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Komatsu Articulated Dump Truck HM300-2 Operation & Maintenance Manual SN 2001 and up – PDF DOWNLOAD
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Komatsu Articulated Dump Truck HM300-2 Operation & Maintenance Manual
Book Code : TEN00112-04
SERIAL NUMBERS 2001 and up
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Description
Komatsu Articulated Dump Truck HM300-2 Operation & Maintenance Manual
FILE DETAILS:
Komatsu Articulated Dump Truck HM300-2 Operation & Maintenance Manual
Size : 9.02 MB
Format : PDF
Language : English
Number of Pages : 287 Pages
Brand: Komatsu
Type of machine: Articulated Dump Truck
Type of document: Operation & Maintenance Manual
Model: HM300-2
Serial: 2001 and up
KOMATSU ARTICULATED DUMP TRUCK HM300-2 OPERATION & MAINTENANCE MANUAL SN 2001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Articulated Dump Truck HM300-2 Operation & Maintenance Manual
FOREWORD:
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules forthe operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
TABLE OF CONTENTS:
Komatsu Articulated Dump Truck HM300-2 Operation & Maintenance Manual
COVER.......................................................................................... 1 FOREWORD....................................................................................... 2 FOREWORD................................................................................... 3 SAFETY INFORMATION......................................................................... 6 INTENDED USE............................................................................... 8 DIRECTIONS OF MACHINE.................................................................. 8 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................. 9 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........................... 9 EPA REGULATIONS, ENGINE NUMBER PLATE................................................... 9 SERVICE METER POSITION................................................................. 10 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................................. 10 CONTENTS....................................................................................... 11 SAFETY......................................................................................... 14 SAFETY..................................................................................... 15 SAFETY LABELS.............................................................................. 17 POSITION FOR ATTACHING SAFETY LABELS................................................... 18 SAFETY LABELS.......................................................................... 19 GENERAL PRECAUTIONS........................................................................ 24 SAFETY RULES........................................................................... 24 IF PROBLEMS ARE FOUND.................................................................. 24 CLOTHING AND PERSONAL PROTECTIVE ITEMS................................................. 24 FIRE EXTINGUISHER AND FIRST AID KIT.................................................... 24 SAFETY FEATURES........................................................................ 25 KEEP MACHINE CLEAN..................................................................... 25 INSIDE OPERATOR'S COMPARTMENT.......................................................... 25 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT......................................... 25 HANDRAILS AND STEPS.................................................................... 26 MOUNTING AND DISMOUNTING............................................................... 26 CRUSHING OR CUTTING PREVENTION......................................................... 26 PREVENTION OF BURNS.................................................................... 27 FIRE PREVENTION........................................................................ 28 ACTION IF FIRE OCCURS.................................................................. 28 WINDOW WASHER LIQUID................................................................... 29 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)........................... 29 PRECAUTIONS FOR ATTACHMENTS, OPTIONS................................................... 29 UNAUTHORIZED MODIFICATION.............................................................. 29 SAFETY AT WORKSITE..................................................................... 29 WORKING ON LOOSE GROUND................................................................ 30 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................................................. 30 ENSURE GOOD VISIBILITY................................................................. 31 PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS...................................... 31 CHECKING SIGNALMAN'S SIGNALS AND SIGNS................................................. 31 EMERGENCY ESCAPE FROM OPERATOR'S CAB................................................... 31 ASBESTOS DUST HAZARD PREVENTION........................................................ 32 PRECAUTIONS DURING OPERATION............................................................... 33 STARTING ENGINE........................................................................ 33 CHECKS BEFORE STARTING ENGINE, ADJUST.............................................. 33 PRECAUTIONS WHEN STARTING.......................................................... 33 PRECAUTIONS IN COLD AREAS.......................................................... 34 OPERATION.............................................................................. 35 CHECKS BEFORE STARTING OPERATION................................................... 35 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE................................... 35 PRECAUTIONS WHEN TRAVELING......................................................... 36 PRECAUTIONS WHEN TRAVELING ON SLOPES............................................... 36 PRECAUTIONS WHEN OPERATING DUMP BODY............................................... 37 PRECAUTIONS WHEN OPERATING......................................................... 37 PRECAUTIONS FOR ACCUMULATED SNOW, ICE.............................................. 37 PARKING MACHINE.................................................................... 38 TRANSPORTATION......................................................................... 39 LOADING AND UNLOADING.............................................................. 39 SHIPPING........................................................................... 39 BATTERY................................................................................ 40 BATTERY HAZARD PREVENTION.......................................................... 40 STARTING WITH BOOSTER CABLES....................................................... 41 TOWING................................................................................. 42 WHEN TOWING........................................................................ 42 PRECAUTIONS FOR MAINTENANCE................................................................ 43 WARNING TAG............................................................................ 43 KEEP WORK PLACE CLEAN AND TIDY......................................................... 43 APPOINT LEADER WHEN WORKING WITH OTHERS................................................ 43 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE............................. 44 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING..................................... 45 PROPER TOOLS........................................................................... 46 HANDLING SUSPENSION CYLINDER, ACCUMULATOR.............................................. 46 PERSONNEL.............................................................................. 46 WORK UNDER THE MACHINE................................................................. 