Komatsu HM300-2 Articulated Dump Truck Operation & Maintenance Manual
319 pages · Publication CEAM017504
Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.
Added to your cart. View cart
- Models
- HM300-2
- Serial coverage
- HM300-2 A11001 and up
- Manual type
- Operation & Maintenance Manual
- Pages
- 319
- Publication
- CEAM017504
- Condition
- Brand new
What's inside
From the manual's own table of contents: 526 sections, 527 entries. See sample pages (PDF, 386 KB)
FOREWORD
SAFETY INFORMATION
Safety Labels
Safety Labels Using Pictogram
INTRODUCTION
Intended Use
Directions of Machine
Visibility From Operator's Seat
Breaking in a New Machine
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Product Identification Number (Pin)/Machine Serial No. Plate
EPA Regulations, Engine Serial No. Plate Position
Service Meter Position1 topic
- Table to Enter Serial Numbers and Distributor
SAFETY AND WARNING DECALS
Location of Safety Decals
GENERAL SAFETY RULES AND PRECAUTIONS
General Safety Rules
Safety Features
Personal Protective Equipment
Fire and Explosion Prevention
Fire Caused by Fuel or Oil
Fire Caused by Accumulation of Flammable Material
Fire Coming from Electric Wiring
Fire Coming from Hydraulic Line
Show all 526 sections
Windshield Washer Fluid
Action if Fire Occurs
Fire Extinguisher and First Aid Kit
Fire Prevention and Suppression
Fire Prevention Steps
Fixed Fire Detection System
Fixed Fire Suppression System
Fire Prevention Procedures
Dust Hazard Precautions
Keep Operator's Cab Clean
Unauthorized Modifications
No People on Dump Body
Leaving Operator’s Compartment
Mounting and Dismounting
No Jumping On or Off Machine
Crush or Pinch Point Dangers
Inside Operator’s Compartment
Precautions When Using ROPS
Precautions Related To Attachments And Options
Precautions When Running Engine Inside Building
PRECAUTIONS BEFORE STARTING OPERATIONS
Pre-Operational Checks
Seat Belt Inspection
Starting Your Work Operations
Work Site Hazards
Avoiding Dangerous Situations
Working Clearances
Operating on Snow or Icy Surfaces
Working on Loose Ground
Asbestos Hazard Alert
RULES FOR ROAD TRAVEL
Precautions When Traveling
When Traveling on Slopes
When Dumping a Load
Ensure Good Visibility
Checking Signs and Signalman's Signals
When Traveling in Reverse
Parking the Machine
PRECAUTIONS DURING MAINTENANCE OPERATIONS
Warning Tags
Equipment Storage
Working Under the Machine
Using Drop Lamps
Keeping the Machine Clean
Performing General Maintenance Procedures
Running the Engine During Maintenance
Proper Tools
Engine System High-voltage
Welding, Grinding or Cutting
When Using Hammer
Refueling the Machine
Cooling System Precautions
Battery Precautions
Starting the Machine
High Pressure Hoses
Safety Handling High-pressure Hoses
Precaution for High Fuel Pressure
High Temperature Areas
Disposal of Waste Materials
Accumulator
Critical Parts
HANDLING TIRES
Precautions When Storing Tires
TRANSPORTATION
Precautions When Transporting
Steps for Transportation
Method of Securing Machine
Method of Lifting Machine
Location of Lifting Points
TOWING MACHINE
GENERAL VIEW
General View of Machine
General View of Controls and Gauges
Machine Monitor
EXPLANATION OF COMPONENTS
Character Display Portion
Service Meter
Odometer
Reverse Travel Odometer
Action Code Display
Filter, Oil, Replacement Time Display
Caution Items
Seat Belt Caution Lamp
Parking Brake Pilot Lamp
Dump Body Pilot Lamp
Emergency Steering Pilot Lamp
Fuel Level Caution Lamp
