komatsu hm300-2 articulated dump truck - operation and maintenance manual - 287 pages - ...

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  • ARTICULATEDDUMP TRUCK

    PEN00101-04

    HM300-2SERIAL NUMBERS 2001 and up

    Unsafe Use of this machine may cause serious injury orDeath.Operators and maintenance personnel must readthis manual before operating or maintaining this machine.This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it .

    WARNING

    Komatsu has Operation & Maintenance Manuals written in some other languages. if a foreign language manual is necessary, contact your local distributor for availability.

    NOTICE

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    FOREWORDFOREWORD

    FOREWORDThis manual provides rules and guidelines which will help you use this machine safely and effectively. Theprecautions in this manual must be followed at all times when performing operation and maintenance. Mostaccidents are caused by the failure to follow fundamental safety rules for the operation and maintenance ofmachines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard whenperforming operation and maintenance.

    WARNINGOperators and maintenance personnel must always do as follows before beginning operation or maintenance.

    Always be sure to read and understand this manual thoroughly before performing operation and maintenance.

    Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that youunderstand them fully.

    Keep this manual in the storage location for the operation and maintenance manual given below, and have all personnel read itperiodically.

    If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsuor your Komatsu distributor.

    If you sell the machine, be sure to give this manual to the new owners together with the machine.

    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 or purchased from someone in another country, it may lack certain safetydevices and specifications that are necessary for use in your country. If there is any question about whether your productcomplies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor beforeoperating the machine.

    Storage location for the Operation and Maintenance Manual:On inside of left door

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    FOREWORD FOREWORD

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    FOREWORDFOREWORD

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    FOREWORD SAFETY INFORMATION

    SAFETY INFORMATIONTo enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to themachine to give explanations of situations involving potential hazards and of the methods of avoiding suchsituations.

    Signal words

    The following signal words are used to inform you that there is a potential hazardous situation that may lead topersonal injury or damage.In this manual and on machine labels, the following signal words are used to express the potential level of hazard.

    Indicates an imminently hazardous situation which, if not avoided, will result in death orserious injury.

    Indicates a potentially hazardous situation which, if not avoided, could result in death orserious injury.

    Indicates a potentially hazardous situation which, if not avoided, may result in minor ormoderate injury. This word is used also to alert against unsafe practices that may causeproperty damage.

    Example of safety message using signal word

    WARNINGWhen standing up from the operator's seat, always place the lock lever in the LOCK position.If you accidentally touch the control levers when they are not locked, this may cause a serious injury or death.

    Other signal words

    In addition to the above, the following signal words are used to indicate precautions that should be followed toprotect the machine or to give information that is useful to know.

    This word is used for precautions that must be taken to avoid actions which could shortenthe life of the machine.

    This word is used for information that is useful to know.

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    FOREWORDSAFETY INFORMATION

    Safety labels

    Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying outoperation or maintenance of the machine that may involve hazard.This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.

    Example of safety label using words

    Safety labels using pictogramSafety pictograms use a picture to express a level of hazardouscondition equivalent to the signal word. These safety pictogramsuse pictures in order to let the operator or maintenance workerunderstand the level and type of hazardous condition at all times.Safety pictograms show the type of hazardous condition at the topor left side, and the method of avoiding the hazardous condition atthe bottom or right side. In addition, the type of hazardous conditionis displayed inside a triangle and the method of avoiding thehazardous condition is shown inside a circle.

    Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibilityto take the necessary steps to ensure safety.In no event should you engage in prohibited uses or actions described in this manual.

    The explanations, values, and illustrations in this manual were prepared based on the latest information availableat that time. Continuing improvements in the design of this machine can lead to changes in detail which may notbe reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of yourmachine or for questions regarding information in this manual.

    The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example:1 J (1))

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    FOREWORD INTENDED USE

    INTENDED USE

    DIRECTIONS OF MACHINE

    In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from theoperator's seat in the direction of travel (front) of the machine.

    (A)(B)(C)

    FRONTREARLEFT

    (D)(E)

    RIGHTOPERATOR'S SEAT

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    FOREWORDLOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTORWhen requesting service or ordering replacement parts, please inform your Komatsu distributor of the followingitems.

    PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATEThis is at the rear right of the cab.The design of the nameplate differs according to the territory.

    EPA REGULATIONS, ENGINE NUMBER PLATEIt is located on the upper left side of the engine cylinder block if you look from the fan side.

    EPA: Environmental Protection Agency, U.S.A.

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    FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

    SERVICE METER POSITIONIt is at the center bottom of the machine monitor.

    TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

    Machine serial No.

    Engine serial No.

    Product identification number (PIN)

    Distributor name

    Address

    Service Personnel

    Phone/Fax

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    FOREWORDCONTENTS

    CONTENTSFOREWORD 1- 1 FOREWORD 1- 2 SAFETY INFORMATION 1- 5 INTENDED USE 1- 7 DIRECTIONS OF MACHINE 1- 7 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 8 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 8 EPA REGULATIONS, ENGINE NUMBER PLATE 1- 8 SERVICE METER POSITION 1- 9 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 9SAFETY 2- 1 SAFETY 2- 2 SAFETY LABELS 2- 4 POSITION FOR ATTACHING SAFETY LABELS 2- 5 SAFETY LABELS 2- 6 GENERAL PRECAUTIONS 2- 11 PRECAUTIONS DURING OPERATION 2- 20 STARTING ENGINE 2- 20 OPERATION 2- 22 TRANSPORTATION 2- 26 BATTERY 2- 27 TOWING 2- 29 PRECAUTIONS FOR MAINTENANCE 2- 30 PRECAUTIONS WITH TIRES 2- 37OPERATION 3- 1 GENERAL VIEW 3- 2 GENERAL VIEW OF MACHINE 3- 2 GENERAL VIEW OF CONTROLS AND GAUGES 3- 3 EXPLANATION OF COMPONENTS 3- 5 MACHINE MONITOR 3- 5 OTHER FUNCTIONS OF MACHINE MONITOR 3- 26 SWITCHES 3- 30 CONTROL LEVERS AND PEDALS 3- 40 BODY PIVOT PIN 3- 45 ARTICULATE LOCK 3- 45 LOCATION OF FIRE EXTINGUISHER 3- 46 DUST INDICATOR 3- 46 CIRCUIT BREAKER 3- 46 FUSES 3- 47 CAR RADIO 3- 50 CAR STEREO 3- 56 AIR CONDITIONER 3- 64 OPERATION 3- 70 CHECK BEFORE STARTING ENGINE 3- 70 STARTING ENGINE 3- 85 OPERATIONS, CHECKS AFTER STARTING ENGINE 3- 87 STOPPING ENGINE 3- 88 CHECKS AFTER STOPPING ENGINE 3- 88 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING 3- 89

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    FOREWORD CONTENTS

    SHIFTING GEAR 3- 94 TRAVELING DOWNHILL 3- 96 STEERING THE MACHINE 3-102 OPERATION USING DIFFERENTIAL LOCK 3-103 LOADING OPERATIONS 3-104 DUMP OPERATIONS 3-105 CAB TILT OPERATION 3-107 PRECAUTIONS FOR OPERATION 3-110 PARKING MACHINE 3-111 CHECKS AFTER COMPLETION OF WORK 3-112 LOCKING 3-112 HANDLING TIRES 3-113 DETERMINING AND MAINTAINING TRAVEL ROAD 3-114 DETERMINING TRAVEL RO

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