Komatsu HM400-3M0 Articulated Dump Truck Operation & Maintenance Manual TEN00618-18 – PDF DOWNLOAD

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Komatsu HM400-3M0 Articulated Dump Truck Operation & Maintenance Manual TEN00618-18 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu HM400-3M0 Articulated Dump Truck Operation & Maintenance Manual TEN00618-18 – PDF DOWNLOAD

SERIAL NUMBERS 5001 and up

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 perform 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.

TABLE OF CONTENTS:

Komatsu HM400-3M0 Articulated Dump Truck Operation & Maintenance Manual TEN00618-18 – PDF DOWNLOAD

CONTENTS (PC-0310-001-A-00-A)
FOREWORD 1-1
BEFORE READING THIS MANUAL 1-2
SAFETY INFORMATION 1-3
INTRODUCTION 1-4
USE OF MACHINE 1-4
DIRECTIONS OF MACHINE 1-4
VISIBILITY FROM OPERATOR’S SEAT 1-5
PROXIMITY VISIBILITY 1-5
12 m CIRCUMFERENCE VISIBILITY 1-5
PRODUCT INFORMATION 1-6
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO PLATE 1-6
ENGINE NUMBER PLATE 1-6
SERVICE METER LOCATION 1-7
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1-7
CONTENTS 1-8
SAFETY 2-1
SAFETY 2-2
SAFETY LABELS 2-4
LOCATION OF SAFETY LABELS 2-5
SAFETY LABELS 2-8
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2-14
PRECAUTIONS BEFORE STARTING OPERATION 2-14
PREPARATIONS FOR SAFE OPERATION 2-15
FIRE PREVENTION 2-17
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2-19
DO NOT GET CAUGHT IN WORK EQUIPMENT 2-22
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2-22
UNAUTHORIZED MODIFICATION 2-22
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2-22
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2-23
PRECAUTIONS FOR OPERATION 2-24
PRECAUTIONS FOR JOBSITE 2-24
STARTING ENGINE 2-26
OPERATION 2-29
TRANSPORTATION 2-33
TOWING 2-34
PRECAUTIONS FOR MAINTENANCE 2-35
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2-35
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2-41
TIRES 2-46
OPERATION 3-1
GENERAL VIEW 3-2
GENERAL VIEW OF MACHINE 3-2
GENERAL VIEW OF CONTROLS AND GAUGES 3-3
EXPLANATION OF COMPONENTS 3-7
MACHINE MONITOR 3-7
SWITCHES 3-77
CONTROL LEVERS AND PEDALS 3-87
CIGARETTE LIGHTER 3-91
ASHTRAY 3-91
DRINK BOX 3-91
CUP HOLDER 3-92
HANDY TRAY 3-92
MAGAZINE BOX 3-92
EMERGENCY ESCAPE HAMMER 3-93
HANDLING AIR CONDITIONER 3-94
HANDLING RADIO 3-107
1-8
FOREWORD CONTENTS
AUXILIARY ELECTRIC POWER 3-112
FUSE 3-113
OPEN AND CLOSE CAB DOOR 3-117
STORAGE FOR TOOLS 3-118
STORAGE FOR FIRE EXTINGUISHER 3-118
BATTERY DISCONNECT SWITCH 3-119
CIRCUIT BREAKER 3-121
DUST INDICATOR 3-121
ARTICULATION LOCK 3-122
BODY PIVOT PINS 3-123
HANDLING REAR VIEW MONITOR 3-124
HANDLING MACHINES EQUIPPED WITH KOMTRAX 3-127
MACHINE OPERATIONS AND CONTROLS 3-129
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE 3-129
STARTING ENGINE 3-153
OPERATIONS AND CHECKS AFTER STARTING ENGINE 3-158
STOPPING ENGINE 3-161
CHECKS AFTER STOPPING ENGINE 3-161
MACHINE OPERATION 3-162
SHIFTING GEARS 3-167
TRAVELING DOWNHILL 3-169
STEERING MACHINE 3-175
HANDLING KOMATSU TRACTION CONTROL SYSTEM (KTCS) 3-176
LOADING WORK 3-178
DUMPING 3-179
HANDLING PAYLOAD METER 3-181
CAB TILT OPERATION 3-192
OPERATION 3-198
PARKING MACHINE 3-199
AFTER DAILY WORK COMPLETION 3-200
