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KOMATSU GALEO HM400-1 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:1001& UP) KOMATSU GALEO HM400-1 – pdf download
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- KOMATSU GALEO HM400-1 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL
- Serial Number:1001& UP
- Publication Number:TEN00113-01
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KOMATSU GALEO HM400-1 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:1001& UP) KOMATSU GALEO HM400-1
KOMATSU GALEO HM400-1 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:1001& UP) KOMATSU GALEO HM400-1 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GALEO HM400-1 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:1001& UP) KOMATSU GALEO HM400-1
- 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 for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
- Operators and maintenance personnel must always do as follows before beginning operation or maintenance. Always be sure to read and understand this manual thoroughly before performing operation and maintenance. Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you understand them fully.
TABLE OF CONTENTS:
KOMATSU GALEO HM400-1 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:1001& UP) KOMATSU GALEO HM400-1
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 ENGINE SERIAL NO. PLATE POSITION....................................................... 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................................................... 17 SAFETY LABELS.......................................................................... 18 GENERAL PRECAUTIONS........................................................................ 23 SAFETY RULES........................................................................... 23 IF PROBLEMS ARE FOUND.................................................................. 23 CLOTHING AND PERSONAL PROTECTIVE ITEMS................................................. 23 FIRE EXTINGUISHER AND FIRST AID KIT.................................................... 23 SAFETY FEATURES........................................................................ 24 KEEP MACHINE CLEAN..................................................................... 24 INSIDE OPERATOR'S COMPARTMENT.......................................................... 24 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT......................................... 24 HANDRAILS AND STEPS.................................................................... 25 MOUNTING AND DISMOUNTING............................................................... 25 CRUSHING OR CUTTING PREVENTION......................................................... 25 PREVENTION OF BURNS.................................................................... 26 FIRE PREVENTION........................................................................ 27 ACTION IF FIRE OCCURS.................................................................. 27 WINDOW WASHER LIQUID................................................................... 28 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)........................... 28 PRECAUTIONS FOR ATTACHMENTS, OPTIONS................................................... 28 UNAUTHORIZED MODIFICATION.............................................................. 28 SAFETY AT WORKSITE..................................................................... 28 WORKING ON LOOSE GROUND................................................................ 29 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................................................. 29 ENSURE GOOD VISIBILITY................................................................. 30 PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS...................................... 30 CHECKING SIGNALMAN'S SIGNALS AND SIGNS................................................. 30 EMERGENCY ESCAPE FROM OPERATOR'S CAB................................................... 30 ASBESTOS DUST HAZARD PREVENTION........................................................ 31 PRECAUTIONS DURING OPERATION............................................................... 32 STARTING ENGINE........................................................................ 32 CHECKS BEFORE STARTING ENGINE, ADJUST.............................................. 32 PRECAUTIONS WHEN STARTING.......................................................... 32 PRECAUTIONS IN COLD AREAS.......................................................... 33 OPERATION.............................................................................. 34 CHECKS BEFORE STARTING OPERATION................................................... 34 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE................................... 34 PRECAUTIONS WHEN TRAVELING......................................................... 35 PRECAUTIONS WHEN TRAVELING ON SLOPES............................................... 35 PRECAUTIONS WHEN OPERATING DUMP BODY............................................... 35 PRECAUTIONS WHEN OPERATING......................................................... 35 PRECAUTIONS FOR ACCUMULATED SNOW, ICE.............................................. 36 PARKING MACHINE.................................................................... 36 TRANSPORTATION......................................................................... 37 LOADING AND UNLOADING.............................................................. 37 SHIPPING........................................................................... 37 BATTERY................................................................................ 38 BATTERY HAZARD PREVENTION.......................................................... 38 STARTING WITH BOOSTER CABLES....................................................... 39 TOWING................................................................................. 40 WHEN TOWING........................................................................ 40 PRECAUTIONS FOR MAINTENANCE................................................................ 41 WARNING TAG............................................................................ 41 KEEP WORK PLACE CLEAN AND TIDY......................................................... 41 APPOINT LEADER WHEN WORKING WITH OTHERS................................................ 41 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE............................. 42 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING..................................... 43 PROPER TOOLS........................................................................... 44 HANDLING SUSPENSION CYLINDER, ACCUMULATOR.............................................. 44 PERSONNEL.............................................................................. 44 WORK UNDER THE MACHINE................................................................. 44 NOISE.................................................................................. 44 PRECAUTIONS WHEN USING HAMMER.......................................................... 45 REPAIR WELDING......................................................................... 45 REMOVING BATTERY TERMINAL.............................................................. 45 PRECAUTIONS WITH HIGH-PRESSURE OIL..................................................... 45 PRECAUTIONS FOR HIGH-PRESSURE FUEL..................................................... 45 HANDLING HIGH-PRESSURE HOSES, PIPING................................................... 46 PRECAUTIONS FOR HIGH VOLTAGE........................................................... 46 WASTE MATERIALS........................................................................ 46 MAINTENANCE OF AIR CONDITIONER......................................................... 