Komatsu HM400-2R Dump Truck Shop Manual SEN03042-18 PDF

Description

Komatsu HM400-2R Dump Truck Shop Manual SEN03042-18 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HM400-2R Dump Truck Shop Manual SEN03042-18 – PDF DOWNLOAD 

Language : English
Pages : 1502
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HM400-2R Dump Truck Shop Manual SEN03042-18 – PDF DOWNLOAD 

SERIAL NUMBERS 7001 and up

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 17
Safety notice 18
How to read the shop manual 24
Explanation of terms for maintenance standard 26
Handling of electric equipment and hydraulic component 28
How to read electric wire code 40
Precautions when carrying out operation 43
Method of disassembling and connecting push-pull type coupler 46
Standard tightening torque table 49
Conversion table 53
01 Specification 59
Specification and technical data 59
Specification drawings 60
Specifications 61
Weight table 64
Fuel, coolant and lubricants 65
10 Structure, function and maintenance standard 69
Engine and cooling system 69
Radiator, oil cooler, aftercooler 70
Output shaft 71
Power train, Part 1 75
Power train skeleton 76
Torque converter and transmission hydraulic piping 80
Brake cooling oil control valve (BCV) 82
Power train pump 83
Torque converter 86
Transmission 92
Transmission control valve 120
ECMV 121
Main relief, torque converter relief valve 128
Power train, Part 2 131
Drive shaft 132
Axle 140
Differential 144
Limited slip differential 158
Final drive 162
Steering system 167
Steering column 168
Brake system 171
Brake piping 172
Brake valve 174
Accumulator charge valve 177
Accumulator 181
Slack adjuster 182
Brake 184
Proportional reducing valve 189
Brake system tank 190
Parking brake 192
Parking brake caliper 194
Spring cylinder 195
Parking brake solenoid 196
Undercarriage and frame 199
Suspension 200
Suspension cylinder 205
Oscillation hitch 207
Hydraulic system 211
Steering, hoist hydraulic piping diagram 212
Dump body control 213
Hydraulic tank and filter 214
Flow amp valve 215
Steering valve 218
Steering cylinder 222
Hoist valve 224
EPC valve 230
Pilot check valve 231
Hoist cylinder 232
Hydraulic pump 233
Cab and its attachments 237
ROPS cab 238
Cab tilt 239
Air conditioner 240
Rear view monitor 248
Controller related 251
Electrical system, Part 1 253
Machine monitor system 254
Electrical system, Part 2 275
Automatic shift control system 276
Transmission controller 279
Retarder control system 308
Auto emergency steering system 320
Dump control lever 321
Electrical system, Part 3 327
Payload meter (Card type) 328
Electrical system, Part 4 361
Sensors, switches 362
KOMTRAX terminal system (if equipped) 371
20 Standard value table 375
Standard service value table 375
Standard value table for engine 376
Standard value table for chassis 377
30 Testing and adjusting 383
Testing and adjusting, Part 1 383
Precautions before work 385
Sketches of special tools 391
Measuring engine speed 392
Testing intake air pressure(boost pressure) 393
Testing exhaust temperature 394
Testing exhaust gas color 395
Adjusting valve clearance 396
Testing compression pressure 397
Testing blow-by pressure 399
Testing engine oil pressure 400
Handling of fuel system devices 401
Releasing residual pressurefrom fuel system 401
Testing fuel pressure 402
Testing fuel return and leakageamount 403
Bleeding air from fuel circuit 406
Testing the fuel circuit for leakage 408
Testing and adjusting fan belttension 409
Testing and adjusting alternatorbelt tension 410
Testing and adjusting airconditioner compressor belttension 411
Adjusting the shims in the bodymount 412
Testing and adjusting, Part 2 415
Testing torque converter stall speed 417
Testing power train oil pressure 418
Testing and adjusting of differential lock oil pressure (differential lock spec ) 426
Adjusting transmission speed sensor 431
Testing and adjusting brake oil pressure 433
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 437
Testing brake performance 445
Releasing remaining pressure in brake circuit 446
Bleeding air from brake circuit 447
Testing wear of wheel brake disc 448
Testing the parking brake pad wear 449
Emergency release of the parking brake 450
Testing and adjusting steering circuit oil pressure 451
Testing and adjusting suspension cylinder 453
Method of tilting cab up 457
Testing and adjusting dump circuit oil pressure 459
Adjusting body positioner sensor 461
