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

StageIV 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 StageIIIB 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

40tonnes that combines with a load-

ing height of only 3.165mm 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

HM400-5

7

First-Class Comfort

Wide and comfortable cab

The wide Komatsu SpaceCab™

with user-friendly controls provides

a comfortable and safe work en-

vironment. A fully adjustable air-

suspended seat dampens vibrations

and reduces the fatigue of long

shifts. Large front and electric side

windows give a superior visibility

and increased confidence. The rear

window can be electrically heated for

quick defrosting.

Unique hydro-pneumatic
suspension

On both the front and rear axle,

Komatsu’s unique trailing arm hydro-

pneumatic suspension gives the

HM400-5 a smooth ride with re-

duced pitching and excellent driving

comfort. Less shocks for the opera-

tor and for the machine components

also mean less spilled material and

increased durability, comfort and

productivity.

Low-noise design

To reduce noise levels, the cab is

mounted on viscous dampeners.

Further noise reduction is achieved

by the integrated cab floor: it makes

the cab air-tight and seals off the

engine compartment. A low-noise

and sound-insulated muffler helps to

bring sound levels way down, to just

72 dB(A).

Set the steering wheel to the most
comfortable position

8

The full size trainer seat has a foldable
cushion and back rest for easy cab entry
and access to the air conditioner filter and
glove compartment

Convenient auxiliary input (MP3 jack) and
12V power supply

HM400-5

Air-suspended seat

A high comfort air-suspended seat, with lumbar

support and multiple adjustments, ensures operator

well-being during the entire work shift. Both seats

can be heated, for an easy start on cold winter days.

9

Information & Communication Technology

Lower operating costs

Komatsu ICT contributes to the

reduction of operating costs by as-

sisting to comfortably and efficiently

manage operations. It raises the level

of customer satisfaction and the

competitive edge of our products.

Large TFT colour monitor

A large user-friendly colour monitor

enables safe, accurate and smooth

work. Multilingual and with all essen-

tial information available at a glance,

it features simple and easy-to-oper-

ate switches and multifunction keys

that provide fingertip access to a

wide range of functions and opera-

ting information.

Eco guidance

The monitor panel displays instant

guidance messages to help promote

energy saving, and the Eco-gauge in-

dicates the actual fuel consumption:

keep the Eco-gauge in the green

zone for better fuel efficiency. To

further improve savings, logs can be

consulted for operations, Eco guid-

ance and fuel consumption.

10

Information at a glance: basic dashboard
LCD monitor

A multifunction monitor displays and
controls a wealth of operational and
maintenance information

Eco guidance supports energy saving in real
time

HM400-5

Tough and Reliable

Market leading Komatsu design

The HM400-5 is built from Komatsu-manufac-

tured components that successfully demonstrate

their durability, day after day. Tested and proven

by several generations of Komatsu trucks, this

top-selling technology sets the mould for all

Komatsu ADTs. The entire power train of the

HM400-5 is Komatsu-designed and the engine,

transmission and axles are perfectly matched, for

unsurpassed productivity and durability.

11

Safety First

Safer with KTCS

By operating only the accelerator,

Komatsu’s unique Traction Control

System (KTCS) allows full-time all-

wheel drive, along with safe and easy

turning on soft ground and slippery

roads. Thanks to this superior steer-

ing, no extra skill is required to drive

an HM400-5.

Wet multiple-disc brakes
and retarder

Wet multiple-disc brakes are tai-

lored for the HM400-5, with proven

performance in larger articulated

and rigid trucks. The large-capacity,

continuously cooled, wet-multiple

disc brakes also function as a

highly responsive retarder for greater

confidence when travelling downhill

at higher speeds. (Retarder absorb-

ing capacity, continuous descent:

510kW 684HP)

Excellent all-round visibility

To keep the working area under con-

trol, a laminated-glass windshield,

wide side windows, a standard rear-

view camera and monitor, 3addition-

al under-view mirrors and 4 rear-view

mirrors combine to minimise blind

spots.

