Komatsu HM400-1L Articulated Dump Truck Shop Manual CEBM015302

Description

• Model List:
  • HM400-1L Articulated Dump Truck

• 0.1. GENERAL
• 0.2. HOW TO READ THE SHOP MANUAL
• 0.3. HOISTING INSTRUCTIONS
• 0.4. COATING MATERIALS
• 0.5. STANDARD TIGHTENING TORQUE
• 0.6. ELECTRIC WIRE CODE
• 0.7. CONVERSION TABLES
• 1. GENERAL
• 1.1. SPECIFICATION DRAWING
• 1.2. SPECIFICATIONS
• 1.3. WEIGHT TABLE
• 1.4. FUEL, COOLANT AND LUBRICANTS
• 2. STRUCTURE AND FUNCTION
• 2.1. RADIATOR, OIL COOLER, AFTERCOOLER
• 2.2. POWER TRAIN SKELETON
• 2.3. OUTPUT SHAFT
• 2.4. TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING
• 2.5. TORQUE CONVERTER
• 2.6. TRANSMISSION
• 2.7. TRANSMISSION VALVE
• 2.8. ECMV (ELECTRONIC CONTROL MODULATION VALVE)
• 2.9. MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
• 2.10. LOCKING DIFFERENTIAL
• 2.11. STEERING COLUMN
• 2.12. ACCUMULATOR CHARGE VALVE
• 2.13. PROPORTIONAL REDUCING VALVE
• 2.14. BRAKE SYSTEM TANK
• 2.15. PARKING BRAKE
• 2.16. PARKING BRAKE CALIPER
• 2.17. SPRING CYLINDER
• 2.18. PARKING BRAKE SOLENOID
• 2.19. SUSPENSION CYLINDER
• 2.20. OSCILLATION HITCH
• 2.21. STEERING, HOIST OIL PRESSURE PIPING DIAGRAM
• 2.22. DUMP BODY CONTROL
• 2.23. HYDRAULIC TANK AND FILTER
• 2.24. STEERING CYLINDER
• 2.25. HOIST VALVE
• 2.26. EPC VALVE
• 2.27. PILOT CHECK VALVE
• 2.28. HOIST CYLINDER
• 2.29. HYDRAULIC PUMP
• 2.30. CAB TILT
• 2.31. AIR CONDITIONER
• 2.32. MACHINE MONITOR SYSTEM
• 2.33. AUTOMATIC SHIFT CONTROL SYSTEM
• 2.34. TRANSMISSION CONTROLLER
• 2.35. AUTO AUXILIARY STEERING SYSTEM
• 2.36. SENSORS, SWITCHES
• 2.37. ACCELERATOR SENSOR
• 2.38. RETARDER CONTROL SYSTEM
• 2.39. BRAKE CONTROL SYSTEM (ESPEC)
• 2.40. DUMP CONTROL LEVER
• 2.41. PLMHM
• 3. TESTING, ADJUSTING AND TROUBLESHOOTIN
• 3.1. STANDARD VALUE TABLE
• 3.2. TOOLS FOR TESTING AND ADJUSTING
• 3.3. ENGINE COMPONENTS
• 3.4. TESTING TORQUE CONVERTER STALL SPEED
• 3.5. MEASURING POWER TRAIN OIL PRESSURES
• 3.6. L AND R DIFFERENTIAL LOCK PRESSURE
• 3.7. ADJUSTING TRANSMISSION SPEED SENSOR
• 3.8. TESTING AND ADJUSTING BRAKE OIL PRESSURE
• 3.9. TESTING BRAKE PERFORMANCE
• 3.10. BLEEDING AIR FROM BRAKE CIRCUIT
• 3.11. CHECKING WEAR LIMIT ON WHEEL BRAKE DISC
• 3.12. RELEASING EMERGENCY PARKING BRAKE
• 3.13. STEERING CIRCUIT PRESSURE
• 3.14. TESTING AND ADJUSTING SUSPENSION CYLINDER
• 3.15. TILTING THE CAB UP
• 3.16. TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE
• 3.17. ADJUSTING BODY POSITIONER SENSOR
• 3.18. ENGINE CONTROLLER HIGHVOLTAGE CIRCUIT
• 3.19. ADJUSTING TRANSMISSION CONTROLLER
• 3.20. ESCAPE METHOD FOR ELECTRICAL SYSTEM
