PDF Shop Manual Komatsu HM400-2 Articulated Dump Truck - 4 MB
This complete shop manual for the Komatsu HM400-2 Articulated Dump Truck is an essential tool for any technician.
It contains detailed, step-by-step procedures for all aspects of testing, adjusting, troubleshooting, and repair.
With comprehensive sections on the engine, transmission, hydraulics, and electrical systems, this manual provides the information needed for even the most complex jobs.
Ensure your truck operates reliably with this factory-level guide.
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--- Page 1 ---
SEN00239-10
ARTICULATED HM400 -2
DUMP TRUCK
SERIAL NUMBERS 2001 and up
--- Page 3 ---
00 Index and foreword SEN00512-10
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
--- Page 4 ---
30 Testing and adjusting SEN00916-04
Symb
Q'ty
Testing and adjusting item Part No. Part name Remarks
ol
21 mm deep socket
Commercially (MITOLOY 4ML 21 or equivalent)
Socket 1
available Applicable engine serial
Removal and installation of
No.:530056–534132
engine coolant temperature -
19 mm deep socket
sensor
(MITOLOY 4ML 19 or equivalent)
795T-981-1010 Socket 1
Applicable engine serial
No.:534133 and up
*: Included in 799-601-9000 and 799-601-9200
*%: Included in 799-601-4101 and 799-601-4201
a For types and part numbers for T-branch boxes and T-branch adapters for troubleshooting for machine
monitor, controller, sensor, actuator, electrical parts and wiring harness, see "T-branch box and T-branch
adapter table" in the troubleshooting section, General information on troubleshooting.
HM400-2 5
--- Page 5 ---
30 Testing and adjusting SEN00916-04
Testing blow-by pressure
a Testing instrument for blow-by pressure
Symbol Part number Part name
F 799 - 201 - 1504 Blow-by checker
k Stop the machine on the level ground, turn
the parking brake switch ON, and set chocks
to the tires.
1. Remove engine under cover (small).
2. Install nozzle [1] and hose [2] to blow-by hose (1)
and connect to gauge [3].
6. When the testing is completed, remove the
instruments and set to the original condition.
3. Start the engine and raise the coolant tempera-
ture of the engine to the operating range.
4. Turn the parking brake switch ON, depress the
brake pedal and set the gear shift lever to the D
position.
k If the gearshift lever is operated to any po-
sition other than the D position, the ma-
chine may move off even if the brake is
being depressed, so always test at the D
position.
5. Depress the accelerator pedal gradually and
check blow-by pressure while the engine is
running at high idle and the torque converter is
stalling.
k There is danger of damage to the internal
parts of the transmission, so never oper-
ate the gear shift lever to any position oth-
er than the D position during the stall
operation.
a After completing the test, lower the engine
speed to low idle, then return the gearshift le-
ver to the N position.
HM400-2 15
--- Page 6 ---
30 Testing and adjusting SEN00916-04
7. Crank the engine with the starting motor and
start the engine.
a The air in the high-pressure circuit is bled au-
tomatically if the engine is cranked.
a If the engine does not start, there still may be
air in the low-pressure circuit. In this case,
repeat the above procedure from step 4.
4. Remove air bleeding plug (3) of fuel main filter
(2) and operate priming pump (4).
a Operate until fuel flows through plug hole and
when fuel is confirmed, install the plug.
3 Air bleeding plug:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
5. Remove air bleeding plug (5) of fuel main filter
and operate priming pump (4).
a Operate until fuel flows through plug hole and
when fuel is confirmed, install the plug.
3 Air bleeding plug:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
6. Loosen supply pump air bleeder (6) and operate
priming pump (4) 90 – 100 times.
a Operate priming pump until fuel flows
through bleeder and when fuel is confirmed,
tighten bleeder and operate several times
more until priming pump becomes stiff.
a Air bleeder:4.9 – 6.9 Nm {0.5 – 0.7 kgm}
HM400-2 25
--- Page 7 ---
30 Testing and adjusting SEN00917-04
Torque converter related 3. Testing torque converter outlet pressure
2.Testing torque converter inlet pressure 1) Tilt the cab up.
