Komatsu HM400-3 User manual

ARTICULATED
DUMP TRUCK
Field Assembly Instruction
GEN00112-03
HM400-3
SERIAL NUMBERS 3001 and up

1. Drawings of removed units ............................................................... 1
2. Dimensions of removed units ........................................................... 1
3. Assembly procedure, necessary equipments, and schedule ........ 2
4. Necessary tools and equipments ..................................................... 2
5. Assembly procedure No. ................................................................... 3
0010 Installation of the slin
g
............................................................ 3
0100 Positionin
g
bare machine ....................................................... 4
0200 Unfoldin
g
of rear view mirror ..................................................
.
5
0210 Installation of left
g
uard ..........................................................
.
6
0500 Installation of antenna ............................................................
.
7
0510 Installation of rear monitor ...................................................... 8
0521 Rear monitor ad
j
ustment 1 ..................................................... 9
0522 Rear monitor ad
j
ustment 2 ..................................................... 10
0523 Rear monitor ad
j
ustment 3 ..................................................... 11
0524 Rear monitor ad
j
ustment 4 ..................................................... 12
0800 Ad
j
ustin
g
N2
g
as of front and rear suspensions ..................... 13
0900 Connectin
g
of hoist c
y
linder ...................................................
.
14
1000 Stickin
g
of decal ....................................................................
.
15
Attached sheet: Mirror adjustment procedure
Attached sheet: Mirror adjustment procedure （WIDE）
Appendix: Field assembly inspection report
Contents

1. Drawings of removed units
Specifications of HM400-3 completed truck
* Values are from the product plan.
2. Dimensions of removed units
No.
1 Bare machine
2--
Self-propelled travel
Unit name Weight (kg)
3,735
(When empty)
11,122 3,45033,660
Specifications
Weight (kg) Overall length (mm) Overall width (mm)
Related items
Overall height (mm)
Exterior parts (2 pcs.)
Overall height (mm)
3,7353,45011,12233,600
Overall length (mm) Overall width (mm)
3.2 -
1. Bare machine
１．Bare machine (Mobile shipping style) 2．Split parts of left handrail
1

3. Assembly procedure, necessary equipments, and schedule
Day
Hour 1 23456 7 8
(1) Positioning chassis (3) Mounting body (4) Adjusting each parts
(2) Installing tires Mirror and antenna
(5) Inspection
Meeting before work Completion of assembly
Unloading
Starting assembly
4. Necessary tools and equipments
(1) Necessary tools
No. Q'ty
1 1 set
21
31
4 1 set
51
61
7 1 set
81
91
10 1 set
11 1
12 1
(2) Necessary equipments
No. Q'ty
12
21
31
41
52
612
(3) Necessary lifting tools
No. Q'ty
１4
21
34
Lifting tire L: 4,000 Chain diamete φ6.3 For tire chassis
Shackle Withstand load ：Min. 1 ton For connecting body and sling tools
Equipment name Specifications Remarks
Nylon sling For 15 ton ｘL: 4,000 For slinging protector
Steel plate t 9 × 1,219 × 2,438 For setting bare machine in place
Wood block 400 × 400 × 900 For setting bare machine in place
Compressor Capacity: Min. 32 ℓFor impact wrench
Stepladder (Work stand) 4 steps (About 1.5m) For work
Crane Min. 25 ton For slinging protector
Forklift Min. 2 ton For mounting tire
Bar For adjustment of holes when mounting tire
Equipment name Specifications Remarks
Suspension gas pouring tool 7926-10-1000 For adjusting suspension pressure
Touch-up paint spray can
Impact wrench GT-S22m or equivalent For mounting tire
Torque wrench Can be measured 927 Nm { 94.5 kgm} For mounting tire
Number of workers
Socket
SpecificationsTool name
Ring wrench
Socket
Remarks
Standard tools （Wrench set）
36 mm （Entry corner 25.4）
2
1st day
Assembly Procedure No.
Assembly unit
No.0010-0900
Remarks
For tightening each place
For mounting tire
For tightening each placeStandard tools ( Socket set )
Paint spray can Clear For touch-up bolt head
Impact wrench For tightening each place
Extension bar Entry corner 25.4 × L:160 For mounting tire
Natural yellow For touch-up body and hoist cylinder
Grease gun For each parts grease-up
Length : 4,000 mm
Specification load : 15 ton
Chain diameter
φ 6.3 mm
Specification load :
3.20 ton
21
3
2

