Komatsu HM300-5 Articulated Dump Truck Operation & Maintenance Manual PEN01447-04 – PDF DOWNLOAD

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Komatsu HM300-5 Articulated Dump Truck Operation & Maintenance Manual PEN01447-04 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu HM300-5 Articulated Dump Truck Operation & Maintenance Manual PEN01447-04 – PDF DOWNLOAD

SERIAL NUMBERS 11193 and up

READ THIS MANUAL:

• 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 perform 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. It is dangerous to perform improper
  operation and maintenance of the machine. It may cause serious injury or death.
• If you sell the machine, be sure to give this manual to the new owner together with the machine.
• Always keep this Operation and Maintenance Manual in the indicated location so that all relevant personnel can
  read it at any time.

TABLE OF CONTENTS:

Komatsu HM300-5 Articulated Dump Truck Operation & Maintenance Manual PEN01447-04 – PDF DOWNLOAD

CONTENTS
FOREWORD 1-1
READ THIS MANUAL 1-6
SAFETY INFORMATION 1-7
INTRODUCTION 1-8
MAIN USE OF MACHINE 1-8
DIRECTIONS OF MACHINE 1-8
VISIBILITY FROM OPERATOR’S SEAT 1-8
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION 1-9
PRODUCT INFORMATION 1-10
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO PLATE 1-10
LOCATION OF ENGINE NUMBER PLATE 1-10
LOCATION OF AUTHORIZATION LABEL OF ANCHOR POINT FOR TIE-OFF 1-11
SERVICE METER LOCATION 1-12
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1-12
ABBREVIATION LIST 1-13
SAFETY 2-1
SAFETY LABELS 2-2
LOCATION OF SAFETY LABELS 2-3
CONTENTS OF SAFETY LABELS 2-7
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2-15
PRECAUTIONS BEFORE STARTING OPERATION 2-15
PREPARATIONS FOR SAFE OPERATION 2-15
PRECAUTIONS TO PREVENT FIRE 2-17
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2-19
DO NOT GET CAUGHT IN WORK EQUIPMENT 2-21
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2-21
UNAUTHORIZED MODIFICATION 2-21
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2-21
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2-22
PRECAUTIONS FOR OPERATION 2-23
PRECAUTIONS FOR JOBSITE 2-23
START ENGINE 2-27
PRECAUTIONS FOR OPERATION 2-30
TRANSPORTATION 2-34
TOWING AND BEING TOWED 2-35
PRECAUTIONS FOR MAINTENANCE 2-36
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2-36
PRECAUTIONS FOR CHECK AND MAINTENANCE 2-43
TIRES 2-49
PRECAUTIONS FOR DEF 2-50
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 2-50
PRECAUTIONS FOR ADDING 2-50
PRECAUTIONS FOR STORING 2-50
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 2-50
OTHER PRECAUTIONS 2-50
OPERATION 3-1
GENERAL VIEW 3-2
MACHINE EQUIPMENT NAME 3-2
CONTROLS AND GAUGES NAMES 3-3
OTHER EQUIPMENT NAME 3-7
EXPLANATION OF COMPONENTS 3-10
EXPLANATION OF MACHINE MONITOR EQUIPMENT 3-10
SWITCHES 3-109
CONTROL LEVERS AND PEDALS 3-121
OTHER EQUIPMENT 3-126
MACHINE OPERATIONS AND CONTROLS 3-172
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE 3-172
METHOD FOR STARTING ENGINE 3-206
METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE 3-210
METHOD FOR STOPPING ENGINE 3-213
METHOD FOR CHECKING AFTER STOPPING ENGINE 3-213
START MACHINE (TRAVEL FORWARD AND REVERSE) AND STOP MACHINE 3-214
METHOD FOR SHIFTING GEARS 3-219
METHOD FOR TRAVELING DOWNHILL 3-221
METHOD FOR TURNING MACHINE 3-227
OPERATE WITH INTER-AXLE DIFFERENTIAL LOCK 3-228
HANDLE AUTOMATIC RETARDER, ACCELERATOR CONTROL (ARAC) 3-229
OPERATION OF ARAC SYSTEM 3-230
HANDLE KOMATSU TRACTION CONTROL SYSTEM (KTCS) 3-231
OPERATION OF KTCS SYSTEM 3-233
OPERATION IF TROUBLES ON SYSTEM OCCUR 3-233
OPERATION IF TIRES ARE STUCK IN GROUND 3-233
METHOD FOR LOADING 3-234
METHOD FOR DUMPING 3-236
METHOD FOR OPERATING CAB TILT 3-238
PRECAUTIONS FOR OPERATION 3-245
METHOD FOR PARKING MACHINE 3-246
METHOD FOR CHECKING AFTER FINISHING WORK 3-247