Adjusting length of spring in body heating spherical joint 462
Adjustment of tilt lock lever of steering wheel 463
Handling of voltage circuit of engine controller 464
Adjusting transmission controller 464
Method for emergency escape at electrical system failure 465
Testing and adjusting, Part 3 471
Setting and adjusting various equipments 472
Special function of machine monitor 481
How to start operation of KOMTRAX terminal 525
Lamp display of KOMTRAX terminal 530
Pm Clinic check sheet 533
40 Troubleshooting 537
Failure code table and fuse locations 537
Failure codes table 538
Fuse locations 545
General information on troubleshooting 553
Precautions before work 554
How to proceed in troubleshooting 557
Check before troubleshooting 559
Classification and procedures of troubleshooting 560
Information in troubleshooting table 564
Troubleshooting method for disconnecting wiring harness of pressuresensor system 566
Phenomena looking like troubles and troubleshooting Nos 569
Connection table for connector pin numbers 571
T- branch box and T- branch adapter table 607
Troubleshooting by failure code (Display of code), Part 1 611
Failure code [1500L0] Detecting dual engagement 613
Failure code [15B0NX] Transmission oil filter: Clogging 614
Failure code [15F0KM] R → F gear shift abuse 1 616
Failure code [15F0MB] R → F gear shift abuse 2 616
Failure code [15F7KM] Transmission forward clutch abuse 617
Failure code [15G0MW] Reverse clutch system failure (Slip is detected) 618
Failure code [15G7KM] Transmission reverse clutch abuse 620
Failure code [15H0MW] Hi clutch system failure (Slip is detected) 622
Failure code [15J0MW] Lo clutch system failure (Slip is detected) 624
Failure code [15K0MW] 1st clutch system failure (Slip is detected) 626
Failure code [15L0MW] 2nd clutch system failure (Slip is detected) 628
Failure code [15M0MW] 3rd clutch system failure (Slip is detected) 630
Failure code [15SBL1] Reverse clutch pressure control valve failure I 632
Failure code [15SBMA] Reverse clutch pressure control valve failure II 635
Failure code [15SCL1] Hi clutch pressure control valve failure I 636
Failure code [15SCMA] Hi clutch pressure control valve failure II 639
Failure code [15SDL1] Lo clutch pressure control valve failure I 640
Failure code [15SDMA] Lo clutch pressure control valve failure II 643
Troubleshooting by failure code (Display of code), Part 2 645
Failure code [15SEL1] 1st clutch pressure control valve failure I 648
Failure code [15SEMA] 1st clutch pressure control valve failure II 651
Failure code [15SFL1] 2nd clutch pressure control valve failure I 652
Failure code [15SFMA] 2nd clutch pressure control valve failure II 655
Failure code [15SGL1] 3rd clutch pressure control valve failure I 656
Failure code [15SGMA] 3rd clutch pressure control valve failure II 659
Failure code [15SJMA] Lockup clutch pressure control valve failure II 660
Failure code [15SKMA] Interaxle differential lock clutch pressure control valve failure II 662
Failure code [2A62L1] Front wheel differential lock pressure control valve failure II 664
Failure code [2A62LH] Front wheel differential lock pressure control valve failure I 666
Failure code [2B62L1] Rear wheel differential lock pressure control valve failure II 668
Failure code [2B62LH] Rear wheel differential lock pressure control valve failure I 670
Failure code [2C4MNX] Retarder cooling oil filter clogging 672
Failure code [2F00KM] Dragging of parking brake 674
Failure code [2G42ZG] Lowering of accumulator oil pressure (front) 676
Failure code [2G43ZG] Lowering of accumulator oil pressure (rear) 676
Failure code [989A00] Engine overrun prevention activated 677
Failure code [989D00] Rear section tipping over alarm (Raising operation on slope) 677
Failure code [A570NX] Engine oil filter clogging 678
Failure code [AA10NX] Air cleaner clogging 680
Failure code [AB00MA] Battery charge circuit failure 682
Failure code [B@BAZG] Lowering of engine oil pressure 683
Failure code [B@BAZK] Lowering of engine oil level 684
Failure code [B@BCNS] Engine overheat 685
Failure code [B@BCZK] Lowering of coolant level 686
Failure code [B@C6NS] Overheat of brake cooling oil temperature (front) 688
Failure code [B@C8NS] Overheat of brake cooling oil temperature (center) 688
Failure code [B@CENS] Overheat of torque converter oil temperature 689
Failure code [B@JANS] Overheat of steering oil temperature 689
Troubleshooting by failure code, Part 3 691
