Resistance
Between (1) – (2)
Approx. 40 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between BRC3 (female) Resis2 Max. 1 z or defective contact in con- (37) – B06 (female) (1) tance nector) Wiring harness between BRC3 (female) ResisMax. 1 z (13) – B06 (female) (2) tance Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between BRC3 (female) 3 ness (Short circuit with GND (37) – B06 (female) (1) circuit) Wiring harness between BRC3 (female) (13) – B06 (female) (2)
Hot short (Short circuit with 4 24 V circuit) in wiring harness
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between BRC3 (female) (37) – B06 (female) (1)
Voltage
Max. 1 V
Wiring harness between BRC3 (female) (13) – B06 (female) (2)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective retarder controller
BRC3 (female) Between (37) – (13)
38
Solenoid
Voltage
ON
20 – 30 V
OFF
Max. 1 V
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to brake cooling oil control valve (rear) solenoid
HM400-2
39
SEN01113-01
40 Troubleshooting
Failure code [DW79KZ] Trouble in front wheel BCV command output system Action code
Failure code
E01
DW79KZ
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Trouble in front wheel BCV command output system (Retarder controller system)
• No current or excessive current flows in solenoid of brake cooling oil control valve (front). • Continues control. • Retarder may overheat since cooling capacity lowers. • Method of reproducing failure code: Start engine + operate retarder control lever.
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective solenoid of brake 1 cooling oil control valve (front) (Internal defect)
B07 (male)
Resistance
Between (1) – (2)
Approx. 40 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between BRC3 (female) Resis2 Max. 1 z or defective contact in con- (27) – B07 (female) (1) tance nector) Wiring harness between BRC3 (female) ResisMax. 1 z (23) – B07 (female) (2) tance Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between BRC3 (female) 3 ness (Short circuit with GND (27) – B07 (female) (1) circuit) Wiring harness between BRC3 (female) (23) – B07 (female) (2)
Hot short (Short circuit with 4 24 V circuit) in wiring harness
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between BRC3 (female) (27) – B07 (female) (1)
Voltage
Max. 1 V
Wiring harness between BRC3 (female) (23) – B07 (female) (2)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective retarder controller
BRC3 (female) Between (27) – (23)
40
Solenoid
Voltage
ON
20 – 30 V
OFF
Max. 1 V
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to brake cooling oil control valve (front) solenoid
HM400-2
41
SEN01113-01
40 Troubleshooting
Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1 Action code E03 Contents of trouble Action of controller
Failure code DX11K4
Trouble
1
Trouble in rear wheel proportional solenoid pressure reducing valve 1 (Retarder controller system)
• When output to retarder proportional pressure reducing valve (rear) is turned OFF, signal from retarder oil pressure switch (rear) is kept ON. • Continues control of retarder control lever. • Continues control of overrun prevention retarder and accelerator-linked retarder.
Problem that appears on machine
• If solenoid is defective, rear brake drags. • If switch is defective or switch circuit has ground fault, gear is difficult to shift up and easy to shift down.
Related information
• Condition of retarder oil pressure switch can be checked with monitoring function. (Monitoring code: BRAKE - D-IN--0------7 - 40932) • Method of reproducing failure code: Start engine + operate retarder control lever to apply brake. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Defective retarder oil pres1 sure switch (rear) (Internal defect)
B23 (male) Between (1) – (2)
Possible causes and standard value in normal state
Resistance
Brake
Max. 1 z
Release
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between BRC1 (female) (5) Resiscircuit) Min. 1 Mz – B23 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective retarder controller
BRC1, BRC3 Between BRC1 (5) – BRC3 (21), (31), (32), (33)
Defective rear brake circuit or hydraulic and mechanical 4 system of retarder proportional pressure reducing valve (rear)
42
Retarder control lever
Retarder control lever
Voltage
Brake
Max. 1 V
Release
8 – 30 V
If causes 1 – 3 are not detected, rear brake circuit or hydraulic and mechanical system of retarder proportional pressure reducing valve (rear) may be defective. Carry out troubleshooting for hydraulic and mechanical system.
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to retarder oil pressure switch (rear)
HM400-2
43
SEN01113-01
40 Troubleshooting
Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid pressure reducing valve Action code E03 Contents of trouble Action of controller Problem that appears on machine Related information
Failure code DX11KA
Trouble
1
Disconnection in output circuit of rear wheel proportional solenoid pressure reducing valve (Retarder controller system)
• When signal is output to retarder proportional pressure reducing valve (rear) circuit, no current flows. • Continues control of retarder control lever. • Continues control of overrun prevention retarder and accelerator-linked retarder. • Retarder (Rear brake) does not operate normally. • Method of reproducing failure code: Start engine + operate retarder control lever to apply brake.
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective retarder propor1 tional pressure reducing valve (rear) (Internal defect) Possible causes and standard value in normal state
Resistance
Between (1) – (2)
10 – 30 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between BRC3 (female) 2 or defective contact in con- (16) – B18 (female) (1) nector) Wiring harness between BRC3 (female) (23) – B18 (female) (2)
3 Defective retarder controller
44
B18 (male)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. BRC3 (female)
Resistance
Between (16) – (23)
10 – 30 z
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to retarder proportional pressure reducing valve (rear)
HM400-2
45
SEN01113-01
40 Troubleshooting
Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid pressure reducing valve Action code E03 Contents of trouble Action of controller Problem that appears on machine Related information
Failure code DX11KB
Trouble
1
Ground fault in output circuit of rear wheel proportional solenoid pressure reducing valve (Retarder controller system)
• When signal is output to retarder proportional pressure reducing valve (rear) circuit, more current flows. • Turns output to retarder proportional pressure reducing valve (rear) OFF. • Continues control of retarder control lever. • Continues control of overrun prevention retarder and accelerator-linked retarder. • Retarder (Rear brake) does not operate normally. • Method of reproducing failure code: Start engine + operate retarder control lever to apply brake.
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective retarder propor1 tional pressure reducing valve (rear) (Internal defect)
Possible causes and standard value in normal state
Resistance
Between (1) – (2)
10 – 30 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between BRC3 (female) Resiscircuit) Min. 1 Mz (16) – B18 (female) (1) tance Short circuit in wiring har3 ness (with another wiring harness)
4 Defective retarder controller
46
B18 (male)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between BRC3 (female) (16) – B18 (female) (1) and between BRC3 (female) (16) – B19 (female) (1)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. BRC3 (female)
Resistance
Between (16) – (23)
10 – 30 z
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to retarder proportional pressure reducing valve (rear)
HM400-2
47
SEN01113-01
40 Troubleshooting
Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid pressure reducing valve Action code E03 Contents of trouble Action of controller Problem that appears on machine Related information
Failure code DX11KY
Trouble
1
Hot short in output circuit of rear wheel proportional solenoid pressure reducing valve (Retarder controller system)
• When output to retarder proportional pressure reducing valve (rear) is turned OFF, some current flows. • Continues control of retarder control lever. • Continues control of overrun prevention retarder and accelerator-linked retarder. • Retarder (Rear brake) does not operate normally. • Method of reproducing failure code: Start engine + operate retarder control lever to apply brake.
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective retarder propor1 tional pressure reducing valve (rear) (Internal defect)
Possible causes and standard value in normal state
Hot short (Short circuit with 2 24 V circuit) in wiring harness
B18 (male)
Resistance
Between (1) – (2)
10 – 30 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between BRC3 (female) (16) – B18 (female) (1)
Voltage
Max. 1 V
Wiring harness between BRC3 (female) (23) – B18 (female) (2)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective retarder controller
BRC3 (female) Between (16) – (23)
48
Retarder control lever
Voltage
Brake
Max. 1 V
Release
20 – 30 V
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to retarder proportional pressure reducing valve (rear)
HM400-2
49
SEN01113-01
40 Troubleshooting
Failure code [DX11MA] Trouble in rear wheel proportional solenoid pressure reducing valve 2 Action code E03 Contents of trouble Action of controller Problem that appears on machine Related information
Failure code DX11MA
Trouble
1
Trouble in rear wheel proportional solenoid pressure reducing valve 2 (Retarder controller system)
• When signal is output to retarder proportional pressure reducing valve (rear) circuit, signal from retarder oil pressure switch (rear) is kept OFF. • Continues control of retarder control lever. • Continues control of overrun prevention retarder and accelerator-linked retarder. • If solenoid is defective, rear brake drags. • If switch is defective or switch circuit has disconnection, condition does not change. • Output current to retarder proportional pressure reducing valve can be checked with monitoring function. (Monitoring code: BRAKE - D-IN--0------7 - 40932) • Method of reproducing failure code: Start engine + operate retarder control lever to apply brake. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Defective retarder oil pres1 sure switch (rear) (Internal defect)
B23 (male) Between (1) – (2)
Retarder control lever
Resistance
Brake
Max. 1 z
Release
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective retarder propor2 tional pressure reducing valve (rear) (Internal defect) Possible causes and standard value in normal state
B18 (male) Between (1) – (2)
Retarder control lever
Resistance
Brake
Max. 1 z
Release
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between BRC1 (female) (5) circuit) – B23 (female) (1)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective retarder controller
BRC3 Between (16) – (23)
Defective rear brake circuit or hydraulic and mechanical 5 system of retarder proportional pressure reducing valve (rear)
Retarder control lever
Resistance
Brake
Max. 1 z
Release
Min. 1 Mz
If causes 1 – 4 are not detected, rear brake circuit or hydraulic and mechanical system of retarder proportional pressure reducing valve (rear) may be defective. Carry out troubleshooting for hydraulic and mechanical system.
Note: This troubleshooting code is not applied to the following serial number # 2038 – 2452.
1
50
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to retarder proportional pressure reducing valve (rear)
HM400-2
51
SEN01113-01
40 Troubleshooting
Failure code [DX12K4] Trouble in front wheel proportional solenoid pressure reducing valve 1 Action code E03 Contents of trouble Action of controller Problem that appears on machine Related information
Failure code DX12K4
Trouble
1
Trouble in front wheel proportional solenoid pressure reducing valve 1 (Retarder controller system)
• When output to retarder proportional pressure reducing valve (front) is turned OFF, signal from retarder oil pressure switch (front) is kept ON. • Continues control of retarder control lever. • Continues control of overrun prevention retarder and accelerator-linked retarder. • If retarder proportional pressure reducing valve (front) is defective, front brake drags. • If sensor switch is defective or switch input circuit has ground fault, gear is difficult to shift up and easy to shift down. • Output current to retarder proportional pressure reducing valve (front) can be checked with monitoring function. (Monitoring code: BRAKE - D-IN--0------7 - 40932) • Method of reproducing failure code: Start engine + operate retarder control lever to apply brake. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Defective retarder oil pres1 sure switch (front) (Internal defect)
B16 (male) Between (1) – (2)
Possible causes and standard value in normal state
Resistance
Brake
Max. 1 z
Release
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between BRC1 (female) (11) Resiscircuit) Min. 1 Mz – B16 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective retarder controller
BRC1, BRC3 Between BRC1 (11) – BRC3 (21), (31), (32), (33)
Defective front brake circuit or hydraulic and mechanical 4 system of retarder proportional pressure reducing valve (front)
52
Retarder control lever
Retarder control lever
Voltage
Brake
Max. 1 V
Release
8 – 30 V
If causes 1 – 3 are not detected, front brake circuit or hydraulic and mechanical system of retarder proportional pressure reducing valve (front) may be defective. Carry out troubleshooting for hydraulic and mechanical system.
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to retarder oil pressure switch (front)
HM400-2
53
SEN01113-01
40 Troubleshooting
Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid pressure reducing valve 1 Action code E03 Contents of trouble Action of controller Problem that appears on machine Related information
Failure code DX12KA
Trouble
Disconnection in output circuit of front wheel proportional solenoid pressure reducing valve (Retarder controller system)
• When signal is output to retarder proportional pressure reducing valve (front) circuit, no current flows. • Continues control of retarder control lever. • Continues control of overrun prevention retarder and accelerator-linked retarder. • Retarder (Front brake) does not operate normally. • Output current to retarder proportional pressure reducing valve (front) can be checked with monitoring function. (Monitoring code: BRAKE - BK OUTP DIR F - 33807) (Monitoring code: TRANSMISSION - BK OUTP DIR F - 33807) • Method of reproducing failure code: Start engine + operate retarder control lever to apply brake. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective retarder propor1 tional pressure reducing valve (front) (Internal defect) Possible causes and standard value in normal state
Resistance 10 – 30 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between BRC3 (female) (6) Resis2 Max. 1 z or defective contact in con- – B19 (female) (1) tance nector) Wiring harness between BRC3 (female) ResisMax. 1 z (13) – B19 (female) (2) tance
3 Defective retarder controller
54
B19 (male) Between (1) – (2)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. BRC3 (female)
Resistance
Between (6) – (13)
10 – 30 z
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to retarder proportional pressure reducing valve (front)
HM400-2
55
SEN01113-01
40 Troubleshooting
Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid pressure reducing valve Action code E03 Contents of trouble Action of controller Problem that appears on machine Related information
Failure code DX12KB
Trouble
1
Ground fault in output circuit of front wheel proportional solenoid pressure reducing valve (Retarder controller system)
• When signal is output to retarder proportional pressure reducing valve (front) circuit, more current flows. • Turns output to retarder proportional pressure reducing valve (front) OFF. • Continues control of retarder control lever. • Continues control of overrun prevention retarder and accelerator-linked retarder. • Retarder (Front brake) does not operate normally. • Output current to retarder proportional pressure reducing valve (front) can be checked with monitoring function. (Monitoring code: BRAKE - BK OUTP DIR F - 33807) (Monitoring code: TRANSMISSION - BK OUTP DIR F - 33807) • Method of reproducing failure code: Start engine + operate retarder control lever to apply brake. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective retarder propor1 tional pressure reducing valve (front) (Internal defect)
Possible causes and standard value in normal state
Resistance
Between (1) – (2)
10 – 30 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between BRC3 (female) (6) Resiscircuit) Min. 1 Mz – B19 (female) (1) tance Short circuit in wiring har3 ness (with another wiring harness)
4 Defective retarder controller
56
B19 (male)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between BRC3 (female) (6) – B19 (female) (1) and between BRC3 (female) (13) – B19 (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. BRC3 (female)
Resistance
Between (6) – (13)
10 – 30 z
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to retarder proportional pressure reducing valve (front)
HM400-2
57
SEN01113-01
40 Troubleshooting
Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid pressure reducing valve Action code E03 Contents of trouble Action of controller Problem that appears on machine Related information
Failure code DX12KY
Trouble
1
Hot short in output circuit of front wheel proportional solenoid pressure reducing valve (Retarder controller system)
• When output to retarder proportional pressure reducing valve (front) is turned OFF, some current flows. • Continues control of retarder control lever. • Continues control of overrun prevention retarder and accelerator-linked retarder. • Retarder (Front brake) does not operate normally. • Output current to retarder proportional pressure reducing valve (front) can be checked with monitoring function. (Monitoring code: BRAKE - BK OUTP DIR F - 33807) (Monitoring code: TRANSMISSION - BK OUTP DIR F - 33807) • Method of reproducing failure code: Start engine + operate retarder control lever to apply brake. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective retarder propor1 tional pressure reducing valve (front) (Internal defect)
Possible causes and standard value in normal state
Hot short (Short circuit with 2 24 V circuit) in wiring harness
B19 (male)
Resistance
Between (1) – (2)
10 – 30 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between BRC3 (female) (6) – B19 (female) (1)
Voltage
Max. 1 V
Wiring harness between BRC3 (female) (13) – B19 (female) (2)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective retarder controller
BRC3 (female) Between (6) – (13)
58
Retarder control lever
Voltage
Brake
Max. 1 V
Release
20 – 30 V
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to retarder proportional pressure reducing valve (front)
HM400-2
59
SEN01113-01
40 Troubleshooting
Failure code [DX12MA] Trouble in front wheel proportional solenoid pressure reducing valve 2 Action code E03 Contents of trouble Action of controller Problem that appears on machine Related information
Failure code DX12MA
Trouble
1
Trouble in front wheel proportional solenoid pressure reducing valve 2 (Retarder controller system)
• When signal is output to retarder proportional pressure reducing valve (front) circuit, signal from retarder oil pressure switch (front) is kept OFF. • Continues control. • If solenoid is defective, front retarder cannot be used. • If switch is defective or switch input circuit has disconnection, condition does not change. • Input signal of retarder oil pressure switch can be checked with monitoring function. (Monitoring code: BRAKE - BK OUTP DIR F - 33807) (Monitoring code: TRANSMISSION - BK OUTP DIR F - 33807) • Method of reproducing failure code: Start engine + operate retarder control lever to apply brake. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Defective retarder oil pres1 sure switch (front) (Internal defect)
B19 Between (1) – (2)
Retarder control lever
Voltage
Brake
Max. 1 V
Release
20 – 30 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective retarder propor2 tional pressure reducing valve (front) (Internal defect) Possible causes and standard value in normal state
B18 (male) Between (1) – (2)
Retarder control lever
Resistance
Brake
Max. 1 z
Release
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between BRC1 (female) (5) circuit) – B23 (female) (1)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective retarder controller
BRC3 Between (6) – (13)
Defective front brake circuit or hydraulic and mechanical 5 system of retarder proportional pressure reducing valve (front)
Retarder control lever
Resistance
Brake
Max. 1 z
Release
Min. 1 Mz
If causes 1 – 4 are not detected, front brake circuit or hydraulic and mechanical system of retarder proportional pressure reducing valve (front) may be defective. Carry out troubleshooting for hydraulic and mechanical system.
Note: This troubleshooting code is not applied to the following serial number # 2038 – 2452.
1
60
HM400-2
40 Troubleshooting
SEN01113-01
Circuit diagram related to retarder oil pressure switch (front) and retarder proportional pressure reducing valve (front)
HM400-2
61
SEN01113-01
40 Troubleshooting
HM400-2 Articulated dump truck Form No. SEN01113-01
© 2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (02)
62
HM400-2
SEN01114-00
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
40 Troubleshooting
1
Troubleshooting by failure code, Part 7 Troubleshooting by failure code, Part 7 .......................................................................................................... 4 Failure code [DX13KA] Disconnection in output circuit of dump EPC valve ........................................ 4 Failure code [DX13KB] Ground fault in output circuit of dump EPC valve........................................... 6 Failure code [DX13KY] Hot short in output circuit of dump EPC valve ................................................ 8 Failure code [DX14KZ] Trouble in rear wheel differential lock command output system ................... 10 Failure code [DX15KZ] Trouble in front wheel differential lock command output system .................. 12 Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch solenoid . 14 Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch solenoid.... 16 Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid ......... 18 Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid ............................. 19 Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid................................ 20 Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid ..................................... 22 Failure code [DXH2KA] Disconnection in output circuit of Hi clutch solenoid .................................... 24 Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid valve .................. 26 Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid valve ....................... 28 Failure code [DXH3KA] Disconnection in output circuit of Lo clutch solenoid ................................... 32
HM400-2
1
SEN01114-00
40 Troubleshooting
Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid valve.................. 34 Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid valve....................... 36 Failure code [DXH4KA] Disconnection in output circuit of 1st clutch solenoid................................... 40 Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid valve................. 42 Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid valve ...................... 44
2
HM400-2
SEN01114-00
40 Troubleshooting
Troubleshooting by failure code, Part 7
1
Failure code [DX13KA] Disconnection in output circuit of dump EPC valve
1
Action code
Failure code
E03
DX13KA
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Disconnection in output circuit of dump EPC valve (Transmission controller system)
• When signal is output to dump EPC valve circuit, no current flows. • Turns output to dump selector valve OFF. • Turns output to dump EPC valve OFF. • Dump body does not move. • Output current to dump EPC valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - HOIST EPC DIR - 45601) • Method of reproducing failure code: Turn starting switch ON + operate dump lever to raise or lower dump body. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Possible causes and standard value in normal state
Defective dump EPC valve (Internal defect)
Resistance
Between (1) – (2)
5 – 20 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (28) 2 or defective contact in con- – T02 (female) (1) nector) Wiring harness between ATC3 (female) (13) – T02 (female) (2) Defective transmission con3 troller
4
T02 (male)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ATC3 (female)
Resistance
Between (28) – (9)
5 – 20 z
HM400-2
40 Troubleshooting
SEN01114-00
Circuit diagram related to dump EPC valve
HM400-2
5
SEN01114-00
40 Troubleshooting
Failure code [DX13KB] Ground fault in output circuit of dump EPC valve Action code
Failure code
E03
DX13KB
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Ground fault in output circuit of dump EPC valve (Transmission controller system)
• When signal is output to dump EPC valve, more current flows. • Turns output to dump selector valve OFF. • Turns output to dump EPC valve OFF. • Dump body does not move. • Output current to dump EPC valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - HOIST EPC DIR - 45601) • Method of reproducing failure code: Turn starting switch ON + operate dump lever to raise or lower dump body. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Possible causes and standard value in normal state
Defective dump EPC valve (Internal defect)
Resistance
Between (1) – (2)
5 – 20 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between ATC3 (female) (28) Resiscircuit) Min. 1 Mz – T02 (female) (1) tance Short circuit in wiring har3 ness (with another wiring harness)
4
6
T02 (male)
Defective transmission controller
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ATC3 (female) (28) – T02 (female) (1) and between ATC3 (female) (9) – T02 (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ATC3 (female)
Resistance
Between (28) – (9)
5 – 20 z
HM400-2
40 Troubleshooting
SEN01114-00
Circuit diagram related to dump EPC valve
HM400-2
7
SEN01114-00
40 Troubleshooting
Failure code [DX13KY] Hot short in output circuit of dump EPC valve 1 Action code
Failure code
E03
DX13KY
Contents of trouble Action of controller
Trouble
Hot short in output circuit of dump EPC valve (Transmission controller system)
• When output to dump EPC valve is turned OFF, some current flows. • Turns output to dump selector valve OFF. • Turns output to dump EPC valve OFF.
Problem that appears on machine Related information
• Output current to dump EPC valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - HOIST EPC DIR - 45601) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Possible causes and standard value in normal state
1
2
Hot short (Short circuit with Wiring harness between ATC3 (female) (28) 24V circuit) in wiring harness – T02 (female) (1)
Voltage
Max. 1 V
Wiring harness between ATC3 (female) (13) – T02 (female) (2)
Voltage
Max. 1 V
Defective transmission controller
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ATC3 (female)
Voltage
Between (28) – (3)
Max. 1 V
Circuit diagram related to dump EPC valve
8
HM400-2
SEN01114-00
40 Troubleshooting
Failure code [DX14KZ] Trouble in rear wheel differential lock command output system 1 Action code
Failure code
E03
DX14KZ
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Trouble in rear wheel differential lock command output system (Retarder controller system)
• When output to rear differential lock solenoid circuit is turned ON, more current flows. • When output to rear differential lock solenoid circuit is turned ON, no current flows. • When output to rear differential lock solenoid circuit is turned OFF, some current flows. • Turns output to rear differential lock solenoid OFF. • Rear differential lock (center differential and rear differential) does not operate. • Operation of rear wheel differential lock can be checked with monitoring function. (Monitoring code: BRAKE - D-OUT-0----7 - 40955) • Method of reproducing failure code: Turn starting switch ON + set right and left differential lock switches to upper position + press right and left differential lock pedals. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective rear differential 1 lock solenoid (Internal defect)
B36 (male)
Resistance
Between (1) – (2)
15 – 35 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between BRC3 (female) 2 or defective contact in con- (17) – B36 (female) (1) nector) Wiring harness between BRC3 (female) (3) – B36 (female) (2) Ground fault in wiring har3 ness (Short circuit with GND circuit)
Short circuit in wiring har4 ness (with another wiring harness)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between BRC3 (female) (17) – B36 (female) (1)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between BRC3 (female) (17) – B36 (female) (1) and between BRC3 (female) (3) – B36 (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 5 24V circuit) in wiring harness Wiring harness between BRC3 (female) Voltage Max. 1 V (17) – B36 (female) (1)
10
HM400-2
40 Troubleshooting
SEN01114-00
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
6 Defective retarder controller
BRC3 (female)
Resistance
Between (17) – (3)
15 – 35 z
Between (17), (3) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. BRC3 (female)
Voltage
Between (17), (3) – chassis ground
Max. 1 V
Circuit diagram related to rear differential lock solenoid
HM400-2
11
SEN01114-00
40 Troubleshooting
Failure code [DX15KZ] Trouble in front wheel differential lock command output system 1 Action code
Failure code
E03
DX15KZ
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Trouble in front wheel differential lock command output system (Retarder controller system)
• When output to front differential lock solenoid circuit is turned ON, more current flows. • When output to front differential lock solenoid circuit is turned ON, no current flows. • When output to front differential lock solenoid circuit is turned OFF, some current flows. • Turns output to front differential lock solenoid OFF. • Front differential lock does not operate. • Operation of front wheel differential lock can be checked with monitoring function. (Monitoring code: BRAKE - D-OUT-0----7 - 40955) • Method of reproducing failure code: Turn starting switch ON + set right and left differential lock switches to upper position + press right and left differential lock pedals. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective front differential 1 lock solenoid (Internal defect)
B35 (male)
Resistance
Between (1) – (2)
15 – 35 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between BRC3 (female) (7) 2 or defective contact in con- – B35 (female) (1) nector) Wiring harness between BRC3 (female) (3) – B35 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between BRC3 (female) (7) Resiscircuit) Min. 1 Mz – B35 (female) (1) tance Short circuit in wiring har4 ness (with another wiring harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between BRC3 (female) (7) – B35 (female) (1) and between BRC3 (female) (3) – B35 (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 5 24V circuit) in wiring harness Wiring harness between BRC3 (female) (7) Voltage Max. 1 V – B35 (female) (1)
12
HM400-2
40 Troubleshooting
SEN01114-00
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
6 Defective retarder controller
BRC3 (female)
Resistance
Between (7) – (3)
15 – 35 z
Between (7), (3) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. BRC3 (female)
Voltage
Between (7), (3) – chassis ground
Max. 1 V
Circuit diagram related to front differential lock solenoid
HM400-2
13
SEN01114-00
40 Troubleshooting
Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch solenoid Action code
Failure code
E01 Contents of trouble Action of controller Problem that appears on machine Related information
DXH0KA
Trouble
• Continues outputting (Since no current flows, solenoid does not operate). • Interaxle differential lock does not operate. • Output voltage to differential lock clutch solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV D DIR - 31607) • Method of reproducing failure code: Turn starting switch ON + set interaxle differential lock switch to upper position.
Defective differential lock 1 clutch solenoid valve (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CN20 (male)
Resistance
Between (1) – (2)
5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (35) 2 or defective contact in con- – CN20 (female) (1) nector) Wiring harness between ATC3 (female) (23) – CN20 (female) (2)
3
14
Disconnection in output circuit of interaxle differential lock clutch solenoid (Transmission controller system)
• When signal is output to differential lock clutch solenoid valve, no current flows.
Cause
Possible causes and standard value in normal state
1
Defective transmission controller
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ATC3 (female)
Resistance
Between (35) – (23)
5 – 15 z
HM400-2
40 Troubleshooting
SEN01114-00
Circuit diagram related to differential lock clutch solenoid valve
HM400-2
15
SEN01114-00
40 Troubleshooting
Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch solenoid Action code
Failure code
E01 Contents of trouble Action of controller Problem that appears on machine Related information
DXH0KB
Trouble
1
Ground fault in output circuit of interaxle differential lock clutch solenoid (Transmission controller system)
• When signal is output to differential lock clutch solenoid valve, abnormally large current flows, or when signal is turned OFF, some current flows. • Turns interaxle differential lock command OFF. • Interaxle differential lock does not operate or is not reset. • Output voltage to differential lock clutch solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV D DIR - 31607) • Method of reproducing failure code: Turn starting switch ON + set interaxle differential lock switch to upper position. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective differential lock 1 clutch solenoid valve (Internal disconnection)
Possible causes and standard value in normal state
CN20 (male)
Resistance
Between (1) – (2)
5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between ATC3 (female) (35) Resiscircuit) Min. 1 Mz – CN20 (female) (1) tance Short circuit in wiring har3 ness (with another wiring harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ATC3 (female) (35) – CN20 (female) (1) and between ATC3 (female) (23) – CN20 (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4
16
Defective transmission controller
ATC3 (female)
Resistance
Between (35) – (23)
5 – 15 z
Between (35), (23) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01114-00
Circuit diagram related to differential lock clutch solenoid valve
HM400-2
17
SEN01114-00
40 Troubleshooting
Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid Action code
Failure code
E03 Contents of trouble Action of controller Problem that appears on machine Related information
DXH0KY
Trouble
1
Hot short in output circuit of interaxle differential lock clutch solenoid (Transmission controller system)
• When output to differential lock clutch solenoid valve is turned OFF, some current flows. • Turns output to interaxle differential lock clutch solenoid valve OFF. • Differential lock is kept ON. • Output voltage to differential lock clutch solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV D DIR - 31607) • Method of reproducing failure code: Turn starting switch ON + set interaxle differential lock switch to lower position. Cause
1 Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between ATC3 (female) (35) – CN20 (female) (1)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 2
Defective transmission controller
ATC3
Voltage
Between (35) – (23)
Max. 1 V
Between (35), (23) – chassis ground
Max. 1 V
Circuit diagram related to differential lock clutch solenoid valve
18
HM400-2
40 Troubleshooting
SEN01114-00
Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid 1 Action code
Failure code
E03
DXH1KA
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Disconnection in output circuit of lockup clutch solenoid (Transmission controller system)
• When signal is output to lockup clutch solenoid, no current flows. • Turns lockup operation OFF. • Lockup system does not operate. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to lockup solenoid can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV LU DIR - 31609) • Method of reproducing failure code: Start engine + travel at F1 + turn lockup lamp ON. Cause
Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective lockup clutch sole1 noid (Internal defect) CN20 (male) Resistance Between (1) – (2) Possible causes and standard value in normal state
5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (6) 2 or defective contact in con- – CN18 (female) (1) nector) Wiring harness between ATC3 (female) (23) – CN18 (female) (2)
3
Defective transmission controller
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ATC3 (female)
Resistance
Between (6) – (23)
5 – 15 z
Circuit diagram related to lockup clutch solenoid valve
HM400-2
19
SEN01114-00
40 Troubleshooting
Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid 1 Action code
Failure code
E03
DXH1KB
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Ground fault in output circuit of lockup clutch solenoid (Transmission controller system)
• When signal is output to lockup clutch solenoid, abnormally large current flows, or when signal is turned OFF, some current flows. • Keeps current gear speed and turns lockup system OFF. • If gearshift lever is set in N, gear speed is kept in neutral. • Lockup system is kept OFF or ON. • If gearshift lever is set in "N", machine cannot restart until it stops (Machine cannot restart even after it stops, depending on trouble condition). • Output current to lockup solenoid can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV LU DIR - 31609) • Method of reproducing failure code: Start engine + travel at F1 + turn lockup lamp ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Possible causes and standard value in normal state
Defective lockup clutch solenoid (Internal defect)
CN18 (male)
Resistance
Between (1) – (2)
5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between ATC3 (female) (6) Resiscircuit) Min. 1 Mz – CN18 (female) (1) tance Short circuit in wiring har3 ness (with another wiring harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ATC3 (female) (6) – CN18 (female) (1) and between ATC3 (female) (23) – CN18 (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4
20
Defective transmission controller
ATC3 (female)
Resistance
Between (6) – (23)
5 – 15 z
Between (6), (23) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01114-00
Circuit diagram related to lockup clutch solenoid valve
HM400-2
21
SEN01114-00
40 Troubleshooting
Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid1 Action code
Failure code
E03
DXH1KY
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Hot short in output circuit of lockup clutch solenoid (Transmission controller system)
• When output to lockup clutch solenoid is turned OFF, some current flows. • Keeps current gear speed and turns lockup system OFF. • Gear cannot be shifted. • Lockup system is kept OFF. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to lockup solenoid can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV LU DIR - 31609) • Method of reproducing failure code: Turn starting switch ON. Cause
1 Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between ATC3 (female) (6) – CN18 (female) (1)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2
Defective transmission controller
ATC3 (female)
Resistance
Between (6) – (23)
5 – 15 z
Between (6), (23) – chassis ground
Min. 1 Mz
Circuit diagram related to lockup clutch solenoid valve
22
HM400-2
SEN01114-00
40 Troubleshooting
Failure code [DXH2KA] Disconnection in output circuit of Hi clutch solenoid1 Action code
Failure code
E03
DXH2KA
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Disconnection in output circuit of Hi clutch solenoid (Transmission controller system)
• When signal is output to Hi clutch ECMV solenoid valve, no current flows. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to Hi clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV H DIR - 31600) • Method of reproducing failure code: Start engine + travel at F2. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective Hi clutch ECMV 1 solenoid valve (Internal defect) Possible causes and standard value in normal state
Resistance
Between (1) – (2)
5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (26) 2 or defective contact in con- – CN10 (female) (1) nector) Wiring harness between ATC3 (female) (13) – CN10 (female) (2)
3
24
CN10 (male)
Defective transmission controller
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ATC3 (female)
Resistance
Between (26) – (13)
5 – 15 z
HM400-2
40 Troubleshooting
SEN01114-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to Hi clutch ECMV solenoid valve
HM400-2
25
SEN01114-00
40 Troubleshooting
Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid valve 1 Action code
Failure code
E03
DXH2KB
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Ground fault in output circuit of Hi clutch ECMV solenoid valve (Transmission controller system)
• When signal is output to Hi clutch ECMV solenoid valve, abnormally large current flows, or when signal is turned OFF, some current flows. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to Hi clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV H DIR - 31600) • Method of reproducing failure code: Start engine + travel at F2. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective Hi clutch ECMV 1 solenoid valve (Internal defect)
Possible causes and standard value in normal state
CN10 (male)
Resistance
Between (1) – (2)
5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between ATC3 (female) (26) Resiscircuit) Min. 1 Mz – CN10 (female) (1) tance Short circuit in wiring har3 ness (with another wiring harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ATC3 (female) (26) – CN10 (female) (1) and between ATC3 (female) (13) – CN10 (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4
26
Defective transmission controller
ATC3 (female)
Resistance
Between (26) – (13)
5 – 15 z
Between (26), (13) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01114-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to Hi clutch ECMV solenoid valve
HM400-2
27
SEN01114-00
40 Troubleshooting
Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid valve Action code
Failure code
E03
DXH2KY
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
• Shifts up and keeps gear speed according to gear speed before trouble and "Table 2". • Turns lockup system OFF. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to Hi clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV H DIR - 31600) • Method of reproducing failure code: Turn starting switch ON. Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 1 24V circuit) in wiring harness Wiring harness between ATC3 (female) (26) Voltage Max. 1 V – CN10 (female) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2
28
Hot short in output circuit of Hi clutch ECMV solenoid valve (Transmission controller system)
• When output to Hi clutch ECMV solenoid valve is turned OFF, some current flows.
