HM400-1 Articulated Dump Truck 2001 wVOL. 47 NO.

148
30
1961
1862
2119
2868
4131
4718 4711 4745
4248
4318
229
371
330
1991 1992 1993 1994 1995 1996 1997 1998 1999 2000
904
1,000
2,000
3,000
4,000
5,000
6,000
127 72
964
375
270
161
187
406
443
1,037
40 50
1,386
646
518
279
213
1,837
1,011
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1,099
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639
583
798
781
1,127
1,830
177 92
1.581
843
878
856 963
811
901
1,607
76
Unit
Payload of
35 tons or more
Payload of
20 tons or less
Payload of
30 35 tons
Payload of
26 30 tons
Payload of
20 26 tons
Introduction of Products
HM400-1 Articulated Dump Truck
Hiroyuki Igusa
The market had strongly requested Komatsu to develop articulated dump trucks by itself. We developed
the first model, the HM400-1, and put it on the Japanese market in May 2001 and on the USA market
(which was the main market) in June 2001.
In this paper, we will introduce the main features of the HM400-1 which has outstanding performance
and durability as a construction machine based on our technologies.
Key words: Articulated Dump Truck, Outstanding Productivity, Outstanding Reliability, Dif ferential Lock,
Interaxle Dif ferential Lock
1. Introduction
The world demand for articulated dump trucks increased
rapidly and has stayed as high as 4,200 to 4,700 units/year in
recent years (Fig. 1). We judged that it was the time to put
a Komatsu articulated dump truck on the market and developed
the HM400-1 (Photo 1).
Photo 1 HM400-1
Fig. 1 Demands for articulated dump trucks of each class
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Securing of reliability and durability
High operating comfort
Priority in safety
Priority in production (m
3
/h)
Securing of price competitive power
Training and arrangement of
special salesmen
Measures to attain
etc.
Target industries
1. Users who have been using articulated
dump trucks
Wet-type multiple-disc brake
Employment of Komatsu-made components
from engine to axle which have been used for
dump truck and wheel loader
Lubrication-free turning ring
General civil engineering, debris treatment, mining
constructor, etc.
Meet requests for improvement of reliability,
durability, and comfort of current OEM products.
2. Lease and rental industry
Meet requests for improvement of reliability,
durability, and comfort of current OEM products.
Design dump truck so that it sells easily when new
and sells at high price after used.
3. Expansion of target industries
(Applied dump trucks)
Japan (Transportation inside yard), Indonesia
(Forestry), etc.
Employment of hydropneumatic suspension
(Front axle)
Wide space in cab
Productivity at least 10% larger than
competitors on upslope with load
Assistance in sales of first product and
feedback of information
Low center of gravity for high resistance to tipping
Inclination caution lamp as standard
Use of wet-type multiple-discs as retarder for higher response
Largest absorption horsepower/ton in class
Securing of absorption horsepower/ton at least 10% larger
than competitors
Development concept
Engine
Reduction of gear shifting shock by
detecting load on transmission
Interaxle differential lock
Turning ring
Front axle
Component made by Komatsu
Explanation
of symbols
Cab
Body
Rear axle
Both differential lock
Brake
Use of field-proven parts used for wheel loader and dump truck
Retarder
Dump truck which has high productivity, reliability,
safety, and comfort and which is liked by owner and
operator and which is gentle to the environment
: Productivity : Reliability and durability
: Comfort : Environment
: Safety
Largest horsepower/ton in class
Secure horsepower/ton at least 5% larger than
competitors (and increase 10% more in future).
Employment of engine conformed to emission
regulations
Engine conformed to Tire 2 Emission Regulations
Conformance to EC Noise Regulation (Optional)
Detect load from throttle opening ratio and
acceleration and control transmission oil pressure
properly to reduce gear shifting shocks.
Employ wet multiple-disc type differential lock
so that interaxle differential lock can be turned
on and off without stopping truck.
Employ taper roller bearing to increase
greasing interval.
Employ hydropneumatic suspension to
improve comfort greatly.
Employ Komatsu-made components from engine to
axle to attain high reliability and durability.
High controllability and wide space in cab
Installation of large-capacity air conditioner (Optional)
Employment of viscous mount; Improvement of comfort
and reduction in noise
Employment of tilt cab for easy maintenance
Operators seat shifted to left so that operator can check
rear through window
Employment of operating system same with rigid dump
truck for easy drive
Built-in ROPS and FOPS
Sufficient body capacity (Specific gravity: 1.65)
Reduction in weight and improving of
durability by use of HB400 material
Employment of duck tail and obtuse corner
(for less spill and sticking of material)
Low loading height
Employment of
hydropneumatic suspension
for much higher comfort
Employment of wet multiple-
disc differential lock for high
travel performance on soft
ground and high turning
performance
Maintenancefree wet-type multiple-
disc brake
Employment of fully hydraulic
brake control for higher reliability
2. Development concept
We basically decided to develop the HM400-1 by using
our components and technologies developed for wheel loaders
and dump trucks, then take the necessary measures to attain
the features and the development concept as shown below
(Tables 1 and 2).
