The Komatsu HM400-3R Articulated Dump Truck is a production truck, hauling dirt, rock, and overburden where you don’t have time for guesswork. This Komatsu HM400-3R Articulated Dump Truck Shop Manual (SEN06205-23) is what shops and field techs reach for when a parts book or operator’s manual just won’t cut it. People use this kind of manual when they’re chasing intermittent faults, doing major component work, or trying to get a down unit back in the lineup without throwing random parts at it.
What this manual helps you do
- Trace hydraulic issues on the dump, steering, and brake circuits using the correct test points and flow paths.
- Diagnose engine, transmission, and brake faults with the procedures you’d expect for workshop-level troubleshooting.
- Follow step‑by‑step disassembly and reassembly sequences for major components like the powertrain, axles, and cylinders.
- Check adjustment procedures for linkages, driveline components, and machine systems after repairs.
- Verify wiring connections and sensor routing on the HM400-3R using model‑specific electrical information.
Who this is for
This shop manual is aimed at field technicians, shop mechanics, and fleet maintenance leads who actually turn wrenches or direct repairs. If you just need basic controls, daily checks, or safe operation info, you’ll be happier with the Operation & Maintenance Manual instead of this one.
FAQ
Q: Is this a PDF I can download and search?
A: Yes, this is a downloadable PDF, so you can search text and print the pages you need for the jobsite.
Q: Is it deep enough for full overhauls and serious fault finding?
A: Yes, the Komatsu HM400-3R Articulated Dump Truck Shop Manual walks through diagnostic procedures, disassembly sequences, and reference data used during workshop-level repairs.
Q: How do I know if it matches my exact HM400-3R?
A: Check your machine’s model designation and match it to HM400-3R; for detailed serial coverage, compare your plate with the SEN06205-23 reference before you buy.
Bottom line: if you’re responsible for repairing or troubleshooting an HM400-3R, this is the right manual; if you’re only operating or doing light daily service, you should look for the operator/maintenance book instead.
📘 Show Index
Table of Contents:
- 00 Index and foreword
- Index
- Foreword, safety and general information
- Important safety notice
- How to read the shop manual
- Explanation of terms for maintenance standard
- Handling equipment of fuel system devices
- Handling of intake system parts
- Handling of hydraulic equipment
- Method of disconnecting and connecting of push-pull type coupler
- Handling of electrical equipment
- How to read electric wire code
- Precautions when performing operation
- Practical use of KOMTRAX
- Standard tightening torque table
- List of abbreviation
- Conversion table
- 01 Specification
- Table of contents
- Specifications
- Specification drawing
- Specifications
- Weight table
- Table of fuel, coolant, and lubricants
- 10 Structure and function
- Table of contents
- Engine and cooling system
- Engine related parts
- Output shaft
- Turbocharger
- Muffler
- Cooling system
- Radiator fan pump
- Aftercooler fan motor
- Radiator fan motor
- Center brake cooling remote motor
- Center brake cooling remote pump
- Oil cooler bypass valve
- Power train
- Power train system
- Drive shaft
- Torque converter and transmission hydraulic piping
- Torque converter
- Transmission
- Transmission control valve
- Forward and reverse clutch ECMV and gear speed clutch ECMV
- Lockup clutch ECMV
- Differential lock clutch ECMV
- Main relief valve, torque converter relief valve, and main flow selector valve
- Axle
- Differential
- Final drive
- Steering system
- Layout of steering devices
- Steering column
- Flow amplifier valve
- Steering valve
- Emergency steering pump
- Emergency steering motor
- Brake system
- Layout of brake parts
- Parking brake solenoid and accumulator charge valve
- Accumulator
- Shut off solenoid valve
- Brake valve
- Proportional pressure reducing valve
- Slack adjuster
- Brake
- Brake system tank
- Parking brake
- Undercarriage and frame
- Suspension
- Suspension cylinder
- Oscillation hitch
- Hydraulic system
- Hydraulic component layout
- Dump body control
- Hydraulic tank
- Steering and hoist pump
- Hoist valve
- Steering pump selector solenoid valve
- Dump EPC valve
- Center brake cooling remote motor
- Front brake cooling relief valve
- Center brake cooling relief valve
- Cab and its attachments
- Electrical system
- Electrical control system
- Machine monitor system
- KOMTRAX system
- System component parts
- Sensor
- 20 Standard value tables