Rear frame inclination sensor

To help avoid personal and machine

damage, the system will issue a

warning if ever there should be a risk

of body tip over.

Supplementary steering and
secondary brakes

Standard features on the HM400-5

include supplementary steering and

secondary brakes. They help to guar-

antee safety in emergency situations.

Built-in ROPS/FOPS to ISO 3471 and SAE
J1040-1988c standards

Safe cab access with handrail, away from
the potentially hazardous articulation

12

Rear-view camera system

Secondary engine shutdown switch

HM400-5

13

710 mm

Easy Maintenance

Basic maintenance screen

Ground level access

Transmission oil filters and brake

systems can be serviced from

ground level.

Ground clearance

With 710 mm free space, the hinge

connection on the HM400-5 stays

out of the mud and its robust mainte-

nance-free build gives it a longer life.

AdBlue® tank

For simple access, the AdBlue® tank

is installed next to the fuel tank.

Lowest brake maintenance
cost

No matter how abrasive the applica-

tion, no need to worry about an early

replacement of the brake disc packs.

Brakes on the HM400-5 are embed-

ded in an oil bath and sealed off from

the environment. Their exceptionally

long overhaul period minimises main-

tenance costs.

Tilting cab

The cab can be electrically tilted

rearward 27 degrees to provide easy

maintenance and service to the en-

gine and transmission.

Radiator fan mode

AdBlue® level and refill guidance

14

Reversible radiator fan

By a touch on the monitor panel, the

radiator can be cleaned easily with a

reversible, hydraulically driven cool-

ing fan. A clean radiator reduces fuel

consumption and increases overall

machine performance.

HM400-5

KOMTRAX™

The way to higher
productivity

KOMTRAX™ uses the latest wireless

monitoring technology. Compat-

ible on PC, smartphone or tablet, it

delivers insightful and cost saving

information about your fleet and

equipment, and offers a wealth of in-

formation to facilitate peak machine

performance. By creating a tightly

integrated web of support it allows

proactive and preventive mainte-

nance and helps to efficiently run a

business.

Knowledge

You get quick answers to basic and

critical questions about your ma-

chines – what they’re doing, when

they did it, where they’re

located, how they can be

used more efficiently, and

when they need to be serviced.

Performance data is relayed by

wireless communication technology

(Satellite, GPRS or 3G depending

on model) from the machine to a

computer and to the local Komatsu

distributor – who’s readily available

for expert analysis and feedback.

Power

The detailed information that

KOMTRAX™ puts at your fingertips

24 hours a day, 7 days a week gives

the power to make better daily and

long-term strategic decisions – at no

extra cost. Problems can be antici-

pated, maintenance schedules cus-

tomised, downtime minimised and

machines kept where they belong:

working on the jobsite.

Convenience

KOMTRAX™ enables convenient

fleet management on the web, wher-

ever you are. Data is analysed and

packaged specifically for effortless

and intuitive viewing in maps, lists,

graphs and charts. You can foresee

eventual maintenance issues and re-

quired spare parts, and troubleshoot

a problem before Komatsu techni-

cians arrive on site.

15

Specifications

ENGINE

Model Komatsu SAA6D140E-7

Type Common rail direct injection,

Engine power

at rated engine speed 2.000 rpm

ISO 14396 353 kW/473 HP

ISO 9249 (net engine power) 348 kW/466 HP

No. of cylinders 6

Bore × stroke 140 × 165 mm

Displacement 15,24 l

Max. torque 2.257 Nm (230 kgf-m)

