Komatsu Articulated Dump Truck HM400-2R service & repair manual

Description Komatsu Articulated Dump Truck HM400-2R service & repair manual

Komatsu Articulated Dump Truck HM400-2R pdf workshop service manual

Serial numbers:
7001 and up

Technical data, specifications, troubleshooting, electrical wiring diagrams, hydraulic schematics, maintenance, adjusting, disassembly, assembly, removal, installation instructions and other information

SERVICE MANUAL CONTENT:
Index and foreword
Composition of shop manual
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

Specification
Specification and technical data
Specification drawings
Weight table
Fuel, coolant and lubricants

Structure, function and maintenance standard
Engine and cooling system
Radiator, oil cooler, aftercooler
Output shaft
Power train, Part 1
Power train skeleton
Torque converter and transmission hydraulic piping
Brake cooling oil control valve (BCV)
Power train pump
Torque converter
Transmission
Transmission control valve
ECMV
Main relief, torque converter relief valve
Power train, Part 2
Drive shaft
Axle
Differential
Limited slip differential
Final drive
Steering system
Steering column
Brake system
Brake piping
Brake valve
Accumulator charge valve
Accumulator
Slack adjuster
Brake
Proportional reducing valve
Brake system tank
Parking brake
Parking brake caliper
Spring cylinder
Parking brake solenoid
Undercarriage and frame
Suspension
Suspension cylinder
Oscillation hitch
Hydraulic system
Steering, hoist hydraulic piping diagram
Dump body control
Hydraulic tank and filter
Flow amp valve
Steering valve
Steering cylinder
Hoist valve
EPC valve
Pilot check valve
Hoist cylinder
Hydraulic pump
Cab and its attachments
ROPS cab
Cab tilt
Air conditioner
Rear view monitor
Controller related
Electrical system, Part 1
Machine monitor system
Electrical system, Part 2
Automatic shift control system
Transmission controller
Retarder control system
Auto emergency steering system
Dump control lever
Electrical system, Part 3
Payload meter (Card type)
Electrical system, Part 4
Sensors, switches
KOMTRAX terminal system (if equipped)

Standard value table
Standard service value table
Standard value table for engine
Standard value table for chassis

Testing and adjusting
Testing and adjusting, Part 1
Precautions before work
Tools for testing, adjusting, and troubleshooting
Sketches of special tools
Measuring engine speed
Testing intake air pressure (boost pressure)
Testing exhaust temperature
Testing exhaust gas color
Adjusting valve clearance
Testing compression pressure
Testing blow-by pressure
Testing engine oil pressure
Handling of fuel system devices
Releasing residual pressure from fuel system
Testing fuel pressure
Testing fuel return and leakage amount
Bleeding air from fuel circuit
Testing the fuel circuit for leakage
Testing and adjusting fan belt tension
Testing and adjusting alternator belt tension
Testing and adjusting air conditioner compressor belt tension
Adjusting the shims in the body mount
Testing and adjusting, Part 2
Testing torque converter stall speed
Testing power train oil pressure
Testing and adjusting of differential lock oil pressure (differential lock spec.)
Adjusting transmission speed sensor
Testing and adjusting brake oil pressure
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas
Testing brake performance
Releasing remaining pressure in brake circuit
Bleeding air from brake circuit
Testing wear of wheel brake disc
Testing the parking brake pad wear
Emergency release of the parking brake
Testing and adjusting steering circuit oil pressure
Testing and adjusting suspension cylinder
Method of tilting cab up
Testing and adjusting dump circuit oil pressure
Adjusting body positioner sensor
Adjusting length of spring in body heating spherical joint
Adjustment of tilt lock lever of steering wheel
Handling of voltage circuit of engine controller
Adjusting transmission controller
Method for emergency escape at electrical system failure
Testing and adjusting, Part 3
Setting and adjusting various equipments
Special function of machine monitor
How to start operation of KOMTRAX terminal
Lamp display of KOMTRAX terminal
Pm Clinic check sheet

Troubleshooting
Failure code table and fuse locations
Failure codes table
Fuse locations
General information on troubleshooting
Precautions before work
Points to remember when performing troubleshooting
How to proceed in troubleshooting
Check before troubleshooting
Classification and procedures of troubleshootin
Information in troubleshooting table
Troubleshooting method for disconnecting wiring harness of pressure sensor system
Phenomena looking like troubles and troubleshooting Nos.
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure code (Display of code)
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
General information on disassembly and assembly
Precautions before work
How to read this manual
Coating materials list
Special tool list
Sketches of special tools
Engine and cooling system (SAA6D140E-5)
Removal and installation of engine assembly
Removal and installation of radiator assembly
Removal and installation of cooling assembly
Removal and installation of aftercooler assembly
Removal and installation of output shaft assembly
Disassembly and assembly of output shaft assembly
Engine (SAA6D140E-5)
Removal and installation of fuel supply pump assembly
Removal and installation of cylinder head assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Replacement procedure of exhaust pipe fire prevention cover
Power train, Part 1
Removal and installation of transmission and front differential assembly
Disconnection and coupling of front differential and transmission
Disassembly and assembly of torque converter assembly
Disassembly and assembly of transmission assembly
Power train, Part 2 (Differential)
Disassembly and assembly of front differential assembly
Removal and installation of center differential assembly
Disassembly and assembly of center differential assembly
Removal and installation of rear differential assembly
Disassembly and assembly of rear differential assembly
Power train, Part 3 (Final drive, brake, axle)
Removal and installation of front final drive and brake assembly
Disassembly and assembly of front final drive and brake assembly
Removal and installation of center final drive and brake assembly
Disassembly and assembly of center final drive and brake assembly
Removal and installation of rear final drive and brake assembly
Disassembly and assembly of rear final drive and brake assembly
Removal and installation of center axle assembly
Removal and installation of rear axle assembly
Undercarriage and frame
Removal and installation of front suspension cylinder assembly
Removal and installation of rear suspension cylinder assembly
Removal and installation of equalizer bar assembly
Removal and installation of front wheel assembly
Removal and installation of rear front wheel assembly
Removal and installation of rear rear wheel assembly
Removal and installation of hitch frame assembly
Disassembly and assembly of hitch frame
Removal and installation of body assembly
Hydraulic system
Disassembly and assembly of steering valve
Removal and installation of flow amplifier valve assembly
Removal and installation of hoist valve assembly
Disassembly and assembly of hoist valve assembly
Disassembly and assembly of steering cylinder assembly
Disassembly and assembly of hoist cylinder assembly
Cab and its attachments
Removal and installation of operator's cab
Removal and installation of operator's cab glass (Stuck glass)
Disassembly and assembly of operator's seat assembly (If equipped)
Electrical system
Removal and installation of air conditioner unit assembly
Removal and installation of engine controller
Removal and installation of retarder controller
Removal and installation of transmission controller assembly

Diagrams and drawings
Hydraulic diagrams and drawings
Power train hydraulic circuit diagram
Steering and hoist hydraulic circuit diagram
Brake hydraulic circuit diagram
Brake cooling hydraulic circuit diagram
Differential lock hydraulic circuit diagram
Electrical diagrams and drawings
Electrical circuit diagram for inside cab
Electrical circuit diagram for outside cab
Electrical circuit diagram for payload meter
Connectors table and arrangement drawing

Engine SAA6D140E-5 workshop service manual