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KOMATSU HM300-1 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:1001 & UP) KOMATSU HM300-1 – PDF DOWNLOAD
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- KOMATSU HM300-1 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL
- PUBLICATION NUMBER:TEN00238-00
- SERIAL NUMBERS :1001 and up
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Description
KOMATSU HM300-1 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:1001 & UP) KOMATSU HM300-1
KOMATSU HM300-1 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:1001 & UP) KOMATSU HM300-1 – PDF DOWNLOAD:
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KOMATSU HM300-1 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:1001 & UP) KOMATSU HM300-1
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.
TABLE OF CONTENTS:
KOMATSU HM300-1 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:1001 & UP) KOMATSU HM300-1
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................................................... 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............................................... 36 PRECAUTIONS WHEN OPERATING......................................................... 36 PRECAUTIONS FOR ACCUMULATED SNOW, ICE.............................................. 37 PARKING MACHINE.................................................................... 37 TRANSPORTATION......................................................................... 38 LOADING AND UNLOADING.............................................................. 38 SHIPPING........................................................................... 38 BATTERY................................................................................ 39 BATTERY HAZARD PREVENTION.......................................................... 39 STARTING WITH BOOSTER CABLES....................................................... 40 TOWING................................................................................. 41 WHEN TOWING........................................................................ 41 PRECAUTIONS FOR MAINTENANCE................................................................ 42 WARNING TAG............................................................................ 42 KEEP WORK PLACE CLEAN AND TIDY......................................................... 42 APPOINT LEADER WHEN WORKING WITH OTHERS................................................ 42 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE............................. 43 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING..................................... 44 PROPER TOOLS........................................................................... 45 HANDLING SUSPENSION CYLINDER, ACCUMULATOR.............................................. 45 PERSONNEL.............................................................................. 45 WORK UNDER THE MACHINE................................................................. 45 NOISE.................................................................................. 45 PRECAUTIONS WHEN USING HAMMER.......................................................... 46 REPAIR WELDING......................................................................... 46 REMOVING BATTERY TERMINAL.............................................................. 46 PRECAUTIONS WITH HIGH-PRESSURE OIL..................................................... 46 PRECAUTIONS FOR HIGH-PRESSURE FUEL..................................................... 46 HANDLING HIGH-PRESSURE HOSES, PIPING................................................... 47 PRECAUTIONS FOR HIGH VOLTAGE........................................................... 47 WASTE MATERIALS........................................................................ 47 MAINTENANCE OF AIR CONDITIONER......................................................... 47 COMPRESSED AIR......................................................................... 47 PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS.......................................... 48 PRECAUTIONS WITH TIRES..................................................................... 49 HANDLING TIRES......................................................................... 49 PRECAUTIONS WHEN STORING TIRE.......................................................... 49 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.............................................................. 89 MECHATRONICS EQUIPMENT CONTROLLER...................................................... 94 BODY PIVOT PIN......................................................................... 95 ARTICULATE LOCK........................................................................ 95 DUST INDICATOR......................................................................... 96 FUSES.................................................................................. 97 CAR RADIO..............................................................................100 CAR STEREO.............................................................................106 AIR CONDITIONER........................................................................114 OPERATION..................................................................................119 CHECK BEFORE STARTING ENGINE...........................................................119 STARTING ENGINE........................................................................132 OPERATIONS, CHECKS AFTER STARTING ENGINE...............................................135 STOPPING ENGINE........................................................................136 CHECKS AFTER STOPPING ENGINE...........................................................136 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING........................................137 SHIFTING GEAR..........................................................................142 TRAVELING DOWNHILL.....................................................................143 STEERING THE MACHINE...................................................................151 OPERATION USING DIFFERENTIAL LOCK......................................................152 LOADING OPERATIONS.....................................................................153 DUMP OPERATIONS........................................................................154 CAB TILT OPERATION.....................................................................156 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 SERVICE PROCEDURE..........................................................................209 