46 COMPRESSED AIR......................................................................... 46 PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS.......................................... 47 PRECAUTIONS WITH TIRES..................................................................... 48 HANDLING TIRES......................................................................... 48 PRECAUTIONS WHEN STORING TIRE.......................................................... 48 OPERATION...................................................................................... 50 GENERAL VIEW............................................................................... 51 GENERAL VIEW OF MACHINE................................................................ 51 GENERAL VIEW OF CONTROLS AND GAUGES.................................................... 52 EXPLANATION OF COMPONENTS.................................................................. 54 MACHINE MONITOR........................................................................ 54 OTHER FUNCTIONS OF MACHINE MONITOR..................................................... 75 SWITCHES............................................................................... 79 CONTROL LEVERS AND PEDALS.............................................................. 90 MECHATRONICS EQUIPMENT CONTROLLER...................................................... 95 BODY PIVOT PIN......................................................................... 96 ARTICULATE LOCK........................................................................ 96 DUST INDICATOR......................................................................... 97 FUSES.................................................................................. 98 CAR RADIO..............................................................................101 CAR STEREO.............................................................................107 AIR CONDITIONER........................................................................115 OPERATION..................................................................................120 CHECK BEFORE STARTING ENGINE...........................................................120 STARTING ENGINE........................................................................133 OPERATIONS, CHECKS AFTER STARTING ENGINE...............................................136 STOPPING ENGINE........................................................................137 CHECKS AFTER STOPPING ENGINE...........................................................137 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING........................................138 SHIFTING GEAR..........................................................................143 TRAVELING DOWNHILL.....................................................................144 STEERING THE MACHINE...................................................................152 OPERATION USING DIFFERENTIAL LOCK......................................................152 LOADING OPERATIONS.....................................................................154 DUMP OPERATIONS........................................................................155 CAB TILT OPERATION.....................................................................157 PRECAUTIONS FOR OPERATION..............................................................159 PARKING MACHINE........................................................................160 CHECKS AFTER COMPLETION OF WORK........................................................161 LOCKING................................................................................161 HANDLING TIRES.........................................................................162 DETERMINING AND MAINTAINING TRAVEL ROAD....................................................163 DETERMINING TRAVEL ROAD................................................................163 MAINTAINING TRAVEL ROAD................................................................163 TRANSPORTATION.............................................................................164 PRECAUTIONS WHEN TRANSPORTING..........................................................164 STEPS FOR TRANSPORTATION...............................................................164 METHOD OF SECURING MACHINE.............................................................165 METHOD OF LIFTING MACHINE..............................................................166 COLD WEATHER OPERATION.....................................................................170 PRECAUTIONS FOR LOW TEMPERATURE........................................................170 PRECAUTIONS AFTER COMPLETION OF WORK...................................................171 AFTER COLD WEATHER.....................................................................172 LONG-TERM STORAGE..........................................................................173 BEFORE STORAGE.........................................................................173 DURING STORAGE.........................................................................173 AFTER STORAGE..........................................................................173 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE...................................173 TROUBLESHOOTING............................................................................174 AFTER RUNNING OUT OF FUEL..............................................................174 METHOD OF TOWING MACHINE...............................................................175 IF BATTERY IS DISCHARGED...............................................................179 OTHER TROUBLE..........................................................................183 MAINTENANCE....................................................................................190 GUIDES TO MAINTENANCE......................................................................191 OUTLINE OF SERVICE.........................................................................193 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................193 OUTLINE OF ELECTRIC SYSTEM.............................................................197 WEAR PARTS.................................................................................198 WEAR PARTS LIST........................................................................198 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................199 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................200 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....202 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................203 TORQUE LIST............................................................................203 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................205 SAFETY CRITICAL PARTS..................................................................206 MAINTENANCE SCHEDULE CHART.................................................................207 MAINTENANCE SCHEDULE CHART.............................................................207 ADJUST INJECTOR........................................................................210 SERVICE PROCEDURE..........................................................................211 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).............................211 WHEN REQUIRED..........................................................................212 CHECK, CLEAN OR REPLACE AIR CLEANER................................................212 CLEAN INSIDE OF COOLING SYSTEM.....................................................215 CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID......................................217 CLEAN AIR CONDITIONER AIR FILTER...................................................218 CHECK REFRIGERANT (GAS) LEVEL......................................................218 