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Komatsu HM400-5 Articulated Dump Truck Service Manual

3,198 pages · Publication SEN06519-05

$319.63
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Models
HM400-5
Serial coverage
10001 and up
Manual type
Service Manual
Pages
3,198
Publication
SEN06519-05
Condition
Brand new
Komatsu HM400-5 Articulated Dump Truck Service Manual, publication SEN06519-05

What's inside

From the manual's own table of contents: 376 sections, 700 entries. See sample pages (PDF, 934 KB)

INDEX AND FOREWORD
ABBREVIATION LIST
FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
SAFETY NOTICE FOR OPERATION
PRECAUTIONS TO PREVENT FIRE
ACTIONS IF FIRE OCCURS
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS
PRECAUTIONS FOR DEF
STORE AdBlue/DEF
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT
PRACTICAL USE OF KOMTRAX
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH
HOW TO READ ELECTRICAL WIRE CODE
Show all 376 sections
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
STANDARD TIGHTENING TORQUE TABLE
CONVERSION TABLE
SPECIFICATIONS
SPECIFICATION DRAWING
WEIGHT TABLE
TABLE OF FUEL, COOLANT, AND LUBRICANTS
STRUCTURE AND FUNCTION
UREA SCR SYSTEM
LAYOUT DRAWING OF UREA SCR SYSTEM
UREA SCR SYSTEM DIAGRAM
FUNCTION OF UREA SCR SYSTEM
COMPONENT PARTS OF UREA SCR SYSTEM
SYSTEM
LAYOUT DRAWING OF BOOT-UP SYSTEM
SYSTEM OPERATING LAMP SYSTEM
BATTERY DISCONNECT SWITCH
ENGINE SYSTEM
LAYOUT DRAWING OF ENGINE SYSTEM
AUTOMATIC IDLE STOP SYSTEM
COMPONENT PARTS OF ENGINE SYSTEM
COOLING SYSTEM
LAYOUT DRAWING OF COOLING SYSTEM
RADIATOR FAN CONTROL SYSTEM2 topics
  • AFTERCOOLER FAN CONTROL SYSTEM
  • COMPONENT PARTS OF COOLING SYSTEM
CONTROL SYSTEM7 topics
  • LAYOUT DRAWING OF CONTROL SYSTEM
  • RETARDER AND HOIST CONTROL SYSTEM
  • MACHINE MONITOR SYSTEM
  • REARVIEW MONITOR SYSTEM
  • KOMTRAX SYSTEM
  • PAYLOAD METER SYSTEM
  • COMPONENT PARTS OF CONTROL SYSTEM
HYDRAULIC SYSTEM2 topics
  • LAYOUT DRAWING OF HYDRAULIC SYSTEM
  • COMPONENT PARTS OF HYDRAULIC SYSTEM
POWER TRAIN SYSTEM7 topics
  • LAYOUT DRAWING OF POWER TRAIN SYSTEM
  • TRANSMISSION CONTROL SYSTEM
  • GEAR SHIFT CONTROL SYSTEM
  • SHIFT HOLD SYSTEM
  • DIRECTION CONTROL SYSTEM
  • KOMATSU TRACTION CONTROL SYSTEM (KTCS)
  • COMPONENT PARTS OF POWER TRAIN SYSTEM
WORK EQUIPMENT SYSTEM3 topics
  • WORK EQUIPMENT CONTROL
  • HOIST CONTROL
  • COMPONENT PARTS OF WORK EQUIPMENT SYSTEM
STEERING SYSTEM4 topics
  • LAYOUT DRAWING OF STEERING SYSTEM
  • FUNCTION OF STEERING SYSTEM
  • STEERING COLUMN
  • COMPONENT PARTS OF STEERING SYSTEM
BRAKE SYSTEM5 topics
  • LAYOUT DRAWING OF BRAKE SYSTEM
  • RETARDER CONTROL
  • PARKING BRAKE INTERLOCK FUNCTION
  • ARAC SYSTEM
  • COMPONENT PARTS OF BRAKE SYSTEM
UNDERCARRIAGE AND FRAME4 topics
  • FRONT SUSPENSION
  • CENTER AND REAR SUSPENSIONS
  • SUSPENSION CYLINDER
  • OSCILLATION HITCH
WORK EQUIPMENT2 topics
  • STRUCTURE OF WORK EQUIPMENT
  • FUNCTION OF WORK EQUIPMENT
CAB AND ITS ATTACHMENTS2 topics
  • ROPS CAB
  • CAB TILT
STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE1 topic
  • STANDARD VALUE TABLE FOR ENGINE: HM400-5
STANDARD VALUE TABLE FOR MACHINE2 topics
  • STANDARD VALUE TABLE FOR MACHINE: HM400-5
  • MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE
STANDARD VALUE TABLE FOR ELECTRICAL1 topic
  • STANDARD VALUE TABLE FOR ELECTRICITY
TESTING AND ADJUSTING
RELATED INFORMATION ON TESTING AND ADJUSTING