• 3.21. ADJUSTING MACHINE MONITOR
• 3.22. FUNCTIONS OF MACHINE MONITOR
• 3.23. TROUBLESHOOTING (GENERAL)
• 3.24. TROUBLESHOOTING OF ENGINE CONTROL SYSTEM (ENG MODE)
• 3.25. TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (TM MODE)
• 3.26. TROUBLESHOOTING OF RETARDER CONTROLLER SYSTEM (BK MODE)
• 3.27. TROUBLESHOOTING MACHINE MONITOR PANEL SYSTEM (MON MODE)
• 3.28. TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
• 4. DISASSEMBLY AND ASSEMBLY
• 4.1. HOW TO USE MANUAL
• 4.2. PRECAUTIONS WHEN CARRYING OUT OPERATION
• 4.3. SPECIAL TOOL LIST
• 4.4. SKETCHES OF SPECIAL TOOLS
• 4.5. FUEL SUPPLY PUMP REMOVAL
• 4.6. FUEL SUPPLY PUMP INSTALLATION
• 4.7. ENGINE ASSEMBLY REMOVAL
• 4.8. ENGINE ASSEMBLY INSTALLATION
• 4.9. CYLINDER HEAD ASSEMBLY REMOVAL
• 4.10. CYLINDER HEAD INSTALLATION
• 4.11. REMOVAL AND INSTALLATION OF NOZZLE TIP
• 4.12. RADIATOR ASSEMBLY REMOVAL
• 4.13. RADIATOR ASSEMBLY INSTALLATION
• 4.14. OUTPUT SHAFT REMOVAL
• 4.15. OUTPUT SHAFT INSTALLATION
• 4.16. OUTPUT SHAFT DISASSEMBLY DIAGRAM
• 4.17. ASSEMBLY OF OUTPUT SHAFT
• 4.18. TRANSMISSION AND FRONT DIFFERENTIAL REMOVAL
• 4.19. TRANSMISSION AND FRONT DIFFERENTIAL INSTALLATION
• 4.20. DISCONNECTION OF FRONT DIFFERENTIAL AND TRANSMISSION
• 4.21. COUPLING OF FRONT DIFFERENTIAL AND TRANSMISSION
• 4.22. DISASSEMBLY OF TORQUE CONVERTER
• 4.23. ASSEMBLY OF TORQUE CONVERTER
• 4.24. DISASSEMBLY OF TRANSMISSION
• 4.25. ASSEMBLY OF TRANSMISSION
• 4.26. DISASSEMBLY OF FRONT DIFFERENTIAL
• 4.27. ASSEMBLY OF FRONT DIFFERENTIAL
• 4.28. REMOVAL OF CENTER DIFFERENTIAL
• 4.29. INSTALLATION OF CENTER DIFFERENTIAL
• 4.30. DISASSEMBLY OF CENTER DIFFERENTIAL
• 4.31. ASSEMBLY OF CENTER DIFFERENTIAL
• 4.32. REAR DIFFERENTIAL REMOVAL
• 4.33. REAR DIFFERENTIAL INSTALLATION
• 4.34. DISASSEMBLY OF REAR DIFFERENTIAL
• 4.35. ASSEMBLY OF REAR DIFFERENTIAL
• 4.36. REMOVAL OF FRONT FINAL DRIVE AND BRAKE
• 4.37. INSTALLATION OF FRONT FINAL DRIVE AND BRAKE
• 4.38. DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
• 4.39. ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
• 4.40. REMOVAL OF CENTER FINAL DRIVE AND BRAKE
• 4.41. INSTALLATION OF CENTER FINAL DRIVE AND BRAKE
• 4.42. DISASSEMBLY OF CENTER FINAL DRIVE AND PLATE
• 4.43. ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE
• 4.44. REMOVAL OF REAR FINAL DRIVE AND BRAKE
• 4.45. INSTALLATION OF REAR FINAL DRIVE AND BRAKE
• 4.46. DISASSEMBLY OF REAR FINAL DRIVE AND BRAKE
• 4.47. ASSEMBLY OF REAR FINAL DRIVE AND BRAKE
• 4.48. REMOVAL OF CENTER AXLE
• 4.49. INSTALLATION OF CENTER AXLE