- Table of contents
- Standard service value table
- Standard value table for engine
- Standard value table for machine
- 30 Testing and adjusting
- Table of contents
- Precautions before work
- Related information on testing and adjusting
- Tools for testing and adjusting
- Sketch of tools for testing and adjusting
- Engine and cooling system
- Testing engine speed
- Testing boost pressure
- Testing exhaust gas temperature
- Testing exhaust gas color
- Adjusting valve clearance
- Testing compression pressure
- Testing blowby pressure
- Testing engine oil pressure
- Testing fuel pressure
- Handling cylinder cutout mode operation
- Handling no‐injection cranking operation
- Testing fuel return rate and leakage
- Bleeding air from fuel system
- Testing fuel circuit for leakage
- Testing radiator fan and aftercooler fan speed
- Testing and adjusting alternator belt tension
- Testing and adjusting air conditioner compressor belt tension
- Power train
- Testing torque converter stall speed
- Testing power train oil pressure
- Adjusting transmission speed sensor
- Adjusting transmission controller
- Retrieval of disabled machine that resulted from a trouble in electrical system
- Retrieval of disabled machine due to traction control system (KTCS) failure
- Steering system
- Testing and adjusting steering circuit oil pressure
- Bleed air from the steering cylinder circuit
- Testing and adjusting articulate angle sensor
- Brake system
- Testing and adjusting brake oil pressure
- Testing accumulator nitrogen gas pressure and charging procedure for accumulator nitrogen gas
- Testing braking performance
- Releasing remaining pressure in brake circuit
- Bleeding air from brake circuit
- Testing wear of wheel brake disc
- Parking brake emergency releasing procedure
- Testing wear of parking brake pad and adjusting clearance
- Hydraulic system
- Testing and adjusting suspension cylinder
- Testing and adjusting dump circuit oil pressure
- Work equipment
- Adjusting dump body positioner sensor
- Cab and its attachments
- Cab tilt up procedure
- Adjusting steering wheel tilt locklever
- Electrical system
- Setting and adjusting each equipment
- Special functions of machine monitor
- KOMTRAX terminal start-up procedure
- Adjusting optical axis of headlamps
- Handling voltage circuit of engine controller
- Handling battery disconnect switch
- Pm clinic
- 40 Troubleshooting
- Table of contents
- Precautions before work
- Related information on troubleshooting
- Troubleshooting points
- Sequence of events in troubleshooting
- Check before troubleshooting
- Inspection procedure before troubleshooting
- Preparation for troubleshooting of electrical system
- Classification and procedures for troubleshooting
- Symptom and troubleshooting numbers
- Information in troubleshooting table
- Procedure for troubleshooting wiring harness of pressure sensor system for open circuit
- Connector list and layout
- Connector contact identification
- T-branch box and T-branch adapter table
- Fuse location table
- Precautions on troubleshooting of machine monitor
- Processing procedure of harness checker for troubleshooting of machine monitor LCD unit
- Failure codes table
- Troubleshooting by failure code (Display of code)
- Failure code [1500L0] Double Engagement of T/M Clutches
- Failure code [15B0NX] Transmission Oil Filter Clogging
- Failure code [15F0KM] Abuse 1 of Gear Shifting from R to F
- Failure code [15F0MB] Abuse 2 of Gear Shifting from R to F
- Failure code [15F7KM] Abuse of TM Forward Clutch Disk
- Failure code [15G0MW] Failure of Clutch (Reverse)
- Failure code [15G7KM] Abuse of TM Reverse Clutch Disk
- Failure code [15H0MW] Failure of Clutch (High)
- Failure code [15J0MW] Failure of Clutch (Low)
- Failure code [15K0MW] Failure of Clutch (1st)
- Failure code [15L0MW] Failure of Clutch (2nd)
- Failure code [15M0MW] Failure of Clutch (3rd)
- Failure code [15SBL1] Release Trouble of ECMV (Reverse)
- Failure code [15SBMA] Malfunction of ECMV (Reverse)
- Failure code [15SCL1] Release Trouble of ECMV (High)
- Failure code [15SCMA] Malfunction of ECMV (High)
- Failure code [15SDL1] Release Trouble of ECMV (Low)
- Failure code [15SDMA] Malfunction of ECMV (Low)
- Failure code [15SEL1] Release Trouble of ECMV (1st)
- Failure code [15SEMA] Malfunction of ECMV (1st)
- Failure code [15SFL1] Release Trouble of ECMV (2nd)
- Failure code [15SFMA] Malfunction of ECMV (2nd)
- Failure code [15SGL1] Release Trouble of ECMV (3rd)
- Failure code [15SGMA] Malfunction of ECMV (3rd)
- Failure code [15SJMA] Malfunction of ECMV (Lockup)
- Failure code [15SKMA] Malfunction of ECMV (Inter-Axle Diff.)
