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KOMATSU HM400-3 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:3001 and up) – PDF DOWNLOAD
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- KOMATSU HM400-3 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:3001 and up
- PUBLICATION NUMBER:TEN00580-03
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Description
KOMATSU HM400-3 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:3001 and up)
KOMATSU HM400-3 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:3001 AND UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU HM400-3 ARTICULATED DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:3001 and up)
- 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 (SN:3001 and up)
COVER.................................................................................. 1 FOREWORD .............................................................................. 2 BEFORE READING THIS MANUAL ........................................................ 3 SAFETY INFORMATION ................................................................ 4 INTRODUCTION ...................................................................... 5 USE OF MACHINE ................................................................ 5 DIRECTIONS OF MACHINE ......................................................... 5 VISIBILITY FROM OPERATORS 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 ................................................................. 17 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ........................... 23 PRECAUTIONS BEFORE STARTING OPERATION ......................................... 23 PREPARATIONS FOR SAFE OPERATION ............................................... 24 FIRE PREVENTION ............................................................... 26 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE .................................... 28 DO NOT GET CAUGHT IN WORK EQUIPMENT ........................................... 31 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES .................................. 31 UNAUTHORIZED MODIFICATION ..................................................... 31 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ................................ 31 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ............................... 32 PRECAUTIONS FOR OPERATION ......................................................... 33 PRECAUTIONS FOR JOBSITE ....................................................... 33 STARTING ENGINE ............................................................... 35 OPERATION ..................................................................... 38 TRANSPORTATION ................................................................ 42 TOWING ........................................................................ 43 PRECAUTIONS FOR MAINTENANCE ....................................................... 44 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ........................ 44 PRECAUTIONS FOR INSPECTION AND MAINTENANCE .................................... 50 TIRES ......................................................................... 55 OPERATION ............................................................................. 56 GENERAL VIEW ...................................................................... 57 GENERAL VIEW OF MACHINE ....................................................... 57 GENERAL VIEW OF CONTROLS AND GAUGES ........................................... 58 EXPLANATION OF COMPONENTS ......................................................... 62 MACHINE MONITOR ............................................................... 62 SWITCHES ......................................................................133 CONTROL LEVERS AND PEDALS .....................................................143 CIGARETTE LIGHTER .............................................................147 ASHTRAY .......................................................................147 DRINK BOX .....................................................................147 CUP HOLDER ....................................................................148 HANDY TRAY ....................................................................148 MAGAZINE BOX ..................................................................148 EMERGENCY ESCAPE HAMMER .......................................................149 HANDLING AIR CONDITIONER ......................................................150 HANDLING RADIO ................................................................163 AUXILIARY ELECTRIC POWER ......................................................167 FUSE ..........................................................................168 OPEN AND CLOSE CAB DOOR .......................................................172 STORAGE FOR TOOLS .............................................................173 STORAGE FOR FIRE EXTINGUISHER .................................................173 BATTERY DISCONNECT SWITCH .....................................................174 CIRCUIT BREAKER ...............................................................176 DUST INDICATOR ................................................................176 ARTICULATION LOCK .............................................................177 BODY PIVOT PINS ...............................................................178 HANDLING REAR VIEW MONITOR ....................................................179 HANDLING KDPF .................................................................182 HANDLING KCCV FILTER ..........................................................192 HANDLING MACHINES EQUIPPED WITH KOMTRAX .......................................193 MACHINE OPERATIONS AND CONTROLS ...................................................195 CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ..................................195 STARTING ENGINE ...............................................................220 OPERATIONS AND CHECKS AFTER STARTING ENGINE ...................................225 STOPPING ENGINE ...............................................................228 CHECKS AFTER STOPPING ENGINE ..................................................229 MACHINE OPERATION .............................................................230 SHIFTING GEARS ................................................................235 TRAVELING DOWNHILL ............................................................237 STEERING MACHINE ..............................................................243 HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL (ARAC) .......................244 HANDLING KOMATSU TRACTION CONTROL SYSTEM (KTCS) ...............................246 LOADING WORK ..................................................................248 DUMPING .......................................................................249 CAB TILT OPERATION ............................................................251 OPERATION .....................................................................253 PARKING MACHINE ...............................................................254 AFTER DAILY WORK COMPLETION ...................................................255 LOCKING .......................................................................255 HANDLING TIRES ................................................................256 DETERMINE AND MAINTAIN TRAVEL ROAD ................................................257 DETERMINE TRAVEL ROAD .........................................................257 MAINTAIN TRAVEL ROAD ..........................................................257 TRANSPORTATION ....................................................................258 TRANSPORTATION ................................................................258 TRANSPORTATION PROCEDURE ......................................................258 SECURING MACHINE ..............................................................259 LIFTING MACHINE ...............................................................260 COLD WEATHER OPERATION ............................................................263 COLD WEATHER OPERATION INFORMATION ............................................263 AFTER DAILY WORK COMPLETION ...................................................264 LONG-TERM STORAGE .................................................................265 BEFORE STORAGE ................................................................265 TROUBLES AND ACTIONS ..............................................................266 RUNNING OUT OF FUEL ...........................................................266 IF TRANSMISSION HAS TROUBLE ...................................................267 LOWERING DUMP BODY IN EMERGENCY ...............................................267 TOWING MACHINE ................................................................268 DISCHARGED BATTERY ............................................................271 OTHER TROUBLE .................................................................275 MAINTENANCE ...........................................................................282 RULES FOR MAINTENANCE .............................................................283 SERVICE METER READING .........................................................283 KOMATSU GENUINE REPLACEMENT PARTS .............................................283 KOMATSU GENUINE LUBRICANTS ....................................................283 ALWAYS USE CLEAN WASHER FLUID .................................................283 FRESH AND CLEAN LUBRICANTS ....................................................283 CHECK DRAINED OIL AND USED FILTER .............................................283 CAUTION FOR REFILLING OIL OR FUEL .............................................283 WELDING INSTRUCTIONS ..........................................................283 DO NOT DROP THINGS INSIDE MACHINE .............................................283 DUSTY JOBSITES ................................................................283 AVOID MIXING OIL ..............................................................284 LOCKING INSPECTION COVERS .....................................................284 BLEEDING AIR FROM HYDRAULIC CIRCUIT ...........................................284 PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ...................................284 CHECKS AFTER INSPECTION AND MAINTENANCE .......................................284 FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE ..........................284 OUTLINE OF MAINTENANCE ............................................................285 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ........................285 HANDLING ELECTRICAL COMPONENTS ................................................289 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS .....................................290 TIGHTENING TORQUE LIST ........................................................290 MAINTENANCE SCHEDULE ..............................................................292 MAINTENANCE SCHEDULE TABLE ....................................................292 MAINTENANCE PROCEDURE .............................................................294 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ................294 WHEN REQUIRED .................................................................295 CHECKS BEFORE STARTING ........................................................317 EVERY 50 HOURS MAINTENANCE ....................................................318 Every 250 hours maintenance ...................................................319 EVERY 500 HOURS MAINTENANCE ...................................................329 EVERY 1000 HOURS MAINTENANCE ..................................................336 EVERY 2000 HOURS MAINTENANCE ..................................................350 EVERY 4000 HOURS MAINTENANCE ..................................................357 EVERY 4500 HOURS MAINTENANCE ..................................................360 EVERY 6000 HOURS MAINTENANCE ..................................................361 EVERY 8000 HOURS MAINTENANCE ..................................................363 EVERY 9000 HOURS MAINTENANCE ..................................................364 SPECIFICATIONS ........................................................................366 SPECIFICATIONS ....................................................................367 ATTACHMENTS AND OPTIONS ...............................................................368 CAB POWER TILT ....................................................................369 REPLACEMENT PARTS .....................................................................372 SAFETY CRITICAL PARTS .............................................................373 SAFETY CRITICAL PARTS LIST ....................................................373 CONSUMABLE PARTS ..................................................................374 CONSUMABLE PARTS LIST .........................................................374 RECOMMENDED FUEL, COOLANT, AND LUBRICANT ..........................................375 LUBRICATION CHART .............................................................375 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ..........378 RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL ....380 INDEX .................................................................................382
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]
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