Komatsu HM400-5D Dump Truck Operation and Maintenance Manual (PEN01001-05)

Komatsu HM400-5D Dump Truck Operation and Maintenance Manual (PEN01001-05)

Format: PDF (Printable Document)

File Language: English

File Pages: 528

File Size: 26.29 MB (Speed Download Link)

Brand: Komatsu

Model: HM400-5D Dump Truck

Book No: PEN01001-05

Type of Document: Operation and Maintenance Manual

Categories: Komatsu PDF, PDF

$ 40

Komatsu HM400-5D Dump Truck Operation and Maintenance Manual (PEN01001-05)

This HM400-5D dump truck manual is what I lean on to keep a production truck working day in, day out on quarries, mines, and heavy earthmoving sites. It walks you through how to run the truck correctly and set up a solid maintenance rhythm so you’re not learning the hard way on the job. If, for example, a driver reports the truck feels “sluggish” on a haul or the body isn’t dumping cleanly, this is the book I’d use to verify basic operating checks, confirm daily inspections, and plan the next service steps before it turns into real downtime.

Applications & Use Cases

Set up daily/weekly checks so operators can spot leaks, loose components, or tire issues early.
Plan preventive maintenance around your actual workload to avoid surprise stoppages.
Trace performance complaints (poor pulling, rough shifting, odd noises) back to basic operating or maintenance issues.
Train new operators on correct warm-up, shutdown, and working techniques to reduce wear.
Verify service work after it’s done, making sure everything’s adjusted and inspected properly before going back to production.

FAQ

Q: Can I keep a digital copy on a tablet in the service truck?

A: Yes, that’s ideal; it lets you zoom diagrams, search terms, and keep the book clean and handy onsite.

Q: Is it worth printing certain pages?

A: I’d print the inspection checklists and routine service procedures to hang in the shop and keep in the cab.

Safety Note

Always follow the manual’s safety directions before inspecting, servicing, or operating the truck.

📘 Show Index

Komatsu HM400-5D Dump Truck Index:

COVER
FOREWORD
- CONTENTS
- READ THIS MANUAL
- SAFETY INFORMATION
- INTRODUCTION
  - MAIN USE OF MACHINE
  - DIRECTIONS OF MACHINE
  - VISIBILITY FROM OPERATOR’S SEAT
- ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION
- PRODUCT INFORMATION
  - LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
  - LOCATION OF ENGINE NUMBER PLATE
  - SERVICE METER LOCATION
  - YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
- ABBREVIATION LIST
SAFETY
- SAFETY LABELS
  - LOCATION OF SAFETY LABELS
  - CONTENTS OF SAFETY LABELS
- GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
  - PRECAUTIONS BEFORE STARTING OPERATION
  - PREPARATIONS FOR SAFE OPERATION
  - PRECAUTIONS TO PREVENT FIRE
  - PRECAUTIONS WHEN GETTING ON OR OFF MACHINE
  - DO NOT GET CAUGHT IN WORK EQUIPMENT
  - PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES
  - UNAUTHORIZED MODIFICATION
  - PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS
  - PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING
- PRECAUTIONS FOR OPERATION
  - PRECAUTIONS FOR JOBSITE
  - START ENGINE
  - PRECAUTIONS FOR OPERATION
  - TRANSPORTATION
  - TOWING AND BEING TOWED
- PRECAUTIONS FOR MAINTENANCE
  - PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE
  - PRECAUTIONS FOR CHECK AND MAINTENANCE
  - TIRES
- PRECAUTIONS FOR DEF
  - GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING
  - PRECAUTIONS FOR ADDING
  - PRECAUTIONS FOR STORING
  - PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE
  - OTHER PRECAUTIONS
OPERATION
- GENERAL VIEW
  - MACHINE EQUIPMENT NAME
  - CONTROLS AND GAUGES NAMES
  - OTHER EQUIPMENT NAME
- EXPLANATION OF COMPONENTS
  - EXPLANATION OF MACHINE MONITOR EQUIPMENT
  - SWITCHES
  - CONTROL LEVERS AND PEDALS
  - OTHER EQUIPMENT
- MACHINE OPERATIONS AND CONTROLS
  - CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE
  - METHOD FOR STARTING ENGINE
  - METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE
  - METHOD FOR STOPPING ENGINE
  - METHOD FOR CHECKING AFTER STOPPING ENGINE
  - START MACHINE (TRAVEL FORWARD AND REVERSE) AND STOP MACHINE
  - METHOD FOR SHIFTING GEARS
  - METHOD FOR TRAVELING DOWNHILL
  - METHOD FOR TURNING MACHINE
  - OPERATE WITH INTER-AXLE DIFFERENTIAL LOCK
  - HANDLE AUTOMATIC RETARDER, ACCELERATOR CONTROL (ARAC)
  - OPERATION OF ARAC SYSTEM
  - HANDLE KOMATSU TRACTION CONTROL SYSTEM (KTCS)
  - OPERATION OF KTCS SYSTEM
  - OPERATION IF TROUBLES ON SYSTEM OCCUR
  - OPERATION IF TIRES ARE STUCK IN GROUND
  - METHOD FOR LOADING
  - METHOD FOR DUMPING
  - METHOD FOR OPERATING CAB TILT
  - PRECAUTIONS FOR OPERATION
  - METHOD FOR PARKING MACHINE
  - METHOD FOR CHECKING AFTER FINISHING WORK
  - LOCK
  - HANDLE TIRE
- HANDLE AIR CONDITIONER
  - EXPLANATION OF AIR CONDITIONER EQUIPMENT
  - METHOD FOR OPERATING AIR CONDITIONER
- HANDLE RADIO
  - EXPLANATION OF RADIO EQUIPMENT
  - METHOD FOR CONTROLLING RADIO
- DUMP BODY HEATING SPECIFICATIONS
- DETERMINE AND MAINTAIN TRAVEL ROAD
- TRANSPORTATION
  - PRECAUTIONS FOR TRANSPORTATION
  - PRECAUTIONS FOR TRANSPORTING MACHINE
  - SELECT TRANSPORTATION METHOD
  - METHOD FOR SECURING MACHINE
  - PRECAUTIONS FOR LIFTING MACHINE
- COLD WEATHER OPERATION
  - COLD WEATHER OPERATION INFORMATION
  - PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER
  - AFTER COLD WEATHER SEASON
- PRECAUTIONS FOR LONG-TERM STORAGE
  - PREPARATION FOR LONG-TERM STORAGE
  - MAINTENANCE DURING LONG-TERM STORAGE
  - STARTING MACHINE AFTER LONG-TERM STORAGE
  - PREPARATION BEFORE TRAVELING AFTER LONG-TERM STORAGE
- TROUBLES AND ACTIONS
  - ACTIONS WHEN RUNNING OUT OF FUEL
  - ACTIONS IF TRANSMISSION HAS TROUBLE
  - METHOD FOR LOWERING DUMP BODY IN EMERGENCY
  - PRECAUTIONS FOR TOWING MACHINE
  - PRECAUTIONS FOR DISCHARGED BATTERY
  - OTHER TROUBLE
MAINTENANCE
- PRECAUTIONS FOR MAINTENANCE
  - CHECK SERVICE METER READING
  - KOMATSU GENUINE REPLACEMENT PARTS
  - KOMATSU GENUINE LUBRICANTS
  - ALWAYS USE CLEAN WASHER FLUID
  - FRESH AND CLEAN LUBRICANTS
  - CHECK DRAINED OIL AND USED FILTER
  - PRECAUTIONS FOR REFILLING OIL OR FUEL
  - PRECAUTIONS FOR ADDING DEF
  - PRECAUTIONS FOR WELDING
  - DO NOT DROP THINGS INSIDE MACHINE
  - PRECAUTIONS FOR KDPF
  - PRECAUTIONS FOR SCR ASSEMBLY
  - DUSTY JOBSITES
  - AVOID MIXING OIL
  - LOCK INSPECTION COVERS
  - BLEED AIR FROM HYDRAULIC CIRCUIT
  - PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES
  - CHECKS AFTER INSPECTION AND MAINTENANCE
  - FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE
- OUTLINE OF MAINTENANCE
  - HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
  - HANDLE ELECTRICAL COMPONENTS
- STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS
- MAINTENANCE SCHEDULE
  - MAINTENANCE SCHEDULE TABLE
- MAINTENANCE PROCEDURE
  - INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)
  - WHEN REQUIRED
  - CHECKS BEFORE STARTING
  - EVERY 50 HOURS MAINTENANCE
  - EVERY 250 HOURS MAINTENANCE
  - EVERY 500 HOURS MAINTENANCE
  - EVERY 1000 HOURS MAINTENANCE
  - EVERY 2000 HOURS MAINTENANCE
  - EVERY 4000 HOURS MAINTENANCE
  - EVERY 4500 HOURS MAINTENANCE
  - EVERY 6000 HOURS MAINTENANCE
  - EVERY 8000 HOURS MAINTENANCE
  - EVERY 9000 HOURS MAINTENANCE
SPECIFICATIONS
- SPECIFICATIONS
ATTACHMENTS AND OPTIONS
- HANDLE AUXILIARY ENGINE STARTING CONNECTOR
  - START ENGINE WITH AUXILIARY ENGINE STARTING CONNECTOR
- HANDLE CAB POWER TILT
- HANDLING PAYLOAD METER
  - OUTLINE OF SYSTEM
  - NORMAL OPERATION DISPLAY
  - EXTERNAL DISPLAY LAMP
  - DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER
  - METHOD FOR DOWNLOADING DATA FROM CONNECTOR FOR DOWNLOAD
  - DISPLAY TOTAL PAYLOAD AND NUMBER OF CYCLES
  - DISPLAY FUEL CONSUMPTION RECORD
  - SETTING MACHINE ID AND OPEN ID
  - METHOD FOR PERFORMING CALIBRATION
- HANDLE AUTO-GREASING SYSTEM
  - METHOD FOR OPERATING AUTO-GREASING SYSTEM
  - METHOD FOR BLEEDING AIR FROM GREASING CIRCUIT
  - METHOD FOR FILLING GREASE
  - GREASING POINTS FOR AUTO-GREASING SYSTEM
- SERVICE CENTER
REPLACEMENT PARTS
- PERIODIC REPLACEMENT OF DEFINED LIFE PARTS
  - DEFINED LIFE PARTS LIST
- CONSUMABLE PARTS
  - CONSUMABLE PARTS LIST
- RECOMMENDED FUEL, COOLANT, AND LUBRICANT
  - LUBRICATION CHART
  - METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
  - RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS
INDEX