- Failure code [2F00KM] Dragging of Parking Brake
- Failure code [2G42ZG] Accumulator Oil Pressure Low (Front)
- Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)
- Failure code [879AKA] A/C Inner Sensor Open Circuit
- Failure code [879AKB] A/C Inner Sensor Short Circuit
- Failure code [879BKA] A/C Outer Sensor Open Circuit
- Failure code [879BKB] A/C Outer Sensor Short Circuit
- Failure code [879CKA] Ventilating Sensor Open Circuit
- Failure code [879CKB] Ventilating Sensor Short Circuit
- Failure code [879EMC] Ventilation Damper Abnormality
- Failure code [879FMC] Air Mix Damper Abnormality
- Failure code [879GKX] Refrigerant Abnormality
- Failure code [989D00] Tilt Caution
- Failure code [989L00] Engine Controller Lock Caution1
- Failure code [989M00] Engine Controller Lock Caution2
- Failure code [989N00] Engine Controller Lock Caution3
- Failure code [AA10NX] Air Cleaner Clogging
- Failure code [AB00KE] Charge Voltage Low
- Failure code [AB00KY] Hot Short of Alternator R Terminal
- Failure code [B@BAZG] Eng Oil Press Low
- Failure code [B@BAZK] Engine Oil Level Low
- Failure code [B@BCNS] Eng Water Overheat
- Failure code [B@BCZK] Eng Water Level Low
- Failure code [B@C6NS] Retarder Oil Overheat (Front)
- Failure code [B@C8NS] Retarder Oil Overheat (Center)
- Failure code [B@CENS] T/C Oil Temp. Overheat
- Failure code [B@JANS] Steering Oil Overheat
- Failure code [CA111] ECM Critical Internal Failure
- Failure code [CA115] Eng Ne and Bkup Speed Sens Error
- Failure code [CA122] Chg Air Press Sensor High Error
- Failure code [CA123] Chg Air Press Sensor Low Error
- Failure code [CA131] Throttle Sensor High Error
- Failure code [CA132] Throttle Sensor Low Error
- Failure code [CA135] Eng Oil Press Sensor High Error
- Failure code [CA141] Eng Oil Press Sensor Low Error
- Failure code [CA144] Coolant Temp Sens High Error
- Failure code [CA145] Coolant Temp Sens Low Error
- Failure code [CA153] Chg Air Temp Sensor High Error
- Failure code [CA154] Chg Air Temp Sensor Low Error
- Failure code [CA187] Sensor 2 Supply Volt Low Error
- Failure code [CA221] Ambient Press Sensor High Error
- Failure code [CA222] Ambient Press Sensor Low Error
- Failure code [CA227] Sensor 2 Supply Volt High Error
- Failure code [CA234] Eng Overspeed
- Failure code [CA238] Ne Speed Sensor Supply Volt Error
- Failure code [CA263] Fuel Temp Sensor High Error
- Failure code [CA265] Fuel Temp Sensor Low Error
- Failure code [CA271] IMV/PCV1 Short Error
- Failure code [CA272] IMV/PCV1 Open Error
- Failure code [CA273] PCV2 Short Error
- Failure code [CA274] PCV2 Open Error
- Failure code [CA322] Inj #1(L#1) Open/Short Error
- Failure code [CA323] Inj #5(L#5) Open/Short Error
- Failure code [CA324] Inj #3(L#3) Open/Short Error
- Failure code [CA325] Inj #6(L#6) Open/Short Error
- Failure code [CA331] Inj #2(L#2) Open/Short Error
- Failure code [CA332] Inj #4(L#4) Open/Short Error
- Failure code [CA342] Calibration Code Incompatibility
- Failure code [CA351] Injectors Drive Circuit Error
- Failure code [CA352] Sensor 1 Supply Volt Low Error
- Failure code [CA386] Sensor 1 Supply Volt High Error
- Failure code [CA431] Idle Validation Sw Error
- Failure code [CA432] Idle Validation Process Error
- Failure code [CA441] Battery Voltage Low Error
- Failure code [CA442] Battery Voltage High Error
- Failure code [CA449] Rail Press Very High Error
- Failure code [CA451] Rail Press Sensor High Error
- Failure code [CA452] Rail Press Sensor Low Error
- Failure code [CA553] Rail Press High Error
- Failure code [CA554] Rail Press Sensor In Range Error
- Failure code [CA559] Rail Press Low Error
- Failure code [CA689] Eng Ne Speed Sensor Error
- Failure code [CA731] Eng Bkup Speed Sens Phase Error
- Failure code [CA757] All Continuous Data Lost Error
- Failure code [CA778] Eng Bkup Speed Sensor Error
- Failure code [CA2185] Throt Sensor Sup Volt High Error
- Failure code [CA2186] Throt Sensor Sup Volt Low Error
- Failure code [CA2249] Rail Press Very Low Error
- Failure code [CA2555] Grid Htr Relay Volt Low Error
- Failure code [CA2556] Grid Htr Relay Volt High Error
- Failure code [D150KB] Ground Fault of Emerg. Steering Relay
- Failure code [D150KZ] Failure of Emerg. Steering Relay
- Failure code [D151KB] Ground Fault of Emerg. Steering Relay 2
- Failure code [D151KZ] Failure of Emerg. Steering Relay 2
- Failure code [D164KY] Hot Short of Head Light High Selector
- Failure code [D19HKZ] Failure of Stop Lamp (R&L)
- Failure code [D19JKZ] Personal Code Relay Abnormality
- Failure code [D1EHKA] Disconnection of Engine Start Relay
- Failure code [D1EHKB] Ground Fault of Engine Start Relay
- Failure code [D1EHKY] Hot Short of Engine Start Relay
- Failure code [D1EMKA] Disconnection of Parking Interlock Relay