[Basic concept]
q Attainment of outstanding productivity and reliability
w Attainment of comfortable operating environment which
is a feature of our construction machines
e Sufficient safety measures
r Facilitation of maintenance
t Dump truck gentle to the environment
Table 1 Measures to attain features and target industries
Table 2 Development concept
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Differential lock switch Interaxle differential lock switch
(If this switch and the differential lock are
pressed, the differential lock is turned on.)
Front suspension type
Rear axle suspension Hydropneumatic suspension
Superior
Superior
Damping performance
Riding comfort
Hydropneumatic
suspension
Long trailing arm
3. Measures to attain
(1) Attainment of outstanding productivity and reliability
q Largest horsepower/ton in the class
Since a powerful and clean Komatsu SAA6D140E-3 engine
is used, the largest horsepower/ton in the class and
powerful and high-speed travel are attained.
w Employment of differential lock and interaxle dif ferential
lock
Since the full-time six-wheel drive system is employed, the
tires do not slip easily and the travel performance is
stabilized. Both differential lock and interaxle differential
lock are wet multiple-disc type and they provide large driving
power under any condition. Since the differential lock can
be turned on and off without stopping the dump truck, the
working efficiency is increased (Photos 2 and 3).
e Employment of electronically controlled transmission
The counter-shaft type transmission which has been used
for wheel loaders, etc. is employed. The gear is shifted
smoothly by the all-gear speed electronic control
modulation system K-ATOMiCS and the engine-
interlocked control which have been used for rigid dump
trucks and evaluated high (Photo 4).
r Employment of fully hydraulic wet-type multiple-disc brake
The fully hydraulic brake has high reliability and response.
It is an enclosed wet-type multiple-disc brake which is
reliable during travel on soft ground. The dump truck
can drive down slopes at high speed by using the wet-
type multiple-disc brake as a retarder similarly to a rigid
dump truck. Consequently, the operating performance is
improved (Photo 5).
t Employment of hydropneumatic suspension
The hydropneumatic suspension which has been used for
the rigid dump trucks is employed. The front axle
suspension employs De Dion type design using a long
trailing arm, allowing the machine to ride more smoothly
over bumps. Since the rear axle is also equipped with
the hydropneumatic suspension, the wheels follow up
changes of the road surface and the operator can drive
on even bad roads comfortably (Figs. 2 and 3).
Photo 2 Differential lock switch
Photo 3 Interaxle dif ferential lock
Photo 4 Transmission
Photo 5 Wet-type multiple-disc brake
Fig. 2 Front suspension
Fig. 3 Suspension
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Fig. 4 Front and rear frames
Photo 7 Inside of cab
y Reliable electric parts and hydraulic piping
All the wiring harnesses are connected by DT-type
(Deutsche) connectors which have high reliability for the
use in construction machinery. Flat face-to-face O-ring
seals are used for the hydraulic piping to reduce oil
leakage (Photo 6).
u Employment of frames having box-section structures
Both front and rear frames have highly rigid box-section
structures. They are designed on the know-how of the
rigid dump trucks used for long years in severe jobsites.
The important parts are made of cast steel to secure high
durability (Fig. 4).
(2) Attainment of comfortable operating environment
q Comfortable wide cab
The wide cab equipped with the power windows and cool
box is employed to secure a comfortable space. The large
window area is secured and the operators seat is shifted
to the left so that the operator can check the rear easily
(Photo 7).
[Main interior parts of cab]
Air suspension seat
Instructors seat
Tilt/Telescopic steering wheel
Air conditioner
Cool box
Power window
Cup holder
w Employment of air suspension seat
The soft air suspension seat is employed as standard. The
headrest, longitudinal position, height, reclining angle, and
hardness of the cushion can be adjusted to take the best
position. The 3-inch retractable seat belt is installed as
standard (Photo 8).
e Low vibration and low noise
The cab is mounted on the viscous mounts which use
rubber and silicone oil. The mechanical vibration and
noise from the truck body are reduced to fatigue the
operator less and improve the operating performance
(Fig. 5).
Photo 6 DT-type (Deutsche) connector
Photo 8 Operators seat
Fig. 5 Viscous mount
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Monitoring system Engine control
Transmission control
Retarder control
Monitoring network
r Refined operation feeling
The control levers, switches, and panels are so arranged
that the operator can operate them easily. The operator
can drive the truck as if he (she) drives a car. Since the
steering wheel, accelerator pedal, and brake pedal are light
to operate, the operator is fatigued less and the operating
performance is improved (Photo 9).
t Air conditioner
The operator can select the five air outlet modes and four
air flow rates of the air conditioner with push buttons
(Standard for Japanese market and optional for foreign
market). The air outlets are arranged in front of the
operators seat so that the cool air will circulate all over
the cab (Figs. 6 and 7).
y Smooth dumping control
An electric body dump control system is employed. The
operator can control dumping lightly and easily. Since
the dumping speed is controlled according to the sensed
dump body position (angle), fewer shocks are made when
the dump body is seated (Photo 10).
u Instruments panel easy to check
Various meters and caution lamps are so arranged that
the operator can check the condition of the truck at a
glance. If any trouble occurs, the operator is notified by
displaying a message. Then, the operator can take proper
actions (Photo 11).