1. Positioning bare machine
2. Preparation of the sling
1. Place protective plate when installing sling.
2. Detail of slinging on front side.
Q'ty Name Q'ty
Nylon sling 15 ton 3 Crane： Min. 25 ton 2
Other remarks
When slinging the machine
Use protective plates not to damage the exterior
parts when installing sling tools.
Sling tools should not contact the side bumper on
front frame side when slinging the machine.
(It may damage the bumper)
No．0010 Installation of the sling
Precautions
Assembly procedure No.
Necessary equipmentNecessary tools
Name
1. Positioning on the flat ground Lock the machine by using a lock bar
Protective plate
When using a double wire
Sling tools are perpendicular. Do not interfere the side bumper
When using single wire
Perform slinging with sling angle 60 deg.
Protective plate
3

1. Positioning bare machine
1. Position machine on the flat ground.
Q'ty Name Q'ty
Other remarks
Assembly procedure No.
Precautions Necessary equipmentNecessary tools
Name
No．0100 Positioning bare machine
4

1. Remove the rear view mirror mounting bolts and change the fixed position of the mirror.
2. Perform the same work on the opposite side.
Q'ty Name Q'ty
Ring wrench （17mm） 1
Other remarks
No．0200
Necessary equipmentNecessary tools
Name
Precautions
Assembly procedure No. Unfolding of rear view mirror
Remove
Loosen
Tighten
Unfold the bracket
and fix it with the
bolts.
5

1. Remove parts (3) to (5) installed to the machine.
2. Install the handrails delivered together with the machine.
Q'ty Name Q'ty
Ring wrench （19mm） 2
Other remarks
Assembly procedure No.
Precautions Necessary equipmentNecessary tools
Name
Installation of left guard
No．0210
①
③
②
④⑤
③
④⑤
No Part No. Part name Q'ty State of parts (Parts list No.)
(1) 56B-54-37341XC Guard 1 Separately Packed （M43-05-020）
(2) 56B-54-37330XC Guard 1 Separately Packed （M43-05-020）
(3) 01024-81245 Bolt, sems 4 Temporarily installed to chassis
(4) 01643-31232 Washer 4 Temporarily installed to chassis
(5) 01580-11210 Nut 4 Temporarily installed to chassis
6

1. Install antenna to top of cab.
(1) KOMTRAX antenna ：Install antenna to top of cab.
(2) Radio antenna ：Install antenna to left top of cab.
Q'ty Name Q'ty
Other remarks
Necessary toolsPrecautions
No．0500
Name
Assembly procedure No. Installation of antenna
Necessary equipment
②
Z
View Z
①
Remove vinyl and
install antenna.
Remove cap and
install antenna.
A
pply Locktite No.262
or equivalent.
Q'ty State of parts (Parts list No.)
(1)
1 Separately Packed （M43-05-050）
(2)
1 Separately Packed （M43-05-060）
Part No. Part name
8A13-10-2100 Antenna
20Y-06-41990 Antenna
7

1. Remove the cover of rear lamp A.
2. Install rear camera A.
3. Install the camera harness according to the figure on the right.
4. Install the cover removed in step 1.
Q'ty Name Q'ty
1
1
Other remarks
Ring wrench （10mm）
Ring wrench （13mm）
Name
Necessary toolsPrecautions
If there is no request for burglar proof, no work is
needed for it since it is already installed to the
machine.
(Perform it in the same way at No.521 to No.524
on next page)
Necessary equipment
Assembly procedure No. No．0510 Installation of rear monitor
①
View Y
②
②
Remove cover
Y
Z
View Z
Rear camera ：Connect
CN_BMN
JOINT CONNECTOR
BACK LAMP (R)
STOP, TAIL AND
TURN SIGNAL LAMPS
(RH)
WINKER LAMP
BACK LAMP (L)
JOINT CONNECTOR
STOP, TAIL AND
TURN SIGNAL LAMPS
(LH)
CICLINATION SENSOR
BACK ALARM SENSOR
No Part No. Part name Q'ty State of parts (Parts list No.)
(1) 7835-33-2000 Camera 1 Separately Packed （M43-05-010）
(2) 01024-80616 Bolt, sems 3 Separately Packed （M43-05-010）
LAMP
STOP TAIL
STOP TAIL
LAMP
WINKER LAMP
8

5. In " Default ", select " Rear View Monitor Setting ".
6. In "Rear View Monitor Setting ", select "Guide Line
Position Adjustment ".
3. Return to the first screen and enter "Service Menu"
4. In "Service Menu", select "Default".
No．0521 Rear monitor adjustment 1 Assembly procedure No.
Turn the key to the ON position and push in the first appeared screen.
後進連動選択モード
HM400
2. In "Rear View Monitor Setting", turn OFF the “Reverse-
interlock enabled mode”.
The rear view is always displayed on the monitor even while
the shift lever is not in "R".
1. Push [???] on the user menu four times to select
"Rear View Monitor Setting".
Rear view
monitor
Setting procedure of rear view monitor
< User menu display method >
Switch panel Luminance Adjustment switch
To No. 0522 Rear View Monitor
Adjustment-2
Guide Line Position Adjustment
02 Guide Line Position Adjustment
While pressing , press in
order.
HM400
9