Cause
Possible causes and standard value in normal state
1
Defective transmission controller
ATC3 (female)
Resistance
Between (26) – (13)
5 – 15 z
Between (26), (13) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01114-00
Table 2 Gear speed before trouble
F6
F5
F4
F3
F2
F1
R3
R2
R1
N
HM400-2
3rd Hi
3rd Lo
2nd Hi
2nd Lo
1st Hi
1st Lo
3rd Reverse
2nd Reverse
1st Reverse
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
3H
F6
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
3L
F5
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
2H
F4
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
2L
F3
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
1H
F2
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
2nd
2R
R2
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
ANY
NONE
No reaction
—
29
SEN01114-00
40 Troubleshooting
Circuit diagram related to Hi clutch ECMV solenoid valve
30
HM400-2
SEN01114-00
40 Troubleshooting
Failure code [DXH3KA] Disconnection in output circuit of Lo clutch solenoid1 Action code
Failure code
E03
DXH3KA
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Disconnection in output circuit of Lo clutch solenoid (Transmission controller system)
• When signal is output to Lo clutch ECMV solenoid valve, no current flows. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to Lo clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV L DIR - 31601) • Method of reproducing failure code: Start engine + travel at F1. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective Lo clutch ECMV 1 solenoid valve (Internal defect) Possible causes and standard value in normal state
Resistance
Between (1) – (2)
5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (16) 2 or defective contact in con- – CN6 (female) (1) nector) Wiring harness between ATC3 (female) (3) – CN6 (female) (2)
3
32
CN6 (male)
Defective transmission controller
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ATC3 (female)
Resistance
Between (16) – (3)
5 – 15 z
HM400-2
40 Troubleshooting
SEN01114-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to Lo clutch ECMV solenoid valve
HM400-2
33
SEN01114-00
40 Troubleshooting
Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid valve 1 Action code
Failure code
E03
DXH3KB
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Ground fault in output circuit of Lo clutch ECMV solenoid valve (Transmission controller system)
• When signal is output to Lo clutch ECMV solenoid valve, abnormally large current flows, or when signal is turned OFF, some current flows. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to Lo clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV L DIR - 31601) • Method of reproducing failure code: Start engine + travel at F1. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective Lo clutch ECMV 1 solenoid valve (Internal defect)
Possible causes and standard value in normal state
CN6 (male)
Resistance
Between (1) – (2)
5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between ATC3 (female) (16) Resiscircuit) Min. 1 Mz – CN6 (female) (1) tance Short circuit in wiring har3 ness (with another wiring harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ATC3 (female) (16) – CN6 (female) (1) and between ATC3 (female) (3) – CN6 (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4
34
Defective transmission controller
ATC3 (female)
Resistance
Between (16) – (3)
5 – 15 z
Between (16), (3) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01114-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to Lo clutch ECMV solenoid valve
HM400-2
35
SEN01114-00
40 Troubleshooting
Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid valve 1 Action code
Failure code
E03
DXH3KY
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
• When output to Lo clutch ECMV solenoid valve is turned OFF, some current flows. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 2". • Turns lockup system OFF. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to Lo clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV L DIR - 31601) • Method of reproducing failure code: Turn starting switch ON. Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 1 24V circuit) in wiring harness Wiring harness between ATC3 (female) (16) Voltage Max. 1 V – CN6 (female) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2
36
Hot short in output circuit of Lo clutch ECMV solenoid valve (Transmission controller system)
Defective transmission controller
ATC3 (female)
Resistance
Between (16) – (3)
5 – 15 z
Between (16), (3) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01114-00
Table 2 Gear speed before trouble
F6
F5
F4
F3
F2
F1
R3
R2
R1
N
HM400-2
3rd Hi
3rd Lo
2nd Hi
2nd Lo
1st Hi
1st Lo
3rd Reverse
2nd Reverse
1st Reverse
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
3H
F6
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
3L
F5
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
2H
F4
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
2L
F3
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
1H
F2
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
2nd
2R
R2
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
ANY
NONE
No reaction
—
37
SEN01114-00
40 Troubleshooting
Circuit diagram related to Lo clutch ECMV solenoid valve
38
HM400-2
SEN01114-00
40 Troubleshooting
Failure code [DXH4KA] Disconnection in output circuit of 1st clutch solenoid1 Action code
Failure code
E03
DXH4KA
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
• When signal is output to 1st clutch ECMV solenoid valve, no current flows. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to 1st clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV 1 DIR - 31602) • Method of reproducing failure code: Start engine + travel at F1. Cause Defective 1st clutch ECMV 1 solenoid valve (Internal defect)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CN12 (male)
Resistance
Between (1) – (2)
5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (36) 2 or defective contact in con- – CN12 (female) (1) nector) Wiring harness between ATC3 (female) (13) – CN6 (female) (2)
3
40
Disconnection in output circuit of 1st clutch solenoid (Transmission controller system)
Defective transmission controller
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ATC3 (female)
Resistance
Between (36) – (13)
5 – 15 z
HM400-2
40 Troubleshooting
SEN01114-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to 1st clutch ECMV solenoid valve
HM400-2
41
SEN01114-00
40 Troubleshooting
Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid valve Action code
Failure code
E03
DXH4KB
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Ground fault in output circuit of 1st clutch ECMV solenoid valve (Transmission controller system)
• When signal is output to 1st clutch ECMV solenoid valve, abnormally large current flows, or when signal is turned OFF, some current flows. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to 1st clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV 1 DIR - 31602) • Method of reproducing failure code: Start engine + travel at F1. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective 1st clutch ECMV 1 solenoid valve (Internal defect)
Possible causes and standard value in normal state
CN12 (male)
Resistance
Between (1) – (2)
5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between ATC3 (female) (36) Resiscircuit) Min. 1 Mz – CN12 (female) (1) tance Short circuit in wiring har3 ness (with another wiring harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ATC3 (female) (36) – CN12 (female) (1) and between ATC3 (female) (13) – CN12 (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4
42
Defective transmission controller
ATC3 (female)
Resistance
Between (36) – (13)
5 – 15 z
Between (36), (13) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01114-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to 1st clutch ECMV solenoid valve
HM400-2
43
SEN01114-00
40 Troubleshooting
Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid valve 1 Action code
Failure code
E03
DXH4KY
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Hot short in output circuit of 1st clutch ECMV solenoid valve (Transmission controller system)
• When output to 1st clutch ECMV solenoid valve is turned OFF, some current flows. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 2". • Turns lockup system OFF. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to 1st clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV 1 DIR - 31602) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective 1st clutch ECMV 1 solenoid valve (Internal defect) Possible causes and standard value in normal state
2
CN12 (male)
Resistance
Between (1) – (2)
5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between ATC3 (female) (36) – CN12 (female) (1)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
44
Defective transmission controller
ATC3 (female)
Resistance
Between (36) – (13)
5 – 15 z
Between (36), (13) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01114-00
Table 2 Gear speed before trouble
F6
F5
F4
F3
F2
F1
R3
R2
R1
N
HM400-2
3rd Hi
3rd Lo
2nd Hi
2nd Lo
1st Hi
1st Lo
3rd Reverse
2nd Reverse
1st Reverse
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
3H
F6
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
3L
F5
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
2H
F4
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
2L
F3
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
1H
F2
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
2nd
2R
R2
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
ANY
NONE
No reaction
—
45
SEN01114-00
40 Troubleshooting
Circuit diagram related to 1st clutch ECMV solenoid valve
46
HM400-2
SEN01114-00
40 Troubleshooting
HM400-2 Articulated dump truck Form No. SEN01114-00
© 2006 KOMATSU All Rights Reserved Printed in Japan 05-06 (02)
48
HM400-2
SEN01115-00
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
40 Troubleshooting
1
Troubleshooting by failure code, Part 8 Troubleshooting by failure code, Part 8 .......................................................................................................... 2 Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch solenoid ................................... 2 Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid valve ................. 4 Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid valve....................... 6 Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch solenoid .................................. 10 Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid valve ................ 12 Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid valve ..................... 14 Failure code [DXH7KA] Disconnection in output circuit of reverse clutch solenoid ........................... 18 Failure code [DXH7KB] Ground fault in output circuit of reverse clutch ECMV solenoid valve ......... 20 Failure code [DXH7KY] Hot short in output circuit of reverse clutch ECMV solenoid valve............... 22
HM400-2
1
SEN01115-00
40 Troubleshooting
Troubleshooting by failure code, Part 8
1
Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch solenoid
1
Action code
Failure code
E03
DXH5KA
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
• When signal is output to 2nd clutch ECMV solenoid valve, no current flows. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to 2nd clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV 2 DIR - 31603) • Method of reproducing failure code: Start engine + travel at F3. Cause Defective 2nd clutch ECMV 1 solenoid valve (Internal defect)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CN14 (male)
Resistance
Between (1) – (2)
5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (5) 2 or defective contact in con- – CN14 (female) (1) nector) Wiring harness between ATC3 (female) (3) – CN14 (female) (2)
3
2
Disconnection in output circuit of 2nd clutch solenoid (Transmission controller system)
Defective transmission controller
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ATC3 (female)
Resistance
Between (5) – (3)
5 – 15 z
HM400-2
40 Troubleshooting
SEN01115-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to 2nd clutch ECMV solenoid valve
HM400-2
3
SEN01115-00
40 Troubleshooting
Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid valve Action code
Failure code
E03
DXH5KB
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Ground fault in output circuit of 2nd clutch ECMV solenoid valve (Transmission controller system)
• When signal is output to 2nd clutch ECMV solenoid valve, abnormally large current flows, or when signal is turned OFF, some current flows. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to 2nd clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV 2 DIR - 31603) • Method of reproducing failure code: Start engine + travel at F3. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective 2nd clutch ECMV 1 solenoid valve (Internal defect)
Possible causes and standard value in normal state
CN14 (male)
Resistance
Between (1) – (2)
5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between ATC3 (female) (5) Resiscircuit) Min. 1 Mz – CN14 (female) (1) tance Short circuit in wiring har3 ness (with another wiring harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ATC3 (female) (5) – CN14 (female) (1) and between ATC3 (female) (3) – CN14 (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4
4
Defective transmission controller
ATC3 (female)
Resistance
Between (5) – (3)
5 – 15 z
Between (5), (3) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01115-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to 2nd clutch ECMV solenoid valve
HM400-2
5
SEN01115-00
40 Troubleshooting
Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid valve 1 Action code
Failure code
E03
DXH5KY
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
• When output to 2nd clutch ECMV solenoid valve is turned OFF, some current flows. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 2". • Turns lockup system OFF. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to 2nd clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV 2 DIR - 31603) • Method of reproducing failure code: Turn starting switch ON. Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 1 24V circuit) in wiring harness Wiring harness between ATC3 (female) (5) Voltage Max. 1 V – CN14 (female) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2
6
Hot short in output circuit of 2nd clutch ECMV solenoid valve (Transmission controller system)
Defective transmission controller
ATC3 (female)
Resistance
Between (5) – (3)
5 – 15 z
Between (35), (23) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01115-00
Table 2 Gear speed before trouble
F6
F5
F4
F3
F2
F1
R3
R2
R1
N
HM400-2
3rd Hi
3rd Lo
2nd Hi
2nd Lo
1st Hi
1st Lo
3rd Reverse
2nd Reverse
1st Reverse
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
3H
F6
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
3L
F5
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
2H
F4
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
2L
F3
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
1H
F2
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
2nd
2R
R2
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
ANY
NONE
No reaction
—
7
SEN01115-00
40 Troubleshooting
Circuit diagram related to 2nd clutch ECMV solenoid valve
8
HM400-2
SEN01115-00
40 Troubleshooting
Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch solenoid Action code
Failure code
E03
DXH6KA
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
• Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to 3rd clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV 3 DIR - 31604) • Method of reproducing failure code: Start engine + travel at F5.
Defective 3rd clutch ECMV 1 solenoid valve (Internal defect)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CN16 (male)
Resistance
Between (1) – (2)
5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (15) 2 or defective contact in con- – CN16 (female) (1) nector) Wiring harness between ATC3 (female) (23) – CN16 (female) (2)
3
10
Disconnection in output circuit of 3rd clutch solenoid (Transmission controller system)
• When signal is output to 3rd clutch ECMV solenoid valve, no current flows.
Cause
Possible causes and standard value in normal state
1
Defective transmission controller
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ATC3 (female)
Resistance
Between (15) – (23)
5 – 15 z
HM400-2
40 Troubleshooting
SEN01115-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to 3rd clutch ECMV solenoid valve
HM400-2
11
SEN01115-00
40 Troubleshooting
Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid valve Action code
Failure code
E03
DXH6KB
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
1
Ground fault in output circuit of 3rd clutch ECMV solenoid valve (Transmission controller system)
• When signal is output to 3rd clutch ECMV solenoid valve, abnormally large current flows, or when signal is turned OFF, some current flows. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to 3rd clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV 3 DIR - 31604) • Method of reproducing failure code: Start engine + travel at F5. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective 3rd clutch ECMV 1 solenoid valve (Internal defect)
Possible causes and standard value in normal state
CN16 (male)
Resistance
Between (1) – (2)
5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between ATC3 (female) (15) Resiscircuit) Min. 1 Mz – CN16 (female) (1) tance Short circuit in wiring har3 ness (with another wiring harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ATC3 (female) (15) – CN16 (female) (1) and between ATC3 (female) (23) – CN16 (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4
12
Defective transmission controller
ATC3 (female)
Resistance
Between (15) – (23)
5 – 15 z
Between (15), (23) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01115-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to 3rd clutch ECMV solenoid valve
HM400-2
13
SEN01115-00
40 Troubleshooting
Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid valve 1 Action code
Failure code
E03
DXH6KY
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
• When output to 3rd clutch ECMV solenoid valve is turned OFF, some current flows. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 2". • Turns lockup system OFF. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to 3rd clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV 3 DIR - 31604) • Method of reproducing failure code: Turn starting switch ON. Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 1 24V circuit) in wiring harness Wiring harness between ATC3 (female) (15) Voltage Max. 1 V – CN16 (female) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2
14
Hot short in output circuit of 3rd clutch ECMV solenoid valve (Transmission controller system)
Defective transmission controller
ATC3 (female)
Resistance
Between (15) – (23)
5 – 15 z
Between (15), (23) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01115-00
Table 2 Gear speed before trouble
F6
F5
F4
F3
F2
F1
R3
R2
R1
N
HM400-2
3rd Hi
3rd Lo
2nd Hi
2nd Lo
1st Hi
1st Lo
3rd Reverse
2nd Reverse
1st Reverse
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
3H
F6
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
3L
F5
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
2H
F4
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
2L
F3
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
1H
F2
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
2nd
2R
R2
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
ANY
NONE
No reaction
—
15
SEN01115-00
40 Troubleshooting
Circuit diagram related to 3rd clutch ECMV solenoid valve
16
HM400-2
SEN01115-00
40 Troubleshooting
Failure code [DXH7KA] Disconnection in output circuit of reverse clutch solenoid 1 Action code
Failure code
E03
DXH7KA
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
• When signal is output to reverse clutch ECMV solenoid valve, no current flows. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to reverse clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV R DIR - 31606) • Method of reproducing failure code: Start engine + travel at R1. Cause Defective reverse clutch 1 ECMV solenoid valve (Internal defect)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CN8 (male)
Resistance
Between (1) – (2)
5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ATC3 (female) (25) 2 or defective contact in con- – CN8 (female) (1) nector) Wiring harness between ATC3 (female) (13) – CN8 (female) (2)
3
18
Disconnection in output circuit of reverse clutch solenoid (Transmission controller system)
Defective transmission controller
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ATC3 (female)
Resistance
Between (25) – (13)
5 – 15 z
HM400-2
40 Troubleshooting
SEN01115-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to reverse clutch ECMV solenoid valve
HM400-2
19
SEN01115-00
40 Troubleshooting
Failure code [DXH7KB] Ground fault in output circuit of reverse clutch ECMV solenoid valve 1 Action code
Failure code
E03
DXH7KB
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
Ground fault in output circuit of reverse clutch ECMV solenoid valve (Transmission controller system)
• When signal is output to reverse clutch ECMV solenoid valve, abnormally large current flows, or when signal is turned OFF, some current flows. • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1". • Turns lockup system OFF. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to reverse clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV R DIR - 31606) • Method of reproducing failure code: Start engine + travel at R1. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective reverse clutch 1 ECMV solenoid valve (Internal defect)
Possible causes and standard value in normal state
CN8 (male)
Resistance
Between (1) – (2)
5 – 15 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between ATC3 (female) (25) Resiscircuit) Min. 1 Mz – CN8 (female) (1) tance Short circuit in wiring har3 ness (with another wiring harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ATC3 (female) (25) – CN8 (female) (1) and between ATC3 (female) (13) – CN8 (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4
20
Defective transmission controller
ATC3 (female)
Resistance
Between (25) – (13)
5 – 15 z
Between (35), (23) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01115-00
Table 1 Gear speed before trouble
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
F6
3rd Hi
3rd
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
F5
3rd Lo
3rd
OFF
NEUTRAL
OFF
Lo
3H
F6
OFF
F4
2nd Hi
2nd
3L
F5
OFF
Hi
3L
F5
OFF
F3
2nd Lo
2nd
3L
F5
OFF
Lo
2H
F4
OFF
F2
1st Hi
1st
2L
F3
OFF
Hi
2L
F3
OFF
F1
1st Lo
1st
2L
F3
OFF
Lo
1H
F2
OFF
R3
3rd Reverse
3rd
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
R2
2nd Reverse
2nd
3R
R3
OFF
Reverse
OFF
NEUTRAL
OFF
R1
1st Reverse
1st
2R
R2
OFF
Reverse
OFF
NEUTRAL
OFF
Circuit diagram related to reverse clutch ECMV solenoid valve
HM400-2
21
SEN01115-00
40 Troubleshooting
Failure code [DXH7KY] Hot short in output circuit of reverse clutch ECMV solenoid valve Action code
Failure code
E03
DXH7KY
Contents of trouble Action of controller Problem that appears on machine Related information
Trouble
• Shifts up and keeps gear speed according to gear speed before trouble and "Table 2". • Turns lockup system OFF. • If gearshift lever is set in "N", machine cannot restart until it stops. • Output current to reverse clutch ECMV solenoid valve can be checked with monitoring function. (Monitoring code: TRANSMISSION - ECMV R DIR - 31606) • Method of reproducing failure code: Turn starting switch ON. Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 1 24V circuit) in wiring harness Wiring harness between ATC3 (female) (25) Voltage Max. 1 V – CN8 (female) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2
22
Hot short in output circuit of reverse clutch ECMV solenoid valve (Transmission controller system)
• When output to reverse clutch ECMV solenoid valve is turned OFF, some current flows.
Cause
Possible causes and standard value in normal state
1
Defective transmission controller
ATC3 (female)
Resistance
Between (25) – (13)
5 – 15 z
Between (25), (13) – chassis ground
Min. 1 Mz
HM400-2
40 Troubleshooting
SEN01115-00
Table 2 Gear speed before trouble
F6
F5
F4
F3
F2
F1
R3
R2
R1
N
HM400-2
3rd Hi
3rd Lo
2nd Hi
2nd Lo
1st Hi
1st Lo
3rd Reverse
2nd Reverse
1st Reverse
Remedy against trouble Clutch having trouble
Action of controller (Selected clutch and gear speed)
ON/OFF state of lockup clutch
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
3H
F6
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
3L
F5
OFF
3rd
3L
F5
OFF
1st
OFF
NEUTRAL
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
2H
F4
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Lo
2L
F3
OFF
3rd
3L
F5
OFF
2nd
2L
F3
OFF
Reverse
OFF
NEUTRAL
OFF
Hi
1H
F2
OFF
2nd
OFF
NEUTRAL
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
1st
OFF
NEUTRAL
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
3rd
3R
R3
OFF
2nd
2R
R2
OFF
Hi
OFF
NEUTRAL
OFF
Lo
OFF
NEUTRAL
OFF
ANY
NONE
No reaction
—
23
SEN01115-00
40 Troubleshooting
Circuit diagram related to reverse clutch ECMV solenoid valve
24
HM400-2
SEN01115-00
40 Troubleshooting
HM400-2 Articulated dump truck Form No. SEN01115-00
© 2006 KOMATSU All Rights Reserved Printed in Japan 05-06 (02)
26
HM400-2
SEN01116-01
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
40 Troubleshooting
1
Troubleshooting for electrical system (E-mode) Before troubleshooting for electrical system ................................................................................................... 3 Information in troubleshooting table................................................................................................................ 9 E-1 Engine does not start (Starting motor does not turn)............................................................................. 10 E-2 Auto preheater does not operate........................................................................................................... 14 E-3 When starting switch is turned ON, machine monitor displays nothing................................................. 18 E-4 When starting switch is turned OFF, machine monitor cannot be operated .......................................... 20 E-5 Alarm buzzer does not stop sounding ................................................................................................... 22 E-6 Machine monitor does not normally display gauges, caution lamps, and character display section..... 23 E-7 Display of character display section cannot be changed ...................................................................... 24 E-8 Power mode selection function does not operate normally................................................................... 28 E-9 AISS function does not operate normally .............................................................................................. 30 E-10 Right and left differential lock function does not operate normally (Differential lock-up specification) ....................................................................................................... 32 E-11 Interaxle differential lock-up function does not operate normally......................................................... 36
HM400-2
1
SEN01116-01
E-12 E-13 E-14 E-15 E-16
2
40 Troubleshooting
Display of seat belt caution lamp is abnormal ..................................................................................... 38 Turn signal lamps and pilot lamps do not operate normally ................................................................ 40 Night lighting is abnormal .................................................................................................................... 45 Backup lamp and backup buzzer operate abnormally......................................................................... 51 Emergency steering system does not operate .................................................................................... 55
HM400-2
40 Troubleshooting
SEN01116-01
Before troubleshooting for electrical system
1
a This connection table shows the devices to which each power supply of the circuit breakers and fuse box supplies power (An accessory power supply is a device which supplies power while the starting switch is in the ON position and an unswitched power supply is a device which supplies power while the starting switch is in the OFF and ON positions). a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers and fuses to see if the power is supplied normally. Locations and connections of circuit breakers (30 A and 80 A)
Type of power supply Unswitched power supply
Accessory power supply
Circuit breaker Circuit breaker No. capacity
Destination of power Fuse box (BT2)
1
30A
2
30A
Fuse box (BT3)
3
80A
Fuse box (BT3)
Fuse box (BT4)
Fuse box (BT1) 4
80A
Fuse box (BT2) Fuse box (BT3) Fuse box (BT4)
HM400-2
3
SEN01116-01
40 Troubleshooting
Location and connection of fuse box (BT1)
Type of power supply
Fuse No.
Fuse capacity
Destination of power Lamp switch circuit (including brightness control switch) BT1-No. 3 power supply (through relay)
1
20A
BT1-No. 4 power supply (through relay) BT1-No. 5 power supply (through switch) BT1-No. 6 power supply (through switch)
Accessory power supply
4
2
10A
Flasher
3
20A
Headlamp (High beam)
4
10A
Headlamp (Low beam)
5
10A
Small lamp (Right)
6
10A
Small lamp (Left)
7
10A
Stop lamp (Right and left)
8
20A
9
20A
Front working lamp (Right and left)
10
20A
Service power supply connector
Backup lamp (Right and left) Backup buzzer
HM400-2
40 Troubleshooting
SEN01116-01
Location and connection of fuse box (BT2)
Type of power supply
Accessory power supply
Unswitched power supply
HM400-2
Fuse No.
Fuse capacity
11
10A
Engine controller (Starting switch ACC signal)
Destination of power
12
10A
KOMTRAX terminal
13
10A
Machine monitor
14
10A
Parking brake solenoid valve
15
10A
Rear view monitor
16
20A
Front wiper motor
17
20A
Rear wiper motor
18
10A
19
10A
Retarder controller
20
20A
Starting switch (Terminal B power supply)
Machine monitor KOMTRAX
21
10A
Transmission controller
22
20A
Hazard lamp (Front, rear, right, and left)
23
10A
Emergency steering relay (motor circuit) and timer
24
10A
25
20A
Room lamp Car radio or car stereo Service power supply connector
5
SEN01116-01
40 Troubleshooting
Location and connection of fuse box (BT3)
Type of power supply
Accessory power supply
Unswitched power supply
6
Fuse No.
Fuse capacity
26
20A
Fog lamp (Right and left)
Destination of power
27
20A
Air conditioner unit
28
10A
Heater
29
10A
Heater
30
10A
31
10A
32
10A
33
10A
Emergency steering relay (signal circuit) and timer
34
20A
Power window motor (Right)
35
20A
Power window motor (Left)
36
—
(Spare)
37
—
(Spare)
38
—
(Spare)
39
30A
Rear glass heater
40
30A
Engine controller
Machine monitor Alarm buzzer Retarder controller Transmission controller Shift lever
HM400-2
40 Troubleshooting
SEN01116-01
Location and connection of fuse box (BT4)
Type of power supply
Accessory power supply
Unswitched power supply Accessory power supply
HM400-2
Fuse No.
Fuse capacity
41
10A
Room lamp 2
Destination of power
42
10A
Car radio or car stereo
43
10A
Yellow rotary lamp
44
20A
Side lamp (Right and left)
45
10A
Intake air heater relay
46
10A
Horn (Right and left)
47
10A
Tachograph
48
10A
Cigarette lighter
49
10A
Air suspension seat
50
10A
Air conditioner unit
7
SEN01116-01
40 Troubleshooting
Location and connection of fuse (V)
Type of power supply
Fuse No.
Fuse capacity
Accessory power supply
V
300A
8
Destination of power Intake air heater
HM400-2
40 Troubleshooting
SEN01116-01
Information in troubleshooting table
1
a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Trouble Related information
Trouble which occurred in the machine Information related to detected trouble or troubleshooting Cause
Standard value in normal state/Remarks on troubleshooting
• Standard value in normal state to judge possible causes • Remarks on judgment
1
• Disconnection Connector is connected defectively or wiring harness is broken. • Ground fault Wiring harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. • Hot short Wiring harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit. • Short circuit Independent wiring harnesses are in contact with each other abnormally.
2 Possible causes and standard value in normal state
Possible causes of trouble (Given numbers are refer ence numbers, which do (1) Method of indicating connector No. and handling of Tnot indicate priority) adapter Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. 3 • If connector No. has no marks of "male" and "female", disconnect connector and insert T-adapters in both male side and female side. • If connector No. has marks of "male" and "female", disconnect connector and connect T-adapter to only male side or female side. (2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting, unless otherwise specified. 4 • Connect positive (+) lead to pin No. or wiring harness entered on front side. • Connect negative (–) lead to pin No. or harness entered on rear side.
Related circuit diagram This drawing is a part of the electric circuit diagram related to troubleshooting. • Connector No.: Indicates (Model – Number of pins) and (Color). • "Connector No. and pin No." from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. • Arrow (i o): Roughly shows the location on the machine.
HM400-2
9
SEN01116-01
40 Troubleshooting
E-1 Engine does not start (Starting motor does not turn) Trouble Related information
1
• Engine does not start (Starting motor does not turn). • Engine starting circuit is equipped with start lock mechanism of gearshift lever. Cause
Standard value in normal state/Remarks on troubleshooting
1
Trip of circuit breaker (30 A, 80 A)
If circuit breaker is broken, circuit probably has ground fault. (See cause 11.)
2
Breakage of fuse (BT2-No. 20, BT3-No. 32)
If fuse is broken, circuit probably has ground fault. (See cause 11.)
3 Discharged battery
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Battery voltage
Electrolyte specific gravity
Min. 24 V
Min. 1.26
a Prepare with starting switch OFF, then keep it in OFF position and start engine and carry out troubleshooting in each case. 4
Defective starting switch (Internal disconnection)
Starting switch Between B – C
Resistance OFF
Min. 1 Mz
START
Max. 1 z
a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
5
Possible causes and standard value in normal state
6
Defective engine cut-off relay Replace engine cut-off relay (Right No.) with another (Internal defect) relay. If engine starts at this time, engine cut-off relay is defective.
Defective engine starting relay (Internal defect)
R38
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Replace engine starting relay (Right No.) with another relay. If engine starts at this time, engine starting relay is defective.
R01
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective diode D01 (Internal 7 short circuit) D01 (female) Continuity (Resistance) Between (1) – (2)
No continuity (Min. 1 Mz)
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Starting motor, 78
Defective starting motor 8 (Internal defect)
Voltage
Between terminal B – chassis ground
Battery voltage
20 – 30 V
Between 78 (1) – chassis ground
Starting signal
20 – 30 V
Between 78 (2) – chassis ground
Generation signal
Max. 1 V
If battery voltage, starting signal, and generation signal are normal but starting motor does not turn, starting motor is defective.
