Komatsu HM400-1L Articulated Dump Truck Operation & Maintenance Manual
259 pages · Publication CEAM015103
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- Models
- HM400-1L
- Serial coverage
- HM400-1L A10001 and up
- Manual type
- Operation & Maintenance Manual
- Pages
- 259
- Publication
- CEAM015103
- Condition
- Brand new
What's inside
From the manual's own table of contents: 367 sections, 368 entries. See sample pages (PDF, 373 KB)
FOREWORD
SAFETY INFORMATION
INTRODUCTION
INTENDED USE
BREAKING IN A NEW MACHINE
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
ENGINE SERIAL NO. PLATE POSITION
SERVICE METER POSITION1 topic
- TABLE TO ENTER SERIAL NUMBERS AND DISTRIBUTOR
SAFETY LABELS
POSITION FOR ATTACHING SAFETY LABELS
GENERAL PRECAUTIONS
SAFETY RULES
IF PROBLEMS ARE FOUND
CLOTHING AND PERSONAL PROTECTIVE ITEMS
FIRE EXTINGUISHER AND FIRST AID KIT
SAFETY FEATURES
KEEP MACHINE CLEAN
INSIDE OPERATOR'S COMPARTMENT
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT
HANDRAILS AND STEPS
MOUNTING AND DISMOUNTING
CRUSHING OR CUTTING PREVENTION
BURN PREVENTION
Show all 367 sections
HOT COOLANT
HOT OIL
FIRE PREVENTION
FIRE CAUSED BY FUEL OR OIL
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL
FIRE COMING FROM ELECTRIC WIRING
FIRE COMING FROM HYDRAULIC LINE
EXPLOSION CAUSED BY LIGHTING EQUIPMENT
ACTION IF FIRE OCCURS
WINDOW WASHER LIQUID
PRECAUTIONS WHEN USING ROPS
PRECAUTIONS FOR ATTACHMENTS
UNAUTHORIZED MODIFICATION
SAFETY AT WORKSITE
WORKING ON LOOSE GROUND
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES
ENSURE GOOD VISIBILITY
PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS
CHECKING SIGNALMAN'S SIGNALS AND SIGNS
EMERGENCY EXIT FROM OPERATOR'S CAB
ASBESTOS DUST HAZARD PREVENTION
PRECAUTIONS FOR OPERATION
BEFORE STARTING ENGINE
CHECKS BEFORE STARTING ENGINE
PRECAUTIONS WHEN STARTING ENGINE
PRECAUTIONS IN COLD AREAS
OPERATION
CHECKS BEFORE STARTING OPERATION
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE
PRECAUTIONS WHEN TRAVELING
PRECAUTIONS WHEN TRAVELING ON SLOPES
PRECAUTIONS WHEN OPERATING DUMP BODY
PRECAUTIONS WHEN OPERATING
PRECAUTIONS FOR ACCUMULATED SNOW, ICE
PARKING MACHINE
TRANSPORTATION
SHIPPING
LOADING AND UNLOADING
BATTERY
BATTERY HAZARD PREVENTION
STARTING WITH BOOSTER CABLES
TOWING
WHEN TOWING
PRECAUTIONS FOR MAINTENANCE
WARNING TAG
KEEP WORK PLACE CLEAN AND TIDY
APPOINT LEADER WHEN WORKING WITH OTHERS
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING
PROPER TOOLS
HANDLING SUSPENSION CYLINDER, ACCUMULATOR
PERSONNEL
ATTACHMENTS
WORK UNDER THE MACHINE
NOISE
PRECAUTIONS WHEN USING A HAMMER
REPAIR WELDING
REMOVING BATTERY TERMINALS
