Komatsu Articulated Dump Truck HM400-3R service & repair manual

Description Komatsu Articulated Dump Truck HM400-3R service & repair manual

Komatsu Articulated Dump Truck HM400-3R pdf workshop service manual

Serial numbers:
8001 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
Foreword, safety and general information
Important safety notice
How to read the shop manual
Explanation of terms for maintenance standard 
Handling equipment of fuel system devices
Handling of intake system parts
Handling of hydraulic equipment
Method of disconnecting and connecting of push-pull type coupler
Handling of electrical equipment
How to read electric wire code
Precautions when performing operation
Practical use of KOMTRAX
Standard tightening torque table
List of abbreviation
Conversion table

Specification
Specification drawing
Weight table
Table of fuel, coolant, and lubricants

Structure and function
Engine and cooling system
Engine related parts
Output shaft
Turbocharger
Muffler
Cooling system
Radiator fan pump
Aftercooler fan motor
Radiator fan motor
Center brake cooling remote motor
Center brake cooling remote pump
Oil cooler bypass valve
Power train
Power train system
Drive shaft
Torque converter and transmission hydraulic piping
Torque converter
Transmission
Transmission control valve
Forward and reverse clutch ECMV and gear speed clutch ECMV
Lockup clutch ECMV
Differential lock clutch ECMV
Main relief valve, torque converter relief valve, and main flow selector valve
Axle
Differential
Final drive
Steering system
Layout of steering devices
Steering column
Flow amplifier valve
Steering valve
Emergency steering pump
Emergency steering motor
Brake system
Layout of brake parts
Parking brake solenoid and accumulator charge valve
Accumulator
Shut off solenoid valve
Brake valve
Proportional pressure reducing valve
Slack adjuster
Brake
Brake system tank
Parking brake
Undercarriage and frame
Suspension
Suspension cylinder
Oscillation hitch
Hydraulic system
Hydraulic component layout
Dump body control
Hydraulic tank
Steering and hoist pump
Hoist valve
Steering pump selector solenoid valve
Dump EPC valve
Center brake cooling remote motor
Front brake cooling relief valve
Center brake cooling relief valve
Cab and its attachments
ROPS cab
Cab tilt
Electrical system
Electrical control system
Machine monitor system
KOMTRAX system
System component parts
Sensor

Standard value tables
Standard service value table
Standard value table for engine
Standard value table for machine

Testing and adjusting
Related information on testing and adjusting
Tools for testing and adjusting
Sketch of tools for testing and adjusting
Engine and cooling system
Testing engine speed
Testing boost pressure
Testing exhaust gas temperature
Testing exhaust gas color
Adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Testing fuel pressure
Handling cylinder cutout mode operation
Handling no‐injection cranking operation
Testing fuel return rate and leakage
Bleeding air from fuel system
Testing fuel circuit for leakage
Testing radiator fan and aftercooler fan speed
Testing and adjusting alternator belt tension
Testing and adjusting air conditioner compressor belt tension
Power train
Testing torque converter stall speed
Testing power train oil pressure
Adjusting transmission speed sensor
Adjusting transmission controller
Retrieval of disabled machine that resulted from a trouble in electrical system
Retrieval of disabled machine due to traction control system (KTCS) failure
Steering system
Testing and adjusting steering circuit oil pressure
Bleed air from the steering cylinder circuit
Testing and adjusting articulate angle sensor
Brake system
Testing and adjusting brake oil pressure
Testing accumulator nitrogen gas pressure and charging procedure for accumulator nitrogen gas
Testing braking performance
Bleeding air from brake circuit
Testing wear of wheel brake disc
Parking brake emergency releasing procedure
Testing wear of parking brake pad and adjusting clearance
Hydraulic system
Testing and adjusting suspension cylinder
Testing and adjusting dump circuit oil pressure
Work equipment
Adjusting dump body positioner sensor
Cab and its attachments
Cab tilt up procedure
Electrical system
Setting and adjusting each equipment
Special functions of machine monitor
KOMTRAX terminal start-up procedure
Handling voltage circuit of engine controller
Handling battery disconnect switch
Pm clinic
Pm Clinic service