(3) Sufficient safety measures
q Employment of cab with built-in ROPS/FOPS
The cab with built-in ROPS/FOPS is installed against an
emergency (Fig. 8).
Fig. 8 ROPS cab
Photo 9 Front of operators seat
Fig. 6 Air conditioner controller
Fig. 7 Air outlets
Photo 10 Dump control lever
Photo 11 Instruments panel
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Engine underguard
Transmission underguard
Drive shaft guard
Large-sized
rear view mirrors
Front
undermirror
w Safe three independent brake systems
The front, rear, and parking brakes are independent
structurally from each other. The front and rear service
brakes have two independent circuits respectively.
e Secondary brake
Should the brake circuit oil pressure lowers for some
reason, the parking brake is operated by spring force to
stop the dump truck.
r Supplementary steering
If the steering circuit oil pressure drops for some reason,
the electric pump works automatically and the supple-
mentary steering system operates. The supplementary
steering system can be operated manually with the switch
in the cab, too.
t Full safety devices
Down-shift inhibitor
Overrun inhibitor
Reverse inhibitor
Forward-Reverse shift inhibitor
Anti-hunting system
Neutral safety
Rear frame inclination sensor
Maximum gear speed limiter (Optional)
y Full safety equipment
Various guards to protect the operator and truck are
installed as standard (Figs. 9, 10 and 11).
Protective guard for rear window
Engine underguard (Fig. 9)
Transmission underguard (Fig. 9)
Drive shaft guard (Fig. 10)
Exhaust thermal guard
Fire prevention cover
Large-sized rear view mirror (Fig. 11)
Front undermirror (Fig. 11)
(4) Facilitation of maintenance
q Employment of fully opening hood and tiltable cab
Since the fully opening hood (which can be set to 45
and 60) is employed, the operator can check the engine
and transmission easily. The cab can be tilted hydraulically
(or with a crane). Since it can be tilted easily, the operator
can maintain it easily in a shorter time (Fig. 12).
Fig. 9 Underguards
Fig. 10 Undergaurd
Fig. 12 Fully opening hood and tiltable cab
Fig. 11 Various mirrors
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Oil seal Taper roller bearing
Rear frame
Front frame
w Employment of lubrication-free hitch frame and rubber
bushings
Taper roller bearings filled with grease are used as the
oscillation bearings of the hitch frame. They do not need
to be supplied with grease until the overhaul time
(Fig. 13). The arms and rods are supported on rubber
bushings to reduce the number of parts which need to be
supplied with grease.
e Centralized filter elements
All the filter elements are centralized on the left side of the
engine hood so that they can be replaced easily (Photo 12).
r Employment of remote greasing
The remote greasing is employed for the parts difficult to
grease. The operator can supply grease to the all parts
to be greased from the ground (Photo 13).
Fig. 13 Hitch frame
Photo 12 Centralized filter elements
Photo 13 Remote greasing
Fig. 14 Outside view of HM400-1
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Introduction of the writer
Hiroyuki Igusa
Entered Komatsu in 1976.
Currently working in Construction
Equipment Technical Center 2,
Development Div.
[A few words from the writer]
While I was in charge of design of the articulated dump trucks
which were new products, many unexpected problems related to
performance and durability occurred. The fact that the whole staf f
worked together to solve those troubles showed the large latent
power of Komatsu. It is now a happy memor y that we executed
the performance test in the daytime and tuned the transmission
in the nighttime on night and day shifts for about three months in
cold winter.
4. Closing remarks
The HM400-1 which is the first model of the articulated
dump truck series made by Komatsu was put on the market
as planned and the second model HM350-1 and the third model
HM300-1 are to be put on the market in February and April
2002 respectively.
The HM400-1 was introduced first in Chattanooga Field
Day Exhibition, then demonstrated and evaluated by many
distributors and users.
In Japan, the HM400-1 was introduced first on the 80th
anniversary held in May 2001, then demonstrated.
The distributors and users evaluate the following items
very high.
q Productivity is very high.
w Very comfortable. The operator is not fatigued even
after driving all day.
e Noise is low inside and out of the cab.
r The gear is shifted smoothly without large shocks.
t The frames, hitch, drive shafts, etc. seem to be very
strong.
The durability and reliability cannot be evaluated in a short
period. The performance is evaluated very high, however, as
we expected.