- Failure code [D1EMKB] Ground Fault of Parking Interlock Relay
- Failure code [D1EMKY] Hot Short of Parking Interlock Relay
- Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay
- Failure code [D5ZHL6] Disconnection of Key SW C
- Failure code [D811MC] KOMTRAX Error
- Failure code [D862KA] GPS Antenna Open Circuit
- Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)
- Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)
- Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2
- Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
- Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON)
- Failure code [DAF0MB] Monitor ROM Abnormality
- Failure code [DAF0MC] Monitor Error
- Failure code [DAF3KK] Controller Power Source Low (MON)
- Failure code [DAF8KB] Camera Power Supply Short Circuit
- Failure code [DAFDKB] Monitor 12V Power Output Short Circuit
- Failure code [DAFGMC] GPS Module Error
- Failure code [DAFLKA] Operating Lamp Open Circuit (MON)
- Failure code [DAFLKB] Operating Lamp Short Circuit (MON)
- Failure code [DAFQKR] CAN2 Discon (Monitor)
- Failure code [DAQ0KK] Controller Power Source Low (T/M)
- Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M)
- Failure code [DAQ0MC] T/M Con Error
- Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M)
- Failure code [DAQ2KK] Solenoid Power Source Low (T/M)
- Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M)
- Failure code [DAQLKA] Operating Lamp Open Circuit (T/M)
- Failure code [DAQLKB] Operating Lamp Short Circuit (T/M)
- Failure code [DAQQKR] CAN2 Discon (Transmission Con)
- Failure code [DAQRKR] CAN1 Discon (Transmission Con)
- Failure code [DAQRMA] Inconsistency of Option Selection (T/M)
- Failure code [DAQV00] Neutral Coast Caution
- Failure code [DAQW00] Neutral Over Speed Caution
- Failure code [DAZ9KQ] A/C Model Selection Abnormality
- Failure code [DAZQKR] CAN2 Discon (Aircon ECU)
- Failure code [DB10KT] Abnormality of Non-volatile Memory (RHC)
- Failure code [DB10MC] RHC Error
- Failure code [DB11KA] Disconnection of Key SW ACC (RHC)
- Failure code [DB12KK] Solenoid Power Source Low (RHC)
- Failure code [DB13KK] Controller Power Source Low (RHC)
- Failure code [DB19KQ] Inconsistency of Model Selection (RHC)
- Failure code [DB1LKA] Disconnection of System Ope. Lamp (RHC)
- Failure code [DB1LKB] Short Circuit of System Ope. Lamp (RHC)
- Failure code [DB1QKR] CAN2 Discon (Retarder Hoist Con)
- Failure code [DB1QMA] Inconsistency of Option Selection (RHC) (
- Failure code [DB1RKR] CAN1 Discon (Retarder Hoist Con)
- Failure code [DB1Z00] Rollover Caution
- Failure code [DB1ZKM] Occurrence of Large Lateral Acceleration
- Failure code [DB2QKR] CAN2 Discon (Engine Con)
- Failure code [DB2QKR] CAN2 Discon (Engine Con) (Machine with payload meter controller: CR720)
- Failure code [DBSQKQ] Inconsistency of Model Selection (PLM)
- Failure code [DBSQKR] CAN2 Discon (PLM)
- Failure code [DBSQKR] CAN2 Discon (PLM) (Machine with payload meter controller: CR720)
- Failure code [DD1ML4] Failure of ARAC SW
- Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch
- Failure code [DDTHKA] Disconnection of Fill Switch (High) Serial No.: 8001 to 8203
- Failure code [DDTHKA] Disconnection of Fill Switch (High) Serial No.: 8204 and up
- Failure code [DDTJKA] Disconnection of Fill Switch (Low) Serial No.: 8001 to 8203
- Failure code [DDTJKA] Disconnection of Fill Switch (Low) Serial No.: 8204 and up
- Failure code [DDTKKA] Disconnection of Fill Switch (1st) Serial No.: 8001 to 8203
- Failure code [DDTKKA] Disconnection of Fill Switch (1st) Serial No.: 8204 and up
- Failure code [DDTLKA] Disconnection of Fill Switch (2nd) Serial No.: 8001 to 8203
- Failure code [DDTLKA] Disconnection of Fill Switch (2nd) Serial No.: 8204 and up
- Failure code [DDTMKA] Disconnection of Fill Switch (3rd) Serial No.: 8001 to 8203
- Failure code [DDTMKA] Disconnection of Fill Switch (3rd) Serial No.: 8204 and up
- Failure code [DDTNKA] Disconnection of Fill Switch (Reverse) Serial No.: 8001 to 8203
- Failure code [DDTNKA] Disconnection of Fill Switch (Reverse) Serial No.: 8204 and up
- Failure code [DF10KA] Disconnection of Shift Lever Input
- Failure code [DF10KB] Ground Fault of Shift Lever Input
- Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor
- Failure code [DGR3KB] Ground Fault of Retarder Oil Temp. S.(C)
- Failure code [DGR3L8] Failure of Retarder Oil Temp. Sensor (C)
- Failure code [DGR4KB] Ground Fault of Retarder Oil Temp. S.(F)
- Failure code [DGR4L8] Failure of Retarder Oil Temp. Sensor (F)
- Failure code [DGR6KB] Ground Fault of Steering Oil Temp. S.
- Failure code [DGR6L8] Failure of Steering Oil Temp. Sensor
- Failure code [DGR7KX] Out of Range of Piston Pump Oil Temp. S.
- Failure code [DGR8KX] Out of Range of CAC Output Temp. S.
- Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor
- Failure code [DHP4KY] Hot Short of Suspension Press. S. (FR)
- Failure code [DHP4KY] Hot Short of Suspension Press. S. (FR) (Machine with payload meter controller: CR720)
- Failure code [DHP4KZ] Failure of Suspension Press. S. (FR)
- Failure code [DHP4KZ] Failure of Suspension Press. S. (FR) (Machine with payload meter controller: CR720)
- Failure code [DHP5KY] Hot Short of Suspension Press. S. (FL)
- Failure code [DHP5KY] Hot Short of Suspension Press. S. (FL) (Machine with payload meter controller: CR720)
- Failure code [DHP5KZ] Failure of Suspension Press. S. (FL)
- Failure code [DHP5KZ] Failure of Suspension Press. S. (FL) (Machine with payload meter controller: CR720)
- Failure code [DHP6KY] Hot Short of Suspension Press. S. (RR)
- Failure code [DHP6KY] Hot Short of Suspension Press. S. (RR) (Machine with payload meter controller: CR720)
- Failure code [DHP6KZ] Failure of Suspension Press. S. (RR)
- Failure code [DHP6KZ] Failure of Suspension Press. S. (RR) (Machine with payload meter controller: CR720)
- Failure code [DHP7KY] Hot Short of Suspension Press. S. (RL)
- Failure code [DHP7KY] Hot Short of Suspension Press. S. (RL) (Machine with payload meter controller: CR720)
- Failure code [DHP7KZ] Failure of Suspension Press. S. (RL)
- Failure code [DHP7KZ] Failure of Suspension Press. S. (RL) (Machine with payload meter controller: CR720)
- Failure code [DHQ2KX] Out of Range of Main Flow Sel. Valve S.
- Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor
- Failure code [DHT5L6] Failure of T/C Oil Press Sensor
- Failure code [DHT8KX] Out of Range of Steering Oil Press. S.
- Failure code [DHT8ZG] Steering Oil Pressure Low
- Failure code [DHU2KX] Out of Range of Acc. Oil Press. S. (F)
- Failure code [DHU3KX] Out of Range of Acc. Oil Press. S. (R)
- Failure code [DHUAKX] Out of Range of Retarder Press. S. (CR)
- Failure code [DHUBKX] Out of Range of Retarder Press. S. (FR)
- Failure code [DHUCKX] Out of Range of Parking Brake Press. S.
- Failure code [DHUDKX] Out of Range of Emerg. Steering Press. S.1
- Failure code [DHUEKX] Out of Range of Emerg. Steering Press. S.2
- Failure code [DHUQKX] Out of Range of Retarder Press. S. (FL)
- Failure code [DHURKX] Out of Range of Retarder Press. S. (CL)
- Failure code [DJF1KA] Disconnection of Fuel Level Sensor
- Failure code [DK30KX] Out of Range of Steering Angle Pot.
- Failure code [DK51L5] Failure of Retarder Lever Pot. and RVS
- Failure code [DK52KX] Out of Range of Hoist Lever Potentio.
- Failure code [DK53L8] Failure of Hoist Lever Potentio.
- Failure code [DK54KX] Out of Range of Body Potentio.
- Failure code [DK60KX] Out of Range of Acceleration Sensor
- Failure code [DK80KT] IMU Internal Error
- Failure code [DK80KR] CAN J1939 Communication Error (IMU)
- Failure code [DKH0KX] Out of Range of Inclination Angle Sensor
- Failure code [DKH1KX] Out of Range of Long. Inclination Angle S.
- Failure code [DKH1KX] Out of Range of Long. Inclination Angle S. (Machine with payload meter controller: CR720)
- Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor
- Failure code [DLF1LC] Failure of T/M Input Speed Sensor
- Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor
- Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor
- Failure code [DLF400] T/M Diff. Overrun Prevention Activated
- Failure code [DLF4KA] Disconnection of T/M Diff. Speed Sensor
- Failure code [DLF4LC] Failure of T/M Diff. Speed Sensor
- Failure code [DLF6LC] Failure of Wheel Speed Sensor (FR)
- Failure code [DLF7LC] Failure of Wheel Speed Sensor (FL)
- Failure code [DLFDLC] Failure of Wheel Speed Sensor (CR)
- Failure code [DLFELC] Failure of Wheel Speed Sensor (CL)
- Failure code [DLFFLC] Failure of Wheel Speed Sensor (Front)
- Failure code [DLFGLC] Failure of Wheel Speed Sensor (Center)
- Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor
- Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor
- Failure code [DLM3MB] Radiator Fan Control Mismatch
- Failure code [DLM4KA] Disconnection of CAC Fan Speed Sensor
- Failure code [DLM4LC] Failure of CAC Fan Speed Sensor
- Failure code [DLM4MB] CAC Fan Control Mismatch
- Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main)
- Failure code [DLT3LC] Failure of Output Speed Sensor (Main)
- Failure code [DPQ1KR] LIN Discon (Switch Panel)
- Failure code [DPQ2KR] LIN Discon (LED Unit)
- Failure code [DPQ3KR] LIN Discon (Rear View Monitor)
- Failure code [DSJ0KR] CAN2 Discon (Meter Unit)
- Failure code [DV00KB] Ground Fault of Buzzer Output
- Failure code [DW2BKA] Disconnection of Main Flow Selector Sol.
- Failure code [DW2BKB] Ground Fault of Main Flow Selector Sol.
- Failure code [DW2BKY] Hot Short of Main Flow Selector Sol.