LOCK 3-247
HANDLE TIRE 3-258
HANDLE AIR CONDITIONER 3-259
EXPLANATION OF AIR CONDITIONER EQUIPMENT 3-260
METHOD FOR OPERATING AIR CONDITIONER 3-267
HANDLE RADIO 3-274
EXPLANATION OF RADIO EQUIPMENT 3-274
METHOD FOR CONTROLLING RADIO 3-277
DUMP BODY HEATING SPECIFICATIONS 3-280
DETERMINE AND MAINTAIN TRAVEL ROAD 3-281
TRANSPORTATION 3-282
PRECAUTIONS FOR TRANSPORTATION 3-282
PRECAUTIONS FOR TRANSPORTING MACHINE 3-282
SELECT TRANSPORTATION METHOD 3-282
METHOD FOR SECURING MACHINE 3-283
PRECAUTIONS FOR LIFTING MACHINE 3-284
COLD WEATHER OPERATION 3-288
COLD WEATHER OPERATION INFORMATION 3-288
PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER 3-290
AFTER COLD WEATHER SEASON 3-290
PRECAUTIONS FOR LONG-TERM STORAGE 3-291
PREPARATION FOR LONG-TERM STORAGE 3-291
MAINTENANCE DURING LONG-TERM STORAGE 3-291
STARTING MACHINE AFTER LONG-TERM STORAGE 3-292
PREPARATION BEFORE TRAVELING AFTER LONG-TERM STORAGE 3-292
TROUBLES AND ACTIONS 3-293
ACTIONS WHEN RUNNING OUT OF FUEL 3-293
ACTIONS IF TRANSMISSION HAS TROUBLE 3-294
METHOD FOR LOWERING DUMP BODY IN EMERGENCY 3-294
PRECAUTIONS FOR TOWING MACHINE 3-295
PRECAUTIONS FOR DISCHARGED BATTERY 3-299
ACTIONS IF DUMP BODY HEATING EXHAUST PIPING IS BROKEN 3-304
OTHER TROUBLE 3-306
MAINTENANCE 4-1
PRECAUTIONS FOR MAINTENANCE 4-2
CHECK SERVICE METER READING 4-2
KOMATSU GENUINE REPLACEMENT PARTS 4-2
KOMATSU GENUINE LUBRICANTS 4-2
ALWAYS USE CLEAN WASHER FLUID 4-2
FRESH AND CLEAN LUBRICANTS 4-2
CHECK DRAINED OIL AND USED FILTER 4-2
PRECAUTIONS FOR REFILLING OIL OR FUEL 4-2
PRECAUTIONS FOR ADDING DEF 4-2
PRECAUTIONS FOR WELDING 4-2
DO NOT DROP THINGS INSIDE MACHINE 4-2
PRECAUTIONS FOR KDPF 4-3
PRECAUTIONS FOR SCR ASSEMBLY 4-3
DUSTY JOBSITES 4-3
AVOID MIXING OIL 4-3
LOCK INSPECTION COVERS 4-3
BLEED AIR FROM HYDRAULIC CIRCUIT 4-3
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES 4-3
CHECKS AFTER INSPECTION AND MAINTENANCE 4-4
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE 4-4
OUTLINE OF MAINTENANCE 4-5
HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4-6
HANDLE ELECTRICAL COMPONENTS 4-12
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS 4-13
MAINTENANCE SCHEDULE 4-15
MAINTENANCE SCHEDULE TABLE 4-15
MAINTENANCE PROCEDURE 4-17
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) 4-17
WHEN REQUIRED 4-18
CHECKS BEFORE STARTING 4-46
EVERY 50 HOURS MAINTENANCE 4-47
EVERY 250 HOURS MAINTENANCE 4-48
EVERY 500 HOURS MAINTENANCE 4-63
EVERY 1000 HOURS MAINTENANCE 4-75
EVERY 2000 HOURS MAINTENANCE 4-91
EVERY 4000 HOURS MAINTENANCE 4-105
EVERY 4500 HOURS MAINTENANCE 4-108
EVERY 6000 HOURS MAINTENANCE 4-111
EVERY 8000 HOURS MAINTENANCE 4-113
EVERY 9000 HOURS MAINTENANCE 4-113
EVERY 6 MONTHS MAINTENANCE 4-113
SPECIFICATIONS 5-1
SPECIFICATIONS 5-2
ATTACHMENTS AND OPTIONS 6-1
HANDLE CAB POWER TILT 6-2
HANDLING PAYLOAD METER 6-6
OUTLINE OF SYSTEM 6-6
NORMAL OPERATION DISPLAY 6-8
EXTERNAL DISPLAY LAMP 6-9
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER 6-10
METHOD FOR DOWNLOADING DATA FROM CONNECTOR FOR DOWNLOAD 6-10
DISPLAY TOTAL PAYLOAD AND NUMBER OF CYCLES 6-13
DISPLAY FUEL CONSUMPTION RECORD 6-15
SETTING MACHINE ID AND OPEN ID 6-17
METHOD FOR PERFORMING CALIBRATION 6-19
HANDLE AUTO-GREASING SYSTEM 6-21
METHOD FOR OPERATING AUTO-GREASING SYSTEM 6-21
METHOD FOR BLEEDING AIR FROM GREASING CIRCUIT 6-22
METHOD FOR FILLING GREASE 6-22
GREASING POINTS FOR AUTO-GREASING SYSTEM 6-23
REPLACEMENT PARTS 7-1
DEFINED LIFE PARTS 7-2
DEFINED LIFE PARTS LIST 7-2
CONSUMABLE PARTS 7-3
CONSUMABLE PARTS LIST 7-3
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 7-4
LUBRICATION CHART 7-7
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS 7-11
INDEX 8-1

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• This is the SAME MANUAL used by the dealerships to diagnose your vehicle
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