Shop Manual Hm400-1 SN 1001 Up General

SAFETY
SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol

is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which are
fixed to the machine.
2. When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose
work clothes, or clothes with buttons missing.
Always wear safety glasses when hitting
parts with a hammer.
Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a
trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, hand shield, cap and
other clothes suited for welding work.
4. When carrying out any operation with two or
more workers, always agree on the operating
procedure before starting. Always inform your
fellow workers before starting any step of the
operation. Before starting work, hang UNDER
REPAIR signs on the controls in the operator's
compartment.
5. Keep all tools in good condition and learn the
correct way to use them.
HM400-1
6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs, park the
machine on hard, level ground, and block the
wheels or tracks to prevent the machine from
moving.
8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
this is not possible, insert the safety pin or use
blocks to prevent the work equipment from falling. In addition, be sure to lock all the control
levers and hang warning signs on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before
starting work.
10.Remove all mud and oil from the steps or other
places used to get on and off the machine.
Always use the handrails, ladders or steps when
getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
handrails, ladders or steps, use a stand to provide safe footing.
00-3
SAFETY
PRECAUTIONS DURING WORK

11. When removing the oil filler cap, drain plug or
hydraulic pressure measuring plugs, loosen
them slowly to prevent the oil from spurting out.
Before disconnecting or removing components
of the oil, water or air circuits, first remove the
pressure completely from the circuit.
12. The water and oil in the circuits are hot when
the engine is stopped, so be careful not to get
burned.
Wait for the oil and water to cool before carrying
out any work on the oil or water circuits.
13.Before starting work, remove the leads from the
battery. Always remove the lead from the negative () terminal first.
14.When raising heavy components, use a hoist or
crane.
Check that the wire rope, chains and hooks are
free from damage.
Always use lifting equipment which has ample
capacity.
Install the lifting equipment at the correct places.
Use a hoist or crane and operate slowly to prevent the component from hitting any other part.
Do not work with any part still raised by the hoist
or crane.
15.When removing covers which are under internal
pressure or under pressure from a spring,
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
SAFETY NOTICE
19.Be sure to assemble all parts again in their original places.

Replace any damaged parts with new parts.
When installing hoses and wires, be sure
that they will not be damaged by contact
with other parts when the machine is being
operated.
20.When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are
dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check
that connecting parts are correctly installed.
21.When assembling or installing parts, always use
the specified tightening torques. When installing
protective parts such as guards, or parts which
vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers
caught in a hole.
23.When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurements.
24.Take care when removing or installing the tracks
of track-type machines.
When removing the track, the track separates
suddenly, so never let anyone stand at either
end of the track.
16.When removing components, be careful not to

break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
HM400-1
FOREWORD
GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make ju dgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made
at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.
HM400-1
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
REVISED EDITION MARK
VOLUMES
Shop manuals are issued as a guide to carrying out
repairs. They are divided as follows:
When a manual is revised, an edition mark (123....)

is recorded on the bottom of the pages.
Chassis volume: Issued for every machine model

Engine volume: Issued for each engine series
Each issued as one
Electrical volume:
Attachments volume: volume to cover all
models
REVISIONS
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with
all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be
available.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-todate information before you start any work.
FILING METHOD
1. See the page number on the bottom of the page.
File the pages in correct order.
2. Following examples show how to read the page
number.
Example 1 (Chassis volume):
10 - 3
Item number (10. Structure and
Function)
Consecutive page number for each
item.
Example 2 (Engine volume):
12 - 5
Unit number (1. Engine)
Item number (2. Testing and Adjusting)
Consecutive page number for each
item.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
12-203
10-4
12-203-1
10-4-1
Added pages
12-203-2
10-4-2
12-204
10-5
00-6
Revised pages are shown in the LIST OF REVISED

PAGES next to the CONTENTS page.
SYMBOLS
So that the shop manual can be of ample practical
use, important safety and quality portions are
marked with the following symbols.
Symbol

Item
Remarks
Safety
Special safety precautions

are necessary when performing the work.
Caution
Special technical precautions or other precautions

for preserving standards
are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary

when selecting hoisting
wire, or when working posture is important, etc.
Tightening
torque
Places that require special

attention for the tightening
torque during assembly.
Coat
Places to be coated with

adhesives and lubricants,
etc.
Oil, water
Places where oil, water or

fuel must be added, and
the capacity.
Drain
Places where oil or water

m u s t b e d r a i n e d , a nd
quantity to be drained.
HM400-1
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Heavy parts (25 kg or more) must be lifted

with a hoist, etc. In the DISASSEMBLY
AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the
symbol
If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the
part to the relative parts.
2) Check for existence of another part causing
interference with the part to be removed.
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below:
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing)
Rope diameter
Allowable load
mm
kN
tons
10
11.5
12.5
14
16
18
20
22.4
30
40
50
60
9.8
13.7
15.7
21.6
27.5
35.3
43.1
54.9
98.1
176.5
274.6
392.2
1.0
1.4
1.6
2.2
2.8
3.6
4.4
5.6
10.0
18.0
28.0
40.0
Slinging near the edge of the hook may cause

the rope to slip off the hook during hoisting, and
a serious accident can result. Hooks have maximum strength at the middle portion.
100%
88%
79%
71%
41%
SAD00479
3) Do not sling a heavy load with one rope alone,

but sling with two or more ropes symmetrically
wound onto the load.
Slinging with one rope may cause turning of
the load during hoisting, untwisting of the
rope, or slipping of the rope from its original
winding position on the load, which can result in a dangerous accident.
4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
when hoisting is made with two ropes, each of
which is allowed to sling up to 9.8 kN {1000 kg}
vertically, at various hanging angles.
When two ropes sling a load vertically, up to
19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg}
when two ropes make a 120 hanging angle.
On the other hand, two ropes are subjected to
an excessive force as large as 39.2 kN {4000
kg} if they sling a 19.6 kN {2000 kg} load at a
lifting angle of 150.
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
HM400-1
00-7
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
_There are 2 types of push-pull type coupler. The method of disassembling and connecting is different, so see the table below when disassembling and connecting the coupler.
Type 1
Type 2
1) Hold the mouthpiece of the tightening portion

and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the
hexagonal portion at the male end.
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact
surface a of the hexagonal portion at the
male end.
2) Hold in the condition in Step 1), and

turn lever (4) to the right (clockwise).
3) 3) Hold in the condition in Steps 1) and 2),

and pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2),

and pull out whole body (2) to disconnect it.
Disassembly
2) Hold in the condition in Step 1), and push

until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
00-8
HM400-1
FOREWORD
Type 1
Hold the mouthpiece of the tightening portion

and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the
hexagonal portion at the male end to connect it.
Hold the mouthpiece of the tightening

portion and push body (2) in straight
until sliding prevention ring (1) contacts
contact surface a of the hexagonal portion at the male end to connect it.
Connection
Type 2
HM400-1
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this list.
Category
Komatsu code
Part No.
Q'ty
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g
(2 pes.)
Polyethylene
container
LT-2
09940-00030
50 g
Polyethylene
container
LT-3
7901299060
(Set of
adhesive and
hardening
agent)
Adhesive:
1 kg
Hardenin
g
agent:
500 g
Can
LT-4
790-129-9040
250 g
Polyethylene
container
Holtz
MH 705
790-126-9120
75 g
Tube
Three bond
1735
790-129-9140
50 g
Polyethylene
container
2g
Polyethylene
container
Adhesives
Aron-alpha
201
790-129-9130
Loctite
648-50
79A-129-9110
50 cc
Polyethylene
container
LG-1
790-129-9010
200 g
Tube
LG-5
790-129-9070
1 kg
Can
Main applications, featuresr
Used to prevent rubber gaskets,

rubber cushions, and cock plug
from coming out.
Used in places requiring an immediately effective, strong adhesive.

Used for plastics (except polyethylene, polyprophylene, tetrafluoroet hl ene and vi nyl chl oride),
rubber, metal and non-metal.
Features: Resistance to heat and

chemicals
Used for anti-loosening and sealant purpose for bolts and plugs.
Used as adhesive or sealant for

metal, glass and plastic.
Used as sealant for machined

holes.
Used as heat-resisting sealant for

repairing engine.
Quick hardening type adhesive

Cure time: within 5 sec. to 3 min.
Used mainly for adhesion of metals, rubbers, plastics and woods.
Quick hardening type adhesive

Quick cure type (max. strength after 30 minutes)
Used mainly for adhesion of rubbers, plastics and metals.
Resistance to heat, chemicals

Used at joint portions subject to
high temperatures.
Used as adhesive or sealant for

gaskets and packing of power
train case, etc.
Used as sealant for various

threads, pipe joints, flanges.
Used as sealant for tapered
plugs, elbows, nipples of hydraulic piping.
Gasket
sealant
LG-6
790-129-9020
200 g
Tube
00-10
Features: Silicon based, resistance to heat, cold

Used as sealant for flange surface, tread.
mab Used as sealant for oil pan,
final drive case, etc.
HM400-1
FOREWORD
Category
COATING MATERIALS
Komatsu code
Part No.
Q'ty
Container
Main applications, featuresr
LG-7
790-129-9070
1g
Tube
Three bond
1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
Adhesives
Molybden
um
disulphide
lubricant
LM-P
09940-00040
200 g
Used as heat-resisting sealant for

repairing engine.
Used as lubricant for sliding portion (to prevent from squeaking).
Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting.
Used as lubricant for linkage,
bearings, etc.
Tube
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA
Various
Various
Molybdenum
disulphide
lubricant
SYG2-400M
400 g
(10 per
case)
Belows type
Grease
HM400-1
Various
Ftures: Silicon based, quick hardening type

Used as sealant for flywheel
housing, intake manifold, oil an,
thermostat housing, etc.
General purpose type
Used for normal temperature,

light load bearing at places in contact with water or steam.
Used for places with heavy load
Various
00-11
FOREWORD
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Thread diameter
of bolt
Width across
flats
mm
mm
Nm
kgm
6
8
10
12
14
10
13
17
19
22
13.2 1.4
31 3
66 7
113 10
177 19
1.35 0.15
3.2 0.3
6.7 0.7
11.5 1
18 2
16
18
20
22
24
24
27
30
32
36
279 30
382 39
549 59
745 83
927 103
27
30
33
36
39
41
46
50
55
60
1320
1720
2210
2750
3290
Thread diameter
of bolt
Width across
flats
mm
mm
Nm
6
8
10
12
10
13
14
27
7.85 1.95
18.6 4.9
40.2 5.9
82.35 7.85
28.5 3
39 4
56 6
76 8.5
94.5 10.5
135 15
175 20
225 25
280 30
335 35
140
190
240
290
340
kgm
0.8
1.9
4.1
8.4
0.2
0.5
0.6
0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below.
SAD00483
Thread diameter
Width across flat
mm
mm
Nm
kgm
14
18
22
24
30
33
36
42
19
24
27
32
36
41
46
55
24.5 4.9
49 19.6
78.5 19.6
137.3 29.4
176.5 29.4
196.1 49
245.2 49
294.2 49
2.5 0.5
52
82
14 3
18 3
20 5
25 5
30 5
00-12
Tightening torque
HM400-1
FOREWORD
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10
12
16
14
17
22
65.7 6.8
112 9.8
279 29
6.7 0.7
11.5 1
28.5 3
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
14
20
24
33
42
Varies depending
on type of
connector.
34.3 4.9
93.1 9.8
142.1 19.6
421.4 58.8
877.1 132.3
3.5 0.5
9.5 1
14.5 2
43 6
89.5 13.5
Norminal No.
02
03, 04
05, 06
10, 12
14
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
08
10
12
14
16
18
20
24
30
33
36
42
52
14
17
19
22
24
27
30
32
32
7.35 1.47
11.27 1.47
17.64 1.96
22.54 1.96
29.4 4.9
39.2 4.9
49 4.9
68.6 9.8
107.8 14.7
127.4 19.6
151.9 24.5
210.7 29.4
323.4 44.1
0.75 0.15
1.15 0.15
1.8 0.2
2.3 0.2
3 0.5
4 0.5
5 0.5
71
11 1.5
13 2
15.5 2.5
21.5 3
33 4.5
Norminal No.
08
10
12
14
16
18
20
24
30
33
36
42
52
HM400-1
36
00-13
FOREWORD
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS)

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter
Tightening torque
mm
Nm
6
8
10
12
10 2
24 4
43 6
77 12
kgm
1.02
2.45
4.38
7.85
0.20
0.41
0.61
1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS)

Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter
Tightening torque
mm
Nm
6
8
10
12
14
82
10 2
12 2
24 4
36 5
kgm
0.81
1.02
1.22
2.45
3.67
0.20
0.20
0.20
0.41
0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (TAPERED SCREWS)

Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter
00-14
Tightening torque
mm
Nm
1/16
1/8
1/4
3/8
1/2
3/4
1
31
82
12 2
15 2
24 4
36 5
60 9
kgm
0.31
0.81
1.22
1.53
2.45
3.67
6.12
0.10
0.20
0.20
0.41
0.41
0.51
0.92
HM400-1
FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal
number
Cable O.D.
(mm)
Current rating
(A)
Applicable circuit
0.88
2.4
12
Starting, lighting, signal etc.
0.32
2.09
3.1
20
Lighting, signal etc.
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
Number of
strands
D ia . o f stra nd s
(mm2)
Cross section
(mm2)
0.85
11
0.32
26
CLASSIFICATION BY COLOR AND CODE

Circuits
Prior-ity
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
Color
W hite
Black
Black
Red
Yellow
Green
Blue
Code
WR
BW
RW
YR
GW
LW
Color
W hite & Red
White & Black
Red & White
Rellow & Red
Green & White
Blue & W hite
Code
WB
BY
RB
YB
GR
LR
Color
White & Black
Black & Yellow
Red & Black
Yellow & Black
Green & Red
Blue & Yellow
Code
WL
BR
RY
YG
GY
LY
Color
W hite & Blue
Black & Red
Red & Yellow
Yellow & Green
Green & Yellow
Blue & Yellow
Code
WG
RG
YL
GB
LB
Color
White & Green
Red & Green
Yellow & Blue
Green & Black
Blue & Black
Code
RL
YW
GL
Color
Red & Blue
Yellow & White
Green & Blue
Classification
Primary
Auxiliary
HM400-1
00-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
from .
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
from .
(3) Take the point where the two lines cross as . This point
gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches
1 mm = 0.03937 in
0
0
10
20
30
40
0
0.394
0.787
1.181
1.575
0.039
0.433
0.827
1.220
1.614
0.079
0.472
0.866
1.260
1.654
0.118
0.512
0.906
1.299
1.693
0.157
0.551
0.945
1.339
1.732
0.197
0.591
0.984
1.378
1.772
0.236
0.630
1.024
1.417
1.811
0.276
0.669
1.063
1.457
1.850
0.315
0.709
1.102
1.496
1.890
0.354
0.748
1.142
1.536
1.929
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
00-16
HM400-1
FOREWORD
CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
Kilogram to Pound
1 kg = 2.2046 lb
0
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
HM400-1
00-17
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon
1
= 0.2642 U.S. Gal
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
Liter to U.K. Gallon
1
= 0.21997 U.K. Gal
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
00-18
HM400-1
FOREWORD
CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
HM400-1
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-20
HM400-1
FOREWORD
CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
C
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
40.0
31.0
22.0
13.0
4.0
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
117.8
179.6
181.4
183.2
185.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
0
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
HM400-1
00-21
FOREWORD
UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses {
}.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kw/rpm {HP/rpm}
g/kwh {g/HPh}
00-22
HM400-1
GENERAL
01 GENERAL
Specification drawings................................................................................................................................... 01-2
Specifications ................................................................................................................................................ 01-3
Weight table................................................................................................................................................... 01-6
Fuel, coolant and lubricants ........................................................................................................................... 01-7
HM400-1
01-1
GENERAL
SPECIFICATION DRAWINGS
SPECIFICATION DRAWINGS
01-2
HM400-1
GENERAL
SPECIFICATIONS
SPECIFICATIONS
Machine model
HM400-1
Serial Numbers
1001 and up
kg
3,0350
Max. payload
kg
3,7000
Overall weight
kg
6,7350
Unloaded (front wheel)
kg
55.4
(front rear wheel)
kg
22.3
(rear rear wheel)
kg
22.3
Fully loaded (front wheel)
kg
28.4
(front rear wheel)
kg
35.8
(rear rear wheel)
kg
35.8
Struck
m3
16.5
22.5
Weight
Unloaded
Weight
Performance
Dump body capacity
Heaped (2:1)
Max. travel speed
km/h
Gradeability (tan 0 )
mm
8,710
70
Overall length
mm
11,025
Overall width
mm
3,450
Overall height
mm
3,700
Wheelbase (front wheel - front rear wheel)
mm
4,350
Wheelbase (front rear wheel - rear rear wheel)
mm
1,970
Front tires
mm
2,690
Rear tires
mm
2,690
Front rear wheel
mm
2,690
mm
600
Min. turning radius
Tread
Rear rear wheel

Engine
Komatsu SAA6D140E-3
Model
4-cycle, water-cooled, in-line 6 cylinder, direct

injection, with turbocharger and air-cooled
after-cooler
Type
No. of cylinders - Bore x stroke
Engine
58.6
0.51
Dumping angle (angle to ground) (deg)
Dimensions
mm
6-140 x 165
Piston displacement
O {cc}
15.24{15,240}
Flywheel horsepower
kW /rpm {H P/rpm }
331/2,000 {444/2,000}
Max. torque
Nm/rpm{kgm/rpm}
2,045/1,400 {208.5/1,400}
g/kW h {g /H P h}
204 {152}
Fuel consumption (rated)

Starting motor
Alternator
Battery
HM400-1
11kw
24V 60A
12V 170Ah x 2
01-3
GENERAL
Power train
Torque converter
Transmission
HM400-1
Serial Numbers
1001 and up
3-element, 1-stage, 2-phase
Type
39. Hydraulically-actuated, wet-type, single-disc

clutch
Lock-up clutch
TORQFLOW multiple-axle transmission, fully

automatic, electrically-hydraulically actuated,
force-feed type pump lubrication type
Type
No. of speeds
Type
Final drive
Travel system
Machine model
F6, R2
Reduction gear
Suspension
SPECIFICATIONS
Straight bevel gear, splash lubrication
Reduction ratio
3.417
Differential type
Straight bevel gear, splash lubrication
Type
Planetary gear, splash lubrication
Reduction ratio
4.941
Type
Axle type
Suspension method
Tires
Size and no.
Fully hydraulic
Front axle
Independent suspension (MacPherson type)
Front rear axle
Rear rear axle
Front axle
Hydropneumatic type
Rear rear axle
Hydropneumatic type
Front tire
29.5 R25 x 2
Front rear tire
29.5 R25 x 2
Rear rear tire
29.5 R25 x 2
kPa
Tire inflation pressure
{kg/cm2}
0.372 {3.8}
Independent front and rear system brake, sealed,
wet- type, multiple disc, hydraulically operated
type
Front wheel
Main brake
Front rear wheel
Brakes
Rear rear wheel

type
type
Parking brake
Retarder
01-4
Spring-boosted, caliper disc type

wet- type, multiple disc, hydraulically operated type
HM400-1
GENERAL
SPECIFICATIONS
Machine model
HM400-1
Serial Numbers
1001 and up
For steering
Type
Gear pump
Discharge amount (O /min)
218
(when engine is at rated speed of 2000 rpm)

For hoist
Type
Gear pump
18.5

For transmission, brake cooling
Type
Gear pump
226
Hydraulic pump, motor
Hydraulic system

For brake cooling
Type
Gear pump
180

For brake
Type
Gear pump
180

For differential lock front
Type
Gear pump
18.5
when engine is at rated speed of 2000 rpm)

For differential lock motor
Type
Gear pump
26.2

For differential lock center, rear
Type
Gear pump
11.7

Hoist cylinder
Cylinders
Type
HM400-1
2-stage piston type

(only 2nd stage double-acting)
No. - bore (1st-2nd) x stroke
2-(160mm-120mm) x 3.602mm
Steering cylinder
Type
Piston type, double acting
No. - bore x stroke
2-120mm x 525mm
01-5
GENERAL
WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
01-6
Machine model
HM400-1
Serial Numbers
1001 and up
Engine assembly
1,470
Output shaft assembly
88
Cooling assembly
349
Fuel tank (individual part)
200
Torque converter assembly
282
Transmission assembly
1324
Drive shaft assembly
295
Front axle assembly
2,131
Differential
428
Final drive
1060
Center axle assembly
2,423
Differential
397
Final drive
1047
Rear axle assembly
2,297
Differential
265
Final drive
1047
Front suspension cylinder
91.2
Rear suspension cylinder
78.2
Oscillation hitch assembly
851.1
Front frame
1,585
Rear frame
2,000
Cab (including platform, interior components)
652
Operators seat
56.1
Steering cylinder (one side)
65.2
Hoist cylinder (one side)
251
Flow amp valve
29
Hoist valve
63
Hydraulic tank
240
Hydraulic pump (SAL(1)21)
2.6
Hydraulic pump (SAR(3)80+(1)25)
19
Hydraulic pump (SAR(3)100)
13
Hydraulic pump (SAR(3)100+100+(1)8)
35.8
Hydraulic motor
13
Body assembly
4,232
HM400-1
GENERAL
FUEL, COOLANT AND LUBRICANTS
FUEL, COOLANT AND LUBRICANTS

AMBIENT TEMPERATURE
RESERVOIR
KIND OF
FLUID
CAPACITY
Specified
Refill
59
55
195
90
165
129
Front suspension
Left and right,

13.8 each
Rear suspension
Left and right,

8.1 each
50
45
SAE 30
SAE 10W
Engine oil pan
SAE 10W-30
SAE 15W-40
SAE 30
Ttansmission case
SAE 10W
Engine oil
Front brake oil tank
Hydraulic tank
SAE 10W
Differential gear case

