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Komatsu HM400-3 Articulated Dump Truck Operation & Maintenance Manual SN 3375 and up – PDF DOWNLOAD
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Komatsu HM400-3 Articulated Dump Truck Operation & Maintenance Manual
Book Code: TEN00632-01
SERIAL NUMBERS 3375 and up
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Description
Komatsu HM400-3 Articulated Dump Truck Operation & Maintenance Manual
FILE DETAILS:
Komatsu HM400-3 Articulated Dump Truck Operation & Maintenance Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Operation & Maintenance Manual
Machine Model: HM400-3
Serial Number: 3375 and up
Language: English
Book Code: TEN00632-01
Pages: 413
File Format: Portable Document Format (PDF)
KOMATSU HM400-3 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL SN 3375 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu HM400-3 Articulated Dump Truck Operation & Maintenance Manual
BEFORE READING THIS MANUAL (HM-0110-010-A-00-A):
This manual gives details of the operation and methods of inspection and maintenance for this machine that must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Read, understand and follow all precautions and warnings in this manual and on the machine before performing operation and maintenance. Failure to do so may result in serious injury or death.
- Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used. Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions. If you carry out any operation, inspection, or maintenance under conditions that are not described in this manual, understand that it is your responsibility to take the necessary precautions to ensure safety.
- In no event should you or others engage in the prohibited uses or actions described in this manual. Improper operation and maintenance of the machine can be hazardous and could result in serious injury or death. If you sell the machine, be sure to give this manual to the new owner together with the machine. Always keep this Operation and Maintenance Manual in the location shown on the right so that all relevant personnel can read it at any time.
- Storage location for the Operation and Maintenance Manual: On inside of left door If this manual is lost or damaged, contact and tell your distributor about the machine model name and the serial No. immediately to arrange for its replacement. For details regarding the machine model name and the serial No., see the machine serial No. plate. In order to arrange the proper Operation and Maintenance Manual, you will need to provide the machine model name and the serial No. to your Komatsu distributor.
- This manual uses the international units (SI) for units of measurement. For reference, units that have been used in the past are given in { }. The explanations, values, and illustrations in this manual have been prepared based on the latest information available as of the date of its publication.
- Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information concerning your machine or with questions regarding information contained in this manual.
- • The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: ① as (1)) Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped.
- If this machine has been purchased in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.
TABLE OF CONTENTS:
Komatsu HM400-3 Articulated Dump Truck Operation & Maintenance Manual
COVER.................................................................................. 1 FOREWORD .............................................................................. 2 BEFORE READING THIS MANUAL ........................................................ 3 SAFETY INFORMATION ................................................................ 4 INTRODUCTION ...................................................................... 5 USE OF MACHINE ................................................................ 5 DIRECTIONS OF MACHINE ......................................................... 5 VISIBILITY FROM OPERATOR’S SEAT ............................................... 5 PRODUCT INFORMATION ............................................................... 6 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE .................. 6 EPA REGULATIONS, ENGINE NUMBER PLATE .......................................... 6 SERVICE METER LOCATION ........................................................ 7 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR ................................... 7 CONTENTS .......................................................................... 8 SAFETY ................................................................................ 12 SAFETY ............................................................................ 13 SAFETY LABELS ..................................................................... 15 LOCATION OF SAFETY LABELS ..................................................... 16 SAFETY LABELS ................................................................. 19 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ........................... 26 PRECAUTIONS BEFORE STARTING OPERATION ......................................... 26 PREPARATIONS FOR SAFE OPERATION ............................................... 27 FIRE PREVENTION ............................................................... 29 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE .................................... 31 DO NOT GET CAUGHT IN WORK EQUIPMENT ........................................... 34 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES .................................. 34 UNAUTHORIZED MODIFICATION ..................................................... 34 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ................................ 34 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ............................... 35 PRECAUTIONS FOR OPERATION ......................................................... 36 PRECAUTIONS FOR JOBSITE ....................................................... 