Maintenance Caution Lamp
Emergency Stop Item
Engine Coolant Temperature Caution Lamp
Torque Converter Oil Temperature Caution Lamp
Retarder Temperature Caution Lamp
Battery Charge Circuit Caution Lamp
Steering Oil Temperature Caution Lamp
Engine Oil Pressure Caution Lamp
Brake Oil Pressure Caution Lamp
Tilt Caution Lamp
Machine Monitor, Option System Caution Lamp
Engine System Caution Lamp
Transmission System Caution Lamp
Retarder System Caution Lamp
Meter Display Portion
Engine Preheating Pilot Lamp
Retarder Pilot Lamp
Inter-axle Differential Lock Pilot Lamp
Lockup Pilot Lamp
Shift Hold Pilot Lamp
Head Lamp High Beam Pilot Lamp
Turn Signal Pilot Lamp
Shift Indicator
Shift Lever Position Pilot Lamp
Power Mode Pilot Lamp
Meters and Gauges
Speedometer
Engine Tachometer
Fuel Gauge
Engine Coolant Temperature Gauge
Torque Converter Oil Temperature Gauge
Retarder Oil Temperature Gauge
Central Warning Lamp
Other Functions of Machine Monitor
Display Method for Reverse Travel Odometer
Reset Method for Filter, Oil Replacement Time
Input Method for Telephone Number
Method for Selecting Language
Switches
Ignition Switch
Lamp Switch
Turn Signal Lever
Dimmer Switch
Hazard Lamp Switch
Night Lighting Dimmer Switch
Power Mode Selector Switch
Emergency Steering Switch
Shift Hold Switch
Parking Brake Switch
AISS Low Switch
Inter-Axle Differential Lock Switch
Fog Lamp Switch
Side Lamp Switch
Working Lamp (Front) Switch
Rear Window Defroster Switch
Yellow Rotating Lamp Switch
Power Window Switch (Right) (Left)
Machine Monitor Mode Selector Switch 1, 2
Cigarette Lighter
Horn Button
Wiper, Window Washer Switch
Room Lamp Switch
Control Levers and Pedals
Brake Pedal
Accelerator Pedal
Shift Lever
Dump Lever
Retarder Control Lever
Safety Lock Knob
DUMP COUNTER
Method of Displaying, Resetting Dumping Counter
DUMP BODY SAFETY PIN
Stowing Safety Pin
ARTICULATE LOCK
FIRE EXTINGUISHER
DUST INDICATOR
CIRCUIT BREAKER
FUSES
Fuse Capacity and Circuit Name
Precautions When Adding Electrical Equipment
AM/FM RADIO-CASSETTE STEREO
Radio Operation
Power Switch/Volume
Auto-Store/Preset Scan Button
Bass Control Knob
Treble Control Knob
Loudness Button
Time/Radio Display Selector Button
Tape Eject Button
Cassette Door
Fast Forward, Rewind Buttons
Preset Buttons
Metal Tape Button
Manual Tuning Buttons
Seek Tuning Buttons
Band Selector Button
Using Radio Feature
Method of Setting Preset Buttons
Manual Memory Button
Listening to Radio
Listening to Cassette Tape
Reversing Tape
Precautions When Using
AIR CONDITIONER
General Locations on Control Panel
On/Off Switch
Fan Switch
Air Conditioner Switch
Mode Selector Switch
Def (Defrost) Switch
Recirc/fresh Selector Switch
Temperature Control Switch
Method of Operation
Cooling
Heating
Dehumidifying, Defrosting
Precautions When Using Air Conditioner
Inspection and Maintenance
OPERATION
Check Before Starting Engine
Walk-Around Check
Check Before Starting
Check Coolant Level, Add Coolant
Check Dust Indicator
Check Oil Level in Engine Oil Pan, Add Oil
Check Oil Level in Transmission Case, Add Oil
Check Oil Level in Hydraulic Tank, Add Oil
Drain Water, Sediment From Fuel Tank
Check Fuel Level, Add Fuel
Check Wheel Hub Bolts, Tighten
Check Central Warning Lamp, Alarm Buzzer, Monitor Lamps and Meters
Check Braking Effect
Check Emergency Steering
Check Back-Up Alarm
Check Electrical Wiring
Check Inflation Pressure of Tires
Check Water Separator
Does Body Positioner Operate Normally?