TOOLS FOR TESTING AND ADJUSTING
SKETCH OF TOOLS FOR TESTING AND ADJUSTING
ENGINE AND COOLING SYSTEM
TEST ENGINE SPEED
TEST BOOST PRESSURE
TEST EXHAUST GAS TEMPERATURE
TEST EXHAUST GAS COLOR
TEST AND ADJUST VALVE CLEARANCE
TEST COMPRESSION PRESSURE
TEST BLOWBY PRESSURE
TEST ENGINE OIL PRESSURE
TEST EGR VALVE AND VGT OIL PRESSURE
TEST FUEL PRESSURE
TEST FUEL RETURN RATE AND LEAKAGE
BLEED AIR FROM FUEL SYSTEM
TEST FUEL CIRCUIT FOR LEAKAGE
HANDLE CYLINDER CUT-OUT MODE OPERATION
HANDLE NO-INJECTION CRANKING OPERATION
CLEAN FUEL DOSER
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER
TEST SCR RELATED FUNCTIONS
CLEAN AdBlue/DEF TANK
TEST TORQUE CONVERTER STALL SPEED
TEST RADIATOR FAN AND AFTERCOOLER FAN SPEED
POWER TRAIN
TEST POWER TRAIN OIL PRESSURE
ADJUST TRANSMISSION SPEED SENSOR
ADJUST TRANSMISSION CONTROLLER
MOVE MACHINE WHICH HAS A TROUBLE IN ELECTRICAL SYSTEM
MOVE MACHINE WHICH HAS A TROUBLE IN TRACTION CONTROL SYSTEM (KTCS)
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE
TEST AND ADJUST BRAKE OIL PRESSURE
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE
TEST BRAKE PERFORMANCE
BLEED AIR FROM BRAKE CIRCUIT
TEST WEAR OF WHEEL BRAKE DISC
RELEASE PARKING BRAKE MANUALLY
TEST AND ADJUST WEAR OF PARKING BRAKE PAD
TEST AND ADJUST SUSPENSION CYLINDER
TEST AND ADJUST DUMP CIRCUIT OIL PRESSURE
TEST AND ADJUST DUMP BODY POSITIONER SENSOR
TEST AND ADJUST DUMP BODY MOUNT
CAB TILT UP
ELECTRICAL SYSTEM
SET AND ADJUST EACH EQUIPMENT
SET AND OPERATE OF MACHINE MONITOR
METHOD FOR STARTING UP KOMTRAX TERMINAL
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER
HANDLE BATTERY DISCONNECT SWITCH1 topic
  • TEST DIODES
Pm CLINIC1 topic
  • Pm CLINIC SERVICE
TROUBLESHOOTING
RELATED INFORMATION ON TROUBLESHOOTING18 topics
  • GENERAL TROUBLESHOOTING POINTS
  • TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM
  • SEQUENCE OF EVENTS IN TROUBLESHOOTING
  • CHECKS BEFORE TROUBLESHOOTING
  • INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
  • TESTING IN ACCORDANCE WITH TESTING PROCEDURE
  • ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION
  • PROCEDURE FOR TESTING AND TROUBLESHOOTING
  • SYMPTOM AND TROUBLESHOOTING NUMBERS
  • INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
  • CONNECTORS LIST AND LAYOUT
  • CONNECTOR CONTACT IDENTIFICATION
  • BOX AND T-BRANCH ADAPTER TABLE
  • FUSE LOCATION TABLE
  • PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)
  • PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR
  • PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT
  • FAILURE CODES TABLE
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)30 topics
  • FAILURE CODE [1500L0]
  • FAILURE CODE [15B0NX]
  • FAILURE CODE [15F0KM]
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FAILURE CODE [879AKB]
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FAILURE CODE [879CKA]
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FAILURE CODE [879EMC]
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FAILURE CODE [989D00]
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FAILURE CODE [CA272]58 topics
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FAILURE CODE [CA3231]58 topics
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FAILURE CODE [D5ZHL6]
FAILURE CODE [D811MC]58 topics
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FAILURE CODE [DHAAMA]
FAILURE CODE [DHACMA]
FAILURE CODE [DHP4KY]
