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KOMATSU HM400-2 ARTICULATED DUMP TRUCK Operation & Maintenance Manual (SN:HM400-2 A11001 and up) KOMATSU HM400-2 – PDF DOWNLOAD
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- KOMATSU HM400-2 ARTICULATED DUMP TRUCK Operation & Maintenance Manual
- SERIAL NUMBER:HM400-2 A11001 and up
- PUBLICATION NUMBER:CEAM017603
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Description
KOMATSU HM400-2 ARTICULATED DUMP TRUCK Operation & Maintenance Manual (SN:HM400-2 A11001 and up) KOMATSU HM400-2
KOMATSU HM400-2 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:HM400-2 A11001 AND UP) KOMATSU HM400-2 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU HM400-2 ARTICULATED DUMP TRUCK Operation & Maintenance Manual (SN:HM400-2 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 HM400-2 ARTICULATED DUMP TRUCK Operation & Maintenance Manual (SN:HM400-2 A11001 and up)
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......................................................................................... 25 SAFETY LABELS.............................................................................. 26 SAFETY AND WARNING DECALS.................................................................. 27 Location of Safety Decals.............................................................. 28 Safety Labels.......................................................................... 28 GENERAL SAFETY RULES AND PRECAUTIONS....................................................... 33 General Safety Rules................................................................... 33 Safety Features........................................................................ 34 Personal Protective Equipment.......................................................... 34 Fire and Explosion Prevention.......................................................... 35 Fire Caused by Fuel or Oil......................................................... 35 Fire Caused by Accumulation of Flammable Material.................................. 35 Fire Coming from Electric Wiring................................................... 36 Fire Coming from Hydraulic Line.................................................... 36 Windshield Washer Fluid............................................................ 36 Action if Fire Occurs.................................................................. 36 Fire Extinguisher and First Aid Kit.................................................... 36 Fire Prevention and Suppression........................................................ 37 Fire Prevention Steps.............................................................. 37 Fixed Fire Detection System........................................................ 37 Fixed Fire Suppression System...................................................... 37 Fire Prevention Procedures......................................................... 37 Dust Hazard Precautions................................................................ 38 Keep Operator's Cab Clean.............................................................. 38 Unauthorized Modifications............................................................. 38 Leaving Operator’s Compartment......................................................... 39 Mounting and Dismounting............................................................... 40 Crush or Pinch Point Dangers........................................................... 40 Inside Operator’s Compartment.......................................................... 41 Precautions When Using ROPS............................................................ 41 PRECAUTIONS BEFORE STARTING OPERATIONS..................................................... 42 Pre-Operational Checks................................................................. 42 Starting Your Work Operations.......................................................... 42 Work Site Hazards...................................................................... 42 Avoiding Dangerous Situations.......................................................... 43 Working Clearances..................................................................... 45 Operating on Snow or Icy Surfaces...................................................... 45 Asbestos Hazard Alert.................................................................. 46 RULES FOR ROAD TRAVEL...................................................................... 47 Precautions When Traveling............................................................. 47 When Traveling on Slopes............................................................... 47 When Dumping a Load.................................................................... 48 Ensure Good Visibility................................................................. 48 When Traveling in Reverse.............................................................. 49 Parking the Machine.................................................................... 50 PRECAUTIONS DURING MAINTENANCE OPERATIONS.................................................. 52 Warning Tags........................................................................... 52 Equipment Storage...................................................................... 52 Working Under the Machine.............................................................. 53 Using Drop Lamps....................................................................... 53 Keeping the Machine Clean.............................................................. 53 Performing General Maintenance Procedures.............................................. 54 Running the Engine During Maintenance.................................................. 55 Proper Tools........................................................................... 56 Engine System High-voltage............................................................. 56 Welding, Grinding or Cutting........................................................... 56 When Using Hammer...................................................................... 57 Refueling the Machine.................................................................. 57 Cooling System Precautions............................................................. 57 Battery Precautions.................................................................... 58 Starting the Machine................................................................... 58 High Pressure Hoses.................................................................... 59 Safety Handling High-pressure Hoses.................................................... 59 Precaution for High Fuel Pressure...................................................... 59 High Temperature Areas................................................................. 59 Disposal of Waste Materials............................................................ 60 Accumulator............................................................................ 60 Critical Parts......................................................................... 60 HANDLING TIRES............................................................................. 61 Precautions When Storing Tires......................................................... 61 TRANSPORTATION............................................................................. 62 Precautions When Transporting.......................................................... 62 Steps for Transportation............................................................... 62 Method of Securing Machine............................................................. 62 Method of Lifting Machine.............................................................. 63 Location of Lifting Points............................................................. 64 TOWING MACHINE............................................................................. 65 OPERATION...................................................................................... 67 GENERAL VIEW............................................................................... 68 Machine................................................................................ 68 Controls and Gauges.................................................................... 69 Machine Monitor........................................................................ 70 EXPLANATION OF COMPONENTS.................................................................. 