36 STARTING ENGINE ............................................................... 38 OPERATION ..................................................................... 41 TRANSPORTATION ................................................................ 45 TOWING ........................................................................ 46 PRECAUTIONS FOR MAINTENANCE ....................................................... 47 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ........................ 47 PRECAUTIONS FOR INSPECTION AND MAINTENANCE .................................... 53 TIRES ......................................................................... 58 OPERATION ............................................................................. 60 GENERAL VIEW ...................................................................... 61 GENERAL VIEW OF MACHINE ....................................................... 61 GENERAL VIEW OF CONTROLS AND GAUGES ........................................... 62 EXPLANATION OF COMPONENTS ......................................................... 66 MACHINE MONITOR ............................................................... 66 SWITCHES ......................................................................138 CONTROL LEVERS AND PEDALS .....................................................148 CIGARETTE LIGHTER .............................................................152 ASHTRAY .......................................................................152 DRINK BOX .....................................................................152 CUP HOLDER ....................................................................153 HANDY TRAY ....................................................................153 MAGAZINE BOX ..................................................................153 EMERGENCY ESCAPE HAMMER .......................................................154 HANDLING AIR CONDITIONER ......................................................155 HANDLING RADIO ................................................................168 AUXILIARY ELECTRIC POWER ......................................................173 FUSE ..........................................................................174 OPEN AND CLOSE CAB DOOR .......................................................178 STORAGE FOR TOOLS .............................................................179 STORAGE FOR FIRE EXTINGUISHER .................................................179 BATTERY DISCONNECT SWITCH .....................................................180 CIRCUIT BREAKER ...............................................................182 DUST INDICATOR ................................................................182 ARTICULATION LOCK .............................................................183 BODY PIVOT PINS ...............................................................184 HANDLING REAR VIEW MONITOR ....................................................185 HANDLING Komatsu Diesel Particulate Filter (KDPF) .............................188 HANDLING Komatsu Closed Crankcase Ventilation (KCCV) ..........................199 HANDLING MACHINES EQUIPPED WITH KOMTRAX .......................................200 MACHINE OPERATIONS AND CONTROLS ...................................................202 CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ..................................202 STARTING ENGINE ...............................................................228 OPERATIONS AND CHECKS AFTER STARTING ENGINE ...................................233 STOPPING ENGINE ...............................................................236 CHECKS AFTER STOPPING ENGINE ..................................................236 MACHINE OPERATION .............................................................237 SHIFTING GEARS ................................................................242 TRAVELING DOWNHILL ............................................................244 STEERING MACHINE ..............................................................250 HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL (ARAC) .......................251 HANDLING KOMATSU TRACTION CONTROL SYSTEM (KTCS) ...............................253 LOADING WORK ..................................................................255 DUMPING .......................................................................256 CAB TILT OPERATION ............................................................258 OPERATION .....................................................................260 PARKING MACHINE ...............................................................261 AFTER DAILY WORK COMPLETION ...................................................262 LOCKING .......................................................................262 HANDLING TIRES ................................................................263 DUMP BODY HEATING SPECIFICATIONS ..................................................264 DETERMINE AND MAINTAIN TRAVEL ROAD ................................................265 DETERMINE TRAVEL ROAD .........................................................265 MAINTAIN TRAVEL ROAD ..........................................................265 TRANSPORTATION ....................................................................266 TRANSPORTATION ................................................................266 SECURING MACHINE ..............................................................267 LIFTING MACHINE ...............................................................268 COLD WEATHER OPERATION ............................................................272 COLD WEATHER OPERATION INFORMATION ............................................272 AFTER DAILY WORK COMPLETION ...................................................273 LONG-TERM STORAGE .................................................................274 BEFORE STORAGE ................................................................274 TROUBLES AND ACTIONS ..............................................................275 