Failure code [CA111] Abnormality in engine controller 694
Failure code [CA115] Engine Ne or Bkup speed sensor error 696
Failure code [CA122] Charge (boost) pressure sensor high error 698
Failure code [CA123] Charge (boost) pressure sensor low error 700
Failure code [CA131] Throttle sensor high error 702
Failure code [CA132] Throttle sensor low error 704
Failure code [CA135] Engine oil pressure sensor high error 706
Failure code [CA141] Engine oil pressure sensor low error 708
Failure code [CA144] Coolant temperature sensor high error 710
Failure code [CA145] Coolant temperature sensor low error 712
Failure code [CA153] Charge (boost) temperature sensor high error 714
Failure code [CA154] Charge (boost) temperature sensor low error 716
Failure code [CA187] Sensor power supply 2 low error 718
Failure code [CA221] Atmospheric pressure sensor high error 720
Failure code [CA222] Atmospheric pressure sensor low error 722
Failure code [CA227] Sensor power supply 2 high error 724
Failure code [CA234] Engine overspeed 725
Failure code [CA238] Ne speed sensor power supply error 726
Failure code [CA263] Fuel Temperature Sensor High Error 728
Failure code [CA265] Fuel Temperature Sensor Low Error 730
Failure code [CA271] PCV1 Short circuit 732
Failure code [CA272] PCV1 Disconnection 733
Failure code [CA273] PCV2 Short circuit 734
Failure code [CA274] PCV2 Disconnection 735
Failure code [CA322] Injector #1 open/short error 736
Failure code [CA323] Injector #5 open/short error 738
Failure code [CA324] Injector #3 open/short error 740
Failure code [CA325] Injector #6 open/short error 742
Failure code [CA331] Injector #2 open/short error 744
Failure code [CA332] Injector #4 open/short error 746
Failure code [CA342] Calibration code inconsistency 748
Failure code [CA351] Injectors drive circuit error 749
Failure code [CA352] Sensor power supply 1 low error 750
Failure code [CA386] Sensor power supply 1 high error 752
Troubleshooting by failure code, Part 4 755
Failure code [CA431] Idle validation switch error 757
Failure code [CA432] Idle validation action error 760
Failure code [CA441] Battery voltage low error 763
Failure code [CA442] Battery voltage high error 764
Failure code [CA449] Common rail pressure high error 2 765
Failure code [CA451] Common rail pressure sensor high error 766
Failure code [CA452] Common rail pressure sensor low error 768
Failure code [CA553] Common rail pressure high error 1 770
Failure code [CA554] Common rail pressure sensor in range error 771
Failure code [CA559] Supply pump pressure very low error 1 772
Failure code [CA689] Engine Ne speed sensor error 776
Failure code [CA731] Engine Bkup speed sensor phase error 778
Failure code [CA757] All continuous data lost error 779
Failure code [CA778] Engine Bkup speed sensor error 780
Failure code [CA1633] KOMNET datalink timeout error 782
Failure code [CA2185] Throttle sensor power supply voltage high error 784
Failure code [CA2186] Throttle sensor power supply voltage low error 786
Failure code [CA2249] Supply pump pressure very low error 2 788
Failure code [CA2555] Intake air heater relay open circuit error 790
Failure code [CA2556] Intake air heater relay short circuit error 792
Troubleshooting by failure code (Display of code), Part 5 795
Failure code [DAF9KM] Wrong connection of connector 798
Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication 799
Failure code [DAQ0KK] Lowering of source voltage 800
Failure code [DAQ0KT] Trouble in non-volatile memory 802
Failure code [DAQ2KK] Trouble in solenoid power supply system 804
Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller) 806
Failure code [DAQRKR] Abnormal CAN communication (Transmission): Abnormal communication 808
Failure code [DAQRMA] Disagreement of option setting (Transmission controller) 813
Failure code [DB10KT] Trouble in non-volatile memory 813
Failure code [DB12KK] Trouble in solenoid power supply system 814
Failure code [DB13KK] Lowering of battery direct voltage 816
Failure code [DB19KQ] Disagreement of model selection (Retarder controller) 818
Failure code [DB1QMA] Disagreement of option setting (Retarder controller) 819
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled 820
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled 824
Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal 830
Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve 832
Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve 833
Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve 834
Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve 835
Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve 836
Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve 837
Failure code [DF10KA] Input of no lever signals 838
Failure code [DF10KB] Input of multiple lever signals 842
Failure code [DGF1KX] Transmission oil temperature out of range 846
Failure code [DGR2KZ] Ground fault in brake oil temperature sensor (rear) 848
Failure code [DGR2L8] Disconnection in brake oil temperature sensor (rear) 850
Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center) 852
Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center) 854
Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front) 856
Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front) 858
Failure code [DGR6KX] Steering oil temperature out of range 860
Troubleshooting by failure code (Display of code), Part 6 863
Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system 866
Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil pressure sensor system 868
Failure code [DHT5L6] Torque converter oil pressure sensor failure 870
Failure code [DHU2KX] Accumulator oil pressure sensor (front) system failure 872
Failure code [DHU3KX] Accumulator oil pressure sensor (rear) system failure 874
Failure code [DJF1KA] Disconnection in fuel level sensor system 876
Failure code [DK51L5] Manual retarder potentiometer and RVS failure 878
Failure code [DK52KX] Dump lever potentiometer 1 failure 880
Failure code [DK53L8] Dump lever potentiometer 2 failure 882
Failure code [DK54KX] Body positioner sensor failure 884
Failure code [DKH0KX] Pitch angle sensor signal out of range 886
Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system 888
Failure code [DLF1LC] Transmission input shaft speed sensor failure 889
Failure code [DLF2KA] Disconnection in transmission intermediate shaft speed sensor system 890
Failure code [DLF2LC] Transmission intermediate shaft speed sensor failure 891
Failure code [DLF4KA] Disconnection in transmission differential speed sensor system 892
Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system 893
Failure code [DV00KB] Short circuit in buzzer output circuit 894
Failure code [DW72KZ] Kick-out solenoid output system failure (disconnection or ground fault) 896
Failure code [DW73KZ] Dump selector valve output system failure 898
Failure code [DW78KZ] Rear wheel BCV command output system failure 900
Failure code [DW79KZ] Front wheel BCV command output system failure 902
Failure code [DX11K4] Rear wheel proportional solenoid pressure reducing valve failure 1 904
Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid pressure reducing valve 906
Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid pressure reducing valve 908
Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid pressure reducing valve 910
Failure code [DX11MA] Rear wheel proportional solenoid pressure reducing valve failure 2 912
Failure code [DX12K4] Front wheel proportional solenoid pressure reducing valve failure 1 914
Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid pressure reducing valve 916
Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid pressure reducing valve 918
Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid pressure reducing valve 920
Failure code [DX12MA] Front wheel proportional solenoid pressure reducing valve failure 2 922
Troubleshooting by failure code (Display of code), Part 7 925
Failure code [DX13KA] Disconnection in output circuit of dump EPC valve 928
Failure code [DX13KB] Ground fault in output circuit of dump EPC valve 930
Failure code [DX13KY] Hot short in output circuit of dump EPC valve 932
Failure code [DX14KZ] Rear wheel differential lock command output system failure 934
Failure code [DX15KZ] Front wheel differential lock command output system failure 936
Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch solenoid 938
Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch solenoid 940
Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid 942
Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid 944
Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid 946
Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid 948
Failure code [DXH2KA] Disconnection in output circuit of Hi clutch ECMV solenoid 950
Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid 952
Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid 954
Failure code [DXH3KA] Disconnection in output circuit of Lo clutch ECMV solenoid 956
Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid 958
Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid 960
Failure code [DXH4KA] Disconnection in output circuit of 1st clutch ECMV solenoid 962
Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid 964
Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid 966
Troubleshooting by failure code (Display of code), Part 8 969
Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch ECMV solenoid 970
Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid 972
Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid 974
Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch ECMV solenoid 976
Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid 978
Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid 980
Failure code [DXH7KA] Disconnection in output circuit of Reverse clutch ECMV solenoid 982
Failure code [DXH7KB] Ground fault in output circuit of Reverse clutch ECMV solenoid 984
Failure code [DXH7KY] Hot short in output circuit of Reverse clutch ECMV solenoid 986
Troubleshooting of electrical system(E-mode) 989
Before troubleshooting for electrical system 991
Information in troubleshooting table 997
E-1 Engine does not start 998
E-2 Auto preheater does not operate 1003
E-3 When starting switch is turned ON, machine monitor displays nothing 1006
E-4 When starting switch is turned OFF, machine monitor cannot be operated 1008
E-5 Alarm buzzer does not sound 1010
E-6 Machine monitor does not normally display gauges, caution lamps, and character display section 1012
E-7 Display of character display section cannot be changed 1013
E-8 Power mode selection function does not operate normally 1016
E-9 AISS function does not operate normally 1018
E-10 Right and left differential lock function does not operate normally (Differential lock-up specification) 1020
E-11 Interaxle differential lock-up function does not operate normally 1024
E-12 Display of seat belt caution lamp is abnormal 1026
E-13 Both turn signal lamps and hazard lamps do not operate normally 1028
E-14 Night lighting is abnormal 1033
E-15 Backup lamp and backup buzzer operate abnormally 1040
E-16 Emergency steering system does not operate 1044
E-17 Indication of the fuel gauge is abnormal 1048
E-18 Dump lever does not operate normally 1050
E-19 KOMTRAX system does not operate normally 1052
E-20 Electric priming pump does not operate or does not stop automatically 1056
E-21 Air conditioner does not operate normally 1058
Troubleshooting of hydraulic and mechanical system (H-mode) 1065
Information in troubleshooting table 1067
H-1 Machine does not start 1068
H-2 Travel is not smooth (Machine hunts) 1070
H-3 Lockup is not reset 1070
H-4 Start shock and gear shift shock are abnormally large 1071
H-5 Gear is not shifted up 1072
H-6 Travel speed or power is low 1074
H-7 Start and gearshift time lag is large 1078
H-8 Torque converter oil temperature is high 1080
H-9 Torque converter oil temperature is low 1081
H-10 Front brake does not work fully 1082
H-11 Center brake does not work fully 1083
H-12 Rear brake does not work fully 1084
H-13 Steering wheel is heavy 1085
H-14 Steering wheel does not move 1086
H-15 Steering wheel waggle 1087
H-16 Dump body raising speed is low 1088
H-17 Dump body does not move 1089
H-18 Hydraulic drift of dump body is large 1090
Troubleshooting of engine (S-mode) 1093
Method of using troubleshooting chart 1095
S-1 Starting performance of engine is poor 1098
S-2 Engine does not start 1099
S-3 Engine does not pick up smoothly 1102
S-4 Engine stops during operation 1103
S-5 Engine does not rotate smoothly 1104
S-6 Engine lack output (or lacks power) 1105
S-7 Exhaust gas is black (incomplete combustion) 1106
S-8 Oil consumption is excessive (or exhaust gas is blue) 1107
S-9 Oil becomes dirty quickly 1108
S-10 Fuel consumption is excessive 1109
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 1110
S-12 Oil pressure drops 1111
S-13 Oil level rises (Entry of coolant or fuel) 1112
S-14 Coolant temperature becomes too high (Overheating) 1113
S-15 Abnormal noise is made 1114
S-16 Vibration is excessive 1115
S-17 Air cannot be bled from fuel circuit 1116
50 Disassembly and assembly 1119
General information on disassembly and assembly 1119
Precautions before work 1120
