Komatsu Articulated Dump Truck HM400-1 SN A10001-UP Service Repair Manual

Models Covered :

 

HM400-1 SN A10001-UP

Manual Covers :

FOREWORD:

SAFETY

GENERAL

HOW TO READ THE SHOP MANUAL

HOISTING INSTRUCTIONS

COATING MATERIALS

STANDARD TIGHTENING TORQUE

ELECTRIC WIRE CODE

CONVERSION TABLES

 

GENERAL:

SPECIFICATION DRAWING

SPECIFICATIONS

WEIGHT TABLE

FUEL, COOLANT AND LUBRICANTS

 

STRUCTURE AND FUNCTION:

RADIATOR, OIL COOLER, AFTERCOOLER

POWER TRAIN SKELETON

OUTPUT SHAFT

TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING

TORQUE CONVERTER

TRANSMISSION

TRANSMISSION VALVE

ECMV (ELECTRONIC CONTROL MODULATION VALVE)

MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE

DRIVE SHAFT

AXLE

LOCKING DIFFERENTIAL

FINAL DRIVE

STEERING COLUMN

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

SUSPENSION

SUSPENSION CYLINDER

OSCILLATION HITCH

STEERING, HOIST OIL PRESSURE 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 TILT

AIR CONDITIONER

MACHINE MONITOR SYSTEM

AUTOMATIC SHIFT CONTROL SYSTEM

TRANSMISSION CONTROLLER

AUTO AUXILIARY STEERING SYSTEM

SENSORS, SWITCHES

ACCELERATOR SENSOR

RETARDER CONTROL SYSTEM

BRAKE CONTROL SYSTEM (E-SPEC)

DUMP CONTROL LEVER

PLM-HM

 

TESTING, ADJUSTING AND TROUBLESHOOTING:

STANDARD VALUE TABLE

TOOLS FOR TESTING AND ADJUSTING

ENGINE COMPONENTS

TESTING TORQUE CONVERTER STALL SPEED

MEASURING POWER TRAIN OIL PRESSURES

“L” AND “R” DIFFERENTIAL LOCK PRESSURE

ADJUSTING TRANSMISSION SPEED SENSOR

TESTING AND ADJUSTING BRAKE OIL PRESSURE

TESTING BRAKE PERFORMANCE

BLEEDING AIR FROM BRAKE CIRCUIT

CHECKING WEAR LIMIT ON WHEEL BRAKE DISC

RELEASING EMERGENCY PARKING BRAKE

STEERING CIRCUIT PRESSURE

TESTING AND ADJUSTING SUSPENSION CYLINDER

TILTING THE CAB UP

TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE

ADJUSTING BODY POSITIONER SENSOR

ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT

ADJUSTING TRANSMISSION CONTROLLER

ESCAPE METHOD FOR ELECTRICAL SYSTEM

ADJUSTING MACHINE MONITOR

FUNCTIONS OF MACHINE MONITOR

TROUBLESHOOTING (GENERAL)

TROUBLESHOOTING OF ENGINE CONTROL SYSTEM (ENG MODE)

TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (TM MODE)

TROUBLESHOOTING OF RETARDER CONTROLLER SYSTEM (BK MODE)

TROUBLESHOOTING MACHINE MONITOR PANEL SYSTEM (MON MODE)

TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEM (H MODE)

 

DISASSEMBLY AND ASSEMBLY:

HOW TO USE MANUAL

PRECAUTIONS WHEN CARRYING OUT OPERATION

SPECIAL TOOL LIST

SKETCHES OF SPECIAL TOOLS

FUEL SUPPLY PUMP REMOVAL

FUEL SUPPLY PUMP INSTALLATION

ENGINE ASSEMBLY REMOVAL

ENGINE ASSEMBLY INSTALLATION

CYLINDER HEAD ASSEMBLY REMOVAL

CYLINDER HEAD INSTALLATION

REMOVAL AND INSTALLATION OF NOZZLE TIP

RADIATOR ASSEMBLY REMOVAL

RADIATOR ASSEMBLY INSTALLATION

OUTPUT SHAFT REMOVAL

OUTPUT SHAFT INSTALLATION

OUTPUT SHAFT DISASSEMBLY DIAGRAM

ASSEMBLY OF OUTPUT SHAFT

TRANSMISSION AND FRONT DIFFERENTIAL REMOVAL

TRANSMISSION AND FRONT DIFFERENTIAL INSTALLATION

DISCONNECTION OF FRONT DIFFERENTIAL AND TRANSMISSION

COUPLING OF FRONT DIFFERENTIAL AND TRANSMISSION

DISASSEMBLY OF TORQUE CONVERTER

ASSEMBLY OF TORQUE CONVERTER

DISASSEMBLY OF TRANSMISSION

ASSEMBLY OF TRANSMISSION

DISASSEMBLY OF FRONT DIFFERENTIAL

ASSEMBLY OF FRONT DIFFERENTIAL

REMOVAL OF CENTER DIFFERENTIAL

INSTALLATION OF CENTER DIFFERENTIAL

DISASSEMBLY OF CENTER DIFFERENTIAL

ASSEMBLY OF CENTER DIFFERENTIAL

REAR DIFFERENTIAL REMOVAL

REAR DIFFERENTIAL INSTALLATION

DISASSEMBLY OF REAR DIFFERENTIAL

ASSEMBLY OF REAR DIFFERENTIAL

REMOVAL OF FRONT FINAL DRIVE AND BRAKE

INSTALLATION OF FRONT FINAL DRIVE AND BRAKE

DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE

ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE

REMOVAL OF CENTER FINAL DRIVE AND BRAKE

INSTALLATION OF CENTER FINAL DRIVE AND BRAKE

DISASSEMBLY OF CENTER FINAL DRIVE AND PLATE

ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE

REMOVAL OF REAR FINAL DRIVE AND BRAKE

INSTALLATION OF REAR FINAL DRIVE AND BRAKE

DISASSEMBLY OF REAR FINAL DRIVE AND BRAKE

ASSEMBLY OF REAR FINAL DRIVE AND BRAKE

REMOVAL OF CENTER AXLE

INSTALLATION OF CENTER AXLE

REMOVAL OF REAR AXLE

INSTALLATION OF REAR AXLE

INSTALLATION OF FRONT SUSPENSION CYLINDER

REMOVAL OF FRONT SUSPENSION CYLINDER

REMOVAL OF REAR SUSPENSION CYLINDER

REMOVAL OF EQUALIZER BAR

INSTALLATION OF EQUALIZER BAR

REMOVAL OF FRONT WHEEL

INSTALLATION OF FRONT WHEEL

REMOVAL AND INSTALLATION OF REAR WHEEL ASSEMBLY

REMOVAL OF HITCH FRAME

INSTALLATION OF HITCH FRAME

DISASSEMBLY OF HITCH FRAME

ASSEMBLY OF HITCH FRAME

STANDARD INTEGRAL ORBIT-ROLL

DISASSEMBLY OF STEERING VALVE

ASSEMBLY OF STEERING VALVE

REMOVAL OF FLOW AMPLIFIER VALVE

INSTALLATION OF FLOW AMPLIFIER VALVE

REMOVAL OF HOIST VALVE

INSTALLATION OF HOIST VALVE

DISASSEMBLY OF HOIST VALVE

ASSEMBLY OF HOIST VALVE

DISASSEMBLY OF STEERING CYLINDER

ASSEMBLY OF STEERING CYLINDER ASSEMBLY

DISASSEMBLY OF HOIST CYLINDER ASSEMBLY

ASSEMBLY OF HOIST CYLINDER

REMOVAL OF BODY ASSEMBLY

INSTALLATION OF BODY ASSEMBLY

DISASSEMBLY AND ASSEMBLY OF OPERATOR’S SEAT

POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM

STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM

DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM

 

OTHERS:

POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM

STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM

DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM

BRAKE HYDRAULIC CIRCUIT DIAGRAM

AIR CONDITIONER

TO ENGINE CONTROLLER (1/2)

TO ENGINE CONTROLLER (2/2)

TO MAIN HARNESS INSIDE OF CAB (1/10)-(10-10)

SWITCH PANEL (1/3)-(3/3)

DISPLAY PANEL (1/2)

DISPLAY PANEL (2/2)

RETARD CONTROLLER (1/2)

RETARD CONTROLLER (2/2)

TO TRANSMISSION CONTROLLER (1/2)

TO TRANSMISSION CONTROLLER (2/2)

TO HARNESS OUTSIDE OF CAB (1/2)

TO HARNESS OUTSIDE OF CAB (2/2)

FUSE BLOCK

LOAD METER (1/2)

LOAD METER (2/2)

 

EXTRAS:

Operation and Maintenance Manual

 

 

 

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

 

Language: English
Format: PDF

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