Komatsu Articulated Dump Truck HM400-5E0 service & repair manual

Description Komatsu Articulated Dump Truck HM400-5E0 service & repair manual

Komatsu Articulated Dump Truck HM400-5E0 pdf workshop service & repair manual

Serial number 20001 and up

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

SERVICE MANUAL CONTENT:
Index and Foreword
Abbreviation List
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions to Prevent Fire
Procedures If Fire Occurs
Precautions for Disposing of Waste Materials
Procedures for Exhaust Gas Regulations
Precautions for DEF
Store DEF
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Precautions When You Handle Fuel System Equipment
Precautions When You Handle Intake System Equipment
Practical Use of KOMTRAX
Disconnect and Connect Push-Pull Type Coupler
Precautions for Disconnection and Connection of Connectors
How to Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
How to Disconnect and Connect Connector with Lock to Pull
How to Disconnect and Connect Connector with Lock to Push
How to Disconnect and Connect Connector with Housing to Rotate
How to Read the Codes for Electric Cable
Explanation of Terms for Maintenance Standard
Standard Tightening Torque Table
Conversion Table

Specifications
Abbreviation List
Specification Drawing
Weight Table
Table of Fuel, Coolant, and Lubricants

Structure and Function
Abbreviation List
Urea SCR System
Layout Drawing of Urea SCR System
Urea SCR System Diagram
Function of Urea SCR System
Component Parts of Urea SCR System
Boot-up System
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal)
Layout Drawing of Boot-up System (Machine with Gateway Function Controller)
System Operating Lamp System
Battery Disconnect Switch
Engine System
Layout Drawing of Engine System
Automatic Idle Stop System
Component Parts of Engine System
Cooling System
Layout Drawing of Cooling System
Radiator Fan Control System
Aftercooler Fan Control System
Component Parts of Cooling System
Control System
Layout Drawing of Control System (Machine with KOMTRAX Terminal)
Layout Drawing of Control System (Machine with Gateway Function Controller)
Retarder and Hoist Control System
Machine Monitor System
Rearview Monitor System
KOMTRAX System
Payload Meter System
Component Parts of Control System
Hydraulic System
Layout Drawing of Hydraulic System
Component Parts of Hydraulic System
Power Train System
Layout Drawing of Power Train System
Transmission Control System
Gear Shift Control System
Shift Hold System
Direction Control System
Komatsu Traction Control System (KTCS)
Component Parts of Power Train System
Work Equipment System
Work Equipment Control
Hoist Control
Component Parts of Work Equipment System
Steering System
Layout Drawing of Steering System
Function of Steering System
Steering Column
Component Parts of Steering System
Brake System
Layout Drawing of Brake System
Retarder Control
Parking Brake Interlock Function
ARAC System
Component Parts of Brake System
Undercarriage and Frame
Front Suspension
Center and Rear Suspensions
Suspension Cylinder
Oscillation Hitch
Work Equipment
Structure of Work Equipment
Function of Work Equipment
CAB Related Parts
ROPS CAB
CAB Tilt

Standard Value Table
Abbreviation List
Standard Value Table for Engine
Standard Value Table for Engine: HM400-5E0
Standard Value Table for Machine
Standard Value Table for Machine: HM400-5E0
Machine Posture and Procedures to Measure Performance
Standard Value Table for Electricity

Testing and Adjusting
Abbreviation List
Related Information on Testing and Adjusting
Tools for Testing and Adjusting
Sketch of Tools for Testing and Adjusting
Engine and Cooling System
Examine Engine Speed
Examine Boost Pressure
Examine Exhaust Gas Temperature
Examine Exhaust Gas Color
Examine Mass Air Flow and Temperature Sensor
Examine and Adjust Valve Clearance
Examine Compression Pressure
Examine Blowby Pressure
Examine Engine Oil Pressure
Examine EGR Valve and VGT Oil Pressure
Examine Fuel Pressure
Examine Fuel Return Rate and Leakage
Bleed Air from Fuel System
Examine Fuel Circuit for Leakage
Handle Cylinder Cut-out Mode Operation
Handle No-Injection Cranking Operation
Clean Fuel Doser
Write Injector Compensation Value to Engine Controller
Write Correction for Ash in Soot Accumulation to Engine Controller
Examine SCR Related Functions
Clean DEF Tank
Clean DEF Pump
Examine Torque Converter Stall Speed
Examine Radiator Fan and Aftercooler Fan Speed
Power Train
Examine Power Train Oil Pressure
Adjust Transmission Speed Sensor
Adjust Transmission Controller
Move Machine Which Has a Trouble in Electrical System
Move Machine Which Has a Trouble in Traction Control System (KTCS)
Steering System
Examine and Adjust Steering Circuit Oil Pressure
Bleed Air from Steering Cylinder Circuit
Brake System
Examine and Adjust Brake Oil Pressure
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas
Release Remained Pressure in Brake Accumulator Circuit
Bleed Air from Brake Circuit
Examine Brake Performance
Examine Wear of Wheel Brake Disc
Release Parking Brake Manually
Examine and Adjust Wear of Parking Brake Pad
Hydraulic System
Examine and Adjust Suspension Cylinder
Examine and Adjust Dump Circuit Oil Pressure
Work Equipment
Examine and Adjust Dump Body Positioner Sensor
Examine and Adjust Dump Body Mount
CAB Related Parts
CAB Tilt Up
Adjust Tilt Lock Lever of Steering Wheel
Adjust Play of Operator Seat
Electrical System
Set and Adjust Each Equipment
Set and Operate Machine Monitor
How to Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal)
How to Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal)
How to Start Up KOMTRAX System (Machine with Gateway Function Controller)
How to Stop Use of KOMTRAX System (Machine with Gateway Function Controller)
Adjust Optical Axis of Head Lamp
Set Region of Bluetooth® Compatible Radio
Handle Voltage Circuit of Engine Controller
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal)
Handle Battery Disconnect Switch (Machine with Gateway Function Controller)
Examine Diodes
Pm Clinic
Pm Clinic Service