• 4.50. REMOVAL OF REAR AXLE
• 4.51. INSTALLATION OF REAR AXLE
• 4.52. INSTALLATION OF FRONT SUSPENSION CYLINDER
• 4.53. REMOVAL OF FRONT SUSPENSION CYLINDER
• 4.54. REMOVAL OF REAR SUSPENSION CYLINDER
• 4.55. REMOVAL OF EQUALIZER BAR
• 4.56. INSTALLATION OF EQUALIZER BAR
• 4.57. REMOVAL OF FRONT WHEEL
• 4.58. INSTALLATION OF FRONT WHEEL
• 4.59. REMOVAL AND INSTALLATION OF REAR WHEEL ASSEMBLY
• 4.60. REMOVAL OF HITCH FRAME
• 4.61. INSTALLATION OF HITCH FRAME
• 4.62. DISASSEMBLY OF HITCH FRAME
• 4.63. ASSEMBLY OF HITCH FRAME
• 4.64. STANDARD INTEGRAL ORBITROLL
• 4.65. DISASSEMBLY OF STEERING VALVE
• 4.66. ASSEMBLY OF STEERING VALVE
• 4.67. REMOVAL OF FLOW AMPLIFIER VALVE
• 4.68. INSTALLATION OF FLOW AMPLIFIER VALVE
• 4.69. REMOVAL OF HOIST VALVE
• 4.70. INSTALLATION OF HOIST VALVE
• 4.71. DISASSEMBLY OF HOIST VALVE
• 4.72. ASSEMBLY OF HOIST VALVE
• 4.73. DISASSEMBLY OF STEERING CYLINDER
• 4.74. ASSEMBLY OF STEERING CYLINDER ASSEMBLY
• 4.75. DISASSEMBLY OF HOIST CYLINDER ASSEMBLY
• 4.76. ASSEMBLY OF HOIST CYLINDER
• 4.77. REMOVAL OF BODY ASSEMBLY
• 4.78. INSTALLATION OF BODY ASSEMBLY
• 4.79. DISASSEMBLY AND ASSEMBLY OF OPERATORS SEAT
• 4.80. POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
• 4.81. STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM
• 4.82. DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM
• 5. OTHERS
• 5.1. POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
• 5.2. STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM
• 5.3. DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM
• 5.4. BRAKE HYDRAULIC CIRCUIT DIAGRAM
• 5.5. AIR CONDITIONER
• 5.6. TO ENGINE CONTROLLER (1/2)
• 5.7. TO ENGINE CONTROLLER (2/2)
• 5.8. TO MAIN HARNESS INSIDE OF CAB (1/10)
• 5.9. TO MAIN HARNESS INSIDE OF CAB (2/10)
• 5.10. TO MAIN HARNESS INSIDE OF CAB (3/10)
• 5.11. TO MAIN HARNESS INSIDE OF CAB (4/10)
• 5.12. TO MAIN HARNESS INSIDE OF CAB (5/10)
• 5.13. TO MAIN HARNESS INSIDE OF CAB (6/10)
• 5.14. TO MAIN HARNESS INSIDE OF CAB (7/10)
• 5.15. TO MAIN HARNESS INSIDE OF CAB (8/10)
• 5.16. TO MAIN HARNESS INSIDE OF CAB (9/10)
• 5.17. TO MAIN HARNESS INSIDE OF CAB (10/10)
• 5.18. SWITCH PANEL (1/3)
• 5.19. SWITCH PANEL (2/3)
• 5.20. SWITCH PANEL (3/3)
• 5.21. DISPLAY PANEL (1/2)
• 5.22. DISPLAY PANEL (2/2)
• 5.23. RETARD CONTROLLER (1/2)
• 5.24. RETARD CONTROLLER (2/2)
• 5.25. TO TRANSMISSION CONTROLLER (1/2)
• 5.26. TO TRANSMISSION CONTROLLER (2/2)
• 5.27. TO HARNESS OUTSIDE OF CAB (1/2)
• 5.28. TO HARNESS OUTSIDE OF CAB (2/2)
• 5.29. FUSE BLOCK
• 5.30. LOAD METER (1/2)
• 5.31. LOAD METER (2/2)