71 Machine Monitor........................................................................ 71 Check Central Warning Lamp, Alarm Buzzer, Monitor Lamps, And Meters................ 72 Character Display Portion.......................................................... 72 Caution Items...................................................................... 77 Emergency Stop Item................................................................ 80 Pilot Display Portion.............................................................. 84 Meter Display Portion.............................................................. 88 Central Warning Lamp............................................................... 90 Other Functions of Machine Monitor................................................. 91 Switches............................................................................... 94 Ignition Switch.................................................................... 95 Lamp Switch........................................................................ 95 Turn Signal Lever.................................................................. 95 Dimmer Switch...................................................................... 96 Hazard Lamp Switch................................................................. 96 Night Lighting Dimmer Switch....................................................... 96 Power Mode Selector Switch......................................................... 96 Emergency Steering Switch.......................................................... 97 Shift Hold Switch.................................................................. 97 Parking Brake Switch............................................................... 98 AISS Low Switch.................................................................... 98 Inter-axle Differential Lock Switch................................................ 99 Left and Right Differential Lock Switch............................................ 99 Fog Lamp Switch....................................................................100 Side Lamp Switch...................................................................100 Working Lamp (Front) Switch........................................................100 Power Window Switch (Right) (Left).................................................101 Machine Monitor Mode Selector Switch 1, 2..........................................101 Cigarette Lighter..................................................................101 Horn Button........................................................................102 Wiper, Window Washer Switch........................................................102 Room Lamp Switch...................................................................102 Switch for Rear Window Glass With Heated Wire......................................103 Yellow Rotating Lamp Switch........................................................103 Control Levers And Pedals..............................................................104 Brake Pedal........................................................................104 Accelerator Pedal..................................................................105 Gear Shift Lever...................................................................105 Dump Lever.........................................................................107 Retarder Control Lever.............................................................107 Left and Right Differential Lock Pedal.............................................107 Dump Safety Lever Lock Knob........................................................108 Safety Pin.............................................................................109 Stowing Safety Pin.................................................................109 Articulate Lock........................................................................110 Location of Fire Extinguisher..........................................................110 Dust Indicator.........................................................................110 Circuit Breaker........................................................................111 Fuses..................................................................................111 Fuse Capacity and Circuit Name.....................................................111 AM/FM Radio-cassette Stereo............................................................114 Radio Operation....................................................................115 Radio Features.....................................................................119 Listening to Radio.................................................................120 Listening to Cassette Tape.........................................................120 Precautions When Using Radio.......................................................121 AIR CONDITIONER............................................................................122 General Locations on Control Panel.....................................................122 ON/OFF Switch......................................................................122 Fan Switch.........................................................................122 Air Conditioner Switch.............................................................122 Mode Selector Switch...............................................................123 DEF (Defrost) Switch...............................................................123 RECIRC/FRESH Selector Switch.......................................................123 Temperature Control Switch.........................................................124 Method of Operation....................................................................124 Cooling............................................................................124 Heating............................................................................124 Dehumidifying, Defrosting..........................................................125 Precautions When Using Air Conditioner.............................................125 Inspection and Maintenance.........................................................125 OPERATION..................................................................................126 Check Before Starting Engine...........................................................126 Walk-around Check..................................................................126 Checks Before Starting.................................................................128 Check Coolant Level, Add Coolant...................................................128 Check Dust Indicator...............................................................128 Check Water Separator, Drain Water (If Equipped)...................................130 Check Oil Level in Engine Oil Pan, Add Oil.........................................132 Check Oil Level in Transmission Case, Add Oil......................................133 Check Oil Level In Hydraulic Tank, Add Oil.........................................133 Drain Water, Sediment From Fuel Tank...............................................133 Check Fuel Level, Add Fuel.........................................................134 Check Wheel Hub Bolts, Tighten.....................................................134 Check Inflation Pressure of Tires..................................................135 Check Central Warning Lamp, Alarm Buzzer, Monitor Lamps and Meters.................135 Check Braking Effect...............................................................135 Check Emergency Steering...........................................................136 Check Back-Up Alarm................................................................136 Check Electrical Wiring............................................................136 Drain Water from Fuel Pre-Filter...................................................137 Check Body Positioner Operation....................................................137 Check Cab Mounting Bolts and Pins For Looseness and Breakage.......................137 Adjustments Before Operation...........................................................138 Adjusting Operator's Seat..........................................................138 Adjust Seat Belt...................................................................139 Adjust Steering Wheel Tilt.........................................................140 Adjusting Mirror...................................................................141 Operations, Checks Before