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KOMATSU HM250-2 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:HM250-2 – 2001 and up) KOMATSU HM250-2 – PDF DOWNLOAD
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- KOMATSU HM250-2 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:HM250-2 – 2001 and up
- PUBLICATION NUMBER:EEAM027602
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Description
KOMATSU HM250-2 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:HM250-2 – 2001 and up) KOMATSU HM250-2
KOMATSU HM250-2 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:HM250-2 – 2001 AND UP) KOMATSU HM250-2 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU HM250-2 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:HM250-2 – 2001 and up) KOMATSU HM250-2
- This manual gives details of the operation and methods of inspection and maintenance for this machine that must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Read, understand and follow all precautions and warnings in this manual and on the machine before performing operation and maintenance.
- Failure to do so may result in serious injury or death. Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used. Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
- If you carry out any operation, inspection, or maintenance under conditions that are not described in this manual, understand that it is your responsibility to take the necessary precautions to ensure safety.
- In no event should you or others engage in the prohibited uses or actions described in this manual. Improper operation and maintenance of the machine can be hazardous and could result in serious injury or death.
TABLE OF CONTENTS:
KOMATSU HM250-2 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:HM250-2 – 2001 and up) KOMATSU HM250-2
FOREWORD....................................................................................... 3 BEFORE READING THIS MANUAL................................................................. 4 SAFETY INFORMATION......................................................................... 5 Noise emission levels.................................................................. 6 Vibration levels....................................................................... 6 Guide to Reduce Vibration Levels on Machine........................................ 7 INTENDED USE............................................................................... 8 USE OF MACHINE......................................................................... 8 DIRECTIONS OF MACHINE.................................................................. 8 VISIBILITY FROM OPERATOR'S SEAT........................................................ 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 MACHINE SERIAL NUMBER PLATE............................................................ 11 MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC)........................... 12 Declaration according Directive 2006/42/EC Annex I point 1.7.4.2 (c)................... 13 FOREWORD............................................................................... 14 SAFETY................................................................................. 14 OPERATION.............................................................................. 15 MAINTENANCE............................................................................ 17 SPECIFICATIONS......................................................................... 20 ATTACHMENTS, OPTIONS................................................................... 20 INDEX.................................................................................. 20 COLOPHON............................................................................... 20 SAFETY......................................................................................... 21 SAFETY..................................................................................... 22 SAFETY LABELS.............................................................................. 25 POSITION FOR ATTACHING SAFETY LABELS................................................... 26 SAFETY LABELS.......................................................................... 27 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE.................................... 36 PRECAUTIONS BEFORE STARTING OPERATION.................................................. 36 PREPARATIONS FOR SAFE OPERATION........................................................ 36 FIRE PREVENTION........................................................................ 38 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE............................................. 40 DO NOT GET CAUGHT IN ARTICULATING PORTION AND DUMP BODY................................ 42 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES........................................... 42 UNAUTHORIZED MODIFICATION.............................................................. 44 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS......................................... 44 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING........................................ 44 PRECAUTIONS FOR OPERATION.................................................................. 45 PRECAUTIONS FOR JOBSITE................................................................ 45 STARTING ENGINE........................................................................ 47 OPERATION.............................................................................. 50 TRANSPORTATION......................................................................... 54 TOWING................................................................................. 55 PRECAUTIONS FOR MAINTENANCE................................................................ 56 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE................................. 56 PRECAUTIONS FOR INSPECTION AND MAINTENANCE............................................. 60 TIRES.................................................................................. 66 DISMANTLING THE MACHINE END OF SERVICE LIVE............................................ 67 OPERATION...................................................................................... 69 GENERAL VIEW............................................................................... 70 GENERAL VIEW OF MACHINE................................................................ 70 GENERAL VIEW OF CONTROLS AND GAUGES.................................................... 71 EXPLANATION OF COMPONENTS.................................................................. 73 MACHINE MONITOR........................................................................ 73 CHARACTER DISPLAY.................................................................. 75 CAUTION ITEMS...................................................................... 81 EMERGENCY STOP ITEM................................................................ 84 METER DISPLAY PORTION.............................................................. 