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Komatsu HM400-3 Articulated Dump Truck Service Manual

2,246 pages · Publication SEN05632-08

$229.67
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Models
HM400-3
Serial coverage
3001 and up
Manual type
Service Manual
Pages
2,246
Publication
SEN05632-08
Condition
Brand new
Komatsu HM400-3 Articulated Dump Truck Service Manual, publication SEN05632-08

What's inside

From the manual's own table of contents: 375 sections, 700 entries. See sample pages (PDF, 865 KB)

Index and foreword
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
Specification
Specifications
Specification drawing
Weight table
Table of fuel, coolant, and lubricants
Structure and function
Engine and cooling system
Engine related parts
Show all 375 sections
Output shaft
KVGT
EGR system piping drawing
EGR system circuit diagram
EGR valve
EGR cooler
KCCV layout drawing
KCCV ventilator
KDPF
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 system5 topics
  • Layout of steering devices
  • Steering column
  • Flow amplifier valve
  • Steering valve
  • Emergency steering pump
Brake system10 topics
  • 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 frame3 topics
  • Suspension
  • Suspension cylinder
  • Oscillation hitch
Hydraulic system10 topics
  • 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 attachments2 topics
  • ROPS cab
  • Cab tilt
Electrical system6 topics
  • Electrical control system
  • Machine monitor system
  • Rear view monitor system
  • KOMTRAX system
  • System component parts
  • Sensor
Standard value tables
Standard service value table2 topics
  • Standard value table for engine
  • Standard value table for machine
Testing and adjusting
Related information on testing and adjusting8 topics
  • Tools for testing and adjusting
  • Sketch of tools for testing and adjusting
  • 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 EGR valve and KVGT driving 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 circuit
Testing fuel circuit for leakage
Testing radiator fan and aftercooler fan speed
Replacing and adjusting belt for alternator and air conditioner compressor
Procedures for cleaning fuel doser
Writing compensation values at replacement of injector and engine controller
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
Testing and adjusting steering circuit oil pressure
Testing and adjusting brake oil pressure
Testing braking performance
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
Testing and adjusting suspension cylinder
Testing and adjusting dump circuit oil pressure
Work equipment
Adjusting dump body positioner sensor
Testing and adjusting body mount
Cab tilt-up procedure
Setting and adjusting each equipment
Special functions of machine monitor
KOMTRAX terminal start-up procedure
Handling voltage circuit of engine controller
Handling battery disconnect switch
Pm clinic
Pm Clinic service
Troubleshooting
Related information on troubleshooting
Troubleshooting points
Sequence of events in troubleshooting
Check before troubleshooting
Inspection procedure before troubleshooting
Classification and procedures for troubleshooting
Symptom and troubleshooting numbers
Information in troubleshooting table
Preparation for troubleshooting of electrical system
Connector list and layout6 topics
  • Connector contact identification
  • T-branch box and T-branch adapter table
  • Fuse location table
  • Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement
  • Precautions on troubleshooting of machine monitor
  • Failure codes table
Troubleshooting by failure code (Display of code)46 topics
  • 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 [A1U0N3] HC Desorb Request 1
  • Failure code [A1U0N4] HC Desorb Request 2
  • 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 [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 Sens High Error
Failure code [CA222] Ambient Press Sens 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 [CA239] Ne Speed Sens Supply Volt High 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 [CA343] ECM Critical Internal Failure
