Komatsu HM400-5 Articulated Dump Truck Operation and Maintenance Manual PEN01001-05

Description

• Model List:
  • HM400-5 Articulated Dump Truck

• 1. COVER
• 2. FOREWORD
• 2.1. CONTENTS
• 2.2. READ THIS MANUAL
• 2.3. SAFETY INFORMATION
• 2.4. INTRODUCTION
• 2.4.1. MAIN USE OF MACHINE
• 2.4.2. DIRECTIONS OF MACHINE
• 2.4.3. VISIBILITY FROM OPERATORS SEAT
• 2.5. ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION
• 2.6. PRODUCT INFORMATION
• 2.6.1. LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
• 2.6.2. LOCATION OF ENGINE NUMBER PLATE
• 2.6.3. SERVICE METER LOCATION
• 2.6.4. YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
• 2.7. ABBREVIATION LIST
• 3. SAFETY
• 3.1. SAFETY LABELS
• 3.1.1. LOCATION OF SAFETY LABELS
• 3.1.2. CONTENTS OF SAFETY LABELS
• 3.2. GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
• 3.2.1. PRECAUTIONS BEFORE STARTING OPERATION
• 3.2.2. PREPARATIONS FOR SAFE OPERATION
• 3.2.3. PRECAUTIONS TO PREVENT FIRE
• 3.2.4. PRECAUTIONS WHEN GETTING ON OR OFF MACHINE
• 3.2.5. DO NOT GET CAUGHT IN WORK EQUIPMENT
• 3.2.6. PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES
• 3.2.7. UNAUTHORIZED MODIFICATION
• 3.2.8. PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS
• 3.2.9. PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING
• 3.3. PRECAUTIONS FOR OPERATION
• 3.3.1. PRECAUTIONS FOR JOBSITE
• 3.3.2. START ENGINE
• 3.3.3. PRECAUTIONS FOR OPERATION
• 3.3.4. TRANSPORTATION
• 3.3.5. TOWING AND BEING TOWED
• 3.4. PRECAUTIONS FOR MAINTENANCE
• 3.4.1. PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE
• 3.4.2. PRECAUTIONS FOR CHECK AND MAINTENANCE
• 3.4.3. TIRES
• 3.5. PRECAUTIONS FOR DEF
• 3.5.1. GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING
• 3.5.2. PRECAUTIONS FOR ADDING
• 3.5.3. PRECAUTIONS FOR STORING
• 3.5.4. PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE
• 3.5.5. OTHER PRECAUTIONS
• 4. OPERATION
• 4.1. GENERAL VIEW
• 4.1.1. MACHINE EQUIPMENT NAME
• 4.1.2. CONTROLS AND GAUGES NAMES
• 4.1.3. OTHER EQUIPMENT NAME
• 4.2. EXPLANATION OF COMPONENTS
• 4.2.1. EXPLANATION OF MACHINE MONITOR EQUIPMENT
• 4.2.2. SWITCHES
• 4.2.3. CONTROL LEVERS AND PEDALS
• 4.2.4. OTHER EQUIPMENT
• 4.3. MACHINE OPERATIONS AND CONTROLS
• 4.3.1. CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE
• 4.3.2. METHOD FOR STARTING ENGINE
• 4.3.3. METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE
• 4.3.4. METHOD FOR STOPPING ENGINE
• 4.3.5. METHOD FOR CHECKING AFTER STOPPING ENGINE
• 4.3.6. START MACHINE (TRAVEL FORWARD AND REVERSE) AND STOP MACHINE
• 4.3.7. METHOD FOR SHIFTING GEARS
• 4.3.8. METHOD FOR TRAVELING DOWNHILL
• 4.3.9. METHOD FOR TURNING MACHINE
• 4.3.10. OPERATE WITH INTERAXLE DIFFERENTIAL LOCK
• 4.3.11. HANDLE AUTOMATIC RETARDER, ACCELERATOR CONTROL (ARAC)
• 4.3.12. OPERATION OF ARAC SYSTEM
• 4.3.13. HANDLE KOMATSU TRACTION CONTROL SYSTEM (KTCS)
• 4.3.14. OPERATION OF KTCS SYSTEM
• 4.3.15. OPERATION IF TROUBLES ON SYSTEM OCCUR
• 4.3.16. OPERATION IF TIRES ARE STUCK IN GROUND
• 4.3.17. METHOD FOR LOADING
• 4.3.18. METHOD FOR DUMPING
• 4.3.19. METHOD FOR OPERATING CAB TILT
• 4.3.20. PRECAUTIONS FOR OPERATION
• 4.3.21. METHOD FOR PARKING MACHINE
• 4.3.22. METHOD FOR CHECKING AFTER FINISHING WORK
• 4.3.23. LOCK
• 4.3.24. HANDLE TIRE
• 4.4. HANDLE AIR CONDITIONER
• 4.4.1. EXPLANATION OF AIR CONDITIONER EQUIPMENT
• 4.4.2. METHOD FOR OPERATING AIR CONDITIONER
• 4.5. HANDLE RADIO
• 4.5.1. EXPLANATION OF RADIO EQUIPMENT
• 4.5.2. METHOD FOR CONTROLLING RADIO
• 4.6. DUMP BODY HEATING SPECIFICATIONS
• 4.7. DETERMINE AND MAINTAIN TRAVEL ROAD
• 4.8. TRANSPORTATION
• 4.8.1. PRECAUTIONS FOR TRANSPORTATION
• 4.8.2. PRECAUTIONS FOR TRANSPORTING MACHINE