SAE 30
Final drive case
Left and right, Left and right,

13 each
17 each
-
ASTM D975 No.2

Fuel tank
Diesel fuel
500
89
ASTM D975 No.1
Cooling system
HM400-1
Water
01-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD
RADIATOR, OIL COOLER, AFTERCOOLER ........................................................................................... 10- 2
POWER TRAIN SKELETON ..................................................................................................................... 10- 4
OUTPUT SHAFT ....................................................................................................................................... 10- 6
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING.................................................... 10- 8
TORQUE CONVERTER............................................................................................................................ 10- 10
TRANSMISSION ....................................................................................................................................... 10- 16
TRANSMISSION VALVE........................................................................................................................... 10- 34
ECMV (Electronic Control Modulation Valve) ............................................................................................ 10- 35
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE......................................................................... 10- 42
DRIVE SHAFT........................................................................................................................................... 10- 44
AXLE ......................................................................................................................................................... 10- 45
DIFFERENTIAL ......................................................................................................................................... 10- 48
FINAL DRIVE ............................................................................................................................................ 10- 56
STEERING COLUMN................................................................................................................................ 10- 60
BRAKE PIPING ......................................................................................................................................... 10- 62
BRAKE VALVE .......................................................................................................................................... 10- 64
ACCUMULATOR CHARGE VALVE.......................................................................................................... 10- 67
ACCUMULATOR ....................................................................................................................................... 10- 71
SLACK ADJUSTER ................................................................................................................................... 10- 72
BRAKE ...................................................................................................................................................... 10- 74
PROPORTIONAL REDUCING VALVE ..................................................................................................... 10- 79
BRAKE SYSTEM TANK ............................................................................................................................ 10- 80
PARKING BRAKE ..................................................................................................................................... 10- 82
PARKING BRAKE CALIPER ..................................................................................................................... 10- 84
SPRING CYLINDER.................................................................................................................................. 10- 85
PARKING BRAKE SOLENOID VALVE ..................................................................................................... 10- 86
SUSPENSION ........................................................................................................................................... 10- 88
SUSPENSION CYLINDER........................................................................................................................ 10- 94
OSCILLATION HITCH ............................................................................................................................... 10- 96
STEERING, HOIST OIL PRESSURE PIPING DIAGRAM ......................................................................... 10-100
DUMP BODY CONTROL .......................................................................................................................... 10-101
HYDRAULIC TANK AND FILTER ............................................................................................................. 10-102
FLOW AMP VALVE ................................................................................................................................... 10-103
STEERING VALVE.................................................................................................................................... 10-106
STEERING CYLINDER ............................................................................................................................. 10-110
HOIST VALVE ........................................................................................................................................... 10-112
EPC VALVE............................................................................................................................................... 10-118
HOIST CYLINDER .................................................................................................................................... 10-119
HYDRAULIC PUMP .................................................................................................................................. 10-120
CAB TILT ................................................................................................................................................... 10-125
AIR CONDITIONER .................................................................................................................................. 10-126
MACHINE MONITOR SYSTEM ................................................................................................................ 10-131
AUTOMATIC SHIFT CONTROL SYSTEM................................................................................................ 10-155
TRANSMISSION CONTROLLER.............................................................................................................. 10-157
AUTO EMERGENCY STEERING SYSTEM ............................................................................................. 10-163
SENSORS, SWITCHES ............................................................................................................................ 10-164
RETARDER CONTROL SYSTEM ............................................................................................................ 10-172
DUMP CONTROL LEVER......................................................................................................................... 10-182
HM400-1
10-1
RADIATOR, OIL COOLER,

AFTERCOOLER
RADIATOR, OIL COOLER, AFTERCOOLER
1. Aftercooler
2. Water filler
3. Reservoir tank
4. Upper tank
5. Lower tank (torque converter, oil cooler)
A. From thermostat
B. To water pump
C. From rear brake
C. From rear brake
D. To oil filter
E. From hoist valve
F. To hydraulic tank
G. From water pump
10-2
Specifications
Radiator
Core type: CF4-5
Total heat dissipation area: 67.93m 2
Torque converter oil cooler
Core type: PTO-LS
Total heat dissipation area: 4.0655m 2
Steering oil cooler
Core type: PTO-OL
Total heat dissipation area: 0.896m2
HM400-1
POWER TRAIN SKELETON
10-4
HM400-1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Engine
Output shaft
Front drive shaft
Brake cooling and brake system pump (SAR(3)80+25)
Torque converter, transmission, front brake cooling, differential lock control pump (SAR(3)100+12+10)
PTO
Torque converter
Steering, hoist control pump (SAR(3)100+100+(1)8)
Transmission
Oscillation hitch
Center drive shaft
Front differential
Front Differential lock
Tire
Final drive (front)
Brake (front)
Rear drive shaft (front)
Center differential
Center differential lock
Tire
Final drive (center)
Brake (center)
Rear drive shaft (rear)
Rear differential
Rear differential lock
Tire
Final drive (rear)
Brake (rear)
HM400-1
10-5
OUTPUT SHAFT
OUTPUT SHAFT
1.
2.
3.
4.
5.
6.
7.
Rubber cushion
Outer body
Flange
Shaft
Coupling
Inner body
Cover
10-6
FUNCTION
The output shaft is installed to the engine flywheel,and absorbs the twisting vibration caused by
changes in the engine torque.
HM400-1
OUTPUT SHAFT
Unit: mm
No.
Check item
Clearance between
flywheel and bearing
Criteria
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
80
0
-0.013
0
-0.030
0.013
0.030
0.02
Standard
size
Clearance between shaft

and bearing
40
-0.009
-0.025
0
-0.012
-0.003
0.025
0.10
Clearance between bearing

and cover
120
0
-0.015
-0.006
-0.028
0.009
0.028

and shaft
65
0.012
-0.007
0
-0.015
-0.007
0.027
0.025
Weaar of oil seal contact surface of coupling
Standard size
Repair limit
95
94.7
Standard backlash
Backlash limit
0.099 0.202
0.4
Original dimension : Lo
Standard backlash (Dimension at smallest width : L)
75
67
Replace
Repair or
replace
Backlash at spline
Deformastion of
rubber cushion
External
HM400-1
Replace
Without cranks
10-7
TORQUE CONVERTER AND TRANSMISSION

HYDRAULIC PIPING
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC

PIPING
10-8
HM400-1
TORQUE CONVERTER AND TRANSMISSION

HYDRAULIC PIPING
1. Engine
2. Torque converter
3. Transmission
4. Oil cooler (built into radiator)
5. Torque converter, transmission, brake cooling return filter
6. Rear brake cooling and brake system pump (SAR(3)80+25)
7. Brake system tank
8. Torque converter, transmission, front brake cooling, differential control pump (SAR(3)100+12+10)
9. Hydraulic tank
HM400-1
10-9
TORQUE CONVERTER
TORQUE CONVERTER
A: Torque converter oil outlet port

B: Torque converter oil inlet port
C: To lockup clutch
1. PTO gear (No. of teeth: 9)
10-10
SPECIFICATIONS
Type:
3 element, 1-stage, 2-phase
with modulation and lockup
clutch
Lockup clutch:
Multiple-disc clutch
Hydraulic control
(with modulation valve)
Stall torque ratio:
2.63
HM400-1
1. Coupling
2. Input shaft
(No. of teeth: 108)
3. Housing
4. Drive case
5. Turbine
6. Race
7. Pump
HM400-1
8.
9.
10.
11.
12.
13.
14.
TORQUE CONVERTER
Starter shaft
One way clutch
Starter
Disc
Piston
Clutch housing
Retainer
10-11
10-12
TORQUE CONVERTER
HM400-1
TORQUE CONVERTER
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
4 95
0
-0.087
4 94.8
Outside diameter of coupling

and oil seal sliding portion
Inside diameter of seal ring

sliding portion of input shaft
sliding portion
4 35
+0.025
0
4 35.5

sliding portion of clutch housing
4 420
+0.097
0
4 420.5

sliding portion of clutch piston
4 295
+0.081
0
4 295.1

sliding portion of pump housing
4 135
+0.040
0
4 135.5

sliding portion of input shaft
4 70
+0.030
0
4 70.5
Width
-0.01
-0.04
4.5
Wear of clutch
housing seal ring
Thickness
0.15
6.85
3.95
0
-0.1
3.55
5.5
0.1
4.95
Wear of stator shaft Width

seal ring
Thickness
Inside diameter of outer race

one-way clutch transmission
surface
4 127.844
0.013
4 127.874
10
Outside diameter of inner race

one-way clutch transmission
surface
4 108.883
0.013
4 108.853
11
Inside diameter of sliding portion of bushing
4 109
+0.015
0
4 109.08
12
Thickness of sliding portion

bushing
0
-0.1
4.5
13
Thickness of clutch disc
5.4
0.1
4.8
14
Backlash between input shaft

and PTO gear
HM400-1
Replace
0.17 0.45
10-13
PATH FOR TRANSMISSION OF POWER

1. When lock-up clutch is disengaged
When the lock-up clutch is disengaged, drive
case (1) and turbine (2) are separated, and the
torque converter functions as normal.
The power generated by the engine goes from
the damper through the drive shaft, is transmitted to coupling (3), input shaft (4) and clutch
housing (5), and rotates drive case (1) and pump
(6) as one unit.
The power from pump (6) uses oil as a medium,
rotates turbine (2), and is transmitted from turbine (2) to transmission output shaft (7).
10-14
TORQUE CONVERTER
2. When lock-up clutch is engaged

When the lock-up clutch is engaged, drive case
(1) and turbine (2) are engaged and form one
unit. Stator (8) is rotated by the rotation of pump
(6) and turbine (2).
The power generated by the engine goes from
the damper through the drive shaft, is transmitted to coupling (3), input shaft (4) and clutch
housing (5), and rotates drive case (1) and pump
(6) as one unit.
In addition, drive case (1) and turbine (2) are engaged by the clutch, so the power is transmitted
directly from turbine (2) to transmission output
shaft (7) without using oil as a medium.
HM400-1
TORQUE CONVERTER
FLOW OF OIL
The oil passes through the main relief valve, is adjusted by the torque converter relief valve to a pressure less than the set pressure, and enters inlet port
A. It then passes through the oil passage in stator
shaft (1) and flows from between pump (2)
and stator (3) to pump (2). The oil is given centrifugal force by pump (2), enters turbine (4), and transmits the energy of the oil to the turbine.
The oil from turbine (4) is sent to stator (3), and enters the pump again. However, part of the oil passes
between turbine (4) and stator (3) and is sent from
outlet port B to the oil cooler to be cooled. It is then
used to lubricate the transmission.
HM400-1
10-15
TRANSMISSION
TRANSMISSION
1.
2.
3.
4.
5.
Transmission case (front)

Transmission case (rear)
Oil filler pipe mount
Transmission control valve
Main relief, torque converter relief valve
10-16
HM400-1
1. R clutch
2. 1st clutch
3. 2nd clutch
4. Differential lock clutch
5. Rear output shaft
6. Rear coupling
7. Front output shaft
HM400-1
TRANSMISSION
8. Lower shaft
9. 3rd clutch
10. Upper shaft
11. FH clutch
12. Input shaft
13. FL clutch
14. Torque converter
10-17
10-18
TRANSMISSION
HM400-1
TRANSMISSION
Unit: mm
No.
Check item
Criteria
Clearance (F) between FL, R clutch

bearing and case
Standard
size
Tolerance
Remedy
Standard
clearance
Clearance
limit
+0.025
-0.014
-0.014
0.050
Shaft
Hole
4 160
0
-0.025
Clearance (R) between FL, R clutch

bearing and case
4 160
0
-0.025
+0.025
-0.014
-0.014
0.050
Clearance (F) between FH, 1st clutch

bearing and case
4 160
0
-0.025
+0.033
0
0
0.058
Clearance (R) between FH, 1st clutch

bearing and case
4 160
0
-0.025
+0.025
-0.014
-0.014
0.050
Clearance (F) between 2nd, 3rd

clutch bearing and case
4 160
0
-0.025
-0.012
-0.052
-0.052
0.013
Clearance (R) between 2nd, 3rd

clutch bearing and case
4 160
0
-0.025
+0.025
-0.014
-0.014
0.050
Clearance (F) between differential

lock clutch bearing and case
4 230
0
-0.030
-0.014
-0.060
-0.060
0.016
Clearance (R) between differential

lock clutch bearing and case
4 230
0
-0.030
-0.014
-0.060
-0.060
0.016
Clearance between front output bearing and cage
4 140
0
-0.018
+0.018
-0.007
-0.007
0.036
10
Clearance between front output bearing and spacer
4 90
+0.035
+0.013
0
-0.020
-0.055
-0.013
Standard size
Tolerance
Repair limit
2.5
+0.18
+0.10
2.7
Width
2.4
0.05
2.2
Thickness
1.7
0
-0.10
1.5
3.2
+0.076
0
3.5
Width
3.1
0.05
2.8
Thickness
2.29
0
-0.10
2.1
Inside diameter of seal ring sliding

portion of each shaft (rear)
4 50
+0.050
0
4 50.1
Width of seal ring groove of each

shaft (rear)
3.2
+0.076
0
3.5
Width
3.1
0
-0.05
2.8
Thickness
Width of input shaft seal ring groove

11
Wear of input shaft
seal ring
Replace
Width of input shaft seal ring groove
12
Wear of input shaft
seal ring
13
Wear of seal ring of

each shaft (rear)
2.05
0.10
1.8

portion of sleeve
4 140
+0.40
0
4 140.1
Width of seal ring groove of sleeve
4.5
+0.05
+0.10
5.0
Width
4.5
-0.08
-0.13
4.1
Thickness
4.0
0.15
3.6
4 85
+0.035
0
4 85.1
3.0
+0.15
+0.10
3.3
Width
3.0
-0.01
-0.03
2.7
Thickness
3.5
0.10
3.35
4 120
0
-0.087
4 119.8
14
sleeve

portion of front output shaft
15
Width of seal ring groove of front output shaft

front output shaft
16
Outside diameter of rear coupling oil

seal sliding portion
HM400-1
10-19
TRANSMISSION
1. Ridler gear (No. of teeth : 35)

2. Strainer
Unit: mm
No.
Check item
Clearance between R idler gear

bearing and case
Clearance between R idler gear

bearing and R idler gear
Criteria
Tolerance
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
4 125
0
-0.018
-0.025
-0.050
-0.050
-0.007
4 70
+0.032
+0.002
0
-0.015
-0.047
-0.002
Outline
The transmission is installed to the rear of the
torque converter. The power from the torque
converter passes through the transmission input
shaft and enters the transmission.
The transmission uses combinations of the FL,
FH, and R clutches and the three speed clutches
to shift the power from the input shaft and selects a speed range from FORWARD 1st - 6th or
REVERSE 1st - 2nd. This is then transmitted to
the output shaft.
Gearshifting is carried out automatically by the
automatic transmission according to the changes in the engine speed.
10-20
Remedy
Replace
Clutch combination and reduction ratio

Speed range
Clutch used
Reduction ratio
F1
FL x 1st
6.061
F2
FH x 1st
3.957
F3
FL x 2nd
2.574
F4
FH x 2nd
1.680
F5
FL x 3rd
1.094
F6
FH x 3rd
0.714
R1
R x 1st
5.851
R2
R x 2nd
2.484
HM400-1
TRANSMISSION
FL - R CLUTCH
A: R clutch oil port

B: FL clutch oil port
C: Lubricating oil port

D: Lock-up clutch oil port
1. Input shaft
2. Idler gear (No. of teeth: 43)
3. FL gear (No. of teeth: 33)
4. FL clutch
5. FL, R cylinder
6. R clutch
7. R gear (No. of teeth: 25)
Unit: mm
No.
Check item
Clearance (F) between FL, R

shaft and bearing (F)
Clearance (R) between FL, R

shaft and bearing (R)
10
Criteria
Shaft
4 75
4 75
Hole
Standard
clearance
Clearance
limit
+0.030
-0.011
0
-0.015
-0.045
-0.011
+0.049
+0.036
0
-0.015
-0.064
-0.036
Standard size
Tolerance
Repair limit
Thickness
2.0
0.05
1.8
Distortion
0.05
0.15
Thickness
3.2
0.08
2.75
Distortion
0.10
0.25
Separator plate
11
Tolerance
Standard
size
Remedy
Friction plate
12
Load of wave spring (height:

3.8 mm)
1274 N
{130 kg}
114.7 N
{11.7 kg}
1088 N
{111 kg}
13
Thickness of FL clutch thrust

washer
0.2
3.6
14
Thickness of R clutch thrust

washer
0.2
3.6
15
End play of FL gear
0.15 0.85
16
End play of R gear
0.17 0.83
HM400-1
Replace
10-21
TRANSMISSION
FH - 1ST CLUTCH
A: 1st clutch oil port

B: FL clutch oil port
1. FH gear (No. of teeth: 57)

2. FH clutch
3. FH, 1st cylinder, idler gear (No. of teeth: 67)
4. 1st clutch
5. 1st gear (No. of teeth: 30)
7. Upper shaft
Unit: mm
No.
Check item
Clearance (F) between FH, 1st

shaft and bearing
Clearance (R) between FH, 1st

shaft and bearing
10
Criteria
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
4 75
+0.071
+0.061
0
-0.015
-0.086
-0.061
4 75
+0.071
+0.061
0
-0.015
-0.086
-0.061
Standard size
Tolerance
Repair limit
Thickness
2.0
0.05
1.8
Distortion
0.05
0.15
Thickness
3.2
0.08
2.75
Distortion
0.10
0.25
Separator plate
11
Tolerance
Remedy
Friction plate
12

3.8 mm)
1274 N
{130 kg}
114.7 N
{11.7 kg}
1088 N
{111 kg}
13
Thickness of FH clutch thrust

washer
0.2
3.6
14
Thickness of 1st clutch thrust

washer
0.2
3.6
15
End play of FH gear
0.17 0.83
16
End play of 1st gear
0.15 0.85
10-22
Replace
HM400-1
TRANSMISSION
2ND - 3RD CLUTCH
A: 2nd clutch oil port

B: 3rd clutch oil port
1. 3rd gear (No. of teeth: 25)

2. 3rd clutch
3. 2nd, 3rd cylinder, idler gear (No. of teeth: 62)
4. 2nd clutch
5. 2nd gear (No. of teeth: 43)

7. Lower shaft
Unit: mm
No.
Check item
Clearance (F) between 2nd,

3rd shaft and bearing
Clearance (R) between 2nd,

3rd shaft and bearing
10
Criteria
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
4 75
+0.030
+0.011
0
-0.015
-0.045
-0.011
4 75
+0.030
+0.011
0
-0.015
-0.045
-0.011
Standard size
Tolerance
Repair limit
Thickness
2.0
0.05
1.8
Distortion
0.05
0.15
Thickness
3.2
0.08
2.75
Distortion
0.10
0.25
Separator plate
11
Tolerance
Remedy
Friction plate
12

3.8 mm)
1274 N
{130 kg}
114.7 N
{11.7 kg}
1088 N
{111 kg}
13
Thickness of 3rd clutch thrust

washer
0.2
3.6
14
Thickness of 2nd clutch thrust

washer
0.2
3.6
15
End play of 3rd gear
0.11 0.89
16
End play of 2nd gear
0.10 0.80
HM400-1
Replace
10-23
TRANSMISSION
DIFFERENTIAL LOCK
A: Lubricating oil port

1.
2.
3.
4.
5.
Front output shaft

Clutch hub
Housing
Differential lock clutch
Sun gear (No. of teeth: 40)
10-24
6. Planet gear (No. of teeth: 20)

7. Ring gear (No. of teeth: 80)
8. Carrier
9. Output gear (No. of teeth: 78)
10. Rear output shaft
HM400-1
TRANSMISSION
Unit: mm
No.
11
Check item
Clearance between housing

and bearing
Criteria
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
4 170
+0.040
+0.015
0
-0.025
-0.065
-0.015
12
Clearance between output gear

and bearing
4 170
+0.040
+0.015
0
-0.025
-0.065
-0.015
13
Clearance between housing

and bearing
4 130
0
-0.018
-0.012
-0.052
-0.052
-0.006
14
Clearance between front output

shaft and bearing
4 75
+0.012
-0.007
0
-0.015
-0.027
-0.007
15
Clearance (F) between output

gear and bearing
4 150
0
-0.020
-0.050
-0.090
-0.090
-0.030
16
Clearance (R) between output

gear and bearing
4 150
0
-0.020
-0.028
-0.068
-0.068
-0.008
17
Clearance between front output

shaft and bearing
4 100
+0.035
+0.013
0
-0.020
-0.055
-0.013
Standard size
Tolerance
Repair limit
Thickness
2.0
0.05
1.8
Distortion
0.15
0.25
Thickness
3.2
0.10
2.75
Distortion
0.20
0.35

3.2 mm)
1480 N
{151 kg}
440 N
{45 kg}
1255 N
{128 kg}

sliding portion of carrier
4 70
+0.030
0
70.1
Width of seal ring groove of

front output shaft
2.1
0.05
2.3
Width
1.95
0
-0.1
1.76
Thickness
1.85
0.1
1.67
18
Separator plate
19
20
21
Friction plate
Wear of seal ring

of front output
shaft
HM400-1
Replace
10-25
TRANSMISSION
OPERATION OF CLUTCHES
Clutch engaged (fixed)
The oil sent from the transmission valve passes
through the oil passage inside shaft (1), reaches
the back face of piston (6) and acts on piston (6).
When piston (6) is actuated, separator plate (2)
and friction plate (3) are pressed together, shaft
(1) and clutch gear (4) form one unit, and the
power is transmitted.
When this happens, the oil is drained from oil
drain hole (5), but the drain amount is less than
the amount of oil supplied, so there is no influence on the actuation of the clutch.
Clutch disengaged (free)

