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Komatsu Dump Truck HD325-6 HD405-6 Operator & Maintenance Manual SN 6188, 2087 and up – PDF DOWNLOAD
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Komatsu Dump Truck HD325-6 HD405-6 Operator & Maintenance Manual
Book Code : SEAM000819T
SERIAL NUMBERS:
HD325-6188
HD405-2087 and up
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Description
Komatsu Dump Truck HD325-6 HD405-6 Operator & Maintenance Manual
FILE DETAILS:
Komatsu Dump Truck HD325-6 HD405-6 Operator & Maintenance Manual
Size: 6.88 MB
Fomat: PDF
language: English
Brand: Komatsu
Type of machine: Generator
Type of document: Operator & Mainteance Manual
Model: HD325-6_6188 HD405-6_2087
Serial: 6188 2087 and up
Number of Page: 302
KOMATSU DUMP TRUCK HD325-6 HD405-6 OPERATOR & MAINTENANCE MANUAL SN 6188, 2087 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Dump Truck HD325-6 HD405-6 Operator & Maintenance Manual
FOREWORD:
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules forthe operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
TABLE OF CONTENTS:
Komatsu Dump Truck HD325-6 HD405-6 Operator & Maintenance Manual
COVER.................................................................................. 1 FOREWORD............................................................................... 2 FOREWORD........................................................................... 3 SAFETY INFORMATION................................................................. 6 INTENDED USE....................................................................... 8 DIRECTIONS OF MACHINE.......................................................... 8 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...................... 9 PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE.................. 9 ENGINE SERIAL NO. PLATE POSITION............................................... 9 SERVICE METER POSITION......................................................... 10 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...................................... 10 CONTENTS............................................................................... 11 SAFETY................................................................................. 14 SAFETY INFORMATION................................................................. 15 SAFETY LABLES...................................................................... 17 POSITION FOR ATTACHING SAFETY LABELS........................................... 17 SAFETY LABELS.................................................................. 18 GENERAL PRECAUTIONS................................................................ 23 SAFETY RULES................................................................... 23 IF ABNORMALITIES ARE FOUND..................................................... 23 CLOTHING AND PERSONAL PROTECTIVE ITEMS......................................... 23 FIRE EXTINGUISHER AND FIRST AID KIT............................................ 23 SAFETY FEATURES................................................................ 24 KEEP MACHINE CLEAN............................................................. 24 INSIDE OPERATOR'S COMPARTMENT.................................................. 24 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT................................. 24 HANDRAILS AND STEPS............................................................ 25 MOUNTING AND DISMOUNTING....................................................... 25 CRUSHING OR CUTTING PREVENTION................................................. 25 PREVENTION OF BURNS............................................................ 26 FIRE PREVENTION................................................................ 26 ACTION IF FIRE OCCURS.......................................................... 27 WINDOW WASHER LIQUID........................................................... 27 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)................... 28 PRECAUTIONS FOR ATTACHMENTS, OPTIONS........................................... 28 UNAUTHORIZED MODIFICATION...................................................... 28 SAFETY AT WORKSITE............................................................. 28 WORKING ON LOOSE GROUND........................................................ 29 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES......................................... 29 ENSURE GOOD VISIBILITY......................................................... 29 PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS.............................. 30 CHECKING SIGNALMAN'S SIGNALS AND SIGNS......................................... 30 EMERGENCY ESCAPE FROM OPERATOR'S CAB........................................... 30 ASBESTOS DUST HAZARD PREVENTION................................................ 30 PRECAUTIONS DURING OPERATION....................................................... 31 STARING ENGINE................................................................. 31 CHECKS BEFORE STARTING ENGINE, ADJUST...................................... 31 PRECAUTIONS WHEN STARTING.................................................. 31 PRECAUTIONS IN COLD AREAS.................................................. 32 OPERATION...................................................................... 33 CHECKS BEFORE STARTING OPERATION........................................... 33 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE........................... 33 PRECAUTIONS WHEN TRAVELING................................................. 33 PRECAUTIONS WHEN TRAVELING ON SLOPS........................................ 34 PRECAUTIONS WHEN OPERATING DUMP BODY....................................... 34 PRECAUTIONS WHEN OPERATING................................................. 34 PRECAUTIONS FOR ACCUMULATED SNOW, ICE...................................... 34 PARKING MACHINE............................................................ 35 TRANSPORTATION................................................................. 