LOCKING 3-200
HANDLING TIRES 3-201
DETERMINE AND MAINTAIN TRAVEL ROAD 3-202
DETERMINE TRAVEL ROAD 3-202
MAINTAIN TRAVEL ROAD 3-202
TRANSPORTATION 3-203
TRANSPORTATION 3-203
TRANSPORTATION PROCEDURE 3-203
SECURING MACHINE 3-204
LIFTING MACHINE 3-205
COLD WEATHER OPERATION 3-209
COLD WEATHER OPERATION INFORMATION 3-209
AFTER DAILY WORK COMPLETION 3-210
LONG-TERM STORAGE 3-211
BEFORE STORAGE 3-211
TROUBLES AND ACTIONS 3-212
RUNNING OUT OF FUEL 3-212
IF TRANSMISSION HAS TROUBLE 3-213
LOWERING DUMP BODY IN EMERGENCY 3-213
TOWING MACHINE 3-214
DISCHARGED BATTERY 3-217
OTHER TROUBLE 3-221
MAINTENANCE 4-1
RULES FOR MAINTENANCE 4-2
SERVICE METER READING 4-2
KOMATSU GENUINE REPLACEMENT PARTS 4-2
KOMATSU GENUINE LUBRICANTS 4-2
ALWAYS USE CLEAN WASHER FLUID 4-2
1-9
OPERATE WITH INTER-AXLE DIFFERENTIAL LOCK 3 -175-1
CONTENTS FOREWORD
FRESH AND CLEAN LUBRICANTS 4-2
CHECK DRAINED OIL AND USED FILTER 4-2
CAUTION FOR REFILLING OIL OR FUEL 4-2
WELDING INSTRUCTIONS 4-2
DO NOT DROP THINGS INSIDE MACHINE 4-2
DUSTY JOBSITES 4-2
AVOID MIXING OIL 4-3
LOCKING INSPECTION COVERS 4-3
BLEED AIR FROM HYDRAULIC CIRCUIT 4-3
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES 4-3
CHECKS AFTER INSPECTION AND MAINTENANCE 4-3
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE 4-3
OUTLINE OF MAINTENANCE 4-4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4-4
HANDLING ELECTRICAL COMPONENTS 4-8
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS 4-9
TIGHTENING TORQUE LIST 4-9
MAINTENANCE SCHEDULE 4-11
MAINTENANCE SCHEDULE TABLE 4-11
MAINTENANCE INTERVAL WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS USED 4-13
MAINTENANCE PROCEDURE 4-14
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) 4-14
WHEN REQUIRED 4-15
CHECKS BEFORE STARTING 4-37
EVERY 50 HOURS MAINTENANCE 4-38
EVERY 250 HOURS MAINTENANCE 4-39
EVERY 500 HOURS MAINTENANCE 4-54
EVERY 1000 HOURS MAINTENANCE 4-61
EVERY 2000 HOURS MAINTENANCE 4-73
EVERY 4000 HOURS MAINTENANCE 4-79
EVERY 6000 HOURS MAINTENANCE 4-82
EVERY 8000 HOURS MAINTENANCE 4-84
SPECIFICATIONS 5-1
SPECIFICATIONS 5-2
ATTACHMENTS AND OPTIONS 6-1
CAB POWER TILT 6-2
HANDLING CENTRALIZED BREATHERS 6-4
EVERY 250 HOURS MAINTENANCE 6-4
CLEAN BREATHER 6-4
EVERY 2000 HOURS MAINTENANCE 6-6
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK 6-6
EVERY 4000 HOURS MAINTENANCE 6-7
REPLACE AIR CLEANER ELEMENT 6-7
CONSUMABLE PARTS LIST 6-9
HANDLING EXTERNAL POWER SUPPLY ELECTRIC HEATER 6-10
POWER OUTLET FOR ENGINE AND TRANSMISSION HEATER 6-10
OPERATION METHOD 6-11
HANDLING FUEL QUICK CHARGE SYSTEM 6-12
PROCEDURE FOR REFUELING 6-12
CHECK AND MAINTENANCE 6-13
REPLACEMENT PARTS 7-1
DEFINED LIFE PARTS 7-2
DEFINED LIFE PARTS LIST 7-2
CONSUMABLE PARTS 7-3
CONSUMABLE PARTS LIST 7-3
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 7-4
LUBRICATION CHART 7-4
1-10
ROLLOVER AVOIDANCE SYSTEM 6-14
OPERATION IF TROUBLES ON SYSTEM OCCUR 6-15
FOREWORD CONTENTS
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT
TEMPERATURE 7-7
RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE
OIL 7-9
INDEX 8-1

Questions? Email us: [email protected]

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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