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FAILURE CODE [DHP5KY]
FAILURE CODE [DHP5KZ]
FAILURE CODE [DHP6KY]
FAILURE CODE [DHP6KZ]
FAILURE CODE [DHP7KY]
FAILURE CODE [DHP7KZ]
FAILURE CODE [DHQ2KX]
FAILURE CODE [DHT5KX]
FAILURE CODE [DHT5L6]
FAILURE CODE [DHT8KX]
FAILURE CODE [DHT8ZG]
FAILURE CODE [DHU2KX]
FAILURE CODE [DHU3KX]
FAILURE CODE [DHUAKX]
FAILURE CODE [DHUBKX]
FAILURE CODE [DHUCKX]
FAILURE CODE [DHUDKX]
FAILURE CODE [DHUEKX]
FAILURE CODE [DHUQKX]
FAILURE CODE [DHURKX]
FAILURE CODE [DJF1KA]
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FAILURE CODE [DKH0KX]
FAILURE CODE [DKH1KX]
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FAILURE CODE [DLF1LC]
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FAILURE CODE [DLF2LC]
FAILURE CODE [DLF400]
FAILURE CODE [DLF4KA]
FAILURE CODE [DLF4LC]
FAILURE CODE [DLF6LC]
FAILURE CODE [DLF7LC]
FAILURE CODE [DLFDLC]
FAILURE CODE [DLFELC]
FAILURE CODE [DLFFLC]
FAILURE CODE [DLFGLC]
FAILURE CODE [DLM3KA]
FAILURE CODE [DLM3LC]
FAILURE CODE [DLM3MB]
FAILURE CODE [DLM4KA]
FAILURE CODE [DLM4LC]58 topics
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  • FAILURE CODE [DLT3KA]
  • FAILURE CODE [DLT3LC]
  • FAILURE CODE [DPQ1KR]
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  • FAILURE CODE [DW7LKB]
  • FAILURE CODE [DW7LKY]
  • FAILURE CODE [DW7LKZ]
  • FAILURE CODE [DW7NKZ]
  • FAILURE CODE [DWNJKZ]
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  • FAILURE CODE [DX13KA]
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FAILURE CODE [DX34KY]
FAILURE CODE [DXH0KA]
FAILURE CODE [DXH0KB]
FAILURE CODE [DXH0KY]
FAILURE CODE [DXH1KA]
FAILURE CODE [DXH1KB]
FAILURE CODE [DXH1KY]
FAILURE CODE [DXH2KA]
FAILURE CODE [DXH2KB]
FAILURE CODE [DXH2KY]
FAILURE CODE [DXH3KA]
FAILURE CODE [DXH3KB]
FAILURE CODE [DXH3KY]
FAILURE CODE [DXH4KA]
FAILURE CODE [DXH4KB]
FAILURE CODE [DXH4KY]
FAILURE CODE [DXH5KA]
FAILURE CODE [DXH5KB]
FAILURE CODE [DXH5KY]
FAILURE CODE [DXH6KA]
FAILURE CODE [DXH6KB]
FAILURE CODE [DXH6KY]
FAILURE CODE [DXH7KA]
FAILURE CODE [DXH7KB]
FAILURE CODE [DXH7KY]
FAILURE CODE [DY30MA]

Inside this manual

Real pages from this service manual (3,198 pages). Open the sample pages (PDF, 933 KB)

Sample pages from the Komatsu HM400-5 Articulated Dump Truck Service Manual: Specifications, Diagram, Troubleshooting, Color page, Color page, Foldout diagram
  • Specifications, page 473: Equipment name
  • Diagram, page 1,208: Ground fault in wiring
  • Troubleshooting, page 1,698: FAILURE CODE [DAQQKR]
  • Color page, page 182: 1: Aftercooler
  • Color page, page 2,986: ENGINE AND COOLING SYSTEM
  • Foldout diagram, page 3,166: INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (3/8)

Other manuals for this machine

Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the HM400-5 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.

This manual: Service Manual SEN06519-05$319.63
Other manuals for the HM400-5

Operator's manuals

Details
Details
Details

This is a service manual

Here's how it compares to the other manual types.

This manual

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.

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.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

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, 3,198 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

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).