36 LOADING AND UNLOADING...................................................... 36 SHIPPING................................................................... 36 BATTERY........................................................................ 37 BATTERY HAZARD PREVENTION.................................................. 37 STARTING WITH BOOSTER CABLES............................................... 38 TOWING......................................................................... 39 WHEN TOWING................................................................ 39 PRECAUTIONS FOR MAINTENANCE........................................................ 40 WARNING TAG.................................................................... 40 KEEP WORK PLACE CLEAN AND TIDY................................................. 40 APPOINT LEADER WHEN WORKING WITH OTHERS........................................ 40 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE..................... 41 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING............................. 42 PROPER TOOLS................................................................... 43 HANDLING SUSPENTION CYLINDER................................................... 43 PERSONNEL...................................................................... 43 WORK UNDER THE MACHINE......................................................... 43 NOISE.......................................................................... 43 PRECAUTIONS WHEN USING HAMMER.................................................. 44 REPAIR WELDING................................................................. 44 REMOVING BATTERY TERMINAL...................................................... 44 PRECAUTIONS WITH HIGH-PRESSURE OIL............................................. 44 PRECAUTIONS FOR HIGH-PRESSURE FUEL............................................. 44 HANDLING HIGH-PRESSURE HOSES, PIPING........................................... 45 PRECAUTIONS FOR HIGH VOLTAGE................................................... 45 WASTE MATERIALS................................................................ 45 MAINTENANCE OF AIR CONDITIONER................................................. 45 COMPRESSED AIR................................................................. 45 PERIODIC REPLACEMENT OF SAFETY-CIRTICAL PARTS.................................. 46 PRECAUTIONS WITH TIRES............................................................. 47 HANDLING TIRES................................................................. 47 PRECAUTIONS WHEN STORING TIRE.................................................. 47 OPERATION.............................................................................. 48 GENERAL VIEW....................................................................... 49 GENERAL VIEW OF MACHINE........................................................ 49 GENERAL VIEW OF CONTROLS AND GAUGES............................................ 50 EXPLANATION OF COMPONENTS.......................................................... 52 MACHINE MONITOR................................................................ 52 SWITCHES....................................................................... 70 CONTROL LEVERS AND PEDALS...................................................... 79 MECHATRONICS EQUIPMENT CONTROLLER.............................................. 83 SAFETY PIN..................................................................... 84 DUST INDICATOR................................................................. 84 LOCATION OF FIRE EXTINGUISHER.................................................. 85 LOCATION OF FIRST AID KIT...................................................... 85 FUSES.......................................................................... 85 CAR RADIO...................................................................... 88 CAR STEREO..................................................................... 94 AIR CONDITIONER................................................................102 OPERATION..........................................................................107 CHECK BEFORE STARTING ENGINE...................................................107 STARTING ENGINE................................................................123 OPERATIONS, CHECKS AFTER STARTING ENGINE.......................................127 STOPPING ENGINE................................................................128 CHECKS AFTER STOPPING ENGINE...................................................128 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING................................129 SHIFTING GEAR..................................................................134 TRAVELING DOWNHILL.............................................................135 STEERING THE MACHINE...........................................................144 LOADING OPERATIONS.............................................................144 DUMP OPERATIONS................................................................145 PRECAUTIONS FOR OPERATION......................................................146 PARKING MACHINE................................................................147 CHECKS AFTER COMPLETION OF WORK................................................148 DRAIN WATER FROM AIR TANK......................................................148 LOCKING........................................................................148 HANDLING TIRES.................................................................149 DETERMINING AND MAINTAINING TRAVEL ROAD............................................153 DETERMINING TRAVEL ROAD........................................................153 MAINTAINING TRAVEL ROAD........................................................153 TRANSPORTATION.....................................................................154 PRECAUTIONS WHEN TRANSPORTING..................................................154 STEPS FOR TRANSPORTATION.......................................................154 COLD WEATHER OPERATION.............................................................155 