- Failure code [DW2BL1] Release Trouble of Main Flow Sel. Valve
- Failure code [DW2BLH] Malfunction of Main Flow Selector Valve
- Failure code [DW4BK4] Release Trouble of Parking Brake Valve
- Failure code [DW4BMA] Malfunction of Parking Brake Valve
- Failure code [DW72KZ] Failure of Kick out Solenoid
- Failure code [DW73KA] Disconnection of Hoist Selector Sol.
- Failure code [DW73KB] Ground Fault of Hoist Selector Sol.
- Failure code [DW73KY] Hot Short of Hoist Selector Sol.
- Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol.
- Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol.
- Failure code [DW7BKZ] Failure of Radiator Fan Rev. Sol.
- Failure code [DW7LKB] Ground Fault of CAC Fan Rev. Sol.
- Failure code [DW7LKY] Hot Short of CAC Fan Rev. Sol.
- Failure code [DW7LKZ] Failure of CAC Fan Rev. Sol.
- Failure code [DW7NKZ] Failure of Steering Pump Selector Sol.
- Failure code [DWNJKZ] Failure of TCS Shut off Sol. (Front)
- Failure code [DWNKKZ] Failure of TCS Shut off Sol. (Center)
- Failure code [DX13KA] Disconnection of Hoist EPC Solenoid
- Failure code [DX13KB] Ground Fault of Hoist EPC Solenoid
- Failure code [DX13KY] Hot Short of Hoist EPC Solenoid
- Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol.
- Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol.
- Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol.
- Failure code [DX29KA] Disconnection of CAC Fan Pump EPC Sol.
- Failure code [DX29KB] Ground Fault of CAC Fan Pump EPC Sol.
- Failure code [DX29KY] Hot Short of CAC Fan Pump EPC Sol.
- Failure code [DX30K4] Release Trouble of Retarder EPC Valve(FL)
- Failure code [DX30KA] Disconnection of Retarder EPC Sol. (FL)
- Failure code [DX30KB] Ground Fault of Retarder EPC Sol. (FL)
- Failure code [DX30KY] Hot Short of Retarder EPC Sol. (FL)
- Failure code [DX30MA] Malfunction of Retarder EPC Valve (FL)
- Failure code [DX31K4] Release Trouble of Retarder EPC Valve(CR)
- Failure code [DX31KA] Disconnection of Retarder EPC Sol. (CR)
- Failure code [DX31KB] Ground Fault of Retarder EPC Sol. (CR)
- Failure code [DX31KY] Hot Short of Retarder EPC Sol. (CR)
- Failure code [DX31MA] Malfunction of Retarder Valve (CR)
- Failure code [DX32K4] Release Trouble of Retarder EPC Valve(CL)
- Failure code [DX32KA] Disconnection of Retarder EPC Sol. (CL)
- Failure code [DX32KB] Ground Fault of Retarder EPC Sol. (CL)
- Failure code [DX32KY] Hot Short of Retarder EPC Sol. (CL)
- Failure code [DX32MA] Malfunction of Retarder EPC Valve (CL)
- Failure code [DX33K4] Release Trouble of Retarder EPC Valve (FR)
- Failure code [DX33KA] Disconnection of Retarder EPC Sol. (FR)
- Failure code [DX33KB] Ground Fault of Retarder EPC Sol. (FR)
- Failure code [DX33KY] Hot Short of Retarder EPC Sol. (FR)
- Failure code [DX33MA] Malfunction of Retarder EPC Valve (FR)
- Failure code [DX34KA] Disconnection of Remote Cooling EPC Sol.
- Failure code [DX34KB] Ground Fault of Remote Cooling EPC Sol.
- Failure code [DX34KY] Hot Short of Remote Cooling EPC Sol.
- Failure code [DXH0KA] Disconnection of ECMV (Inter-Axle Diff.)
- Failure code [DXH0KB] Ground Fault of ECMV (Inter-Axle Diff.)
- Failure code [DXH0KY] Hot Short of ECMV (Inter-Axle Diff.)
- Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup)
- Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup)
- Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup)
- Failure code [DXH2KA] Disconnection of ECMV Solenoid (High)
- Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High)
- Failure code [DXH2KY] Hot Short of ECMV Solenoid (High)
- Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low)
- Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low)
- Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low)
- Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)
- Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st)
- Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st)
- Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)
- Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd)
- Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd)
- Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd)
- Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd)
- Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd)
- Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse)
- Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse)
- Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)
- Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor
- Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor
- Failure code [DY30ME] Emerg. Steering Long-Time Activated
- Failure code [DY32MC] Malfunction 2 of Emerg. Steering Motor 2
- Troubleshooting of electrical system (E-mode)
- E-1 Engine does not start (Engine does not crank)
- E-2 Manual preheating system does not work
- E-3 Automatic preheating system does not work
- E-4 While preheating is working, preheating monitor does not light up
- E-5 All of LCD unit, LED unit and meter unit on machine monitor display nothing
- E-6 LCD unit on machine monitor displays nothing
- E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers)
- E-8 LCD on machine monitor does not display properly
- E-9 Meter unit display on machine monitor is abnormal
- E-10 Night lighting lamp of meter unit on machine monitor is abnormal
- E-11 LED unit lamp on machine monitor is abnormal
- E-12 Night lighting lamp of switch panel on machine monitor is abnormal or switches does not operate properly
- E-13 2 switches operation of switch panel on machine monitor does not function
- E-14 Switch panel buzzer of machine monitor is abnormal
- E-15 Some items of gauges and caution lamps on machine monitor are not displayed properly
- E-16 Fuel level gauge does not indicate correct level
- E-17 Seat belt caution lamp indication is abnormal
- E-18 Machine monitor cannot be operated when starting switch is in OFF position
- E-19 Alarm buzzer does not sound
- E-20 Alarm buzzer does not stop sounding
- E-21 Engine mode selector function does not operate properly
- E-22 AISS function does not operate properly
- E-23 Hoist lever does not operate properly
- E-24 Turn signal lamp and winker lamp (hazard lamp) do not operate properly
- E-25 All of small lamp (clearance lamp and tail lamp) and head lamp do not light up
- E-26 Small lamp (clearance lamp) does not light up
- E-27 Tail lamp does not light up
- E-28 Low beam head lamp does not light up
- E-29 High beam head lamp does not light up
- E-30 Neither Low beam nor High beam head lamps lights up
- E-31 High beams do not light up while passing switch is operated
- E-32 KOMTRAX does not operate properly
- Troubleshooting of hydraulic and mechanical system (H-mode)
- Information described in troubleshooting table (H-mode)
- System chart of hydraulic and mechanical systems
- Failure mode and cause table
- H-1 Machine does not start
- H-2 Machine does not travel smoothly (engine hunts)
- H-3 Lockup clutch is not disengaged
- H-4 Abnormally large shocks result from starting of machine and gear shifting
- H-5 Machine does not upshift
- H-6 Machine lacks travel speed or power during travel in lockup drive mode through all gear speeds
- H-7 Machine lacks travel speed or power during travel in torque converter drive mode
- H-8 Machine lacks travel speed or power during travel in specific gear speed
- H-9 Machine starts or gear speed shifts with long time lag
- H-10 Torque converter oil temperature is high
- H-11 Torque converter oil pressure is low
- H-12 Front brake does not work sufficiently
- H-13 Center brake does not work sufficiently
- H-14 Steering wheel is heavy to turn
- H-15 Steering wheel does not move
- H-16 Steering wheel swings
- H-17 Dump body raise speed or power is slow
- H-18 Dump body does not move
- H-19 Hydraulic drift of dump body is large
- H-20 Radiator fan speed is abnormal (high, low, or stationary)
- H-21 Aftercooler fan speed is abnormal (high, low, or stationary)
- H-22 Unusual noise is heard from around radiator fan
- H-23 Unusual noise is heard from around aftercooler fan
- Troubleshooting of engine (S-mode)
- Information mentioned in troubleshooting table (S mode)
- S-1 Engine does not crank when starting switch is turned to START position
- S-2 The engine cranks but exhaust smoke does not come out
- S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not)
- S-4 Engine startability is poor
- S-5 Engine does not pick up smoothly
- S-6 Engine stops during operation
- S-7 Engine runs rough or is unstable
- S-8 Engine lacks power
- S-9 Exhaust smoke is black
- S-10 Engine oil consumption is excessive
- S-11 Oil becomes contaminated quickly
- S-12 Fuel consumption is excessive
- S-13 Oil is in coolant (or coolant spurts or coolant level goes down)
- S-14 Oil pressure drops
- S-15 Fuel mixes into engine oil
- S-16 Water mixes into engine oil (milky)
- S-17 Coolant temperature rises too high (overheating)
- S-18 Unusual noise is heard
- S-19 Vibration is excessive
- S-20 Air cannot be bled from fuel circuit
- 50 Disassembly and assembly
- Table of contents
- Precautions before work
- Related information on disassembly and assembly
- How to read this manual
- Coating materials list
- Special tools list
- Sketches of special tools
- Engine and cooling system
- Removal and installation of supply pump assembly
- Removal and installation of injector assembly
- Removal and installation of cylinder head assembly
- Removal and installation of radiator assembly
- Removal and installation of radiator core assembly
- Removal and installation of cooling fan and fan motor assembly for radiator
- Removal and installation of aftercooler assembly
- Removal and installation of cooling fan and fan motor assembly foraftercooler
- Removal and installation of engine assembly
- Removal and installation of engine front oil seal
