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KOMATSU HM350-2 ARTICULATED DUMP TRUCK Operation & Maintenance Manual (SN:HM350-2 A11001 and up) – PDF DOWNLOAD
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- KOMATSU HM350-2 ARTICULATED DUMP TRUCK Operation & Maintenance Manual
- SERIAL NUMBER:HM350-2 A11001 and up
- PUBLICATION NUMBER:CEAM017703
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Description
KOMATSU HM350-2 ARTICULATED DUMP TRUCK Operation & Maintenance Manual (SN:HM350-2 A11001 and up)
KOMATSU HM350-2 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:HM350-2 A11001 AND UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU HM350-2 ARTICULATED DUMP TRUCK Operation & Maintenance Manual (SN:HM350-2 A11001 and up)
- This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance. Keep this manual handy and have all personnel read it periodically.
- If this manual is lost or becomes dirty and can not be read, request a replacement manual from your local Komatsu distributor. If you sell the machine, be sure to give this manual to the new owner. Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual.
- Consult your local distributor or KOMATSU AMERICA CORP. for the latest available information on your machine or for questions regarding information in this manual.
- This manual may contain attachments and optional equipment that are not available in your area. Consult your local distributor or KOMATSU AMERICA CORP. for those items that you may require.
TABLE OF CONTENTS:
KOMATSU HM350-2 ARTICULATED DUMP TRUCK Operation & Maintenance Manual (SN:HM350-2 A11001 and up)
HM350-2ARTICULATED DUMP TRUCK s/n A11001-up.................................................... 0 INTRODUCTION................................................................................... 3 FOREWORD................................................................................... 4 SAFETY INFORMATION......................................................................... 5 Safety Labels.......................................................................... 6 Safety Label Using Words........................................................... 6 Safety Labels Using Pictogram...................................................... 6 INTRODUCTION............................................................................... 7 Intended Use........................................................................... 7 Use of Machine..................................................................... 7 Directions of Machine.............................................................. 7 Visibility From Operator's Seat.................................................... 7 Breaking in a New 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 Serial No. Plate Position...................................... 9 Service Meter Position................................................................. 10 Table to Enter Serial Numbers and Distributor.......................................... 10 TABLE OF CONTENTS.......................................................................... 11 SAFETY......................................................................................... 23 SAFETY LABELS.............................................................................. 24 SAFETY AND WARNING DECALS.................................................................. 25 Location of Safety Decals.............................................................. 26 Safety Labels.......................................................................... 26 GENERAL SAFETY RULES AND PRECAUTIONS....................................................... 31 General Safety Rules................................................................... 31 Safety Features........................................................................ 32 Personal Protective Equipment.......................................................... 32 Fire and Explosion Prevention.......................................................... 33 Fire Caused by Fuel or Oil......................................................... 33 Fire Caused by Accumulation of Flammable Material.................................. 33 Fire Coming from Electric Wiring................................................... 34 Fire Coming from Hydraulic Line.................................................... 34 Windshield Washer Fluid............................................................ 34 Action if Fire Occurs.................................................................. 34 Fire Extinguisher and First Aid Kit.................................................... 34 Fire Prevention and Suppression........................................................ 35 Fire Prevention Steps.............................................................. 35 Fixed Fire Detection System........................................................ 35 Fixed Fire Suppression System...................................................... 35 Fire Prevention Procedures......................................................... 35 Dust Hazard Precautions................................................................ 36 Keep Operator's Cab Clean.............................................................. 36 Unauthorized Modifications............................................................. 36 Leaving Operator’s Compartment......................................................... 37 Mounting and Dismounting............................................................... 38 Crush or Pinch Point Dangers........................................................... 38 Inside Operator’s Compartment.......................................................... 39 Precautions When Using ROPS............................................................ 39 PRECAUTIONS BEFORE STARTING OPERATIONS..................................................... 40 Pre-Operational Checks................................................................. 40 Starting Your Work Operations.......................................................... 40 Work Site Hazards...................................................................... 40 Avoiding Dangerous Situations.......................................................... 41 Working Clearances..................................................................... 43 Operating on Snow or Icy Surfaces...................................................... 43 Asbestos Hazard Alert.................................................................. 44 RULES FOR ROAD TRAVEL...................................................................... 45 Precautions When Traveling............................................................. 45 When Traveling on Slopes............................................................... 45 When Dumping a Load.................................................................... 46 Ensure Good Visibility................................................................. 46 When Traveling in Reverse.............................................................. 47 Parking the Machine.................................................................... 48 PRECAUTIONS DURING MAINTENANCE OPERATIONS.................................................. 50 Warning Tags........................................................................... 50 Equipment Storage...................................................................... 50 Working Under the Machine.............................................................. 51 Using Drop Lamps....................................................................... 51 Keeping the Machine Clean.............................................................. 51 Performing General Maintenance Procedures.............................................. 52 Running the Engine During Maintenance.................................................. 53 Proper Tools........................................................................... 54 Engine System High-voltage............................................................. 