Governor Electronically controlled

Lubricating system Gear pump, force lubrication

Filter Full-flow filter

Air-filter type Dry type with double elements

water-cooled, emissionised,

turbocharged, after-cooled diesel

and precleaner (cyclonpack

type), plus dust indicator

TRANSMISSION

Torque converter 3-elements, 1-stage, 2-phase

Transmission Full-automatic, counter-shaft type

Speed range 6 speeds forward and 2 reverse

Lock-up clutch Wet, single-disc clutch

Forward Torque converter drive in 1st gear,

Reverse Torque converter drive

Shift control Electronic shift control with automatic

Max. travel speed 56 km/h

direct drive in 1st lock-up

and all higher gears

and direct drive in all gears

clutch modulation in all gears

STEERING SYSTEM

Type Articulated type, fully hydraulic

Supplementary steering Automatically actuated,

Minimum turning radius, wall
to wall

Articulation angle 45° each direction

power steering with two

double-acting cylinders

electrically powered

8,89 m

AXLES

Full time all wheel drive with Komatsu Traction Control System.

Final drive type Planetary gear

Ratios:

Differential 3,727

Planetary 4,941

BRAKES

Service brakes Independent front and center wheel

brakes, full-hydraulic control,
oil-cooled, multiple-disc type

Parking brake Spring applied, calliper disc type

Retarder Front and centre axle

brakes act as retarder

MAIN FRAME

Type Articulated type, box-sectioned

construction on front and rear.

Connected by strong torque tubes.

SERVICE REFILL CAPACITIES

Fuel tank 518 l

Engine oil 50 l

Torque converter, transmission and retarder cooling 125 l

Differentials (total) 108 l

Final drives (total) 32 l

Hydraulic system 167 l

Suspension (total) 21,4 l

AdBlue® tank 32,8 l

HYDRAULIC SYSTEM

Hoist cylinder Twin, 1-stage type

Relief pressure 28,4 MPa (290 kg/cm²)

Hoist time 12 s

16

SUSPENSION

Front Hydro-pneumatic suspension

Rear Combined hydro-pneumaticand

rubber suspension system

TYRES

Standard tyres 29.5 R25

CAB

Complies ISO 3471 ROPS (Roll-Over Protective Structure)
ISO 3449 FOPS (Falling Object Protection Structure) standards.

ENVIRONMENT

Engine emissions Fully complies with EU Stage IV

exhaust emission regulations

Noise levels

LwA external 110 dB(A) (2000/14/EC Stage II)

LpA operator ear 72 dB(A) (ISO 6396 dynamic test)

Vibration levels (EN 12096:1997)*

Hand/arm ≤ 2,5 m/s² (uncertainty K = 1,31 m/s²)

Body ≤ 0,5 m/s² (uncertainty K = 0,42 m/s²)

* For the purpose of risk assessment under directive 2002/44/EC,
please refer to ISO/TR 25398:2006.

HM400-5

Dimensions & Performance Figures

WEIGHT (APPROX.)

Empty weight 35.055 kg

Gross vehicle weight 75.135 kg

Weight distribution

Empty:

Front axle 56,9%

Centre axle 23,1%

Rear axle 19,5%

Loaded:

Front axle 30,4%

Centre axle 35,8%

Rear axle 33,8%

BODY

Capacity:

Struck 18,2 m³

Heaped (2:1, SAE) 24,0 m³

Payload 40 tons

Material 130 kg/mm²

Material thickness:

Bottom 16 mm

Front 8 mm

Sides 12 mm

Target area
(inside length × width)

Heating Exhaust heating

High tensile strength steel

5.667 mm × 3.194 mm

17

Dimensions & Performance Figures

45

°

R4170

3194

3450

1675

3845

2690

3450

All measurements with tyres 29.5 R25

3735

°

25

2985

R8885

1350

710

11105

5667

°

70

7171

3164

620

19704350

1800

770

18

706050403020100

km/h

kg

0102030405060708090 100

01

km/h

TRAVEL PERFORMANCE

TRAVEL PERFORMANCE

HM400-5

BRAKE PERFORMANCE

BRAKE PERFORMANCE

x103 kg

50

40

F1

30

20

10

9
8
7

6

5

4

RIMPULL

3

2

1

0

GRADE DISTANCE: CONTINUOUS DESCENT

30 40 50 5535 45 60 70 80 90 100

GROSS WEIGHT

EMPTY

F2

F3

F4

F5

F6

LOADED

35.040.0

30.0

25.0

20.0

15.0

14.0

13.0

12.0

11.0

10.0

9.0

8.0

7.0

6.0

5.0

4.0

3.0

2.0

3

x10

TOTAL RESISTANCE

(GRADE + ROLLING) (%)

