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Komatsu HM400-3M0 Articulated Dump Truck Service Manual

1,987 pages · Publication SEN06284-06

$199.51
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Models
HM400-3M0
Serial coverage
5001 and up
Manual type
Service Manual
Pages
1,987
Publication
SEN06284-06
Condition
Brand new
Komatsu HM400-3M0 Articulated Dump Truck Service Manual, publication SEN06284-06

What's inside

From the manual's own table of contents: 383 sections, 700 entries. See sample pages (PDF, 767 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 383 sections
Output shaft
Turbocharger
EGR system layout drawing
EGR system circuit diagram
EGR valve
Bypass valve
Venturi system
EGR cooler
Muffler
Cooling system
Radiator fan pump
Aftercooler fan motor
Radiator fan motor
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 system6 topics
  • Layout of steering devices
  • Steering column
  • Flow amplifier valve
  • Steering valve
  • Emergency steering pump
  • Emergency steering motor
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 drive pressure of EGR valve and bypass valve
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
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
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
Preparation for troubleshooting of electrical system
Classification and procedures for troubleshooting
Symptom and troubleshooting numbers
Information in troubleshooting table
Connector list and layout5 topics
  • Connector contact identification
  • T-branch box and T-branch adapter table
  • Fuse location table
  • Precautions on troubleshooting of machine monitor
  • Failure codes table
Troubleshooting by failure code (Display of code)51 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 [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 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 [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 [CA1228] EGR valve servo error 1
Failure code [CA1625] EGR Valve Servo Error 2
Failure code [CA1626] Bypass Valve Solenoid Current High Error
Failure code [CA1627] Bypass Valve Solenoid Current Low Error
Failure code [CA1628] Bypass Valve Servo Error 1
Failure code [CA1629] Bypass Valve Servo Error 2
Failure code [CA1631] BP valve Lift Position Sensor High Error
Failure code [CA1632] BP valve Lift Position Sensor Low Error
Failure code [CA2185] Throt Sensor Sup Volt High Error59 topics
  • Failure code [CA2186] Throt Sensor Sup Volt Low Error
  • Failure code [CA2249] Rail Press Very Low Error
  • Failure code [CA2271] EGR Valve Pos Sens High Error
  • Failure code [CA2272] EGR Valve Pos Sens Low Error
  • Failure code [CA2351] EGR Valve Solenoid Short Error
  • Failure code [CA2352] EGR Valve Solenoid Open 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 [DB2QKR] CAN2 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 [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 [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 Sensor59 topics
  • 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 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)
Engine does not start (Engine does not crank)
Manual preheating system does not work
Automatic preheating system does not work
While preheating is working, preheating monitor 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 abnormal26 topics
  • 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)22 topics
  • 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 swings
  • 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)
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
Exhaust smoke is black
Engine oil consumption is excessive
Oil becomes contaminated quickly
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
Disassembly and assembly
Related information on disassembly and assembly
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 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 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 air cleaner assembly
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly
Removal and installation of fire prevention cover on exhaust pipe
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 assembly24 topics
  • 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
  • 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
Body10 topics
  • Removal and installation of dump body assembly
  • 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
  • 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 unit3 topics
  • Removal and installation of air conditioner unit assembly
  • Removal and installation of air conditioner compressor assembly
  • Removal and installation of air conditioner condenser
Maintenance standard11 topics
  • Engine mount
  • Output shaft
  • Radiator fan pump
  • Radiator fan motor
  • Aftercooler fan motor
  • Drive shaft
  • Torque converter and transmission mount
  • Torque converter
  • Transmission
  • Transmission control valve
  • Forward and reverse clutch ECMV and gear speed clutch ECMV
Steering column
Steering cylinder
Emergency steering pump
Slack adjuster
Brake
Parking brake
Suspension
Suspension cylinder
Oscillation hitch
Steering and hoist pump
Center brake cooling pump
Brake charge pump
Center brake cooling remote pump
Center brake cooling remote motor
Hoist valve
Hoist cylinder
Appendix
Air conditioner components
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
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
Testing vent (mode) changeover
Testing FRESH/RECIRC air changeover
Testing (dual) pressure switch for refrigerant
Testing relays
Troubleshooting chart 1
Troubleshooting chart 2

Inside this manual

Real pages from this service manual (1,987 pages). Open the sample pages (PDF, 766 KB)

Sample pages from the Komatsu HM400-3M0 Articulated Dump Truck Service Manual: Specifications, Diagram, Troubleshooting, Foldout diagram
  • Specifications, page 82: 01 Specification
  • Diagram, page 862: Circuit diagram related to injector #4
  • Troubleshooting, page 1,132: Failure code [DLFFLC] Failure of Wheel Speed Sensor (Front)
  • Foldout diagram, page 1,957: Inside cab electric circuit diagram (3/8)

Other manuals for this machine

Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the HM400-3M0 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 SEN06284-06$199.51
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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, 1,987 pages

Quantity one is the manual described above.

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