PRECAUTIONS FOR LOW TEMPERATURE................................................155 PRECAUTIONS AFTER COMPLETION OF WORK...........................................156 AFTER COLD WEATHER.............................................................157 LONG-TERM STORAGE..................................................................158 BEFOR STORAGE..................................................................158 DURING STORAGE.................................................................158 AFTER STORAGE..................................................................158 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE...........................158 TROUBLESHOOTING....................................................................159 AFTER RUNNING OUT OF FUEL......................................................159 TOWING THE MACHINE.............................................................161 IF BATTERY IS DISCHARGED.......................................................164 OTHER TROUBLE..................................................................168 MAINTENANCE............................................................................176 GUIDES TO MAINTENANCE..............................................................177 OUTLINES OF SERVICE................................................................179 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.........................179 OUTLINE OF ELECTRIC SYSTEM.....................................................181 WEAR PARTS.........................................................................182 WEAR PARTS LIST................................................................182 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...............183 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....................................190 TORQUE LIST....................................................................190 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS......................................191 SAFETY CRITICAL PARTS..........................................................191 MAINTENANCE SCHEDULE CHART.........................................................192 MAINTENANCE SCHEDULE CHART.....................................................192 ADJUST INJECTOR................................................................195 SERVICE PROCEDURE..................................................................196 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).....................196 WHEN REQUIRED..................................................................197 CHECK, CLEAN OR REPLACE AIR CLEANER .......................................197 CLEAN INSIDE OF COOLING SYSTEM.............................................199 CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID..............................202 CLEAN AIR CONDITIONER AIR FILTER...........................................202 CHECK REFRIGERANT (GAS) LEVEL..............................................203 CHECK DUMP BODY............................................................203 CHECK ELECTRIC INTAKE AIR HEATER...........................................203 CHECK LENGTH OF SUSPENSION CYLINDER, CHECK OIL LEVEL.......................204 BLEED AIR FROM REAR BRAKE..................................................205 BLEED AIR FROM FRONT BRAKE.................................................206 ADJUSTING PARKING BRAKE....................................................207 BLEED AIR FROM HYDRAULIC CIRCUIT OF FRONT DRIVE............................208 ADJUST BODY POSITIONER.....................................................209 CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT..............................210 SELECTION AND INSPECTION OF TIRES..........................................211 DRAIN WATER FROM WATER SEPARETOR...........................................213 CHECK BEFORE STARTING..........................................................214 EVERY 50 HOURS SERVICE.........................................................215 LUBRICATION................................................................215 EVERY 100 HOURS SERVICE........................................................217 CHECK ALCOHOL LEVEL IN ALCOHOL INJECTOR, ADD ALCOHOL.......................217 EVERY 250 HOURS SERVICE........................................................218 CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL ............................218 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL ..............................218 LUBRICATE DRIVE SHAFT (5 PLACES)...........................................219 CHECK DRIVE SHAFT..........................................................219 CHECK LEVEL OF BATTERY ELECTROLYTE.........................................220 CHECK ALTERNATOR BELT TENSION, ADJUST......................................222 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST......................223 CLEAN BREATHERS............................................................224 CHECK FRAME................................................................225 CHECK BRAKING CAPACITY OF FOOT BRAKE.......................................225 CHECK BRAKING CAPACITY OF RETARDER BRAKE...................................226 CHECK BRAKING CAPACITY OF PARKING BRAKE....................................226 CHECK WEAR OF PARKING BRAKE PADS...........................................226 CHECK, CLEAN AUTOMATIC SUSPENSION..........................................227 CLEAN CENTRAL BREATHER BOX AND CENTRAL BREATHER AIR CLEANER................228 EVERY 500 HOURS SERVICE........................................................229 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..........229 REPLACE FUEL FILTER CARTRIDGE .............................................230 CLEAN FUEL TANK STRAINER...................................................232 REPLACE TRANSMISSION OIL FILTER ELEMENT ...................................233 REPLACE ELEMENT OF FRONT DRIVE OIL FILTER..................................234 CHECK WEAR OF FRONT DISK BRAKE PADS........................................234 CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS...........................235 CHECK FAN BELT TENSION, ADJUST.............................................235 LUBRICATE TENSION PULLEY (1 PLACE).........................................236 REPLACE ADDITIONAL FUEL FILTER CARTRIDGE (IF EQUIPPED).....................237 EVERY 1000 HOURS SERVICE.......................................................239 REPLACE CORROSION RESISTOR CARTRIDGE.......................................239 CHANGE OIL IN TRANSMISSION CASE, CLEAN TRANSMISSION CASE STRAINER..........240 CHANGE OIL IN FRONT FINAL DRIVE............................................241 CHANGE OIL IN FRONT DRIVE OIL TANK, CLEAN FRONT DRIVE OIL TANK STRAINER....242 REPLACE HYDRAULIC FILTER ELEMENT ..........................................243 LUBRICATION................................................................244 CHECK WEAR OF REAR BRAKE DISC..............................................245 CHECK TIGHTENING PARTS FOR TURBOCHARGER....................................245 REPLACE FUEL FILTER CARTRIDGE..............................................245 EVERY 2000 HOURS SERVICE.......................................................246 CHANGE OIL IN HYDRAULIC TANK...............................................246 CAHNGE OIL IN FINAL DRIVE CASE.............................................247 CHANGE OIL IN DIFFERENTIAL CASE............................................247 CLEAN DIFFERNTIAL CASE BREATHER............................................248 CLEAN ENGINE BREATHER ELEMENT .............................................248 CLEAN AIR DRYER FILTER AND DEFLECTOR (IF EQUIPPED).........................249 CLEAN EMERGENCY RALAY VALVE................................................249 CHECK ALTERNATOR, STARTING MOTOR...........................................249 CHECK, ADJUST ENGINE VALVE CLEARANCE.......................................249 CHECK INJECTOR.............................................................249 CLEAN, CHECK TURBOCHARGER .................................................250 CHECK PLAY OF TURBOCHARGER ROTOR...........................................250 EVERY 4000 HOURS SERVICE.......................................................251 CHECK WATER PUMP...........................................................251 CHECK AIR COMPRESSOR.......................................................251 CHECK FAN PULLEY AND TENSION PULLEY........................................251 CHECK VIBRATION DAMPER.....................................................251 CHECK INJECTOR.............................................................251 REPLACE INJECTOR ASSEMBLY..................................................251 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HANDENING OF RUBBER.........251 CHEKCING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER........252 EVERY 8000 HOURS SERVICE.......................................................253 REPLACE INJECTOR NOZZLE TIP................................................253 REPLACE HIGH-PRESSURE PIPING CLAMP.........................................253 REPLACE FUEL SPRAY PREVENTION CAP..........................................253 SPECIFICATIONS.........................................................................254 SPECIFICATIONS.....................................................................255 ATTACHMENTS, OPTIONS...................................................................256 HANDLING PAYLOAD METER.............................................................257 NAME OF PARTS..................................................................257 EXTERNAL DISPLAY LAMPS.........................................................258 OPERATING PAYLOAD METER........................................................261 SELECTING DUMP BODY................................................................269 TACHOGRAPH (TCO 15-6)..............................................................270 EXPLANATION OF COMPONENTS......................................................270 METHOD OF USING KEY............................................................272 METHOD OF USE..................................................................272 REVO TACHOGRAPH (TCO 15-7).........................................................274 EXPLANATION OF COMPONENTS......................................................274 METHOD OF USE..................................................................276 USING DIFFERENTIAL LOCK............................................................278 DIFFERENTIAL LOCK PEDAL........................................................278 PRECAUTIONS AND METHOD OF USE..................................................279 OPERATION OF ABS AND ABS/ASR.......................................................280 EXPLANATION OF COMPONENTS .....................................................280 OPERATION METHOD ..............................................................282 PRECAUTIONS FOR USE............................................................283 TROUBLESHOOTING................................................................283 HANDLING AUTO-GREASING SYSTEM......................................................284 METHOD OF OPERATING AUTO-GREASING SYSTEM.......................................284 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM.................................290 TROUBLESHOOTING................................................................290 ARSC (AUTOMATIC RETARDER SPEED CONTROL)............................................291 EXPLANATION OF COMPONENTS......................................................291 METHOD OF OPERATION............................................................293 TROUBLESHOOTING................................................................295 HANDLING OIL FILTER CUATION .......................................................298 METHOD OF USE..................................................................298 INDEX..................................................................................300
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