02030405060708090 100

F1

F2

EMPTY

F3

TRAVEL SPEED

GROSS WEIGHT

F4

F5

TRAVEL SPEED

LOADED

F6

x103 kg

-45-50

-40

-35

-30

-25

-20

-15

TOTAL RESISTANCE

(GRADE + ROLLING) (%)

-10

-5

19

Standard and Optional Equipment

ENGINE

Komatsu SAA6D140E-7 turbocharged common rail
direct injection diesel engine

EU Stage IV compliant

Remote hydraulically driven, variable speed,
reversible cooling fan

Auto-deceleration function

Adjustable idle shutdown

Alternator 160 A/24 V

Starter motor 11 kW/24 V

Batteries 2 × 12 V/136 Ah

SERVICE AND MAINTENANCE

Electrically tilting cab

Centralised greasing

Large TFT colour monitor panel

KOMTRAX™ – Komatsu wireless monitoring
system

Komatsu CARE™ – complimentary maintenance
program for customers

Electric refuelling pump with automatic shut-off
function

Vandalism protection

Gas charge tool for suspension cylinders

OTHER EQUIPMENT

Mud guards

Engine underguard

Propeller shaft guards, front and rear

Transmission underguard

Komatsu Diesel Particulate Filter (KDPF) thermal
guard

Fire prevention covers

Automatic retarder with acceleration control (ARAC)

Tool box storage compartment

Payload meter (PLM)

CABIN

ROPS/FOPS cab, sound suppression type



Operator seat, reclining, air suspension type with



50 mm width 3-point seat belt

Trainer seat with 2-point seat belt



Steering wheel, tilt and telescopic



Air conditioner



Heated rear window (electric)



Power window (l.h.)



Sun visor, front window



Body dump counter

Cigarette lighter, ashtray, cup holder, space for
lunch box

Pre radio installation kit

Power mode, economy mode



Odometer



Eco guidance



2× 12 Volt power supply





LIGHTING SYSTEM



Back-up light



Turn indicator lights front/rear with hazard function



Headlights high and low beam with dimmer switch

Side lamps back cabin

Fog lights

LED stop and tail lights, turn indicator lights

Back work lights, left and right side









BODY



Electronic hoist control system



Body exhaust heating kit



Body liner

Tail gate, wire type, overall width 2.998 mm





Body side extension, 200 mm

SAFETY EQUIPMENT

Back-up alarm



Anti-slip material on fenders



Automatic supplementary steering



Coolant temperature alarm and light



Battery main switch



Hand rails for platform



Horn, electric



Ladders, left and right hand side



Protective grille for rear window



Protective fence around engine hood

Rear-view mirrors (heated)



Under-view mirrors



Steering joint locking assembly



Side marker



Rear-view camera system



Side inclination caution alarm



Emergency engine stop switch

Fire extinguisher



AXLES AND TYRES



Komatsu Traction Control System



Differential lock switch



Tyres 29.5 R25



Tyres 30/65 R25 (750/65 R25)





Further equipment on request

 standard equipment

 optional equipment

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Your Komatsu partner:

EENSS20130 05/2015

Printed in Europe – This specification sheet may contain attachments and optional equipment that are not available in your area.

Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice.

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International N.V.

Mechelsesteenweg 586
B-1800 VILVOORDE (BELGIUM)
Tel. [phone]
Fax [phone]

www.komatsu.eu

is a trademark of Komatsu Ltd. Japan.

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