46 NOISE.................................................................................. 46 PRECAUTIONS WHEN USING HAMMER.......................................................... 47 REPAIR WELDING......................................................................... 47 REMOVING BATTERY TERMINAL.............................................................. 47 PRECAUTIONS WITH HIGH-PRESSURE OIL..................................................... 47 PRECAUTIONS FOR HIGH-PRESSURE FUEL..................................................... 47 HANDLING HIGH-PRESSURE HOSES, PIPING................................................... 48 PRECAUTIONS FOR HIGH VOLTAGE........................................................... 48 WASTE MATERIALS........................................................................ 48 MAINTENANCE OF AIR CONDITIONER......................................................... 48 COMPRESSED AIR......................................................................... 48 PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS.......................................... 49 PRECAUTIONS WITH TIRES..................................................................... 50 HANDLING TIRES......................................................................... 50 PRECAUTIONS WHEN STORING TIRE.......................................................... 50 OPERATION...................................................................................... 52 GENERAL VIEW............................................................................... 53 GENERAL VIEW OF MACHINE................................................................ 53 GENERAL VIEW OF CONTROLS AND GAUGES.................................................... 54 EXPLANATION OF COMPONENTS.................................................................. 56 MACHINE MONITOR........................................................................ 56 OTHER FUNCTIONS OF MACHINE MONITOR..................................................... 77 SWITCHES............................................................................... 81 CONTROL LEVERS AND PEDALS.............................................................. 91 BODY PIVOT PIN......................................................................... 96 ARTICULATE LOCK........................................................................ 96 LOCATION OF FIRE EXTINGUISHER.......................................................... 97 DUST INDICATOR......................................................................... 97 CIRCUIT BREAKER........................................................................ 97 FUSES.................................................................................. 98 CAR RADIO..............................................................................101 CAR STEREO.............................................................................107 AIR CONDITIONER........................................................................115 OPERATION..................................................................................121 CHECK BEFORE STARTING ENGINE...........................................................121 STARTING ENGINE........................................................................136 OPERATIONS, CHECKS AFTER STARTING ENGINE...............................................138 STOPPING ENGINE........................................................................139 CHECKS AFTER STOPPING ENGINE...........................................................139 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING........................................140 SHIFTING GEAR..........................................................................145 TRAVELING DOWNHILL.....................................................................147 STEERING THE MACHINE...................................................................153 OPERATION USING DIFFERENTIAL LOCK......................................................154 LOADING OPERATIONS.....................................................................155 DUMP OPERATIONS........................................................................156 CAB TILT OPERATION.....................................................................158 PRECAUTIONS FOR OPERATION..............................................................161 PARKING MACHINE........................................................................162 CHECKS AFTER COMPLETION OF WORK........................................................163 LOCKING................................................................................163 HANDLING TIRES.........................................................................164 DETERMINING AND MAINTAINING TRAVEL ROAD....................................................165 DETERMINING TRAVEL ROAD................................................................165 MAINTAINING TRAVEL ROAD................................................................165 TRANSPORTATION.............................................................................166 PRECAUTIONS WHEN TRANSPORTING..........................................................166 STEPS FOR TRANSPORTATION...............................................................166 METHOD OF SECURING MACHINE.............................................................167 METHOD OF LIFTING MACHINE..............................................................168 COLD WEATHER OPERATION.....................................................................172 PRECAUTIONS FOR LOW TEMPERATURE........................................................172 PRECAUTIONS AFTER COMPLETION OF WORK...................................................173 AFTER COLD WEATHER.....................................................................174 LONG-TERM STORAGE..........................................................................175 BEFORE STORAGE.........................................................................175 DURING STORAGE.........................................................................175 AFTER STORAGE..........................................................................175 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE...................................175 TROUBLESHOOTING............................................................................176 AFTER RUNNING OUT OF FUEL..............................................................176 IF TRANSMISSION HAS TROUBLE............................................................177 METHOD OF LOWERING DUMP BODY IN EMERGENCY..............................................177 METHOD OF TOWING MACHINE...............................................................178 IF BATTERY IS DISCHARGED...............................................................182 OTHER TROUBLE..........................................................................186 MAINTENANCE....................................................................................192 GUIDES TO MAINTENANCE......................................................................193 OUTLINE OF SERVICE.........................................................................195 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................195 OUTLINE OF ELECTRIC SYSTEM.............................................................199 WEAR PARTS.................................................................................200 WEAR PARTS LIST........................................................................200 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................201 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................202 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....203 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................204 TORQUE LIST............................................................................204 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................206 