The oil sent from the transmission valve is shut
off, so the pressure of the oil acting on the back
face of piston (6) goes down.
Piston (6) is returned to its original position by
wave spring (7), and shaft (1) and clutch gear (4)
are separated.
When the clutch is disengaged, centrifugal force
is used to drain the oil at the back face of the piston through oil drain hole (5). This acts to prevent the clutch from being partially applied.
Oil drain hole (5) forms part of the structure

of only the 2nd, 3rd, and differential lock
clutches.
10-26
Oil drain hole (5) forms part of the structure of

only the 2nd, 3rd, and differential lock clutches.
HM400-1
TRANSMISSION
FORWARD 1ST
Operation
In the case of FORWARD 1st, FL clutch (3) and

1st clutch (11) are engaged. The power from the
torque converter is transmitted to input shaft (1),
and then transmitted to front and rear output
shafts (28) and (29).
FL clutch (3) and 1st clutch (11) hold each clutch
disc in position with the oil pressure applied to
the piston.
The power from the torque converter is transmitted from input shaft (1) through FL clutch (3),
goes to FL gear (5), and is then transmitted to
FH, 1st cylinder gear (8).
HM400-1
1st clutch (11) is engaged, so the power transmitted to FH, 1st cylinder gear (8) passes
through 1st clutch (11), and goes from 1st gear
(12) to 2nd, 3rd cylinder gear (14). It then goes
through idler gear (19) and output gear (20),
and is transmitted to differential lock carrier
(21).
When the differential lock switch is OFF, the
front output force passes from planet gear (25)
through sun gear (26), and is transmitted to front
output shaft (28). The rear output force passes
from planet gear (25) through ring gear (27),
and is transmitted to rear output shaft (29).
10-27
TRANSMISSION
FORWARD 2ND
Operation
In the case of FORWARD 2nd, FH clutch (10)
and 1st clutch (11) are engaged. The power
from the torque converter is transmitted to input
shaft (1), and then transmitted to front and rear
output shafts (28) and (29).
FH clutch (10) and 1st clutch (11) hold each
clutch disc in position with the oil pressure applied to the piston.
The power from the torque converter is transmitted from input shaft (1) to idler gear (2) and goes
to FH gear (9), passes through FH clutch (10),
and is then transmitted to FH, 1st cylinder gear
(8).
10-28
(21).
When the differential lock switch is ON, the
front output force passes from housing (22)
through differential lock clutch (23) and clutch
hub (24), and is transmitted to front output shaft
(28). The rear output force passes from planet
gear (25) through ring gear (27), and is transmitted to rear output shaft (29).
HM400-1
TRANSMISSION
FORWARD 3RD
Operation
In the case of FORWARD 3rd, FL clutch (3) and
2nd clutch (17) are engaged. The power from
the torque converter is transmitted to input shaft
(1), and then transmitted to front and rear output
FL clutch (3) and 2nd clutch (17) hold each
goes to FL gear (5), and is then transmitted
through FH, 1st cylinder gear (8) and idler gear
(13), and goes to 2nd gear (15).
HM400-1
2nd clutch (17) is engaged, so the power transmitted to 2nd gear (15) passes through 2nd
clutch (17), and goes to 2nd, 3rd cylinder gear
(14). It then goes through idler gear (19) and
output gear (20), and is transmitted to differential lock carrier (21).
10-29
TRANSMISSION
FORWARD 4TH
Operation
In the case of FORWARD 4th, FH clutch (10)
and 2nd clutch (17) are engaged. The power
FH clutch (10) and 2nd clutch (17) hold each
The power from the torque converter is transmitted from input shaft (1), goes to idler gear (2)
and FH gear (9), passes through FH clutch (10),
and is then transmitted through FH, 1st cylinder
gear (8) and idler gear (13), and is transmitted
to 2nd gear (15).
10-30
2nd clutch (17) is engaged, so the power transmitted to 2nd gear (15) passes through 2nd
clutch (17), and goes to 2nd, 3rd cylinder gear
(14). It then goes through idler gear (19) and
output gear (20), and is transmitted to differential lock carrier (21).
HM400-1
TRANSMISSION
FORWARD 5TH
Operation
In the case of FORWARD 5th, FL clutch (3) and
3rd clutch (18) are engaged. The power from
the torque converter is transmitted to input shaft
(1), and then transmitted to front and rear output
FL clutch (3) and 3rd clutch (18) hold each clutch
the piston.
goes to FL gear (5), and is then transmitted
through FH, 1st cylinder gear (8) to 3rd gear
(16).
HM400-1
3rd clutch (18) is engaged, so the power transmitted to 3rd gear (16) passes through 3rd clutch
(18), and goes to 2nd, 3rd cylinder gear (14). It
then goes through idler gear (19) and output
gear (20), and is transmitted to differential lock
carrier (21).
10-31
TRANSMISSION
FORWARD 6TH
Operation
In the case of FORWARD 6th, FH clutch (10)
and 3rd clutch (18) are engaged. The power
FH clutch (10) and 3rd clutch (18) hold each
The power from the torque converter is transmitted from input shaft (1), goes to idler gear (2)
and FH gear (9), passes through FH clutch (10),
and is then transmitted through FH, 1st cylinder
gear (8) to 3rd gear (16).
10-32
3rd clutch (18) is engaged, so the power transmitted to 3rd gear (16) passes through 3rd clutch
(18), and goes to 2nd, 3rd cylinder gear (14). It
then goes through idler gear (19) and output
gear (20), and is transmitted to differential lock
carrier (21).
HM400-1
TRANSMISSION
REVERSE 1ST
Operation
In the case of REVERSE 1st, R clutch (4) and
1st clutch (11) are engaged. The power from the
torque converter is transmitted to input shaft (1),
and then transmitted to front and rear output
R clutch (4) and 1st clutch (11) hold each clutch
the piston.
The power from the torque converter is transmitted from input shaft (1) through R clutch (4),
goes to R gear (6), is rotated in the opposite direction by R idler gear (7), passes through idler
gear (13), and is then transmitted to FH, 1st
cylinder gear (8).
HM400-1
(21).
10-33
TRANSMISSION VALVE
TRANSMISSION VALVE
A.
B.
C.
D.
E.
F.
G.
H.
Lock-up clutch oil pressure detection port

2nd clutch oil pressure detection port
3rd clutch oil pressure detection port
R clutch oil pressure detection port
FL clutch oil pressure detection port
1st clutch oil pressure detection port
FH clutch oil pressure detection port
Differential lock clutch oil pressure detection port
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
ECMV (for lock-up clutch)

ECMV (for 2nd clutch)
ECMV (for 3rd clutch)
ECMV (for R clutch)
ECMV (for FL clutch)
ECMV (for 1st clutch)
ECMV (for FH clutch)
ECMV (for differential lock clutch)
Seat
Last chance filter
ECMV clutch operation table

ECMV
FL
FH
1st
2nd
3rd
Speed range
F1
Z
Z
F2
F3
F6
R1
R2
Z
Z
F4
F5
Z
Z
Z
Z
Z
Z
Z
Z
Z
10-34
HM400-1
ECMV (Electronic Control

Modulation Valve)
ECMV (Electronic Control Modulation Valve)
A:
P:
T:
Dr:
P1:
P2:
No.
1.
2.
3.
4.
5.
6.
To clutch
From pump
Drain
Drain
Clutch oil pressure detection port
Pilot oil pressure detection port
Check item
Clearance between pressure
control valve and valve body
C lea ra n ce b etw e e n oil p re ss u re
de te ctio n v a lve a n d v a lve b od y
Connector for fill switch

Connector for proportional solenoid
Oil pressure detection valve
Fill switch
Proportional solenoid
Pressure control valve
Criteria
Tolerance
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
4 15.5
-0.020
-0.030
+0.011
0
0.020
0.041
0.045
4 13
-0.025
-0.030
+0.011
0
0.025
0.041
0.045
Standard size
9
10
Pressure control valve spring
Oil pressure detection valve

spring
HM400-1
Remedy
Repair limit
Free
length
Installed
length
Installed
load
Free
length
Installed
load
24.5
20.5
78.5 kN
{8.0 kg}
24.2
70.6 kN
{7.2 kg}
16.8
9.0
35.2 kN
{3.59 kg}
16.5
31.7 kN
{3.23 kg}
Replace
10-35

Modulation Valve)
ECMV FOR LOCK-UP CLUTCH

Outline
This valve acts to set the lock-up clutch oil pressure to the set pressure, and also to switch the
lock-up clutch.
It forms a modulation wave pattern, so the lockup clutch is engaged smoothly to reduce the
shock when shifting gear. In addition, it prevents
generation of peak torque in the power train. As
a result, it provides a comfortable ride for the operator and
greatly increases the durability of the power
train.
10-36
Operation
During torque converter travel
When the transmission is in torque converter
travel, no current flows to proportional solenoid
(1).
Pressure control valve (3) drains the oil at clutch
port A through drain port Dr and cancels the
lock-up clutch.
When this happens, there is no oil pressure acting on oil pressure detection valve (4), so fill
switch (6) is OFF.
HM400-1

Modulation Valve)
DURING DIRECT TRAVEL

(torque converter travel direct travel)
1. When filling
When the transmission is in direct travel (lockup), if electric current is applied to proportional
solenoid (1) by the electric signal, a hydraulic
force balancing with the force of the solenoid
acts on chamber B, and pressure control valve
spool (3)
moves to the left. As a result, the circuit
between pump port P and clutch port A opens,
and oil starts to fill the clutch. When the clutch
is filled with oil, fill switch (6) is turned ON.
HM400-1
2. Adjusting pressure
When electric current flows to proportional solenoid (1), the solenoid generates a propulsion
force proportional to the current. The pressure
is adjusted so that the total of this propulsion
force of the solenoid, the propulsion force of the
oil pressure
at the clutch port, and the reaction force of pressure control valve spring (2) is balanced.
To reduce the shock when shifting gear, the oil
pressure of the lock-up clutch is temporarily
lowered during the gearshifting operation.
The oil pressure at this point is an oil pressure
which balances the pushing force of the lock-up
piston and the pressure inside the torque converter.
10-37
ECMV FOR SPEED CLUTCH

Outline of ECMV
The ECMV (Electronic Control Modulation
Valve) consists of two components: the pressure
control valve and the fill switch.
Pressure control valve
The proportional solenoid receives the flow of
electricity sent from the transmission controller,
and the pressure control valve converts this into
hydraulic pressure.
Fill switch
This detects when oil has filled the clutch. It has
the following functions.
1) When the clutch is filled with oil, it sends a
signal (fill signal) to the controller to inform
the controller that the filling is completed.
2) While oil pressure is applied to the clutch, it
outputs a signal (fill signal) to the controller
to inform the controller of the existence of
the oil pressure.
A range: Before gear shifting (drained)
B range: Filling starts (trigger issued)
C range: Filling completed
D range: Regulation
E range: Filling

Modulation Valve)
ECMV and proportional solenoid

There is one proportional solenoid installed to
each ECMV.
It generates propulsion as shown in the diagram below according to the command current
from the controller.
The propulsion generated by the proportional
solenoid acts on the pressure control valve
spool and generates oil pressure as shown in
the diagram below. In this way, the command
current is controlled and the propulsion force
varies to actuate the pressure control valve and control the oil flow and oil
pressure.
ECMV and fill switch

There is one fill switch installed to each ECMV.
When the filling of the clutch is completed, the fill
switch is turned on by the clutch pressure. With
this signal, the oil pressure starts to build up.
10-38
HM400-1
OPERATION OF ECMV
The ECMV is controlled by the command current
from the transmission controller to the proportional solenoid and the fill switch output signal.
The relationship between the ECMV proportional solenoid command current and the clutch
input pressure and fill switch output signal is as
shown in the diagram below.

Modulation Valve)
1. When gear shifting (during draining)

(Range A in graph)
When no current is flowing to proportional solenoid (1), pressure control valve spool (3) drains
the oil at clutch port A through drain port Dr.
When this happens, there is no hydraulic force
acting on pressure detection valve (4), so fill
switch (6) is turned OFF.
A range: Before gear shifting (drained)

B range: Filling starts (trigger issued)
C range: Filling completed
D range: Regulation
E range: Filling
HM400-1
10-39
2. When filling (when trigger command is input

to pressure control valve)
(Ranges B and C in graph)
When there is no oil inside the clutch, if electric current is applied to proportional solenoid
(1), a hydraulic force balancing the force of the
solenoid acts on chamber B, and pressure control valve spool (3) moves to the left. As a
result, the
circuit between pump port P and clutch port A
opens, and oil starts to fill the clutch. When the
clutch is filled with oil, fill switch (6) is turned
ON.
10-40

Modulation Valve)
3. Adjusting pressure (Range D in graph)

When electric current flows to proportional solenoid (1), the solenoid generates a propulsion
force proportional to the current. The pressure
is adjusted so that the total of this propulsion
force of the solenoid, the propulsion force of the
oil pressure
at the clutch port, and the reaction force of pressure control valve spring (2) is balanced.
HM400-1

Modulation Valve)
ECMV FOR DIFFERENTIAL LOCK

Operation
1. When differential lock switch is turned ON
OFF
When the differential lock switch is turned OFF,
there is no electric current flowing from the controller to proportional solenoid (1) of the ECMV,
so the oil at clutch port A passes through drain
port Dr and is drained. As a result, the force of
the oil
pressure at clutch port A goes down and piston
(2) is returned to its original position by wave
spring (5). Carrier (6) and front output shaft (7)
are separated, and the power is transmitted by
the planetary gear.
The proportion of the torque at this point is as
follows:
Front 1: Rear 2
HM400-1
2. When differential lock switch is turned OFF

ON
When the differential lock switch is turned ON, and
electric signal is sent from the controller to proportional solenoid (1) of the ECMV, and oil starts to fill
clutch port A. As a result, piston (2) is actuated,
presses separator plate (3) and friction
plate (4) together, so carrier (6) and front output
shaft (7) form one unit and transmit the power.
The proportion of the torque at this point is as follows:

Front 1: Rear 1
10-41
MAIN RELIEF, TORQUE CONVERTER

RELIEF VALVE
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
A:
B:
C:
D:
E:
P1:
P2:
1. Body
2. Piston
3. Torque converter relief valve
4. Piston
5. Main relief valve
Drain (torque converter relief)

Drain
From pump
Drain
To torque converter
Main relief oil pressure detection port
Torque converter relief oil pressure detection
port
Unit: mm
No.
Check item
Clearance between main relief
valve and valve body
C le aran c e b e tw ee n to rq ue c on v erte r relief va lv e a n d v al ve
b od y
Criteria
Tolerance
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
4 28
-0.035
-0.045
+0.013
0
0.035
0.058
0.078
4 22
-0.035
-0.045
+0.013
0
0.035
0.058
0.078
Standard size
8
Main relief valve spring (outside)
Remedy
Repair limit
Free
length
Installed
length
Installed
load
Free
length
Installed
load
108
79.5
275 N
{28.0 kg}
104.8
261 N
{26.6 kg}
Main relief valve spring (inside)
108
79.5
326 N
{33.2 kg}
104.8
309 N
{31.5 kg}
10
Torque converter relief valve

spring
50
41
173 N
{17.6 kg}
48.5
164 kN
{16.7 kg}
10-42
Replace
HM400-1
OUTLINE
Torque converter relief valve
The torque converter relief valve protects the torque
converter from abnormally high pressure. It is installed in the torque converter inlet port circuit to hold
the oil pressure in the torque converter inlet port circuit below the set pressure.
Set pressure: 0.91 MPa {9.31 kg/cm2}
(Cracking pressure)
MAIN RELIEF, TORQUE CONVERTER

RELIEF VALVE
Operation of main relief valve

The oil from the hydraulic pump passes through
the filter and enters port A of the relief valve. It
then passes through orifice a of spool (6) and
enters chamber B.
When the oil from the pump fills the circuit, the
oil pressure starts to rise.
Main relief valve

The main relief valve holds the oil pressure in the
transmission and brake at the set pressure.
Set pressure: 2.53 MPa {25.8 kg/cm2}
(Engine at rated speed)
Operation
Operation of torque converter relief valve
The oil relieved by the main relief valve flows
from port C into the torque converter, and at the
same time, passes through orifice b of spool (2)
and enters chamber D.
When the circuit leading to the torque converter
becomes filled with oil, the oil pressure starts to
rise.
As the oil pressure in the circuit rises, the oil entering

chamber B pushes piston (4). The reaction force
compresses valve spring (7) and moves spool (6) to
the left to open the circuit between port A and port C.
When this happens, the oil at port A is relieved to
port C and flows from port C to the torque converter.
The oil pressure at port A at this point is 2.53 MPa
{25.8 kg/cm2} (engine at rated speed).
As the oil pressure going to the torque converter

rises, the oil entering chamber D pushes piston
(9). The reaction force compresses valve spring
(3) and moves spool (2) to the right to open the
circuit between port C and port E.
When this happens, the oil at port C is relieved
to port E and drains to the oil tank.
The oil pressure at port C at this point is 0.91
MPa {9.31 kg/cm2} (cracking pressure).
HM400-1
10-43
DRIVE SHAFT
DRIVE SHAFT
1.
2.
3.
4.
5.
6.
Drive shaft (right)

Front drive shaft
Drive shaft (left)
Center drive shaft
Rear drive shaft (rear)
10-44
Outline
The power from the engine goes from the output
shaft through front drive shaft (2), the transmission, and the front axle, and is transmitted by left
and right drive shafts (1) and (3).
The rest of the power passes through center
drive shaft (4) and the oscillation hitch, and is
transmitted by rear drive shafts (5) and (6) to
the rear axles.
The drive shaft does not simply act to transmit
the power. It also has the following purposes.
When articulating, or when there is impact from
the road surface during travel operations or
impact during operations, the position of the
engine, transmission, and axles changes.
To enable the power to be transmitted without
causing damage to any components by the
impact or change in position, the drive shaft has
a universal joint and slipping joint to enable it to
cope with any changes in the angle or length.
HM400-1
AXLE
AXLE
FRONT
1. Drive shaft
2. Front differential
3. Brake
4. Final drive
HM400-1
10-45
AXLE
CENTER
1.
2.
3.
4.
5.
Center differential
Center axle
Brake
Final drive
Drain plug
10-46
HM400-1
AXLE
REAR
1. Drain plug
2. Rear differential
3. Rear axle
4. Brake
5. Final drive
HM400-1
10-47
DIFFERENTIAL
DIFFERENTIAL
FRONT
1.
2.
3.
4.
Bevel gear (No. of teeth: 41)

Bevel pinion (No. of teeth: 12)
Differential case
Side gear (No. of teeth: 24)
10-48
5.
6.
7.
8.
Pinion gear (No. of teeth: 14)

Shaft
Plate
Disc
HM400-1
DIFFERENTIAL
Unit: mm
No.
Check item
Wear of coupling oil seal contact surface
Criteria
Remedy
Standard size
Tolerance
Repair limit
95
0
-0.087
94.9
10
110
0
-0.087
109.9
11
Thickness of side gear thrust

washer
0.05
3.5
12
Thickness of disc
3.5
13
Thickness of plate
2.1
14
Backlash between bevel gear

and pinion
HM400-1
0.1
0.1
3.1
Repair or
replace
Replace
1.9
0.42 0.65 (in circumferential direction at outside diameter)
Adjust
10-49
DIFFERENTIAL
CENTER
1.
2.
3.
4.
Disc
Plate
Differential case
10-50
5.
6.
7.
8.
Shaft
HM400-1
DIFFERENTIAL
Unit: mm
No.
Check item
Criteria
Standard size
Tolerance
95
0
-0.087
94.9
0.05
3.5
10

washer
11
Thickness of disc
3.5
12
Thickness of plate
2.1
13

and pinion
HM400-1
Remedy
0.1
0.1
Repair limit
3.1
Repair or
replace
Replace
1.9
0.42 0.65 (in circumferential direction at outside diameter)
Adjust
10-51
DIFFERENTIAL
REAR
1.
2.
3.
4.
5.
6.
7.
8.

