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Komatsu HM400-2 Articulated Dump Truck Operation & Maintenance Manual SN 2001 And Up – PDF DOWNLOAD
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Komatsu HM400-2 Articulated Dump Truck Operation & Maintenance Manual
Book Code : TEN00128-04
MACHINE MODEL SERIAL NUMBER
HM400-2 – 2001 and up
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Description
Komatsu HM400-2 Articulated Dump Truck Operation & Maintenance Manual
FILE DETAILS:
Komatsu HM400-2 Articulated Dump Truck Operation & Maintenance Manual
Size : 9.21 MB
Format : PDF
Language : English
Number of Pages : 327 Pages
Brand: Komatsu
Type of machine: Articulated Dump Truck
Type of document: Operation & Maintenance Manual
Model: GALEO HM400-2
Serial: 2001 and up
KOMATSU HM400-2 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL SN 2001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu HM400-2 Articulated Dump Truck Operation & Maintenance Manual
FOREWORD:
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 forthe operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
TABLE OF CONTENTS:
Komatsu HM400-2 Articulated Dump Truck Operation & Maintenance Manual
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 EPA REGULATIONS, ENGINE NUMBER PLATE................................................... 9 SERVICE METER POSITION................................................................. 10 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................................. 10 CONTENTS....................................................................................... 11 SAFETY......................................................................................... 14 SAFETY..................................................................................... 15 SAFETY LABELS.............................................................................. 17 POSITION FOR ATTACHING SAFETY LABELS................................................... 17 SAFETY LABELS.......................................................................... 18 GENERAL PRECAUTIONS........................................................................ 23 SAFETY RULES........................................................................... 23 IF PROBLEMS ARE FOUND.................................................................. 23 CLOTHING AND PERSONAL PROTECTIVE ITEMS................................................. 23 FIRE EXTINGUISHER AND FIRST AID KIT.................................................... 23 SAFETY FEATURES........................................................................ 24 KEEP MACHINE CLEAN..................................................................... 24 INSIDE OPERATOR'S COMPARTMENT.......................................................... 24 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT......................................... 24 HANDRAILS AND STEPS.................................................................... 25 MOUNTING AND DISMOUNTING............................................................... 25 CRUSHING OR CUTTING PREVENTION......................................................... 25 PREVENTION OF BURNS.................................................................... 26 FIRE PREVENTION........................................................................ 27 ACTION IF FIRE OCCURS.................................................................. 27 WINDOW WASHER LIQUID................................................................... 28 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)........................... 28 PRECAUTIONS FOR ATTACHMENTS, OPTIONS................................................... 28 UNAUTHORIZED MODIFICATION.............................................................. 28 SAFETY AT WORKSITE..................................................................... 28 WORKING ON LOOSE GROUND................................................................ 29 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................................................. 29 ENSURE GOOD VISIBILITY................................................................. 30 PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS...................................... 30 CHECKING SIGNALMAN'S SIGNALS AND SIGNS................................................. 30 EMERGENCY ESCAPE FROM OPERATOR'S CAB................................................... 30 ASBESTOS DUST HAZARD PREVENTION........................................................ 31 PRECAUTIONS DURING OPERATION............................................................... 32 STARTING ENGINE........................................................................ 32 CHECKS BEFORE STARTING ENGINE, ADJUST.............................................. 32 PRECAUTIONS WHEN STARTING.......................................................... 32 PRECAUTIONS IN COLD AREAS.......................................................... 33 OPERATION.............................................................................. 34 CHECKS BEFORE STARTING OPERATION................................................... 34 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE................................... 34 PRECAUTIONS WHEN TRAVELING......................................................... 35 PRECAUTIONS WHEN TRAVELING ON SLOPES............................................... 35 PRECAUTIONS WHEN OPERATING DUMP BODY............................................... 36 PRECAUTIONS WHEN OPERATING......................................................... 36 PRECAUTIONS FOR ACCUMULATED SNOW, ICE.............................................. 36 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.............................................................. 90 BODY PIVOT PIN......................................................................... 95 ARTICULATE LOCK........................................................................ 95 LOCATION OF FIRE EXTINGUISHER.......................................................... 96 DUST INDICATOR......................................................................... 96 CIRCUIT BREAKER........................................................................ 96 CIRCUIT BREAKER........................................................................ 96 FUSES.................................................................................. 97 CAR RADIO..............................................................................100 CAR STEREO.............................................................................106 AIR CONDITIONER........................................................................114 OPERATION..................................................................................120 CHECK BEFORE STARTING ENGINE...........................................................120 STARTING ENGINE........................................................................134 OPERATIONS, CHECKS AFTER STARTING ENGINE...............................................136 STOPPING ENGINE........................................................................137 CHECKS AFTER STOPPING ENGINE...........................................................137 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING........................................138 SHIFTING GEAR..........................................................................143 TRAVELING DOWNHILL.....................................................................145 STEERING THE MACHINE...................................................................151 OPERATION USING DIFFERENTIAL LOCK......................................................151 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 IF TRANSMISSION HAS TROUBLE............................................................175 METHOD OF LOWERING DUMP BODY IN EMERGENCY..............................................175 METHOD OF TOWING MACHINE...............................................................176 IF BATTERY IS DISCHARGED...............................................................180 OTHER TROUBLE..........................................................................184 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....201 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................202 TORQUE LIST............................................................................202 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................204 SAFETY CRITICAL PARTS..................................................................205 MAINTENANCE SCHEDULE CHART.................................................................206 MAINTENANCE SCHEDULE CHART.............................................................206 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.....................................................216 CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID......................................219 CLEAN AIR CONDITIONER AIR FILTER...................................................219 CHECK REFRIGERANT (GAS) LEVEL......................................................220 CHECK DUMP BODY....................................................................221 CHECK LENGTH OF SUSPENSION CYLINDER................................................221 BLEED AIR FROM FRONT BRAKE.........................................................222 BLEED AIR FROM CENTER BRAKE........................................................223 BLEED AIR FROM REAR BRAKE..........................................................224 CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT......................................225 SELECTION AND INSPECTION OF TIRES..................................................226 CHECK BEFORE STARTING..................................................................229 EVERY 50 HOURS SERVICE.................................................................230 LUBRICATION........................................................................230 EVERY 250 HOURS SERVICE................................................................231 LUBRICATION........................................................................231 LUBRICATE DRIVE SHAFT..............................................................233 CHECK DRIVE SHAFT..................................................................233 CLEAN BREATHERS....................................................................234 CLEAN OVERFLOW HOSE................................................................236 CHECK LEVEL OF BATTERY ELECTROLYTE.................................................237 CHECK ALTERNATOR BELT TENSION, ADJUST..............................................239 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..............................240 CHECK FRAME, A-ARM.................................................................241 CHECK BRAKING CAPACITY OF FOOT BRAKE...............................................242 CHECK BRAKING CAPACITY OF RETARDER BRAKE...........................................242 CHECK BRAKING CAPACITY OF PARKING BRAKE............................................243 CHECK WEAR OF PARKING BRAKE PADS...................................................243 CHECK OF ACCUMULATOR GAS PRESSURE..................................................244 EVERY 500 HOURS SERVICE................................................................245 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................245 REPLACE FUEL PREFILTER CARTRIDGE...................................................246 LUBRICATE CAB MOUNT PIN (LEFT AND RIGHT: 1 PLACE EACH).............................247 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.......................................247 CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL......................................248 CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS...................................250 CHECK FAN BELT TENSION, ADJUST.....................................................251 RECOVER OIL LEAKING FROM FLOATING SEAL.............................................252 EVERY 1000 HOURS SERVICE...............................................................254 REPLACE FUEL MAIN FILTER CARTRIDGE.................................................254 REPLACE CORROSION RESISTOR CARTRIDGE...............................................255 REPLACE TRANSMISSION FILTER ELEMENT................................................256 CHANGE OIL IN TRANSMISSION CASE....................................................257 CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT.....................259 LUBRICATION........................................................................262 CHECK WEAR OF BRAKE DISC...........................................................264 CHECK OF ENGINE AIR INTAKE PIPING CLAMPS FOR LOOSENESS.............................265 EVERY 2000 HOURS SERVICE...............................................................266 CHANGE OIL IN FINAL DRIVE CASE.....................................................266 CHANGE OIL IN DIFFERENTIAL CASE....................................................267 REPLACE HYDRAULIC FILTER ELEMENT...................................................269 CLEAN HYDRAULIC TANK STRAINER......................................................270 CLEAN TRANSMISSION CASE STRAINER...................................................271 CLEAN STRAINER IN DIFFERENTIAL LOCK HYDRAULIC CIRCUIT..............................272 CLEAN BREATHER.....................................................................274 CHECK ACCUMULATOR GAS PRESSURE.....................................................274 CHECK, ADJUST ENGINE VALVE CLEARANCE...............................................274 EVERY 4000 HOURS SERVICE...............................................................275 CHANGE OIL IN HYDRAULIC TANK.......................................................275 LUBRICATE FAN PULLEY...............................................................275 CHECK ALTERNATOR, STARTING MOTOR...................................................275 CHECK WATER PUMP...................................................................275 CHECK AIR COMPRESSOR...............................................................275 CHECK FAN PULLEY AND TENSION PULLEY................................................275 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.................276 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER................276 EVERY 6000 HOURS SERVICE...............................................................277 LUBRICATE DRIVE SHAFT..............................................................277 EVERY 8000 HOURS SERVICE...............................................................278 REPLACE HIGH-PRESSURE PIPING CLAMP.................................................278 REPLACE FUEL SPRAY PREVENTION CAP..................................................278 OVERHAUL STARTING MOTOR AND ALTERNATOR.............................................278 SPECIFICATIONS.................................................................................280 SPECIFICATIONS.............................................................................281 ATTACHMENTS, OPTIONS...........................................................................282 HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC).....................................283 EXPLANATION OF COMPONENTS..............................................................283 METHOD OF OPERATION....................................................................284 HANDLING PAYLOAD METER HM..................................................................285 FEATURES OF PAYLOAD METER HM...........................................................285 METHOD OF USING ACCURATELY.............................................................286 GENERAL LOCATIONS......................................................................288 CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)................................291 EXTERNAL DISPLAY LAMPS.................................................................293 DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER......................................295 OPERATION OF SWITCHES..................................................................298 ABNORMALITY AND WARNING DISPLAY (ERROR CODE)...........................................311 WHEN ERROR CODE F-09 IS DISPLAYED......................................................313 OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED...........................................313 PROCEDURE WHEN DOWNLOADING.............................................................314 OTHERS.................................................................................317 USE OF REAR VIEW MONITOR...................................................................318 NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR.....................................318 SETTING OF REAR VIEW MONITOR...........................................................321 CAUTIONS WHEN USING REAR VIEW MONITOR..................................................321 HANDLING DUMPING COUNTER...................................................................322 HANDLING MACHINES EQUIPPED WITH KOMTRAX....................................................323 BASIC PRECAUTIONS......................................................................323 INDEX..........................................................................................324
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
1 review for Komatsu HM400-2 Articulated Dump Truck Operation & Maintenance Manual SN 2001 And Up – PDF DOWNLOAD
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Maximiliano Forrest –
so far so good havnt got manual yet