• 4.8.3. SELECT TRANSPORTATION METHOD
• 4.8.4. METHOD FOR SECURING MACHINE
• 4.8.5. PRECAUTIONS FOR LIFTING MACHINE
• 4.9. COLD WEATHER OPERATION
• 4.9.1. COLD WEATHER OPERATION INFORMATION
• 4.9.2. PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER
• 4.9.3. AFTER COLD WEATHER SEASON
• 4.10. PRECAUTIONS FOR LONGTERM STORAGE
• 4.10.1. PREPARATION FOR LONGTERM STORAGE
• 4.10.2. MAINTENANCE DURING LONGTERM STORAGE
• 4.10.3. STARTING MACHINE AFTER LONGTERM STORAGE
• 4.10.4. PREPARATION BEFORE TRAVELING AFTER LONGTERM STORAGE
• 4.11. TROUBLES AND ACTIONS
• 4.11.1. ACTIONS WHEN RUNNING OUT OF FUEL
• 4.11.2. ACTIONS IF TRANSMISSION HAS TROUBLE
• 4.11.3. METHOD FOR LOWERING DUMP BODY IN EMERGENCY
• 4.11.4. PRECAUTIONS FOR TOWING MACHINE
• 4.11.5. PRECAUTIONS FOR DISCHARGED BATTERY
• 4.11.6. OTHER TROUBLE
• 5. MAINTENANCE
• 5.1. PRECAUTIONS FOR MAINTENANCE
• 5.1.1. CHECK SERVICE METER READING
• 5.1.2. KOMATSU GENUINE REPLACEMENT PARTS
• 5.1.3. KOMATSU GENUINE LUBRICANTS
• 5.1.4. ALWAYS USE CLEAN WASHER FLUID
• 5.1.5. FRESH AND CLEAN LUBRICANTS
• 5.1.6. CHECK DRAINED OIL AND USED FILTER
• 5.1.7. PRECAUTIONS FOR REFILLING OIL OR FUEL
• 5.1.8. PRECAUTIONS FOR ADDING DEF
• 5.1.9. PRECAUTIONS FOR WELDING
• 5.1.10. DO NOT DROP THINGS INSIDE MACHINE
• 5.1.11. PRECAUTIONS FOR KDPF
• 5.1.12. PRECAUTIONS FOR SCR ASSEMBLY
• 5.1.13. DUSTY JOBSITES
• 5.1.14. AVOID MIXING OIL
• 5.1.15. LOCK INSPECTION COVERS
• 5.1.16. BLEED AIR FROM HYDRAULIC CIRCUIT
• 5.1.17. PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES
• 5.1.18. CHECKS AFTER INSPECTION AND MAINTENANCE
• 5.1.19. FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE
• 5.2. OUTLINE OF MAINTENANCE
• 5.2.1. HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
• 5.2.2. HANDLE ELECTRICAL COMPONENTS
• 5.3. STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS
• 5.4. MAINTENANCE SCHEDULE
• 5.4.1. MAINTENANCE SCHEDULE TABLE
• 5.5. MAINTENANCE PROCEDURE
• 5.5.1. INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)
• 5.5.2. WHEN REQUIRED
• 5.5.3. CHECKS BEFORE STARTING
• 5.5.4. EVERY 50 HOURS MAINTENANCE
• 5.5.5. EVERY 250 HOURS MAINTENANCE
• 5.5.6. EVERY 500 HOURS MAINTENANCE
• 5.5.7. EVERY 1000 HOURS MAINTENANCE
• 5.5.8. EVERY 2000 HOURS MAINTENANCE
• 5.5.9. EVERY 4000 HOURS MAINTENANCE
• 5.5.10. EVERY 4500 HOURS MAINTENANCE
• 5.5.11. EVERY 6000 HOURS MAINTENANCE
• 5.5.12. EVERY 8000 HOURS MAINTENANCE
• 5.5.13. EVERY 9000 HOURS MAINTENANCE
• 6. SPECIFICATIONS
• 6.1. SPECIFICATIONS
• 7. ATTACHMENTS AND OPTIONS
• 7.1. HANDLE AUXILIARY ENGINE STARTING CONNECTOR
• 7.1.1. START ENGINE WITH AUXILIARY ENGINE STARTING CONNECTOR
• 7.2. HANDLE CAB POWER TILT
• 7.3. HANDLING PAYLOAD METER
• 7.3.1. OUTLINE OF SYSTEM
• 7.3.2. NORMAL OPERATION DISPLAY
• 7.3.3. EXTERNAL DISPLAY LAMP
• 7.3.4. DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER
• 7.3.5. METHOD FOR DOWNLOADING DATA FROM CONNECTOR FOR DOWNLOAD
• 7.3.6. DISPLAY TOTAL PAYLOAD AND NUMBER OF CYCLES
• 7.3.7. DISPLAY FUEL CONSUMPTION RECORD
• 7.3.8. SETTING MACHINE ID AND OPEN ID
• 7.3.9. METHOD FOR PERFORMING CALIBRATION
• 7.4. HANDLE AUTOGREASING SYSTEM
• 7.4.1. METHOD FOR OPERATING AUTOGREASING SYSTEM
• 7.4.2. METHOD FOR BLEEDING AIR FROM GREASING CIRCUIT
• 7.4.3. METHOD FOR FILLING GREASE
• 7.4.4. GREASING POINTS FOR AUTOGREASING SYSTEM
• 7.5. SERVICE CENTER
• 8. REPLACEMENT PARTS
• 8.1. PERIODIC REPLACEMENT OF DEFINED LIFE PARTS
• 8.1.1. DEFINED LIFE PARTS LIST
• 8.2. CONSUMABLE PARTS
• 8.2.1. CONSUMABLE PARTS LIST
• 8.3. RECOMMENDED FUEL, COOLANT, AND LUBRICANT
• 8.3.1. LUBRICATION CHART
• 8.3.2. METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
• 8.3.3. RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS
• 9. INDEX