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA352] Sensor 1 Supply Volt Low Error
Failure code [CA356] Mass Air Flow Sensor High Error
Failure code [CA357] Mass Air Flow Sensor 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 [CA515] Rail Press Sens Sup Volt High Error
Failure code [CA516] Rail Press Sens Sup Volt Low Error
Failure code [CA553] Rail Press High Error
Failure code [CA555] Crankcase Press High Error 1
Failure code [CA556] Crankcase Press High Error 2
Failure code [CA559] Rail Press Low Error
Failure code [CA595] Turbo Speed High Error 2
Failure code [CA687] Turbo Speed Low Error
Failure code [CA689] Eng Ne Speed Sensor Error59 topics
  • Failure code [CA691] Intake Air Temp Sens High Error
  • Failure code [CA692] Intake Air Temp Sens Low Error
  • Failure code [CA697] ECM Internal Temp Sensor High Error
  • Failure code [CA698] ECM Int Temp Sensor Low Error
  • Failure code [CA731] Eng Bkup Speed Sens Phase Error
  • Failure code [CA778] Eng Bkup Speed Sensor Error
  • Failure code [CA1117] Persistent Data Lost Error
  • Failure code [CA1664] KDOC Malfunction
  • Failure code [CA1691] Regeneration Ineffective
  • Failure code [CA1695] Sensor 5 Supply Volt High Error
  • Failure code [CA1696] Sensor 5 Supply Volt Low Error
  • Failure code [CA1843] Crankcase Press Sens High Error
  • Failure code [CA1844] Crankcase Press Sens Low Error
  • Failure code [CA1879] KDPF Delta P Sensor High Error
  • Failure code [CA1881] KDPF Delta P Sensor Low Error
  • Failure code [CA1883] KDPF Delta P Sens In Range Error
  • Failure code [CA1921] KDPF Soot Load High Error 1
  • Failure code [CA1922] KDPF Soot Load High Error 2
  • Failure code [CA1923] Dosing Fuel Valve 1 High Error
  • Failure code [CA1924] Dosing Fuel Valve 1 Low Error
  • Failure code [CA1925] Dosing Fuel Valve 1 In Range Error
  • Failure code [CA1927] Dosing Fuel Press Sens High Error
  • Failure code [CA1928] Dosing Fuel Press Sens Low Error
  • Failure code [CA1942] Crankcase Press Sens In Range Error
  • Failure code [CA1963] Dosing Fuel Valve 1 Servo Error
  • Failure code [CA1977] Fuel Doser Open/Short Error
  • Failure code [CA1993] KDPF Delta Pressure Low 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 [CA2265] Fuel Feed Pump Open Error
  • Failure code [CA2266] Fuel Feed Pump Short Error
  • Failure code [CA2271] EGR Valve Pos Sens High Error
  • Failure code [CA2272] EGR Valve Pos Sens Low Error
  • Failure code [CA2349] EGR Valve Solenoid Open Error
  • Failure code [CA2353] EGR Valve Solenoid Short Error
  • Failure code [CA2357] EGR Valve Servo Error
  • Failure code [CA2381] KVGT Pos Sens High Error
  • Failure code [CA2382] KVGT Pos Sens Low Error
  • Failure code [CA2383] KVGT Solenoid Open Error
  • Failure code [CA2386] KVGT Solenoid Short Error
  • Failure code [CA2387] KVGT Servo Error
  • Failure code [CA2555] Grid Htr Relay Volt Low Error
  • Failure code [CA2556] Grid Htr Relay Volt High Error
  • Failure code [CA2637] KDOC Face Plugging
  • Failure code [CA2639] Manual Stationary Regeneration Request
  • Failure code [CA2732] Dosing Fuel Valve 2 High Error
  • Failure code [CA2733] Dosing Fuel Valve 2 Low Error
  • Failure code [CA2741] Dosing Fuel Valve Swap Error
  • Failure code [CA2765] Inj Trim Data Error
  • Failure code [CA2878] Dosing Fuel Valve 2 Servo Error
  • Failure code [CA2881] Dosing Fuel Pressure Low Error 1
  • Failure code [CA3133] KDPF Outlet Press Sens High Error
  • Failure code [CA3134] KDPF Outlet Press Sens Low Error
  • Failure code [CA3135] KDPF Outlet Press Sens In Range Error
  • Failure code [CA3167] Fuel Doser Degradation
  • Failure code [CA3251] KDOC Inlet Temp High Error
  • Failure code [CA3253] KDOC Temp Error - Non Regeneration
  • Failure code [CA3254] KDOC Outlet Temp High Error 1
Failure code [CA3255] KDPF Temp Error - Non Regeneration
Failure code [CA3256] KDPF Outlet Temp High Error 1
Failure code [CA3311] KDOC Outlet Temp High Error 2
Failure code [CA3312] KDPF Outlet Temp High Error 2
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error