Shaft
Differential case
Plate
Disc
10-52
HM400-1
DIFFERENTIAL
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Tolerance
90
0
-0.087
89.9
0.05
3.5
10

washer
11
Thickness of disc
3.5
12
Thickness of plate
2.1
13

and pinion
0.1
0.1
0.42 0.65
Repair limit
3.1
Repair or
replace
Replace
1.9
Adjust
Operation
The power from the engine is transmitted
through the output shaft, front drive shaft, torque
converter, and transmission to each axle.
Inside the axle, the power is transmitted from
pinion gear (5) to bevel gear (1), is converted
and sent at 90 1, has its speed reduced, and is
transmitted through pinion gear (6) and side
gear (3) to the axle shaft.
The power transmitted to the axle shaft has its
speed further reduced by the planetary gear
type final drive, and is transmitted to the wheels.
When turning
When the machine is turned, the speed that the
wheels turn on the left and right sides is different, so pinion gear (6) and side gear (3) inside
the differential rotate according to the difference
in the turning speed on the left and right sides,
and transmit the power of differential case (2) to
the left and right shafts.
When traveling in a straight line

When the machine is traveling in a straight line,
the speed that the wheels turn on the left and
right sides is the same, so pinion gear (6) inside
the differential assembly does not turn, and the
power of differential case (2) is transmitted
equally through side gear (3) to the left and right
shafts.
HM400-1
10-53
DIFFERENTIAL
When differential lock is actuated

If the load resistance on the wheel on one side
is lost (such as when the wheel is in mud), only
the wheel on the side where there is little load resistance turns, and as a result, the power cannot
be transmitted.
In such a case, it becomes impossible to travel,
so differential lock (7) is actuated to stop the
rotation of pinion gear (4) and transmit the
power equally to left and right axle shafts (2).
10-54
HM400-1
FINAL DRIVE
FINAL DRIVE
FRONT
1.
2.
3.
4.
5.
6.
7.
Axle shaft
Ring gear (No. of teeth: 67)
Planet gear (No. of teeth: 24)
Planet carrier
Sun gear (No. of teeth: 17)
Drain plug
Brake
10-56
HM400-1
FINAL DRIVE
Unit: mm
No.
Check item
Criteria
Backlash between planet gear

and sun gear
0.19 0.43

and ring gear
10
Curvature of drive shaft
11
Thickness of spacer
Remedy
Replace
12
Wear of outside diameter of

portion of axle tube inserted
into bearing
13

into bearing
0.19 0.53
Repair limit: 0.7TIR
Repair or replace
Standard size
Tolerance
Repair limit
12
0.1
11.5
180
0
-0.025
179.8
Replace
Correct
14
Clearance between shaft (outside diameter) and bushing
Standard
size
65
HM400-1
0
-0.025
170
Tolerance
169.8
Shaft
Hole
Standard
clearance
0
-0.013
+0.337
+0.251
0.251
0.350
Clearance
limit
Replace
0.4
10-57
FINAL DRIVE
CENTER, REAR
1.
2.
3.
4.
5. Sun gear (No. of teeth: 17)

6. Drain plug
7. Brake
Axle shaft
Ring gear (No. of teeth: 67)
Planet gear (No. of teeth: 24)
Planet carrier
Unit: mm
No.
Check item
Criteria

and sun gear
0.19 0.43

and ring gear
0.19 0.53
10
Curvature of drive shaft
11
Thickness of spacer
Remedy
Replace
12

into bearing
13

into bearing
Repair limit: 1.5TIR
Repair or replace
Standard size
Tolerance
Repair limit
26
0.1
11.5
180
0
-0.025
179.8
Replace
Correct
10-58
170
0
-0.025
169.8
HM400-1
FINAL DRIVE
Function
The final drive uses a planetary gear mechanism
to reduce the speed in order to give a large drive
force, and transmits this drive force to the tires.
Operation
The power from the differential passing through
axle shaft (1) is transmitted to sun gear (5) and
then goes to planet gear (3).
The planet gear rotates on the inside of fixed
ring gear (2) and transmits the reduced speed
to planetary carrier (4). This power is then
transmitted to the wheels that are installed to
the planetary carrier.
HM400-1
10-59
STEERING COLUMN
STEERING COLUMN
1.
2.
3.
4.
5.
6.
Steering shaft
Steering column
Lock lever
Yoke
Join shaft
Steering valve
10-60
HM400-1
BRAKE PIPING
BRAKE PIPING
10-62
HM400-1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
BRAKE PIPING
Accumulator charge valve

Shuttle valve
Slack adjuster
Brake filter
Brake valve
Brake system tank
Accumulator (for front)
Accumulator (for rear)
Accumulator (for parking)
Proportional reducing valve
Parking brake valve
HM400-1
10-63
BRAKE VALVE
BRAKE VALVE
1.
2.
3.
4.
5.
6.
Pilot piston
Rod
Lower cylinder
Spool
Upper cylinder
Spool
10-64
A.
B.
C.
D.
E.
To center, rear brake

To front brake
To brake system tank
From front accumulator
From rear accumulator
HM400-1
OPERATION
Upper portion
When brake pedal (1) is depressed, the operating force is transmitted to spool (3) through rod
(2) and spring (4). When spool (3) goes down,
drain port a is closed, and the oil from the pump
and accumulator flows from port A to port C and
actuates the center and rear brake cylinders.
BRAKE VALVE
Applying brake when upper valve fails

Even if there is leakage of oil in the upper piping,
spool (5) is moved down mechanically when
pedal (1) is depressed, and the lower portion is
actuated normally.
The upper brake is not actuated.
Applying brake when lower valve fails
Even if there is leakage of oil in the lower piping,
the upper portion is actuated normally.
Lower portion
When brake pedal (1) is depressed, the operating force is transmitted to spool (3) through rod
(2) and spring (4). When spool (3) goes down,
spool (5) is also pushed down by plunger (6).
When this happens, drain port b is closed, and
the oil from the pump and accumulator flows
from port B to port D and actuates the front
brake cylinders.
When actuation is balanced

Upper portion
When oil fills the center and rear brake cylinders
and the pressure between port A and port C becomes high, the oil entering port H from orifice e
of spool (3) pushes against spring (4). It pushes
up spool (3) and shuts off the circuit between
port A and port C. When this happens, drain port
a stays closed, so the oil entering the brake cylinder is held and the brake remains applied.
HM400-1
10-65
Lower portion
When spool (3) in the upper portion moves up
and the circuit between port A and port C is shut
off, oil also fills the front brake cylinder at the
same time, so the pressure in the circuit between port B and port D rises. The oil entering
port J from orifice f of spool (5) pushes up spool
(5) by the same amount that spool (3) moves,
and shuts off port B and port D. Drain port b is
closed, so the oil entering the brake cylinder is
held, and the brake is applied.
The pressure in the space in the upper portion is
balanced with the operating force of the pedal,
and the pressure in the space in the lower portion is balanced with the pressure in the space in
the upper portion. When spools (3) and (5) move
to the end of their stroke, the circuits between
ports A and C and between ports B and D are
fully opened, so the pressure in the space in the
upper and lower portions and the pressure in the
left and right brake cylinders is the same as the
pressure from the pump.
Therefore, up to the point where the piston
moves to the end of its stroke, the effect of the
brake can be adjusted by the amount that the
pedal is depressed.
10-66
BRAKE VALVE
Brake released
Upper portion
When pedal (1) is released and the operating
force is removed from the top of the spool, the
back pressure from the brake cylinder and the
force of the spool return spring move spool (3)
up. Drain port a is opened and the oil from the
brake cylinder flows to the brake system tank return circuit to release the center and rear brakes.
Lower portion
When the pedal is released, spool (3) in the upper portion moves up. At the same time, the
back pressure from the brake cylinder and the
force of the spool return spring move spool (5)
up. Drain port b is opened and the oil from the
brake cylinder flows to the brake system tank return circuit to release the front brake.
HM400-1
ACCUMULATOR CHARGE VALVE
ACC.
P.
PP.
T.
To accumulator
To accumulator
From hydraulic pump
To brake tank
HM400-1
Function
The accumulator charge valve is actuated to
maintain the oil pressure from the pump at the
specified pressure and to store it in the accumulator.
When the oil pressure reaches the specified
pressure, the oil from the pump is connected to
the drain circuit to reduce the load of the pump.
10-67
1. Main relief valve (R3)

2. Valve body
3. Relief valve (R1)
10-68
4. Relief valve (H1)

5. Filter
6. Filter
HM400-1
OPERATION
1. When no oil is being supplied to accumulator
(cut-out condition)
The pressure at port B is higher than the set
pressure of the relief valve (R1), so piston (8) is
forcibly pushed up by the oil pressure at port B.
Poppet (6) is opened, so port C and port T are
short circuited.
The spring chamber at the right end of spool (15)
is connected to port C of the relief valve (R1), so
the pressure becomes the brake oil tank pressure. The oil from the pump enters port P, pushes spool (15) to the right at a low pressure
equivalent to the load on spring (14).
It also passes through orifices (17), (18) and
(16), and flows to the brake oil tank.
HM400-1
2. When oil supplied to accumulator

1) Cut-in condition
When the pressure at port B is lower than the set
pressure of the relief valve (R1), piston (8) is
pushed back down by spring (5).
Valve seat (7) and poppet (6) are brought into
tight contact, and port C and port T are shut off.
is also shut off from port T, so the pressure rises,
and the pressure at port P also rises in the same
way.
When the pressure at port P goes above the
pressure at port B (accumulator pressure), the
supply of oil to the accumulator starts immediately. In this case, it is decided by the size (area)
of orifice (17) and the pressure difference
(equivalent to the load on spring (14)) generated
on both sides of the orifice. A fixed amount is
supplied regardless of the engine speed.
10-69
2) When cut-out pressure is reached

When the pressure at port B (accumulator pressure) reaches the set pressure of the relief valve
(R1), poppet (6) separates from valve seat (7),
so an oil flow is generated and the circuit is relieved.
When the circuit is relieved, a pressure difference is generated above and below piston (8),
so piston (8) moves up, poppet (6) is forcibly
o pen ed, and p ort C and p ort T are sh ort
circuited.
is connected to port C of the relief valve (R1), so
the pressure becomes the brake oil tank pressure.
The pressure at port P drops in the same way to
a pressure equivalent to the load on spring (14),
so the supply of oil to port B is stopped.
10-70
3. Main relief valve (R3)

If the pressure at port P (pump pressure) goes
above the set pressure of the relief valve (R3),
the oil from the pump pushes spring (3). Ball (11)
is pushed up and the oil flows to the brake oil
tank circuit, so this set the maximum pressure in
the brake circuit and protects the circuit.
HM400-1
ACCUMULATOR
ACCUMULATOR
1.
2.
3.
4.
Valve
Top cover
Cylinder
Piston
Function
The accumulator is installed between the accumulator charge valve and the brake valve. It is
charged with nitrogen gas between cylinder (3)
and free piston (4), and uses the compressibility
of the gas to absorb the pulse of the hydraulic
pump or to maintain the braking force and to
make it possible to operate the machine if the
engine should stop.
Specifications
Gas used:
Nitrogen gas
Charge amount:
4,000 cc
Charging pressure: 4.4 0.15MPa
{45 1.5kg/cm2}
HM400-1
10-71
SLACK ADJUSTER
SLACK ADJUSTER
1.
2.
3.
4.
5.
Bleeder
Cylinder
Check valve
Spring
Piston
A. Outlet port
B. Inlet port
Unit: mm
No.
Check item
Front
Clearance
between body and
piston
Center
rear
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
55
-0.030
-0.076
+0.074
0
0.030
0.150
0.25
55
-0.030
-0.076
+0.074
0
0.030
0.150
0.25
Standard size
Slack adjuster
spring
Front
Center
rear
10-72
Replace
Repair limit
Free
length
Installed
length
Installed
load
Free
length
Installed
load
230
88
118 N
{12 kg}
198
38
43.2 N
{4.4 kg}
HM400-1
FUNCTION
The slack adjuster is installed in the brake oil line
from the brake valve to the brake piston. It acts
to keep the clearance between the brake piston
and discs constant even when the brake discs
are worn. in this way it acts to keep a constant
time lag when the brake is operated.
SLACK ADJUSTER
If the brake pedal is depressed further, and the

oil pressure discharged from the brake valve
goes above to set pressure, check valve (3)
opens and the pressure is applied to port C to
act as the braking force.
Therefore, when the brake is applied, the time
lag is a fixed value.
OPERATION
1. When brake pedal is depressed
Before the brake is depressed, piston (4) is returned by the distance of stoke S (full stroke).
When the brake pedal is depressed, the oil discharged from the brake valve flows from port P
of the slack adjuster and is divided to left and
right cylinders (2), where it moves piston (4) by
stroke S to the left and right.
2. When brake pedal is released
When the brake is released, piston (4) is returned by brake return spring (8) by an amount
equivalent to the oil for the stroke S, and the
brake is released.
In other words, return stroke T of brake piston
(7) is determined by the amount of oil for stroke
S of the slack adjuster. The time lag of the
brake is always kept constant regardless of the
wear of the brake disc.
When this is done, brake piston (7) moves by a

distance of stroke S. In this condition, the closer
the clearance between the brake piston and dics
is to 0, the greater the braking force becomes.
HM400-1
10-73
BRAKE
BRAKE
FRONT
1.
2.
3.
4.
5.
6.
7.
Stud pin
Cylinder
Brake piston
Disc
Plate
Hub gear (No. of teeth: 112)
Outer gear (No. of teeth: 164)
10-74
HM400-1
BRAKE
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
0.52 0.90
1.5
0.52 0.90
1.5
Standard size
Repair limit
2.4
2.15
5.1
4.6
Backlash between outer gear

and plate
Backlash between hub gear

and plate
Thickness of plate
Thickness of disc
Thickness of damper
6.9
5.1
Warping of disc friction surface
Standard warping
Repair limit
Max 0.45
0.7
Warping of plate and damper

friction surface
Max 0.50
0.7
Assemble thickness of plate

and disc
Standard warping
Repair limit
56.4
51.4
Retainer oil seal contact surface
430
0 -0.155
HM400-1
Replace
Correct or
replace
10-75
BRAKE
CENTER, REAR
1.
2.
3.
4.
5.
6.
7.
Stud pin
Cylinder
Brake piston
Disc
Plate
Hub gear (No. of teeth: 112)
Outer gear (No. of teeth: 164)
10-76
HM400-1
BRAKE
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
0.52 0.90
1.5
0.52 0.90
1.5
Standard size
Repair limit
2.4
2.15
Thickness of disc
5.1
4.6
Thickness of damper
6.9
5.1
Standard warping
Repair limit
Max 0.45
0.7
Max 0.50
0.7
Standard warping
Repair limit
56.4
51.4
430
0 -0.155
Backlash between outer gear

and plate
Backlash between hub gear

and plate
Thickness of plate
4
5
6
Warping of disc friction surface
Warping of plate and damper

friction surface
Assemble thickness of plate

and disc
Retainer oil seal contact surface
HM400-1
Replace
Correct or
replace
10-77
BRAKE
Function
There are wet-type multiple disc brakes installed
to all of the six wheels.
Operations
When the brake pedal is depressed, pressure oil
from the brake valve moves brake piston (3) to
the right in the direction of the arrow. This presses disc (7) and plate (6) together and generates
friction between the disc and plate. The wheel is
rotating together with the disc, so this friction reduces the travel speed and stops the machine.
When the brake pedal is released, the pressure

at the back face of brake piston (3) is released,
so the piston is moved to the left in the direction
of the arrow by the internal pressure, and this releases the brake.
10-78
HM400-1
PROPORTIONAL REDUCING VALVE
PROPORTIONAL REDUCING VALVE
1. Filter
2. Connector
3. Solenoid assembly
A. From brake valve (outlet)
P. To brake valve (inlet)
T. To brake system tank
HM400-1
Function
The proportional reducing valve is a valve used
for retarder control. It is installed between the
brake valve and the brake system tank in the
brake circuit.
It varies the discharge pressure of the pressure
oil in accordance with the turning angle of the
retarder control lever, so the retarder control
can be carried out as desired.
10-79
BRAKE SYSTEM TANK
BRAKE SYSTEM TANK
1. Boss
2. Inlet hose
3. Outlet hose
A.
B.
C.
D.
To hydraulic pump
From accumulator charge valve
Oil filler port
Drain port
10-80
HM400-1
PARKING BRAKE
PARKING BRAKE
1. Spring cylinder
2. Parking brake disc
10-82
Function
The parking brake is a disc type and is installed
to the front axle.
It is actuated mechanically by the force of the
spring inside the spring cylinder and is released
by hydraulic pressure.
The parking brake caliper is fixed to the front differential.
The disc is installed to the differential yoke and
rotates together with the coupling.
HM400-1
PARKING BRAKE
Unit: mm
No.
3
Check item
Criteria
Remedy
Standard backlash
Repair limit
0.4
0.8
Repair or
replace
Face runout of disc
Rebuid
(Thickness of
disc must not be
under 20 mm)
Min. 20
4
Thickness of disc
25
Max. 20
Replace
Thickness of pad (including

thickness of plate)
Clearance between blade and

brake assembly
21.5
Standard dim ension of blade
Tolerance
22.3
0
-0.3
Standard
dim ension of
brake assem bly
22.3
HM400-1
11.5
Tolerance
Standard
clearance
1.0 0.4
Allowable
clearance
Correct or
replace
1.5
+0.4
-0.1
10-83
PARKING BRAKE CALIPER
PARKING BRAKE CALIPER
1.
2.
3.
4.
5.
Adjuster
Piston
Piston shaft
Pad
Caliper
10-84
Outline
A piston guide is installed to caliper (5). Piston
(2) and piston shaft (3) are inserted, and the rotation of piston shaft (3) moves piston (2) in the
axial direction to bring pad (4) into tight contact.
The lever is joined by a spline to the spline side
of piston shaft (3).
Pad (4) is inserted together with caliper (5) into
the caliper mounting plate and is held in position.
HM400-1
SPRING CYLINDER
SPRING CYLINDER
1.
2.
3.
4.
5.
6.
Outer spring
Inner spring
Piston
Cylinder
Boot
Rod
HM400-1
OUTLINE
The oil pressure from the parking brake solenoid
valve pushes the spring and releases the parking brake.
When the engine is stopped, the parking brake
is applied by springs (1) and (2), so the machine
is prevented from moving.
10-85
PARKING BRAKE SOLENOID VALVE
PARKING BRAKE SOLENOID VALVE
1. Solenoid valve assembly

2. Block
A: Outlet port
P: Inlet port
T: Drain port
10-86
Function
The parking brake solenoid valve is installed on
the right side inside the front frame. When the
parking brake switch is turned ON, the solenoid
valve is energized. This sends the brake oil to
the parking brake spring cylinder and sets the
parking brake to the PARKING position. When
the parking brake is turned OFF, the solenoid
valve is de-energized, and the brake oil pressure
is removed from the parking brake spring cylinder to set the machine to the TRAVEL condition.
Parking brake solenoid energized: TRAVEL
de-energized : PARKING
HM400-1
SUSPENSION
SUSPENSION
FRONT
10-88
HM400-1
1.
2.
3.
4.
SUSPENSION
Front suspension cylinder

Arm
Lateral rod
Dust cover
Unit: mm
No.
Check item
Clearance between pin and

bushing

bushing
HM400-1
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
60
-0.030
-0.076
+0.046
0
0.030
0.122
0.3
60
-0.030
-0.076
+0.046
0
0.030
0.122
0.3
Replace
10-89
SUSPENSION
REAR
10-90
HM400-1
1.
2.
3.
4.
5.
6.
SUSPENSHION
Arm
Equalizer bar
Lateral rod (center)
Spring
Rear suspension
Lateral rod (rear)
10-92
HM400-1
SUSPENSHION
Unit: mm
No.
Check item
Criteria
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
60
-0.030
-0.076
+0.046
0
0.030
0.122
0.3

bushing
60
-0.030
-0.076
+0.046
0
0.030
0.122
0.3

bushing
60
-0.030
-0.076
+0.046
0
0.030
0.122
0.3

bushing
Standard
size
Remedy
Outline
The suspension supports the weight of the machine. It also reduces any impact caused by unevenness in the road surface and provides a
comfortable ride for the operator. By ensuring
that all the tires are always in contact with the
road surface, it maintains the stability of the machine, and also fulfills the operating performance by ensuring that the machine can carry out
acceleration, braking, and turning.
The suspension cylinders reducing the impact
from the road surface are a hydropneumatic
type. The inside of the suspension cylinder is
charged (sealed) with oil and nitrogen gas. In
this way, the compression and expansion of the
nitrogen gas and oil act as a spring and shock
absorber, and is used to absorb the load from
the road surface.
Replace
2. Center, rear suspension

The center axle and rear axle are both fixed to arms.
The center axle is joined to the equalizer bar through
a spring, and the rear axle is joined through the rear
suspension cylinder. The arm and equalizer bar oscillate in accordance with the condition
of the road surface to keep the wheels in contact with
the road surface.
The main frame and arm are connected by a lateral
rod and receive the lateral load.
Function
1. Front suspension
The front suspension cylinder has the function of a
shock absorber and spring. It is joined to the arm
and main frame by a spherical bearing, and the arm
oscillates according to the extension and retraction
of the front suspension cylinder.
The main frame and arm are joined by a lateral rod
and receive the lateral load.
HM400-1
10-93
SUSPENSION CYLINDER
SUSPENSION CYLINDER
1.
2.
3.
4.
5.
6.
Oil level valve

Feed valve
Retainer
Rod
Flange
Cylinder
10-94
HM400-1
SUSPENSION CYLINDER
Unit: mm
No.
Check item
Criteria
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
140
-0.043
-0.106
+0.240
+0.060
0.103
0.346
0.4
Clearance between piston rod

and bushing
140
-0.043
-0.106
Clearance between cylinder

and wear ring
140
0
-0.21

and bushing
Standard
size
Remedy
+0.240
+0.060
+0.010
0
Replace
0.103
0.346
0.7
0 0.22
0.8
Structure and operation