How to read this manual 1121
Coating materials list 1123
Special tool list 1126
Sketches of special tools 1131
Engine and cooling system (SAA6D140E-5) 1147
Removal and installation of engine assembly 1148
Removal and installation of radiator assembly 1157
Removal and installation of cooling assembly 1161
Removal and installation of aftercooler assembly 1165
Removal and installation of output shaft assembly 1168
Disassembly and assembly of output shaft assembly 1173
Engine (SAA6D140E-5) 1177
Removal and installation of fuel supply pump assembly 1178
Removal and installation of cylinder head assembly 1183
Removal and installation of fuel injector assembly 1199
Removal and installation of engine front seal 1203
Removal and installation of engine rear seal 1205
Replacement procedure of exhaust pipe fire prevention cover 1209
Power train, Part 1 1219
Removal and installation of transmission and front differential assembly 1220
Disconnection and coupling of front differential and transmission 1227
Disassembly and assembly of torque converter assembly 1228
Disassembly and assembly of transmission assembly 1236
Power train, Part 2 (Differential) 1281
Disassembly and assembly of front differential assembly 1282
Removal and installation of center differential assembly 1299
Disassembly and assembly of center differential assembly 1302
Removal and installation of rear differential assembly 1317
Disassembly and assembly of rear differential assembly 1319
Power train, Part 3 (Final drive, brake, axle) 1333
Removal and installation of front final drive and brake assembly 1334
Disassembly and assembly of front final drive and brake assembly 1337
Removal and installation of center final drive and brake assembly 1353
Disassembly and assembly of center final drive and brake assembly 1355
Removal and installation of rear final drive and brake assembly 1367
Disassembly and assembly of rear final drive and brake assembly 1368
Removal and installation of center axle assembly 1369
Removal and installation of rear axle assembly 1372
Undercarriage and frame 1377
Removal and installation of front suspension cylinder assembly 1378
Removal and installation of rear suspension cylinder assembly 1380
Removal and installation of equalizer bar assembly 1382
Removal and installation of front wheel assembly 1384
Removal and installation of rear front wheel assembly 1385
Removal and installation of rear rear wheel assembly 1385
Removal and installation of hitch frame assembly 1386
Disassembly and assembly of hitch frame 1394
Removal and installation of body assembly 1399
Hydraulic system 1403
Disassembly and assembly of steering valve 1404
Removal and installation of flow amplifier valve assembly 1414
Removal and installation of hoist valve assembly 1416
Disassembly and assembly of hoist valve assembly 1418
Disassembly and assembly of steering cylinder assembly 1420
Disassembly and assembly of hoist cylinder assembly 1426
Cab and its attachments 1433
Removal and installation of operator’s cab 1434
Removal and installation of operator’s cab glass (Stuck glass) 1439
Disassembly and assembly of operator’s seat assembly (If equipped) 1446
Electrical system 1457
Removal and installation of air conditioner unit assembly 1458
Removal and installation of engine controller 1463
Removal and installation of retarder controller 1466
Removal and installation of transmission controller assembly 1468
90 Diagrams and drawings 1471
Hydraulic diagrams and drawings 1471
Power train hydraulic circuit diagram 1473
Steering and hoist hydraulic circuit diagram 1475
Brake hydraulic circuit diagram 1476
Brake cooling hydraulic circuit diagram 1477
Differential lock hydraulic circuit diagram 1478
Electrical diagrams and drawings 1481
Electrical circuit diagram for inside cab (1/4) 1483
Electrical circuit diagram for inside cab (2/4) 1485
Electrical circuit diagram for inside cab (3/4) 1487
Electrical circuit diagram for inside cab (4/4) 1489
Electrical circuit diagram for outside cab (1/3) 1491
Electrical circuit diagram for outside cab (2/3) 1493
Electrical circuit diagram for outside cab (3/3) 1495
Electrical circuit diagram for payload meter 1497
Connectors table and arrangement drawing HM400-2R 1499

DESCRIPTION:

Komatsu HM400-2R Dump Truck Shop Manual SEN03042-18 – PDF DOWNLOAD 

SERIAL NUMBERS 7001 and up

How to read the shop manual 
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

S.V 29/12/24