54 Welding, Grinding or Cutting........................................................... 55 When Using Hammer...................................................................... 55 Refueling the Machine.................................................................. 55 Cooling System Precautions............................................................. 56 Battery Precautions.................................................................... 57 Starting the Machine................................................................... 57 High Pressure Hoses.................................................................... 58 Safety Handling High-pressure Hoses.................................................... 58 Precaution for High Fuel Pressure...................................................... 58 High Temperature Areas................................................................. 58 Disposal of Waste Materials............................................................ 59 Accumulator............................................................................ 59 Critical Parts......................................................................... 59 HANDLING TIRES............................................................................. 60 Precautions When Storing Tires......................................................... 60 TRANSPORTATION............................................................................. 61 Precautions When Transporting.......................................................... 61 Steps for Transportation............................................................... 61 Method of Securing Machine............................................................. 61 Method of Lifting Machine.............................................................. 62 Location of Lifting Points............................................................. 63 TOWING MACHINE............................................................................. 64 OPERATION...................................................................................... 65 GENERAL VIEW............................................................................... 66 Machine................................................................................ 66 Controls and Gauges.................................................................... 67 Machine Monitor........................................................................ 68 EXPLANATION OF COMPONENTS.................................................................. 69 Machine Monitor........................................................................ 69 Check Central Warning Lamp, Alarm Buzzer, Monitor Lamps, And Meters................ 70 Character Display Portion.......................................................... 70 Caution Items...................................................................... 75 Emergency Stop Item................................................................ 78 Pilot Display Portion.............................................................. 82 Meter Display Portion.............................................................. 86 Central Warning Lamp............................................................... 88 Other Functions of Machine Monitor................................................. 89 Switches............................................................................... 92 Ignition Switch.................................................................... 93 Lamp Switch........................................................................ 93 Turn Signal Lever.................................................................. 93 Dimmer Switch...................................................................... 94 Hazard Lamp Switch................................................................. 94 Night Lighting Dimmer Switch....................................................... 94 Power Mode Selector Switch......................................................... 94 Emergency Steering Switch.......................................................... 95 Shift Hold Switch.................................................................. 95 Parking Brake Switch............................................................... 96 AISS Low Switch.................................................................... 96 Inter-axle Differential Lock Switch................................................ 97 Left and Right Differential Lock Switch............................................ 97 Fog Lamp Switch.................................................................... 98 Side Lamp Switch................................................................... 98 Working Lamp (Front) Switch........................................................ 98 Switch For Rear Window Defogger.................................................... 98 Yellow Rotating Lamp Switch........................................................ 99 Power Window Switch (Right) (Left)................................................. 99 Machine Monitor Mode Selector Switch 1, 2.......................................... 99 Cigarette Lighter..................................................................100 Horn Button........................................................................100 Wiper, Window Washer Switch........................................................100 Room Lamp Switch...................................................................101 Control Levers And Pedals..............................................................102 Brake Pedal........................................................................102 Accelerator Pedal..................................................................103 Gear Shift Lever...................................................................103 Dump Lever.........................................................................105 Retarder Control Lever.............................................................105 Left and Right Differential Lock Pedal.............................................105 Dump Lever Safety Lock Knob........................................................106 Body Pivot Pin.........................................................................107 Stowing Body Pivot Pin.............................................................107 Articulate Lock........................................................................108 Location of Fire Extinguisher..........................................................108 Dust Indicator.........................................................................108 Circuit Breaker........................................................................109 Fuses..................................................................................109 Fuse Capacity and Circuit Name.....................................................109 AM/FM Radio-cassette Stereo............................................................112 Radio Operation....................................................................113 Radio Features.....................................................................117 Listening to Radio.................................................................118 Listening to Cassette Tape.........................................................118 Precautions When Using Radio.......................................................119 AIR CONDITIONER............................................................................120 General Locations on Control Panel.....................................................120 ON/OFF Switch......................................................................120 Fan Switch.........................................................................120 Air Conditioner Switch.............................................................120 Mode Selector Switch...............................................................121 DEF (Defrost) Switch...............................................................121 RECIRC/FRESH Selector Switch.......................................................121 Temperature Control Switch.........................................................122 Method of Operation....................................................................122 Cooling............................................................................122 Heating............................................................................122 Dehumidifying, Defrosting..........................................................123 Precautions When Using Air Conditioner.............................................123 Inspection and Maintenance.........................................................123 OPERATION..................................................................................124 Check Before Starting Engine...........................................................124 Walk-around Check..................................................................124 Checks Before Starting.................................................................126 Check Coolant Level, Add Coolant...................................................126 Check Dust Indicator...............................................................126 Check Water Separator, Drain Water (If Equipped).......................................128 Check Oil Level in Engine Oil Pan, Add Oil.........................................130 Check Oil Level in Transmission Case, Add Oil......................................131 Check Oil Level In Hydraulic Tank, Add Oil.........................................131 Drain Water, Sediment From Fuel Tank...............................................131 Check Fuel Level, Add Fuel.........................................................132 Check Wheel Hub Bolts, Tighten.....................................................133 Check Inflation Pressure Of Tires..................................................133 Check Central Warning Lamp, Alarm Buzzer, Monitor Lamps and Meters.................134 Check Braking Effect...............................................................134 Check Emergency Steering...........................................................134 Check Back-Up Alarm................................................................134 Check Electrical Wiring............................................................135 Check Water Separator..............................................................135 Check Body Positioner Operation....................................................136 Check Cab Mounting Bolts and Pins For Looseness and Breakage.......................136 Adjustments Before Operation...........................................................137 Adjusting Operator's Seat..........................................................137 Adjust Seat Belt...................................................................138 Adjust Steering Wheel Tilt.........................................................139 Adjusting Mirror...................................................................140 Operations, Checks Before Starting.....................................................141 Starting the Engine....................................................................143 Operations, Checks After Starting Engine...............................................145 Breaking-In the Machine............................................................145 Warming-Up Operation...............................................................145 Canceling Dump Body Hold Condition.................................................146 Stopping Engine........................................................................146 Checks After Stopping Engine.......................................................146 Moving the Machine.....................................................................147 Moving Machine Forward.............................................................147 Moving Machine in Reverse..........................................................149 Stopping the Machine...............................................................150 Shifting Gears.....................................................................151 Traveling Downhill.................................................................153 Brake Performance Curve............................................................155 Steering the Machine...................................................................159 Operation Using Differential Lock..................................................159 Loading Operations.....................................................................161 Handling Tailgate......................................................................161 Dump Operations........................................................................162 Cab Tilt Operation.....................................................................164 When Using Crane...................................................................165 When Using Tilt Cylinder...........................................................166 Precautions for Operation..........................................................167 Permissible Water Depth................................................................167 Parking Machine........................................................................168 Checks After Completion of Work........................................................169 Locking............................................................................169 Handling of KOMTRAX....................................................................170 Outline of System..................................................................170 Basic Precautions..................................................................171 Check Before Starting..............................................................171 Handling Tires.........................................................................172 Precautions When Handling Tires....................................................172 Precautions for Long Distance Travel...............................................172 Determining and Maintaining Travel Road................................................173 Determining Travel Road............................................................173 Maintaining Travel Road............................................................173 TRANSPORTATION.............................................................................174 Precautions When Transporting..........................................................174 Steps for Transportation...............................................................174 Method of Securing Machine.............................................................174 Method of Lifting Machine..............................................................176 Location of Lifting Position Mark..................................................177 Weight Table.......................................................................177 Lifting Procedure..................................................................178 COLD WEATHER OPERATION.....................................................................180 Precautions for Low Temperature........................................................180 Fuel and Lubricants................................................................180 Coolant............................................................................180 Installation of Radiator Curtain...................................................180 Battery............................................................................181 Precautions After Completion of Work...................................................181 After Cold Weather.....................................................................181 LONG-TERM STORAGE..........................................................................182 Before Storage.........................................................................182 