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).............................209 WHEN REQUIRED..........................................................................210 CHECK, CLEAN OR REPLACE AIR CLEANER................................................210 CLEAN INSIDE OF COOLING SYSTEM.....................................................213 CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID......................................215 CLEAN AIR CONDITIONER AIR FILTER...................................................216 CHECK REFRIGERANT (GAS) LEVEL......................................................216 CHECK DUMP BODY....................................................................217 CHECK ELECTRIC INTAKE AIR HEATER...................................................217 CHECK LENGTH OF SUSPENSION CYLINDER................................................217 BLEED AIR FROM FRONT BRAKE.........................................................218 BLEED AIR FROM CENTER BRAKE........................................................219 CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT......................................220 SELECTION AND INSPECTION OF TIRES..................................................221 ADJUST PARKING BRAKE...............................................................223 DRAIN WATER FROM WATER SEPARATOR...................................................223 CHECK BEFORE STARTING..................................................................224 EVERY 50 HOURS SERVICE.................................................................225 LUBRICATION........................................................................225 EVERY 250 HOURS SERVICE................................................................226 LUBRICATION........................................................................226 CHECK DRIVE SHAFT..................................................................227 CHECK LEVEL OF BATTERY ELECTROLYTE.................................................228 CHECK FAN BELT AND ALTERNATOR BELT TENSION, ADJUST.................................230 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..............................231 CHECK FRAME, A-ARM.................................................................232 CHECK BRAKING CAPACITY OF FOOT BRAKE...............................................233 CHECK BRAKING CAPACITY OF RETARDER BRAKE...........................................233 CHECK BRAKING CAPACITY OF PARKING BRAKE............................................234 CHECK WEAR OF PARKING BRAKE PADS...................................................234 EVERY 500 HOURS SERVICE................................................................235 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................235 REPLACE FUEL FILTER CARTRIDGE......................................................236 CLEAN FUEL TANK STRAINER...........................................................237 LUBRICATION........................................................................237 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.......................................238 CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL......................................239 CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS...................................240 EVERY 1000 HOURS SERVICE...............................................................241 REPLACE CORROSION RESISTOR CARTRIDGE...............................................241 REPLACE TRANSMISSION FILTER ELEMENT................................................242 CHANGE OIL IN TRANSMISSION CASE....................................................243 CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT.....................245 LUBRICATION........................................................................247 CHECK WEAR OF BRAKE DISC...........................................................248 CHECK TIGHTENING PARTS OF TURBOCHARGER.............................................248 CHECK PLAY OF TURBOCHARGER ROTOR...................................................248 EVERY 2000 HOURS SERVICE...............................................................249 CHANGE OIL IN FINAL DRIVE CASE.....................................................249 CHANGE OIL IN DIFFERENTIAL CASE....................................................250 REPLACE HYDRAULIC FILTER ELEMENT...................................................251 CLEAN TRANSMISSION CASE STRAINER...................................................252 CLEAN BREATHER.....................................................................252 CLEAN ENGINE BREATHER ELEMENT......................................................254 CHECK ALTERNATOR, STARTING MOTOR...................................................254 CHECK, ADJUST ENGINE VALVE CLEARANCE...............................................254 CLEAN, CHECK TURBOCHARGER..........................................................254 CHECK INJECTOR.....................................................................254 CHECK VIBRATION DAMPER.............................................................254 EVERY 4000 HOURS SERVICE...............................................................255 CHANGE OIL IN HYDRAULIC TANK.......................................................255 CHECK WATER PUMP...................................................................255 CHECK AIR COMPRESSOR...............................................................255 CHECK FAN PULLEY AND TENSION PULLEY................................................255 REPLACE INJECTOR ASSEMBLY..........................................................255 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.................256 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER................256 EVERY 6000 HOURS SERVICE...............................................................257 LUBRICATE DRIVE SHAFT..............................................................257 EVERY 8000 HOURS SERVICE...............................................................257 REPLACE HIGH-PRESSURE PIPING CLAMP.................................................257 REPLACE FUEL SPRAY PREVENTION CAP..................................................257 SPECIFICATIONS.................................................................................258 SPECIFICATIONS.............................................................................259 INDEX..........................................................................................260
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