PRECAUTIONS WITH HIGH-PRESSURE OIL
PRECAUTIONS FOR HIGH-PRESSURE FUEL
HANDLING HIGH-PRESSURE HOSES
WASTE MATERIAL
MAINTENANCE OF AIR CONDITIONER
COMPRESSED AIR
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
HANDLING TIRES
PRECAUTIONS WHEN STORING TIRES
GENERAL VIEW
MACHINE
CONTROLS AND GAUGES
MACHINE MONITOR
EXPLANATION OF COMPONENTS
METERS
CHARACTER DISPLAY PORTION
CAUTION ITEMS
EMERGENCY STOP ITEM
METER DISPLAY PORTION
CENTRAL WARNING LAMP
OTHER FUNCTIONS OF MACHINE MONITOR
SWITCHES
STARTING SWITCH
LAMP SWITCH
TURN SIGNAL LEVER
DIMMER SWITCH
MACHINE MONITOR BULB CHECK SWITCH
EXHAUST BRAKE SWITCH
HAZARD LAMP SWITCH
NIGHT LIGHTING DIMMER SWITCH
POWER MODE SELECTOR SWITCH
EMERGENCY STEERING SWITCH
SHIFT HOLD SWITCH
PARKING BRAKE SWITCH
AISS LOW SWITCH
INTER-AXLE DIFFERENTIAL LOCK SWITCH
LEFT AND RIGHT DIFFERENTIAL LOCK SWITCH
FOG LAMP SWITCH
SIDE LAMP SWITCH
WORKING LAMP (FRONT) SWITCH
WORKING LAMP (REAR) SWITCH
YELLOW ROTATING LAMP SWITCH
POWER WINDOW SWITCH (RIGHT) (LEFT)
MACHINE MONITOR MODE SELECTOR SWITCH 1, 2
CIGARETTE LIGHTER
HORN BUTTON
WIPER, WINDOW WASHER SWITCH
ROOM LAMP SWITCH
DUMP COUNTER RESET SWITCH
DUMP COUNTER DISPLAY
DUMP TIME DISPLAY
CONTROL LEVERS AND PEDALS
BRAKE PEDAL
ACCELERATOR PEDAL
SHIFT LEVER
DUMP LEVER
RETARDER CONTROL LEVER
LEFT AND RIGHT DIFFERENTIAL LOCK PEDAL
SAFETY LOCK KNOB
MECHATRONICS EQUIPMENT CONTROLLER
TRANSMISSION CONTROLLER
ENGINE CONTROLLER
RETARDER CONTROLLER
SAFETY PIN
STOWING SAFETY PIN
ARTICULATE LOCK
DUST INDICATOR
FUSES
FUSE CAPACITY AND CIRCUIT NAME
AM/FM RADIO-CASSETTE STEREO
RADIO OPERATION
RADIO FEATURES
LISTENING TO RADIO
LISTENING TO CASSETTE TAPE
PRECAUTIONS WHEN USING RADIO
AIR CONDITIONER
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL
FAN SWITCH
AIR CONDITIONER SWITCH
MODE SELECTOR SWITCH
FRESH/RECIRC SELECTOR SWITCH
TEMPERATURE CONTROL SWITCH
METHOD OF OPERATION
PRECAUTIONS WHEN USING AIR CONDITIONER
CHECK BEFORE STARTING ENGINE
WALK-AROUND CHECK
CHECK BEFORE STARTING
CHECK COOLANT LEVEL, ADD COOLANT
CHECK DUST INDICATOR
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL
DRAIN WATER, SEDIMENT FROM FUEL TANK
CHECK FUEL LEVEL, ADD FUEL
CHECK WHEEL HUB BOLTS, TIGHTEN
CHECK BRAKING EFFECT
CHECK EMERGENCY STEERING
CHECK BACKUP ALARM
CHECK ELECTRICAL WIRING
CHECK INFLATION PRESSURE OF TIRES
ADJUSTMENT BEFORE OPERATION
ADJUSTING OPERATOR'S SEAT
ADJUST SEAT BELT
ADJUST STEERING WHEEL TILT
OPERATIONS, CHECKS BEFORE STARTING
STARTING ENGINE
NORMAL STARTING
STARTING IN COLD WEATHER
OPERATIONS, CHECKS AFTER STARTING ENGINE
BREAKING-IN THE MACHINE
WARMING-UP OPERATION
CANCELING DUMP BODY HOLD CONDITION
STOPPING ENGINE
CHECKS AFTER STOPPING ENGINE