9
10
Defective alternator (Internal short circuit)
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Alternator Between R – chassis ground
Generation signal
Voltage Max. 1 V
HM400-2
40 Troubleshooting
SEN01116-01
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Wiring harness between terminal battery (-) – chassis ground (ER)
Resistance
Max. 1 z
Wiring harness between battery (+) – junction block - battery relay (66) – circuit breaker (82)
Resistance
Max. 1 z
Wiring harness between circuit breaker (84) – BT2 (19)
Resistance
Max. 1 z
Wiring harness between BT2 (20) – starting switch (B)
Resistance
Max. 1 z
Wiring harness between starting switch (C) R38 (female) (3)
Resistance
Max. 1 z
Disconnection in wiring har- Wiring harness between R38 (female) (6) – ness (Disconnection in wiring R01 (female) (5) 10 or defective contact in conWiring harness between R01 (female) (3) – nector) 78 (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between battery relay (69) – junction block - circuit breaker (65)
Resistance
Max. 1 z
Wiring harness between circuit breaker (64) – BT3 (13)
Resistance
Max. 1 z
Wiring harness between BT3 (14) – SF1 (female) (1)
Resistance
Max. 1 z
Wiring harness between SF1 (female) (5) – R01 (female) (1)
Resistance
Max. 1 z
Wiring harness between R01 (female) (2) – JCA – chassis ground (ER2)
Resistance
Max. 1 z
Wiring harness between battery relay (69) – starting motor (B)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
HM400-2
Wiring harness between battery (+) – junction block – battery relay (66) – circuit breaker (82)
Resistance
Min. 1 Mz
Wiring harness between circuit breaker (84) – BT2 (19) or circuit branch end
Resistance
Min. 1 Mz
Wiring harness between BT2 (20) – starting switch (B)
Resistance
Min. 1 Mz
Wiring harness between starting switch (C) Ground fault in wiring har11 ness (Short circuit with GND – R38 (female) (3) or circuit branch end circuit) Wiring harness between R38 (female) (6) – R01 (female) (5)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between R01 (female) (3) – 78 (female) (1) or circuit branch end
Resistance
Min. 1 Mz
Wiring harness between battery relay (69) – junction block – circuit breaker (65)
Resistance
Min. 1 Mz
Wiring harness between circuit breaker (64) – BT3 (13) or circuit branch end
Resistance
Min. 1 Mz
Wiring harness between BT3 (14) – SF1 (female) (1) or circuit branch end
Resistance
Min. 1 Mz
11
SEN01116-01
40 Troubleshooting
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ossible causes and standard value in normal state
Ground fault in wiring harWiring harness between SF1 (female) (5) – 11 ness (Short circuit with GND R01 (female) (1) or circuit branch end circuit) Wiring harness between battery relay (69) – starting motor (B)
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 12
13
12
Resistance
Hot short (Short circuit with Wiring harness between 78 (female) (2) – 24V circuit) in wiring harness CJU - alternator (R), D01 (female) (2), ATC1 (female) (15), BRC1 (female) (1), or circuit branch end Defective engine controller power supply
Voltage
Max. 1 V
Engine controller power supply may be defective. Carry out troubleshooting for "Failure code CA111".
HM400-2
40 Troubleshooting
SEN01116-01
Circuit diagram related to engine starting system
HM400-2
13
SEN01116-01
40 Troubleshooting
E-2 Auto preheater does not operate Trouble Related information
1
• Auto preheater does not operate. • If engine coolant temperature is below -5°C, auto preheater operates for up to 40 seconds. • If trouble is detected in auto preheat relay (R07), failure codes [CA2555] and [CA2556] are displayed. Cause
Standard value in normal state/Remarks on troubleshooting
1
Trip of circuit breaker (30 A, 80 A)
If circuit breaker is broken, circuit probably has ground fault. (See cause 9.)
2
Breakage of fuse (BT2-No. 11, BT4-No. 45)
If fuse is broken, circuit probably has ground fault. (See cause 9.)
3 Breakage of fuse (300 A)
If fuse is broken, circuit probably has ground fault. (See cause 9.) a Prepare with starting switch OFF, then keep it in OFF position and turn it ON and carry out troubleshooting in each case.
4
Defective starting switch (Internal disconnection)
Starting switch Between terminals B and ACC
Resistance OFF
Min. 1 Mz
ON
Max. 1 z
a Prepare with starting switch OFF (with wiring harness connected), then turn starting switch ON and carry out troubleshooting. 5
Defective intake air heater (Internal disconnection)
Intake air heater
Voltage
Between heater terminal – chassis ground
20 – 30 V
If above voltage is normal but heater mounting part is not warmed, intake air heater is defective. Possible causes and standard value in normal state
a Prepare with starting switch OFF (with wiring harness connected), then turn starting switch ON and carry out troubleshooting. Intake air heater relay 6
Defective intake air heater relay (Internal defect)
Voltage/Resistance
Between E11 – chassis ground
Signal
20 – 30 V
Between E12 – terminal PH0
Contact
Max. 1 z
If signal voltage is normal but contact resistance is abnormal, intake air heater relay is defective. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
7
Defective auto preheat relay Replace auto preheat relay (Right No.) with another (Internal defect) relay. If auto preheater operates at this time, auto preheat relay is defective.
R07
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between terminal battery (-) – chassis ground (ER)
Disconnection in wiring harWiring harness between battery (+) – juncness (Disconnection in wiring 8 tion block – battery relay (66) – circuit or defective contact in conbreaker (82) nector) Wiring harness between circuit breaker (84) – BT2 (19) Wiring harness between BT2 (20) – starting switch (B)
14
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
HM400-2
40 Troubleshooting
SEN01116-01
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between starting switch (ACC) – BT2 (1)
Resistance
Max. 1 z
Wiring harness between BT2 (2) – J2P (female) (39)
Resistance
Max. 1 z
Wiring harness between battery relay (69) – junction block – circuit breaker (62)
Resistance
Max. 1 z
Wiring harness between circuit breaker (63) Disconnection in wiring har- – BT4 (9) ness (Disconnection in wiring Wiring harness between circuit breaker BT4 8 or defective contact in con- (10) – R07 (female) (5) nector) Wiring harness between R07 (3) – E11
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Wiring harness between battery relay (69) – fuse
Resistance
Max. 1 z
Wiring harness between fuse – E12
Resistance
Max. 1 z
Wiring harness between PH0 – heater terminal
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between battery (+) – junction block – battery relay (66) – circuit breaker (82)
Resistance
Min. 1 Mz
Wiring harness between circuit breaker (84) – BT2 (19) or circuit branch end
Resistance
Min. 1 Mz
Wiring harness between BT2 (20) – starting switch (B)
Resistance
Min. 1 Mz
Wiring harness between starting switch (ACC) – BT2 (1) or circuit branch end
Resistance
Min. 1 Mz
Wiring harness between BT2 (2) – J2P (female) (39)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between circuit breaker (63) – BT4 (9) or circuit branch end
Resistance
Min. 1 Mz
Wiring harness between circuit breaker BT4 (10) – R07 (female) (5)
Resistance
Min. 1 Mz
Wiring harness between R07 (3) – E11
Resistance
Min. 1 Mz
Wiring harness between battery relay (69) – fuse
Resistance
Min. 1 Mz
Wiring harness between fuse – E12
Resistance
Min. 1 Mz
Wiring harness between PH0 – heater terminal
Resistance
Min. 1 Mz
Ground fault in wiring har9 ness (Short circuit with GND Wiring harness between battery relay (69) – circuit) junction block – circuit breaker (62)
HM400-2
15
SEN01116-01
40 Troubleshooting
Circuit diagram related to engine preheater
16
HM400-2
40 Troubleshooting
HM400-2
SEN01116-01
17
SEN01116-01
40 Troubleshooting
E-3 When starting switch is turned ON, machine monitor displays nothing1 Trouble
• When starting switch is turned ON, machine monitor displays no lamps and gauges.
Related information Cause
Standard value in normal state/Remarks on troubleshooting
1 Trip of circuit breaker (30 A)
If circuit breaker is broken, circuit probably has ground fault. (See cause 5.)
2
Breakage of fuse (BT2-No. 13 and No. 20)
If fuse is broken, circuit probably has ground fault. (See cause 5.) a Prepare with starting switch OFF, then keep it in OFF position and turn it ON and carry out troubleshooting in each case.
3
Defective starting switch (Internal disconnection)
Starting switch Between terminals B and ACC
Resistance OFF
Min. 1 Mz
ON
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Wiring harness between terminal battery (-) – chassis ground (ER)
Resistance
Max. 1 z
Wiring harness between battery (+) – junction block - battery relay (66) – circuit breaker (82)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between starting switch (ACC) – BT2 (5)
Resistance
Max. 1 z
Wiring harness between BT2 (6) – DPC1 (female) (6), (7)
Resistance
Max. 1 z
Wiring harness between DPC1 (female) (9), (10) – CJL - chassis ground (ER)
Resistance
Max. 1 z
Disconnection in wiring har- Wiring harness between circuit breaker (84) ness (Disconnection in wiring – BT2 (19) 4 or defective contact in conWiring harness between BT2 (20) – starting nector) switch (B)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between battery (+) – junction block - battery relay (66) – circuit breaker (82)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between starting switch (ACC) – BT2 (5) or circuit branch end
Resistance
Min. 1 Mz
Wiring harness between BT2 (6) – DPC1 (female) (6), (7)
Resistance
Min. 1 Mz
Wiring harness between circuit breaker (84) Ground fault in wiring har5 ness (Short circuit with GND – BT2 (19) circuit) Wiring harness between BT2 (20) – starting switch (B)
6 Defective machine monitor
18
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. DPC1
Voltage
Between (6), (7) – (9), (10)
20 – 30 V
HM400-2
40 Troubleshooting
SEN01116-01
Circuit diagram related to machine monitor power supply
HM400-2
19
SEN01116-01
40 Troubleshooting
E-4 When starting switch is turned OFF, machine monitor cannot be operated Trouble
1
• When starting switch is turned OFF and switches are operated, service meter & integrated odometer, turn signal pilot lamp, and headlamp high beam pilot lamp on machine monitor are not turned ON or OFF.
Related information Cause
Standard value in normal state/Remarks on troubleshooting
1 Trip of circuit breaker (30 A)
If circuit breaker is broken, circuit probably has ground fault. (See cause 4.)
2
Breakage of fuse (BT2-No. 18)
If fuse is broken, circuit probably has ground fault. (See cause 4.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between terminal battery (-) – chassis ground (ER)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between BT2 (16) – DPC1 (female) (4), (5)
Resistance
Max. 1 z
Wiring harness between DPC1 (9), (10) – CJL – chassis ground(ER)
Resistance
Max. 1 z
Wiring harness between battery (+) – juncDisconnection in wiring har- tion block – battery relay (66) – circuit ness (Disconnection in wiring breaker (82) 3 or defective contact in conWiring harness between circuit breaker (84) nector) – BT2 (15) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between battery (+) – junction block – battery relay (66) – circuit Ground fault in wiring har4 ness (Short circuit with GND breaker (82) circuit) Wiring harness between circuit breaker (84) – BT2 (15) or circuit branch end Wiring harness between BT2 (16) – DPC1 (female) (4), (5) or circuit branch end
5 Defective machine monitor
20
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. DPC1
Voltage
Between (4), (5) – (9), (10)
20 – 30 V
HM400-2
40 Troubleshooting
SEN01116-01
Circuit diagram related to machine monitor power supply
HM400-2
21
SEN01116-01
40 Troubleshooting
E-5 Alarm buzzer does not stop sounding
1
Trouble
• When starting switch is turned ON, central warning lamp lights up and alarm buzzer does not stop sounding.
Related information
• Causes 2 – 7 are alarms for avoiding dangers in operation, which stop when problem in operation is solved. Cause
1 Failure detection
2
Possible causes and standard value in normal state
Parking brake dragging warning
• When failure is detected, central warning lamp lights up and alarm buzzer sounds (Note: Lamp/Buzzer may not light up/ sound, depending on each failure) • In this case, perform troubleshooting for that code (Check fault history, too) • When gear shift lever is set in position other than "N" with engine started and parking brake switch in "Park" position, central warning lamp lights up and alarm buzzer sounds • If parking brake switch is set in "Travel" position or gear shift lever is set in "N" position, alarm is turned OFF
3 Overrun warning
• If travel speed exceeds set speed or engine speed increases abnormally, central warning lamp lights up and alarm buzzer sounds • If travel speed decreases below set speed or engine speed decreases to normal range, alarm is turned OFF
4 Dump body up warning
• If gear shift lever is set in position other than "N" with parking brake switch in "Travel" position while engine is running and dump body is raised (dump body pilot lamp in machine monitor is lighting), central warning lamp lights up and alarm buzzer sounds • If dump body is lowered or parking brake switch is set in "Park position" or gear shift lever is set in "N" position, alarm is turned OFF
5 Neutral safety warning
• If starting switch is turned from OFF to ON, while gear shift lever is not in "N" position, central warning lamp lights up and alarm buzzer sounds • If gear shift lever is set in "N" position, alarm is turned OFF
Warning by dump body up 6 caution (if equipped)
• If engine is started and dump body is raised (body pilot lamp in machine monitor is lighting) while this option is set, central warning lamp lights up and alarm buzzer sounds • If dump body is lowered, alarm is turned OFF
Warning for start with gear shift lever not in neutral
• If engine start signal (key switch terminal C) is detected while gear shift lever is not in "N" position, central warning lamp lights up and alarm buzzer sounds. • If gear shift lever is set in "N" position or engine start signal is turned OFF, alarm is turned OFF
Retarder oil pressure drop detection
• If accumulator oil pressure is still low after engine is started, retarder caution lamp (accumulator oil pressure drop detection) of machine monitor and central warning lamp light up and alarm buzzer sounds (Reference: Failure code [2G42ZG] or [2G43ZG] and [DHU2KX] or [DHU3KX] are turned ON after 30 seconds) • Check retarder hydraulic circuit (accumulator oil pressure)
7
8
9 Defective initialization
10
22
Standard value in normal state/Remarks on troubleshooting
Defective machine monitor or controller
• If initialization is not performed normally after controller is replaced, central warning lamp lights up and alarm buzzer sounds • Perform initialization correctly • If any of above causes is not detected, machine monitor or a controller may be defective ((Since trouble is in system, troubleshooting cannot be performed)
HM400-2
40 Troubleshooting
SEN01116-01
E-6 Machine monitor does not normally display gauges, caution lamps, and character display section 1 Trouble
(1) Display of gauges is different from machine condition.
Related information Cause Possible causes and standard value in normal state
Trouble
Standard value in normal state/Remarks on troubleshooting
Defective sensor signal sys- Signal system of related sensor may be defective. Check that sen1 tem sor. 2 Defective machine monitor
When starting switch is turned from OFF position to ON position, if system does not check gauges normally, machine monitor is defective.
(2) Display of caution lamps is different from machine condition.
Related information Cause Possible causes and standard value in normal state
Trouble
1
Standard value in normal state/Remarks on troubleshooting
Defective sensor signal sys- Signal system of related sensor or switch may be defective. Check tem that sensor or switch.
2 Defective machine monitor
When starting switch is turned from OFF position to ON position, if system does not check lamps normally (lamps must be turned ON for 2 seconds and then OFF for 1 second), machine monitor is defective.
(3) Character display section displays nothing or displays abnormally.
Related information
Possible causes and standard value in normal state
HM400-2
Cause
Standard value in normal state/Remarks on troubleshooting
1 Defective machine monitor
When starting switch is turned from OFF position to ON position, if system does not check character display section normally ("KOMATSU SYSTEM CHECK" must be displayed for 3 seconds and then OFF for 1 second), machine monitor is defective.
23
SEN01116-01
40 Troubleshooting
E-7 Display of character display section cannot be changed Trouble
1
(1) When machine monitor mode selector switch 1 is operated, display of character display section does not change normally.
Related information Cause 1
Breakage of fuse (BT2-No. 18)
Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault. (See cause 4.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective machine monitor mode selector switch 1 2 (Internal disconnection or short circuit)
CH1 (female) Between (2) – (3) Between (1) – (3)
Machine monitor mode selector switch 1
Resistance
[U] is pressed
Max. 1 z
Neutral
Min. 1 Mz
Neutral
Min. 1 Mz
[t] is pressed
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector)
Possible causes and standard value in normal state
Wiring harness between BT2 (16) – CH1 (male) (3)
Resistance
Max. 1 z
Wiring harness between DPC2A (female) (8) – CH1 (male) (2)
Resistance
Max. 1 z
Wiring harness between DPC2A (female) (14) – CH1 (male) (1)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between BT2 (16) – CH1 Ground fault in wiring har(male) (3) or circuit branch end 4 ness (Short circuit with GND Wiring harness between DPC2A (female) circuit) (8) – CH1 (male) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between DPC2A (female) (14) – CH1 (male) (1)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5
Hot short (Short circuit with Wiring harness between DPC2A (female) 24V circuit) in wiring harness (8) – CH1 (male) (2)
Voltage
Max. 1 V
Wiring harness between DPC2A (female) (14) – CH1 (male) (1)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Machine monitor mode selector switch 1
Voltage
Between (8) – chassis ground
[U] is pressed
20 – 30 V
Neutral
Max. 1 V
Between (14) – chassis ground
Neutral
Max. 1 V
[t] is pressed
20 – 30 V
DPC2A 6 Defective machine monitor
24
HM400-2
40 Troubleshooting
Trouble
SEN01116-01
(2) When machine monitor mode selector switch 2 is operated, display of character display section does not change normally.
Related information Cause 1
Breakage of fuse (BT3-No. 30)
Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault. (See cause 4.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective machine monitor mode selector switch 2 2 (Internal disconnection or short circuit)
CH2 (female) Between (2) – (3) Between (1) – (3)
Machine monitor mode selector switch 2
Resistance
[>] is pressed
Max. 1 z
Neutral
Min. 1 Mz
Neutral
Min. 1 Mz
[] is pressed
20 – 30 V
Neutral
Max. 1 V
Between (15) – chassis ground
Neutral
Max. 1 V
[ Turn over the assembly and remove mounting bolts (36) 12 pieces of bevel gear assembly (35) of case (34), then remove bevel gear assembly (35). a Check the match marks on the b ev el ge ar an d c as e b efo r e removing the bevel gear assembly (on the tooth surface side of the bevel gear).
2> Using puller [5], remove bearing inner race (38a) from bevel gear and case assembly (37). 3> Remove case (39) from bevel gear (40).
6
Remove washer (41) and differential side gear (42).
10] Remove pinion gear assembly (43) and cross shaft (44) in 1 unit.
HM400-2
50 Disassembly and assembly
11] Remove washer (45), pinion gear (46), and bushing (sleeve) (47).
SEN01445-02
8.
Disassembly of side carrier and shaft assembly 1) Disassemble the side carrier and shaft assembly on the bevel gear side according to the following procedure. 1] Remove seal (49).
12] Remove side gear (48).
2]
Shaft and bearing inner race assembly 1> Remove shaft and bearing inner race assembly (50)
2> Using push tool [6], remove bearing inner race (51a).
HM400-2
7
SEN01445-02
3]
50 Disassembly and assembly
2> Using push tool [7], remove bearing inner race (56a).
Remove bearing (53) and bearing outer races (38b) and (51b) from case (52). a Bearing (53) is divided into the inner race and outer race when the shaft is removed (pulled out).
3)
2)
Disassemble the side carrier and shaft assembly on the opposite side of the bevel gear according to the following procedure. 1] Remove seal (54).
2]
8
Remove bearing (58) and bearing outer races (24b) and (56b) from case (57). a Bearing (58) is divided into the inner race and outer race when the shaft is removed (pulled out).
Shaft and bearing inner race assembly 1> Remove shaft and bearing inner race assembly (55).
HM400-2
50 Disassembly and assembly
SEN01445-02
Assembly a If a tool for installing a seal is not specified (for the input shaft in particular), use a push tool of a proper size for each part. 1. Assembly of side carrier and shaft assembly 1) Assemble the side carrier and shaft assembly on the bevel gear side according to the following procedure. 1] Install bearing outer races (38b), (51b), and (53b) to case (52).
2]
Shaft and bearing inner race assembly 1> Using tool H4, press fit bearing inner race (51a) to shaft (59).
3> Adjust the shims for the bearing according to the following procedure. a) Measure the starting tangential force in the tangential direction of the bolt hole (ø234) of the case. a Standard tangential force: Max. 21.5 N {2.2 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. a If the starting tangential force is tool large, disassemble shaft and bearing inner race as sem bly ( 50) an d c as e assembly (61) and increase the shims, then execute 2] above.
2> Set the standard shims (having the thickness and quantity checked when disassembled) and install coupling (17). Using push tool [7], press holder (60) to press fit case assembly (61) to shaft and bearing inner race assembly (50).
HM400-2
9
SEN01445-02
3]
2)
50 Disassembly and assembly
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).
Using tool H3, press fit seal (49).
Assemble the side carrier and shaft assembly on the opposite side of the bevel gear according to the following procedure. 1] Install bearing outer races (24b), (56b), and (58b) to case (57).
2]
Shaft and bearing inner race assembly 1> Using tool H4, press fit bearing inner race (56a) to shaft (63).
3]
10
3> Adjust the shims for the bearing according to the following procedure, similarly to the side carrier on the bevel gear side. a) Measure the starting tangential force in the tangential direction of the bolt hole (ø208) of the case. a Standard tangential force: 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. a If the starting tangential force is tool large, disassemble shaft and bearing inner race assembly (55) and cas e ass embl y ( 65) a nd increase the shims, then execute 2] above. Using tool H3, press fit seal (54).
HM400-2
50 Disassembly and assembly a The procedure for installing both side carrier and shaft assemblies to the body is explained in 3 below. 2.
SEN01445-02
3]
Install pinion gear assembly (43) and cross shaft (44) in 1 unit.
4]
Install differential side gear (42) and washer (41).
Differential gear and differential lock assembly 1) Assemble the differential gear and differential lock assembly according to the following procedure. 1] Install side gear (48).
2]
HM400-2
Install bushing (sleeve) (47), pinion gear (46), and washer (45).
11
SEN01445-02
5]
Bevel gear assembly 1> Install case (39) to bevel gear (40). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm} 2> Install bearing inner race (38a) to bevel gear and case assembly (37) by shrink fit. a Shrink fit temperature: 120°C for 30 minutes
50 Disassembly and assembly
7]
Install seal ring (30) and thrust washer (68) to piston case (27). a When installing the seal ring, take care of its direction.
8]
Install seal ring (29) to piston (28). a When installing the seal ring, take care of its direction.
9]
Install piston (28) to case (27).
3> Install bevel gear assembly (35) to case (34). a Match the match marks to each other.
6]
Install pin (33), plate (31), and disc (32). a Apply engine oil (EO-30) to the surfaces of the disc and plate.
10] Install case and piston assembly (26). 3 Mounting bolt: 157 – 196 Nm {16 – 20 kgm}
12
HM400-2
50 Disassembly and assembly
SEN01445-02
2)
Sling differential gear and differential lock assembly (22) and install it to differential gear case (67) and tighten the retainer mounting bolts (21) 3 pieces.
11] Install seal ring (25). a When installing the seal ring, take care of its direction.
12] Using push tool [9], press fit bearing inner race (24a) and retainer (23) in 1 unit.
HM400-2
3.
Side carrier and shaft assembly 1) Sling the differential gear case and set the standard shims (having the thickness and quantity checked when disassembled) and install side carrier and shaft assembly (19) on the bevel gear side. 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
13
SEN01445-02
2)
3)
4)
14
Under the above condition, set the standard shim (having the thickness and quantity checked when disassembled) and install side carrier and shaft assembly (20) on the opposite side. 3 Mounting bolt: 157 – 196 Nm {16 – 20 kgm}
Adjusting preload on side bearing 1] Measure the initial rotating force of the periphery of the bevel gear in the tangential direction. a Initial rotating force: 6.86 – 25.0 N {0.7 – 2.55 kg} 2] If the rotating force is larger than the standard level, increase the thickness/quantity of the shims. If the former is in the standard range, it is normal. a After adjusting the tooth contact and backlash, the shims on both sides may be exchanged with each other. Do not change the total quantity and thickness of the shims on both sides, however. After adjusting the preload, be sure to tighten the mounting bolts to the specified torque in 1).
50 Disassembly and assembly
4.
Right and left output shaft couplings Install couplings (17) and (18) on both sides. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 490 – 608 Nm {50 – 62 kgm}
5.
Pinion and case assembly 1) Assemble pinion and case assembly (9) according to the following procedure. 1] Using push tool [10], install bearing outer race (13b) to case (11). 2] Using push tool [11], install bearing outer race (16b) to case (11).
3] 4]
Using tool H1, press fit bearing inner race (13a) to pinion (10). Install spacer (12).
HM400-2
50 Disassembly and assembly
2)
SEN01445-02
Using tool H1, press fit case assembly (11) to pinion (10). a Never push the case assembly with a press. a Press fit bearing inner race (16a) with tool H1. a Press fitting force: 0 – 8,134 N {0 – 830 kg} a Press fit case assembly (11), turning it.
3)
1]
Using push tool [12], press fit seal (15) to case (11). 2 Apply Sealend 242 to the periphery of the seal. a Taking care of the direction of the seal, press fit it until it is flush with the case as shown in the figure. a Press fit the seal so that standard dimension (a) will be 110 mm. 2] Using tool H2, press fit seal (14) to case (11). 2 Apply Sealend 242 to the periphery of the seal. a Taking care of the direction of the seal, press fit it until it is flush with the case as shown in the figure.
HM400-2
6.
Set the standard shim (having the thickness and quantity checked when disassembled) and install pinion and case assembly (9). a Tighten 3 mounting bolts first. a After adjusting the tooth contact, tighten the all mounting bolts. 3 Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm}
Input shaft coupling and holder 1) Using push tool [13], press fit speed detection gear (8) to coupling (7). a Press fit the gear until it is flush with the coupling.
15
SEN01445-02
2)
7.
Install coupling and gear assembly (6) and holder (5). 2 Holder end (Face to be in contact with bearing at bottom): Adhesive (LMP) 2 Holder mounting bolt: Adhesive (LT-2) 3 Holder mounting bolt: 824 – 1,030 Nm {84 – 105 kgm}
Adjusting tooth contact and backlash q Adjust the backlash and tooth contact simultaneously. 1) Adjust the backlash according to the following procedure. 1] Move the bevel gear by increasing or decreasing shims (69) and (70) of the right and left carrier assemblies. At this time, do not change the total quantity and thickness of the shims on both sides so that the preload on the bearing will not change.
2]
a
16
50 Disassembly and assembly
2)
Adjust the tooth contact according to the following procedure. 1] Adjust the projection of the bevel pinion with shim (71) between the differential case and bearing case.
q
When the backlash is below standard value Loosen the adjustment nut on the bevel gear side and tighten the adjustment nut on the right side by the same angle (to move the bevel gear in the direction of A).
q
When the backlash is above standard value Loosen the adjustment nut on the left side and tighten the adjustment nut on the bevel gear side by the same angle (to move the bevel gear in the direction of B).
Apply dial gauge [13] perpendicularly to the reversing tooth surface at the outer end of the bevel gear. Adjust the backlash so that the gauge will indicate 0.3 – 0.4mm. Adjust the backlash at 3 – 4 places and measure it with the pinion fixed.
HM400-2
50 Disassembly and assembly
(1) Checking tooth contact Apply red lead thinly to the surfaces of 7 8 teeth of the bevel gear and turn the bevel gear in the forward and reverse directions, then check the tooth contact pattern on the bevel gear. a The center of the tooth contact must be as follows. q Middle of tooth height q Point on tooth at distance of (x) from small end (C) (Approx. 33% of tooth length) a Width (y) of the tooth contact must be 30 - 60% of the tooth length. a Check that there is not a strong contact at tip (A), bottom (B), small end (C) or large end (D).
SEN01445-02
q
In this case, adjust the tooth contact according the following procedure
If bevel pinion is too far from bevel gear a The tooth contact pattern is as follows. q Decrease the shims of the bevel pinion to move the bevel pinion in direction (C). q Move the bevel gear in direction (D).
If bevel pinion is too close to bevel gear a The tooth contact pattern is as follows. q Increase the shims of the bevel pinion to move the bevel pinion in direction (E). q Move the bevel gear in direction (F). (2) Adjusting tooth contact If the tooth contact pattern is not proper, adjust the tooth contact according to the procedure shown in the following page. a After adjusting the tooth contact, check the backlash again.
HM400-2
17
SEN01445-02
If bevel gear is too close to bevel pinion a The tooth contact pattern is as follows. q Decrease the shims of the bevel pinion to move the bevel pinion in direction (C). q Move the bevel gear in direction (D).
If bevel gear is too far from bevel pinion a The tooth contact pattern is as follows. q Increase the shims of the bevel pinion to move the bevel pinion in direction (E). q Move the bevel gear in direction (F).
a
q q q q
18
50 Disassembly and assembly
8.
Bevel gear supporting bolt Install bevel gear supporting bolt (4). a Bring the bolt end in contact with the back of the gear, then return it by 3/4 turn and secure it with the locknut. 2 Bolt: Gasket sealant (LG-5) 3 Locknut: 196 – 245 Nm {20 – 25kgm}
9.
Speed sensor and top cover Install speed sensor (1) and top cover (2). 2 Top cover: Gasket sealant (LT-515) 3 Top cover mounting bolt: 157 – 196 Nm {16 – 20 kgm}
After adjusting the tooth contact, refer to the following sections and observe the application of adhesive and tightening torque. Mounting bolts of right and left bevel gear side carriers Right and left output shaft couplings Pinion and case assembly Input shaft
HM400-2
50 Disassembly and assembly
Removal and installation of center differential assembly 1
SEN01445-02
4.
Drive shaft between center differential and rear differential Remove the guard and disconnect the center differential end of drive shaft (3) between then center differential and rear differential. [*2]
5.
Coupling on rear differential side Remove the holder, coupling (4) on the rear differential side, and cover (5). [*3]
6.
Rear differential drive shaft and bearing cage assembly Using forcing screw [1], remove rear differential drive shaft (6) and bearing cage assembly (7) in 1 unit.
Removal k k
Disconnect the cable from the negative (–) terminal of the battery. Raise the dump body and insert the lock 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).
3.
Drive shaft between hitch frame and center differential Remove the guard and lift and disconnect the center differential end of drive shaft (2) between the hitch frame and center differential. [*1] 4
a
Drive shaft between hitch frame and center differential (Only center differential end): 35 kg
Make match marks so that the spline will not shift in the circumferential direction.
HM400-2
19
SEN01445-02
7.
8.
Piping and wiring harness Disconnect differential lock hoses (8) – (10), brake hose (11), brake cooling hoses (12) 3 pieces, and rear retarder oil temperature sensor connector (CN-T14) (13), then remove brake cooling tube (14).
Center differential assembly Sling center differential (15) temporarily. Using forcing screws (M14 x 2), pull out the center differential. After pulling out the differential halfway, change the slinging position (increase the number of slings) and remove the differential. [*4] 4
Center differential assembly: 380 kg
50 Disassembly and assembly
Installation q
Carry out installation in the reverse order to removal.
[*1] a 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. 2 Mounting bolt of drive shaft between hitch frame and center differential: Adhesive (LT-2) 3 Mounting bolt of drive shaft between hitch frame and center differential: 157 – 198 Nm {16 – 20 kgm} [Target: 177 Nm {18 kgm}] [*2] a 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. 2 Mounting bolt of drive shaft between center differential and rear differential: Adhesive (LT-2) 3 Mounting bolt of drive shaft between center differential and rear differential: 98 – 123 Nm {10 – 12.5 kgm} [Target: 113 Nm {11.5 kgm}] [*3] a When installing a seal to a cover, use a push tool matched to the diameter of that seal. 2 Seal lip: Grease (G2-LI) 3 Cover mounting bolt: 98 – 123 Nm {10 – 12.5 kgm} a Install the rear (output) coupling so that the phase difference between it and the front (input) coupling will be 6° or less. 2 Coupling holder mounting bolt: Adhesive (LT-2) 3 Coupling holder mounting bolt: 490 – 608 Nm {50 – 62 kgm} [Target: 550 Nm {56 kgm}] [*4] 3 Center differential mounting bolt: 157 – 198 Nm {16 – 20 kgm} [Target: 177 Nm {18 kgm}] k
20
After installing, bleed air from the brake circuit. For details, see "Testing and adjusting, Bleeding air from brake circuit".