Starting.....................................................142 Starting the Engine....................................................................144 Operations, Checks After Starting Engine...............................................146 Breaking-In the Machine............................................................146 Warming-Up Operation...............................................................146 Canceling Dump Body Hold Condition.................................................147 Stopping Engine........................................................................147 Checks After Stopping Engine.......................................................147 Moving the Machine.....................................................................148 Moving Machine Forward.............................................................148 Moving Machine in Reverse..........................................................150 Stopping the Machine...............................................................151 Shifting Gears.....................................................................153 Traveling Downhill.................................................................155 Brake Performance Curve............................................................157 Steering the Machine...................................................................161 Operation Using Differential Lock..................................................161 When Tires are Stuck in Ground.....................................................163 Loading Operations.....................................................................163 Handling Tailgate......................................................................163 Handling Extension for Hauling Coal................................................164 Dump Operations........................................................................166 Cab Tilt Operation.....................................................................168 When Using Crane...................................................................169 When Using Tilt Cylinder...........................................................170 Precautions for Operation..........................................................171 Permissible Water Depth................................................................171 Parking Machine........................................................................172 Checks After Completion of Work........................................................173 Locking............................................................................173 Handling of KOMTRAX....................................................................174 Outline of System..................................................................174 Basic Precautions..................................................................175 Check Before Starting..............................................................175 Handling Tires.........................................................................176 Precautions When Handling Tires....................................................176 Precautions for Long Distance Travel...............................................176 Determining and Maintaining Travel Road................................................177 Determining Travel Road............................................................177 Maintaining Travel Road............................................................177 TRANSPORTATION.............................................................................178 Precautions When Transporting..........................................................178 Steps for Transportation...............................................................178 Method of Securing Machine.............................................................178 Method of Lifting Machine..............................................................180 Location of Lifting Position Mark..................................................181 Weight Table.......................................................................181 Lifting Procedure..................................................................182 COLD WEATHER OPERATION.....................................................................184 Precautions for Low Temperature........................................................184 Fuel and Lubricants................................................................184 Coolant............................................................................184 Installation of Radiator Curtain...................................................184 Battery............................................................................185 Precautions After Completion of Work...................................................185 After Cold Weather.....................................................................185 LONG-TERM STORAGE..........................................................................186 Before Storage.........................................................................186 During Storage.........................................................................186 After Storage..........................................................................186 Precautions Before Traveling After Long-term Storage...............................186 TROUBLESHOOTING............................................................................187 After Running Out of Fuel..............................................................187 If Transmission has Trouble............................................................187 Method of Lowering Dump Body in Emergency..............................................187 Method of Towing Machine...............................................................188 When Engine Runs...................................................................190 When Engine Does Not Run...........................................................190 When Parking Brake has Been Actuated in Emergency......................................191 Method of Releasing Parking Brake......................................................191 When Final Drive, Differential, Transmission, Transfer Have Broken Down................191 PRECAUTIONS FOR CHARGING BATTERY...........................................................192 Charging Battery when Mounted on Machine...............................................192 If Battery is Discharged...............................................................192 Removal and Installation of Battery....................................................193 Starting Engine with Booster Cable.....................................................194 Precautions When Connecting and Disconnecting Booster Cable........................194 Connecting the Booster Cables......................................................194 Starting the Engine................................................................194 Disconnecting the Booster Cables...................................................195 OTHER TROUBLE..............................................................................196 Electrical System......................................................................196 Chassis................................................................................197 If Accelerator Pedal has Failed........................................................198 Engine.................................................................................199 ACTION CODE................................................................................201 MAINTENANCE....................................................................................203 GUIDES TO MAINTENANCE......................................................................204 Check Service Meter....................................................................204 Komatsu Genuine Replacement Parts......................................................204 Komatsu Genuine Oils...................................................................204 Always Use Clean Washer Fluid..........................................................204 Always Use Clean Oil and Grease........................................................204 Checking Foreign Materials in Drained Oil and on Filters...............................204 Fueling................................................................................204 Welding Instructions...................................................................204 