1) Install hose [1] of hydraulic tester K1 to oil 2) Remove oil pressure inspecting plug (3),
pressure inspecting coupler (2). then install nipple [1] and hose [2] of
hydraulic tester K1.
a Pull the hose out to the rear of the trans-
mission.
2) Connect hydraulic tester K2.
3) Start the engine and raise the temperature of
the torque converter oil to the operating
range. 3) Tilt the cab down and return it to its original
4) While keeping the gear shift lever at the N position.
position, inspect the oil pressure at high idle. 4) Connect oil pressure gauge [3] of hydraulic
tester K1.
a If oil pressure gauges are of the analog
type, use the one with rated pressure 6
MPa {60 kg/cm2}.
5) Start the engine and raise the temperature of
the torque converter oil to the operating
range.
6) While keeping the gear shift lever at the N
position, inspect the oil pressure at high idle.
When operate retarder control lever at actua-
tion position and release position.
5) When the test is completed, remove the
instruments and restore to the original condi-
tion.
7) When the test is completed, remove the
instruments and restore to the original condi-
tion.
HM400-2 5
--- Page 8 ---
30 Testing and adjusting SEN00917-04
3. Adjusting the differential lock oil pressure for rear axle
a If the rear axle differential lock oil pressure is
not normal, adjust it with relief valve (13) of
rear differential lock valve according to the
following procedures.
a Procedure for adjustment is the same as for
center differential lock valve.
HM400-2 15
--- Page 9 ---
30 Testing and adjusting SEN00917-04
Carging accumulator with nitrogen gas chart 10. Remove gas charge tool R1 from valve (4) of
Ambient Carging nitrogen gas accumulator (1) according to the following
temperture Remarks procedure.
°C Mpa kg/cm2 1) Turn handle (a) to the left to close the valve
15 4.34 44.2 of the accumulator.
16 4.35 44.4 2) Turn handle (b) to the left to open and
17 4.37 44.5
18 4.38 44.7
discharge nitrogen gas remaining in gas
19 4.40 44.8 charge tool R1 and hoses.
Standard gas 3) Remove gas charge tool R1 from valve (4) of
20 4.41 45.0
pressure the accumulator.
21 4.43 45.2
22 4.44 45.3
11. Apply soap water to valve (4) of the accumulator
23 4.46 45.5
24 4.47 45.6 to check that nitrogen gas is not leaking.
25 4.49 45.8
26 4.50 45.9 12. Install cap (3) and valve guard (2) to accumulator
27 4.52 46.1 (1) .
28 4.53 46.2 3 Cap:9.8 – 12.7 Nm {1.0 – 1.3 kgm}
29 4.55 46.4
30 4.56 46.5
31 4.58 46.7
32 4.59 46.8
33 4.61 47.0
34 4.62 47.2
35 4.64 47.3
36 4.65 47.5
37 4.67 47.6
38 4.68 47.8
39 4.70 47.9
40 4.71 48.1
41 4.73 48.2
42 4.74 48.4
43 4.76 48.5
44 4.77 48.7
45 4.79 48.8
13. In a week after charging the accumulator with
t = Gas temperature at time of charge (°C)
nitrogen gas, check that the nitrogen gas pres-
Reference: t may be assumed to be ambient
sure has not lowered.
temperature.
a Check the functions in 5 minutes after stop-
ping the engine. (If the engine is stopped for
9. After the accumulator is charged to the standard more than 5 minutes, the brake circuit pres-
pressure, close the valve of nitrogen gas sure lowers and the functions cannot be
cylinder (c). checked accurately.)
q If the accumulator is charged too much, turn
1) Stop the machine on a level place and set the
handle (b) to the left slowly with the valve of
parking brake switch in the "PARK" position.
nitrogen gas cylinder (c) closed to release
the nitrogen gas gradually to adjust. 2) Start the engine and run it at medium speed
for 1 minute and then stop it.
3) Turn the starting switch to the ON position
and press the brake pedal repeatedly. Count
the number of presses until the brake oil
pressure caution lamp lights up.
q If number of presses is less than 5: Accu-
mulator gas pressure may have lowered.
q If number of presses is 5 or more: Accu-
mulator gas pressure is normal.