MOVING THE MACHINE
MOVING MACHINE FORWARD
MOVING MACHINE IN REVERSE
STOPPING THE MACHINE
SHIFTING GEARS
TRAVELING DOWNHILL
BRAKE PERFORMANCE CURVE
STEERING THE MACHINE
OPERATION USING DIFFERENTIAL LOCK
LOADING OPERATIONS
DUMP OPERATIONS
CAB TILT OPERATION
WHEN USING CRANE
WHEN USING TILT CYLINDER
CHECKS AFTER COMPLETION OF WORK
LOCKING
PRECAUTIONS WHEN HANDLING TIRES
PRECAUTIONS FOR LONG DISTANCE TRAVEL
DETERMINING AND MAINTAINING TRAVEL ROAD
DETERMINING TRAVEL ROAD
MAINTAINING TRAVEL ROAD
PRECAUTIONS WHEN TRANSPORTING
STEPS FOR TRANSPORTATION
METHOD OF SECURING MACHINE
METHOD OF LIFTING MACHINE
LOCATION OF LIFTING POSITION MARK
WEIGHT TABLE
LIFTING PROCEDURE
COLD WEATHER OPERATION
PRECAUTIONS FOR LOW TEMPERATURE
FUEL AND LUBRICANTS
COOLANT
INSTALLATION OF RADIATOR CURTAIN
PRECAUTIONS AFTER COMPLETION OF WORK
AFTER COLD WEATHER
LONG-TERM STORAGE
BEFORE STORAGE
DURING STORAGE
AFTER STORAGE
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE
TROUBLESHOOTING
AFTER RUNNING OUT OF FUEL
PROCEDURE FOR BLEEDING AIR
METHOD OF TOWING MACHINE
WHEN ENGINE RUNS
WHEN ENGINE DOES NOT RUN
WHEN PARKING BRAKE HAS BEEN ACTUATED IN EMERGENCY
METHOD OF RELEASING PARKING BRAKE
DOWN
IF BATTERY IS DISCHARGED
REMOVAL AND INSTALLATION OF BATTERY
PRECAUTIONS FOR CHARGING BATTERY WHEN MOUNTED ON MACHINE
STARTING ENGINE WITH BOOSTER CABLE
OTHER TROUBLE
ELECTRICAL SYSTEM
CHASSIS
IF ACCELERATOR PEDAL HAS FAILED
ENGINE
ACTION CODE
GUIDES TO MAINTENANCE
CHECK SERVICE METER
KOMATSU GENUINE REPLACEMENT PARTS
KOMATSU GENUINE OILS
ALWAYS USE CLEAN WASHER FLUID
ALWAYS USE CLEAN OIL AND GREASE
CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS
FUEL STRAINER
WELDING INSTRUCTIONS
DO NOT DROP THINGS INSIDE THE MACHINE
DUSTY WORKSITES
AVOID MIXING OIL
LOCKING INSPECTION COVERS
BLEEDING AIR FROM HYDRAULIC CIRCUIT
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES
CHECKS AFTER INSPECTION AND MAINTENANCE
OUTLINES OF SERVICE
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
FUEL
COOLANT AND WATER FOR DILUTION
GREASE
PERFORMING KOWA (KOMATSU OIL WEAR ANALYSIS)
STORING OIL AND FUEL
FILTERS
OUTLINE OF ELECTRIC SYSTEM
WEAR PARTS LIST
RECOMMENDED FUEL, COOLANT, AND LUBRICANT
USE OF FUEL, COOLANT AND LUBRICANTS
SELECTION ACCORDING TO AMBIENT TEMPERATURE
KOMATSU GENUINE OIL
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
TORQUE LIST
SAFETY CRITICAL PARTS
REGULAR SCHEDULED MAINTENANCE
MAINTENANCE SCHEDULE CHART
ADJUST INJECTOR
A REGULATION AREA
B REGULATION AREA
SERVICE PROCEDURES
INITIAL 250 HOURS SERVICE
WHEN REQUIRED
CHECK, CLEAN OR REPLACE AIR CLEANER
CLEAN INSIDE OF COOLING SYSTEM
CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID
CLEAN AIR CONDITIONER AIR FILTER
CHECK REFRIGERANT LEVEL
CHECK DUMP BODY
CHECK ELECTRIC INTAKE AIR HEATER
CHECK LENGTH OF SUSPENSION CYLINDER
BLEED AIR FROM FRONT BRAKE
BLEED AIR FROM CENTER BRAKE
BLEED AIR FROM REAR BRAKE
CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT
SELECTION AND INSPECTION OF TIRES
EVERY 50 HOURS SERVICE
LUBRICATION
EVERY 250 HOURS SERVICE
LUBRICATE DRIVE SHAFT
CHECK DRIVE SHAFT
CLEAN BRAKE DRAIN TUBE
CHECK LEVEL OF BATTERY ELECTROLYTE
CHECK ALTERNATOR BELT TENSION, ADJUST
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST
CHECK FRAME, A-ARM
CHECK BRAKING CAPACITY OF FOOT BRAKE
CHECK BRAKING CAPACITY OF RETARDER BRAKE
CHECK BRAKING CAPACITY OF PARKING BRAKE
CHECK WEAR OF PARKING BRAKE PADS
EVERY 500 HOURS SERVICE
REPLACE ADDITIONAL FUEL FILTER CARTRIDGE
CLEAN FUEL TANK STRAINER
LUBRICATE CAB MOUNT PIN (LEFT AND RIGHT: 1 PLACE EACH)
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL
CLEAN, CHECK RADIATOR FINS AND AFTERCOOLER FINS
CHECK FAN BELT TENSION, ADJUST
EVERY 1000 HOURS SERVICE
REPLACE FUEL FILTER CARTRIDGE
REPLACE CORROSION RESISTOR CARTRIDGE
REPLACE TRANSMISSION FILTER ELEMENT
CHANGE OIL IN TRANSMISSION CASE
CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT
CHECK WEAR OF BRAKE DISC
CHECK TIGHTENING PARTS OF TURBOCHARGER
EVERY 2000 HOURS SERVICE
CHANGE OIL IN FINAL DRIVE CASE
CHANGE OIL IN DIFFERENTIAL CASE
REPLACE HYDRAULIC FILTER ELEMENT
CLEAN HYDRAULIC TANK STRAINER
CLEAN TRANSMISSION CASE STRAINER
CLEAN STRAINER IN DIFFERENTIAL LOCK HYDRAULIC CIRCUIT
CLEAN BREATHER
CLEAN ENGINE BREATHER ELEMENT
CHECK ALTERNATOR, STARTING MOTOR
CHECK, ADJUST ENGINE VALVE CLEARANCE
CHECK INJECTOR
CLEAN, CHECK TURBOCHARGER
CHECK PLAY OF TURBOCHARGER ROTOR
EVERY 4000 HOURS SERVICE
CHANGE OIL IN HYDRAULIC TANK
CHECK WATER PUMP
CHECK AIR COMPRESSOR
CHECK FAN PULLEY AND TENSION PULLEY
CHECK VIBRATION DAMPER
REPLACE INJECTOR ASSEMBLY
RUBBER
EVERY 6000 HOURS SERVICE
EVERY 8000 HOURS SERVICE
REPLACE INJECTOR NOZZLE TIP
REPLACE HIGH-PRESSURE PIPING CLAMP
REPLACE FUEL SPRAY PREVENTION CAP
SPECIFICATIONS
Inside this manual
Real pages from this operation & maintenance manual (259 pages). Open the sample pages (PDF, 372 KB)
- Controls and operation, page 91: CONTROL LEVERS AND PEDALS
- Specifications, page 154: TRANSPORTATION
- Maintenance, page 199: SERVICE PROCEDURES
This is an operator's manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
This manual
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 259 pages
Quantity one is the manual described above.
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Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).