Troubleshooting
Related information on troubleshooting
Troubleshooting points
Sequence of events in troubleshooting
Check before troubleshooting
Inspection procedure before troubleshooting
Preparation for troubleshooting of electrical system
Classification and procedures for troubleshooting
Symptom and troubleshooting numbers
Information in troubleshooting table
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit
Connector list and layout
Connector contact identification
T-branch box and T-branch adapter table
Precautions on troubleshooting of machine monitor
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit
Fuse location table
Failure codes 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
Related information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of supply pump assembly
Removal and installation of injector assembly
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of radiator core assembly
Removal and installation of cooling fan and fan motor assembly for radiator
Removal and installation of aftercooler assembly
Removal and installation of cooling fan and fan motor assembly for aftercooler
Removal and installation of engine assembly
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Removal and installation of output shaft assembly
Disassembly and assembly of output shaft assembly
Removal and installation of air cleaner assembly
Removal and installation of fire prevention cover on exhaust pipe
Power train
Removal and installation of transmission and front differential assembly
Disconnection and connection of front differential assembly and transmission assembly
Disassembly and assembly of front differential assembly
Disassembly and assembly of torque converter assembly
Disassembly and assembly of transmission assembly
Removal and installation of center differential assembly
Disassembly and assembly of center differential assembly
Removal and installation of rear differential assembly
Disassembly and assembly of rear differential assembly
Removal and installation of front final drive and brake assembly
Disassembly and assembly of front final drive and brake assembly
Removal and installation of center final drive and brake assembly
Disassembly and assembly of center final drive and brake assembly
Removal and installation of rear final drive assembly
Disassembly and assembly of rear final drive assembly
Removal and installation of center axle assembly
Removal and installation of rear axle assembly
Steering system
Disassembly and assembly of steering cylinder assembly
Undercarriage and frame
Removal and installation of front suspension cylinder assembly
Removal and installation of rear suspension cylinder assembly
Disassembly and assembly of suspension cylinder assembly
Removal and installation of equalizer bar assembly
Removal and installation of front wheel assembly
Removal and installation of rear (front side) wheel assembly
Removal and installation of rear (rear side) wheel assembly
Removal and installation of hitch frame assembly
Disassembly and assembly of hitch frame assembly
Hydraulic system
Removal and installation of flow amplifier valve assembly
Removal and installation of hoist valve assembly
Disassembly and assembly of hoist valve assembly
Disassembly and assembly of hoist cylinder assembly
Disassembly and assembly of hoist cylinder assembly
Body
Removal and installation of dump body assembly
Cab and its attachments
Removal and installation of operator's cab assembly
Removal and installation of operator's cab glass (adhered glass)
Removal and installation of operator's seat assembly
Removal and installation of seat belt
Electrical system
Removal and installation of machine monitor assembly
Removal and installation of engine controller assembly
Removal and installation of retarder and hoist controller assembly
Removal and installation of transmission controller assembly
Removal and installation of KOMTRAX terminal assembly
Air conditioner unit
Removal and installation of air conditioner unit assembly
Removal and installation of air conditioner compressor assembly
Removal and installation of air conditioner condenser

Maintenance standard
Engine and cooling system
Engine mount
Output shaft
Radiator fan pump
Aftercooler fan motor
Radiator fan motor
Power train
Drive shaft
Torque converter and transmission mount
Torque converter
Transmission
Transmission control valve
Forward and reverse clutch ECMV and gear speed clutch ECMV
Lockup clutch ECMV
Differential lock clutch ECMV
Main relief valve, torque converter relief valve, and main flow selector valve
Differential
Axle
Final drive
Steering system
Steering column
Steering cylinder
Emergency steering pump
Brake system
Slack adjuster
Brake
Parking brake
Undercarriage and frame
Suspension
Suspension cylinder
Oscillation hitch
Hydraulic system
Steering and hoist pump
Pump for driving torque converter, transmission, aftercooler fan, and center brake cooling motors
Center brake cooling pump
Brake charge pump
Center brake cooling remote pump
Center brake cooling remote motor
Hoist valve
Hoist cylinder

Appendix
Air conditioner components
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Dual pressure switch
Air conditioner controller
Compressor
Condenser
Receiver drier
Outer temperature sensor (outside air temperature sensor)
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Input and output signals of the air conditioner controller
Parts and connectors layout
Testing air leakage (duct)
Testing with self-diagnosis function
How to open the electrical system abnormality record screen in service mode of the machine monitor
Testing vent (mode) changeover
Testing FRESH/RECIRC air changeover
Testing (dual) pressure switch for refrigerant
Testing relays
Troubleshooting chart
Information in troubleshooting table
A-1 Troubleshooting for power supply system (Air conditioner does not operate)
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
A-4 Troubleshooting for FRESH/RECIRC air changeover
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting air conditioner piping
Handling of compressor oil

Diagrams and drawings
Hydraulic circuit diagram
Symbols in hydraulic circuit diagram
Power train hydraulic circuit diagram
Electric circuit diagram
Symbols in electric circuit diagram
Inside cab electrical circuit diagram
Inside cab electrical circuit diagram (Machine with payload meter controller: CR720)
Outside cab electrical circuit diagram
Electrical circuit diagram of engine

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