7. Return to the first screen (standard screen).
12. Select Rear View Monitor Setting.
8. Enter User menu and select Rear View Monitor Setting.
13. Select Guide Line Position Adjustment.
9. Turn off reverse-interlock enabled mode.
10. Return to the first screen, then enter "Service Menu".
11. Select Default.
Assembly procedure No. No．0522 Rear monitor adjustment 2
( Rear view monitor is always displayed, even if shift
lever is not in " R ")
後進連動選択モード
リヤ
To No. 0523 Rear View Monitor
Adjustment-3
Guide Line Position Adjustment
While pressing , press
in order.
02 Guide Line Position Adjustment
HM400
10

* Decide horizontal and vertical positions on main monitor, then adjust position with this luminance adjustment
switch while watching rear view monitor.
* Perform only horizontal position adjustment in points 3 and 4 (since they are not related to rear end of body)
.
14. Select point from Guide Line Position Adjustment.
15. Select Horizontal Adjustment in Point 1 and adjust
to tire outside width with Luminance Adjustment switch.
16. Select Vertical Adjustment in Point 1 and adjust
to body rear end with Luminance Adjustment switch.
17. Screen returns to point selection screen.
Adjust guide line positions of points 2 to 4 similarly.
No．0523Assembly procedure No. Rear monitor adjustment 3
Point 1
Point 3
Point 2
Point 4
Horizontal Adjustment
Vertical Adjustment
Guide Line Position Adjustment method
< Luminance
Adjustment
switch >
< Luminance
Adjustment
switch >
Rear View MonitorMain Monitor
Adjust to tire outside width
Adjust to body rear end
After setting all points, go to
No. 0524 Rear monitor adjustment-4
11

18. Return to first screen and enter User menu.
19. Select Rear View Monitor Setting.
20. In "Rear View Monitor Setting ", turn ON "Guide Line”.
Turn on Reverse-interlock enabled mode.
Assembly procedure No. No．0524 Rear monitor adjustment 4
後進連動選択モード
ON
ON
リヤ
Reference Line
If guide line is displayed as shown at right only
when shift lever is in R1 or R2, rear view monitor
setting is completed
* If body rear end guide line is displayed yellow, No. 0521
5. "Rear View Monitor Initialize" may not be performed.
[Reference] Relationship between
guide line and machine
Body rear endTire outside width Tire outside width
Turn the key to the ON position and push
in the first appeared screen.
12

1. Adjusting N2 gas of front and rear suspension
s
Adjust the quantity of N2 gas (front and rear, 4 places).
Q'ty Name Q'ty
Suspension gas pouring tool 1
(7926-10-1000)
Other remarks
Adjustment. (If it is steered, the piping may be broken.)
1. Bleed air from the cylinders.
1. Loosen the air bleeding valves of the right and left front suspension cylinders and bleed air thoroughly. (Check that air does not
come out any more (and only oil flows out) and tighten the valves again. Tightening torque: 39.2 - 49.0 Nm {4 - 5 kgm})
2. Check that the valves are closed and install the suspension gas pouring tool to the gas cylinder.
3. Connect the hoses of the suspension gas pouring tool to the nitrogen gas pouring valves. (Since there are 2 hoses, connect
them to the right and left suspension cylinders and pour the nitrogen gas simultaneously so that pressure will be applied to both
cylinders evenly.)
4. Open the valve of the suspension gas pouring tool gradually.
stroke end.
4. After moving the machine forward and in reverse,
stop it without applying the brake.
5. Do not steer the machine before finishing this
cylinders simultaneously.
3. Do not extend the suspension cylinders to the
5. When the suspension cylinders rise to the specified level shown above, close the valve. (Pour the gas to the front suspension
cylinders until they rise to the level indicated by the decalcomania. Pour the gas to the rear suspension cylinders until they rise
to the level shown in the above figure.)
6. Remove the hoses from the nitrogen gas pouring valves and move the machine forward and in reverse to the suspension cylin-
ders and then stop without applying the brake. (Finally, stop the machine without applying the brake to prevent an uneven load
caused by braking.)
7. Apply the parking brake and check the length of the suspension cylinders.
8. If the length of the suspension cylinders is out of the standard range, repeat steps 3 -7. (Usually, adjustment is completed by
Name
Assembly procedure No.
2. Pour nitrogen gas in the right and left suspension
No．0800 Adjusting N2 gas of front and rear suspensions
Precautions Necessary tools Necessary equipment
repeating those steps 3 - 4 times.)
N2 gas pouring valve
Before adjusting suspension gas,
remove the cover. After adjusting install it.
Installing position of suspension gas
pouring tool
Air bleeding valve
Air bleeding valve
Before adjusting suspension gas,
remove the cover. After adjusting install it.
N2 gas pouring valve
Installing position of suspension gas
pouring tool
Rear suspension cylinder
←Chassis side
Axle side →
A70
Front suspension cylinder
A
←Chassis side
Axle side →
80
When cylinder is retracted fully: MIN (40±1)
Specified quantity of filled oil: OIL 101±3
When empty: EMPTY (176±10)
When cylinder is extracted fully: MAX (217±1）
Dimension A (Front side)
When cylinder is retracted fully: MIN (36±1)
Specified quantity of filled oil: OIL 76±3
When empty: EMPTY (106±5)
When cylinder is extracted fully: MAX (126±1）
Dimension A (Rear side)
13