Do Not Drop Things Inside Machine:.....................................................204 Dusty Work Sites.......................................................................205 Avoid Mixing Oil.......................................................................205 Locking Inspection Covers..............................................................205 Bleeding Air From Hydraulic Circuit....................................................205 Precautions When Installing Hydraulic Hoses............................................205 Checks After Inspection and Maintenance................................................205 OUTLINES OF SERVICE........................................................................206 Handling Oil, Fuel, Coolant, and Performing Oil Clinic.................................207 Oil................................................................................207 Fuel...............................................................................207 Coolant and Water for Dilution.....................................................208 Grease.............................................................................208 Performing KOWA (Komatsu Oil Wear Analysis)........................................209 Storing Oil and Fuel...............................................................210 Filters............................................................................210 Outline of Electric System.............................................................210 WEAR PARTS LIST............................................................................211 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................212 USE OF FUEL, COOLANT AND LUBRICANTS........................................................213 Selection According to Ambient Temperature.............................................213 Recommended Brands, Recommended Quality for Products other than Komatsu Genuine Oil....214 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................215 Torque List............................................................................215 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................217 Safety Critical Parts..................................................................217 REGULAR SCHEDULED MAINTENANCE..............................................................218 Maintenance Schedule Chart.............................................................218 Initial 250 Hours Service (Only After the First 250 Hours).............................220 When Required..........................................................................221 Check, Clean or Replace Air Cleaner................................................221 Clean Inside of Cooling System.....................................................228 Check Level of Window Washer Fluid, Add Fluid......................................231 Clean Air Conditioner Air Filter...................................................231 Check Refrigerant (Freon) Level....................................................232 Check Dump Body....................................................................233 Check Length of Suspension Cylinder................................................233 Check Water Separator, Wash inside of Filter Case..................................234 Procedure for Bleeding Air From Fuel Circuit.......................................236 Bleed Air From Front Brake.........................................................240 Bleed Air From Center Brake........................................................241 Bleed Air From Rear Brake..........................................................242 Check Output Coupling Play of Output Shaft.........................................243 Selection and Inspection of Tires..................................................244 Check Before Starting..................................................................247 Every 50 Hours Service.................................................................248 Lubrication........................................................................248 Every 250 Hours Service................................................................249 Lubrication........................................................................249 Lubricate Drive Shaft..............................................................251 Check Drive Shaft..................................................................251 Clean Breathers....................................................................252 Clean Overflow Hose................................................................254 Check Level of Battery Electrolyte.................................................255 When Checking Electrolyte Level From Side of Battery...............................255 When Impossible to Check Electrolyte Level From Side of Battery....................256 When Possible to Use Indicator to Check Electrolyte Level..........................256 Check Alternator Belt Tension, Adjust..............................................257 Check Air Conditioner Compressor Belt Tension, Adjust..............................258 Check Frame, A-Arm.................................................................259 Check Braking Capacity of Foot Brake...............................................260 Check Braking Capacity of Retarder Brake...........................................260 Check Braking Capacity of Parking Brake............................................261 Check Wear of Parking Brake Pads...................................................261 Check of Accumulator Gas Pressure..................................................262 Every 500 Hours Service................................................................263 Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge..................263 Replace Fuel Prefilter Cartridge...................................................264 Lubrication Cab Mount Pin..........................................................265 Check Oil Level In Final Drive Case, Add Oil.......................................265 Check Oil Level In Differential Case, Add Oil......................................266 Clean, Check Radiator Fins and After Cooler Fins...................................267 Check Fan Belt Tension, Adjust.....................................................268 Recover Oil Leaking From Floating Seal.............................................270 Every 1000 Hours Service...............................................................272 Replace Fuel Main Filter Cartridge.................................................272 Replace Fuel Tank Breather Element.................................................273 Replace Corrosion Resistor Cartridge...............................................273 Replace Transmission Filter Element................................................274 Change Oil in Transmission Case....................................................275 Change Brake Oil in Tank, Replace Brake Oil Filter Element.........................277 Lubrication........................................................................279 Lubricating Parking Brake..........................................................280 Check Wear of Brake Disc...........................................................281 Check Engine Air Intake Piping Clamps for Looseness................................282 Every 2000 Hours Service...............................................................283 Change Oil in Final Drive Case.....................................................283 Change Oil in Differential Case....................................................284 Clean Hydraulic Tank Strainer......................................................286 Replace Hydraulic Filter Element...................................................287 Clean Transmission Case Strainer...................................................287 Clean Strainer In Differential Lock Hydraulic Circuit..............................288 Clean Breathers....................................................................289 Check Accumulator Gas Pressure.....................................................290 Check Alternator...................................................................290 Check, Adjust Engine Valve Clearance...............................................290 Check Vibration Damper.............................................................290 Every 4000 Hours Service...............................................................291 