CHECK DUMP BODY....................................................................219 CHECK ELECTRIC INTAKE AIR HEATER...................................................219 CHECK LENGTH OF SUSPENSION CYLINDER................................................219 BLEED AIR FROM FRONT BRAKE.........................................................220 BLEED AIR FROM CENTER BRAKE........................................................221 BLEED AIR FROM REAR BRAKE..........................................................222 CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT......................................223 SELECTION AND INSPECTION OF TIRES..................................................224 CHECK BEFORE STARTING..................................................................227 EVERY 50 HOURS SERVICE.................................................................228 LUBRICATION........................................................................228 EVERY 250 HOURS SERVICE................................................................229 LUBRICATION........................................................................229 LUBRICATE DRIVE SHAFT..............................................................230 CHECK DRIVE SHAFT..................................................................231 CLEAN BREATHERS....................................................................232 CLEAN BRAKE DRAIN TUBE.............................................................234 CHECK LEVEL OF BATTERY ELECTROLYTE.................................................235 CHECK ALTERNATOR BELT TENSION, ADJUST..............................................237 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..............................238 CHECK FRAME, A-ARM.................................................................239 CHECK BRAKING CAPACITY OF FOOT BRAKE...............................................240 CHECK BRAKING CAPACITY OF RETARDER BRAKE...........................................240 CHECK BRAKING CAPACITY OF PARKING BRAKE............................................241 CHECK WEAR OF PARKING BRAKE PADS...................................................241 EVERY 500 HOURS SERVICE................................................................242 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................242 REPLACE FUEL FILTER CARTRIDGE......................................................243 CLEAN FUEL TANK STRAINER...........................................................244 LUBRICATE CAB MOUNT PIN (LEFT AND RIGHT: 1 PLACE EACH).............................245 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.......................................245 CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL......................................246 CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS...................................247 CHECK FAN BELT TENSION, ADJUST.....................................................248 EVERY 1000 HOURS SERVICE...............................................................249 REPLACE CORROSION RESISTOR CARTRIDGE...............................................249 REPLACE TRANSMISSION FILTER ELEMENT................................................250 CHANGE OIL IN TRANSMISSION CASE....................................................251 CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT.....................253 LUBRICATION........................................................................255 CHECK WEAR OF BRAKE DISC...........................................................256 CHECK TIGHTENING PARTS OF TURBOCHARGER.............................................256 EVERY 2000 HOURS SERVICE...............................................................257 CHANGE OIL IN FINAL DRIVE CASE.....................................................257 CHANGE OIL IN DIFFERENTIAL CASE....................................................258 REPLACE HYDRAULIC FILTER ELEMENT...................................................259 CLEAN HYDRAULIC TANK STRAINER......................................................260 CLEAN TRANSMISSION CASE STRAINER...................................................261 CLEAN STRAINER IN DIFFERENTIAL LOCK HYDRAULIC CIRCUIT..............................261 CLEAN BREATHER.....................................................................263 CLEAN ENGINE BREATHER ELEMENT......................................................264 CHECK ALTERNATOR, STARTING MOTOR...................................................264 CHECK, ADJUST ENGINE VALVE CLEARANCE...............................................264 CHECK INJECTOR (EPA EXHAUST GAS REGULATION AREAS ONLY).............................264 CLEAN, CHECK TURBOCHARGER..........................................................264 CHECK PLAY OF TURBOCHARGER ROTOR...................................................264 EVERY 4000 HOURS SERVICE...............................................................265 CHANGE OIL IN HYDRAULIC TANK.......................................................265 CHECK WATER PUMP...................................................................265 CHECK AIR COMPRESSOR...............................................................265 CHECK FAN PULLEY AND TENSION PULLEY................................................265 CHECK VIBRATION DAMPER.............................................................265 CHECK INJECTOR (ALL AREAS EXCEPT EPA EXHAUST GAS REGULATION AREAS).................265 REPLACE INJECTOR ASSEMBLY (EPA EXHAUST GAS REGULATION AREAS ONLY)..................265 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.................266 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER................266 EVERY 6000 HOURS SERVICE...............................................................267 LUBRICATE DRIVE SHAFT..............................................................267 EVERY 8000 HOURS SERVICE...............................................................267 REPLACE INJECTOR NOZZLE TIP (ALL AREAS EXCEPT EPA EXHAUST GAS REGULATION AREAS)....267 REPLACE HIGH-PRESSURE PIPING CLAMP.................................................267 REPLACE FUEL SPRAY PREVENTION CAP..................................................267 SPECIFICATIONS.................................................................................268 SPECIFICATIONS.............................................................................269 ATTACHMENTS, OPTIONS...........................................................................270 HANDLING PAYLOAD METER HM..................................................................271 FEATURES OF PAYLOAD METER HM...........................................................271 METHOD OF USING ACCURATELY.............................................................272 GENERAL LOCATIONS......................................................................274 CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)................................277 EXTERNAL DISPLAY LAMPS.................................................................279 DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER......................................281 OPERATION OF SWITCHES..................................................................284 ABNORMALITY AND WARNING DISPLAY (ERROR CODE)...........................................297 WHEN ERROR CODE F-09 IS DISPLAYED......................................................299 OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED...........................................299 PROCEDURE WHEN DOWNLOADING.............................................................300 OTHERS.................................................................................303 INDEX..........................................................................................304
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