HM400-2
50 Disassembly and assembly
SEN01445-02
Refilling with oil q Pour the specified oil in the center differential case and final drive case to the specified level. q Check the oil level in the transmission case and add the specified oil to the specified level if necessary. q Check the oil level in the hydraulic tank and add the specified oil to the specified level if necessary.
HM400-2
21
SEN01445-02
50 Disassembly and assembly
Disassembly and assembly of center differential assembly
2.
Cover Remove cover (1).
3.
Transfer input coupling and holder Remove holder (2) and coupling (3).
4.
Cage 1) Using forcing screw [1], remove cage assembly (4). a Check the thickness and quantity of the shims.
1
5 792T-423-1130 Push tool 6
7
H 9
t 1 N Q
792-103-0901
Wrench
t 1
792-222-1110
Adapter
t 2
795-525-1000
Micrometer
t 1
796-751-1500
Wrench assembly t 1
795-630-1803
Torque wrench
8 792T-422-1250 Push tool
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1 t 1 N Q
790-501-5000
Unit repair stand
t 1
790-501-5200
Unit repair stand
t 1
790-901-2110
Bracket
t 1
793-310-2141
Plate
t 1 R Q
792T-423-1140 Push tool
t 1 N Q
790-101-5421
Grip
t 1
01010-51240
Bolt
t 1
Push tool kit
t 1
11 790-101-5401 790-101-5451
• Plate
1
790-101-5421
• Grip
1
01010-51240
• Bolt
1
Disassembly 1.
22
Set the center differential gear assembly to tool H9.
HM400-2
50 Disassembly and assembly
2)
5.
Remove side seal (5), oil seal (6), and bearing outer race (7b) from cage (12).
SEN01445-02
6.
Input shaft holder a Place a wood block, etc. so that the bevel pinion will not fall. 1) Remove holder (13). a Check the thickness and quantity of the shims.
Transfer input shaft and gear assembly 1) Remove transfer input shaft and gear assembly (8). 2)
2)
Remove holder (14) and key (15).
Disassemble transfer input shaft and gear assembly (8) according to the following procedure. q Remove bearing inner race (7a), spacer (11), and gear (12) from transfer input shaft (9).
HM400-2
23
SEN01445-02
7.
Transfer case 1) Using forcing screw [2], remove transfer case assembly (16).
2)
50 Disassembly and assembly
8.
Input gear and spacer Remove spacer (19) and input gear (20). a Check the identification mark (A – J) of the spacer.
9.
Cage assembly 1) Using forcing screw [3], remove cage assembly (21). a Check the thickness and quantity of the shims.
Remove bearing outer race (10b) and bearing (18) from transfer case (17).
2)
24
Remove bearing outer race (23b) from cage (22).
HM400-2
50 Disassembly and assembly
SEN01445-02
10. Pinion assembly 1) Remove pinion assembly (24).
5) 2)
Disassemble pinion assembly according to the following procedure. Remove bearing inner race (21a) from pinion (25).
Disassemble the differential gear case assembly according to the following procedure. 1] 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). 2] Remove washer (37) and pin (38). 3] Remove piston (39). q Remove seal ring (40) from piston (39). 4] Using a bearing puller, remove bearing inner race (41a). 5] Remove sleeve (42).
11. Differential gear and differential lock assembly a Sling the differential case in advance. 1) Remove locks (26) and (27). 2) Using tool H6, loosen adjustment nuts (28) and (29) to the degree that you can turn them with fingers. 3) Loosen bolts (30) 4 pieces. 4) Using wires, sling the differential gear case assembly. Remove bearing caps (31) and (32), nuts (28) and (29) and differential gear case assembly. a Take care not to drop the bearing outer race.
HM400-2
25
SEN01445-02
6] 7]
50 Disassembly and assembly
Remove plate (43) and disc (44). Remove pins (45) 4 pieces.
9] 8]
Bevel gear assembly 1> Turn over the assembly and remove mounting bolts (48) 12 pieces of bevel gear assembly (47) of case (46), then remove bevel gear assembly (47). a Check the match marks on the b ev el ge ar an d c as e b efo r e removing the bevel gear assembly (on the tooth surface side of the bevel gear).
2> Using puller [4], remove bearing inner race (50a) from bevel gear and case assembly (49). 3> Remove case (51) from bevel gear (52).
26
Remove washer (53) and differential side gear (54).
10] Remove pinion gear assembly (55) and cross shaft (56) in 1 unit.
HM400-2
50 Disassembly and assembly
11] Remove washer (57), pinion gear (58), and bushing (sleeve) (59).
SEN01445-02
Assembly a If a tool for installing a seal is not specified (for the input shaft in particular), use a push tool of a proper size for each part. 1.
Differential gear and differential lock assembly 1) Assemble the differential gear and differential lock assembly according to the following procedure. 1] Install side gear (60).
12] Remove side gear (60).
2]
HM400-2
Install bushing (sleeve) (59), pinion gear (58), and washer (57).
27
SEN01445-02
3]
Install pinion gear assembly (55) and cross shaft (56) in 1 unit.
4]
Install differential side gear (54) and washer (53).
50 Disassembly and assembly
5]
Bevel gear assembly 1> Install case (51) to bevel gear (52). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm} 2> Install bearing inner race (50a) to bevel gear and case assembly (49) by shrink fit. a Shrink fit temperature: 120°C for 30 minutes
3> Install bevel gear assembly (47) to case (46). a Match the match marks to each other.
28
HM400-2
50 Disassembly and assembly
6]
Turn over the case and install pin (45), disc (44), and plate (43). a Apply engine oil (EO-30) to the surfaces of the disc and plate.
7]
Install seal ring (40) to piston (39). a Take care of the direction of the seal ring. Install seal rings (35) to case (34). a Take care of the direction of the seal rings. Install pin (38) and washer (37). Install piston (39) to case (34). Install the case and piston assembly, matching it to the position of pin (45). 3 Case mounting bolt: 157 – 196 Nm {16 – 20 kgm} Install seal ring (36) to case (34). a Take care of the direction of the seal rings. Install sleeve (42), taking care not to damage seal ring (36). Install bearing (41a) to case (34) by shrink fit. a Shrink fit temperature: 120°C for 30 minutes
8] 9] 10] 11]
12] 13] 14]
HM400-2
SEN01445-02
2.
Assembly of differential 1) Differential gear assembly 1] Install nuts (28) and (29), matching them to the grooves of differential case (61). 2] Sling gear case (62) and install the outer race to the bearing, then install them to differential case (61).
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}
29
SEN01445-02
4.
Adjusting preload on bearing 1) Rotate the adjustment rings (28) and (29) with bar H6 until the ring gear reaches the pinion gear and the backlash is eliminated. a Rotate the bearing sufficiently so that it will come in contact with the other contact surfaces and hit the ring gear with a copper hammer, etc. a Apply sufficient amount of oil to the bearing. a 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}
50 Disassembly and assembly
5.
Assembly of transfer input shaft Assemble transfer input shaft assembly (8) according to the following procedure. q Install gear (12) and spacer (11) to transfer input shaft (9). Using push tools [7] and [8], press fit bearing inner race (7a).
6.
Assembly of cage of transfer input shaft 1) Assemble cage assembly (4) according to the following procedure. 1] Install bearing outer race (7b). 2] Using push tool [9], install oil seal (6).
3]
30
Using push tool [10], install side seal (5).
HM400-2
50 Disassembly and assembly
7.
Assembly of transfer case Install bearing outer race (10b) and bearing outer race (18b) to transfer case (17).
8.
Adjusting preload on bearing of transfer input shaft 1) Install input shaft and gear assembly (8) to transfer case (17) without inserting any shim. Install cage assembly (12) and tighten mounting bolts (64) 8 pieces to 113.0 Nm {11.5 kgm}. a At this time, tighten mounting bolts (64) repeatedly, rotating the bearing, until rotation is stabilized. 2) Sling the coupling with a crane and measure the end play after adjustment with dial gauge [11]. Determine the thickness of the shims (a) 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 (12).
SEN01445-02
9.
Assembly of bevel pinion assembly Assemble bevel pinion assembly according to the following procedure. q Using push tool [12], press fit bearing inner race (21a) to pinion (25).
10. Adjustment of preload on bevel pinion support bearing 1) Install pinion assembly (24).
2)
HM400-2
Cage assembly 1] Install bearing outer race (23b) to cage (22).
31
SEN01445-02
2]
3)
50 Disassembly and assembly
Install cage assembly (21).
MD shim thickness range
Part No. of spacer
Letter stamped on spacer
Spacer width
0.013 - 0.113
56B-23-16910
A
25.887±0.025
0.114 - 0.213
56B-23-16920
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
4)
32
5)
Bearing inner race Using push tool [13], press fit bearing inner race (18a).
6)
Input shaft holder 1] Install holder (14) and key (15).
Input gear and spacer Install input gear (20) and spacer (19). a Install the spacer checked when disassembled.
Transfer case Install transfer case assembly (16). a Check that the bearing of the pinion is fitted accurately.
HM400-2
50 Disassembly and assembly
2]
SEN01445-02
Set the standard shim (having the thickness and quantity checked when disassembled) and install holder (13). 3 Mounting bolt: 824 – 1,030 Nm {84 – 105 kgm} a Execute "11. Adjusting tooth contact and backlash", then determine the quantity and thickness of the shims.
2]
7)
Apply dial gauge [11] 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. a Adjust the backlash at 3 – 4 places and measure it with the pinion fixed.
Measurement of turning torque Measure the starting tangential force (torque) of the input shaft with push-pull scale [14] and check that the result is as follows. a Starting tangential force (torque) Starting torque:514.8 – 1,543.5 Nm {52.5 – 157.5 kgm} (Measure this torque by putting a wrench to the shaft end bolt.)
2)
Adjust the tooth contact according to the following procedure. 1] Adjust the projection of the bevel pinion with shim (65) between differential case (64) and transfer case (17). 2] Adjusting tooth contact a See "Adjusting tooth contact" in 3) below
11. Adjusting tooth contact and backlash Adjust the backlash and tooth contact simultaneously. 1) Adjust the backlash according to the following procedure. 1] Move the bevel gear with adjustment nuts (28) and (29). At this time, turn the nuts on both sides by the same angle in the same direction so that the preload on the bearing will not change.
HM400-2
33
SEN01445-02
3) q
q
Adjusting tooth contact of bevel gear and bevel pinion When the backlash is below standard value Loosen the adjustment nut on the bevel gear side and tighten the adjustment nut on the right side by the same angle (to move the bevel gear in the direction of A). When the backlash is above standard value Loosen the adjustment nut on the left side and tighten the adjustment nut on the bevel gear side by the same angle (to move the bevel gear in the direction of B).
(1) Checking tooth contact Apply red lead thinly to the surfaces of 7 – 8 teeth of the bevel gear and turn the bevel gear in the forward and reverse directions, then check the tooth contact pattern on the bevel gear. a The center of the tooth contact must be as follows. q Middle of tooth height q Point on tooth at distance of (x) from small end (C) (Approx. 33% of tooth length) a Width (y) of the tooth contact must be 30 – 60% of the tooth length. a Check that there is not a strong contact at tip (A), bottom (B), small end (C) or large end (D).
34
50 Disassembly and assembly
(2) Adjusting tooth contact If the tooth contact pattern is not proper, adjust the tooth contact according to the procedure shown in the following page. a After adjusting the tooth contact, check the backlash again. If bevel pinion is too far from bevel gear a The tooth contact pattern is as follows. q Decrease the shims of the bevel pinion to move the bevel pinion in direction (C). q Move the bevel gear in direction (D).
If bevel pinion is too close to bevel gear a The tooth contact pattern is as follows. q Increase the shims of the bevel pinion to move the bevel pinion in direction (E). q Move the bevel gear in direction (F).
HM400-2
50 Disassembly and assembly
If bevel gear is too close to bevel pinion a The tooth contact pattern is as follows. q Decrease the shims of the bevel pinion to move the bevel pinion in direction (C). q Move the bevel gear in direction (D).
SEN01445-02
13. Cage 1) Install bearing outer race (7b) to cage (10). Using tool H11, press fit oil seal (6). a Press fit oil seal (6) so that clearance (c) between the periphery of oil seal (6) and cage (10) will be 10 ± 0.5 mm.
2)
Using tool H5, press fit side seal (5) to cage (10). a If the side seal is press fitted with this tool until it is flush with the cage, it is positioned accurately.
3)
Set the standard shims and install cage assembly (4).
If bevel gear is too far from bevel pinion a The tooth contact pattern is as follows. q Increase the shims of the bevel pinion to move the bevel pinion in direction (E). q Move the bevel gear in direction (F).
12. Transfer input shaft and gear assembly Install transfer input shaft and gear assembly (8).
HM400-2
35
SEN01445-02
14. Transfer input coupling and holder Install coupling (3) and holder (2). 2 End of bearing (Part A): Grease (G2-LI) 2 End of side seal (Part B): Grease (G2-LI) 2 Holder mounting bolt: Adhesive (LT-2) 3 Holder mounting bolt: 824 – 1,030 Nm {84 – 105 kgm}
50 Disassembly and assembly
16. Bevel gear supporting bolt Install bevel gear supporting bolt (66). a 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. 2 Bolt: Gasket sealant (LG-5) 3 Locknut: 196 – 245 Nm {20 – 25kgm}
a
For disassembly and assembly of the output section of the center axle transfer, see "Removal and installation of center differential assembly".
15. Cover Install cover (1).
36
HM400-2
50 Disassembly and assembly
Removal and installation of rear differential assembly 1
SEN01445-02
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).
5.
Rear differential assembly Sling rear differential (10) temporarily. Using forcing screws (M14 x 2), pull out the rear differential. After pulling out the differential halfway, change the slinging position (increase the number of slings) and remove the differential. [*2] a Support the rear differential from its underside, too, with transmission jack [1], etc. a Since the rear side of the rear differential is a little low, it does not come out easily. Accordingly, use guide bolt [2], etc. to pull out the rear differential forward carefully. 4 Rear differential assembly: 280 kg
Removal k k
Disconnect the cable from the negative (–) terminal of the battery. Raise the dump body and insert the lock pin.
1.
Draining oil Drain oil from the rear differential case and rear final drive case.
2.
Sun gear and drive shaft Remove the rear final drive cover and pull out sun gear and drive shaft (1) (from both sides).
3.
Drive shaft between center differential and rear differential Remove the guard and disconnect the center differential end of drive shaft (2) between then center differential and rear differential. [*1]
HM400-2
37
SEN01445-02
50 Disassembly and assembly
Installation q
Carry out installation in the reverse order to removal.
[*1] a 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. 2 Mounting bolt of drive shaft between center differential and rear differential: Adhesive (LT-2) 3 Mounting bolt of drive shaft between center differential and rear differential: 98 – 123 Nm {10 – 12.5 kgm} [Target: 113 Nm {11.5 kgm}] [*2]
2
k
Rear differential mounting bolt: 157 – 198 Nm {16 – 20 kgm} [Target: 177 Nm {18 kgm}]
After installing, bleed air from the brake circuit. For details, see "Testing and adjusting, Bleeding air from brake circuit".
Refilling with oil Pour the specified oil in the rear differential case and rear final drive case to the specified level. q Check the oil level in the transmission case and add the specified oil to the specified level if necessary. q Check the oil level in the hydraulic tank and add the specified oil to the specified level if necessary. q
38
HM400-2
50 Disassembly and assembly
SEN01445-02
Disassembly and assembly of rear differential assembly
3.
1
5 792T-423-1130 Push tool 6
9 H
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1 N Q
792-103-0901
Wrench
t 1
792-222-1110
Adapter
t 2
795-525-1000
Micrometer
t 1
790-501-5000
Unit repair stand
t 1
790-501-5200
Unit repair stand
t 1
790-901-2110
Bracket
t 1
793-310-2141
Plate
t 1 R Q
792T-423-1140 Push tool
t 1 N Q
790-101-5421
Grip
t 1
01010-51240
Bolt
t 1
Push tool kit
t 1
11 790-101-5401
Pinion and cage assembly 1) Using forcing screw [1], remove pinion and cage assembly (3). a Check the thickness and quantity of the shims.
790-101-5451
• Plate
1
790-101-5421
• Grip
1
01010-51240
• Bolt
1
Disassembly 1.
Set the rear differential gear assembly to tool H9.
2.
Input coupling and holder Remove holder (1) and coupling (2).
HM400-2
2)
Remove side seal (6) and oil seal (7) from pinion and cage assembly (5).
39
SEN01445-02
3)
Remove pinion assembly (8) from cage assembly (9).
4)
Disassembly of pinion assembly Remove spacer (11) and bearing inner race (12a) from pinion (10).
5)
Disassembly of cage assembly Remove bearing (14) and bearing outer race (12b) from cage (13). a The inner race of bearing (14) was removed in 3) above.
50 Disassembly and assembly
4.
Differential gear and differential lock assembly a Sling the differential case in advance. 1) Remove locks (26) and (27). 2) Using tool H6, loosen adjustment nuts (28) 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. a Take care not to drop the bearing outer race.
5)
40
Disassemble the differential gear case assembly according to the following procedure. 1] 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). 2] Remove washer (37) and pin (38). 3] Remove piston (39). q Remove seal ring (40) from piston (39).
HM400-2
50 Disassembly and assembly
4] 5]
SEN01445-02
Using a bearing puller, remove bearing inner race (41a). Remove sleeve (42).
2> Using puller [4], remove bearing inner race (50a) from bevel gear and case assembly (49). 3> Remove case (51) from bevel gear (52).
6] 7]
Remove plate (43) and disc (44). Remove pins (45) 4 pieces.
8]
Bevel gear assembly 1> Turn over the assembly and remove mounting bolts (48) 12 pieces of bevel gear assembly (47) of case (46), then remove bevel gear assembly (47). a 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).
HM400-2
41
SEN01445-02
9]
50 Disassembly and assembly
Remove washer (53) and differential side gear (54).
11] Remove washer (57), pinion gear (58), and bushing (sleeve) (59).
12] Remove side gear (60).
10] Remove pinion gear assembly (55) and cross shaft (56) in 1 unit.
42
HM400-2
50 Disassembly and assembly
Assembly
SEN01445-02
3]
Install pinion gear assembly (55) and cross shaft (56) in 1 unit.
4]
Install differential side gear (54) and washer (53).
5]
Bevel gear assembly 1> Install case (51) to bevel gear (52). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm}
a If a tool for installing a seal is not specified (for the input shaft in particular), use a push tool of a proper size for each part. 1.
Differential gear and differential lock assembly 1) Assemble the differential gear and differential lock assembly according to the following procedure. 1] Install side gear (60).
2]
HM400-2
Install bushing (sleeve) (59), pinion gear (58), and washer (57).
43
SEN01445-02
2> Install bearing inner race (50a) to bevel gear and case assembly (49) by shrink fit. a Shrink fit temperature: 120°C for 30 minutes
50 Disassembly and assembly
7]
8]
9] 10] 11]
12]
3> Install bevel gear assembly (47) to case (46). a Match the match marks to each other.
6]
44
13] 14]
Install seal ring (40) to piston (39). a Take care of the direction of the seal ring. Install seal rings (35) to case (34). a Take care of the direction of the seal rings. Install pin (38) and washer (37). Install piston (39) to case (34). Install the case and piston assembly, matching it to the position of pin (45). 3 Case mounting bolt: 157 – 196 Nm {16 – 20 kgm} Install seal ring (36) to case (34). a Take care of the direction of the seal rings. Install sleeve (42), taking care not to damage seal ring (36). Install bearing (41a) to case (34) by shrink fit. a Shrink fit temperature: 120°C for 30 minutes
Turn over the case and install pin (45), disc (44), and plate (43). a Apply engine oil (EO-30) to the surfaces of the disc and plate.
HM400-2
50 Disassembly and assembly
2.
Assembly of differential 1) Differential gear assembly 1] Install nuts (28) and (29), matching them to the grooves of differential case (61). 2] Sling gear case (62) and install the outer race to the bearing, then install them to differential case (63).
3.
Caps 1) Install caps (31) and (32) and tighten bolt (30) temporarily. 2) Using tools [5] and [6], tighten bolt (21). 3 Bolt: 824 – 1,040 Nm {84 – 105 kgm}
SEN01445-02
2)
5.
4.
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}
Assembly of pinion and cage assembly Assemble pinion and cage assembly (8) according to the following procedure. 1) Assembly of cage assembly Install bearing outer races (12b) and (14b) to cage (13).
Adjusting preload on bearing 1) Rotate the adjustment rings (28) and (29) with bar H6 until the ring gear reaches the pinion gear and the backlash is eliminated. a Rotate the bearing sufficiently so that it will come in contact with the other contact surfaces and hit the ring gear with a copper hammer, etc. a Apply sufficient amount of oil to the bearing. a If you loosened either adjustment ring by 1 turn, tighten the other one by 1 turn.
HM400-2
45
SEN01445-02
2)
50 Disassembly and assembly
Assembly of pinion assembly Install bearing inner race (12a) to pinion (10). a Install bearing inner race (12a) by shrink fit or by using push tool [7].
4)
3)
46
Using push tool [8] and turning cage assembly (9), install bearing inner race (14a). a Never push bearing inner race (14a) with a press. a Apply oil to bearing inner race (14a).
Erect pinion assembly (8) and insert spacer (11) to pinion assembly and install cage assembly (9).
HM400-2
50 Disassembly and assembly
6.
5)
Using tool H11, press fit oil seal (7). a 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). a Press fit side seal (5) so that its periphery will be flush with cage (13).
SEN01445-02
7.
Input coupling and holder Install coupling (2) and holder (1). 2 End of bearing (Part A): Grease (G2-LI) 2 End of side seal (Part B): Grease (G2-LI) 2 Holder mounting bolt: Adhesive (LT-2) 3 Holder mounting bolt: 824 – 1,030 Nm {84 – 105 kgm}
Pinion and cage assembly Set the standard shim (having the thickness and quantity checked when disassembled) and install pinion and cage assembly (3). a Execute 8. "Adjusting tooth contact and backlash", then determine the quantity and thickness of the shims.
HM400-2
47
SEN01445-02
8.
Adjusting tooth contact and backlash Adjust the backlash and tooth contact simultaneously. 1) Adjust the backlash according to the following procedure. 1] Move the bevel gear with adjustment nuts (28) and (29). At this time, turn the nuts on both sides by the same angle in the same direction so that the preload on the bearing will not change.
50 Disassembly and assembly
2)
Adjust the tooth contact according to the following procedure. 1] Adjust the projection of the bevel pinion with shim (65) between differential case (64) and transfer case (17). 2] Adjusting tooth contact a See "Adjusting tooth contact" in 3) below
3)
Adjusting tooth contact of bevel gear and bevel pinion When the backlash is below standard value Loosen the adjustment nut on the bevel gear side and tighten the adjustment nut on the right side by the same angle (to move the bevel gear in the direction of A).
q
q
2]
48
Apply dial gauge [11] 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. a Adjust the backlash at 3 – 4 places and measure it with the pinion fixed.
q
When the backlash is above standard value Loosen the adjustment nut on the left side and tighten the adjustment nut on the bevel gear side by the same angle (to move the bevel gear in the direction of B).
HM400-2
50 Disassembly and assembly
(1) Checking tooth contact Apply red lead thinly to the surfaces of 7 – 8 teeth of the bevel gear and turn the bevel gear in the forward and reverse directions, then check the tooth contact pattern on the bevel gear. a The center of the tooth contact must be as follows. q Middle of tooth height q Point on tooth at distance of (x) from small end (C) (Approx. 33% of tooth length) a Width (y) of the tooth contact must be 30 – 60% of the tooth length. a
SEN01445-02
If bevel pinion is too close to bevel gear a The tooth contact pattern is as follows. q Increase the shims of the bevel pinion to move the bevel pinion in direction (E). q Move the bevel gear in direction (F).
Check that there is not a strong contact at tip (A), bottom (B), small end (C) or large end (D).
If bevel gear is too close to bevel pinion a The tooth contact pattern is as follows. q Decrease the shims of the bevel pinion to move the bevel pinion in direction (C). q Move the bevel gear in direction (D).
(2) Adjusting tooth contact If the tooth contact pattern is not proper, adjust the tooth contact according to the procedure shown in the following page. a After adjusting the tooth contact, check the backlash again. If bevel pinion is too far from bevel gear a The tooth contact pattern is as follows. q Decrease the shims of the bevel pinion to move the bevel pinion in direction (C). q Move the bevel gear in direction (D).
HM400-2
49
SEN01445-02
50 Disassembly and assembly
If bevel gear is too far from bevel pinion a The tooth contact pattern is as follows. q Increase the shims of the bevel pinion to move the bevel pinion in direction (E). q Move the bevel gear in direction (F).
9.
50
Bevel gear supporting bolt Install bevel gear supporting bolt (66). a 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. 2 Bolt: Gasket sealant (LG-5) 3 Locknut: 196 – 245 Nm {20 – 25kgm}
HM400-2
50 Disassembly and assembly
HM400-2
SEN01445-02
51
SEN01445-02
50 Disassembly and assembly
HM400-2 Articulated dump truck Form No. SEN01445-02
© 2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (02)
52
HM400-2
SEN01446-01
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
50 Disassembly and assembly1 Power train, Part 3 Removal and installation of front final drive and brake assembly ................................................................... 2 Disassembly and assembly of front final drive and brake assembly............................................................... 4 Removal and installation of center final drive and brake assembly .............................................................. 17 Disassembly and assembly of center final drive and plate assembly ........................................................... 19 Removal and installation of rear final drive and brake assembly .................................................................. 28 Disassembly and assembly of rear final drive and brake assembly ............................................................. 30 Removal and installation of center axle assembly ........................................................................................ 40 Removal and installation of rear axle assembly............................................................................................ 43
HM400-2
1
SEN01446-01
Removal and installation of front final drive and brake assembly 1
50 Disassembly and assembly
4.
Removal 1.
Draining oil from front final drive case Drain oil from the front final drive case.
2.
Jacking up front frame 1) Jack up the front (sub) frame and support it on stand [1], etc. 2) Using jack [2], raise the front axle support.
4
5.
3.
2
Front wheels Sling the front wheels (2) temporarily, then remove the mounting bolts and front wheels (2). [*1] Front wheel assembly: 800 kg
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. [*2]
Left fender Lift of left fender (1).
HM400-2
50 Disassembly and assembly
6.
Brake cooling tubes and brake drive hose Disconnect brake cooing tubes (4) 2 pieces and brake drive hose (5).
SEN01446-01
Installation q
Carry out installation in the reverse order to removal.
[*1]
3
Front wheel mounting bolt: 824 – 1,030 Nm {84 – 105 kgm} [Target: 926 Nm {94.5 kgm}]
[*2] 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. 2 Mounting bolt of drive shaft between front differential and front final drive: Adhesive (LT-2) 3 Mounting bolt of drive shaft between front differential and front final drive: 98 – 123 Nm {10 – 12.5 kgm}
q
k
7.
Front final drive and brake and side drive shaft assembly Lift off front final drive and brake and side drive shaft assembly (6). a When removing, take extreme care that the spline at the center of the side drive shaft will not come out. 4
HM400-2
After installing, bleed air from the brake circuit. For details, see Testing and adjusting, "Bleeding air from brake circuit".
Refilling with oil q Pour the specified oil in the final drive case to the specified level. q Check the oil level in the transmission case and add the specified oil to the specified level if necessary. q Check the oil level in the hydraulic tank and add the specified oil to the specified level if necessary.
Front final drive and brake and side drive shaft assembly: 610 kg
3
SEN01446-01
50 Disassembly and assembly
Disassembly and assembly of front final drive and brake assembly
1
1
J 2
792T-422-1210 Fixture
t 3 N Q
792T-427-1110 Fixture
t 3 N Q
01010-61435
Bolt
t 3
01010-62440
Bolt
t 3
792T-422-1220 Plate
t 1 N Q
790-101-5421
Grip
t 1
01010-51240
Bolt
t 1
3 792T-422-1230 Push tool
t 1 N Q
Installer
t 1
792-530-1600
Push tool
t 1
790-434-1620
Installer
t 1
792-520-2110 5
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Disassembly 1.
2.
4
Drive shaft (1) Remove drive shaft (1). a 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).
Cover and shaft Remove cover (2) and snap ring (3), then remove shaft (4) toward the opposite side. a Drain the oil remaining in the case. a 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 level difference measured on a level place is larger than 0.3 mm, do not use it again (but replace it).
HM400-2
50 Disassembly and assembly
5.
SEN01446-01
Carrier assembly 1) Remove carrier assembly (6).
6.
Thrust washer Remove thrust washer (11).
2)
7.
Plate Using forcing screw [1], remove plate (12).
8.
Retainer and shim 1) Using tools J1 secure inner gear (13) and outer gear (14). a Install tools J1 to 3 places equally spaced on the periphery of inner gear (13). a Be sure to install tool J1 to protect the floating seal before removing retainer (15). 2) Remove the mounting bolts, retainer (15), and shim.
Disassemble the carrier assembly according to the following procedure. 1] Remove shaft (7). a Take care not to lose ball (8). 2] Remove planetary gear (9) and bearing (10).
HM400-2
5
SEN01446-01
9.
50 Disassembly and assembly
Ring gear Remove ring gear (16).
1)
Disassemble the ring gear according to the following procedure. 1] Remove mounting bolts (17) and holder (18). 2] 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). a Make match marks in advance.
10. Floating seal cage and floating seal Remove floating seal cage (21) [including a half part of floating seal (22a)]. a Use a forcing screw of M10 (long size) to remove the floating seal cage.
6
HM400-2
50 Disassembly and assembly
2)
SEN01446-01
2> Remove seal rings (28) and (29) from cylinder (26) and piston (27).
Disassemble the brake assembly according to the following procedure. 1] Remove tools J1.
2]
Remove cylinder assembly (25).
3) 3]
HM400-2
Disconnect the cylinder assembly according to the following procedure. 1> Remove piston (27) from cylinder (26).
Remove damper (end plate) (30), plate (31), and disc (32). a Check the position of notch of the plate.
7
SEN01446-01
13. Hub (Inner gear) and outer gear 1) Remove outer gear (34) from hub (inner gear) (33).
2)
8
50 Disassembly and assembly
3)
Remove floating seal (37a) from floating seal and cage assembly (36).
4)
Remove cover (39) from outer gear (38), then remove seal (40).
5)
Remove floating seal (37b) from outer gear (38).
Remove floating seal and cage assembly (36) and floating seal (22b) from hub (inner gear) (35).Check the cut of the plate.
HM400-2
50 Disassembly and assembly
14. Shaft (Tube) assembly Remove bearing inner race (42), retainer (43), seal (44), and bushing (45) from shaft (tube) (41).
SEN01446-01
Assembly a
If a tool for installing a seal is not specified (for the input shaft in particular), use a push tool of a proper size for each part.
1.
Shaft (Tube) assembly 1) Install retainer (43) to shaft (tube) (41), then using tool J4, install bearing inner race (42).
2)
HM400-2
Install bushing (45) and seal (44) to shaft (tube) (41) a Dimension (c) between shaft (tube) end and seal end: 29 ± 0.2 mm a Dimension (b) between shaft (tube) mounting part and bushing end: 5 ± 0.2 mm.
9
SEN01446-01
2.