During Storage.........................................................................182 After Storage..........................................................................182 Precautions Before Traveling After Long-term Storage...............................182 TROUBLESHOOTING............................................................................183 After Running Out of Fuel..............................................................183 If Transmission has Trouble............................................................183 Method of Lowering Dump Body in Emergency..............................................183 Method of Towing Machine...............................................................184 When Engine Runs...................................................................186 When Engine Does Not Run...........................................................186 When Parking Brake has Been Actuated in Emergency......................................187 Method of Releasing Parking Brake......................................................187 When Final Drive, Differential, Transmission, Transfer Have Broken Down................187 PRECAUTIONS FOR CHARGING BATTERY...........................................................188 Charging Battery when Mounted on Machine...............................................188 If Battery is Discharged...............................................................188 Removal and Installation of Battery....................................................189 Starting Engine with Booster Cable.....................................................189 Precautions When Connecting and Disconnecting Booster Cable........................189 Connecting the Booster Cables......................................................190 Starting the Engine................................................................190 Disconnecting the Booster Cables...................................................190 OTHER TROUBLE..............................................................................191 Electrical System......................................................................191 Chassis................................................................................192 If Accelerator Pedal has Failed........................................................193 Engine.................................................................................194 ACTION CODE................................................................................196 MAINTENANCE....................................................................................197 GUIDES TO MAINTENANCE......................................................................198 Check Service Meter....................................................................198 Komatsu Genuine Replacement Parts......................................................198 Komatsu Genuine Oils...................................................................198 Always Use Clean Washer Fluid..........................................................198 Always Use Clean Oil and Grease........................................................198 Checking Foreign Materials in Drained Oil and on Filters...............................198 Fueling................................................................................198 Welding Instructions...................................................................198 Do Not Drop Things Inside Machine:.....................................................198 Dusty Work Sites.......................................................................199 Avoid Mixing Oil.......................................................................199 Locking Inspection Covers..............................................................199 Bleeding Air From Hydraulic Circuit....................................................199 Precautions When Installing Hydraulic Hoses............................................199 Checks After Inspection and Maintenance................................................199 OUTLINES OF SERVICE........................................................................200 Handling Oil, Fuel, Coolant, and Performing Oil Clinic.................................201 Oil................................................................................201 Fuel...............................................................................201 Coolant and Water for Dilution.....................................................202 Grease.............................................................................202 Performing KOWA (Komatsu Oil Wear Analysis)........................................203 Storing Oil and Fuel...............................................................204 Filters............................................................................204 Outline of Electric System.............................................................204 WEAR PARTS LIST............................................................................205 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................206 USE OF FUEL, COOLANT AND LUBRICANTS........................................................208 Selection According to Ambient Temperature............................................. 0 Recommended Brands, Recommended Quality for Products other than Komatsu Genuine Oil....210 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................211 Torque List............................................................................211 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................213 Safety Critical Parts..................................................................213 REGULAR SCHEDULED MAINTENANCE..............................................................214 Maintenance Schedule Chart.............................................................214 Initial 250 Hours Service (Only After the First 250 Hours).............................216 When Required..........................................................................217 Check, Clean or Replace Air Cleaner................................................217 Clean Inside of Cooling System.....................................................223 Check Level of Window Washer Fluid, Add Fluid......................................226 Clean Air Conditioner Air Filter...................................................226 Check Refrigerant (Freon) Level....................................................227 Check Dump Body....................................................................227 Check Water Separator, Wash inside of Filter Case..................................228 Procedure for Bleeding Air From Fuel Circuit.......................................230 Machines Equipped with Manual Priming Pump.....................................230 Machines Equipped with Electric Priming Pump...................................231 Bleed Air From Front Brake.........................................................234 Bleed Air From Center Brake........................................................235 Bleed Air From Rear Brake..........................................................236 Check Output Coupling Play of Output Shaft.........................................237 Selection and Inspection of Tires..................................................238 Check Before Starting..................................................................240 Every 50 Hours Service.................................................................241 Lubrication........................................................................241 Every 250 Hours Service................................................................242 Lubrication........................................................................242 Lubricate Drive Shaft..............................................................244 Check Drive Shaft..................................................................244 Clean