The suspension cylinder has the function of both a
shock absorber and spring.
When a fixed amount of oil is sent from oil chamber
(1) through orifices (4) and (5) to cavity (3), the oil is
throttled by the orifices and a shock-absorbing effect
is obtained.
1. Retracting action
When the machine is traveling and it hits a
bump or object on the road, the wheels are
pushed up, and the cylinder rod is pushed
inside the cylinder.
When this happens, the nitrogen gas inside
chamber (2) is compressed, the oil in chamber
(1) is sent through both orifices (4) and (5) to
cavity (3), and cavity (3) is filled more quickly
than when extending.
2. Extending action
When the machine has passed any bump or
object on the road surface, the cylinder rod is
pushed up by the weight of the wheels and axle
and the pressure of the nitrogen inside chamber
(2).
As a result, the amount of oil in cavity (3) is
reduced, and pressure is applied to the oil
remaining in cavity (3).
This pressurized oil closes orifice (4) with check
ball (6), and is sent to chamber (1) through only
orifice (5), so the flow of oil passing through the
orifice is controlled so that it is less than during
retraction.
In this way, the amount of oil returning to chamber (1) is restricted to provide a shock absorbing effect.
HM400-1
1.
2.
3.
4.
5.
6.
Oil chamber
Nitrogen gas chamber
Cavity
Orifice
Orifice
Check ball
10-95
OSCILLATION HITCH
OSCILLATION HITCH
1.
2.
3.
4.
5.
6.
Steering cylinder
Front frame
Center drive shaft
Rear frame
Pin
10-96
7.
8.
9.
10.
11.
12.
Hitch frame
Disc
Coupling
Shaft
Coupling
Pin
HM400-1
10-98
OSCILLATION HITCH
HM400-1
OSCILLATION HITCH
Unit: mm
No.
Check item
Standard shim thickness
Criteria
Standard
size
Tolerance
Shaft
Hole
Remedy
Standard
clearance
Clearance
limit
Clearance between bushing

and front frame
115
-0.036
-0.090
+0.054
0
0.036
0.144
Clearance between shaft and

bushing
85
-0.036
-0.066
+0.054
0
0.036
0.120

bearing
85
-0.036
-0.058
0
-0.020
0.016
0.058

bushing
85
-0.036
-0.058
+0.054
0
0.036
0.112
Clearance between front frame

and shaft
85
-0.036
-0.058
+0.054
0
0.036
0.112

and pin
85
-0.036
-0.058
+0.054
0
0.036
0.112
10

bearing
85
-0.036
-0.058
0
-0.020
0.016
0.058
11

and pin
85
-0.036
-0.058
+0.054
0
0.036
0.112
12
Clearance between hitch frame

and bearing
150
0
-0.018
0
-0.040
-0.040
0.018
13
Clearance between hitch frame

and bearing
340
0
-0.057
0
-0.040
-0.040
0.057
14
Clearance between rear frame

and bearing
460
0
-0.045
-0.017
-0.080
-0.080
0.028
15

and bearing
435
-0.020
-0.083
+0.063
0
0.020
0.146
16

and bearing
420
0
-0.045
-0.013
-0.080
-0.080
0.032
17

and hitch frame
300
-0.056
-0.108
0
-0.036
0.020
0.108
18
Outline
The front frame and the rear frame are connected by the oscillation hitch.
Front frame (2) is connected with bearings and
pins (6) and (12); rear frame (4) is connected
with a spacer, retainer, and bearing. This makes
it possible for the front and rear frames to articulate and oscillate.
HM400-1
Replace
In addition, the output from the transmission is

transmitted from center drive shaft (3) to coupling (9). It is then transmitted from coupling
(11) through the rear drive shaft to the rear axle.
10-99
STEERING, HOIST OIL PRESSURE

PIPING DIAGRAM
STEERING, HOIST OIL PRESSURE PIPING DIAGRAM
1. Steering, hoist control pump

(SAR(3)100+100+(1)8)
2. Steering cylinder
3. Hydraulic tank
4. Flow amp valve
5. Steering valve
6. Check valve
7. Hoist valve
8. Hoist cylinder
9. Filter
10-100
HM400-1
DUMP BODY CONTROL
DUMP BODY CONTROL
1.
2.
3.
4.
5.
6.
7.
Dump control lever

Check valve
EPC valve
Hoist cylinder
Hoist valve
Hydraulic pump (SAR(3)100+100+(1)8)
Body positioner sensor
HM400-1
Function
This control is carried out by the body position
sensors. When the dump body is rising, and it
comes to the set position of the body position
sensor, the sensor is automatically actuated.
The signal from the dump control lever is controlled by the retarder controller, and actuates
the EPC valve. The pilot pressure generated by
the EPC valve moves the spool of the hoist valve
and controls the hoist cylinder.
10-101
HYDRAULIC TANK AND FILTER
HYDRAULIC TANK AND FILTER
1.
2.
3.
4.
5.
6.
Hydraulic oil filter

Breather
Oil level gauge
Drain plug
Bypass valve
Element
10-102
HM400-1
FLOW AMP VALVE
FLOW AMP VALVE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Valve
Valve
Orifice
Spring
Pin
Valve
Valve
Plug
Valve
Spool
Valve body
Stopper
HM400-1
CL. To steering cylinder

L. To steering valve
P. To steering valve
PP. From steering valve
HP. From hydraulic pump
LS. From steering valve
HT. From hoist valve
T. To steering valve
EF. To hoist valve
R. From steering valve
CR.To steering cylinder
Outline
The flow amp valve consists of the directional
valve, amplifying stage, priority valve, relief
valve, pressure control valve, and suction valve.
It amplifies the oil flow sent from ports L and R of
the steering unit by the specified ratio. The amplified oil then goes from ports CL and CR of the
flow amp valve and flows to the steering cylinder.
The amplified oil flow is proportional to the
amount the steering wheel is turned.
10-103
FLOW AMP VALVE
Operation
Operation
1. At neutral
Port P of steering unit (7) is closed and the flow
amp valve is closed at chamber M of pressure
control valve (3).
Ports L, R, and T of steering unit (7) are connected to each other, so the oil passes through port
T of the flow amp valve and is drained to the hydraulic tank.
By connecting in this way, directional valve (6)
is always held at the neutral position by the
springs on both sides. For this reason, at the
neutral position, the reaction or impact from the
steering cylinder is not transmitted to steering
unit (7).
10-104
For priority valve (2) also, the oil is drained from

relief valve (1).
Before starting, priority valve (2) is pushed
strongly to the left by the spring, so in reality,
port EF of the flow amp valve is almost closed.
At the same time as the engine starts, oil flows
to port HP of the flow amp valve and then flows
to port P of steering unit (7). At the same time,
the pilot pressure that is connected to port PP
suddenly rises. As a result of balancing with
the spring and moving to the right, port EF opens
and the oil flows to the hoist piping.
HM400-1
2. When turning
When steering unit (7) is actuated, the oil sent
from port P of priority valve (2) passes through
ports P and L of steering unit (7) and enters port
L of directional valve (6).
At the same time, oil from priority valve (2) also
enters chamber M of pressure control valve (3).
When the oil entering directional valve (6) rises
to a pressure greater than the force of the
spring, it pushes the spool to the right, and enters chamber C of pressure control valve (3).
When it rises to a pressure greater than the
force of the spring in chamber C also, it pushes
the spool to the left.
The oil that is already in chamber M of pressure
control valve (3) enters chamber N when the
spool is pushed to the left by the action of steering unit (7). It then flows from port P, goes out
from port CL of directional valve (6), and flows
from suction valve (5) to the bottom end of the
steering cylinder.
HM400-1
FLOW AMP VALVE
The oil at the steering cylinder head end goes

out from suction valve (5). It then goes from port
CR of directional valve (6) through check valve
(4) and is drained to the hydraulic tank from port
HT of the flow amp valve.
If there are rocks on the road or the the road surface is uneven, and any abnormal external force
is applied to the tires and steering cylinder, relief
valves (8) and (9) of suction valve (5) open at a
pressure of 23.5 Mpa {240 kg/cm2}, so the oil
passes through directional valve (6) and is
drained to the hydraulic tank.
10-105
STEERING VALVE
STEERING VALVE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Cover
Drive shaft
Valve body
Center pin
Bearing
Spool
Centering spring
Sleeve
Stator
Rotor
Lover cover
10-106
L.
LS.
P.
R.
T.
To flow amp valve

To flow amp valve
From flow amp valve
To flow amp valve
To flow amp valve
HM400-1
Outline
The steering valve is connected directly to the
shaft of the steering wheel. It switches the flow
of oil from the steering pump to the left and right
steering cylinders to determine the direction of
travel of the machine.
The orbit-roll valve, broadly speaking, consists
of the following components: rotary type spool
(9) and sleeve (8), which have the function of selecting the direction, and the Girotor set (a combination of rotor (5) and stator (10)), which acts
as hydraulic motor during normal steering operations, and as a hand pump (in fact, the operating force of the steering wheel is too high, so it
cannot be operated) when the steering pump or
engine have failed and the supply of oil is
stopped.
HM400-1
STEERING VALVE
Structure
Spool (9) is connected to the drive shaft of the
steering wheel, and is connected to sleeve (8)
by center pin (7) (this is not touching the spool
when the steering wheel is at the neutral position) and centering spring (2).
Drive shaft (3) is meshed at the top with center

pin (7) and forms one unit with sleeve (8). The
bottom is meshed with the spline of rotor (5) of
the Gerotor set.
Valve body (4) has five ports. These are connected to the pump circuit, tank circuit, steering
cylinder head end, bottom end, and flow amp
valve pilot end. In addition, the port at the pump
end and the port at the tank end are connected
by the check valve inside the body. If there is
any failure in the pump or engine, this check
valve acts to suck in oil directly from the tank.
10-107
STEERING VALVE
CONNECTION BETWEEN HAND PUMP AND SLEEVE
The diagrams above show the connections with

the sleeve ports used to connect the suction and
discharged ports of the Girotor.
If the steering wheel has been turned to the
right, ports a, c, e, g, i, and k are connected by
the vertical grooves in the spool to the pump
side. At the same time, ports b, d, f, h, j, and l are
connected to the head end of the left steering
cylinder in the same way.
In the condition in Fig. 1, ports 1, 2, and 3 are
the discharge ports of the Girotor set.
They are connected to ports l, b, and d, so the
oil is sent to the cylinder.
Ports 5, 6, and 7 are connected and the oil
flows in from the pump.
In the steering wheel is turned 90, the condition changes to the condition shown in Fig. 2. In
this case, ports 1, 2, and 3 are the suction ports,
and are connected to ports i, k, and c. Ports 5,
6, and 7 are discharge ports, and are connected
to ports d, f, and h.
10-108
Suctiion /
discharge port
SBW00727
In this way, the ports of the Girotor acting as delivery ports are connected to ports which are
connected to the end of the steering valve spool.
The ports acting as suction ports are connected
to the pump circuit.
Adjusting delivery in accordance with angle of
steering wheel:
For every 1/7 turn of the steering wheel, the
inner teeth of the Girotor gear advance one
po sitio n s o the oil flo w fr om the p ump is
adjusted by this movement. In this way, the oil
delivered from the pump is directly proportional
to the amount the steering wheel is turned.
HM400-1
STEERING VALVE
FUNCTION OF CENTER SPRING

Centering spring (2) consists of four layers of
leaf springs crossed to form an X shape.
The springs are assembled in spool (9) and
sleeve (8) as shown in the diagram on the right.
When the steering wheel is turned, the spring is
compressed and a difference in rotation (angle
variation) arises between the spool and the
sleeve.
Because of this, the ports in the spool and
sleeve are connected and oil is sent to the cylinder. When the turning of the steering wheel is
stopped, the Girotor also stops turning, so no
more oil is sent to the cylinder and the oil pressure rises.
To prevent this, when the turning of the steering
wheel is stopped, the action of the centering
spring only allows it to turn by an amount equal
to the difference in angle of rotation (angle variation) of the sleeve and spool, so the steering
wheel returns to the NEUTRAL position.
HM400-1
10-109
STEERING CYLINDER
STEERING CYLINDER
Unit: mm
No.
Check item

and bushing
Criteria
Shaft
Hole
Standard
clearance
Clearance
limit
60
-0.030
-0.104
+0.271
+0.075
0.105
0.375
0.475
0
-0.074
+0.174
+0.100
0.100
0.248
1.0
0
-0.074
+0.174
+0.100
0.100
0.248
1.0

support shaft and bushing
60

bottom support shaft and
bushing
65
Replace
Standard size
Tolerance
Repair limit
120
+0.15
0
Cylinder bore
10-110
Tolerance
Standard
size
Remedy
HM400-1
HOIST VALVE
HOIST VALVE
10-112
HM400-1
AB:
AH:
P:
PA:
PB:
T:
T2:
1.
2.
3.
4.
5.
HOIST VALVE
To hoist cylinder bottom

To hoist cylinder head
From demand valve
From EPC valve (pressurizing for LOWER, FLOAT)
From EPC valve (pressurizing for RAISE)
To hydraulic tank
To pilot check valve
Valve body
Hoist spool
Check valve
Housing
Relief valve
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
A
Spool return spring
Spool return spring
Repair limit
Free length
x O.D.
Installed
length
Installed
load
Free
length
Installed
load
63.4 x 61
61
308 N
{31.4 kg}
277 N
{28.2 kg}
47 x 36
47
0N
{0 kg}
Replace spring
if damaged or
277 N
{28.2 kg} deformed
Spool return spring
47.5 x 41
45.2
308 N
{31.4 kg}
Spool return spring
87.6 x 52
60
1372 N
{140 kg}
1235 N
{126 kg}
Spool return spring
97.8 x 35
86
822 N
{83.9 kg}
740 N
{75.5 kg}
Check valve return spring
84.7 x 26.6
47.5
13 N
{1.3 kg}
11 N
{1.12 kg}
HM400-1
10-113
HOIST VALVE
OPERATION
1. Hoist valve at HOLD position
The oil from the demand of valve enters port C.

The passage to the hoist cylinder is blocked by
hoist spool (2), so the oil is drained from tank D
to the tank.
10-114
The ports to the hoist cylinder are blocked at

both the bottom end and head end, so the hoist
cylinder is held in position.
HM400-1
HOIST VALVE
2. Hoist valve at RAISE position
When the hoist lever inside the cab is operated

to the RAISE position, hoist spool (2) is moved
to the left by the solenoid valve.
As a result, the oil flows from chamber C, opens
check valve (3), and enters chamber A.
From chamber A, the oil enters the bottom end
of the hoist cylinder, extends the hoist cylinder,
and raises the dump body.
HM400-1
At the same time, the return oil from the head

end flows from port B to port D, and flows to the
tank circuit.
10-115
HOIST VALVE
3. Hoist valve at FLOAT position

to the FLOAT position, hoist spool (2) is moved
to the right by the solenoid valve. As a result,
chamber C and chamber D, and chamber B and
chamber H and chamber D are connected.
The oil from the demand valve passes from
chamber C through chamber B and flows to the
hoist cylinder. Oil also flows from chamber C to
chamber D, and then flows to the brake oil cooler circuit.
10-116
The bottom end and head end of the hoist cylinder are connected inside the hoist valve, so the
hoist cylinder is placed in the free condition.
HM400-1
HOIST VALVE
4. Hoist valve at LOWER position

from the FLOAT position to the LOWER position, hoist spool (2) is moved further to the right
from the FLOAT position by the solenoid valve.
As a result, the oil flows from chamber C, pushes open check valve (3), and enters chamber
B.
The oil from chamber B enters the head end of
the hoist cylinder, retracts the cylinder, and lowers the dump body.
HM400-1
At the same time, the return oil from the head

end of the hoist cylinder flows from chamber A to
chamber H.
When the dump body is lowered, the output
pressure of the solenoid valve rises and becomes greater than the cracking pressure of the
pilot check valve. As a result, the return oil from
chamber H returns to the tank through two lines:
one from chamber D to the tank, and the other
from chamber E to the tank.
10-117
EPC VALVE
EPC VALVE
1. Manual operation button

A.
B.
P1.
T1.
T2.
To hoist valve
From hoist valve
From hydraulic pump
To hydraulic tank
To hydraulic tank
10-118
Function
With the EPC valve, the oil from the hydraulic
pump is controlled by the retarder controller. It
is then sent to the spool of the hoist valve, and
switches the pilot pressure to control the hoist
valve.
HM400-1
HOIST CYLINDER
HOIST CYLINDER
Unit: mm
No.
Check item

and bushing
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
140
-0.043
-0.143
+0.277
+0.061
0.104
0.420
0.720

and bushing
90
-0.036
-0.123
+0.270
+0.061
0.097
0.393
0.693

support pin and bearing
60
+0.004
-0.019
1.0

support pin and bushing
60
+0.004
-0.019
1.0
HM400-1
Replace
10-119
HYDRAULIC PUMP
HYDRAULIC PUMP
STEERINGHOIST+PILOT PUMP
SAR(3) 100+100+(1)8
Unit: mm
No.
Check item
Criteria
Model
Side clearance
Clearance between inside

diameter of plain bearing and
outside of diameter of gear
shaft
Standard clearance
Clearance limit
0.13 0.18
0.21
0.10 0.15
0.19
0.060 0.149
0.20
0.06 0.144
0.20
SAR(3)-100
SAR(3)-100
SAR(1)-8
SAR(3)-100
SAR(3)-100
Model
3
Depth for knocking in pin
SAR(3)-100
SAR(1)-8
Rotating torque of spline shaft
Discharge amount
Oil: EO10-CD
Oil temperature: 4555C
Tolerance
14
0
-0.5
10
0
-0.5
D e live ry Standard
Rotating
pre ss ure delivery
speed
{MPa
amount
(rpm)
(kg/cm2)} (l/min)
SAR(3)-100
SAR(3)-100
SAR(1)-8
10-120
Standard size
Repair limit
8.7 20.7 Nm {0.9 2.1 kgm}
Model
Replace
SAR(1)-8
SAR(3)-100
Remedy
2,500
20.6
{210}
Delivery
amount limit
(l/min)
231.5
213.5
17.2
15.8
HM400-1
HYDRAULIC PUMP
TRANSMISSION+DIFFERENTIAL LOCK PUMP

SAR100+012+010
Unit: mm
No.
Check item
Side clearance
Criteria
Model
Standard clearance
Clearance limit
SAR100
0.13 0.18
0.21
0.10 0.15
0.19
SAR012
SAR010

shaft
4
5
SAR100
0.06 0.149
SAR012
Standard size
Tolerance
Repair limit
14
0
-0.5
10
Discharge amount
Oil: EO10-CD
Replace
10.9 21.6 Nm {1.1 2.2 kgm}

D e live ry Standard
Rotating
pre ssu re delivery
speed
{MPa
amount
(rpm)
(kg/cm2)} (l/min)
SAR100
SAR012
SAR010
HM400-1
0.20
0.06 0.144
SAR010
Model
Remedy
2,500
20.6
{210}
Delivery
amount limit
(l/min)
231.5
213.5
26.8
24.6
22.7
19.7
10-121
HYDRAULIC PUMP
BRAKE COOLING+BRAKE PUMP

SAR(3)80+(1)25
Unit: mm
No.
Check item
Criteria
Model
Side clearance
Remedy
Standard clearance
Clearance limit
0.10 0.15
0.19
SAR80
SAR25

shaft
SAR80
0.06 0.149
SAR25
0.06 0.144
Standard size
Tolerance
Repair limit
14
0
-0.5
0.20
Replace
3
4
5
10
8.9 16.7 Nm {0.9 1.7 kgm}
Model
Discharge amount
Oil: EO10-CD
Rotating
speed
(rpm)
SAR80
D eliv ery Standard

p res sure delivery
{MPa
amount
(kg/cm 2)} (l/min)
Delivery
amount limit
(l/min)
2.9
{30}
200
20.6
{210}
57.0
50.7
2,500
SAR25
10-122
HM400-1
HYDRAULIC PUMP
EMERGENCY STEERING PUMP

SBL(1)21
Unit: mm
No.
1
Check item
Remedy
Standard clearance
Clearance limit
0.10 0.15
0.19
0.060 0.119
0.20
Side clearance
shaft
Criteria
Standard size
Tolerance
Repair limit
10
0
-0.5
Discharge amount
Oil: EO10-CD
HM400-1
Replace
2.0 4.9 Nm {0.2 0.5 kgm}

Rotating
speed
(rpm)
Delivery
pressure
{MPa
(kg/cm2)}
Standard
delivery
amount
(l/min)
Delivery
amount limit
(l/min)
3,500
20.6
{210}
67.6
62.4
10-123
HYDRAULIC PUMP
DIFFERENTIAL LOCK PUMP

SBR8+8
Unit: mm
No.
1
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.10 0.15
0.19
Side clearance
shaft
Discharge amount
Oil: EO10-CD
10-124
Replace
0.060 0.119
0.20
Rotating
speed
(rpm)
Delivery
pressure
{MPa
(kg/cm2)}
Standard
delivery
amount
(l/min)
Delivery
amount limit
(l/min)
3,500
20.6
{210}
25.2
23.7
HM400-1
CAB TILT
CAB TILT
1.
2.
3.
4.
Tilt stopper bar

Tilt cylinder
Breather
Adapter
HM400-1
10-125
AIR CONDITIONER
AIR CONDITIONER
1.
2.
3.
4.
5.
6.
Air conditioner unit

Filter
Control panel
Compressor
Receiver dryer
Condenser
10-126
FUNCTION
The air conditioner makes a pleasant operating
environment for the operator and acts to reduce
fatigue.
HM400-1
AIR CONDITIONER
AIR CONDITIONER UNIT
1.
2.
3.
4.
A.
B.
C.
D.
E.
FRESH/RECIRC selector damper

Evaporator
Heater core
Blower motor
Hot water inlet port
Hot water outlet port
Refrigerant gas inlet port
Refrigerant gas outlet port
Dehumidified water drain port
HM400-1
10-127
AIR CONDITIONER
RECEIVER DRYER
1.
2.
3.
4.
Body
Sight glass
Dryer
Dryer
10-128
HM400-1
AIR CONDITIONER
CONDENSER
1. Fin
2. Tube
A. Refrigerant gas inlet port
B. Refrigerant gas outlet port
HM400-1
10-129
AIR CONDITIONER
COMPRESSOR
1. Case
2. Clutch
A. Suction service valve
B. Discharge service valve
10-130
HM400-1
MACHINE MONITOR SYSTEM
Network data
1. From machine monitor to each controller
Switch input data
Option setting data
2. From each controller to machine monitor
Display data related to each controller
Service mode data
Troubleshooting data
3. From transmission controller to machine monitor
Model selection data
HM400-1
10-131
Outline
With the machine monitor system, the controllers on the network use the data from the sensors installed to all parts of the machine to
observe and control the condition of the machine
and transmit that data as network data to the
machine monitor.
The machine monitor is a system to display
these data and inform the operator of the condition of the machine.
There are two types of display on the machine
monitor: the normal mode and the service mode.
The items that are always displayed for the operator are the normal mode items. Their main
content is as follows.
1. Normal display items
Meters (speedometer, tachometer)
Gauges (engine water temperature,
torque converter oil temperature, retarder oil temperature, fuel level)
Pilot display
Service meter, odometer (character display)
2. Items displayed when there is abnormality
Caution, action code display (if an action
code is being displayed, press machine
monitor mode selector switch (2), then
release it. A failure code (6-digit) is then displayed.)
3. When the filter, oil replacement interval is
reached, the item needing replacement is
displayed in the character display.
4. Other functions using the character display
and the machine monitor mode selector
switch to operate include the following: Total
reverse distance traveled display, filter, oil
rep lacement inte rva l re se t, tele phone
number input, and language selection.
To make it easier to carry out troubleshooting of

the controllers (including the monitor panel itself), a service mode function is provided. Its
main content is as follows.
1. Displaying trouble data for electrical components, deleting from memory
Displays electrical components failure
data from each controller that is saved
in machine monitor
Deletes data from memory
2. Trouble data for machine
Displays machine failure data from each
controller that is saved in machine monitor
3. 3. Real-time monitor
Takes input and output signal values
recognized by each controller on network and displays in real time
10-132
4. Reduced cylinder mode

