Komatsu Articulated Dump Truck HM400-3 service & repair manual

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

Komatsu Articulated Dump Truck HM400-3 pdf workshop service repair manual + operation & maintenance manual

Serial numbers:
3001 and up

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

SERVICE MANUAL CONTENT:
Foreword and general information
Safety notice
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
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
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
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 solenoid valve

Undercarriage and frame
Suspension
Suspension cylinder
Oscillation hitch

Hydraulic system
Steering, hoist oil pressure piping diagram
Dump body control
Hydraulic tank and filter
Flow amp valve
Steering valve
Steering cylinder
Hoist valve
Dump control 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
Machine monitor system
Automatic shift control system
Transmission controller
Retarder control system
Auto emergency steering system
Battery disconnector switch
Emergency engine stop switch
Dump control lever
Playload meter (Card type)
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
Tools for testing, adjusting, and troubleshooting
Measuring engine speed
Testing intake air pressure (boost pressure)
Testing exhaust temperature
Testing exhaust gas color
Adjusting valve clearance

Troubleshooting
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Check before troubleshooting
Classification and procedures for troubleshooting
Connection table for connector pin numbers
T-branch box and T-branch adapter table
Troubleshooting by failure code, General
Troubleshooting by failure code, General
Failure codes table
Before troubleshooting by failure code
Information in troubleshooting table

Disassembly and assembly
General information on disassembly and assembly
List of adhesives
Special tool list
Sketches of special tools
Engine and cooling system
Removal and installation of fuel supply pump
Removal and installation of engine assembly
Removal and installation of cylinder head assembly
Removal and installation of fuel injector assembly
Removal and installation of radiator assembly
Removal and installation of cooling assembly
Removal and installation of aftercooler
Removal and installation of engine front seal
Removal and installation of engine rear seal
Replacement procedure of exhaust pipe fire prevention cover
Power train
Removal and installation of output shaft assembly
Disassembly and assembly of output shaft assembly
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
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
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 plate 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
Disassembly and assembly of front and rear suspension cylinder 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 operators cab
Removal and installation of operators cab glass (Stuck glass)
Disassembly and assembly of operators seat assembly
Removal and installation of air conditioner unit assembly
Electrical system
Removal and installation of retarder controller assembly
Removal and installation of transmission controller assembly
Removal and installation of engine 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

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