HM400-2 25
--- Page 10 ---
30 Testing and adjusting SEN00917-04
7) Remove suspension tools P2 to P5, and then
remove gas supply valve (3).
3 Air intake valve:
39.2 - 49.0 Nm {4 - 5 kgm}
4) Operate the hydraulic jack to lower the frame
slowly until the suspension cylinder is
retracted to the specified oil volume length.
k Operate the hydraulic jack carefully to
prevent the suspension cylinder from
being retracted too far and suffering
damage.
a Specified front oil volume length (a):
53±3 mm
a Specified rear oil volume length (b):
66±3 mm
3. Adjusting of oil level
a Adjust the oil level after completing the re-
lease of nitrogen gas.
1) Check that the suspension cylinder is the
specified oil volume length.
a Specified front oil volume length (a):
53±3 mm
a Specified rear oil volume length (b):
4. Charging with nitrogen gas
66±3 mm
a Charge with nitrogen gas after completing
k Operate the hydraulic jack carefully.
the adjustment of oil level.
2) Remove oil level valve (2).
1) Remove the cap at the top of air supply valve
3) Remove the valve body from gas supply (3).
valve (3), and then install joint P6.
2) Connect suspension tools P7 to P12 as
4) Install fitting P5 to joint P4, and then connect shown in the figure.
hose P3 and pump P2. a Connect joint P10 to the air supply valve.
5) Operate pump P2 to release the gas from the a Before installing the regulator, blow the
mounting port of oil level valve (2). filter at the mouthpiece thoroughly with ni-
a Keep sending oil to let the inside oil flow
trogen gas (min. 0.98 MPa {10 kg/cm2})
out from the mounting port until the oil
to prevent the entry of foreign materials.
without air bubbles flow out.
3) Open valve [2] of nitrogen gas cylinder [1]and
a Front cylinder oil charge amount (refer-
check the pressure (internal pressure of the
ence): 6.0 l
cylinder) indicated by gauge P12.
a Rear cylinder oil charge amount (refer-
a The indicated pressure must be higher
ence): 4.2 l
than the internal pressure of the cylinder
6) Install oil level valve (2).
3 Oil level valve:
by at least 0.98 MPa {10 kg/cm2}.
39.2 - 49.0 Nm {4 - 5 kgm} a Cylinder internal pressure
Front: 4.31 MPa {44.0 kg/cm2}
Rear: 1.18 MPa {12.0 kg/cm2}
HM400-2 35
--- Page 11 ---
30 Testing and adjusting SEN00917-04
Method for emergency escape at electrical system failure
If any problem occurs in the electrical system of the engine or transmission control system, it may disable the
engine to start or the machine to move off.
If such a problem occurs, temporarily restore the engine or transmission electrical system to move the ma-
chine to a safe place, then carry out regular troubleshooting.
1. When any problem occurs in the engine control system and the engine cannot be started:
a Decide the escape method according to the following flowchart.
a Refer to "Special functions of machine monitor" for the method of checking the failure code.
Note:If the engine cannot be started and the machine is to be towed, release the parking brake temporarily
referring to "Method for emergency release of parking brake", since it cannot be released by operating the
switch.
HM400-2 45
--- Page 12 ---
40 Troubleshooting SEN01107-03
Classification and procedures for troubleshooting
Classification of troubleshooting
Type Contents
Display of code Troubleshooting by failure code
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical system
S mode Troubleshooting of 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 supposed to show troubles", and then carry out troubleshooting corresponding
to that phenomenon in the "E mode", "H mode", or "S mode".
HM400-2 5
--- Page 13 ---
40 Troubleshooting SEN01107-03
HM400-2 15
--- Page 14 ---
40 Troubleshooting SEN01107-03
HM400-2 25
--- Page 15 ---
40 Troubleshooting SEN01107-03
HM400-2 35
--- Page 17 ---
40 Troubleshooting SEN01107-03
T-adapter kit
Number of pins
799 - 601 - 7500
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identificati
Part No. Part name
on symbol
799-601-7140 Adapter for M 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
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
799-601-7240 Case q q
799-601-7270 Case q