Troubleshooting
Abbreviation List
Related Information to Troubleshooting
General Troubleshooting Points
Troubleshooting Points for Urea SCR System
Sequence of Events in Troubleshooting
Checks Before Troubleshooting
Inspection Procedure Before Troubleshooting
Test in Accordance with Testing Procedure
Preparation for Troubleshooting of Electrical System
Procedure for Troubleshooting
Symptom and Troubleshooting Numbers
Information Shown in Troubleshooting Table
Connector List and Layout
Connector Contact Connection Table
T-Branch Box and T-Branch Adapter Table
Fuse Location Table (Machine with KOMTRAX Terminal)
Fuse Location Table (Machine with Gateway Function Controller)
Precautions When You Clean and Replace KDPF (KCSF and KDOC)
Prepare Troubleshoot Machine Monitor
Procedure to Make Harness Checker on Machine Monitor LCD Unit
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])
Failure Code Table
Troubleshooting by Failure Code (Display of Code)
Troubleshooting of Electrical System (E-Mode)
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
Troubleshooting of Engine (S-Mode)

Disassembly and Assembly
Abbreviation List
Related Information on Disassembly and Assembly
How to Read This Manual
Coating Materials List
Special Tool List
Sketches of Special Tools
Engine and Cooling System
Remove and Install Supply Pump Assembly
Remove and Install Injector Assembly
Remove and Install Fuel Doser Assembly
Remove and Install Cylinder Head Assembly
Remove and Install EGR Valve Assembly
Remove and Install EGR Cooler Assembly
Remove and Install Starter Assembly
Remove and Install Alternator Belt
Remove and Install Radiator Assembly
Remove and Install Cooling Fan and Fan Motor Assembly
Remove and Install Aftercooler Assembly
Remove and Install Aftercooler Fan and Fan Motor Assembly
Remove and Install Engine Assembly
Remove and Install Engine Front Oil Seal
Remove and Install Engine Rear Oil Seal
Remove and Install Output Shaft
Disassemble and Assemble Output Shaft
Remove and Install DEF Tank Assembly
Remove and Install DEF Tank Sensor Flange Assembly
Remove and Install DEF Tank Sensor
Remove and Install DEF Tank Strainer
Remove and Install KDPF Assembly
Disassemble and Assemble KDPF Assembly
Remove and Install SCR Assembly
Remove and Install KCCV Assembly
Remove and Install DEF Mixing Tube
Remove and Install DEF Injector
Remove and Install DEF Pump
Remove and Install DEF Hose
Remove and Install Air Cleaner Assembly
Remove and Install Air Conditioner Compressor Assembly
Power Train
Remove and Install Transmission and Front Differential Assembly
Disconnect and Connect Transmission and Front Differential Assembly
Disassemble and Assemble Front Differential Assembly
Disassemble and Assemble Torque Converter Assembly
Disassemble and Assemble Transmission Assembly
Remove and Install Center Differential Assembly
Disassemble and Assemble Center Differential Assembly
Remove and Install Rear Differential Assembly
Disassemble and Assemble Rear Differential Assembly
Remove and Install Front Final Drive and Brake Assembly
Disassemble and Assemble Front Final Drive and Brake Assembly
Remove and Install Center Final Drive and Brake Assembly
Disassemble and Assemble Center Final Drive and Brake Assembly
Remove and Install Rear Final Drive Assembly
Disassemble and Assemble Rear Final Drive Assembly
Remove and Install Center Axle Assembly
Remove and Install Rear Axle Assembly
Remove and Install Brake Accumulator
Steering System
Disassemble and Assemble Steering Valve
Disassemble and Assemble Steering Cylinder Assembly
Undercarriage and Frame
Remove and Install Front Suspension Cylinder Assembly
Remove and Install Rear Suspension Cylinder Assembly
Disassemble and Assemble Suspension Cylinder Assembly
Remove and Install Equalizer Bar Assembly
Remove and Install Front Wheel Assembly
Remove and Install Rear (Front Side) Wheel Assembly
Remove and Install Rear (Back Side) Wheel Assembly
Remove and Install Hitch Frame Assembly
Disassemble and Assemble Hitch Frame Assembly
Hydraulic System
Remove and Install Hydraulic Tank Assembly
Remove and Install Flow Amplifier Valve Assembly
Remove and Install Hoist Valve Assembly
Disassemble and Assemble Hoist Valve Assembly
Disassemble and Assemble Hoist Cylinder Assembly
Work Equipment
Remove and Install Dump Body Assembly
CAB Related Parts
Remove and Install Operator Cab Assembly
Remove and Install Operator Cab Glass (Adhered Glass)
Remove and Install Air Conditioner Unit Assembly
Remove and Install Operator Seat Assembly (Made by GRAMMER)
Remove and Install Operator Seat Assembly (Made by SEARS)
How to Remove and Install Seat Belt
Electrical System
Remove and Install Engine Controller Assembly
Remove and Install Retarder and Hoist Controller Assembly
Remove and Install Transmission Controller Assembly
Remove and Install Machine Monitor Assembly
Remove and Install Mass Air Flow and Temperature Sensor
Remove and Install SCR Temperature Sensor
Remove and Install KOMTRAX Terminal Assembly
Remove and Install Gateway Function Controller Assembly
Remove and Install Communication Terminal Wiring Harness
Remove and Install Communication Terminal