88 CENTRAL WARNING LAMP............................................................... 94 OTHER FUNCTIONS OF MACHINE MONITOR..................................................... 95 SWITCHES............................................................................... 99 CONTROL LEVERS AND PEDALS..............................................................111 BODY PIVOT PIN.........................................................................116 ARTICULATE LOCK........................................................................117 LOCATION OF FIRE EXTINGUISHER..........................................................117 DUST INDICATOR.........................................................................117 HANDLING BATTERY DISCONNECTOR SWITCH.......................................................118 CIRCUIT BREAKER........................................................................119 FUSES..................................................................................120 FUSE CAPACITY AND CIRCUIT NAME.....................................................121 CAR RADIO..............................................................................124 EXPLANATION OF COMPONENTS..........................................................124 METHOD OF OPERATION................................................................127 PRECAUTIONS FOR USE................................................................129 CAR STEREO.............................................................................130 EXPLANATION OF COMPONENTS..........................................................130 METHOD OF OPERATION................................................................135 PRECAUTIONS FOR USE................................................................137 AIR CONDITIONER........................................................................138 GENERAL LOCATIONS ON CONTROL PANEL.................................................138 METHOD OF OPERATION................................................................141 PRECAUTIONS WHEN USING AIR CONDITIONER.............................................143 INSPECTION AND MAINTENANCE.........................................................143 OPERATION..................................................................................144 CHECK BEFORE STARTING ENGINE...........................................................144 WALK-AROUND CHECK..................................................................144 CHECK BEFORE STARTING..............................................................147 ADJUSTMENT BEFORE OPERATION........................................................155 OPERATIONS, CHECKS BEFORE STARTING.................................................160 STARTING ENGINE........................................................................161 OPERATIONS, CHECKS AFTER STARTING ENGINE...............................................163 BREAKING-IN THE MACHINE............................................................163 WARMING-UP OPERATION...............................................................163 CANCELLING DUMP BODY HOLD CONDITION................................................164 STOPPING ENGINE........................................................................164 CHECKS AFTER STOPPING ENGINE...........................................................164 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING........................................165 MOVING MACHINE FORWARD.............................................................165 MOVING MACHINE IN REVERSE..........................................................167 STOPPING MACHINE...................................................................168 SHIFTING GEAR..........................................................................170 TRAVELLING DOWNHILL....................................................................172 BRAKE PERFORMANCE CURVE............................................................174 STEERING THE MACHINE...................................................................178 OPERATION USING DIFFERENTIAL LOCK......................................................179 METHOD OF USING INTER-AXLE DIFFERENTIAL LOCK.......................................179 WHEN TIRES ARE STUCK IN GROUND.....................................................180 LOADING OPERATIONS.....................................................................180 HANDLING TAILGATE..................................................................181 DUMP OPERATIONS........................................................................182 CAB TILT OPERATION.....................................................................184 WHEN USING CRANE...................................................................185 WHEN USING TILT CYLINDER...........................................................186 PRECAUTIONS FOR OPERATION..............................................................187 PERMISSIBLE WATER DEPTH............................................................187 PARKING MACHINE........................................................................188 CHECKS AFTER COMPLETION OF WORK........................................................189 LOCKING................................................................................189 HANDLING TIRES.........................................................................190 PRECAUTIONS WHEN HANDLING TIRES....................................................190 PRECAUTIONS FOR LONG DISTANCE TRAVEL...............................................191 DETERMINING AND MAINTAINING TRAVEL ROAD....................................................192 DETERMINING TRAVEL ROAD................................................................192 MAINTAINING TRAVEL ROAD................................................................192 TRANSPORTATION.............................................................................193 PRECAUTIONS WHEN TRANSPORTING..........................................................193 STEPS FOR TRANSPORTATION...............................................................193 METHOD OF SECURING MACHINE.............................................................194 METHOD OF LIFTING MACHINE..............................................................195 LOCATION OF LIFTING POSITION MARK..................................................196 WEIGHT TABLE.......................................................................196 LIFTING PROCEDURE..................................................................197 COLD WEATHER OPERATION.....................................................................199 PRECAUTIONS FOR LOW TEMPERATURE........................................................199 FUEL AND LUBRICANTS................................................................199 COOLANT............................................................................199 BATTERY............................................................................200 INSTALLATION OF RADIATOR CURTAIN...................................................200 PRECAUTIONS AFTER COMPLETION OF