Breathers....................................................................245 Clean Overflow Hose................................................................247 Check Level of Battery Electrolyte.................................................248 When Checking Electrolyte Level From Side of Battery...............................248 When Impossible to Check Electrolyte Level From Side of Battery....................249 When Possible to Use Indicator to Check Electrolyte Level..........................249 Check Alternator Belt Tension, Adjust..............................................250 Check Air Conditioner Compressor Belt Tension, Adjust..............................251 Check Frame, A-Arm.................................................................252 Check Braking Capacity of Foot Brake...............................................253 Check Braking Capacity of Retarder Brake...........................................253 Check Braking Capacity of Parking Brake............................................254 Check Wear of Parking Brake Pads...................................................254 Check Length of Suspension Cylinder................................................255 Check of Accumulator Gas Pressure..................................................255 Every 500 Hours Service................................................................256 Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge..................256 Replace Fuel Prefilter Cartridge...................................................257 Lubrication Cab Mount Pin..........................................................258 Check Oil Level In Final Drive Case, Add Oil.......................................258 Check Oil Level In Differential Case, Add Oil......................................259 Clean, Check Radiator Fins and After Cooler Fins...................................260 Check Fan Belt Tension, Adjust.....................................................261 Recover Oil Leaking From Floating Seal.............................................262 Every 1000 Hours Service...............................................................263 Replace Fuel Main Filter Cartridge.................................................263 Replace Fuel Tank Breather Element.................................................264 Replace Corrosion Resistor Cartridge...............................................264 Replace Transmission Filter Element................................................265 Change Oil in Transmission Case....................................................266 Change Brake Oil in Tank, Replace Brake Oil Filter Element.........................268 Lubrication........................................................................270 Lubricating Parking Brake..........................................................271 Check Wear of Brake Disc...........................................................272 Check Engine Air Intake Piping Clamps for Looseness................................273 Every 2000 Hours Service...............................................................274 Change Oil in Final Drive Case.....................................................274 Change Oil in Differential Case....................................................275 Clean Hydraulic Tank Strainer......................................................277 Replace Hydraulic Filter Element...................................................278 Clean Transmission Case Strainer...................................................278 Clean Strainer In Differential Lock Hydraulic Circuit..............................279 Clean Breathers....................................................................280 Check Accumulator Gas Pressure.....................................................281 Check, Adjust Engine Valve Clearance...............................................281 Check Vibration Damper.............................................................281 Every 4000 Hours Service...............................................................282 Change Oil in Hydraulic Tank.......................................................282 Lubricate Fan Pulley...............................................................282 Check Alternator, Starting Motor...................................................282 Check Water Pump...................................................................282 Check Air Compressor...............................................................282 Check Fan Pulley And Tension Pulley................................................282 Checking for Looseness of High-pressure Clamp, Hardening of Rubber.................283 Checking for Missing Fuel Spray Prevention Cap, Hardening of Rubber................284 Check Exhaust Pipe Fire Prevention Cover...........................................284 Every 6000 Hours Service...............................................................285 Lubricate Drive Shaft..............................................................285 Every 8000 Hours Service...............................................................286 Replace High-Pressure Piping Clamp.................................................286 Replace Fuel Spray Prevention Cap..................................................286 Overhaul Starting Motor and Alternator.............................................286 SPECIFICATIONS.................................................................................287 SPECIFICATIONS.............................................................................288 OPTIONS, ATTACHMENTS...........................................................................289 HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC).....................................290 Explanation of Components..............................................................290 Automatic Retarder, Accelerator Control Switch.....................................291 Retarder Control Lever.............................................................291 Accelerator Pedal..................................................................291 Brake Pedal........................................................................291 Retarder Pilot Lamp................................................................291 Method Of Operation....................................................................291 Actuation of ARAC System...........................................................291 USE OF REAR VIEW MONITOR...................................................................292 Name and Function of Each Part of Rear View Monitor....................................292 Auto Switch........................................................................293 Manual Switch......................................................................293 Zoom/IRIS Switch (Reverse Light Compensation Switch)...............................293 Bright/Dim Light Selector Switch...................................................294 Mark Switch........................................................................294 Contrast Adjustment Knob...........................................................294 Brightness Adjustment Knob.........................................................295 Setting of Rear View Monitor...........................................................295 Cautions When Using Rear View Monitor..................................................295 HANDLING DUMPING COUNTER...................................................................296 Method of Displaying, Resetting Dumping Counter........................................296 HANDLING BATTERY DISCONNECTOR SWITCH.......................................................297 HANDLING MACHINES EQUIPPED WITH KOMTRAX....................................................298 Basic Precautions......................................................................298
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It was challenging at first, but I contacted the seller and everything turned out perfect. I have only looked through the manual.