- Removal and installation of engine rear oil seal
- Removal and installation of output shaft assembly
- Disassembly and assembly of output shaft assembly
- Removal and installation of air cleaner assembly
- Removal and installation of fire prevention cover on exhaust pipe
- Power train
- Removal and installation of transmission and front differential assembly
- Disconnection and connection of front differential assembly andtransmission assembly
- Disassembly and assembly of front differential assembly
- Disassembly and assembly of torque converter assembly
- Disassembly and assembly of transmission assembly
- Removal and installation of center differential assembly
- Disassembly and assembly of center differential assembly
- Removal and installation of rear differential assembly
- Disassembly and assembly of rear differential assembly
- Removal and installation of front final drive and brake assembly
- Disassembly and assembly of front final drive and brake assembly
- Removal and installation of center final drive and brake assembly
- Disassembly and assembly of center final drive and brake assembly
- Removal and installation of rear final drive assembly
- Disassembly and assembly of rear final drive assembly
- Removal and installation of center axle assembly
- Removal and installation of rear axle assembly
- Steering system
- Disassembly and assembly of steering cylinder assembly
- Undercarriage and frame
- Removal and installation of front suspension cylinder assembly
- Removal and installation of rear suspension cylinder assembly
- Disassembly and assembly of suspension cylinder assembly
- Removal and installation of equalizer bar assembly
- Removal and installation of front wheel assembly
- Removal and installation of rear (front side) wheel assembly
- Removal and installation of rear (rear side) wheel assembly
- Removal and installation of hitch frame assembly
- Disassembly and assembly of hitch frame assembly
- Hydraulic system
- Removal and installation of flow amplifier valve assembly
- Removal and installation of hoist valve assembly
- Disassembly and assembly of hoist valve assembly
- Disassembly and assembly of hoist cylinder assembly
- Disassembly and assembly of hoist cylinder assembly
- Body
- Removal and installation of dump body assembly
- Cab and its attachments
- Removal and installation of operator's cab assembly
- Removal and installation of operator's cab glass (adhered glass)
- Removal and installation of operator's seat assembly
- Removal and installation of seat belt
- Electrical system
- Removal and installation of machine monitor assembly
- Removal and installation of engine controller assembly
- Removal and installation of retarder and hoist controller assembly
- Removal and installation of transmission controller assembly
- Removal and installation of KOMTRAX terminal assembly
- Air conditioner system
- Removal and installation of air conditioner unit assembly
- Removal and installation of air conditioner compressor assembly
- Removal and installation of air conditioner condenser
- 60 Maintenance standard
- Table of contents
- Engine and cooling system
- Engine mount
- Output shaft
- Radiator fan pump
- Aftercooler fan motor
- Radiator fan motor
- Power train
- Drive shaft
- Torque converter and transmission mount
- Torque converter
- Transmission
- Transmission control valve
- Forward and reverse clutch ECMV and gear speed clutch ECMV
- Lockup clutch ECMV
- Differential lock clutch ECMV
- Main relief valve, torque converter relief valve, and main flow selector valve
- Differential
- Axle
- Final drive
- Steering system
- Steering column
- Steering cylinder
- Emergency steering pump
- Brake system
- Slack adjuster
- Brake
- Parking brake
- Undercarriage and frame
- Suspension
- Suspension cylinder
- Oscillation hitch
- Hydraulic system
- Steering and hoist pump
- Pump for driving torque converter, transmission, aftercooler fan, and center brake cooling motors
- Center brake cooling pump
- Brake charge pump
- Center brake cooling remote pump
- Center brake cooling remote motor
- Hoist valve
- Hoist cylinder
- 80 Appendix
- Table of contents
- Precautions before work
- Air conditioner components
- Precautions for refrigerant
- Air conditioner component
- Configuration and function of refrigeration cycle
- Air conditioner unit
- Dual pressure switch
- Air conditioner controller
- Compressor
- Condenser
- Receiver drier
- Outer temperature sensor (outside air temperature sensor)
- Procedure for testing and troubleshooting
- Circuit diagram and arrangement of connector pins
- System diagram
- Input and output signals of the air conditioner controller
- Parts and connectors layout
- Testing air leakage (duct)
- Testing with self-diagnosis function
- How to open the electrical system abnormality record screen in service mode of the machine monitor
- Testing vent (mode) changeover
- Testing FRESH/RECIRC air changeover
- Testing (dual) pressure switch for refrigerant
- Testing relays
- Troubleshooting chart 1
- Troubleshooting chart 2
- Information in troubleshooting table
- Failure code list related to air conditioner
- Failure code [879AKA] A/C Inner sensor Open Circuit
- Failure code [879AKB] A/C Inner sensor Short Circuit
- Failure code [879BKA] A/C Outer sensor Open Circuit
- Failure code [879BKB] A/C Outer sensor Short Circuit
- Failure code [879CKA] Ventilating sensor Open Circuit
- Failure code [879CKB] Ventilating sensor Short Circuit
- Failure code [879EMC] Ventilating Damper Abnormality
- Failure code [879FMC] Air Mix Damper Abnormality
- Failure code [879GKX] Refrigerant Abnormality
- A-1 Troubleshooting for power supply system (Air conditioner does not operate)
- A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)
- A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
- A-4 Troubleshooting for FRESH/RECIRC air changeover
- Troubleshooting with gauge pressure
- Connection of service tool
- Precautions for disconnecting and connecting air conditioner piping
- Handling of compressor oil
- 90 Diagrams and drawings
- Table of contents
- Hydraulic circuit diagram
- Symbols in hydraulic circuit diagram
- Power train hydraulic circuit diagram
- Hydraulic circuit diagram
- Electric circuit diagram
- Symbols in electric circuit diagram
- Inside cab electrical circuit diagram (Serial No.: 8001 to 8203)
- Inside cab electrical circuit diagram (Serial No.: 8204 and up)
- Inside cab electrical circuit diagram (Machine with payload meter controller: CR720)
- Outside cab electrical circuit diagram
- Electrical circuit diagram of engine
- INDEX
Komatsu