WORK...................................................201 AFTER COLD WEATHER.....................................................................201 LONG-TERM STORAGE..........................................................................202 BEFORE STORAGE.........................................................................202 DURING STORAGE.........................................................................202 AFTER STORAGE..........................................................................203 PRECAUTIONS BEFORE TRAVELLING AFTER LONG-TERM STORAGE..................................203 TROUBLESHOOTING............................................................................204 AFTER RUNNING OUT OF FUEL..............................................................204 IF TRANSMISSION HAS TROUBLE............................................................205 METHOD OF LOWERING DUMP BODY IN EMERGENCY..............................................205 METHOD OF TOWING MACHINE...............................................................206 WHEN ENGINE RUNS...................................................................208 WHEN ENGINE DOES NOT RUN...........................................................208 WHEN PARKING BRAKE HAS BEEN ACTUATED IN EMERGENCY..................................209 IF BATTERY IS DISCHARGED...............................................................210 REMOVAL AND INSTALLATION OF BATTERY................................................210 PRECAUTIONS FOR CHARGING BATTERY...................................................211 STARTING ENGINE WITH BOOSTER CABLE.................................................212 OTHER TROUBLE..........................................................................214 ELECTRICAL SYSTEM..................................................................214 CHASSIS............................................................................215 ENGINE.............................................................................217 ACTION CODE........................................................................219 MAINTENANCE....................................................................................221 GUIDES TO MAINTENANCE......................................................................222 OUTLINE OF SERVICE.........................................................................225 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................226 OIL................................................................................226 FUEL...............................................................................227 COOLANT AND WATER FOR DILUTION.....................................................228 GREASE.............................................................................228 CARRYING OUT KOWA (Komatsu Oil Wear Analysis)......................................229 STORING OIL AND FUEL...............................................................230 FILTERS............................................................................230 OUTLINE OF ELECTRIC SYSTEM.............................................................230 WEAR PARTS.................................................................................231 WEAR PARTS LIST........................................................................231 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................232 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................233 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....235 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................236 TORQUE LIST............................................................................236 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................238 SAFETY CRITICAL PARTS..................................................................239 MAINTENANCE SCHEDULE CHART.................................................................240 MAINTENANCE SCHEDULE CHART.............................................................240 SERVICE PROCEDURE..........................................................................242 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).............................242 WHEN REQUIRED..........................................................................243 CHECK, CLEAN OR REPLACE AIR CLEANER................................................243 CLEAN INSIDE OF COOLING SYSTEM.....................................................249 CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID......................................252 CLEAN AIR CONDITIONER AIR FILTER...................................................252 CHECK REFRIGERANT (GAS) LEVEL......................................................253 CHECK DUMP BODY....................................................................254 CHECK LENGTH OF SUSPENSION CYLINDER................................................254 BLEED AIR FROM FRONT BRAKE.........................................................255 BLEED AIR FROM CENTRE BRAKE........................................................256 CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT......................................257 SELECTION AND INSPECTION OF TIRES..................................................258 ADJUST PARKING BRAKE...............................................................260 CLEAN HYDRAULIC TANK STRAINER......................................................261 CHECK BEFORE STARTING..................................................................262 EVERY 50 HOURS SERVICE.................................................................263 LUBRICATION........................................................................263 EVERY 250 HOURS SERVICE................................................................264 LUBRICATION........................................................................264 CHECK DRIVE SHAFT..................................................................265 CLEAN OVERFLOW HOSE................................................................266 CHECK LEVEL OF BATTERY ELECTROLYTE.................................................267 CHECK FAN BELT AND ALTERNATOR BELT TENSION, ADJUST.................................269 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..............................270 CHECK FRAME, A-ARM.................................................................271 CHECK BRAKING CAPACITY OF FOOT BRAKE...............................................272 CHECK BRAKING CAPACITY OF RETARDER BRAKE...........................................272 CHECK BRAKING CAPACITY OF PARKING BRAKE............................................273 CHECK WEAR OF PARKING BRAKE PADS...................................................273 CHECK OF ACCUMULATOR GAS PRESSURE..................................................274 EVERY 500 HOURS SERVICE................................................................275 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................275 REPLACE FUEL PREFILTER CARTRIDGE...................................................277 LUBRICATE CAB MOUNT PIN (LEFT AND RIGHT: 1 PLACE EACH).............................278 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.......................................279 CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL......................................280 CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS...................................281 RECOVER OIL LEAKING FROM FLOATING SEAL.............................................282 EVERY 1000 HOURS SERVICE...............................................................284 REPLACE FUEL MAIN FILTER CARTRIDGE.................................................284 REPLACE FUEL TANK BREATHER ELEMENT.................................................285 REPLACE CORROSION RESISTOR CARTRIDGE...............................................286 REPLACE TRANSMISSION FILTER ELEMENT................................................287 CHANGE OIL IN TRANSMISSION CASE....................................................289 CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT.....................291 LUBRICATION........................................................................294 CHECK WEAR OF BRAKE DISC...........................................................295 CHECK OF ENGINE AIR INTAKE PIPING CLAMPS FOR LOOSENESS.............................296 EVERY 2000 HOURS SERVICE...............................................................297 CHANGE OIL IN FINAL DRIVE CASE.....................................................297 CHANGE OIL IN DIFFERENTIAL CASE....................................................298 REPLACE HYDRAULIC FILTER ELEMENT...................................................299 CLEAN TRANSMISSION CASE STRAINER...................................................300 CLEAN BREATHER.....................................................................301 CHECK ACCUMULATOR GAS PRESSURE.....................................................303 CHECK ALTERNATOR...................................................................303 CHECK, ADJUST ENGINE VALVE CLEARANCE...............................................303 CHECK VIBRATION DAMPER.............................................................303 EVERY 4000 HOURS SERVICE...............................................................304 CHANGE OIL IN HYDRAULIC TANK.......................................................304 CHECK STARTING MOTOR...............................................................304 CHECK WATER PUMP...................................................................304 CHECK AIR COMPRESSOR...............................................................304 CHECK FAN PULLEY AND TENSION PULLEY................................................304 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.................305 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER................305 EVERY 6000 HOURS SERVICE...............................................................306 LUBRICATE DRIVE SHAFT..............................................................306 EVERY 8000 HOURS SERVICE...............................................................307 REPLACE HIGH-PRESSURE PIPING CLAMP.................................................307 REPLACE FUEL SPRAY PREVENTION CAP..................................................307 OVERHAUL STARTING MOTOR AND ALTERNATOR.............................................307 SPECIFICATIONS.................................................................................309 SPECIFICATIONS.............................................................................310 ATTACHMENTS, OPTIONS...........................................................................311 GENERAL PRECAUTIONS........................................................................312 AUTHORIZED OPTIONAL EQUIPMENT..........................................................312 PRECAUTIONS RELATED TO SAFETY..........................................................312 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT....................................313 HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL (ARAC)....................................314 EXPLANATION OF COMPONENTS..............................................................314 METHOD OF OPERATION....................................................................315 ACTUATION OF ARAC SYSTEM...........................................................315 USE OF REAR VIEW MONITOR...................................................................316 NAME AND FUNCTION OF EACH PART OF REAR VIEW MONITOR....................................316 SETTING OF REAR VIEW MONITOR...........................................................319 CAUTIONS WHEN USING REAR VIEW MONITOR..................................................320 HANDLING DUMPING COUNTER...................................................................321 METHOD OF DISPLAYING, RESETTING DUMPING COUNTER........................................321 HANDLING MACHINES EQUIPPED WITH KOMTRAX....................................................322 BASIC PRECAUTIONS......................................................................322 INDEX..........................................................................................325 <A>........................................................................................327 <B>........................................................................................327 <C>........................................................................................327 <D>........................................................................................327 <E>........................................................................................327 <F>........................................................................................327 <G>........................................................................................327 <H>........................................................................................327 <I>........................................................................................327 <L>........................................................................................327 <M>........................................................................................328 <O>........................................................................................328 <P>........................................................................................328 <R>........................................................................................328 <S>........................................................................................328 <T>........................................................................................328 <U>........................................................................................328 <W>........................................................................................328 COLOPHON.......................................................................................329
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
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