Maintenance Standard
Abbreviation List
Engine and Cooling System
Maintenance Standard for Engine Mount
Maintenance Standard for Damper
Maintenance Standard for Radiator Fan Pump
Maintenance Standard for Radiator Fan Motor
Maintenance Standard for Aftercooler Fan Motor
Power Train
Maintenance Standard for Drive Shaft
Maintenance Standard for Torque Converter and Transmission Mount
Maintenance Standard for Torque Converter and PTO
Maintenance Standard for Lockup Clutch ECMV
Maintenance Standard for Transmission
Maintenance Standard for Transmission Control Valve
Maintenance Standard for Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV
Maintenance Standard for Differential Lock Clutch ECMV
Maintenance Standard for Main Relief Valve, Torque Converter Relief Valve, and Main Flow Selector Valve
Maintenance Standard for Front Axle
Maintenance Standard for Center Axle
Maintenance Standard for Rear Axle
Maintenance Standard for Front Differential
Maintenance Standard for Center Differential
Maintenance Standard for Rear Differential
Maintenance Standard for Front Final Drive
Maintenance Standard for Center Final Drive
Maintenance Standard for Rear Final Drive
Steering System
Maintenance Standard for Steering Column
Maintenance Standard for Steering Cylinder
Brake System
Maintenance Standard for Front Slack Adjuster
Maintenance Standard for Center Slack Adjuster
Maintenance Standard for Front Brake
Maintenance Standard for Center Brake
Maintenance Standard for Parking Brake
Undercarriage and Frame
Maintenance Standard for Front Suspension
Maintenance Standard for Center and Rear Suspensions
Maintenance Standard for Front Suspension Cylinder
Maintenance Standard for Rear Suspension Cylinder
Maintenance Standard for Oscillation Hitch
Hydraulic System
Maintenance Standard for Steering and Hoist Pump
Maintenance Standard for Power Train and Front Brake Cooling Duplex Pump, Aftercooler Fan Pump, and Center Brake Cooling Remote Motor Drive Pump
Maintenance Standard for Center Brake Cooling Pump
Maintenance Standard for Center Brake Cooling Remote Pump
Maintenance Standard for Center Brake Cooling Remote Motor
Maintenance Standard for Brake Charge Pump
Maintenance Standard for Hoist Valve
Work Equipment
Maintenance Standard for Hoist Cylinder

Appendix
Abbreviation List
Air Conditioner System
Precautions for Refrigerant
Air Conditioner Component
Specifications of Air Conditioner
Structure and Function of Refrigeration Cycle
Outline of Refrigeration Cycle
Component Parts of Air Conditioner System
Air Conditioner Unit
Component Parts of Air Conditioner Unit
Air Conditioner Controller
Compressor
Condenser
Receiver Drier
Air Conditioner Related Sensors
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner
Circuit Diagram and Configuration of Connector Pins of Air Conditioner
System Diagram of Air Conditioner
Input and Output Signals of Air Conditioner Controller
Locations of Air Conditioner Parts and Layout of Connectors
Examine Air Leakage (Duct)
How to Examine Air Leakage (Duct)
Examine Air Conditioner with Self-Diagnosis Function
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor
Examine Vent (Mode) Changeover
How to Examine Vent (Mode) Changeover
Examine Fresh/Recirc Air Changeover
How to Examine Fresh/Recirc Air Changeover
Examine Refrigerant (Dual) Pressure Switch
How to Examine Refrigerant (Dual) Pressure Switch
Examine Relay
How to Examine Relay
Air Conditioner Troubleshooting Chart
Information Shown 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 by Gauge Pressure
Connect Service Tool
How to Connect Service Tool
Precautions for Disconnection and Connection of Air Conditioner Piping
Handle Compressor Oil

Circuit Diagrams
Abbreviation List
Hydraulic Circuit Diagram
Symbols Used in Hydraulic Circuit Diagram
Power Train Hydraulic Circuit Diagram
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram

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