RUNNING OUT OF FUEL ...........................................................275 IF TRANSMISSION HAS TROUBLE ...................................................276 LOWERING DUMP BODY IN EMERGENCY ...............................................276 TOWING MACHINE ................................................................277 DISCHARGED BATTERY ............................................................280 OTHER TROUBLE .................................................................284 MAINTENANCE ...........................................................................290 RULES FOR MAINTENANCE .............................................................291 SERVICE METER READING .........................................................291 KOMATSU GENUINE REPLACEMENT PARTS .............................................291 KOMATSU GENUINE LUBRICANTS ....................................................291 ALWAYS USE CLEAN WASHER FLUID .................................................291 FRESH AND CLEAN LUBRICANTS ....................................................291 CHECK DRAINED OIL AND USED FILTER .............................................291 CAUTION FOR REFILLING OIL OR FUEL .............................................291 WELDING INSTRUCTIONS ..........................................................291 DO NOT DROP THINGS INSIDE MACHINE .............................................291 DUSTY JOBSITES ................................................................291 AVOID MIXING OIL ..............................................................292 LOCKING INSPECTION COVERS .....................................................292 BLEEDING AIR FROM HYDRAULIC CIRCUIT ...........................................292 PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ...................................292 CHECKS AFTER INSPECTION AND MAINTENANCE .......................................292 FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE ..........................292 OUTLINE OF MAINTENANCE ............................................................293 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ........................293 HANDLING ELECTRICAL COMPONENTS ................................................297 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS .....................................298 TIGHTENING TORQUE LIST ........................................................298 MAINTENANCE SCHEDULE ..............................................................300 MAINTENANCE SCHEDULE TABLE ....................................................300 MAINTENANCE PROCEDURE .............................................................302 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ................302 WHEN REQUIRED .................................................................303 CHECKS BEFORE STARTING ........................................................327 EVERY 50 HOURS MAINTENANCE ....................................................328 EVERY 250 HOURS MAINTENANCE ...................................................329 EVERY 500 HOURS MAINTENANCE ...................................................341 EVERY 1000 HOURS MAINTENANCE ..................................................349 EVERY 2000 HOURS MAINTENANCE ..................................................364 EVERY 4000 HOURS MAINTENANCE ..................................................371 EVERY 4500 HOURS MAINTENANCE ..................................................374 EVERY 6000 HOURS MAINTENANCE ..................................................375 EVERY 8000 HOURS MAINTENANCE ..................................................377 EVERY 9000 HOURS MAINTENANCE ..................................................378 SPECIFICATIONS ........................................................................380 SPECIFICATIONS ....................................................................381 ATTACHMENTS AND OPTIONS ...............................................................382 CAB POWER TILT ....................................................................383 HANDLING PAYLOAD METER ............................................................385 OUTLINE OF SYSTEM .............................................................385 DISPLAY DURING NORMAL OPERATION ...............................................386 EXTERNAL DISPLAY LAMP .........................................................387 DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER .............................388 PROCEDURE WHEN DOWNLOADING ....................................................389 DISPLAY TOTAL PAYLOAD / NUMBER OF CYCLES ......................................392 DISPLAY LOAD AND FUEL EFFICIENCY RECORD .......................................393 SETTING MACHINE ID AND OPEN ID ................................................394 CARRYING OUT CALIBRATION ......................................................396 PAYLOAD OF CYCLE DATA .........................................................398 SERVICE FUNCTION ..............................................................398 THE OTHER INFORMATION .........................................................398 REPLACEMENT PARTS .....................................................................400 SAFETY CRITICAL PARTS .............................................................401 SAFETY CRITICAL PARTS LIST ....................................................401 CONSUMABLE PARTS ..................................................................402 CONSUMABLE PARTS LIST .........................................................402 RECOMMENDED FUEL, COOLANT, AND LUBRICANT ..........................................403 LUBRICATION CHART .............................................................403 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ..........406 RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL ....408 INDEX .................................................................................410
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