This function is used to stop the supply of
fuel sprayed from the fuel injector. This
makes it possible to determine the cylinder
where there is defective combustion.
5. ECMV compensation
This is used for the initial adjustment of the
transmission.
6. Changing replacement time for filter, oil
This changes the original setting for the
replacement interval.
7. Controller initialize
This function is used to set the machine
monitor when the machine is shipped from
the factory.
The service mode has the following functions.
Setting service meter
This can set service meter values recorded
in machine monitor memory
However, values can only be increased from
present value (they cannot be decreased).
Setting total travel distance
This can set travel distance values recorded
in machine monitor memory
However, values can only be increased

from present value (they cannot be decreased).
Setting distance traveled in reverse
This can set values for distance traveled in
reverse recorded in machine monitor memory.
However, values can only be increased from
present value (they cannot be decreased).
The machine monitor system consists of the

monitor panel, buzzer, and switches, network,
controllers on the network, and the sensors inputting data to the monitor panel.
HM400-1
MACHINE MONITOR
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Speedometer
Engine tachometer
Retarder oil temperature gauge
Torque converter oil temperature gauge
Engine water temperature gauge
Fuel gauge
Character display
Turn signal pilot lamp (R, H)
Turn signal pilot lamp (L, H)
Front lamp high beam pilot lamp
Gearshift lever position pilot lamp
Shift indicator
Lock-up pilot lamp
Shift hold pilot lamp
Power mode pilot lamp (power mode)
Power mode pilot lamp (economy mode)
Central warning lamp
Maintenance caution lamp
Battery charge circuit caution lamp
Steering oil temperature caution lamp
HM400-1
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
Engine oil pressure caution lamp

Retarder oil pressure caution lamp
M achine m onitor, option system caution lam p
Engine system caution lamp
Transmission system caution lamp
Retarder system caution lamp
Tilt caution lamp
Seat belt caution lamp
Parking brake pilot lamp
Retarder pilot lamp
Exhaust brake pilot lamp (option)
Inter-axle differential lock pilot lamp
Left and right differential lock pilot lamp
Dump body pilot lamp
Emergency steering pilot lamp
Preheating pilot lamp
Retarder oil temperature caution lamp
T orque converter oil tem perature caution lam p
Engine water temperature caution lamp
Fuel level caution lamp
10-133
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
Travel speed compensation switch [SW1]

Rotary switch [SW2]
Rotary switch [SW3]
Switch for setting left and right differential lock [SW5-4]
Dipswitch [SW5-3]
Switch for setting exhaust brake [SW5-2]
Dipswitch [SW5-1]
Dipswitch [SW6-4]
Dipswitch [SW6-3]
Dipswitch [SW6-2]
Dipswitch (SW6-1]
10-134
HM400-1
OPTION SETTING CONNECTOR DIAGRAM
52.
53.
54.
55.
56.
57.
58.
Option setting connector [OP1]

Setting connector [OP7]
ADJUSTING MACHINE MONITOR

1. For details of the setting of the rotary switches, the switches, and options setting connectors at the rear
face of the machine monitor, see TESTING AND ADJUSTING, Adjusting machine monitor.
2. Precautions
1) When setting, follow the instructions in TESTING AND ADJUSTING, Adjusting machine monitor, and
do not change them.
2) When moving the switches, use a precision screwdriver and turn slowly.
3) Be careful not to touch anything except the switches inside the grommet.
4) Be careful not to let any dirt or dust get in.
5) After completing the setting, return the grommet securely to its original position.
HM400-1
10-135
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS
?: Lights up 7: Sounds intermittently

1: ? means that lamps light up while machine monitor check switch is ON
2: ? shows that all lamps light up for approx. 2 seconds after starting all off for 1 second
Related actuation
No.
Display
item
Display
category
Meter
1
Travel
speed
Backlight
Meter
2
Engine
speed
Backlight
Gauge
3 Re ta rde r oil
37 tem p era tu re
Fuel level
gauge
LED
Amber
When side lamps light

up
Scale:
0 - 3400 rpm (red
Movement White, red zone: More than 2500
Background
rpm)
color: Black
LED
Amber

up
Scale:
50 - 150C
White, red
Movement Background (red zone: More than
120)
color: Black
Alarm
buzzer
Analog
display
(Note)
Lights up
when
actuated
Analog
display
(Note)
Lights up
when
actuated
Analog
display
(Note)
When temperature is
more than 120
Lights up
when
abnormal
Backlight
LED
Amber

up
Lights up
when
actuated
Analog
display
(Note)
Scale:
50 - 135C
Movement White, red (red zone: More than
Background
120)
color: Black
Caution
LED
Red
When temperature is
more than 120
Lights up
when
abnormal
Backlight
LED
Amber

up
Lights up
when
actuated
Analog
display
(Note)
Scale:
50 - 135C
Movement White, red (red zone: More than
Background
102)
color: Black
Caution
LED
Red
When temperature is
more than 102
Lights up
when
abnormal
Backlight
LED
Amber

up
Lights up
when
actuated
EMPTY-FULL
Analog
display
(Note)
Scale:
White, red
Movement Background
color: Black
Remarks
Note: When machine monitor

check switch is operated, display
starts from present position,
completes one cycle, and
returns to the starting position





Caution
LED
Red
When below specified

level (amount of fuel
remaining in tank is
less than 75 L)
Lights up
when
abnormal
Backlight
LED
Amber

up
Lights up
when
actuated
0 - 65535.0h
* Displayed on top
line of character
display
Actuated
when
engine is
running
Ratio of
movement
to time 1:1
When time exceeds 65535.0h,

stops at 65535.0h
0 - 999999.9km
* Displayed on bottom
line of character
display
Actuated
when
traveling
When distance exceeds

999999.9km, stops at
999999.9km
Service
meter
(normal
display
items)
Service
meter
Odometer
(normal
display
items)
Odometer
10-136
Scale:
0 - 80 km/h or 0 - 50
White
mph
Movement Background (mph display is only
color: Black when non-SI is used)
Method of Central
display
warning
lamp
Red
Gauge
6
40
Display range/
conditions
LED
Gauge
E n gine
5
w a te r
39 tem p era tu re
Color
Caution
Gauge
To rqu e
4
con ve rter
o il
38
tem p era tu re
Device
1 When
2
machine Im m e d iate ly
a fte r
monitor
s ta rtin g
check
sw itch is
switch is
operated tu rne d O N
LCD
Display
letters:
Black
Background
color:
Green
HM400-1
Related actuation
No
Display item
Action code
Failure code
Display
category
Device
Color
Action code
Failure
code
7
Reverse
travel
distance
meter, filter,
oil
Other displays replacement
time reset,
telephone
No. setting,
language
selection
Night lighting
Backlight
Right turn
signal
Display range/
conditions
Method of display
When abnormality or
failure occurs on
machine
* Displayed on top and
bottom lines of
character display
When abnormality
or failure occurs on
machine, top line
shows action
code; bottom line
displays remedy or
nature of failure
Top line displays

failure code (6
When there is
digit) and
abnormality or failure,
controller that
press mode switch ">". detected problem;
* Displayed on top
bottom line
and bottom lines of
displays system
character display
that is abnormal or
nature of
abnormality
Central
warning
lamp
Alarm
buzzer
When
machine
monitor
check
switch is
operated
Note 1
Note 2
Note 1: Top line displays

"HM400-1"
Note 2: Top line displays
"KOMATSU", bottom
displays "SYSTEM
CHECK"
Operate machine
Press machine monitor
monitor mode
mode selector switch selector switch ">"
"< >"
or "<" to switch
screen
See separate information

for details of failure
display
LED
Green
LED
Green
Brightness
When side lamps light reduced one level
up
when side lamps
light up
When operated
When operated:
Lights up
When not
operated: Goes
out
?
?
?
?
?
?
?
?
?
?
Left turn signal
LED
Green
When operated
10
High beam
LED
Blue
When operated
When operated:
Lights up
When not
operated: Goes
out
11 Gearshift lever
(R2 ) position R2
LED
Green
When gearshift lever is

at R2
Lights up (*)
11 Gearshift lever
(R1 ) position R1
LED
Green

at R1
Lights up (*)
11 Gearshift lever
(N)
position N
LED
Orange When gearshift lever is

at N
Lights up
LED
Green

at D
Lights up (*)
11 Gearshift lever
(5)
position 5
LED
Green

at 5
Lights up (*)
11 Gearshift lever
(4)
position 4
LED
Green

a4
Lights up (*)
11 Gearshift lever
(3)
position 3
LED
Green

at 3
Lights up (*)
11 Gearshift lever
(2)
position 2
LED
Green

at 2
Lights up (*)
11 Gearshift lever
(1)
position 1
LED
Green

at 1
Lights up (*)
?
?
?
?
?
?
?
?
?
Shift indicator
LED
F1,F2,F3,F4,F5,F6,N,R
1,R2,R3
* According to shift
range signal received
BackWhen shift range
from transmission
ground
signal is received
controller
color:
from transmission
* When alarm is
controller
Gray
actuated when making
emergency escape, "E"
and "N" are displayed in
turn
All light up
Night lighting
LED
Amber
Pilot
12
HM400-1
Remarks
See separate information

for details of failure
display
When operated:
Lights up
When not
operated: Goes
out
11 Gearshift lever
(D)
position D
Im m ed ia te ly
a fter
startin g
s w itc h is
tu rn e d O N
* Flashes when neutral

safety is actuated
safety is actuated

safety is actuated
safety is actuated
safety is actuated
safety is actuated
safety is actuated
safety is actuated
All light up
10-137
Related actuation
No
13
Display
item
Display
category
Lock-up
Device
LED
LED
Im m e d ia te ly
a fte r
sta rting
sw itch is
tu rn e d O N
Color
Green
When torque
converter lock-up is
actuated and
transmission is set to
direct drive
When
operated:
Lights up
When not
operated:
Goes out
When shift hold

switch is operated
When
operated:
Lights up
When not
operated:
Goes out
Power mode
Power
mode:
Lights up
When not
actuated:
Goes out
Economy mode
Economy
mode:
Lights up
When not
actuated:
Goes out
Green
Method of Central
display
warning
lamp
When
machine
monitor
check
switch is
operated
Display range/
conditions
Alarm
buzzer
Remarks
14
Shift hold
15
Output
mode
(power
mode)
16
Output
mode
(economy
mode)
LED
Green
17
Central
warning
lamp
LED
Red
Lights up
When there is
when
abnormality in system
abnormal
LED
Red
When warning is
issued for
maintenance system, Lights up or
or when filter, oil
flashes
replacement interval
has passed
LED
Red
When there is
abnormality in charge
circuit
Lights up
when
abnormal
LED
Red
When steering oil

temperature rises
Lights up
when
abnormal
Note: Actuated only when

alternator R terminal = ON
Actually only used when failure

occurs in machine monitor
Pilot
LED
18 Maintenance
caution
19
Battery
charge
circuit
caution
Ste e rin g oil

20 tem p era tu re
ca utio n
Green
21
Engine oil
pressure
caution
LED
Red
When engine oil

pressure drops
Lights up
when
abnormal
22
Brake oil
pressure
caution
LED
Red
When brake oil

pressure drops
Lights up
when
abnormal
23
Machine
monitor or
option
system
caution
LED
Red
When there is
abnormality in
machine monitor or
option controller
system
Lights up
when
abnormal
24
Engine
system
caution
LED
Red
When there is
abnormality in engine
control system
Lights up
when
abnormal
25
Transmission
system
caution
LED
Red
When there is
abnormality in
transmission control
system
Lights up
when
abnormal
26
Retarder
system
caution
LED
Red
When there is
abnormality in
retarder control
system
Lights up
when
abnormal
LED
Red
When dump body is

raised and there is
excessive tilt to left or
right
Lights up
when
abnormal
Red
When seat belt is not

fastened
When
actuated:
Lights up
When not
actuated:
Goes outs
27 Tilt caution
28
Seat belt
caution
10-138
Caution
LED
?(Note) 7(Note)
Note 1: Lamp lights up and at

same time action code E01 and
location for warning is displayed
on character display
Note 2: See Operation and
Maintenance Manual for details
of applicable item
HM400-1
Related actuation
No
Display
item
Display
category
Device
Parking
29 brake pilot
lamp
30
Retarder
pilot lamp
31
Exhaust
brake
actuation
lamp
(option)
LED
Inter-axle
32 differential
lock pilot
lamp
Left and
right
33 differential
lock lamp
34
Body pilot
lamp
Emergency
35
steering
ready lamp
36
Preheating
pilot lamp
HM400-1
LED
Pilot
LED
LED
LED
LED
Im m e d iate ly
a fte r
s ta rtin g
sw itch is
tu rne d O N
Color
Red
When parking brake

is applied
Lights up
when
applied
Orange
When brake is
applied
Lights up
when
applied
Orange
When exhaust brake

is actuated
Lights up
when
actuated
Orange
When
Lights up when inter- operated:
axle differential lock is Lights up
When not
operated
operated:
Goes out
Orange
Lights up when left

and right differential
lock is actuated
Method of Central
display
warning
lamp
When
machine
monitor
check
switch is
operated
Display range/
conditions
Alarm
buzzer
?(Note) 7(Note)
Red
Red
When
operated:
Lights up when
Lights up
emergency steering is When not
actuated
operated:
Goes out
When
operated:
Lights up
When not
operated:
Goes out
Red
Note: Actuated when parking

brake is applied and gearshift
lever is at position other than N
When
actuated:
Lights up
When not
actuated:
Goes out
When
For details, see
operated:
Operation and
Lights up
Maintenance Manual When not
operated:
Goes out
Lights up when
electric heater for
engine preheating is
actuated
Remarks
?(Note) 7(Note)
Note: Actuated when gearshift

lever is at position other than N
10-139
Self-diagnostic function when operating starting switch

1. When the starting switch is turned to the ON position before starting the engine, the central warning lamp,
caution lamps, and pilot lamps light up for approx. 2 seconds and then go out for 1 second to carry out a
system check.
The alarm buzzer sounds for 2 seconds and then stops for 1 second.
The shift indicator displays 88 for 2 seconds and then goes out for 1 second.
The indicator gauges and meters carry out the above system check for three seconds and then start
normal actuation.
KOMATSU SYSTEM CHECK is displayed for 3 seconds on the character display.
2. If the starting switch is turned to the START position before three seconds have passed with the starting
switch at the ON position, everything will go to the normal operating condition.
However, even if everything goes to the normal operating condition, the indicator gauges and meters
will not work until 3 seconds have passed after the starting switch was turned to the ON position.
Check central warning lamp, alarm buzzer, caution lamps, pilot lamps, indicator gauges and meters
Before starting the engine, turn the starting switch to the ON position, then press the machine monitor check
switch. In addition to the instruments and gauges in the system check when the starting switch is turned ON,
the indicator gauges and meters will be actuated. When this is done, the character display gives the model
and software version of the machine monitor.
Service meter display
The service meter shows the total number of hours of operation of the machine on the top line of the character
display.
If the engine is running, the service meter will advance even if the machine is not moving.
The service meter will advance by 0.1 for every 0.1 hour that the engine is running, regardless of the engine
speed.
Odometer
The odometer shows the total distance that the machine has traveled in units of km on the bottom part of the
character display.
* If dipswitch 1 (position: 1) at the rear of the machine monitor is set to ON, the display is given in units of
miles.
* Even if the starting switch is OFF, the service meter and odometer can be displayed while the top ( ) of
machine monitor mode selector switch 1 is kept pressed.
Note: If the starting switch is OFF, and the service meter and odometer are displayed even though the top ( )
of machine monitor mode selector switch 1 is not being pressed, there is probably a failure on the machine, so carry out inspection and maintenance.
Example of service meter and odometer display
10-140
HM400-1
User code (action code) display

If any problem occurs on the machine, or if it is necessary to change the method of operation, or if it is necessary
to carry out inspection and maintenance, action codes E01, E02, or E03 are displayed on the character display
to recommend suitable action.
If more than one problem occurs at the same time, the action code for the problem with the higher level of importance is displayed. The order of importance is E03 (most serious), E02, E01 (least serious).
If the action code is E02 or of E03, the alarm buzzer sounds intermittently and the central warning lamp lights up.
E03: Stop the machine immediately and contact
your Komatsu distributor
E02: If a problem related to overrun is displayed: Reduce the engine speed and the speed of the machine while
continuing operations
If a problem related to overheating is displayed: Stop the machine and run the engine at a mid-range
speed under no load
E01: After completion of operations or when changing operators, carry out inspection and maintenance
Example of user code of display
When user code is E03
The above displays are shown from the left in turn for three seconds each.
It is possible to set the telephone number and display it on the right side of the CALL display.
For details of the method of setting the telephone number, see the section on Machine monitor, other functions (telephone number input function).
If no telephone number is set, the area to the right of the CALL display is blank.
HM400-1
10-141
The bottom line of the character display shows

the condition of the machine.
The condition of the machine means overheating or overrun related.
If there is a failure in the machine system, such as a drop in the engine water temperature, the bottom line
of the character display shows the condition of the machine.
10-142
HM400-1
Failure code display

If a user code is displayed in the character display, display the failure code as follows.
Method of displaying failure code
HM400-1
10-143
1. If a user code is being displayed, press the machine monitor selector switch (>), then release it.
Example of failure code
The 6-digit code displayed at the left end on the top line of the character display is the failure code.
The code displayed after the space on the right side of the failure code indicates the controller that has
detected the failure code.
MON: Machine monitor
ENG: Engine controller
TM: Transmission controller
BK: Retarder controller
The bottom line of the character display shows the system where the failure has occurred.
2. Press the machine monitor selector switch (>) again, then release it.
After displaying the items when the machine condition is normal (service meter/odometer) for 3 seconds, it returns to the user code display screen.
If multiple errors are being generated, it goes on to the next failure code.
Filter, oil replacement interval display
When the filter or oil replacement interval is reached, after the starting switch is turned ON and the system check
is completed, the character display shows the items that need replacement for a fixed time. At the same time,
the maintenance caution lamp flashes or lights up.
After replacing the filter or oil, reset the replacement interval. For details, see "Resetting filter, oil replacement
interval" in the section on Machine monitor, other functions.
Filter, oil replacement interval items
Replacement interval (h)
Display for item name

on character display
ID No.
Fuel filter
500
FUEL FILT
03
Engine oil filter
500
ENG FILT
02
Engine oil
500
ENG OIL
01
Corrosion resistor
1000
CORR RES
06
Transmission oil
1000
TM OIL
12
Transmission oil filter
1000
TM FILT
13
Brake oil
1000
BK OIL
17
Brake oil filter
1000
BK OIL FILT
14
Brake cooling oil filter
1000
BK C FILT
16
Hydraulic filter
2000
HYD FILT
04
Differential case oil
2000
DIFF OIL
11
Final drive oil
2000
FNL OIL
08
Hydraulic oil
4000
HYD OIL
10
Item
10-144
HM400-1
Example of display: Transmission oil filter (when the language is English)
If the replacement interval has passed, a minus value is given on the display.
Display when filter or oil replacement interval has been reached

Change in display after the starting switch is turned ON and self check is completed
(1) Time remaining to replacement 30H T 0H
Maintenance caution lamp flashes.
Message (see example of display) is displayed on character display.

(2) Time remaining to replacement 0H T -30H

Maintenance caution lamp lights up
Message (see example of display) is displayed on character display.

(3) Time remaining to replacement T < -30H

The maintenance caution lamp does not flash or light up, and no message is given on the character display.
After the starting switch is turned ON and the initial display is given, this display is given together with the
maintenance caution lamp for 30 seconds.
After 30 seconds have passed, if the display returns to the normal display, it is not displayed until the starting
switch is turned ON again.
The display is not given while the user code is being displayed.
If there is more than one display item, the items are displayed in a cycle for three seconds each. If there
are more than 10 items, all the items are displayed once and the display returns to the normal display.
HM400-1
10-145
Rotary switch for travel speed compensation

1. Outline
Use rotary switch 1 inside the grommet at the rear of the machine monitor to compensate the travel speed
according to the difference in the tire size.
Machine monitor, other functions
The machine monitor system has the following functions.
Total distance traveled in reverse
Use this to check the total distance that the machine has traveled in reverse.
Resetting filter, oil replacement interval
When the filter and oil replacement interval has been reached and the message is displayed on the character display, replace the applicable filter or oil, then use this function to reset the timer.
Inputting telephone number
It is possible to display the telephone number at the right side of the CALL message displayed on the character display when an error has been generated for action code (E03).
Selecting language
Use this to select the language used for messages on the character display.
Method of displaying total distance traveled in reverse
1. Check that the character display is displaying the service meter/odometer or an action code.
If the display is not the above, turn the starting switch OFF, then turn it ON again and wait until the above
display appears.
10-146
HM400-1
2. Press the ( ) of the machine monitor mode selector switch, then release it.
Example of displaying (when the language is English)
3. When finishing the operation, press machine monitor mode ( ), then release it. Or turn the starting switch
OFF.
* If dipswitch 1 (position 1) at the rear of the machine monitor is turned ON, the speed is displayed in
units of km/h.
Method of resetting filter, or oil replacement interval
1. Set to the display for the total distance traveled in reverse.
2. Use machine monitor mode selector switches (>) or (<) to set to the display below. (When the language is
English)
3. Press the ( ) of the machine monitor mode selector switch, then release it.
The replacement interval is displayed on the left side of the bottom line, and the number of times of
replacement is displayed on the right side of the bottom line. (When the language is English)
HM400-1
10-147
4. Use machine monitor mode selector switches (>) or (<) to display the filter or oil replacement interval set for
the item.
5. Press the ( ) of the machine monitor mode selector switch, then release it to give the display below. (When
the language is English)
6. When resetting the replacement interval, press the (<>) of the machine monitor mode selector switch, align
the cursor with YES, press machine monitor mode selector switch ( ), then release it.
When machine monitor mode selector switch ( ) is pressed and then released, the display returns to the
previous screen.
7. When continuing to reset the replacement interval for another item, repeat Step 4.
After completing the resetting procedure, press machine monitor mode selector switch ( ), release it, then
press and release it once more. Or turn the starting switch OFF.
Method of inputting telephone number

1. Set the reverse travel distance gauge to the display condition.
2. Use machine monitor mode selector switches (>) or (<) to set to the display below.
10-148
HM400-1
3. Press the ( ) of the machine monitor mode selector switch, then release it to give the display below.
Once the telephone number is input, the screen will display the input telephone number from then on.
4. Up to 12 digits can be displayed for the telephone number.