Check Cab Mounting Bolts and Pins
Adjustment Before Operation
Adjusting Operator's Seat
Adjust Seat Belt
Adjust Steering Wheel Tilt
Adjusting Mirrors
Operations, Checks Before Starting
STARTING ENGINE
OPERATIONS, CHECKS AFTER STARTING ENGINE
Breaking-In the Machine
Warming-Up Operation
Canceling Dump Body Hold Condition
STOPPING ENGINE
Checks After Stopping Engine
MOVING MACHINE
Moving Machine Forward
Moving Machine In Reverse
STOPPING THE MACHINE
Normal Stopping
Stopping in Emergency
Shifting Gear
Shifting Up
Shifting Down
Down Shift Inhibit
Shifting Down When Using Foot Brake
Overrun Protection Device
Traveling Downhill
Brake Performance Curve
STEERING THE MACHINE
Operation Using Differential Lock
Method of Using Inter-Axle Differential Lock
When Tires are Stuck in Ground
LOADING OPERATIONS
Handling Tailgate
DUMP OPERATIONS
CAB TILT OPERATION
When Using Crane
When Using Tilt Cylinder
PRECAUTIONS FOR OPERATION
PERMISSIBLE WATER DEPTH
PARKING MACHINE
CHECKS AFTER COMPLETION OF WORK
LOCKING THE MACHINE
KOMTRAX SYSTEM
Outline of System
Basic Precautions
Precautions When Handling Tires
Precautions for Long Distance Travel
DETERMINING AND MAINTAINING TRAVEL ROAD
Determining Travel Road
Maintaining Travel Road
Securing the Machine
Location of Lifting Position Mark
Weight Table
Lifting Procedure
COLD WEATHER OPERATION
Precautions for Low Temperature
Fuel and Lubricants
Coolant
Battery
Installation of Radiator Curtain
Precautions After Completion Of Work
AFTER COLD WEATHER
LONG-TERM STORAGE
Before Storage
During Storage
After Storage
Precautions Before Traveling After Long-Term Storage
TROUBLESHOOTING
After Running Out of Fuel
Procedure for Bleeding Air from Fuel Circuit
If Transmission has Trouble
Method of Lowering Dump Body in Emergency
METHOD OF TOWING MACHINE
When Engine Runs
When Engine Does Not Run
When Parking Brake Has Been Actuated in Emergency
Method of Releasing Parking Brake
PRECAUTIONS FOR CHARGING BATTERY
Charging Battery When Mounted on Machine
If Battery Is Discharged
Removal and Installation of Battery
Starting Engine with Booster Cable
Precautions When Connecting and Disconnecting Booster Cable
Connecting the Booster Cables
Starting the Engine
Disconnecting the Booster Cables
OTHER TROUBLE
Electrical System
Chassis
If Accelerator Pedal Has Failed
Engine
ACTION CODE
GUIDES TO MAINTENANCE
Check Service Meter
Komatsu Genuine Replacement Parts
Komatsu Genuine Oils
Always Use Clean Washer Fluid
Always Use Clean Oil and Grease
Checking Foreign Materials in Drained Oil and on Filters
Fueling
Welding Instructions
Do Not Drop Things Inside Machine
Dusty Work Sites
Avoid Mixing Oil
Locking Inspection Covers
Bleeding Air From Hydraulic Circuit
Precautions When Installing Hydraulic Hoses
Checks After Inspection and Maintenance
OUTLINES OF SERVICE
Handling Oil, Fuel, Coolant, and Performing Oil Clinic
Fuel
Coolant and Water for Dilution
Grease
Performing KOWA (Komatsu Oil Wear Analysis)
Storing Oil and Fuel
Filters
Outline of Electric System
WEAR PARTS LIST
RECOMMENDED FUEL, COOLANT, AND LUBRICANT
USE OF FUEL, COOLANT AND LUBRICANTS
Selection According to Ambient Temperature
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
Torque List
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
Safety Critical Parts
REGULAR SCHEDULED MAINTENANCE
Maintenance Schedule Chart
Initial 250 Hours Service (Only After the First 250 Hours)
When Required
Check, Clean or Replace Air Cleaner
Clean Outer Element
Replace Outer Element
Clean Inside of Cooling System
Check Level of Window Washer Fluid, Add Fluid
Clean Air Conditioner Air Filters
Check Refrigerant (Freon 134a) Level
Check Dump Body
Check Length of Suspension Cylinder
Bleed Air From Front Brake
Bleed Air From Center Brake
Check Play of Output Coupling of Output Shaft
Selection and Inspection of Tires
Selection of Tires
Check Inflation Pressure of Tires and Inflation of Them
Precautions When Replacing Tire
Adjust Parking Brake
Clean Hydraulic Tank Strainer
Every 50 Hours Service
Lubrication
Every 250 Hours Service
Check Drive Shaft
Lubricate Drive Shaft
Clean Overflow Hose
Check Level of Battery Electrolyte
When Checking Electrolyte Level From Side of Battery
When Impossible to Check Electrolyte Level From Side of Battery
When Possible to Use Indicator to Check Electrolyte Level
Check Fan Belt and Alternator Belt Tension, Adjust
Check Air Conditioner Compressor Belt Tension, Adjust
Check Frame, A-Arm
Check Braking Capacity of Foot Brake