Failure code [CA3314] KDOC Inlet Temp Sens High Error
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error
Failure code [CA3316] KDOC Outlet Temp Sens Low Error
Failure code [CA3317] KDOC Outlet Temp Sens High Error
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error
Failure code [CA3319] KDPF Outlet Temp Sens High Error
Failure code [CA3321] KDPF Outlet Temp Sens Low Error
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low 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 [DAZ9KQ] A/C Model Selection Abnormality
Failure code [DAZQKR] CAN2 Discon (Aircon ECU)59 topics
  • 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 [DB2QKR] CAN2 Discon (Engine Con)
  • Failure code [DB2RKR] CAN1 Discon (Engine Con)
  • Failure code [DBSQKR] CAN2 Discon (PLM)
  • Failure code [DBSQKQ] Inconsistency of Model Selection (PLM)
  • Failure code [DD1ML4] Failure of ARAC SW
  • Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch
  • Failure code [DDTHKA] Disconnection of Fill Switch (High)
  • Failure code [DDTJKA] Disconnection of Fill Switch (Low)
  • Failure code [DDTKKA] Disconnection of Fill Switch (1st)
  • Failure code [DDTLKA] Disconnection of Fill Switch (2nd)
  • Failure code [DDTMKA] Disconnection of Fill Switch (3rd)
  • Failure code [DDTNKA] Disconnection of Fill Switch (Reverse)
  • 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 [DGT1KX] Out of Range of T/C Oil Temp. Sensor
  • Failure code [DHP4KY] Hot Short of Suspension Press. S. (FR)
  • Failure code [DHP4KZ] Failure of Suspension Press. S. (FR)
  • Failure code [DHP5KY] Hot Short of Suspension Press. S. (FL)
  • Failure code [DHP5KZ] Failure of Suspension Press. S. (FL)
  • Failure code [DHP6KY] Hot Short of Suspension Press. S. (RR)
  • Failure code [DHP6KZ] Failure of Suspension Press. S. (RR)
  • Failure code [DHP7KY] Hot Short of Suspension Press. S. (RL)
  • Failure code [DHP7KZ] Failure of Suspension Press. S. (RL)
  • 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 [DKH0KX] Out of Range of Inclination Angle Sensor
Failure code [DKH1KX] Out of Range of Long. Inclination Angle S
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 Sol53 topics
  • 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)5 topics
  • Engine does not start (Engine does not rotate)
  • Manual preheating system does not work
  • Automatic preheating system does not work
  • While preheating is working, preheating pilot lamp does not light up
  • All of LCD unit, LED unit and meter unit on machine monitor display nothing
LCD unit on machine monitor displays nothing
LCD on machine monitor does not display properly
Meter unit display on machine monitor is abnormal
Night lighting lamp of meter unit on machine monitor is abnormal
LED unit lamp on machine monitor is abnormal
switches operation of switch panel on machine monitor does not function
Switch panel buzzer of machine monitor is abnormal
Rear view monitor does not light up or backlight flickers
Rear view monitor images are not displayed clearly
Rear view monitor brightness cannot be adjusted
Night lighting lamp of rear view monitor is abnormal
Guide line on rear view monitor is not displayed while guide line is set
Fuel level gauge does not indicate correct level
Seat belt caution lamp indication is abnormal
Machine monitor cannot be operated when starting switch is in OFF position
Alarm buzzer does not sound
Alarm buzzer does not stop sounding
Engine mode selector function does not operate properly
AISS function does not operate properly
Hoist lever does not operate properly
Turn signal lamp and winker lamp (hazard lamp) do not operate properly
None of headlamp, clearance lamp, and tail lamp lights
Clearance lamp does not light up
Tail lamp does not light up
Low beam of headlamp does not light up
High beam of headlamp does not light up
Neither Low beam nor High beam of headlamp lights up
High beams do not light up while passing switch is operated
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
Machine does not start
Machine does not travel smoothly (engine hunts)