When inputting the telephone number, input the numbers starting from the beginning. The cursor is displayed at the input position, so use machine monitor mode selector switches (>) or (<) to input numerals
from 0 to 9, and input an * for the blanks.
After completing the input of each number, press machine monitor mode selector switch ( ) and release it
to confirm the input, then move the cursor to the next position.
5. Repeat the operation in Step 4 to input all the digits.
Input the final digit, then press machine monitor mode selector switch ( ) to return to the previous screen.
If there is any mistake in the input or if the input is to be stopped, press machine monitor mode selector
switch ( ) to return to the previous screen.
6. After completing the input procedure, press machine monitor mode selector switch ( ), release it, then
press and release it once more. Or turn the starting switch OFF.
Method for selecting language

1. Set to the display for the total distance traveled in reverse.
2. Use machine monitor mode selector switches (>) or (<) to set to the display below. (When the language is
English)
HM400-1
10-149
3. Press the ( ) of the machine monitor mode selector switch, then release it to give the display below. (When
the language is English)
Self-diagnostic function when operating starting switch

1. When the starting switch is turned to the ON position before starting the engine, the system check is carried
out for 3 seconds.
2. If the starting switch is turned to the START position before 3 seconds have passed with the starting switch
at the ON position, everything will go to the normal operating condition. However, even if everything goes
to the normal operating condition, the indicator gauges and meters will not work until 3 seconds have
passed after the starting switch was turned to the ON position.
Check function of central warning lamp, alarm buzzer, monitor lamps, and meters
To check the normal display functions of the machine monitor, press the machine monitor check switch to check
the actuation. For details of the actuation, see "When operating machine monitor normal display functions with
machine monitor check switch".
10-150
HM400-1
OUTLINE OF SERVICE MODE

1. Outline
1) Trouble data for electrical system
The system is used to check the trouble data for the electrical system of each controller saved in the
machine monitor. For details of the failure codes displayed for the trouble data of the electrical system,
see the troubleshooting section. After repairing the failure, check that the system works properly, then
delete the trouble data.
The trouble data display for the electrical system is displayed on the character display as shown below.
*** : Displays order of trouble data items

###### : Displays failure code
$$$ : Displays number of times that applicable failure code has occurred
%%%%% : Displays time that has elapsed since failure first occurred (Present service meter reading - Service meter reading when problem first occurred = Time elapsed)
@@@@@ : Displays time that has elapsed since failure last occurred (Present service meter reading - Service meter reading when problem last occurred = Time elapsed)
The failure code flashes for failures that are still occurring at present.
The number of times that the failure code for the machine system has occurred is saved in memory.
2) Trouble data for machine system
The system is used to check the trouble data for the machine system of each controller saved in the
machine monitor. For details of the failure codes displayed for the trouble data of the machine system, see the troubleshooting section. After repairing the failure, check that the system works properly,
then delete the trouble data.
The trouble data display for the machine system is displayed on the character display as shown below.
*** : Displays order of trouble data items

###### : Displays failure code
$$$ : Displays number of times that applicable failure code has occurred
%%%%% : Displays time that has elapsed since failure first occurred
@@@@@ : Displays time that has elapsed since failure last occurred
The failure code flashes for failures that are still occurring at present. The number of times that the failure code for the machine system has occurred is saved in memory.
HM400-1
10-151
3) Real-time monitor
This function is used when checking the input and output signals recognized by the controllers on the
network.
The real-time monitor display on the character display is as shown below.
*** : Displays name of item

##### : Displays ID No. given to each item
%%% : Displays data. If units are used, the unit is displayed on the right side of the data
By specifying the ID No. given to each item, it is possible to display the desired 2 items at the same
*** : Displays specified ID No

%%% : Displays data. If units are used, the unit is displayed on the right side of the data
10-152
HM400-1
4) Reduced cylinder mode

For details of this function, see TESTING AND ADJUSTING, Engine reduced cylinder mode operation.
5) ECMV compensation
For details of this function, see TESTING AND ADJUSTING, Adjusting transmission, 2. ECMV compensation.
6) Changing filter, oil replacement time
For details of this function, see the Operation and Maintenance Manual, OPERATION, Character display portion, Filter, oil replacement time display. This is used when changing the replacement interval.
7) Controller initialize
This function is used only at the factory, so do not touch it.
8) Setting service meter
This is used when replacing the machine monitor with a new part, and setting the appropriate service
meter reading for the machine. For details of the method of operation, see TESTING AND ADJUSTING, Adjusting machine monitor.
9) Setting travel distance total
This is used when replacing the machine monitor with a new part, and setting the appropriate travel
distance total value for the machine. For details of the method of operation, see TESTING AND
ADJUSTING, Adjusting machine monitor.
10) Setting reverse travel distance total
This is used when replacing the machine monitor with a new part, and setting the appropriate reverse
travel distance total value for the machine. For details of the method of operation, see TESTING AND
ADJUSTING, Adjusting machine monitor.
HM400-1
10-153
2. Method of operation
For details of the method of operating each service mode function, see TROUBLESHOOTING.
For details of the method for setting the service meter, travel distance total, and reverse travel distance
total, see TESTING AND ADJUSTING. REMARK : When the starting switch is turned OFF, it returns to the
normal mode.
10-154
HM400-1
AUTOMATIC SHIFT CONTROL SYSTEM

(Transmission control system with all-range electronic modulation)
HM400-1
10-155
OUTLINE
The transmission controller receives the shift position signal for the gearshift lever, the accelerator signal for the accelerator pedal, the speed
signal for the transmission, and the other signals
from the switches and sensors. It then automatically controls the transmission and shifts it to
the optimum speed range.
In addition to the shift control, the transmission
controller also controls the torque converter
lock-up solenoid and operates the brake to prevent overrun.
Each clutch pack of the clutch packs and torque
converter lock-up clutch in the transmission is
equipped with an electronically controlled modulation valve, and each clutch pack is independently controlled.
In this way, the initial pressure, build-up ratio,
and torque-off time for each clutch is controlled
according to the condition of the machine. This
reduces the gearshifting shock and prevents
shift hunting, and in this way contributes to
improving the durability of the clutches.
The transmission shift controller uses the signals from the switches and sensors to drive the
machine monitor displays and caution and pilot
lamps, and transmits these data to the network.
10-156
HM400-1
TRANSMISSION CONTROLLER
1.
2.
3.
4.
5.
6.
Self-diagnostic display window

Connector
Case
Motherboard
Model selector switch (rotary switch 1)
Model selector switch (rotary switch 2)
Outline
The transmission controller controls the transmission system.
It has the following features and functions.
1. It has a high power mode and economy
mode, and the gearshifting pattern can be
selected.
2. The braking mode is the mode when the
brake is used. By raising the gearshifting
point and increasing the speed of the brake
cooling pump it is possible to raise the cooling effect of the retarder and make effective
use of the engine brake.
3. It controls the torque converter lock-up solenoid valve, overrun prevention solenoid
valve, and exhaust brake solenoid valve.
4. It controls the inter-axle differential lock solenoid valve according to the output command from the retarder controller.
5. To reduce the shock when shifting gear, it
outputs the throttle correction command to
the engine controller when shifting gear and
limits the engine speed.
HM400-1
6. Speed sensors are installed at three places

(transmission input shaft, intermediate
shaft, and output shaft). This makes it possible to detect slippage of the transmission
clutches and to protect the transmission
when there is any abnormality in the hydraulic system.
7. It connects to the network and shares various data with other controllers.
8. It receives input of the model selection data
(what model it is mounted on), and uses the
network to contact other controllers. (For
details of the method of setting, see INSPECTION, MAINTENANCE, AND TROUBLESHOOTING.)
9. It has a self-diagnostic function which divides the input and output systems further
into small parts.
10. The self-diagnostic function is displayed in
two digits.
11. When an abnormality is detected, it transmits the details to the network and displays
it on the other displays.
12. It uses the machine monitor to display if the
failure is still existing.
13. It provides an escape function for use when
there is a failure in the electrical system.
14. It is separate from the gearshift lever.
10-157
ATC1
ATC3A
ATC4
2 Transmission input shaft speed

input
Power source output (24V) for

3 torque converter oil pressure
sensor
Power source input (24V) for
4 overrun prevention solenoid output
command
Power source input (24V) for
5 exhaust brake solenoid output
command
Battery direct power source input

7 (24V)
1 Connector check
3 Transmission output shaft speed

input
2 Hydraulic tank level signal input

(opt)
3
4
3 Radiator cooling water level signal

input
Engine load condition signal input
Throttle correction command

5
output
6 Potentiometer power source
output (5V)
Torque converter oil pressure
7 signal input
8
Inter-axle differential lock

command input
9
9 Power source input (24V)
11
12
13 Overrun prevention solenoid

output command
Exhaust brake solenoid output
14 command
ATC5A
Connector check
8 GND
10
10 Emergency escape switch input

Steering oil temperature signal
11 input
6 Network signal output

7
10 Network signal GND

11
12 Network signal output
6 Transmission oil filter condition

signal input
Speed range N action command 1
7 signal input
Speed range N action command 2
8 signal input
9 Hydraulic filter condition signal
input
10 Fill switch input Low
11 Fill switch input lock-up
12 Fill switch input High
12 Transmission intermediate shaft

speed input
13 Fill switch input 1st
13 Engine speed input
14 Fill switch input 2nd
14 GND (for speed input)
15 Fill switch input 3rd
15
16 Fill switch input Rev
15 Transmission cut relay

16 GND (for sensor)
16 GND
17 Power source input (24V)
17 Fill switch input inter-axle

differential lock
GND input for torque converter oil

17 pressure
18 Start signal input
GND input for inter-axle differential

18 lock
Emergency steering actuation

19 signal 1 input
19 Air cleaner filter condition signal

input
20
20 Learning data reset switch input
ATC2
ATC3B
Proportional solenoid power

1 source input 24V
2
2
ECMV output 1st (+)
ECMV output 3rd (+)
ECMV output High (+)
ECMV output Rev (+)
ATC5B
1 Alternator terminal R input
Retarder oil temperature (front

wheel) signal input
4 Fuel level signal input

5
7 ECMV output Low (+)
Torque converter oil temperature

7 signal input
ECMV output inter-axle differential

8 lock (+)
8 Retarder oil temperature (center

wheel) signal input
9 ECMV output 2nd (+)
9 Transmission oil temperature

signal input
10 ECMV output lock-up (+)

11

12 source input 24V
13 ECMV output 1st, 3rd (-)
14 Sensor power source output (12V)
15 ECMV output High, Rev (-)
16
Retarder oil temperature (rear

10 wheel) signal input
11 Accelerator signal input
Emergency steering actuation

1 signal 2 input
2 Gearshift lever position R1 signal
input
Gearshift lever position R2 signal
3 input
Gearshift lever position N signal
4 input
5 Gearshift lever position D signal
input
Gearshift lever position 1 signal
6 input
7 input
8 Gearshift lever position 3 signal
input
9 input
10 input
11 Shift hold signal input
12
13
17 ECMV output Low (-)
14 Model selection 1 input
18 ECMV output inter-axle differential

lock (-)
19 ECMV output 2nd (-)
20 ECMV output lock-up (-)

21 GND
10-158
HM400-1
GEARSHIFT LEVER POSITION AND AUTOMATIC GEARSHIFTING RANGE

The relationship between each gearshift position and the automatic gearshifting range is as as shown in the
table below.
Gearshifting characteristics
Shifting the transmission up and down is carried
out according to the shift map saved in the controller memory.
There are three types of shift map, depending
on the condition of the input signals.
The settings for each mode are as shown in the
table below.
Mode
Braking mode
Set conditions
When either of the following conditions is fulfilled
1. Brake signal ON
(footbrake, retarder brake operated)
2. Accelerator pedal released
Power mode
When the following three conditions are fulfilled

1. Brake signal OFF
(footbrake, retarder brake not operated)
2. Accelerator pedal depressed
3. Power mode selector switch is at high power
Economy
mode
When the following three conditions are fulfilled

1. Brake signal OFF
(footbrake, retarder brake not operated)
2. Accelerator pedal depressed
3. Power mode selector switch is at economy
Power mode:
The power mode uses the power of the machine to
the maximum to provide the maximum payload.
However, when the machine is unloaded or has only
a light load (high acceleration), an acceleration sensitive type variable shifting point is used. This detects
the acceleration of the machine and shifts the transmission up sooner to provide better acceleration and
to improve the fuel consumption, noise, and transmission shock.
Economy mode:
When the machine is being used under light load,
such as when traveling unloaded or on flat ground,
the shift-up point and shift-down point are both lowered, the engine speed is maintained at a lower level, and the fuel consumption, noise, and transmission shock are improved. In this mode, the engine
output is limited to 90% of the maximum engine output.
Braking mode:
The shift-down point and the shift-up point are both
raised, the engine speed is maintained at a higher
level, and the amount of cooling oil for the retarder is
ensured to provide greater effect when the engine is
used as a brake.
HM400-1
10-159
AUTOMATIC GEARSHIFTING GRAPH

The shift-up/shift-down points, the torque converter lock-up ON/OFF points, and the automatic braking (for
overrun prevention) ON/OFF points of each mode are as shown in the figure below.
Note:
1. Power mode
For the shift-up point, the optimum point between 1750 and 2070 min-1 is selected according to the amount the accelerator pedal is
depressed, the acceleration of the machine, and
the speed range.
For the shift-down point also, the optimum point
between 1120 and 1250 min -1 is selected according to the amount the accelerator pedal is
depressed and the speed range.
2. Economy mode
For the shift-up point, the optimum point between 1750 and 1900 min-1 is selected according to the amount the accelerator pedal is
depressed, the acceleration of the machine, and
the speed range.
For the shift-down point also, the optimum point
between 1120 and 1200 min -1 is selected according to the amount the accelerator pedal is
depressed and the speed range.
10-160
3. Lock-up
For the lock-up ON point, the optimum point between 1050 and 1400 min-1 is selected according to the torque converter input speed (engine
speed) and output speed (transmission input
shaft speed).
The lock-up OFF point when the footbrake or retarder brake are operated is 950 min -1.
When the footbrake or retarder brake are not operated, it is 850 min-1.
When the machine moves off downhill with the
accelerator pedal released, the lock-up is not
engaged until the accelerator pedal is depressed or the footbrake is applied.
4. The auto brake ON point when traveling in F6 is

2400 min - 1.
HM400-1
Gearshift lever positions and method of shifting

1) Gearshift lever position D
When shifting up (in high power mode)
I) When the gearshift lever is set at position D, the
transmission is set to F2 torque converter
range.
II) When the accelerator pedal is depressed, the
engine speed rises and accelerates. When the
transmission input shaft speed reaches 1050 1400 min-1, the lock-up clutch is engaged, so
the torque converter is directly engaged and the
transmission is set to direct travel.
III) As the engine speed rises further and reaches
1750 - 2070 min-1, the transmission shifts up to
F3.
While the transmission is shifting up, the engine
speed is also lowered (a command is output to
the engine controller) in order to reduce the
shock when shifting gear.
IV) Immediately after shifting up, the engine speed
momentarily goes down, but as the machine
accelerates, it rises again and the transmission
shifts up in turn to F4 to F6 in the same way as
in III) above.
When shifting down (in high power mode)
When the load increases and the engine speed
drops to 1120 - 1250 min-1, the transmission
shifts down one speed.
(For example, when traveling in F6, the transmission shifts down to F5.)
While the transmission is shifting up, the engine
speed is also raised (a command is output to
the engine controller) in order to reduce the
shock when shifting gear.
II) As the engine speed goes down further and the
transmission shifts down in turn to F2, the
torque converter lock-up clutch is disengaged
and the transmission enters the torque converter drive.
I)
(Manual shift)
The safety functions related to travel in reverse
are the directional inhibitor and reverse safety.
If the operation is not correct, gearshifting is
restricted.
4) Gearshift lever position N
At the neutral position, none of the transmission
clutches are actuated.
Shift hold function
Press the hold switch on the gearshift lever once
to hold the transmission in the present speed
range.
Press the hold switch again to cancel the shift
hold function.
If the speed of the transmission input shaft goes
below 750 min-1 while the shift hold function is
being actuated, the shift hold function is automatically canceled.
Gearshifting load time
In the automatic shift range, to prevent mistaken
operation caused by excessive variation in the
speed when shifting gear, a time delay is used to
prevent the gears from being shifted within the
set time.
The gearshifting time delay is controlled precisely by each gearshifting pattern through the
use of the all-range electronic modulation system.
The approximate values for the gearshifting pattern and gearshifting time delay are shown in
the diagram below.
In the above explanation, the set speed or actuation may differ according to the travel condition s. Fo r d etails, see the au to matic
gearshifting graph.
2) Gearshift lever positions 5, 4, 3, 2, 1

The method of shifting automatically from F1 to
F5 (F4, F3, F2) is the same as for gearshift
lever position D above.
3) Gearshift lever positions R1, R2
These are the gearshift lever positions for
traveling in reverse. The transmission shifts to
the range (R1 or R2) specified by the gearshift
lever position.
HM400-1
10-161
Safety functions
1) Down-shift inhibitor function
If gearshift lever is operated D 5 - 1, 5 4 1, 4 3 - 1, 3 2 - 1, 2 1
For example, when traveling in D (F6), even if
the gearshift lever is operated to 4, the transmission does not shift directly F6 F4. It shifts
down F6 F5 F4 in turn according to the
engine speed.
(The transmission does not jump two speed
ranges if the operator makes a mistake when
operating the gearshift lever. This is to prevent
the engine from overrunning.)
2) Neutral safety function
This circuit prevents the engine from starting if
the gearshift lever is not at the N position, even
if the starting switch is turned to the START
position.
(This is a safety circuit to prevent the machine
from moving unexpectedly when the engine is
started.)
3) Directional inhibit function
When traveling in reverse at a speed of more
than 3.8 km/h, even if the gearshift lever is
operated to D or positions 5 to 1, the transmission will not be shifted immediately to travel forward. The engine speed is lowered to reduce
the travel speed, and when the travel speed
goes below 3.8 km/h, the transmission is shifted
to FORWARD.
When traveling forward at a speed of more than
1.9 km/h, even if the gearshift lever is operated
to positions R1 or R2, the transmission will not
be shifted immediately to travel in reverse. The
speed range is shifted to N and the engine
speed is lowered to reduce the travel speed.
When the travel speed goes below 1.9 km/h,
the transmission is shifted to REVERSE.
When traveling in reverse at a speed of more
than 7.2 km/h with the gearshift lever at position
R2, even if the gearshift lever is operated from
R2 to R1, the transmission does not shift to R1.
When the travel speed goes below 1.9 km/h,
the transmission is shifted to R1.
When starting the engine, if the machine is
already traveling forward or in reverse at a
speed of more than 3.8 km/h, even if the gearshift lever is operated to a position other than N,
the machine will not move and the transmission
will be held at N.
When the travel speed goes below 1.9 km/h, it
is permitted to move the machine off.
(To prevent overload on power train, to improve
durability and reliability)
4) Power train overrun prevention rear brake function
10-162
If the engine speed rises to more than 2400

min-1 (more than 2350 min-1 in F6), the central
warning lamp flashes and the alarm buzzer
sounds.
If the engine speed rises to more than 2450
min-1 (more than 2400 min-1 in F6), the rear
brake is automatically actuated.
(To prevent overrun of engine, torque converter,
and transmission, to improve durability and reliability)
5) REVERSE safety
The machine will not travel in reverse if the
dump control lever is not at FLOAT and the
dump body is not completely lowered.
(Turnover prevention function)
However, if the gearshift lever is at the R1 position and the shift hold switch is pressed, it is
possible to travel in reverse while the switch is
being pressed, even if the dump body is not
fully lowered.
6) Speed range limit function when dump body is
raised
After dumping the load, if the body is not completely lowered, shifting up is limited.
If the gearshift lever is at D, the machine starts
in F2, and if it is at positions 5 to 1, the machine
starts in F1. The transmission does not shift up
until the body is completely lowered.
Self-diagnostic function
The controller carries out self-diagnosis of the system and displays any abnormalities.
The details of the self-diagnosis are displayed as a
2-digit code with LEDs.
If any abnormality is detected by the self-diagnosis
function, the abnormality data is transmitted to the
network and is displayed as an action code on the
machine monitor. The transmission system caution,
warning lamp, or alarm buzzer may also be actuated.
HM400-1
AUTO EMERGENCY STEERING SYSTEM
AUTO EMERGENCY STEERING SYSTEM
1.
2.
3.
4.
5.
6.
Emergency steering motor