Hub (Inner gear) and outer gear 1) Using tool J5, install floating seal (37b) to outer gear (38).
2)
3)
10
50 Disassembly and assembly
4)
Using tool J5, install floating seal (37a) to cage (46). a Measure height (A) at portion (a) of the seal above the gear, hub, and ratainer (at 4 places on the periphery) and check that its dispersion is less than 1 mm.
5)
Using tool J5, install floating seal (22b) to hub (inner gear) (35).
6)
Install floating seal and cage assembly (36) to hub (internal gear) (35).
Using tool J2, install seal (40) to outer gear (38).
Install cover (39) to outer gear (38).
HM400-2
50 Disassembly and assembly
7)
3.
Install outer gear (34) to hub (inner gear) (33). a Take extreme care that the floating seal will not be damaged or rolled up.
SEN01446-01
2)
Assemble the brake assembly according to the following procedure. 1] Assemble the cylinder assembly according to the following procedure. 1> Install seal rings (28) and (29) to cylinder (26) and piston (27).
Brake assembly 1) Install disc (32), plate (31), and damper (end plate) (30). a When installing the plate, match the 6 cuts on its per.
2> Install piston (27) to cylinder (26).
HM400-2
11
SEN01446-01
2]
Install cylinder assembly (25). Cylinder mounting bolt: 157 – 196 Nm {16 – 20 kgm}
3
3]
50 Disassembly and assembly
4.
Place the assembly with the brake side down.
5.
Floating seal cage and floating seal 1) Using tool J5, install floating seal (22a) to cage (21). a Measure height (A) at portion (a) of the seal above the gear, hub, and ratainer (at 4 places on the periphery) and check that its dispersion is less than 1 mm.
Install tools J1.
2)
3)
12
Install floating seal cage (21) {including a half part of floating seal (22a)}.
Install brake assembly (24) to shaft (23).
HM400-2
50 Disassembly and assembly
6.
Ring gear 1) Assemble the ring gear according to the following procedure. 1] Using tool J3, press fit bearing inner race (46) to inner hub (20).
Install holder (18) and tighten mounting bolts (17). 3 Holder mounting bolt: 27.5 – 34 Nm {2.8 – 3.5 kgm}
SEN01446-01
7.
Retainer and shim 1) Adjust the preload on the bearing according to the following procedure. 1] Install retainer (15) with the bolts temporarily without inserting any shim. 2] Remove tools J1 from 3 places and tighten the bolts.
2]
3] 4]
2)
Secure the brake assembly to forklift [1] etc. While rotating inner gear (13) by 20 – 30 turns, tighten 4 retainer mounting bolts alternately and evenly. a Tighten the retainer mounting bolts evenly to 78.5 ± 4.9 Nm {8 ± 0.5 kgm}. a If the retainer mounting bolts are tightened without rotating the inner gear (13), the bearing does not fit and proper preload is not applied to it.
Install ring gear (16).
HM400-2
13
SEN01446-01
5]
6]
2)
14
Using depth micrometer [2], measure distance (c) between the ends of the shaft and retainer (15). a Measure the distance at 2 places and obtain the average. 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.
Put in the shims selected in the foregoing section, install retainer (15) and tighten the mounting bolts. a Rotating inner gear (13), tighten the mounting bolt evenly until the tightening torque becomes constant. 2 Threaded parts of retainer mounting bolt: Adhesive (LT-2) 3 Retainer mounting bolt: 157 – 196 Nm {16 – 20 kgm} a After tightening the mounting bolts, turn inner gear (13) and check that it rotates normally.
50 Disassembly and assembly
8.
Shaft Install shaft (4).
9.
Plate Install plate (12).
HM400-2
50 Disassembly and assembly
10. Thrust wawher Install thrust washer (11).
11. Carrier assembly 1) Assemble the carrier assembly according to the following procedure. 1] Install bearing (10) and planetary gear (9). 2] Install shaft (7). a Be careful not to forget to put ball (8) in.
SEN01446-01
2)
Install carrier assembly (6).
12. Sun gear Install sun gear (5) and snap ring (3). a 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). 3 Cover mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
HM400-2
15
SEN01446-01
50 Disassembly and assembly
14. Drive shaft Install drive shaft (1). 2 Threaded parts of retainer mounting bolt: Adhesive (LT-2) 3 Drive shaft mounting bolt: 98 –123 Nm {10 – 12.5 kgm}.
16
HM400-2
50 Disassembly and assembly
SEN01446-01
Removal and installation of center final drive and brake assembly 1 Removal 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). [*1] 4
4.
Brake cooling tubes and brake drive hose Disconnect brake cooing tubes (2) 2 pieces and brake drive hose (3).
HM400-2
5.
Sun gear and drive shaft Remove the center final drive cover and sun gear and drive shaft (4).
6.
Center final drive assembly Lift off center final drive assembly (5).
Rear (Front) wheel assembly: 800 kg
4
Center final drive assembly: 500 kg
17
SEN01446-01
50 Disassembly and assembly
Installation q
Carry out installation in the reverse order to removal.
[*1]
3
k
Rear wheel mounting bolt: 824 – 1,030 Nm {84 – 105 kgm} [Target: 926 Nm {94.5 kgm}]
After installing, bleed air from the brake circuit. For details, see Testing and adjusting, "Bleeding air from brake circuit".
Refilling with oil q Pour the specified oil in the final drive case to the specified level. q Check the oil level in the transmission case and add the specified oil to the specified level if necessary. q Check the oil level in the hydraulic tank and add the specified oil to the specified level if necessary.
18
HM400-2
50 Disassembly and assembly
SEN01446-01
Disassembly and assembly of center final drive and plate assembly
1
1
J
2
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
792T-422-1210 Fixture
t 3 N Q
792T-427-1110 Fixture
t 3 N Q
01010-61435
Bolt
t 3
01010-62440
Bolt
t 3
792T-422-1220 Plate
t 1 N Q
790-101-5421
Grip
t 1
01010-51240
Bolt
t 1
3 792T-422-1230 Push tool
t 1 N Q
4 792T-422-1240 Push tool
t 1 N Q
5
792-520-2110
Installer
t 1
792-530-1600
Push tool
t 1
790-434-1620
Installer
t 1
Disassembly a
The sun gear was removed when the final drive and brake assembly was removed.
1.
Place the assembly with the brake side down.
2.
Carrier assembly 1) Remove carrier assembly (1).
2)
3.
Retainer and shim 1) Using tools J1, secure inner gear (6) and outer gear (7). a Install tools J1 to 3 places equally spaced on the periphery of inner gear (6). a Be sure to install tools J1 to protect the floating seal before removing retainer (8). 2) Remove the mounting bolts, retainer (8), and shim.
Disassemble the carrier assembly according to the following procedure. 1] Remove shaft (2). a Take care not to lose ball (3). 2] Remove planetary gear (4) and bearing (5).
HM400-2
19
SEN01446-01
4.
50 Disassembly and assembly
Ring gear Remove ring gear (9).
1)
Disassemble the ring gear according to the following procedure. 1] Remove mounting bolts (10) and holder (11). 2] Remove inner hub (13) from ring gear (12).
6. 7.
5.
Place the assembly with the brake side up. Brake assembly 1) Remove brake assembly (17) from shaft (16). a Make match marks in advance.
Floating seal cage and floating seal Remove floating seal cage (14) [including a half part of floating seal (15a)]. a Use a forcing screw of M10 (long size) to remove the floating seal cage.
2)
20
Disassemble the brake assembly according to the following procedure. 1] Remove tools J1.
HM400-2
50 Disassembly and assembly
2]
SEN01446-01
Remove cylinder assembly (18).
3) 3]
Disconnect the cylinder assembly according to the following procedure. 1> Remove piston (20) from cylinder (19).
Remove damper (end plate) (23), plate (24), and disc (25). a Check the cut of the plate.
2> Remove seal rings (21) and (22) from cylinder (19) and piston (20).
8.
HM400-2
Hub (Inner gear) and outer gear 1) Remove outer gear (27) from hub (inner gear) (26).
21
SEN01446-01
2)
3)
22
50 Disassembly and assembly
Remove floating seal and cage assembly (29) and floating seal (15b) from hub (inner gear) (28).
Remove floating seal (30a) from floating seal and cage assembly (29).
9.
4)
Remove cover (32) from outer gear (31), then remove seal (33).
5)
Remove floating seal (30b) from outer gear (31).
Shaft (Tube) assembly Remove bearing inner race (35) and retainer (36) from shaft (tube) (34).
HM400-2
50 Disassembly and assembly
Assembly a
If a tool for installing a seal is not specified (for the input shaft in particular), use a push tool of a proper size for each part.
1.
Shaft (Tube) assembly 1) Install retainer (36) to shaft (tube) (34), then install bearing inner race (35).
2.
SEN01446-01
3)
Install cover (32) to outer gear (31).
4)
Using tool J5, install floating seal (30a) to cage (36). a Measure height (A) at portion (a) of the seal above the gear, hub, and ratainer (at 4 places on the periphery) and check that its dispersion is less than 1 mm.
5)
Using tool J5, install floating seal (15b) to hub (inner gear) (28).
Hub (Inner gear) and outer gear 1) Using tool J5, install floating seal (30b) to outer gear (31).
2)
Using tool J2, install seal (33) to outer gear (31).
HM400-2
23
SEN01446-01
6)
50 Disassembly and assembly
Install floating seal and cage assembly (29) to hub (internal gear) (28).
2) 7)
3.
Install outer gear (26) to hub (inner gear) (27). a Take extreme care that the floating seal will not be damaged or rolled up.
Assemble the brake assembly according to the following procedure. 1] Assemble the cylinder assembly according to the following procedure. 1> Install seal rings (21) and (22) to cylinder (19) and piston (20).
Brake assembly 1) Install disc (25), plate (24), and damper (end plate) (23). a When installing the plate, match the 6 cuts on its periphery.
2> Install piston (20) to cylinder (19).
24
HM400-2
50 Disassembly and assembly
2]
Install cylinder assembly (18). Cylinder mounting bolt: 157 – 196 Nm {16 – 20 kgm}
3]
Install tools J1.
SEN01446-01
3
3)
Install brake assembly (17) to shaft (16).
4.
Place the assembly with the brake side down.
5.
Floating seal cage and floating seal 1) Using tool J5, install floating seal (15a) to cage (14). 2) Install floating seal cage (14) [including a half part of floating seal (15a)]. a Measure height (A) at portion (a) of the seal above the gear, hub, and ratainer (at 4 places on the periphery) and check that its dispersion is less than 1 mm.
HM400-2
25
SEN01446-01
6.
50 Disassembly and assembly
Ring gear 1) Assemble the ring gear according to the following procedure. 1] Using tool J3, press fit bearing inner race (39) to inner hub (13).
3]
While rotating inner gear (6) by 20 – 30 turns, tighten 4 retainer mounting bolts alternately and evenly. a Tighten the retainer mounting bolts evenly to 73.5 ± 0.98 Nm {7.5 ± 0.1 kgm}. a If the retainer mounting bolts are tightened without rotating the inner gear (6), the bearing does not fit and proper preload is not applied to it.
4]
Using depth micrometer [1], measure distance (c) between the ends of the shaft and retainer (8). a Measure the distance at 2 places and obtain the average. Remove retainer (8) 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.
2]
Install holder (11) and tighten mounting bolts (10). 3 Holder mounting bolt: 27.5 – 34 Nm {2.8 – 3.5 kgm}
5]
2)
Install ring gear (9).
2) 7.
26
Retainer and shim 1) Adjust the preload on the bearing according to the following procedure. 1] Install retainer (8) with the bolts temporarily without inserting any shim. 2] Remove tools J1 from 3 places and tighten the bolts.
Set a shim of proper thickness and retainer (8) and tighten the mounting bolts. a Rotating inner gear (6), tighten the mounting bolt evenly until the tightening torque becomes constant. 2 Threaded parts of retainer mounting bolt: Adhesive (LT-2) 3 Retainer mounting bolt: 157 – 196 Nm {16 – 20 kgm}
HM400-2
50 Disassembly and assembly a
8.
SEN01446-01
After tightening the mounting bolts, rotate inner gear (6) and check that it rotates normally.
Carrier assembly 1) Assemble the carrier assembly according to the following procedure. 1] Install bearing (5) and planetary gear (4). 2] Install shaft (2). a Be careful not to forget to put ball (3) in.
2)
Install carrier assembly (1).
a
Install the sun gear when installing the final drive and brake assembly.
HM400-2
27
SEN01446-01
50 Disassembly and assembly
Removal and installation of rear final drive and brake assembly 1
2)
Disconnect brake drive hose (3).
Removal 1.
Remove the body assembly. For details, see "Removal and installation 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 the mounting bolts to remove rear wheels (1). [*1] 4
5.
28
6.
Sun gear and drive shaft Remove the rear final drive cover and sun gear and drive shaft (4).
7.
Rear final drive and brake assembly Lift off the rear final drive and brake assembly.
Rear wheel assembly: 800 kg
Brake cooling tubes and brake drive hose 1) Disconnect brake cooing tubes (2) 2 pieces.
4
Rear final drive and brake assembly: 500 kg
HM400-2
50 Disassembly and assembly
SEN01446-01
Installation q
Carry out installation in the reverse order to removal.
[*1]
3
k
Rear wheel mounting bolt: 824 – 1,030 Nm {84 – 105 kgm} [Target: 926 Nm {94.5 kgm}]
After installing, bleed air from the brake circuit. For details, see Testing and adjusting, "Bleeding air from brake circuit".
Refilling with oil q Pour the specified oil in the final drive case to the specified level. q Check the oil level in the transmission case and add the specified oil to the specified level if necessary. q Check the oil level in the hydraulic tank and add the specified oil to the specified level if necessary.
HM400-2
29
SEN01446-01
50 Disassembly and assembly
Disassembly and assembly of rear final drive and brake assembly
2]
Remove planetary gear (4) and bearing (5).
1
1
J 2
792T-422-1210 Fixture
t 3 N Q
792T-427-1110 Fixture
t 3 N Q
01010-61435
Bolt
t 3
01010-62440
Bolt
t 3
792T-422-1220 Plate
t 1 N Q
790-101-5421
Grip
t 1
01010-51240
Bolt
t 1
3 792T-422-1230 Push tool
t 1 N Q
Installer
t 1
792-530-1600
Push tool
t 1
790-434-1620
Installer
t 1
792-520-2110 5
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Disassembly a
The sun gear was removed when the final drive and brake assembly was removed.
1.
Place the assembly with the brake side down.
2.
Carrier assembly 1) Remove carrier assembly (1).
2)
30
3.
Retainer and shim 1) Using tools J1 (Install them to 3 places on the periphery, equally spaced), secure inner gear (6) and outer gear (7). a Be sure to install tools J1 to protect the floating seal before removing retainer (8). a Install tools J1 to 3 places on the periphery, equally spaced. 2) Remove the mounting bolts, retainer (8), and shim.
Disassemble the carrier assembly according to the following procedure. 1] Remove shaft (2). a Take care not to lose ball (3).
HM400-2
50 Disassembly and assembly
4.
Ring gear Remove ring gear (9).
1)
5.
SEN01446-01
Disassemble the ring gear according to the following procedure. 1] Remove mounting bolts (10) and holder (11). 2] 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). a Make match marks in advance.
Floating seal cage and floating seal Remove floating seal cage (14) [including a half part of floating seal (15a)]. a Use a forcing screw of M10 (long size) to remove the floating seal cage.
HM400-2
31
SEN01446-01
2)
50 Disassembly and assembly
2> Remove seal rings (21) and (22) from cylinder (19) and piston (20).
Disassemble the brake assembly according to the following procedure 1] Remove tools J1.
2]
Remove cylinder assembly (18).
3) 3]
32
Disconnect the cylinder assembly according to the following procedure. 1> Remove piston (20) from cylinder (19).
Remove damper (end plate) (23), plate (24), and disc (25). a Check the cut of the plate.
HM400-2
50 Disassembly and assembly
8.
Hub (Inner gear) and outer gear 1) Remove outer gear (27) from hub (inner gear) (26).
2)
SEN01446-01
3)
Remove floating seal (30a) from floating seal and cage assembly (29).
4)
Remove cover (32) from outer gear (31), then remove seal (33).
5)
Remove floating seal (30b) from outer gear (31).
Remove floating seal and cage assembly (29) and floating seal (15b) from hub (inner gear) (28).
HM400-2
33
SEN01446-01
9.
Shaft (Tube) assembly Remove bearing inner race (35), retainer (36), seal (37), and bushing (38) from shaft (tube) (34).
50 Disassembly and assembly
Assembly a
If a tool for installing a seal is not specified (for the input shaft in particular), use a push tool of a proper size for each part.
1.
Shaft (Tube) assembly Install retainer (36) to shaft (tube) (34), then install bearing inner race (35).
2.
Hub (Inner gear) and outer gear 1) Using tool J5, install floating seal (30b) to outer gear (31).
2)
34
Using tool J2, install seal (33) to outer gear (31).
HM400-2
50 Disassembly and assembly
3)
Install cover (32) to outer gear (31).
4)
Using tool J5, install floating seal (30a) to cage (36). a Measure height (A) at portion (a) of the seal above the gear, hub, and ratainer (at 4 places on the periphery) and check that its dispersion is less than 1 mm.
5)
SEN01446-01
6)
Install floating seal and cage assembly (29) to hub (internal gear) (28).
7)
Install outer gear (26) to hub (inner gear) (27). a Take extreme care that the floating seal will not be damaged or rolled up.
Using tool J5, install floating seal (15b) to hub (inner gear) (28).
HM400-2
35
SEN01446-01
3.
50 Disassembly and assembly
Brake assembly 1) Install disc (25), plate (24), and damper (end plate) (23). a When installing the plate, match the 6 cuts on its periphery.
2> Install piston (20) to cylinder (19).
2]
Install cylinder assembly (18). Cylinder mounting bolt: 157 – 196 Nm {6 – 20 kgm}
3
2)
36
Assemble the brake assembly according to the following procedure. 1] Assemble the cylinder assembly according to the following procedure. 1> Install seal rings (21) and (22) to cylinder (19) and piston (20).
HM400-2
50 Disassembly and assembly
3]
3)
SEN01446-01
Install tools J1.
Install brake assembly (17) to shaft (16).
4.
Place the assembly with the brake side down.
5.
Floating seal cage and floating seal 1) Using tool J5, install floating seal (15a) to cage (14). 2) Install floating seal cage (14) {including a half part of floating seal (15a)}. a Measure height (A) at portion (a) of the seal above the gear, hub, and ratainer (at 4 places on the periphery) and check that its dispersion is less than 1 mm.
HM400-2
37
SEN01446-01
6.
50 Disassembly and assembly
Ring gear 1) Assemble the ring gear according to the following procedure. 1] Using tool J3, press fit bearing inner race (39) to inner hub (13).
3]
While rotating inner gear (6) by 20 – 30 turns, tighten 4 retainer mounting bolts alternately and evenly. a Tighten the retainer mounting bolts evenly to 73.5 ± 0.98 Nm {7.5 ± 0.1 kgm}. a If the retainer mounting bolts are tightened without rotating the inner gear (6), the bearing does not fit and proper preload is not applied to it.
4]
Using depth micrometer [1], measure distance (c) between the ends of the shaft and retainer (8) a Measure the distance at 2 places and obtain the average. Remove retainer (8) 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.
2]
Install holder (11) and tighten mounting bolts (10). 3 Holder mounting bolt: 27.5 – 34 Nm {2.8 – 3.5 kgm}
5]
2)
Install ring gear (9).
2) 7.
38
Retainer and shim 1) Adjust the preload on the bearing according to the following procedure. 1] Install retainer (8) with the bolts temporarily without inserting any shim. 2] Remove tools J1 from 3 places and tighten the bolts.
Set a shim of proper thickness and retainer (8) and tighten the mounting bolts. a Rotating inner gear (6), tighten the mounting bolt evenly until the tightening torque becomes constant. 2 Threaded parts of retainer mounting bolt: Adhesive (LT-2) 3 Retainer mounting bolt: 157 – 196 Nm {16 – 20 kgm}
HM400-2
50 Disassembly and assembly a
8.
SEN01446-01
After tightening the mounting bolts, rotate inner gear (6) and check that it rotates normally.
Carrier assembly 1) Assemble the carrier assembly according to the following procedure. 1] Install bearing (5) and planetary gear (4). 2] Install shaft (2). a Be careful not to forget to put ball (3) in.
2)
Install carrier assembly (1).
a
HM400-2
Install the sun gear when installing the final drive and brake assembly.
39
SEN01446-01
50 Disassembly and assembly
Removal and installation of center axle assembly 1 Removal k
Disconnect the cable from the negative (–) terminal of the battery.
1.
Remove the body assembly. For details, see "Removal and installation of body assembly".
2.
Jacking up frame 1) Jack up the rear frame and support it on stand [1], etc. 2) Using jacks [2] and [3], raise the center axle and rear axle.
3.
Rear (Front) wheels Sling both rear (front) wheels temporarily, then remove the mounting bolts and rear (front) wheels (1). [*1] 4
Rear (Front) wheel assembly: 800kg
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. [*2]
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 sling and fix it to the rear frame. [*3] 4
4.
40
Drive shaft between hitch frame and center differential:85 kg
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).
HM400-2
50 Disassembly and assembly
7.
Lateral rod Remove lateral rod (10) [*4] 4
8.
9.
Lateral rod: 60 kg
Equalizer bar spring Remove equalizer bar spring (11). [*5]
Center axle and arm assembly 1) Sling center axle and arm assembly (12) temporarily.
2)
SEN01446-01
Installation q
Carry out installation in the reverse order to removal.
[*1]
3
Center wheel mounting bolt: 824 – 1,030 Nm {84 – 105 kgm} [Target: 926 Nm {94.5 kgm}]
[*2] a 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. 2 Mounting bolt of drive shaft between center differential and rear differential: Adhesive (LT-2) 3 Mounting bolt of drive shaft between center differential and rear differential: 98 – 123 Nm {10 – 12.5 kgm} [Target: 113 Nm {11.5 kgm}] [*3] a When installing the lateral rod, match tap hole (a) to the center line of bearing (15) as shown in Fig.
Remove holder plate (13) of the center axle arm support, then remove center axle and arm assembly (12) down. 4 Center axle and arm assembly: 2,200kg
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41
SEN01446-01
50 Disassembly and assembly
[*4] a Install the center axle and arm assembly so that dimensions (X), (Z) and (Y) will be as follows. Distance (X) between rear suspension cylinder pins: 574 mm Distance (Z) between rear axle top and rear frame bottom: 130 mm Distance (Y) between rear frame top and equalizer spring top: 201 mm
k
a
After installing, bleed air from the brake circuit. For details, see Testing and adjusting, "Bleeding air from brake circuit". Adjust the suspension cylinder length. For details, see Testing and adjusting, "Testing and adjusting suspension cylinder".
Refilling with oil Check the oil level in the transmission case and add the specified oil to the specified level if necessary. q Check the oil level in the hydraulic tank and add the specified oil to the specified level if necessary. q
42
HM400-2
50 Disassembly and assembly
SEN01446-01
Removal and installation of rear axle assembly 1 Removal k
Disconnect the cable from the negative (–) terminal of the battery.
1.
Remove the body assembly. For details, see "Removal and installation of body 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].
3.
Rear (Rear) wheels Sling both rear (rear) wheels temporarily, then remove the mounting bolts and rear (rear) wheels (1). [*1] 4
4.
Rear (Rear) wheel assembly: 800 kg
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. [*2]
6.
Lateral rod Remove lateral rod (9). [*3] 4
Lateral rod: 60 kg
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).
HM400-2
43
SEN01446-01
7.
Bracket (left) Remove bracket (left) (10).
8.
Rear axle and arm assembly 1) Sling rear axle and arm assembly (11) temporarily.
2)
44
50 Disassembly and assembly
3)
Pull out lower pin (14) of rear suspension cylinder (13) and remove rear axle and arm assembly (11) down. [*4] 4 Rear axle and arm assembly: 2, 200 kg
Remove holder plate (12) of the rear axle arm support pin.
HM400-2
50 Disassembly and assembly
Installation q
Carry out installation in the reverse order to removal.
[*1]
3
Rear wheel mounting bolt: 824 – 1,030 Nm {84 – 105 kgm} [Target: 926 Nm {94.5 kgm}]
[*2] a 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. 2 Mounting bolt of drive shaft between center differential and rear differential: Adhesive (LT-2) 3 Mounting bolt of drive shaft between center differential and rear differential: 98 – 123 Nm {10 – 12.5 kgm} [Target: 113 Nm {11.5 kgm}] [*3] a When installing the lateral rod, match tap hole (a) to the center line of bearing (15) as shown in Fig.
SEN01446-01
[*4] a Install the center axle and arm assembly so that dimensions (X), (Z) and (Y) will be as follows. Distance (X) between rear suspension cylinder pins: 574 mm Distance (Z) between rear axle top and rear frame bottom: 130 mm Distance (Y) between rear frame top and equalizer spring top: 201 mm
k
a
After installing, bleed air from the brake circuit. For details, see Testing and adjusting, "Bleeding air from brake circuit". Adjust the suspension cylinder length. For details, see Testing and adjusting, "Testing and adjusting suspension cylinder".
Refilling with oil q Check the oil level in the transmission case and add the specified oil to the specified level if necessary. q Check the oil level in the hydraulic tank and add the specified oil to the specified level if necessary.
HM400-2
45
SEN01446-01
50 Disassembly and assembly
HM400-2 Articulated dump truck Form No. SEN01446-01
© 2007 KOMATSU All Rights Reserved Printed in Japan 02-07 (02)
46
HM400-2
SEN01447-02
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
50 Disassembly and assembly1 Undercarriage and frame Removal and installation of front suspension cylinder assembly .................................................................... 2 Removal and installation of rear suspension cylinder assembly..................................................................... 4 Removal and installation of equalizer bar assembly ....................................................................................... 5 Removal and installation of front wheel assembly .......................................................................................... 7 Removal and installation of rear front wheel assembly................................................................................... 8 Removal and installation of rear rear wheel assembly ................................................................................... 8 Removal and installation of hitch frame assembly .......................................................................................... 9 Disassembly and assembly of hitch frame.................................................................................................... 15 Removal and installation of body assembly .................................................................................................. 18
HM400-2
1
SEN01447-02
50 Disassembly and assembly
Removal and installation of front suspension cylinder assembly 1 Removal 1.
Jacking up 1) Jack up the front (sub) frame and support it on stand [1], etc. 2) Using jack [2], raise the front axle support.
a
4. 2.
Left fender Lift off left fender (1).
3.
Front wheels Sling the front wheels (2) temporarily, then remove the mounting bolts and front wheels (2). [*1] 4
2
Check that the front frame is jacked up. Referring to Testing and adjusting, "Testing and adjusting suspension cylinder", release the nitrogen gas from the front suspension cylinder.
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]
Front wheel assembly: 800 kg
HM400-2
50 Disassembly and assembly
SEN01447-02
Installation q
Carry out installation in the reverse order to removal.
[*1]
3
Front wheel mounting bolt: 824 – 1,030 Nm {84 – 105 kgm} [Target: 926 Nm {94.5 kgm}]
[*2] a Adjust the suspension cylinder length. For details, see Testing and adjusting, "Testing and adjusting suspension cylinder".
HM400-2
3
SEN01447-02
Removal and installation of rear suspension cylinder assembly 1
50 Disassembly and assembly
3.
Removal a
Release nitrogen gas from the rear suspension cylinder. For details, see Testing and adjusting, "Testing and adjusting suspension cylinder".
1.
Jacking up 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. [*1]
k
Rear suspension cylinder Using balancing rod [3], etc., remove upper and lower pins (3) and (4) and rear suspension cylinder assembly (5). [*2]
Since the lateral rod cannot be slung, secure it (with a rope, etc.) and remove it, watching your steps carefully.
4
Lateral rod: 60 kg
Installation q
Carry out installation in the reverse order to removal.
[*1] a When installing the lateral rod, match tap hole (a) to the center line of bearing (15) as shown in figure.
2.
Bracket Remove bracket (2).
[*2] a Adjust the suspension cylinder length. For details, see Testing and adjusting, "Testing and adjusting suspension cylinder".
4
HM400-2
50 Disassembly and assembly
Removal and installation of equalizer bar assembly
SEN01447-02
3)
1
4
Removal k k
1.
Remove rod pin (3) and hoist cylinder (4). [*2] Hoist cylinder: 230 kg
Open the manual valve in the hydraulic tank to release the internal pressure. Loosen the oil filler cap to release the remaining pressure from the hydraulic tank. Release the nitrogen gas. Release nitrogen gas from the rear suspension cylinder. For details, see Testing and adjusting, "Testing and adjusting suspension cylinder". [*1]
q
2. 3.
Remove the body assembly. For details, see "Removal and installation of body assembly". Remove the hoist cylinder. 1) Disconnect hoses (1) and (2) a Plug the hoses to prevent the oil from flowing out. k Pull the hoist cylinder toward inside of the machine body in advance. (If the rod pin is removed, the hoist cylinder falls (swings). Accordingly, be sure to pull the cylinder toward inside of the machine body in advance.)
2)
4.
Remove the rear wheels (front and rear) on the side from which the equalizer bar will be removed. For details, see "Removal and installation of rear wheel assembly".
5.
Remove bottom pin (5) of the rear suspension cylinder and bring cylinder (6) down toward the rear of the vehicle body.
6.
Remove 4 mounting bolts (8) of the equalizer bar above cushion (7).
Sling the hoist cylinder temporarily and bring it down at a right angle to vehicle body.
HM400-2
5
SEN01447-02
50 Disassembly and assembly
7.
Sling the equalizer bar temporarily.
Installation
8.
Remove 6 mounting bolts (10) of plate (9) at the center of the equalizer bar. [*3]
q
9.
Using forcing screw [1], remove bushing (11).
Carry out installation in the reverse order to removal.
[*1] Refill the rear suspension cylinder with nitrogen gas. For details, see "Testing and adjusting suspension cylinder". [*2]
3
10. Lift off equalizer bar (12). 4
Equalizer bar: 220 kg
Rod pin: 157 – 196 Nm {16 – 20 kgm}
[*3] a When installing, measure the distances (a), (b) and (c) between the machine body and equalizer bar and adjust the difference between distances (a) and (b) and between (c) and (d) will not exceed 2 mm respectively. 3 Plate Diameter of thread: 24 mm: 824 – 1,030 Nm {84 – 105 kgm} Diameter of thread: 14 mm: 157 – 196 Nm {16 – 20 kgm} a Install so that dimensions (X), (Z) and (Y) will be as follows. Distance (X) between rear suspension cylinder pins: 574 mm Distance (Z) between rear axle top and rear frame top: 130 mm Distance (Y) between rear frame top and equalizer spring top: 201 mm
Adjusting body a Adjust the body positioner. For details, see Testing and adjusting, "Adjusting body positioner". Refilling with oil a Add engine oil (TO10) up to the specified level and start the engine. Raise and lower the body 2 to 3 times to check the oil level again.
6
HM400-2
50 Disassembly and assembly
Removal and installation of front wheel assembly 1
SEN01447-02
Installation q
Removal 1.
Jacking up 1) Jack up the front (sub) frame and support it on stand [1], etc. 2) Using jack [2], raise the front axle support.
2.
Left fender Lift off left fender (1).
3.
Front wheels Sling the front wheels (2) temporarily, then remove the mounting bolts and front wheels (2). [*1] 4
HM400-2
Carry out installation in the reverse order to removal.
[*1]
3
Front wheel mounting bolt: 824 – 1,030 Nm {84 – 105 kgm} [Target: 926 Nm {94.5 kgm}]
Front wheel assembly: 800 kg
7
SEN01447-02
50 Disassembly and assembly
Removal and installation of rear front wheel assembly 1
Removal and installation of rear rear wheel assembly 1
Removal
Removal
1.
Draining oil from center final drive case Drain the oil in the center final drive case.
1.
2.
Jacking up center axle Jack up the center axle.
Remove the body assembly, referring to "Removal of body assembly". a When using a forklift truck for removal, the work in this item may be skipped over.
2. 3.
Rear front wheel Sling the rear front wheel temporarily and remove the mounting bolts to detach rear front wheel (1). [*1]
Jacking up rear axle Jack up the rear axle.
3.
Rear rear wheel Sling the rear rear wheel temporarily and remove the mounting bolts to detach rear rear wheel (1). [*1]
4
Rear front wheel assembly: 800 kg.
4
Rear rear wheel assembly: 800 kg
Installation q
Carry out installation in the reverse order to removal.
Installation q
[*1]
3
8
Rear front wheel mounting bolt: 824 – 1,030 Nm {84 – 105 kgm} [Target: 926 Nm {94.5 kgm}]
Carry out installation in the reverse order to removal.
[*1]
3
Rear rear wheel mounting bolt: 824 – 1,030 Nm {84 – 105 kgm} [Target: 926 Nm {94.5 kgm}]
HM400-2
50 Disassembly and assembly
Removal and installation of hitch frame assembly 1
SEN01447-02
2.
Parking brake assembly 1) Release the parking brake. 2) Remove pad expansion spring bracket (12). [*2] 3) Remove the mounting bolts of plate (13) and parking brake and cylinder assembly (14).
3.
Drive shaft between hitch frame and center differential Remo ve the guar d a nd d ri ve sh aft ( 15) between the hitch frame and center differential. [*3]
Removal k k
1.
Disconnect the cable from the negative (–) terminal of the battery. Raise the dump body and insert the lock pin. Piping, hoses, and wiring harnesses 1) Disconnect hoist cylinder hoses (1) and (2), differential lock hose, brake hoses (3) – (6), brake cooling hoses (7) and (8), and parking brake hose (9). [*1] 2) Disconnect joint connectors (CN-J015) (10) and (CN-J013) (11) and differential lock connector (CN-B36).
4
HM400-2
Drive shaft between hitch frame and center differential: 80 kg
9
SEN01447-02
4.
50 Disassembly and assembly
Parking brake disc and coupling assembly Remove the coupling holder, then remove parking brake disc and coupling assembly (16) [*4] 4
7.
Steering cylinder Remove head pin (19) and disconnect steering cylinders (20) (on both sides). [*6]
8.
Jacking up vehicle body 1) [Front operator's cab side] 1] Sling the front part with a crane (chain [1]) 2] Place a stand under the rear frame for safety.
Parking brake and coupling assembly : 55 kg
5.
Parking brake bracket. Remove parking brake bracket (17). 4
Parking brake bracket : 55 kg
2) 6.
Drive shaft between transmission and hitch frame Remove the guard. Sling and disconnect the transmission end of drive shaft (18) between the transmission and hitch frame. [*5] 4
10
[Rear body side] 1] Support the rear body end with block [2] etc. 2] Support the front frame with a jack, etc. for safety.
Drive shaft between transmission and hitch frame: 55 kg
HM400-2
50 Disassembly and assembly
9.
SEN01447-02
Hinge pins 1) Align the hinge pins by finely moving the rear part of the front frame and the front part of the rear frame up and down with jacks [3] and [4].
2) 3) 4)
Remove plate (21) and pin lock plate (21A) and remove (pull down out) upper hinge pin (22). Remove pin bushing (21B) upward. Remove (pull up out) lower hinge pin (23) with a jack etc. [*7]
HM400-2
10. Disconnection of front and rear sections Hold the front part of the front frame with a forklift and a crane and move it forward to disconnect from the rear frame. k Keep the level of the sections around the pins in the forward-backward directions until the rear part of the front f rame is separated f rom th e hit ch frame. k Check that there are clearances (a) and (b) between the rear part of the front frame and the hitch frame, and then disconnect the front frame from the rear frame. k Move the rear part of the front frame 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.
11
SEN01447-02
50 Disassembly and assembly
11. Hitch frame assembly 1) Remove rear seal and retainer (large) assembly (24). [*8]
12
2)
Using forcing screw [5], remove end retainer (25). [*9]
3)
While pulling out hitch frame assembly (26) forward, lift it off. a When pulling out the hitch frame assembly forward, hold bearing inner race (26a) so that it will not fall. a Push out the side end of hitch frame (26) forward with a thin and small puller etc., and the hitch frame will be pulled out easily. a 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.
HM400-2
50 Disassembly and assembly
Installation q
Carry out installation in the reverse order to removal
[*1] a Bleed air from the brake circuit. For details, see Testing and adjusting, "Bleeding air from brake circuit". [*2] a Test the wear of the brake pad and adjust the brake pad clearance. For details, see Testing and adjusting, "Testing wear of parking brake pad". [*3] a Before installing, check that the yoke of drive shaft between the hitch frame and center differential and the yoke of drive shaft between center differential and rear differential are shifted from each other by 45° ± 6°. 2 Mounting bolt of drive shaft between hitch frame and center differential: Adhesive (LT-2) 3 Mounting bolt of drive shaft between hitch frame and center differential: 157 – 198 Nm {16 – 20 kgm} [Target: 177 Nm {18 kgm}] [*4]
2 2
3
Coupling spline: LM-G Coupling bolt: Adhesive (LT-2) Coupling bolt: 824 – 1,030 Nm {84.0 – 105.0 kgm}
[*5] a When installing the drive shafts, check that convex section on the spider cap completely engages with groove of the counter yoke, and then tighten the mounting bolts. 2 Mounting bolt of drive shaft between transmission and hitch frame: Adhesive (LT-2) 3 Mounting bolt of drive shaft between transmission and hitch frame: 157 – 198 Nm {16 – 20 kgm} [Target: 177 Nm {18 kgm}] [*6]
k
SEN01447-02
[*7] a Install the hinge pin in the following steps. 1) Set bushing (58) to the front frame. 2) Set bushing (35) to the hitch frame and match the articulation center (position of center pin) by moving the front frame assembly to the rear. 2 Dust seal lip face: Grease (G2-LI) 3) Insert lower hinge pin (34) from above. 2 Dust seal lip face: Grease (G2-LI) 2 Bearing inside perimeter: Lubricant containing molybdenum disulfide (LM-P) 4) Install 2 O-rings (33). 2 O-ring: Grease (G2-LI) 5) Measure thickness (f) of retainer (30). 6) Insert upper hinge pin (31) from below. 2 Dust seal lip: Grease (G2-LI) 2 Upper hinge pin outside perimeter: Lubricant containing molybdenum disulfide (LM-P) 7) Assemble bushing (32) from above. 8) Assemble retainer (30) by tightening the mounting bolt (52). 3 Retainer mounting bolt: 245 – 309 Nm {25.0 – 31.5 kgm} a After confirming thorough running-in of each contact surface, tighten mounting bolt (52) again to the specified torque. 9) Measure dimension (gg) with clearance between top of retainer (30) and the front frame at 3 points. 10) Select appropriate shims and assemble them in so that the total shim thickness is (g), i.e. the difference between (gg) and (f) dimensions (g = gg – f) minus 0.08 to 0.18 mm. 0.08 < g = gg – f < 0.18 (mm) q Kind of shim thickness: 0.1 mm and 0.5 mm q Standard shim thickness: 2 mm 11) Install a combination of the selected shims to retainer (30) and tighten retainer mounting bolts (52) and (53). 2 Retainer mounting bolt: Liquid adhesive (LT-2) 3 Retainer mounting bolt: 245 – 309 Nm {25.0 – 31.5 kgm}
When aligning the pinholes, never put a finger into the hole.
HM400-2
13
SEN01447-02
50 Disassembly and assembly
3) 4)
5) 6)
Measure dimension (d) with a micrometer. Rotate hitch frame (37) by 5 – 6 turns, then repeat steps 2) and 3) above. a Repeat steps 2) – 4) above until dimension (d) is stabilized. Combine shims so that difference (e) of the measured values = (d – t) will be 0 – 0.15 mm. After finishing the above adjustment, tighten all mounting bolts (36) to the following torque. 3 Mounting bolt: 385 Nm {39.25 kgm} (Target)
[*8] a When installing rear seal (27) to rear retainer (28), use push tool [6] matched to the diameter of the seal.
[*9] a 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 (36) (3 pieces) to the following torque without inserting shim (29). 3 Mounting bolt: 68.6 Nm {7 kgm}
14
HM400-2
50 Disassembly and assembly
Disassembly and assembly of hitch frame
SEN01447-02
3.
1
Center shaft 1) Remove center shaft and bearing assembly (8) from hitch frame (7).
Disassembly 1.
Coupling Remove coupling holder (1) and coupling (2).
2)
2.
Remove rear bearing (10) and front bearing inner race (11a) from center shaft (9).
Rear retainer 1) Using forcing screw [1], remove retainer assembly (3).
4.
2)
Remove ring (5), dust seal (6), grease fitting (19), and nipple (20) from rear retainer (4).
HM400-2
Disassembly of hitch frame 1) Remove front cage assembly (13), ring (14), front bearing outer race (11b), and rings (15) and (16) from hitch frame (12). 2) Remove dust seal (18) from front cage (17).
15
SEN01447-02
Assembly a
If a tool for installing a seal is not specified (for the input shaft in particular), use a push tool of a proper size for each part.
1.
Center shaft Using the push tool, press fit rear bearing (10) and bearing inner race (11a) to center shaft (9).
2.
Assembly of hitch frame Install ring (15) and front bearing outer race (11b) to the front side of hitch frame (12). Install ring (16) to the rear side of the hitch frame (12). 2 Fill the inside space of ring (15) with grease [Part A: 100 % pack (127 g), Part B: 100 % pack (147 g)]. 2 Fill the inside space of front bearing outer race (11b) with grease [Part C: 100 % pack (123 g)]. 2 Fill the inside space of rear bearing (10) with grease [Part D: 100 % pack (85 g)]. a Fill with grease: G2-LI
16
50 Disassembly and assembly
3.
Installation of center shaft and bearing assembly Install the center shaft and bearing assembly (8) to hitch frame (7) carefully from rear. a At this time, press fit rear bearing (10) to hitch frame (7), too. 2 Fill the inside space of rear bearing (10) with grease [Part D: 100 % pack (85 g)]. a Fill with grease: G2-LI (For part D, see 2 above.)
HM400-2
50 Disassembly and assembly
4.
Ring and front cage assembly 1) Install ring (14) to hitch frame (12). 2) Install dust seal (18) and O-ring to front cage (17), then install front cage (13) to hitch frame (12). 2 Apply grease to the lip of dust seal (18). 2 Fill the inside space of dust seal (18) with grease [Part F: Full pack (25 g), Part E: 100 % pack (123 g)]. a Fill with grease: G2-LI
5.
Coupling Install coupling (2) and coupling holder (1). 2 Coupling spline: LM-G 3 Coupling bolt: 824 – 1,030 Nm {84.0 – 105.0 kgm}
HM400-2
SEN01447-02
6.
Rear retainer 1) Press fit dust seal (6) to rear retainer (4). 2 Lip: Grease (G2-LI) 2) Install ring (5) and O-ring to rear retainer (4). a Fill the groove of the ring with grease of about 85 g. 2 Groove of ring: Grease (G2-LI) 3) Install nipple (20) and grease fitting (19) to rear retainer (4). 4) Install rear retainer assembly (3). a Supply grease of 200 g to the retainer through the grease fitting (19). 2 Inside of retainer: Grease (G2-LI)
17
SEN01447-02
Removal and installation of body assembly 1
50 Disassembly and assembly
3.
Sling the body temporarily.
4.
Disconnect body potentiometer linkage (2) from the body.
5.
Remove body hinge pins (3) on both sides. [*2]
6.
Lift off body assembly (4). [*3]
Removal 1.
Remove right and left hoist cylinder rod pins (1). [*1] a Sling the bottom of the hoist cylinder. a After removing pin (1) from each cylinder rod, pull the hoist cylinder toward the machine body with lever block [1] to prevent it from falling down. k If rod pin (1) is removed, the hoist cylinder falls outward. Accordingly, be sure to pull the cylinder toward inside of the machine body in advance.
4
2.
18
Body assembly: 4,450 kg
While loosening lever block [1], lower the crane to place the bottom of the hoist cylinder on the tire. a Place block (2) between the bottom of the hoist cylinder and tire. a Pull the hoist cylinder toward the machine body with lever block [1] to prevent it from falling down.
HM400-2
50 Disassembly and assembly
Installation q
Carry out installation in the reverse order to removal.
[*2] a When installing the body hinge pin, check the thickness and quantity of the shims. 3 Body hinge pin: 157 – 196 Nm {16 – 20 kgm]
"Open" manual valve (9) installed to hydraulic tank (8) and align the pin holes with a bar etc. After aligning the pin holes, be sure to close the manual valve.
q
[*1]
k
SEN01447-02
Procedure for "opening" manual valve 1) Loosen locknut (9a). 2) Rotate shaft (9b) counterclockwise to "Open" the valve. 3) Rotate shaft (9b) clockwise and fix it with locknut (9a).
3
[*3] Adjustment of body mount shims 1) Install spacer (5) 58 mm high to the end of body (4). (1 place on each side) 2) Measure clearance (a) between the center of the mounting part of bottom mount (6) and frame top (7). a Measure at (A), (B), and (C) on both side, 6 places in total.
Bottom pin (Diameter of thread: 14 mm): 157 – 196 Nm {16 – 20 kg}
3) 4) 5) 6)
HM400-2
Calculate the thickness of the shims to be installed to each part. a Thickness of shims = (a – 26) mm Insert shims of the calculated thickness. a Standard thickness of shims: 4 mm Lower the body and check that all of the 6 parts of the bottom mount are in contact with the frame top. After installing the body, adjust the body positioner sensor. a For details, see Testing and adjusting volume, "Adjusting body positioner sensor".
19
SEN01447-02
50 Disassembly and assembly
HM400-2 Articulated dump truck Form No. SEN01447-02
© 2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (02)
20
HM400-2
SEN01448-02
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
50 Disassembly and assembly1 Hydraulic system Disassembly and assembly of steering valve ................................................................................................. 2 Removal and installation of flow amplifier valve assembly ........................................................................... 12 Removal and installation of hoist valve assembly......................................................................................... 14 Disassembly and assembly of hoist valve assembly .................................................................................... 16 Disassembly and assembly of steering cylinder assembly ........................................................................... 18 Disassembly and assembly of hoist cylinder assembly ................................................................................ 24
HM400-2
1
SEN01448-02
50 Disassembly and assembly
Disassembly and assembly of steering valve
1
Component parts
Tools needed for disassmbly and assembly q Torque wrench (torque capacity: 49 Nm {5 kgm}) q 5/12 in - 12 point socket q Flat-headed screwdriver (large) q Flat-headed screwdriver (small) q Spring insertion tool (P/N: 600057) q 3/16 in hexagonal wrench
2
q q q q q
Plastic hammer Small amount of grease Vise Oil-based felt pen Tweezers
HM400-2
50 Disassembly and assembly
SEN01448-02
Parts list Part No.
Part name
Q‘ty
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
Remarks
Centering spring
6
For standard input torque specification
Centering spring
4
For low input torque specification
14
Flat spring
15
Race bearing
(2) 1
16
Thrust needle
1
17
O-ring
1
18
Oil seal
1
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
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
HM400-2
Only for low input torque specification
X-ring or Teflon seal
(Cannot be disassembled)
Seal kit (X-ring)
Part No.: BA0271A
Seal kit (Teflon seal)
Part No.: BA0273A
3
SEN01448-02
Disassembly a a
k
1.
2.
4
50 Disassembly and assembly
3.
Remove spacer (5) inside spline on inside of star of Gerotor (4). Remove Gerotor (4). Be careful not to drop star from ring of outer cicumference of Gerotor. Remove O-ring (22) from Gerotor.
4.
Remove drive (8), then remove spacer plate (7). Remove O-ring (23) from housing.
5.
Using flat-headed screwdriver, remove adapter screw (39). Remove housing from vise, set upside down, then remove ball (40). a Be careful not to drop or lose the ball.
When disassembling the valve, cleanliness is extremely important. Carry out the work in a clean place. In the following explanation diagrams, it is not absolutely necessary to hold the unit in a vise, but it is recommended to use a vise as far as possible. Be extremely careful not to injure yourself on the edges of sleeves, spool, housing, and other machined parts. Put end cap (3) at the top, fit side face of housing between copper sheets in vise [8], and be careful not to tighten vise too strongly.
Remove 6 screws (1) and 1 retainer screw (2), then remove end cap (3). Remove O-ring (22) from end cap (3).
HM400-2
50 Disassembly and assembly
6.
Set housing upside down, remove 2 springs (31), 2 retainer plugs (30), and 2 balls (32). a Be careful not to drop or lose the parts.
7.
Set on clean cloth with flange surface of housing facing up to prevent damage to finished surface. Use flat-headed screwdriver to raise tip of retaining ring (20), then remove from housing. k The retaining ring may fly out from the housing, so always wear protective glasses.
SEN01448-02 a
9.
8.
Set housing on clean cloth with axial line of valve horizontal. Turn spool and sleeve assembly to set sleeve pin in horizontal position, then push out spool and sleeve assembly slightly, and remove seal gland bushing (21) from housing. Remove oil seal and dust seal from gland bushing.
HM400-2
When removing the seal, be careful not to damage the seal gland bushing.
Remove 2 race bearings (15) and thrust needle (16).
10. Push spline portion inside spool with thumb and remove spool and sleeve assembly from opposite side of housing flange. When doing this, be careful not to let outside diameter of sleeve get caught in inside diameter of housing. a Depending on the assembly of sleeve and spool, it may not work properly if it is assembled 180° from the proper direction, so make marks to show the position of spool and sleeve (43). Remove pin (12). k Center spring (13) may jump out of the spool. Accordingly, be sure to put on safety glasses.
5
SEN01448-02
11. Push out spool inside sleeve slightly, and remove centering spring (13) carefully by hand from spool.
50 Disassembly and assembly
14. Disassembly of overload 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). a The valve seat is stuck to the housing and cannot be removed.
12. Rotate spool slowly and pull out spool (11) from sleeve (10). Remove O-ring from housing.
13. Disassembly of steering relief valve Using hexagonal wrench (width across flats: 3/ 16 inch), remove plug (28). Remove O-ring (29) from plug. Using tweezers, remove spring (27) and poppet (26). a The valve seat is stuck to the housing and cannot be removed.
6
HM400-2
50 Disassembly and assembly
Assembly a
k
a
a
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 modify with a file. Be extremely careful not to injure yourself on the edges of sleeves, spools, housing, and other machined parts. As a basic rule, assemble new O-rings and seal after disassembling. Coat the O-rings 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.
2.
Align 2 spring grooves st 180° in spool and sleeve, then stand on a horizontal plate. Insert spring insertion tool (Part No.: 600057) in spring groove, then fit centering spring to insertion tool so that notched portions at both ends are at bottom.When doing this, it is easier to insert if spool is lifted up slightly from sleeve. Hold 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.
HM400-2
SEN01448-02 k
3.
The centering spring may fly out from the spool, so always wear protective glasses.
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. a 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. a Insert so that the end face of the spool and sleeve assembly is level with the end face of the housing. If it is inserted further, the pin will fall inside the housing, so stop inserting when the end face is level.
7
SEN01448-02
4.
50 Disassembly and assembly a
Place housing on clean flat surface, then assemble O-ring (17). Assemble 2 race bearings (15) and thrust needle (16). Always insert thrust needle between race bearings.
6. 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. a There are two types of seal: Teflon seal and standard seal. a Assemble the oil seal carefully so that there is no twisting or deformation. a The diagram below is the Teflon seal specification drawing; (44) is the distinguishing groove.
After assembling seals, rotate seal gland bushing (21) and insert to spool. Tap with plastic hammer to insert to specified position. Assemble retaining ring (20) to housing. a Push open with a flat-headed screwdriver so that the whole circumference of the retaining ring fits securely in the groove in the housing. k The retaining ring may fly out from the housing, so always wear protective glasses.
a
8
The diagram below is the standard seal specification drawing.
Seal assembly drawing Screwdriver [9], dust seal (19), retaining ring (20), seal gland bushing (21), oil seal (18), O-ring (17).
HM400-2
50 Disassembly and assembly
7.
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.
8.
Assembly of overload relief valve Assemble O-ring (38) to plug (37). Fit grease to ball holder (35) and install ball (34). Using tweezers, assemble ball holder (35) and spring (36) to housing. Using hexagonal wrench (width across flats: 3/16 inch), assemble plug (37) to housing. a The size of the overload valve ball and the anti-cavitation check valve ball is different, so be careful not to mix them.
HM400-2
SEN01448-02
9.
Assembly of anti-cavitation check valve Grip the port surface and side surface of the housing lightly in a vise. Fit copper sheets in the vise, and be careful not to tighten the vise 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. a Be careful not to drop or lose the ball. a Be careful of the assembly direction of the retainer plug.
10. Assembly of gerotor Lightly hold the housing by sides (45) of the ports section with a vise (the part 25 mm wide to hold with the vise). Apply copper plates etc. to the vise and take care not to tighten too strongly.
9
SEN01448-02
11. Of the 7 bolt holes in the end face of the housing, insert ball (40) in the holes shown in the drawing. Assemble adapter screw (39) in holes in same drawing.
12. Assemble O-ring (23) to housing. Set spacer plate (7) on top and align position of bolt holes. a The pitch diameter of the bolt holes and oil holes is different.
50 Disassembly and assembly
14. Assemble O-ring (22) to Gerotor (4).
15. Set the O-ring side of the gerotor end face to spacer plate (7) side. While matching roots (48) of the gerotor star teeth to the line drawn on the end face of drive (8) matched to pin (12), install the gerotor. At this time, check that lines (A), (B), (C) and (D) are in parallel. a Match the bolt holes by turning the gerotor ring without separating the drive and gerotor star from each other. a The above procedure is important for aligning the valve timing.
13. Turn spool and sleeve assemblly and set pin (12) and port surface (46) of housing in parallel. Insert drive (8) into portion (47), then mate drive yoke and pin (12). To carry out positioning exactly, use a felt pen to draw line on end face of drive (8) parallel to pin.
10
HM400-2
50 Disassembly and assembly
16. Assemble spacer (5) to spline Gerotor star. a Do not assemble spacers to 51 cc/rev and 69 cc/rev discharge capacity Orbit-rolls. Asseble 2 spacers to 184 cc/rev discharge capacity Orbit-roll. Assemble O-ring (22) to end cap (3), set on top of Gerotor, then align bolt holes. Coat 6 screws (1) and thread of retainer screw assembly (2) with oil, then assemble to end cap. Install retainer screw assemblies to bolt holes where adapter screws have already been assembled. 14.7 Nm {1.5 kgm}, then tighten in order to following torque.
SEN01448-02
17. Order for tightening end cap mounting screws is as shown in diagram below.
a
After tightening to torque given below, install handle to spool and check that spool rotates.
Screw tightening torque Discharge capacity (cc/rev)
Tightening torque (Nm {kgm})
51 – 230
22.6 {2.3}
277
23.5 {2.4}
369 – 737
28.4 {2.9}
List of capacities and spacers
HM400-2
Discharge capacity symbol
Discharge capacity (cc/rev)
Spacer thickness (mm)
A
51
—
B
69
—
C
96
3.6
D
120
6.1
E
159
12.2
G
184
12.2 3.6
K
230
22.0
M
277
24.4
P
369
41.1
S
461
53.7
T
553
66.4
U
737
91.8
11
SEN01448-02
50 Disassembly and assembly
2.
Remove inner cover (1) of the left fender.
3.
Open up the engine hood.
4.
Remove 4 each mounting bolts from the right and left mounts at the front of the cab. a Check the thickness, quantity, and positions of the inserted shims.
5.
Sling operator's cab (32) and tilt it up. a Use 2 shackles (S) so that hook (F) of the sling will not hit glass (G) of the cab assembly.
6.
Pull lock lever (31) and set lock bar (30) with the care the direction of the lock bar (30). k Check that the lock lever (31) closes and the operator cab assembly (32) is held securely in position by the lock bar (30). For details about cab tilt, see "Method of tilting cab up" in chapter Testing and adjusting. a Pump assembly X2 is necessary for tilting up by tilt cylinder.
Part No.
X 2
792-454-1100
Part name
Pump assembly
Drain hydraulic oil. 6
Hydraulic tank: 120l l
Sketch
Symbol
New/Remodel
Special tools
Q'ty
1.
Necessity
Removal and installation of flow amplifier valve assembly 1
q 1
Removal k
k
k k k
q
k k k
k k k
k k
12
When tilting the cab, observe the following precautions to prevent a serious injury or fatal accident caused by fall of the cab. To prevent interference between the cab and the dump body, set the steering in a st raight ah ea d pos ition a nd stop the machine on the level ground. Lock the dump lever with the dump lever lock knob. Turn the parking brake switch ON and chock the wheels. Set the lock bar to the frame and lock front and rear frame. Precautions in tilting cab When tilting the cab, check that the lock lever is fixed securely. Do not start the engine while the cab is tilted. When it is obliged to start the engine for testing etc., check that there is nobody under the cab. Do not operate the gear shift lever or dump lever. Do not give a large shock to the machine. Do not tilt the cab while it is loaded. Disconnect the cable from the negative (–) terminal of the battery. Loosen the hydraulic oil filler cap to release the internal pressure of the hydraulic tank.
HM400-2
50 Disassembly and assembly
SEN01448-02
4) 5)
6)
7.
Disconnect pump circuit (HP) hose (8) and remove tank circuit (HT) piping (9). Disconnect steering cylinder circuit pipes (CL) (10) and (CR) (11) from the steering valve and fix them. Remove flow-amplifier valve (12). 4 Flow-amplifier valve: 35 kg
Flow-amplifier valve 1) Remove cover (2) on the top of the left fender and cover (2a) on the left side of the flow-amplifier valve. 2) Remove the wire harness clamp and disconnect the steering hose and R, P, T, L, and LS circuit hoses (3) – (6).
Installation q
3)
Carry out installation in the reverse order to removal.
Remove the mounting bolts of pipe (7) of priority circuit (EF) (the circuit to the port P of the hoist valve) and keep pipe (7) away from the steering valve. a Loosen the mounting bolts of port P of the hoist valve.
HM400-2
13
SEN01448-02
50 Disassembly and assembly
Removal and installation of hoist valve assembly 1
1.
Drain the hydraulic oil.
2.
Left fender Lift off left fender (1).
3.
Open up the engine hood.
4.
Remove 4 each mounting bolts from the right and left mounts at the front of the cab. a Check the thickness, quantity, and positions of the inserted shims.
5.
Sling operator's cab (32) and tilt it up. a Use 2 shackles (S) so that hook (F) of the sling will not hit glass (G) of the cab assembly.
6.
Pull lock lever (31) and set lock bar (30) with the care the direction of the lock bar (30). k Check that the lock lever (31) closes and the operator cab assembly (32) is held securely in position by the lock bar (30). For details about cab tilt, see "Method of tilting cab up" in chapter Testing and adjusting. a Pump assembly X2 is necessary for tilting up by tilt cylinder.
792-454-1100
Pump assembly
Sketch
X 2
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
q 1
Removal k
k
k k k
q
k k k
k k k
k k k
14
When tilting the cab, observe the following precautions to prevent a serious injury or fatal accident caused by fall of the cab. To prevent interference between the cab and the dump body, set the steering in a st raight ah ea d pos ition a nd stop the machine on the level ground. Lock the dump lever with the dump lever lock knob. Turn the parking brake switch ON and chock the wheels. Set the lock bar to the frame and lock front and rear frame. Precautions in tilting cab When tilting the cab, check that the lock lever is fixed securely. Do not start the engine while the cab is tilted. When it is obliged to start the engine for testing etc., check that there is nobody under the cab. Do not operate the gear shift lever or dump lever. Do not give a large shock to the machine. Do not tilt the cab while it is loaded. Disconnect the cable from the negative (–) terminal of the battery. Check that the body is lowered completely. Loosen the hydraulic oil filler cap to release the internal pressure of the hydraulic tank.
HM400-2
50 Disassembly and assembly
SEN01448-02
3) 4) 5)
7.
Flow-amplifier valve Remove the flow-amplifier valve assembly. For details, see "Removal and installation of flowamplifier valve assembly".
8.
Hoses and piping 1) Disconnect port P tube of the hoist valve and tank circuit hoses (2), (3) and (4). 2) Remove bracket (5) and tank circuit tube (6). a Remove the throttle between tube (6) and hoist valve, too.
9.
Disconnect hoses (7) and (8) of pilot ports (PA) and (PB). Remove check valve (9). [*1] Disconnect tube (10) and (11) of hoist cylinder ports (A) and (B). a Loosen the rear tube clamp and move the tubes toward the hydraulic tank.
Hoist valve Remove hoist valve assembly (12). 4 Hoist valve assembly: 65 kg
Installation q
Carry out installation in the reverse order to removal.
[*1]
3
Check valve mounting bolt Thread 12 mm in diameter: 98 – 123 Nm {10 – 12.5 kgm}
Refilling with oil Add specified oil to the specified level.
q
HM400-2
15
SEN01448-02
50 Disassembly and assembly
Disassembly and assembly of hoist valve assembly
1
Disassembly
1.
Housing assembly 1) Remove housing (2) from body (1). 2) Loosen nut (3). 3) Remove screw (4), spacer (5), spring (6) and puppet (7). 4) Remove plug (8). 5) Loosen sleeve (9) and remove spring (10), seat (11), piston (12), spring (13), seal (14), puppet (15), sleeve (16) and orifice (17).
2.
Spring case assembly 1) Remove spring case (18) from body (1) and then remove springs (19) and (20) and retainer (21). 2) Remove spring case (22) from body (1) and then remove retainer (23). 3) Remove plug (24). 4) Remove flange (25) from spring case (22), then r emo ve s pri ngs (26 ) and ( 27) , retainer (28) and spring (29).
16
3.
Body assembly 1) Remove spool (30) and plug (31) from body (1). 2) Remove seat (32), spring (33) and valve (34) from body (1).
HM400-2
50 Disassembly and assembly
SEN01448-02
Assembly
q q
Clean all the parts carefully and remove burrs. Apply engine oil to the sliding parts before installing.
1.
Body assembly 1) Install valve (34), spring (33) and seat (32) to body (1). 2) Install plug (31) and spool (30) to body (1).
2.
Spring case assembly 1) Install spring (29), retainer (28) and springs (27) and (26) to spring case (22) and then install flange (25). 2) Install plug (24). 3) Install retainer (23) to body (1) and then install spring case (22). 4) Install retainer (21) and springs (20) and (19) to body (1) and then install spring case (18).
HM400-2
3.
Housing assembly 1) Install orifice (17), sleeve (16), puppet (15), seal (14), spring (13), piston (12), seat (11) and spring (10) to housing (2) and tighten sleeve (9). 2) Tighten plug (8). 3) Install puppet (7), spring (6) and spacer (5) and tighten screw (4) and nut (3). 4) Install housing (2) to body (1). 2 Mating faces of housing and body: Sealant (LOCTITE #572 or 575 or Sealend #242) 3 Housing Thread 12 mm in diameter: 98 – 123 Nm {10 – 12.5 kgm} Thread 14 mm in diameter: 157 – 196 Nm {16 – 20 kgm}
17
SEN01448-02
50 Disassembly and assembly
Disassembly and assembly of steering cylinder assembly
Disassembly
1
1 2 3
4
U
790-502-1003
Cylinder repair stand
t 1
790-101-1102
Hydraulic pump
t 1
790-102-3802
Wrench assembly t 1
790-102-4300
Wrench assembly t 1
790-102-4310
Pin
t 2
790-720-1000
Expander
t 1
796-720-1670
Ring
t 1
07281-01279
Clamp
t 1
790-201-1702
Push tool kit
t 1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
790-201-1811
• Push tool (Outside diameter: 135 mm, Inside diameter: 130 mm, Length: 35 mm)
1
790-201-1500
Push tool kit
790-101-5021
• Grip
1
01010-50816
• Bolt
1
790-201-1620
• Plate (Outside diameter of dust seal press fitting part: 146 mm)
1
5
6
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
1.
Piston rod assembly 1) Remove the piping from the cylinder assembly. 2) Remove mounting bolts (1a) and seal cage assembly (1). 3) Remove check valve (1b). a Put an oil pan etc. under the cylinder to receive the oil.
4) 5)
Set cylinder assembly (2) to tool U1. Loosen the cylinder head nut and remove cylinder head assembly (3) with tool U2.
6)
Pull out and remove cylinder head and piston rod assembly (4) from cylinder (5). a When the piston rod assembly is pulled out from the cylinder, oil will come out, so catch it in a container. Remove cylinder (5) from tool U1.
t 1
7)
18
HM400-2
50 Disassembly and assembly
8)
Disassemble the piston rod assembly according to the following procedure. 1] Set piston rod assembly (4) to tool U1.
2]
a
HM400-2
Remove piston assembly lock screw (5). Screw size: M12, P = 1.75 mm
If screw (5) is so caulked that you cannot remove it, tighten it temporarily and cut the threads on it with tap [1], and then remove it.
SEN01448-02
3]
Using tool U3, remove piston assembly (6). q When not using tool U3, loosen the piston assembly by using the drilled holes (DH) (ø10: 2 places).
4] 5] 6]
Remove head assembly (7). Remove seal cage (8). Remove plate (8a).
7]
Remove cap (9), 9 balls (10) and plunger (11).
19
SEN01448-02
2.
Disassembly of piston assembly 1) Remove wear rings (12). 2) Remove piston ring (13). 3) Remove the O-ring and backup ring (14).
50 Disassembly and assembly
Assembly a a a a
3.
4.
20
Take care not to damage the packings, dust seals, O-rings, etc. Clean all the parts. After installing them, cover the piping ports and pin holes to prevent dirt from entering. Do not insert each backup ring forcibly, but warm it in water at 50 – 60 °C and then insert it. Clean all the parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing.
1.
Assembly of seal cage 1) Install seal ring (21). 2) Install ring (20).
2.
Assembly of head assembly 1) Using tool U5, press fit bushing (18). 2) Install rod packing (17). 3) Using tool U6, press fit dust seal (19). 4) Install O-ring (16). 5) Install backup ring and O-ring (15).
Disassembly of cylinder head assembly 1) Remove the O-ring and backup ring (15). 2) Remove O-ring (16) 3) Remove rod packing (17). 4) Remove bushing (18). 5) Remove dust seal (19).
Disassembly of seal cage assembly 1) Remove ring (20). 2) Remove seal ring (21).
HM400-2
50 Disassembly and assembly
SEN01448-02
4.
3.
Assembly of piston assembly 1) Using tool U4, expand piston ring (13). a Set the piston ring to tool U4 and give the handle 8 – 10 turns to expand the piston ring. 2) Set tool U4 and contract piston ring (13).
3) 4)
Install backup ring and O-ring (14). Install wear ring (12). a Do not increase the closed gap of the ring too much. 2 Ring groove: Grease (G2-LI)
HM400-2
Piston rod assembly 1) Set piston rod assembly (2) to tool U1.
2)
Set plunger (11) to the piston rod. Install 9 balls (10) and secure them with cap (9). a Check that there is some play at the plunger end.
3) 4) 5)
Install plate (8a). Install seal cage (8). Install head assembly (7).
21
SEN01448-02
6)
50 Disassembly and assembly
Assemble piston assembly (6) according to the following procedure. q Perform this work when reusing piston rod assembly (2) and piston assembly (6). a Clean the parts thoroughly to remove metal chips and dirt. 1] Tighten piston assembly (6). Then, using tool U3, tighten piston assembly (6) until screw holes (H) are aligned. a Remove the burrs from the threads with a file.
3]
After making the hole, remove all the chips and dirt and clean thoroughly.
4]
Tighten screw (5). 2 Threaded part (b) of screw: Adhesive (LT-2) 3 Screw: 58.9 – 73.6 Nm {6 – 7.5 kgm} Caulk 4 points (a) of the threaded part with a punch.
5]
q
1]
2]
q
22
When replacing either or both of the rod and piston Screw in piston assembly (6) until it touches rod end [B] and then tighten it to the specified torque with tool U4.
Make 1 screw hole to install the screw. a Make 1 hole horizontally with a d r i l l a t t h e V- g r o o v e o f t h e threaded part of piston (6) and rod (3). Threading dimensions (mm)
Diameter of tap drill hole
Depth of tap drill hole
Tap to be used
Tapping depth
10.3
27
12 x 1.75
20
HM400-2
50 Disassembly and assembly
7)
5.
Remove piston rod assembly (2) form tool U1.
SEN01448-02
4) 5)
Install seal cage (1) and tighten bolts (1a). Install check valve (1b). 3 Check valve: 83.4 – 147 Nm {8.5 – 15 kgm}
Piston rod assembly 1) Set cylinder (5) to tool U1. 2) Install cylinder head and piston rod assembly (4) to cylinder (5). 3) Using tool U2, tighten cylinder head assembly (3). 3 Cylinder head nut: 932 ± 93 Nm {95 ± 9.5 kgm}
HM400-2
23
SEN01448-02
50 Disassembly and assembly
Disassembly and assembly of hoist cylinder assembly
Disassembly
1
1 2 3
4
U 5
6
24
790-502-1003
Cylinder repair stand
t 1
790-101-1102
Hydraulic pump
t 1
790-102-3802
Wrench assembly t 1
790-102-4300
Wrench assembly t 1
790-102-4310
Pin
t 1
790-720-1000
Expander
t 1
796-720-1670
Ring
t 1
07281-01279
Clamp
t 1
790-201-1702
Push tool kit
t 1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
790-201-1811
• Push tool (Outside diameter: 135 mm, Inside diameter: 130 mm, Length: 35 mm)
1
790-201-1881
• Push tool
1
790-201-1841
• Push tool
1
790-201-1500
Push tool kit
790-101-5021
• Grip
1
01010-50816
• Bolt
1
790-201-1620
• Plate (Outside diameter of dust seal press fitting part: 146 mm)
1
790-201-1690
• Plate
1
790-201-1650
• Plate
1
Set cylinder assembly (1) to tool U1.
2.
Using tool U2, loosen and remove cylinder head assembly (1).
3.
Remove No. 2 cylinder and rod assembly (20) from No. 1 cylinder (2).
4.
Remove snap ring (12) from No. 2 cylinder (4).
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
1.
t 1
HM400-2
50 Disassembly and assembly
5.
SEN01448-02
2)
Lift off rod (5) from No. 2 cylinder (4).
1)
Using tool U3, remove piston assembly (13). a When not using tool U3, loosen the piston assembly by using the drilled holes (DH) (ø 10: 2 places).
Remove piston assembly lock screw (24).
a
HM400-2
6.
Remove cylinder head assembly (6) from No. 2 cylinder (4).
7.
Remove wear ring (7).
8.
Disassembly of cylinder head assembly 1) Remove the O-ring backup ring (22), snap ring (21), dust seal (9) and rod packing (10). 2) Remove bushing (11).
If screw (24) is so caulked that you cannot remove it, tighten it temporarily and cut the threads on it with tap [1], and then remove it.
25
SEN01448-02
9.
Disassembly of piston assembly Remove piston ring (14), wear ring (15), O-ring and backup ring (23) from piston assembly (13).
50 Disassembly and assembly
Assembly a a a a
Take care not to damage the packings, dust seals, O-rings, etc. Clean all the parts. After installing them, cover the piping ports and pin holes to prevent dirt from entering. Do not insert each backup ring forcibly, but warm it in water at 50 – 60 °C and then insert it. Clean all the parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing.
1.
Using tool U5, press fit bushing (19) to No. 2 cylinder (4).
2.
Install rod packing (18) to No. 2 cylinder (4). a Check the installed direction of the rod packing.
3.
Using tool U6, press fit dust seal (17) to No. 2 cylinder (4).
10. Remove snap ring (16) from No. 2 cylinder (4) and then remove dust seal (17), rod packing (18) and bushing (19).
26
HM400-2
50 Disassembly and assembly
4.
Install snap ring (16).
5.
Assembly of piston assembly 1) Using tool U4, expand piston ring (14) and install it to piston (13). a Set the piston ring to the tool and give the handle 8 – 10 turns to expand the piston ring. 2) Set tool U4 and contract piston ring (14). 3) Install wear ring (15). 4) Install O-ring and backup ring (23).
HM400-2
SEN01448-02
6.
Assembly of cylinder head assembly 1) Using tool U5, press fit bushing (11).
2)
Install rod packing (10) to cylinder head (6). a Check the installed direction of the rod packing.
27
SEN01448-02
3) 4) 5) 6)
7.
28
Using tool U6, install dust seal (9). Install snap ring (21). Install O-ring and backup ring (22). Install rod packing (10).
50 Disassembly and assembly
2)
Install rod packing (18).
3)
Using tool U6, install dust seal (17).
4)
Install snap ring (16).
Assembly of No. 2 cylinder assembly 1) Using tool U5, press fit bushing (19).
HM400-2
50 Disassembly and assembly
8.
Install cylinder head (6) to No. 2 cylinder (4).
9.
Install wear ring (7).
SEN01448-02
2)
q
Make 1 screw hole to install the screw. a Make 1 hole horizontally with a drill at the V-groove of the threaded part of piston (13) and rod (5). Threading dimensions (mm)
Diameter of Depth of tap drill hole tap drill hole 10.3
10. Assemble piston assembly (13) according to the following procedure. q When reusing piston rod assembly (5) and piston assembly (6) a Clean the parts thoroughly and remove metal chips and dust. 1) Using tool U3, tighten piston assembly (13) until the screw holes (H) are aligned. a Remove burrs and fins from the threads with a file etc.
1)
Tapping depth
12 x 1.75
20
3)
After making the hole, remove all the chips and dirt and clean thoroughly.
4)
Tighten screw (24). 2 Threaded part of screw: Adhesive (LT-2) 3 Screw: 58.9 – 73.6 Nm {6 – 7.5 kgm} Caulk 4 points of the threaded part with punch (a).
5)
q
27
Tap to be used
When replacing either or both of the rod and piston Screw in piston assembly (13) until it touches rod end [B] and then tighten it with tool U4 to the specified torque.
HM400-2
29
SEN01448-02
11. Sling rod (5) and install it to No. 2 cylinder (4).
50 Disassembly and assembly
14. Install cylinder head (1) to No. 1 cylinder (2) and tighten it with tool U2. 3 Cylinder head: 1.25 ± 0.13 kNm {128 ± 12.8 kgm}
12. Install snap ring (12) to No. 2 cylinder (4).
13. Install No. 2 cylinder and rod assembly (20) to No. 1 cylinder (2).
30
HM400-2
50 Disassembly and assembly
HM400-2
SEN01448-02
31
SEN01448-02
50 Disassembly and assembly
HM400-2 Articulated dump truck Form No. SEN01448-02
© 2008 KOMATSU All Rights Reserved Printed in Japan 03-08 (02)
32
HM400-2
SEN01449-02
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
50 Disassembly and assembly1 Cab and its attachments Removal and installation of operator's cab ..................................................................................................... 2 Removal and installation of operator's cab glass (Stuck glass) ...................................................................... 7 Disassembly and assembly of operator’s seat assembly ............................................................................. 13 Removal and installation of air conditioner unit assembly ............................................................................ 23
HM400-2
1
SEN01449-02
50 Disassembly and assembly k
Removal and installation of operator's cab
1
X4 792-454-1100
Pump assembly
q 1
N
Sketch
Part name
New/Remodel
Part No.
Necessity
Symbol
Q'ty
Special tools
In the case that you do not drain the coolant, if you disconnect the heater hose when the coolant temperature in the radiator is high, you may be scalded. In this case, wait until the coolant temperature lowers and then disconnect the heater hose.
1. Open engine hood (1).
Removal k
k
k k k
q
k k k
k k k
When tilting the cab, observe the following precautions to prevent a serious injury or fatal accident caused by fall of the cab. To prevent interference between the cab and the dump body, set the steering in a st raight ah ea d pos ition a nd stop the machine on the level ground. Lock the dump lever with the dump lever lock knob. Turn the parking brake switch ON and chock the wheels. Set the lock bar to the frame and lock front and rear frame. Precautions in tilting cab When tilting the cab, check that the lock lever is fixed securely. Do not start the engine while the cab is tilted. When it is obliged to start the engine for testing etc., check that there is nobody under the cab. Do not operate the gear shift lever or dump lever. Do not give a large shock to the machine. Do not tilt the cab while it is loaded.
k
Disconnect the cable from the negative (–) terminal of the battery. k Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k
2
2. Remove 4 each mounting bolts from the right and left mounts at the front of the cab. a Check the thickness, quantity, and positions of the inserted shims. 3. Sling operator's cab (3) and tilt it up. a Use 2 shackles (S) so that hook (F) of the sling will not hit glass (G) of the cab assembly. 4. Pull lock lever (2-1) and set lock bar (2) with the care the direction of the lock bar (2). k Check that the lock lever (2-1) closes and the operator cab assembly (3) is held securely in position by the lock bar (2). For details about cab tilt, see "Method of tilting cab up" in chapter Testing and adjusting. a Pump assembly X4 is necessary for tilting up by tilt cylinder.
If refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, put on protective goggles while you are collecting the refrigerant (R134a) or filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted by a qualified person.
HM400-2
50 Disassembly and assembly
SEN01449-02
6. Disconnect air conditioner hoses (10). [*1] a Stop the openings with tapes, etc. to prevent air from entering them 7. Disconnect heater hoses (11). a Prepare an oil container. 8. Disconnect hoses (12) from steering valve (SV).
a Underview of operator's cab.
9. Disconnect connectors (13) – (20). • (13): J08, (14): J01 • (15): J09, (16): J02 • (17): J03, (18): J05 • (19): J04, (20): J06 5. Disconnect hoses (5) – (9) from brake valve (BV). • (5), (6): Port PA and PB • (7): Port T • (8): Port B • (9): Port A • (SV): Steering valve a Check the destination of each hose. a Prepare an oil container. a Put plugs to the hoses. a When disconnecting the hose from brake valve (BV), make a matchmark at the position of the hose clamp and take care that noise will not be increased by the sag of the hose.
HM400-2
3
SEN01449-02
10. Disconnect ground terminal (22). 11. Fix cylinder (24) temporarily to prevent it from falling down and remove pin (23). a Retract cylinder (24). a Check the thickness, quantity, and positions of the inserted shims.
50 Disassembly and assembly
2) Remove cover (31) a Disconnect connector PWR from inside of the cover. 3) Remove cover (32).
4) Remove covers (33) and (34). 12. Return the operator's cab assembly (3) to the horizontal position. 13. Disconnect rearview monitor cable (21) in the following steps.
5) Remove storage box (35). 6) Remove cover (36). 7) Remove clamp (37) from rear view monitor cable (21).
1) Remove seat (30).
4
HM400-2
50 Disassembly and assembly
8) Remove the external air filter cover (38) from outside of the operator's cab and remove the external air filter. 9) Remove external air filter box (39).
10) Remove the rear mounting bolts and remove cover (40) from the dashboard.
11) Disconnect band (41). 12) Disconnect connector (42) from monitor (M). 13) Remove the molding material of grommet (G). [*2] 14) Drop monitor cable (21) below the operator's cab.
HM400-2
SEN01449-02
14. Sling the operator's cab assembly temporarily by using plate (P).
15. Remove pin (25).[*3] a Check the thickness, quantity, and positions of the inserted shims.
16. Lift off operator's cab assembly (3). 4
Operator's cab assembly: 1,200 kg
5
SEN01449-02
50 Disassembly and assembly
Installation • [*1]
[*3]
Carry out installation in the reverse order to removal. a When installing the air conditioner circuit hoses, take care that dirt and water will not enter them. a When installing each air conditioner hose, check that the O-ring is fitted to the joint. a Check each O-ring for a flaw and deterioration. a When connecting the refrigerant piping, coat the O-rings with compressor oil for new refrigerant R134a (DENSO: ND-OIL 8, ZEXEL: ZXL 100 PG (equivalent to PAG 46). 3 Tightening torque for air conditioner piping Thread size
Tightening torque
16 x 1.5 22 x 1.5
11.8 – 14.7 Nm {1.2 – 1.5 kgm} 19.6 – 24.5 Nm {2.0 – 2.5 kgm}
24 x 1.5
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
•
Filling air conditioner circuit with refrigerant (R134a) Fill the air conditioner circuit with refrigerant (R134a). a Quantity of refrigerant: 1,200 ± 50 g
•
Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again.
[*2] Make seal the grommet (G) area of the monitor cable. 2 Oblique line area in the grommet (G) (100% full): CEMEDINE 366E or equivalent
6
a Adjust the shims so that the clearance between operator's cab (3) and mount (26) will be (a) on each side. • Standard clearance (a): 0.2 mm (Each side) • Kinds of shim thickness: 0.5 mm, 1.0 mm, 2.3 mm
HM400-2
50 Disassembly and assembly
Removal and installation of operator's cab glass (Stuck glass)1 a Among the panes of window glass on the 4 sides of the operator's cab, 5 panes (1) – (5) shown in the figure are stuck. a In this section, the procedure for replacing the stuck glass is explained. (1) Front window glass (2) Left rear window glass (3) Rear window glass (4) Right rear window glass (5) Right door sash assembly (Sash is stuck)
SEN01449-02
Procedure Preparation (Cleaning) O Applying primer • Cab side: SUNSTAR 435-95 • Glass side: SUNSTAR 435-40 O
Dry for at least 5 minutes and stick within 24 hours. Sticking both-sided adhesive tape (cab side) O Positioning window glass O Applying adhesive (SUNSTAR Industrial sealant, Petaseal 551) (cab side) O
Within 5 minutes
Sticking window glass * Keep pressing the glass for at least 10 hours.
HM400-2
7
SEN01449-02
50 Disassembly and assembly
X
2 793-498-1210 3 20Y-54-13180
Lifter (Suction cup) Stopper rubber
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 2 t 2
a If the window glass is broken finely, it may be removed with knife [4] and a screwdriver. a Widening the cut with a flat-head screwdriver, cut the adhesive and both-sided adhesive tape with knife [4]. (The following figure shows the operator's cab of a wheel loader.)
Removal a Remove the window glass to be replaced according to the following procedure. 1. Using seal cutter [1], cut the adhesive between broken window glass (7) and operator's cab (metal sheet) (8).
2. Remove the window glass.
a If a seal cutter is not available, make holes on the adhesive and both-sided adhesive tape with a drill and pass a fine wire (piano wire, etc.) [2] through the holes. Grip the both ends of the wire with pliers [3], etc. (or hold them by winding them onto something) and move the wire to the right and left to cut the adhesive and both-sided adhesive tape. Since the wire may be broken by the frictional heat, apply lubricant to it. (The following figure shows the operator's cab of a wheel loader.)
8
HM400-2
50 Disassembly and assembly
Installation Preparation 1. Using a knife and scraper [5], remove the remaining adhesive and both-sided adhesive tape from the metal sheets (glass sticking surfaces) of the operator's cab. a Remove the adhesive and both-sided adhesive tape to a degree that they will not affect adhesion of the new adhesive. Take care not to scratch the painted surfaces. (If the painted surfaces are scratched, adhesion will be lowered.) (The following figure shows the operator's cab of a wheel loader.)
SEN01449-02
Applying primer 3. Apply primer (10). a The using limit of the primer is 4 months after the date of manufacture. Do not use the primer after this limit. a Use the primer within 2 hours after unpacking it. a Even if the primer is packed again just after it is unpacked, use it within 24 hours after it is unpacked for the first time. (Discard the primer 24 hours after it is unpacked.) 1) Stir both of the paint primers and glass primer sufficiently before using them. a If the primer has been stored in a refrigerator, leave it at the room temperature for at least half a day before stirring it. (If the primer is unpacked just after taken out of the refrigerator, water will be condensed. Accordingly, leave the primer at the room temperature for a sufficient time.) 2) When reusing primer brush (11), wash it in white gasoline. a After washing the brush, check it again for dirt and foreign matter. a Prepare respective brushes for the paint primer and glass primer.
2. Remove oil, dust, dirt, etc. from the sticking surfaces of cab (8) and window glass (9) with white gasoline. a If the sticking surfaces are not cleaned well, the glass may not be stuck perfectly. a Clean the all black part on the back side of the window glass. a After cleaning the sticking surfaces, leave them in air for at least 5 minutes to dry. (The following figure shows the operator's cab of a wheel loader.)
HM400-2
9
SEN01449-02
3) Evenly apply paint primer to the surfaces to stick both-sided adhesive tapes. (a): Min. 30 mm 2 Primer for cab (painted surface): SUNSTAR 435-95 a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.) a Never apply wrong primer. If you have applied the glass primer, etc. by mistake, wipe it off with white gasoline. a After applying the primer, leave it for at least 5 minutes in air to dry and stick the both-sided adhesive tape within 24 hours. (The figure shows the operator's cab of a hydraulic excavator.)
50 Disassembly and assembly
4) Evenly apply glass primer all around inside of the black coated surface of window glass (9). (a): Min. 30 mm 2 Glass primer: SUNSTAR 435-40 a The black coating is for prevention of deterioration by light. a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)
a (8): Cab
a (9): Glass
a Never apply wrong primer. If you have applied the paint primer, etc. by mistake, wipe it off with white gasoline.
10
HM400-2
50 Disassembly and assembly
Sticking both-sided adhesive tape 4. Stick both-sided adhesive tape (6) along the edge of cab (8). a Do not remove the release tape of the bothsided adhesive tape on the glass sticking side before sticking the glass. a When sticking the both-sided adhesive tape, do not touch the cleaned surface as long as possible. a Take that the both-sided adhesive tape will not float at each corner of the window frame.
a When sticking both-sided adhesive tape (6) around a frame, do not lap its finishing end over the starting end but make clearance (e) of about 5 mm between them. 1) Stick both-sided adhesive tape (6) for right window glass (1) as shown in the figure. a (The figure shows the operator's cab of a hydraulic excavator.)
HM400-2
SEN01449-02 a (8): Cab a (a): Range to apply primer (Described above) a (15): Adhesive (Described below)
Positioning window glass 5. Position the new window glass. 1) Check the clearance between the window glass and the operator's cab on the right, left, upper, and lower sides, and then adjust it evenly. 2) Stick tapes [6] between window glass (9) and operator's cab (8) and draw positioning line (n). a Stick tapes [6] to the right, left, and lower parts of the glass for accurate positioning. 3) Cut the tape between window glass (9) and operator's cab (8) with a knife, and then remove the window glass. a Do not remove the release tape of the both-sided adhesive tape on the glass sticking side before sticking the glass. (The figure shows the operator's cab of a hydraulic excavator.)
11
SEN01449-02
Applying adhesive 6. Prepare for applying the adhesive. • Adhesive: SUNSTAR Industrial sealant, Petaseal 551 a The using limit of the adhesive is 4 months after the date of manufacture. Do not use the adhesive after this limit. a Keep the adhesive in a dark place where the temperature is below 25°C. a Never heat the adhesive higher than 30°C. a When reusing the adhesive, remove the all hardened part from the nozzle tip. 1) Set adhesive cartridge (12) to caulking gun [7]. a An electric caulking gun is more efficient.
50 Disassembly and assembly
7. Apply the adhesive. a Apply adhesive (15) to dimensions (s) and (t) of both-sided adhesive tape (6) of operator's cab (8). • Dimension (s): 10 mm • Dimension (t): 15 mm 2 Adhesive: SUNSTAR Industrial sealant, Petaseal 551 a Apply adhesive (15) higher than both-sided adhesive tape (6). a Apply the adhesive evenly. a (a): Range to apply primer (Described above) a Stick the glass within 5 minutes after applying the adhesive.
2) Cut the tip of the adhesive nozzle (14) so that dimensions (q) and (r) will be as follows. • Dimension (q): 10 mm • Dimension (r): 15 mm
3) Remove the release tape of the both-sided adhesive tape on the glass side.
12
HM400-2
50 Disassembly and assembly
SEN01449-02
Disassembly and assembly of operator’s seat assembly a
1
a
The procedure for disassembling and assembling the operator's seat assembly [with air suspension (manufactured by ISRING HAUSEN)] is shown below. This operator's seat is if equipped.
A: B: C: D:
Headrest Seatback Seat cushion Right-hand armrest
E: Left-hand armrest F: Suspension cover G: Sliderails
Disassembly 1.
Headrest 1) Referring to the figure, check the positions of the 2 clips (2) of headrest stay (1) on both sides.
HM400-2
13
SEN01449-02
2)
Apply force (b) to part (a) of each clip (2) in the direction of the arrow to turn the clip. Release headrest stay (1) from part (d) of the clip and pull out up headrest (3).
a
14
50 Disassembly and assembly
2.
Seatback 1) Disconnect 3 air hoses (5) from the rear left of seatback (4). a Before disconnecting the air hoses, check their types.
2)
Remove seatback hinge mounting bolt (6) (M8 bolt).
3)
Bring seatback (4) down forward.
Pushing in both clips (2) simultaneously, remove headrest (3).
HM400-2
50 Disassembly and assembly
4) 5) 6)
SEN01449-02
2)
Apply force (E) to the right side of seatback (4) in the direction of the arrow. Applying the force to seatback (4), pull its right side up. Slide seatback (4) sideway and remove it.
3)
4. 3.
Seat cushion 1) Push cushion adjuster lever (7) inward and slide seat cushion (8) to the front end.
HM400-2
Push cushion stopper wire (9) down with screwdriver [1], etc. Pull out seat cushion (8) forward and remove it.
Armrest The procedure for disassembling righthand armrest (10) is shown below. (Disassemble left-hand armrest (11) similarly.)
q
15
SEN01449-02
1)
2)
16
6)
Remove plastic cap (12) from the armrest hinge. a Use a flat-head screwdriver, etc. to remove the cap. Loosen armrest hinge mounting bolt (13).
3)
Remove plastic cap (14), and then remove lower mounting bolt (15A) (M8 bolt) of right-hand armrest (10).
4)
Turn right-hand armrest (10) up by 180 °. a If the armrest is not turned, you cannot apply the tool to upper mounting bolt (15B). Remove plastic cap (14) and upper mounting bolt (15B).
5)
50 Disassembly and assembly
5.
Remove right-hand armrest (10). a There are 2 position adjustment washers (16) installed to each bolt between the armrest and seatback. Take care not lose them.
Suspension cover 1) Remove right-hand hinge cover (17). 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.
HM400-2
50 Disassembly and assembly
3)
SEN01449-02
6)
Remove 4 suspension cover fixing rings (19).
7)
4)
Remove 4 mounting bolts (20), cushion rear fixing plate (21), 2 cushion rails (22), and 4 bushings (23).
6.
5)
Remove 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 Remove suspension cover (27). a If you remove the suspension cover without performing the work in steps 5) and 6), the suspension cover may be broken.
Rails 1) Turn over the seat assembly to set rails (28) on the upside.
Remove 3 metallic suspension cover clips (24).
HM400-2
17
SEN01449-02
2) 3)
Slide rails (28) to the rear end. Remove 1 hexagon socket head bolt (29) and 1 lock washer (30) from the front part of each rail.
4) 5)
Slide rails (28) to the front end. Remove 1 hexagon socket head bolt (29) and 1 lock washer (30) from the rear part of each rail, and then remove rails (28).
a
18
50 Disassembly and assembly
Assembly 1.
Rails 1) Put height adjustment washers (31) between rails (28) and suspension, and then set rails (28) in position.
2)
Set rails (28) to the front end and install 1 lock washer (30) and 1 hexagon socket head bolt (29) to each rail. 3 Hexagon socket head bolt: 21.4 – 27.6 Nm {2.18 – 2.82 kgm}
Take care not to lose height adjustment washers (31) between the rails and suspension.
HM400-2
50 Disassembly and assembly
3)
2.
Set rails (28) to the rear end and install 1 lock washer (30) and 1 hexagon socket head bolt (29) to each rail. 3 Hexagon socket head bolt: 21.4 – 27.6 Nm {2.18 – 2.82 kgm}
SEN01449-02
2)
Install 3 metallic suspension cover clips (24).
3)
Set 4 bushings (23) and 2 cushion rails (22), and then install cushion rear fixing plate (21), and 4 mounting bolts (20). 3 Cushion rail mounting bolt: 21.4 – 27.6 Nm {2.18 – 2.82 kgm}
4)
Install 4 suspension cover fixing rings (19).
Suspension cover 1) Set suspension cover (27) in position and install 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
HM400-2
19
SEN01449-02
5) 6)
Install plastic plate (18) to the rear. Install right-hand hinge cover (17).
50 Disassembly and assembly
2) 3) 4)
5)
3.
Tighten lower mounting bolt (15A) lightly and turn armrest (10) by 180°. Tighten upper mounting bolt (15B) lightly. Tighten lower mounting bolt (15A) and upper mounting bolt (15B) permanently. 3 Upper and lower armrest mounting bolt: 21.4 – 27.6 Nm {2.18 – 2.82 kgm} Install 2 plastic caps (14).
Armrest The procedure for assembling right-hand armrest (10) is shown below. (Assemble left-hand armrest (11) similarly.)
q
6)
7)
1)
20
Tighten armrest hinge mounting bolt (13). a Tighten the bolt so that the arm will move smoothly. q Operating effort at armrest end: 49 – 78.4 N {5 – 8 kg} Install plastic cap (12).
Install 2 position adjustment washers (16) for each bolt and set right-hand armrest (10) in position.
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50 Disassembly and assembly
4.
Seat cushion Slide in the seat cushion from the front of the fitting position. a If seat cushion (8) is slid to the rear, it is locked by cushion stopper wire (9).
SEN01449-02
5.
Seatback 1) Insert the left side of seatback (4), and then lower and set the right side.
2)
HM400-2
Install seatback hinge mounting bolt (6) (M8 bolt). 3 Seatback hinge mounting bolt: 21.4 – 27.6 Nm {2.18 – 2.82 kgm}
21
SEN01449-02
3)
6.
22
50 Disassembly and assembly
Connect 3 air hoses (5) to the rear left of the seatback (4).
Headrest Insert headrest (3) in seatback (4). a Check that 2 clips (2) on both sides are locked securely.
HM400-2
50 Disassembly and assembly
SEN01449-02
Removal and installation of air conditioner unit assembly
2)
1
X 1
799-703-1200
Service tool kit
t 1
799-703-1100
Vacuum pump (100V)
t 1
799-703-1111
Vacuum pump (220V)
t 1
799-703-1121
Vacuum pump (240V)
t 1
799-703-1401
Gas leak detecter t 1
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Tilt up operator's cab (3). a Using 2 shackles (S), arrange sling hook (F) so that it will not hit glass (G) of the cab assembly. k Check that lock (2) is applied securely. a Keep slinging operator's cab (3) (temporarily).
Removal k
k k k
k k
1.
Stop the machine on a level ground, apply the parking brake, and then lock the tires with chocks. Set the lock bar to the frame. Disconnect the cable from the negative (–) terminal of the battery. If the radiator coolant temperature is high, wait until it lowers to avoid scalding yourself before disconnecting the heater hose. Collect the air conditioner refrigerant (R134a) in advance. If refrigerant (R134a) gets in your eyes, you may lose your sight. Accordingly, when collecting or adding it, you must be qualified for handling the refrigerant and put on protective goggles. Operator's cab and engine hood 1) Tilt up engine hood (1). k Check that the engine hood is locked securely.
HM400-2
2.