1. Connect the hoist cylinder
1) Adjust the height by crane, and assemble the hoist cylinder and body.
2) Tighten the pin fixing bolt with the torque described.
3) After assembly, remove the nylon sling.
4) Remove the plate between cylinder and hose, and reassemble the hose at (6).
Q'ty Name Q'ty
Impact wrench 1
Spanner （19mm）1
Socket （17mm）1
Other remarks
Name
Assembly procedure No.
Necessary equipmentNecessary tools
No．0900 Connecting of hoist cylinder
Precautions
Ｚ
Facing directly above
⑥Reassemble
Tightening torque(3)：
157 - 196 Nm
{16.0- 20.0 kgm}
Body heating specifications
Connect hose and cover with
care not to interfere each
other
View Z
①Section D-D ③② ④
⑤
Work on right and left
sides similarly
Clearance always
is there
L.H.
R.H.
⑥Reassemble
○mark : Remove plates and plugs
at 4 places marked with ○, and
connect them.
* Check that no paint remains on mounting
seat surface of WASHER of pin fixing
SHEET and inner surface of the screw. If
paint still remains, remove the paint
surface completely by using paint thinner
or etc.
No. Part No. Part Name Q'ty State of part (Parts list No.)
(1) 56B-74-31530 Pin 2 Separately Packed （M43-03-050）
(2)
569-40-61710 Washer 2 Separately Packed （M43-03-050）
(3)
01010-81425 Bolt 2 Separately Packed （M43-03-050）
(4) 56B-74-31570 Spacer 4 Separately Packed （M43-03-050）
(5) 01024-81016 Bolt, sems 4 Separately Packed （M43-03-050）
(6) 07375-21035 Bolt, sems 8 Separately Packed （M43-03-050）
14

1. Stick the decals to the body. (Right and left)
Q'ty Name Q'ty
Other remarks
After bonding ｆit each decal perfectly and leave
no bubbles. Name
Assembly procedure No.
Necessary equipmentNecessary tools
No．1000 Sticking of decal
Precautions
①
②
④
③
Ｚ
③
④
53
29
63
MARK (L.H & R.H.)
MARK: MODEL (R.H.)
MARK: MODEL (L.H.) MARK (LOGO)
50035
View Z （Location to stick)
No. Part No. Part Name Q'ty State of part (Parts list No.)
(1) 56B-93-31310 Mark L.H. 1 Separately Packed （M43-03-100）
(2) 56B-93-31320 Mark R.H. 1 Separately Packed （M43-03-100）
(3) 56B-93-31330 Mark 2 Separately Packed （M43-03-100）
(4) 09690-P1800 Mark 2 Separately Packed （M43-03-100）
15

A B C
D
E
F
GROUND POINT
GROUND POINT
Referring to the following figures, adjust the mirrors. Watch each mirror from the operator's seat.
HM400-3 Mirror adjustment
ADJUST MIRRORS ACCORDING TO THE RIGHT TABLE TO SEE THE ARBITRARY 200MM AREA WITHIN 1500MM (*MARKED) FROM GROUND AND TO SEE A PART OF THE MACHINE.
REAR MONITOR SEE THE AREA F.
SEE THE AREA E , THE GROUND CONTACT POINTS OF TIRE H , AND GROUND POINT K .
SEE FORWARD OF MACHINE.
SEE THE AREA D.
SEE THE AREA B. SEE THE AREA A.
SEE THE AREA C , THE GROUND CONTACT POINTS OF TIRE G , AND GROUND POINT J .
GROUND CONTACT POINT OF TIRE
GROUND CONTACT POINT OF TIRE
RANGE OF VIEW
MIRROR NUMBER
J K
Assembly procedure No.
Attached sheet
Mirror adjustment procedure

1. Mirror adjustment
Referring to the following figures, adjust the mirrors.
Watch each mirror from the operator's seat.
Adjust each mirror so that it will reflect a part of the machine as showh below.
Q'ty Name Q'ty
Assembly procedure No.
Necessary equipmentNecessary tools
Mirror adjustment procedure (WIDE)
Precautions
Attached sheet
Others
Name
①
BC
②
④
A