Emergency steering pump
Hydraulic tank
Steering oil pressure sensor
Steering valve
Battery relay
HM400-1
Outline
If the engine stops or an abnormality occurs in
the h ydra ulic p ump wh en the mach ine is
traveling, and the oil in the steering circuit goes
below the specified oil flow, the auto emergency
steering system automatically actuates the
emergency steering pump to ensure the steering oil pressure and to make it possible to operate the steering. It is also possible to operate it
manually.
10-163
SENSORS, SWITCHES
SENSORS, SWITCHES
ENGINE SPEED SENSOR
1.
2.
3.
4.
Magnet
Locknut
Wiring harness
Connector
Function
The engine speed sensor is installed to the ring
gear of the flywheel housing. It uses the rotation
of the gear teeth to generate a pulse voltage and
transmits a signal to the transmission controller.
10-164
HM400-1
SENSORS, SWITCHES
ACCELERATOR SENSOR
1. Connector
2. Connector
3. Pedal
OUTLINE
Accelerator signal
This is installed under the operators cab. The
accelerator pedal and accelerator sensor are
connected by a link. When the accelerator pedal
is depressed, the movement is passed through
the link and rotates the shaft of the potentiometer inside the accelerator sensor.
As a result, the resistance changes. A fixed
voltage is impressed between the No. 1 3 pins
of the potentiometer. A voltage signal corresponding to the angle of the accelerator pedal is
sent from the No. 2 pin to the transmission controller.
Idling validation signal
This is installed under the operators cab.
When the accelerator pedal is released, signal
2 (No. 5 pin) is connected to the ground; when
the accelerator pedal is depressed, signal 3
(No. 6 pin) is connected to the ground.
The engine controller then detects the condition.
HM400-1
10-165
SENSORS, SWITCHES
ENGINE WATER TEMPERATURE SENSOR

RETARDER OIL TEMPERATURE SENSOR
1.
2.
3.
4.
Thermistor
Plug
Wiring harness
Connector
Function
The sensors are installed to the retarder piping.
They take the change in resistance of the thermistor as the change in the temperature and
transmit a signal to the transmission controller.
The signal is sent from the transmission controller through the network to the machine monitor
panel to display the temperature level. When the
display on the monitor panel reaches the specified position, the lamp flashes and the buzzer
sounds to warn of an abnormality.
STEERING OIL TEMPERATURE SENSOR
1. Sensor
2. Terminal
3. Connector
Function
The steering oil temperature sensor is installed
to the steering and hoist piping. The sensor portion detects the temperature, and when the oil
temperature goes above the specified level, the
warning lamps lights up and a message is displayed on the character display of the monitor
panel.
10-166
HM400-1
SENSORS, SWITCHES
Fuel level sensor
1.
2.
3.
4.
5.
6.
7.
Connector
Float
Arm
Body
Spring
Contact
Spacer
HM400-1
Function
The fuel sensor is installed to the side face of the
fuel tank. The float moves up and down according to the fuel level. This movement of the float
is transmitted by the arm and actuates a variable
resistance. This sends a signal to the monitor
panel to indicate the remaining fuel level. When
the display of the monitor panel reaches a certain level, a warning lamp flashes.
10-167
SENSORS, SWITCHES
TILT SENSOR
1. Magnetic resistance particle

2. Leaf spring
3. Damper oil
Function
The tilt sensor is installed to the rear of the chassis. A magnet supported by a leaf spring is installed to a case charged with damper oil. It uses
the position in relation to the magnetic resistance element to detect the tilt angle of the chassis.
The magnet is supported by the leaf spring, so
it does not detect the front-to-rear tilt of the
chassis.
10-168
HM400-1
SENSORS, SWITCHES
AIR CLEANER CLOGGING SENSOR
1. Indicator
2. Spring
3. Adapter
Function
The air cleaner clogging sensor is installed to
the outward port of the air cleaner. If the air
cleaner becomes clogged and reaches the set
pressure (negative pressure), the maintenance
warning lamp lights up to warn of the abnormality.
HM400-1
10-169
SENSORS, SWITCHES
HYDRAULIC OIL FILTER SENSOR
1. Connector
2. Float
3. Switch
Function
The hydraulic filter sensor is installed to the side
face of the hydraulic tank. When the oil goes below the specified level, the float goes down, the
switch is turned OFF, and the maintenance caution lamp lights up to warn of the abnormality.
10-170
HM400-1
SENSORS, SWITCHES
BODY POSITIONER SENSOR
1. Bearing
2. Rotor
3. Connector
Function
The body position sensor is installed to the rear
of the chassis. When the angle of the dump body
changes, the shaft receives sliding resistance
through the link installed to the dump body, and
the dump body angle is detected.
HM400-1
10-171
RETARDER CONTROL SYSTEM
10-172
HM400-1
RETARDER CONTROLLER
1.
2.
3.
4.
5.
Self-diagnostic display window

Rotary switch
Motherboard
Case
Connector
Outline
The retarder controller has the following functions.
1. Retarder control
The electromagnetic proportional valve for the front and rear wheels is controlled according to the operating angle of the retarder control lever and actuates the retarder.
2. Overrun prevention, retarder control when there is transmission abuse
The electromagnetic proportional valve for the front and rear wheels is controlled based on the command
(ON/OFF command) from the transmission controller and actuates the retarder by a fixed amount.
3. Hoist control
This controls the hoist EPC valve (electromagnetic proportional valve) and hoist selector valve (ON/OFF
valve) according to the position of the dump control lever and actuates the dump body.
4. Differential lock control
1) Inter-axle differential lock control
The differential lock command is output to the transmission controller according to the condition of the
machine (differential lock switch, travel speed, etc.).
Based on the command from the retarder controller, the transmission controller drives the ECMV and
actuates the inter-axle differential lock.
HM400-1
10-173
2) Left and right differential lock control

Depending on the setting of the left and right differential lock selector switch, if the differential lock foot
switch is ON and the speed range is low (F1, F2, F3, R1, R2), the left and right differential lock is actuated.
5. Exhaust brake control
Based on the command from the transmission controller, the exhaust brake solenoid is driven and the
exhaust brake is actuated.
6. Transmission of network data
1) Retarder actuation, float caution, parking brake actuation, exhaust brake actuation, inter-axle differential lock actuation, accumulator oil pressure drop warning, and other data are transmitted to the monitor panel.
2) The exhaust brake command, overrun prevention, retarder command when there is abuse, and other
data sent from the transmission controller are received.
3) The inter-axle differential lock actuation command, reverse inhibit, and other data are transmitted to
the transmission controller.
10-174
HM400-1
BRC1
BRC3A
Power source for +24V output

1 sensor
BRC4
Connector check
BRC5A
1 RS422 TX(+)
Connector check 2
2 RS422 RX(+)
Exhaust brake switch
2 Rear wheel differential lock

solenoid
3 RS232 TXD
Service brake switch
Exhaust brake solenoid
4 RS232C TXD
Retarder switch
Brake cut relay (+24V IN)
5 RS485 (+)
Parking brake emergency brake

5 switch
5
6
7
6 Sensor power source +5V (hoist

lever potentiometer, body position)
Neutral signal 1
7
Battery direct power source input
GND
Power source +24V
10
6 S-NET (+)
6
Lever validation switch 1
Lever validation switch 2
Brake system filter switch
Retarder filter switch
7 RS422 TX(-)
8 FLASH SW. (ON/OFF)
9 RS422 RX(-)
10 GND. (SERIAL)
10
10 Front wheel differential lock

solenoid
11
11
11 Kick-out solenoid
12 Transmission front axle speed
12
12 Hoist selector valve
13 Transmission output shaft speed
13
13 Brake cut relay
14 GND (pulse)
14
15
16
11 RS485(-)
12 S-NET (+)
14
15
15 Neutral signal 2
16 GND (analog)
16 GND
17
17
17 Power source +24V
18
19
18 Starting switch terminal C (engine

start signal)
20
BRC2
BRC3A

1 source +24V
2
6 Inter-axle differential lock

command
7
Rear wheel retarder

9 electromagnetic proportional
reducing valve (+)
10 Hoist EPC valve (+)
11

12
source +24V
13
14 Sensor power source +12V (pulse)

15
20
BRC5B
Brake wear switch FL
Brake wear switch FR
4 Exhaust brake command (FRONT

TRANSMISSION)
Accumulator oil pressure (FRONT)
Accumulator oil pressure (REAR)
7 Accumulator gas pressure

(FRONT)
8
Front wheel retarder

reducing valve (+)
19
Overrun command (FRONT

5 TRANSMISSION)
6
Brake wear switch RL
Brake wear switch RR
Brake wear switch ML
Brake wear switch MR
Accumulator gas pressure (REAR)
10
11
10
11
12
13
14
15
16
12 Hoist lever potentiometer 2

13 Body position sensor
14 Hoist lever potentiometer 1
15 Steering angle potentiometer
Manual retarder lever
16 potentiometer
16 Sensor power source +5V

(retarder lever potentiometer)
17
Front wheel retarder

reducing valve (-)
Rear wheel retarder
reducing valve (-)
20 Hoist EPC valve (-)
21 GND
HM400-1
10-175
RETARDER CONTROL FUNCTION

RETARDER CONTROL SYSTEM DIAGRAM
Retarder lever control

The operating angle of the retarder lever is detected by the potentiometer and a current corresponding to this
is output to the electromagnetic proportional valve for the front and rear wheels to actuate the retarder.
Overrun prevention, retarder control when there is transmission abuse

The electromagnetic proportional valve for the front and rear wheels is controlled based on the command (ON/
OFF command) from the transmission controller and actuates the retarder by a fixed amount.
10-176
HM400-1
Relationship between retarder lever potentiometer and output to electromagnetic proportional valve

To improve the initial response of the electromagnetic proportional reducing valve, the output (trigger output) is set to a high value.
To make the actuation of the hydraulic pressure smooth in the low pressure range, the output is set to a
high value.
In the range where the retarder is normally used, the output is proportional to the angle of the lever.
To make the opening of the hydraulic pressure smooth in the low pressure range, the output is set to a low
value.
HM400-1
10-177
HOIST CONTROL FUNCTION

HOIST CONTROL SYSTEM DIAGRAM
1. Hoist control function

When the engine is running, the EPC and valve (electromagnetic proportional valve) and selector valve
are controlled according to the operation of the dump control lever and operate the dump body.
2. Lever positioner function
The dump control lever has four positions: RAISE, HOLD, FLOAT, and LOWER.
If the dump control lever is operated to the RAISE position, the dump body is raised, and when the top of
the dump body reaches the set position of the body position sensor, the lever is returned to the HOLD position.
If the lever is kept at the RAISE position, the RAISE output continues to be given.
3. Body seating speed control
When the dump body is lowered and reaches the position just before it is seated, the area of opening of
the EPC valve is throttled to control the lowering speed of the dump body and reduce the shock when the
dump body comes into contact with the chassis.
10-178
HM400-1
4. Control when starting switch is turned to ON, OFF, or START

Starting switch at ON:
The output is set to HOLD, regardless of the position of the lever.
If the engine is not started, even if the hoist lever is operated, the condition remains at HOLD.
Starting switch at OFF:
The dump body is held in position regardless of the position of the lever.
Engine started:
Immediately after the engine is started, the output is set to HOLD, regardless of the position of the lever.
After the lever is moved to the HOLD position, it becomes possible to carry out normal operations.
5. Float caution function
If the output is not FLOAT or the dump body is not fully lowered, the float caution lamp on the monitor panel
lights up.
"FLOAT OUTPUT" and "SEATED" Float caution OFF
"NO FLOAT OUTPUT" or "NOT SEATED" Float caution ON
6. Reverse inhibit function
The retarder controller judges if it is permissible to travel in reverse or not, and transmits the result of the
judgment through the network to the transmission controller.
"FLOAT OUTPUT" and "SEATED" Reverse travel permitted
"NO FLOAT OUTPUT" or "NOT SEATED" Reverse travel not permitted
7. Calibration function
To absorb any inherent error in the dump body potentiometer, calibration is carried out to recognize the
dump body seating and the body cylinder stopper condition.
After adjusting the installation of the body potentiometer or after replacing the retarder controller, carry out
calibration in the following order.
Order of dump control calibration (hydraulic oil temperature: 80 - 90 1C)
(1) Lower the dump body completely, run the engine, and keep the lever at HOLD for at least 5 seconds.
(Check that the float caution has gone out.)
(2) Operate the lever to the RAISE position until and raise the dump body until it contacts the stopper.
Keep the lever at the RAISE position with the cylinder at the stopper position for at least 5 seconds.
(3) Run the engine at low idling and operate RAISE FLOAT with the dump body raised to the maximum
height, then lower the dump body completely. Repeat this operation 10 times.
(4) Run the engine at high idling and operate RAISE FLOAT with the dump body raised to the maximum height, then lower the dump body completely. Repeat this operation 10 times.
HM400-1
10-179
DIFFERENTIAL LOCK CONTROL FUNCTION

DIFFERENTIAL LOCK CONTROL SYSTEM DIAGRAM
1. Inter-axle differential lock control

The inter-axle differential lock is actuated automatically, or manually by turning the inter-axle differential
lock switch ON/OFF.
Manual differential lock:
In low speed ranges (F1, F2, F3, R1, R2) or N, the inter-axle differential lock command is output when
the differential lock switch is ON.
Emergency braking control (automatic):
The inter-axle differential lock command is output when the travel speed is more than 35 km/h and the
brake is ON.
Brake ON control (automatic):
The inter-axle differential lock command is output according to the difference in speed between the
front and rear axles when the brake is ON.
Control (automatic) when there is variation in transmission output shaft speed:
The inter-axle differential lock command is output when the variation in the transmission output shaft
speed exceeds the set value.
The inter-axle differential lock command is an analog signal and is transmitted to the transmission controller. To cancel the inter-axle differential lock the transmission controller outputs electric current to the
electromagnetic proportional valve.
2. Left and right differential lock control
Depending on the setting of the left and right differential lock selector switch, one of the following is
selected:
rear wheel left and right differential lock ON;
front and rear wheel left and right differential
lock ON; or
front and rear wheel left and right differential lock OFF.
If
or
are selected, the differential lock foot switch is pressed, and the speed range is low (F1, F2, F3,
R1, R2), the differential lock command is output.

10-180

HM400-1
Inter-axle differential lock output

The inter-axle differential lock command is an analog signal and is transmitted from the retarder controller to the
transmission controller. The transmission controller outputs electric current to the electromagnetic proportional
valve.
The differential lock clutch is engaged by a pressure proportional to the current
.
Output specification from retarder controller to transmission controller

The retarder controller output is constant value A when starting to control the differential lock. After A is output,
when the filled signal (signal reporting the completion of filling the electromagnetic proportional valve with oil)
comes ON, it provides an output and angle -1 to line B and angle -2 to target output line C.
Left and right differential lock output
The left and right differential lock command drives the left and right differential lock solenoid (for front wheels,
for rear wheels) from the retarder controller.
Retarder control lever
The manual retarder potentiometer and lever validation switches 1 and 2 are built into the lever.
The manual retarder potentiometer output is a voltage signal matching the position of the lever and is sent to
the retarder controller.
The lever validation switches output the ON/OFF data for the lever position to the retarder controller.
Dump control lever
The dump control lever potentiometer and lever kick-out solenoid are built into the dump control lever.
The dump control lever potentiometer output is a voltage signal matching the position of the lever and is sent to
the retarder controller.
The lever kick-out solenoid fixes the lever at the RAISE position when it receives the ON signal from the retarder
controller and returns the lever to the HOLD position when it receives the OFF signal.
HM400-1
10-181
DUMP CONTROL LEVER
DUMP CONTROL LEVER
10-182
HM400-1
DUMP CONTROL LEVER
1. Lever
2. Rod
3. Spring
4. Spring
5. Retainer
6. Body
7. Body
8. Bushing
9. Solenoid
10. Nut
11. Rod
12. Detent spring
13. Retainer
14. Ball
15. Seat
16. Potentiometer
17. Lever
18. Rod
19. Rod
20. Detent spring
HM400-1
10-183
DUMP CONTROL LEVER
Function
When lever (1) is operated, rod (18) moves up or
down according to the amount the lever is operated, and rotates potentiometer (16).
The amount the control lever is operated (travels) is detected by the potentiometer, and this is
sent as a signal voltage to the controller.
One potentiometer is installed and outputs two
related signal voltages as shown in the "Output
voltage characteristics" graph.
Operation
1. Dump control lever operated to FLOAT
When LOWER rod (2) is pushed by lever (1) and
moves down, ball (14) contacts protrusion a of
rod (11) during the stroke. (Before start of actuation of mechanical detent)
When rods (2) and (11) are pushed in further,
ball (14) is being held by detent spring (12).
While pushing retainer (13) up, it escapes to the
outside, and rod (11) passes over protrusion a.
When this happens, rod (18) on the opposite
side is pushed up by spring (4). Ball (14) is
moved to the small diameter side of protrusion b
of rod (19) by retainer (13) that is being held by
detent spring (20).
Even if the lever is released, rod (18) is held in
position by the pushing force of the ball and protrusion b of rod (19), so the lever is held at the
FLOAT position.
10-184
HM400-1
2. Dump control lever FLOAT canceled

When lever (1) is returned from the FLOAT position, it is pushed down by a force greater than
the holding force of rod (19), detent spring (20),
retainer (13), and ball (14).
3. Dump control lever operated to LOWER
When lever (1) is operated further from the
FLOAT position, it moves to the LOWER position.
Rod (18) is pushed up by the spring (4) in accordance with the amount lever (1) is operated.
Lever (17) and rod (19), which are installed to
the rotating shaft of potentiometer (16), are interconnected, so a voltage matching the up or
down movement of the rod is output from potentiometer (16).
HM400-1
DUMP CONTROL LEVER
4. Dump control lever operated to RAISE

When RAISE rod (18) is pushed by lever (1) and
moves down, ball (14) contacts protrusion a of
rod (19) during the stroke. (Before start of actuation of mechanical detent)
When rods (18) and (19) are pushed in further,
ball (14) is being held by detent spring (20).
While pushing retainer (13) up, it escapes to the
outside, and rod (19) passes over protrusion a.
When this happens, rod (2) on the opposite side
is pushed up by spring (4).
When an electric current is flowing to solenoid
(19), if rod (2) is pushed up, nut (10) is held in
contact with bushing (8).
As a result, rod (2) is held at the pushed up position, so even if the lever is released, it is held
at the RAISE position.
10-185
DUMP CONTROL LEVER
5. Dump control lever RAISE canceled

When lever (1) is returned from the RAISE position, it is pushed down by a force greater than
the attraction force of the solenoid.
Or, when the solenoid power source is turned
OFF, the RAISE position is canceled and the
lever returns to the N position.
10-186
HM400-1
OTHERS
90 OTHERS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM ...................................................................................... 90-2
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM ........................................................................ 90-3
DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM ........................................................................... 90-4
BRAKE HYDRAULIC CIRCUIT DIAGRAM ................................................................................................... 90-5
DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER ..................................................................... 90-6
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/7)......................................................................... 90-7
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (2/7)......................................................................... 90-9
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (3/7)....................................................................... 90-11
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (4/7)....................................................................... 90-13
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (5/7) ................................................................... 90-15
HM400-1
90-1
OTHERS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
90-2
HM400-1
OTHERS
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM
HM400-1
90-3
OTHERS
DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM
DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM
90-4
HM400-1
OTHERS
BRAKE HYDRAULIC CIRCUIT DIAGRAM
BRAKE HYDRAULIC CIRCUIT DIAGRAM
HM400-1
90-5
OTHERS
DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER
DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER
90-6
HM400-1
OTHERS
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/7)
HM400-1
90-7
OTHERS
HM400-1
90-9
OTHERS
HM400-1
90-11
OTHERS
HM400-1
90-13
OTHERS
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (5/7)
HM400-1
90-15
OTHERS
AGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (6/7)
HM400-1
90-17
OTHERS
HM400-1
90-19

Shop Manual Hm400-1 SN 1001 Up General

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Shop Manual Hm400-1 SN 1001 Up General

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SAFETY

To prevent injury to workers, the symbol

6. Decide a place in the repair workshop to keep

PRECAUTIONS DURING WORK

19.Be sure to assemble all parts again in their original places.

16.When removing components, be careful not to

STRUCTURE AND FUNCTION

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

When a manual is revised, an edition mark (123....)

Chassis volume: Issued for every machine model

Revised pages are shown in the LIST OF REVISED

Special safety precautions

Special technical precautions or other precautions

Weight of parts of systems. Caution necessary

Places that require special

Places to be coated with

Places where oil, water or

Places where oil or water

Heavy parts (25 kg or more) must be lifted

If a part cannot be smoothly removed from the

Slinging near the edge of the hook may cause

3) Do not sling a heavy load with one rope alone,

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

1) Hold the mouthpiece of the tightening portion

2) Hold in the condition in Step 1), and

3) 3) Hold in the condition in Steps 1) and 2),

3) Hold in the condition in Steps 1) and 2),

2) Hold in the condition in Step 1), and push

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Hold the mouthpiece of the tightening portion

Hold the mouthpiece of the tightening

Main applications, featuresr

Used to prevent rubber gaskets,

Used in places requiring an immediately effective, strong adhesive.

Features: Resistance to heat and

Used as adhesive or sealant for

Used as sealant for machined

Used as heat-resisting sealant for

Quick hardening type adhesive

Quick hardening type adhesive

Resistance to heat, chemicals

Used as adhesive or sealant for

Used as sealant for various

Features: Silicon based, resistance to heat, cold

Main applications, featuresr

Used as heat-resisting sealant for

Used as lubricant for sliding portion (to prevent from squeaking).

Ftures: Silicon based, quick hardening type

General purpose type

Used for normal temperature,

Used for places with heavy load

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Width across flat

STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Width across flat

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS