Komatsu HM400-5 Service Manual
ARTICULATED DUMP TRUCK
HM400-5
EU Stage IV Engine
ENGINE POWER
353 kW / 473 HP @ 2.000 rpm
BODY CAPACITY, HEAPED
24 m³
MAX. PAYLOAD
40 ton
Walk-Around
ENGINE POWER
353 kW / 473 HP @ 2.000 rpm
2
BODY CAPACITY, HEAPED
24 m³
MAX. PAYLOAD
40 ton
PRODUCTIVITY ON DEMAND
HM400-5
Powerful and Environmentally Friendly
• EU Stage IV engine
• Komatsu fuel-saving technology
• Eco guidance & Eco-gauge
First-Class Comfort
• Fully air-suspended operator seat
• Low-noise design
• Hydro-pneumatic suspension
Maximised Efficiency
• Komatsu Traction Control System (KTCS)
• Selectable working modes
• Adjustable idle shutdown
• Integrated payload meter (optional)
Safety First
• Komatsu SpaceCab™ – Built-in ROPS/FOPS
• Rear-view camera system
• Safe cab access
Easy Maintenance
• Ground level access to filters
• Reversible radiator fan
• Power cab tilt
KOMTRAX™
• Komatsu Wireless Monitoring System
• 3G mobile communications
• Integrated communication antenna
• Increased operational data and fuel savings
Complimentary maintenance
program for customers
3
Powerful and Environmentally Friendly
Productivity on demand
With a powerful Komatsu EU
StageIV engine, the advanced
Komatsu Traction Control System,
selectable working modes for on-
demand performance adjustments,
a robust exterior, and state-of-the-
art solutions for its suspension and
retarder, the HM400-5 is a perfect
choice for any jobsite, in any condi-
tions.
4
Komatsu fuel-saving
technology
The variable displacement piston
pump reduces Power Take-Off (PTO)
loss. Improvements in transmission
and axles increase energy savings,
and the sophisticated electronic con-
trol of the engine operation helps to
achieve optimal energy efficiency.
Adjustable idle shutdown
To reduce unnecessary fuel con-
sumption and exhaust emissions,
and for lower operating costs, the
Komatsu auto idle shutdown auto-
matically turns off the engine after it
idles for a set period of time, which
can be easily programmed from 5 to
60 minutes. An Eco-gauge and Eco
guidance tips on the cab monitor fur-
ther encourage efficient operations.
SCR
AdBlue® mixing tube
Exhaust Gas Recirculation (EGR)
Cooled EGR is a technology well-proven
in current Komatsu engines. The increased
capacity of the EGR cooler now ensures
very low NOx emissions and a better engine
performance.
KVGT
KDPF
AdBlue® injector
Komatsu Closed Crankcase Ventilation
(KCCV)
Crankcase emissions (blow-by gas) are
passed through a CCV filter. The oil mist
trapped in the filter is returned back to the
crankcase while the filtered gas is returned
to the air intake.
HM400-5
Komatsu EU Stage IV
The Komatsu EU Stage IV engine is
productive, dependable and efficient.
With ultra-low emissions, it provides
a lower environmental impact and a
superior performance to help reduce
operating costs and lets the operator
work in complete peace of mind.
Heavy-duty aftertreatment
The aftertreatment system com-
bines a Komatsu Diesel Particulate
Filter (KDPF) and Selective Catalytic
Reduction (SCR). The SCR injects
the correct amount of AdBlue® into
the system at the proper rate to
break down NOx into water (H2O)
and non-toxic nitrogen gas (N2). NOx
emissions are reduced by 80% vs.
EU StageIIIB engines.
AdBlue® mixing tube
High-Pressure Common Rail (HPCR)
To achieve complete fuel burn and lower
exhaust emissions, the heavy-duty HighPressure Common Rail fuel injection
system is computer controlled to deliver a
precise quantity of pressurised fuel into the
redesigned engine combustion chamber by
multiple injections.
Adjustable idle shutdown
Clean exhaust
Komatsu Variable Geometry Turbo
(KVGT)
The KVGT provides optimal airflow to the
engine combustion chamber under all speed
and load conditions. Exhaust gas is cleaner,
fuel economy is improved while machine
power and performance are maintained.
Ammonia oxidation catalyst
Selective reduction catalyst
for NOx
Fuel consumption historyEco-gauge and Eco guidance
5
Maximised Efficiency
Komatsu Traction Control
System (KTCS)
For its world renowned rigid dump
trucks, Komatsu developed vari-
ous wheel slip control systems that
were refined and combined with new
technologies to produce the ad-
vanced traction control system that
equips all HM400-5 machines. KTCS
automatically provides optimum
traction in any ground condition. If
tyre slippage is detected by one of
the speed sensors located on four of
the wheels, it triggers the automatic
application of the inter-axle differ-
ential lock. If slippage persists, the
intelligent brakes systems automati-
cally control the slipping wheel and
regain traction on the opposite side.
This improves productivity and tyre
durability.
K-ATOMiCS transmission
Komatsu’s exclusive electroni-
cally controlled transmission, or
K-ATOMiCS, is tuned perfectly for
the HM400-5. The “total control
system” manages both the engine
and transmission by monitoring the
vehicle’s condition. This Komatsu-
designed technology guarantees
smooth shifting and maximises
transmission life.
Large capacity body
The HM400-5 has a payload of
40tonnes that combines with a load-
ing height of only 3.165mm to en-
able easy loading. The truck features
a low centre of gravity and a high
ground clearance.
Selectable working modes
“Power mode” is for high production
jobs and uphill hauling. It increases
the engine’s maximum output and
raises the upshift and downshift
engine speeds during operation.
For lighter work on flat ground, the
“Economy mode” will lower the
engine’s maximum output and the
upshift and downshift speeds.
Payload meter (optional)
The loaded weight is displayed on
the cab monitor, and its status is also
communicated to the loader operator
with an external light, located on top
of the cab. PLM data is stored in the
truck’s controller: it can be directly
downloaded to a PC and is included
in the KOMTRAX™ data you can ac-
cess via the internet.
Komatsu Traction Control System (KTCS):
maximum machine performance on soft and
slippery ground
6
Payload meter displays the loaded weight
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