Check Braking Capacity of Retarder Brake
Check Braking Capacity of Parking Brake
Check Wear of Parking Brake Pads
Check of Accumulator Gas Pressure
Every 500 Hours Service
Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge
Replace Fuel Pre-filter Cartridge
Lubrication Cab Mount Pin
Check Oil Level in Final Drive Case, Add Oil
Check Oil Level in Differential Case, Add Oil
Clean, Check Radiator Fins and After Cooler Fins
Recover Oil Leaking From Floating Seal
Every 1000 Hours Service
Replace Main Fuel Filter Cartridge
Replace Fuel Tank Breather Element
Replace Corrosion Resistor Cartridge
Replace Transmission Filter Element
Change Oil in Transmission Case
Change Brake Oil in Tank, Replace Brake Oil Filter Element
Lubricating Parking Brake
Check Wear of Brake Disc
Check Engine Air Intake Piping Clamps for Looseness
Every 2000 Hours Service
Change Oil in Final Drive Case
Change Oil In Differential Case
Replace Hydraulic Filter Element
Clean Transmission Case Strainer
Clean Breathers
Check Accumulator Gas Pressure
Check Alternator
Check, Adjust Engine Valve Clearance
Check Vibration Damper
Every 4000 Hours Service
Change Oil in Hydraulic Tank
Check Starting Motor
Check Water Pump
Check Air Compressor
Check Fan Pulley And Tension Pulley
Checking for Looseness of High-pressure Clamp, Hardening of Rubber
Checking for Missing Fuel Spray Prevention Cap, Hardening of Rubber
Check Exhaust Pipe Fire Prevention Cover
Every 6000 Hours Service
Greasing Procedure for Front Drive Shaft
Every 8000 Hours Service
Replace High-Pressure Piping Clamp
Replace Fuel Spray Prevention Cap
Overhaul Starting Motor and Alternator
SPECIFICATIONS
HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL (ARAC)
Automatic Retarder, Accelerator Control Switch
Actuation of ARAC System
HANDLING PAYLOAD METER HM
Features of Payload Meter HM
Measuring Loading
Three Measurement Methods
Panel Display
External Display Lamp
Writing Operation Data
Method of Using Accurately
Length of Suspension Cylinder
Performing Calibration
Method Using Travel Mode
Method Using Dumping Mode
Method Using Loading Mode
Downloading
General Locations
Controller Screen
Left Face of Controller
External Display Lamps
Communications Cable Connection Port for Personal Computer
Content of Display (Controller, External Display Lamps)
When Power is ON
Display During Normal Operations
Display Level for Lamps
Estimate Display
Details of Data Stored in Memory of Payload Meter
Cycle Data
Engine ON/OFF Data
Abnormality, Warning Data
Operation of Switches
When Calibrating
Preparations Before Calibrating
Method of Calibrating (Method of Operation)
Forced Display of Total Payload and Overall Number of Cycles
Method for Forced Display Operation
Method of Clearing Total Payload and Overall Number of Cycles
Operator Check Mode
Memory Card Dump Operation
Open ID Setting
Machine ID Setting
Adjusting Time, Date
Data All Clear Operation
Dimming Lights on Monitor Display
Service Check Mode
Abnormality and Warning Display (Error Code)
When Error Code F-09 Is Displayed
Procedure When Downloading
Downloading From Download Connector Inside Cab
Download Software
Others
USE OF REAR VIEW MONITOR
Name and Function of Each Part of Rear View Monitor
Auto Switch
Manual Switch
Zoom/IRIS Switch (Reverse Light Compensation Switch)
Bright/Dim Light Selector Switch
Mark Switch
Contrast Adjustment Knob
Brightness Adjustment Knob
Setting of Rear View Monitor
How to Set Display Mode
Cautions When Using Rear View Monitor
HANDLING DUMPING COUNTER
HANDLING MACHINES EQUIPPED WITH KOMTRAX
HANDLING BATTERY DISCONNECTOR SWITCH
Inside this manual
Real pages from this operation & maintenance manual (319 pages). Open the sample pages (PDF, 385 KB)
- Controls and operation, page 95: Switches
- Specifications, page 175: Location of Lifting Position Mark
- Maintenance, page 211: Initial 250 Hours Service (Only After the First 250 Hours)
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the HM300-2 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Operation & Maintenance Manual CEAM017504$69.97
Added to your cart. View cart
This is an operator's manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
This manual
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 319 pages
Quantity one is the manual described above.
Fast free USA shipping
Ships in 1 business day.
60-day returns
Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy
Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).