Change Oil in Hydraulic Tank.......................................................291 Lubricate Fan Pulley...............................................................291 Check Starting Motor...............................................................291 Check Water Pump...................................................................291 Check Air Compressor...............................................................291 Check Fan Pulley And Tension Pulley................................................291 Checking for Looseness of High-pressure Clamp, Hardening of Rubber.................292 Checking for Missing Fuel Spray Prevention Cap, Hardening of Rubber................293 Check Exhaust Pipe Fire Prevention Cover...........................................293 Every 6000 Hours Service...............................................................294 Lubricate Drive Shaft..............................................................294 Every 8000 Hours Service...............................................................295 Replace High-Pressure Piping Clamp.................................................295 Replace Fuel Spray Prevention Cap..................................................295 Overhaul Starting Motor and Alternator.............................................295 SPECIFICATIONS.................................................................................297 SPECIFICATIONS.............................................................................298 OPTIONS, ATTACHMENTS...........................................................................299 HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL (ARAC)....................................300 Explanation of Components..............................................................300 Automatic Retarder, Accelerator Control Switch.....................................301 Retarder Control Lever.............................................................301 Accelerator Pedal..................................................................301 Brake Pedal........................................................................301 Retarder Pilot Lamp................................................................301 Method Of Operation....................................................................301 Actuation of ARAC System...........................................................301 HANDLING PAYLOAD METER HM..................................................................302 Features of Payload Meter HM...........................................................302 Measuring Loading..................................................................302 Three Measurement Methods..........................................................302 Panel Display......................................................................302 External Display Lamp..............................................................302 Writing Operation Data.............................................................302 Method of Using Accurately.............................................................303 Length of Suspension Cylinder......................................................303 Performing Calibration.............................................................303 Method Using Travel Mode...........................................................303 Method Using Dumping Mode..........................................................303 Method Using Loading Mode..........................................................304 Downloading........................................................................304 General Locations......................................................................305 Controller Screen..................................................................305 Left Face of Controller............................................................306 External Display Lamps.............................................................307 Communications Cable Connection Port for Personal Computer.........................307 Content of Display (Controller, External Display Lamps)................................308 When the Power is ON...............................................................308 Display During Normal Operations...................................................309 External Display Lamps.................................................................310 Display Level for Lamps............................................................310 Estimate Display...................................................................311 Details of Data Stored in Memory of Payload Meter......................................312 Cycle Data.........................................................................312 Engine ON/OFF Data.................................................................313 Abnormality, Warning Data..........................................................314 Operation of Switches..................................................................314 Performing Calibration.................................................................315 When Calibrating...................................................................315 Preparations Before Calibrating....................................................315 Method of Calibrating (Method of Operation)........................................315 Forced Display of Total Payload and Overall Number of Cycles...........................316 Method for Forced Display Operation................................................316 Method of Clearing Total Payload and Overall Number of Cycles......................317 Operator Check Mode................................................................318 Method of Operation....................................................................320 A) Memory Card Dump Operation......................................................321 B) Open ID Setting.................................................................322 C) Machine ID Setting..............................................................323 D) Adjusting Time, Date............................................................324 E) Data All Clear Operation........................................................326 Dimming Lights on Monitor Display......................................................327 Service Check Mode.....................................................................327 Abnormality and Warning Display (Error Code)...........................................328 When Error Code F-09 Is Displayed..................................................329 Procedure When Downloading.............................................................330 Downloading From Download Connector Inside Cab.....................................330 Download Software..................................................................330 Others.............................................................................333 USE OF REAR VIEW MONITOR...................................................................334 Name and Function of Each Part of Rear View Monitor....................................334 Auto Switch........................................................................335 Manual Switch......................................................................335 Zoom/IRIS Switch (Reverse Light Compensation Switch)...............................335 Bright/Dim Light Selector Switch...................................................336 Mark Switch........................................................................336 Contrast Adjustment Knob...........................................................336 Brightness Adjustment Knob.........................................................337 Setting of Rear View Monitor...........................................................337 How to Set Display Mode............................................................337 Cautions When Using Rear View Monitor..................................................338 HANDLING DUMPING COUNTER...................................................................338 Method of Displaying, Resetting Dumping Counter........................................338 HANDLING BATTERY DISCONNECTOR SWITCH.......................................................339 HANDLING MACHINES EQUIPPED WITH KOMTRAX....................................................340 Basic Precautions......................................................................340
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