Lockup clutch is not disengaged
Abnormally large shocks result from starting of machine and gear shifting
Machine does not upshift
Machine lacks travel speed or power during travel in specific gear speed
Machine starts or gear speed shifts with long time lag
Torque converter oil temperature is high
Torque converter oil pressure is low
Front brake does not work sufficiently
Center brake does not work sufficiently
Steering wheel is heavy to turn
Steering wheel does not move
Steering wheel swings7 topics
  • Dump body raise speed or power is slow
  • Dump body does not move
  • Hydraulic drift of dump body is large
  • Radiator fan speed is abnormal (high, low, or stationary)
  • Aftercooler fan speed is abnormal (high, low, or stationary)
  • Unusual noise is heard from around radiator fan
  • Unusual noise is heard from around aftercooler fan
Troubleshooting of engine (S-mode)23 topics
  • Information mentioned in troubleshooting table (S mode)
  • When starting switch is turned to START position, engine is not cranked
  • The engine cranks but exhaust smoke does not come out
  • Engine startability is poor
  • Engine does not pick-up smoothly
  • Engine stops during operation
  • Engine runs rough or is unstable
  • Engine lacks power
  • KDPF gets clogged in a short time
  • Engine oil consumption is excessive
  • Engine oil becomes contaminated early
  • Fuel consumption is excessive
  • Oil is in coolant (or coolant spurts or coolant level goes down)
  • Oil pressure drops
  • Fuel mixes into engine oil
  • Water mixes into engine oil (milky)
  • Coolant temperature rises too high (overheating)
  • Unusual noise is heard
  • Vibration is excessive
  • Air cannot be bled from fuel circuit
  • Active regeneration is executed frequently
  • Active regeneration takes a long time
  • White smoke is exhausted during active regeneration
Disassembly and assembly
Related information on disassembly and assembly21 topics
  • How to read this manual
  • Coating materials list
  • Special tools list
  • Sketches of special tools
  • 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 cooling fan and fan motor assembly for radiator
  • Removal and installation of aftercooler assembly
  • Removal and installation of cooling fan and fan motor assembly for aftercooler
  • 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 KDPF assembly
  • Disassembly and assembly of KDPF assembly
  • Removal and installation of KCCV assembly
  • Removal and installation of air cleaner assembly
  • Removal and installation of transmission and front differential 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
Disassembly and assembly of steering cylinder assembly
Disassembly and assembly of steering valve
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 (back side) wheel assembly
Removal and installation of hitch frame assembly
Disassembly and assembly of hitch frame assembly
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
Body
Removal and installation of dump body assembly

Inside this manual

Real pages from this service manual (2,246 pages). Open the sample pages (PDF, 864 KB)

Sample pages from the Komatsu HM400-3 Articulated Dump Truck Service Manual: Diagram, Troubleshooting, Specifications, Foldout diagram
  • Diagram, page 942: Procedure, measuring location, criteria and remarks
  • Troubleshooting, page 1,078: Failure code [CA2878] Dosing Fuel Valve 2 Servo Error
  • Specifications, page 1,656: Troubleshooting of hydraulic and mechanical system (H-
  • Foldout diagram: Inside cab electric circuit diagram (3/7)

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Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the HM400-3 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.

This manual: Service Manual SEN05632-08$229.67
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Details
Details

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 2,246 pages

Quantity one is the manual described above.

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Binder not included

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