Heater hose 1) Disconnect heater hose (4). a Check the connecting parts of the heater hose. a Prepare an oil receiver. 2) Remove covers (5) and (6).
3)
Disconnect drain hose clamps (7) and (8).
23
SEN01449-02
3.
Return the operator's cab tilted up to the horizontal position.
4.
Remove navigator's seat (9).
5.
Remove right pillar cover (10).
6.
Remove cover (11) under the navigator's seat.
50 Disassembly and assembly
8.
Remove frame (13).
9.
Remove relay plate assembly (14) and move it to this side.
10. Remove the 4 mounting bolts and retarder controller (15). 7.
24
Remove seat rear cover (12).
HM400-2
50 Disassembly and assembly
11. Disconnect connectors BRC1 (16), BRC2 (17) and BRC3 (18) from retarder controller (15).
SEN01449-02
14. Remove controller mounting frame (23).
15. Remove center console (24). 12. Remove the 4 mounting bolts and transmission controller (19).
13. Disconnect connectors ATC1 (20), ATC2 (21) and ATC3 (22) from transmission controller (19).
HM400-2
16. Remove upper plate (25).
17. Remove duct (26).
25
SEN01449-02
50 Disassembly and assembly
18. Remove duct (27).
23. Remove external air filter box (34).
19. Disconnect hose (28).
24. Remove rear mounting bolts (35) and (36) of air conditioner unit assembly (37).
20. Remove mounting bolt (29) and disconnect hose assembly (30). 21. Remove mounting bolt (31) and disconnect air conditioner hose assembly (32). [*1] a Cover the hose end with a tape etc. to seal it from the outside air. a Take care that the O-ring of the hose adapter will not fall.
22. Remove external air filter cover (33) from the outside of the operator's cab. a Remove the air conditioner unit assembly mounting bolts (rear 4 bolts) through this opening.
26
HM400-2
50 Disassembly and assembly
25. Remove front mounting bolts (38). While lifting up air conditioner unit assembly (37), pull it out. 26. After air conditioner unit assembly (37) is pulled out halfway, disconnect the following. q Connector AC1 (39) a Disconnect the wiring harness clamp, too. q Drain hose (40) from bottom
SEN01449-02
Installation q
Carry out installation in the reverse order to removal.
[*1] a When installing the air conditioner circuit hoses, take care that dirt, dust, water, etc. will not enter them. a When connecting each air conditioner hose, check that the O-rings are fitted to its joints. a Check that each O-ring is not damaged or deteriorated. a When connecting the refrigerant hoses, apply compressor oil for new refrigerant (R134a) ( DEN SO : ND- O IL8, ZE XE L: ZXL 100 PG (equivalent to PAG46)) to their O-rings. 3 Air conditioner hose assembly mounting bolt: 8 – 12 Nm {0.8 – 1.2 kgm} Charging air conditioner with refrigerant gas q Using tool X1, charge the air conditioner circuit with refrigerant (R134a). a Quantity of refrigerant: 1,200 ± 50 g Refilling with coolant q Add coolant up to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again.
HM400-2
27
SEN01449-02
50 Disassembly and assembly
HM400-2 Articulated dump truck Form No. SEN01449-02
© 2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (02)
28
HM400-2
SEN01450-02
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
50 Disassembly and assembly1 Electrical system Removal and installation of retarder controller assembly ............................................................................... 2 Removal and installation of transmission controller assembly........................................................................ 4 Removal and installation of engine controller assembly ................................................................................. 6
HM400-2
1
SEN01450-02
Removal and installation of retarder controller assembly
50 Disassembly and assembly
5.
Remove frame (5).
6.
Remove relay plate assembly (6) and move it to this side.
7.
Remove the 4 mounting bolts and retarder controller (7). a The device on the right is the transmission controller.
1
Removal k
k k
1.
2. 3.
4.
2
Stop the machine on a level ground, apply the parking brake, and then lock the tires with chocks. Set the lock bar to the frame. Disconnect the cable from the negative (–) terminal of the battery. Remove navigator's seat (1).
Remove right pillar cover (2). Remove cover (3) under the navigator's seat.
Remove seat rear cover (4).
HM400-2
50 Disassembly and assembly
8.
SEN01450-02
Disconnect connectors BRC1 (8), BRC2 (9) and BRC3 (10) from retarder controller.
Installation q
Carry out installation in the reverse order to removal.
HM400-2
3
SEN01450-02
Removal and installation of transmission controller assembly
50 Disassembly and assembly
5.
Remove frame (5).
6.
Remove relay plate assembly (6) and move it to this side.
7.
Remove the 4 mounting bolts and transmission controller (7). a The device on the left is the retarder controller.
1
Removal k
k k
1.
Stop the machine on a level ground, apply the parking brake, and then lock the tires with chocks. Set the lock bar to the frame. Disconnect the cable from the negative (–) terminal of the battery. Remove navigator's seat (1).
2.
Remove right pillar cover (2).
3.
Remove cover (3) under the navigator's seat.
4.
Remove seat rear cover (4).
4
HM400-2
50 Disassembly and assembly
8.
SEN01450-02
Disconnect connectors ATC1 (8), ATC2 (9) and ATC3 (10) from transmission controller (7).
Installation q
Carry out installation in the reverse order to removal.
HM400-2
5
SEN01450-02
50 Disassembly and assembly
Removal and installation of engine controller assembly
1.
1
792-454-1100
Pump assembly
Sketch
X4
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Operator's cab and engine hood 1) Tilt up engine hood (1). k Check that the engine hood is locked securely.
q 1
Removal k
k
k k k
q
k k k
k k k
k k
6
When tilting the cab, observe the following precautions to prevent a serious injury or fatal accident caused by fall of the cab. To prevent interference between the cab and the dump body, set the steering in a st raight ah ea d pos ition a nd stop the machine on the level ground. Lock the dump lever with the dump lever lock knob. Turn the parking brake switch ON and chock the wheels. Set the lock bar to the frame and lock front and rear frame. Precautions in tilting cab When tilting the cab, check that the lock lever is fixed securely. Do not start the engine while the cab is tilted. When it is obliged to start the engine for testing etc., check that there is nobody under the cab. Do not operate the gear shift lever or dump lever. Do not give a large shock to the machine. Do not tilt the cab while it is loaded.
2)
3)
Sling operator's cab assembly (2) and tilt it up. a Use 2 shackles (S) so that hook (F) of the sling will not hit glass (G) of the cab assembly. Pull lock lever (2-1) and set lock bar (B) with the care the direction of the lock bar (B). k Check that the lock lever (2-1) closes and the operator cab assembly (2) is held securely in position by the lock bar (B). For details, see Testing and adjusting, Method of tilting up cab. a Pump assembly X4 is necessary for tilting up by tilt cylinder.
Disconnect the cable from the negative (–) terminal of the battery. If the coolant temperature in the radiator is high, you may be scalded. In this case, wait until the coolant temperature lowers and then drain the coolant.
HM400-2
50 Disassembly and assembly
2.
Remove power train filter (3) from crossbar (4).
3.
Remove connector (5) from engine controller (6).
4.
Remove engine controller (6).
SEN01450-02
Installation q
Carry out installation in the reverse order to removal.
HM400-2
7
SEN01450-02
50 Disassembly and assembly
HM400-2 Articulated dump truck Form No. SEN01450-02
© 2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (02)
8
HM400-2
SEN00533-02
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
90 Diagrams and drawings
1
Hydraulic diagrams and drawings Power train hydraulic circuit diagram .............................................................................................................. 3 Steering and hoist hydraulic circuit diagram ................................................................................................... 5 Brake hydraulic circuit diagram....................................................................................................................... 7 Brake cooling hydraulic circuit diagram .......................................................................................................... 8 Differential lock hydraulic circuit diagram........................................................................................................ 9
HM400-2
1
SEN00533-02
2
90 Diagrams and drawings
HM400-2
90 Diagrams and drawings
Power train hydraulic circuit diagram
HM400-2
SEN00533-02
Power train hydraulic circuit diagram HM400-2
3
90 Diagrams and drawings
Steering and hoist hydraulic circuit diagram
SEN00533-02
1
Serial No.: 2001 – 2603
HM400-2
5
SEN00533-02
90 Diagrams and drawings
Serial No.: 2604 and up
6
HM400-2
90 Diagrams and drawings
SEN00533-02
Brake hydraulic circuit diagram 1
HM400-2
7
SEN00533-02
90 Diagrams and drawings
Brake cooling hydraulic circuit diagram
8
1
HM400-2
90 Diagrams and drawings
SEN00533-02
Differential lock hydraulic circuit diagram
1
HM400-2
9
SEN00533-02
90 Diagrams and drawings
HM400-2 Articulated dump truck Form No. SEN00533-02
© 2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (02)
10
HM400-2
SEN00534-04
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model
Serial number
HM400-2
2001 and up
90 Diagrams and drawings
1
Electrical diagrams and drawings Electrical circuit diagram for inside cab (1/4) .................................................................................................. 3 Electrical circuit diagram for inside cab (2/4) Serial No.: 2001 – 2188 ........................................................... 5 Electrical circuit diagram for inside cab (2/4) Serial No.: 2189 and up ........................................................... 7 Electrical circuit diagram for inside cab (3/4) Serial No.: 2001 – 2188 ........................................................... 9 Electrical circuit diagram for inside cab (3/4) Serial No.: 2189 and up ..........................................................11 Electrical circuit diagram for inside cab (4/4) ................................................................................................ 13 Electrical circuit diagram for outside cab (1/3) .............................................................................................. 15 Electrical circuit diagram for outside cab (2/3) .............................................................................................. 17 Electrical circuit diagram for outside cab (3/3) .............................................................................................. 19 Electrical circuit diagram for payload meter .................................................................................................. 21 Connectors table and arrangement drawing................................................................................................. 23
HM400-2
1
SEN00534-04
2
90 Diagrams and drawings
HM400-2
Electrical circuit diagram for inside cab (1/4)
HM400-2
Electrical circuit diagram for inside cab (1/4) HM400-2
1
SEN00534-04
3
Electrical circuit diagram for inside cab (2/4) Serial No.: 2001 – 2188
HM400-2
Electrical circuit diagram for inside cab (2/4) Serial No.: 2001 – 2188 1 HM400-2
SEN00534-04
5
Electrical circuit diagram for inside cab (2/4) Serial No.: 2189 and up
HM400-2
Electrical circuit diagram for inside cab (2/4) Serial No.: 2189 and up 1 HM400-2
SEN00534-04
7
Electrical circuit diagram for inside cab (3/4) Serial No.: 2001 – 2188
HM400-2
Electrical circuit diagram for inside cab (3/4) Serial No.: 2001 – 2188 1 HM400-2
SEN00534-04
9
Electrical circuit diagram for inside cab (3/4) Serial No.: 2189 and up
HM400-2
Electrical circuit diagram for inside cab (3/4) Serial No.: 2189 and up 1 HM400-2
SEN00534-04
11
Electrical circuit diagram for inside cab (4/4)
HM400-2
Electrical circuit diagram for inside cab (4/4) HM400-2
1
SEN00534-04
13
Electrical circuit diagram for outside cab (1/3)
HM400-2
Electrical circuit diagram for outside cab (1/3) HM400-2
1
SEN00534-04
15
Electrical circuit diagram for outside cab (2/3)
HM400-2
Electrical circuit diagram for outside cab (2/3) HM400-2
1
SEN00534-04
17
Electrical circuit diagram for outside cab (3/3)
HM400-2
Electrical circuit diagram for outside cab (3/3) HM400-2
1
SEN00534-04
19
Electrical circuit diagram for payload meter
HM400-2
Electrical circuit diagram for payload meter HM400-2
1
SEN00534-04
21
Connectors table and arrangement drawing HM400-2
Connectors table and arrangement drawing HM400-2 Address
Connector No.
Type of connector
Number of pins
Address
Connector No.
Type of connector
Battery relay
L-1
CH1
M
8
Battery relay
K-1
CH2
M
8
2
Emergency steering relay
L-3
CHK1
X
Terminal
1
Emergency steering relay
M-3
CHK2
56
Terminal
1
Emergency steering relay
M-3
57
Terminal
2
Emergency steering relay
58
Terminal
2
59
Terminal
60 61
Number of pins
Machine monitor mode selector switch 1
O-2
EGR
DT
2
Machine monitor mode selector switch 2
O-2
ENG
—
60
1
KOMTRAX set switch 1
R-7
ER
Terminal
3
Chassis ground (battery room)
X
1
KOMTRAX set switch 2
Q-7
ER
Terminal
1
CJA
DT2
6
Joint connector
ER
Terminal
M-3
CJB
DT2
8
Joint connector
B-8
ER1
Emergency steering relay
K-2
CJE
DT2
8
Joint connector
A-8
1
Emergency steering relay
K-2
CJE4
DT2B
6
Joint connector
Terminal
1
Emergency steering relay
K-2
CJF
DT2
8
Terminal
2
Emergency steering relay
M-3
CJG
DT2
8
62
Terminal
1
Circuit breaker (80 A)
N-2
CJK
DT2
63
Terminal
1
Circuit breaker (80 A)
N-2
CJL
64
Terminal
1
Circuit breaker (80 A)
N-2
65
Terminal
1
Circuit breaker (80 A)
66
Terminal
2
69
Terminal
70 71
Type of connector
Number of pins
R04
Relay
6
Brake lamp relay
Z-1
R05
Relay
6
Backup lamp and buzzer relay
Z-1
E-1
R06
Relay
6
Fog lamp relay (if equipped)
Z-2
Chassis ground (front frame)
F-1,H-2,I-3
R07
Relay
5
Auto preheat relay
Z-2
1
Chassis ground (rear frame)
M-5
R08
Relay
5
Yellow rotary lamp relay (if equipped)
Z-2
Terminal
1
Chassis ground (in cab)
E-8
R09
Relay
6
Working lamp (front) relay
Z-1
ER1
Terminal
1
Chassis ground (rear frame)
G-9
R10
Relay
5
Horn relay
Z-1
AG-3
ER2
Terminal
1
Chassis ground (in cab)
Z-7
R11
Relay
6
Side lamp relay (if equipped)
Z-2
Joint connector
B-9
ER3
Terminal
1
Chassis ground (in cab)
Q-2
R12
Relay
6
Hazard relay 1
Z-2
Joint connector
B-8
FE1
DT2
2
Transmission differential speed sensor
I-2
R13
Relay
5
Hazard relay 2
Z-1
6
Joint connector
M-8
FLS
4
Flasher
V-1
R14
Relay
5
Headlamp relay
Z-1
DT2
8
Joint connector
N-2
FOG
6
Fog lamp (if equipped)
P-1
R15
Relay
5
Headlamp selector relay
Z-1
CJP
DT2
6
Joint connector
C-2
FWL
2
Front working lamp (left)
F-9
R16
Relay
6
Headlamp Hi relay
AA-2
N-2
CJR
DT2
8
Joint connector
A-9
FWM
2
Front window washer motor (front)
A-4
R17
Relay
5
Parking brake safety relay
AA-2
Battery relay
K-2
CJS
DT2
8
Joint connector
A-8
FWR
2
Front working lamp (right)
D-7
R21
Relay
5
Rear glass heater relay
Z-1
3
Battery relay
K-2
CJT
DT2
8
Joint connector
A-8
G
SUMITOMO
3
Engine Bkup speed sensor
AE-2
R22
Relay
5
Emergency steering timer
Z-1
Terminal
2
Emergency steering relay
L-3
CJU
DT2
6
Joint connector
M-7
G1
Terminal
1
Chassis ground (front frame)
Terminal
2
Emergency steering relay
L-3
CJY
DT2
8
Joint connector
A-3
GS
Terminal
2
Chassis ground (engine)
72
Terminal
1
Emergency steering relay
L-4
CJZ
DT2
6
Joint connector
M-8
HAZ
6
73
Terminal
2
Emergency steering relay
L-4
CM
DT2
8
Lamp/Turn signal/Dimmer switch
S-1
HEAT
74
Terminal
2
Emergency steering relay
K-3
CM
DT2
2
Intermediate connector
E-1
75
Terminal
2
Emergency steering relay
K-3
CN1
DT
2
Injector #1
76
Terminal
1
Emergency steering relay
K-3
CN2
DT
2
77
Terminal
2
Emergency steering relay
K-3
CN3
DT
Connector No.
Type of connector
Number of pins
50
Terminal
1
53
Terminal
1
54
Terminal
55
Location
Location
M
Location
Address
Connector No.
EGR valve solenoid
AC-6
Engine controller
AH-4
Location
Address
A-3
R25
11
Power window relay
Z-8
AH-6
R33
6
Parking brake switch
W-1
Hazard lamp switch
R-7
R34
7
Power window switch (right) (if equipped)
V-9
6
Rear glass heater (if equipped)
O-2
R35
7
Power window switch (left)
V-9
HEAT1
1
Rear glass heater (if equipped)
E-8
R38
5
Engine cut-off relay
Z-1
AC-6
HEAT2
1
Rear glass heater (if equipped)
I-9
RAD
9
Cassette radio
Q-3
Injector #2
AD-8
HN
1
Horn switch
R-2
RE1
2
Resistor
S-1
2
Injector #3
AF-8
HSL
DT2
4
Damper lever potentiometer
Y-2
RES
2
Service connector
M
Relay
DT
AG-8
78
DT2
2
Starting motor
AD-8
CN3
DT2
2
Transmission input shaft speed sensor
AI-7
J01
HD
9
Intermediate connector
C-8
RL
2
Room lamp
E-8
80
Terminal
1
Alternator (terminal R)
AC-5
CN4
DT
2
Injector #4
AG-8
J02
HD
31
Intermediate connector
D-8
RL2
2
Room lamp 2
G-9
81
Terminal
1
Circuit breaker (30 A)
L-1
CN4
DT2
2
Transmission intermediate shaft speed sensor
AN-4
J03
HD
31
Intermediate connector
C-9
RTL
6
Retarder lever potentiometer
S-2
82
Terminal
2
Circuit breaker (30 A)
N-2
CN5
DT
2
Injector #5
AG-7
J04
HD
31
Intermediate connector
D-9
RWM
2
Window washer motor (rear)
A-4
83
Terminal
1
Circuit breaker (30 A)
L-1
CN5
DT2
2
Transmission output shaft speed sensor
AN-5
J05
HD
14
Intermediate connector
D-9
SBP
DT
4
Bypass valve lift sensor
84
Terminal
1
Circuit breaker (30 A)
M-1
CN6
DT
2
Injector #6
AG-7
J06
DT06
4
Intermediate connector
Z-5
SBS
ST2
2
Seat belt switch
Y-2
86
DT1
2
Intermediate connector
J-3
CN6
DT2
2
Lo clutch ECMV solenoid valve
AM-8
J08
HD
14
Intermediate connector
C-9
SDE
M
6
Side lamp switch (if equipped)
P-2
94
Terminal
1
Chassis ground (rear frame)
M-8
CN7
DT2
2
Lo clutch ECMV fill switch
AM-8
J09
HD
31
Intermediate connector
C-9
SEGR
DT
4
EGR valve lift sensor
DPC3B
12
Machine monitor
S-7
CN8
DT2
2
R clutch ECMV solenoid valve
AM-8
J12
DT2
12
Intermediate connector
J-3
SF1
DT2
12
Gearshift lever
X-1
A1
1
Emergency escape switch
Y-8
CN9
DT2
2
R clutch ECMV fill switch
AM-8
J13
DT2
12
Intermediate connector
M-6
SF2
DT2
2
Gearshift lever
X-1
Air conditioner unit
W-9
CN10
DT2
2
Hi clutch ECMV solenoid valve
AN-7
J14
DT2
14
Intermediate connector
K-4
SLL
DT1
2
Side lamp (left) (if equipped)
K-3
8
Air conditioner control panel
P-5
CN11
DT2
2
Hi clutch ECMV fill switch
AN-7
J15
DT2
14
Intermediate connector
M-6
SLR
2
Side lamp (right) (if equipped)
C-7
6
Retarder switch linked with accelerator
Q-3
CN12
DT2
2
1st clutch ECMV solenoid valve
AN-7
J18
DT2B
12
Intermediate connector
F-1
SPARE
4
Service power supply connector
X-9
H-2
SPL
2
Speaker (left)
H-9
2
Speaker (right)
F-8
AC1 AC2
AMP
ACC
DT2
X
AE-8
AC-3
ACC
Terminal
1
Starting switch
Q-7
CN13
DT2
2
1st clutch ECMV fill switch
AM-8
J19
HD
9
Intermediate connector
ACRD
X
2
Air conditioner gas pressure switch
C-2
CN14
DT2
2
2nd clutch ECMV solenoid valve
AL-8
J1939
DT
3
Service connector
AE-8
SPR
6
AISS LOW switch
Q-6
CN15
DT2
2
2nd clutch ECMV fill switch
AL-9
J2P
DT
50
Engine controller
E-1,AH-5
ST1
Terminal
1
Emergency steering switch
O-9
AISS AS1
DT2
6
Accelerator sensor
R-2
CN16
DT2
2
3rd clutch ECMV solenoid valve
AL-8
J3P
DT
4
Engine controller
D-1,AH-3
ST2
Terminal
1
Emergency steering switch
O-8
AS2
DT2
2
Accelerator sensor Serial No. 2093 and up
R-2
CN17
DT2
2
3rd clutch ECMV fill switch
AL-8
JCA
SWP
16
Joint connector
X-9
ST3
Terminal
1
Emergency steering switch
O-8
ASS
DT2
2
Air suspension seat
Z-5
CN18
DT2
2
Lockup clutch solenoid valve
AK-9
JCC
SWP
16
Joint connector
T-1
ST4
Terminal
1
Emergency steering switch
P-9
ATC1
DRC
24
Transmission controller
AB-7
CN20
DT2
2
Differential lockup solenoid valve
AN-7
JCD
SWP
16
Joint connector
T-1
T1
Terminal
1
Chassis ground (transmission)
ATC2
DRC
40
Transmission controller
AB-7
CN22
DT2
3
Torque converter intermediate oil pressure sensor
AI-8
JCE
SWP
16
Joint connector
T-1
T01
DT2
3
Dump selector valve
L-4
ATC3
DRC
40
Transmission controller
AA-8
CN23
DT2
2
Torque converter oil temperature sensor
AI-5
JM01
—
6
Junction wiring harness
AH-5
T02
DT2
2
Dump EPC valve
K-4
ATC6
X
4
Service connector
Y-9
CN24
DT2
2
Transmission oil temperature sensor
AI-6
JM02
—
6
Junction wiring harness
AH-4
T03
DT2
2
Transmission oil filter clogging switch
E-8
B
Terminal
1
Starting switch
P-7
CNS1
DT2
12
Intermediate connector
Y-2
JM04
—
4
Junction wiring harness
AG-3
T04
DT2
2
Steering oil temperature sensor
M-5
AN-6
B06
DT2
2
Brake cooling oil control valve (rear)
H-2
CNS2
DT2
12
Intermediate connector
X-2
JM05
—
3
Junction wiring harness
AH-5
T10
DT2
3
Pitch angle sensor
M-9
B07
DT2
2
Brake cooling oil control valve (front)
A-5
CNS3
DT2
12
Intermediate connector
X-2
JM06
—
3
Junction wiring harness
AH-5
T14
DT2
3
Boom positioner sensor
K-9
B09
DT2
2
Intermediate connector
I-3
COMP
DT2
2
Air conditioner compressor
B-2
JM07
—
4
Junction wiring harness
AF-8
TC200
40
KOMTRAX terminal
R-8
B14
DT2
2
Parking brake solenoid valve
H-9
D01
2
Diode
P-4
KAI
1
Yellow rotary lamp (if equipped)
D-7
TCHET
X
4
Heater and tachograph unit
P-5
B15
DT2
2
Service brake oil pressure switch
M-6
D02
2
Diode
AB-1
LKO
2
Dump lever kick-out solenoid
Z-3
TEL
DT2
12
Intermediate connector
P-8
B16
DT2
2
Retarder oil pressure switch (front)
M-6
D03
2
Diode
AB-1
LS
3
Brightness control switch
V-1
TFUEL
PACKARD
2
Fuel temperature sensor
AH-7
B17
DT2
2
Parking brake oil pressure switch
M-7
D04
2
Diode
AA-2
M01
DT2
2
Coolant level switch
H-2
TIM
PACKARD
2
Charge temperature sensor
AH-7
B18
DT2
2
Retarder proportional pressure reducing valve (rear)
M-7
D05
2
Diode
AA-2
M02
DT2
2
Hydraulic oil level switch (if equipped)
L-5
TWTR
PACKARD
2
Engine coolant temperature sensor
AG-8
DT2
B19
DT2
2
Retarder proportional pressure reducing valve (front)
H-9
D06
2
Diode
AA-2
M03
DT2
2
Hydraulic oil filter clogging switch (if equipped)
L-4
WFM
6
Wiper motor (front)
U-1
B21
DT2
2
Accumulator oil pressure switch (front)
C-6
D07
2
Diode
P-5
M04
DT2
2
Brake oil temperature sensor (center)
K-9
WFR
6
Wiper relay (front)
U-1
B22
DT2
2
Accumulator oil pressure switch (rear)
C-7
D08
2
Diode
P-4
M06
DT2
2
Fuel level sensor
B-2
WM
4
Intermediate connector
P-4
B23
DT2
2
Retarder oil pressure switch (rear)
I-9
D09
2
Diode
P-5
M07
DT2
2
Brake oil temperature sensor (front)
B-2
WPS
DT2
12
Wiper and window washer switch
S-1
B24
DT2
3
Accumulator oil pressure sensor (rear)
C-7
D10
2
Diode
AA-2
M08
DT2
2
Retarder oil filter clogging switch (if equipped)
G-1
WRF
M
6
Working lamp (front) switch
P-1
B25
DT2
3
Accumulator oil pressure sensor (front)
C-6
D11
2
Diode
AB-2
M11
DT2
2
Air cleaner clogging sensor
A-4
WRM
4
Wiper motor (rear)
J-9
B35
DT2
2
Differential lock solenoid valve (front)
A-5
D12
2
Diode
AB-2
M-2
Terminal
1
Emergency steering motor
G-1
B36
DT2
2
Differential lock solenoid valve (rear)
M-7
D13
2
Diode
AB-2
M-2
Terminal
1
Emergency steering motor
G-1
B39
DT2
2
Differential lock oil pressure switch (front)
A-5
D14
2
Diode
AB-2
MON
AMP
4
Rear view monitor
B40
DT2
2
Differential lock oil pressure switch (Center)
J-9
D15
2
Diode
N-2
NE
FRAMATONE
3
Engine Ne speed sensor
AH-5
P-6
B41
DT2
2
Differential lock oil pressure switch (rear)
K-9
DEF
6
Interaxle differential lockup switch
P-3
OF
1
Engine oil filter clogging switch
AH-7
BA49
DT2
2
Back buzzer
L-9
DEL
6
Right and left differential lockup switch
Q-2
OL
DT1
2
Engine oil level switch
AF-2
BL47
2
Backup lamp
M-8
DFS
DT2
3
Right and left differential lockup pedal
R-2
OP7
M
1
Option selector connector
U-1
BL4B
2
Backup lamp
L-9
DL
DT2
12
Service connector
Y-8
P01
3
Headlamp (left)
C-1
P-1
DPC1
20
Machine monitor
T-8
P01
3
Headlamp (right)
A-4
AD-8
DPC2A
18
Machine monitor
S-8
P02
3
Front combination lamp (left)
C-1
BLS
M
6
Yellow rotary lamp switch (if equipped)
BP
DT
2
Bypass valve solenoid
BR
Terminal
1
Starting switch
Q-6
DPC2B
12
Machine monitor
S-7
P02
3
Front combination lamp (right)
A-3
BR
Terminal
1
Starting motor terminal BR
AD-8
DPC3A
18
Machine monitor
S-7
P05
DT2
2
Turn lamp (left)
M-5
BRC1
DRC
24
Retarder controller
AA-8
DPC4
12
Machine monitor
T-8
P05A
DT2
2
Intermediate connector
M-6
BRC2
DRC
40
Retarder controller
AA-8
DPC6
8
Machine monitor
R-7
P06
DT2
2
Turn lamp (right)
D-7
BRC3
DRC
40
Retarder controller
Z-8
DPC7
4
Service connector
R-7
P07
2
Fog lamp (left) (if equipped)
D-1
BRC6
X
4
Service connector
Y-9
DSL
1
Door switch (left)
F-9
P07
2
Fog lamp (right) (if equipped)
A-3
BT1
—
—
Fuse box
AA-4
DSR
1
Door switch (right)
D-7
P13
2
Horn valve (left)
D-1
BT2
—
—
Fuse box
AA-4
DT
DT2
8
Intermediate connector
E-1
P13
2
Horn valve (right)
A-4
BT3
—
—
Fuse box
AA-4
DT1
DT2
6
Intermediate connector
A-5
P20
6
Rear combination lamp (left)
M-9
BT4
—
—
Fuse box
AA-4
DT2
DT2
12
Intermediate connector
B-6
P21
6
Rear combination lamp (right)
L-9
BT-1A
Terminal
1
Battery
N-3
DT4
DT2
12
Intermediate connector
J-3
P22
2
Intermediate connector
A-9
BT-1B
Terminal
1
Battery
M-3
DT5
DT2
8
Intermediate connector
B-9
PAMB
FRAMATONE
3
Ambient pressure sensor
AH-4
BT-2A
Terminal
1
Battery
N-3
DT6
DT2
8
Intermediate connector
B-9
PCV1
SUMITOMO
2
Supply pump #1
AD-2
BT-2B
Terminal
1
Battery
N-3
DT7
DT2
12
Intermediate connector
Z-4
PCV2
SUMITOMO
2
Supply pump #2
AE-2
BT-3A
Terminal
1
Battery (cold district specification)
DT8
DT2
4
Intermediate connector
Z-4
PEVA
CANNON
3
EGR inlet pressure sensor
AC-7
BT-3B
Terminal
1
Battery (cold district specification)
DT8
DT2
12
Intermediate connector
D-1
PFUEL
AMP
3
Common rail pressure sensor
AF-2
BT-4A
Terminal
1
Battery (cold district specification)
DT9
DT2
12
Intermediate connector
A-3
PHO
Terminal
1
Intake air heater relay
M-1
BT-4B
Terminal
1
Battery (cold district specification)
E02
DT2
2
Emergency steering oil pressure switch
I-2
PIM
CANNON
4
Charge pressure sensor
AH-6
2
Alarm buzzer
V-1
E1
Terminal
1
Alternator (terminal E)
AC-6
POIL
CANNON
3
Engine oil pressure sensor
AG-3
Power window motor (left)
M-5
Power mode selector switch
P-3
Power window motor (right) (if equipped)
E-8
BZ2
X
C
Terminal
1
Starting switch
Q-7
E3
Terminal
1
Chassis ground (battery room)
M-1
PWL
1×2
CAB1
SWP
12
Intermediate connector
B-6
E3
Terminal
1
Chassis ground (rear frame)
AD-3
PWM
6
CAB2
X
8
Intermediate connector
B-6
E11
Terminal
1
Intake air heater relay
M-1
PWR
1×2
3
CAN terminal resistor
AG-3
E12
Terminal
1
Intake air heater relay
L-1
R01
Relay
5
Engine start relay
Z-2
3
CAN terminal resistor
S-1
E-2
Terminal
1
Emergency steering motor
G-1
R02
Relay
5
Parking brake relay
Z-2
2
Cigarette lighter
P-3
E-2
Terminal
1
Emergency steering motor
G-1
R03
Relay
5
Dust indicator relay
Z-2
CAN1 CAN2 CG
DT2
SEN00534-04 HM400-2
23
90 Diagrams and drawings
HM400-2
SEN00534-04
25
SEN00534-04
90 Diagrams and drawings
HM400-2 Articulated dump truck Form No. SEN00534-04
© 2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (02)
26
HM400-2