SAFETY CRITICAL PARTS..................................................................207 MAINTENANCE SCHEDULE CHART.................................................................208 MAINTENANCE SCHEDULE CHART.............................................................208 SERVICE PROCEDURE..........................................................................210 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).............................210 WHEN REQUIRED..........................................................................211 CHECK, CLEAN OR REPLACE AIR CLEANER................................................211 CLEAN INSIDE OF COOLING SYSTEM.....................................................217 CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID......................................220 CLEAN AIR CONDITIONER AIR FILTER...................................................220 CHECK REFRIGERANT (GAS) LEVEL......................................................221 CHECK DUMP BODY....................................................................222 CHECK LENGTH OF SUSPENSION CYLINDER................................................222 BLEED AIR FROM FRONT BRAKE.........................................................223 BLEED AIR FROM CENTER BRAKE........................................................224 CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT......................................225 SELECTION AND INSPECTION OF TIRES..................................................226 ADJUST PARKING BRAKE...............................................................228 CLEAN HYDRAULIC TANK STRAINER......................................................229 CHECK BEFORE STARTING..................................................................230 EVERY 50 HOURS SERVICE.................................................................231 LUBRICATION........................................................................231 EVERY 250 HOURS SERVICE................................................................232 LUBRICATION........................................................................232 CHECK DRIVE SHAFT..................................................................234 CLEAN OVERFLOW HOSE................................................................235 CHECK LEVEL OF BATTERY ELECTROLYTE.................................................236 CHECK FAN BELT AND ALTERNATOR BELT TENSION, ADJUST.................................238 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..............................239 CHECK FRAME, A-ARM.................................................................240 CHECK BRAKING CAPACITY OF FOOT BRAKE...............................................241 CHECK BRAKING CAPACITY OF RETARDER BRAKE...........................................241 CHECK BRAKING CAPACITY OF PARKING BRAKE............................................242 CHECK WEAR OF PARKING BRAKE PADS...................................................242 CHECK OF ACCUMULATOR GAS PRESSURE..................................................243 EVERY 500 HOURS SERVICE................................................................244 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................244 REPLACE FUEL PREFILTER CARTRIDGE...................................................245 LUBRICATE CAB MOUNT PIN (LEFT AND RIGHT: 1 PLACE EACH).............................246 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.......................................246 CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL......................................247 CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS...................................248 RECOVER OIL LEAKING FROM FLOATING SEAL.............................................249 EVERY 1000 HOURS SERVICE...............................................................251 REPLACE FUEL MAIN FILTER CARTRIDGE.................................................251 REPLACE CORROSION RESISTOR CARTRIDGE...............................................252 REPLACE TRANSMISSION FILTER ELEMENT................................................253 CHANGE OIL IN TRANSMISSION CASE....................................................254 CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT.....................256 LUBRICATION........................................................................259 CHECK WEAR OF BRAKE DISC...........................................................260 CHECK OF ENGINE AIR INTAKE PIPING CLAMPS FOR LOOSENESS.............................261 EVERY 2000 HOURS SERVICE...............................................................262 CHANGE OIL IN FINAL DRIVE CASE.....................................................262 CHANGE OIL IN DIFFERENTIAL CASE....................................................263 REPLACE HYDRAULIC FILTER ELEMENT...................................................264 CLEAN TRANSMISSION CASE STRAINER...................................................265 CLEAN BREATHER.....................................................................265 CHECK ACCUMULATOR GAS PRESSURE.....................................................267 CHECK ALTERNATOR...................................................................267 CHECK, ADJUST ENGINE VALVE CLEARANCE...............................................267 CHECK VIBRATION DAMPER.............................................................267 EVERY 4000 HOURS SERVICE...............................................................268 CHANGE OIL IN HYDRAULIC TANK.......................................................268 CHECK STARTING MOTOR...............................................................268 CHECK WATER PUMP...................................................................268 CHECK AIR COMPRESSOR...............................................................268 CHECK FAN PULLEY AND TENSION PULLEY................................................268 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.................269 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER................269 EVERY 6000 HOURS SERVICE...............................................................270 LUBRICATE DRIVE SHAFT..............................................................270 EVERY 8000 HOURS SERVICE...............................................................271 REPLACE HIGH-PRESSURE PIPING CLAMP.................................................271 REPLACE FUEL SPRAY PREVENTION CAP..................................................271 OVERHAUL STARTING MOTOR AND ALTERNATOR.............................................271 SPECIFICATIONS.................................................................................272 SPECIFICATIONS.............................................................................273 ATTACHMENTS, OPTIONS...........................................................................274 HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL (ARAC)....................................275 EXPLANATION OF COMPONENTS..............................................................275 METHOD OF OPERATION....................................................................276 USE OF REAR VIEW MONITOR...................................................................277 NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR.....................................277 SETTING OF REAR VIEW MONITOR...........................................................280 CAUTIONS WHEN USING REAR VIEW MONITOR..................................................280 HANDLING DUMPING COUNTER...................................................................281 HANDLING MACHINES EQUIPPED WITH KOMTRAX....................................................282 BASIC PRECAUTIONS......................................................................282 INDEX..........................................................................................284
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