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Komatsu Dump Truck HD325-7 HD405-7 Operation & Maintenance Manual SN 7569 and up – PDF DOWNLOAD
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Komatsu Dump Truck HD325-7 HD405-7 Operation & Maintenance Manual
SERIAL NUMBERS :
HD325-7569 and up
HD405-7569 and up
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Description
Komatsu Dump Truck HD325-7 HD405-7 Operation & Maintenance Manual
FILE DETAILS:
Komatsu Dump Truck HD325-7 HD405-7 Operation & Maintenance Manual
Size : 8.28 MB
Format : PDF
Language : English
Number of Pages: 359 Pages
Brand: Komatsu
Type of machine: Dump Truck
Type of document: Operation & Maintenance Manual
Model: HD325-7 HD 405-7
Serial: 7569 and up
KOMATSU DUMP TRUCK HD325-7 HD405-7 OPERATION & MAINTENANCE MANUAL SN 7569 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Dump Truck HD325-7 HD405-7 Operation & Maintenance Manual
BEFORE READING THIS MANUAL:
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 carry out 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. Always keep this Operation and Maintenance Manual in the location shown on the right so that all relevant personnel can read it at any time. Storage location for the Operation and Maintenance Manual: Pocket (1) at rear of operator’s seat If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement.
- For details regarding the machine serial No. you will need to provide your Komatsu distributor, see “TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR (PAGE 1-7)”. This manual uses the international units (SI) for units of measurement. For reference, units that have been used in the past are given in ( ). The explanations, values, and illustrations in this manual have been prepared based on the latest information available as of the date of its publication.
- Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information concerning your machine or with questions regarding information contained in this manual.
- The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example:1 → (1)) 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, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.
TABLE OF CONTENTS:
Komatsu Dump Truck HD325-7 HD405-7 Operation & Maintenance Manual
COVER.......................................................................................... 1 FOREWORD....................................................................................... 2 BEFORE READING THIS MANUAL................................................................. 3 SAFETY INFORMATION......................................................................... 4 INTENDED USE............................................................................... 5 USE OF MACHINE......................................................................... 5 DIRECTIONS OF MACHINE.................................................................. 5 VISIBILITY FROM OPERATOR'S SEAT........................................................ 5 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................. 6 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........................... 6 EPA REGULATIONS, ENGINE NUMBER PLATE................................................... 6 SERVICE METER POSITION................................................................. 7 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................................. 7 CONTENTS................................................................................... 8 SAFETY......................................................................................... 12 SAFETY..................................................................................... 13 SAFETY LABELS.............................................................................. 16 POSITION FOR ATTACHING SAFETY LABELS................................................... 17 SAFETY LABELS.......................................................................... 18 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE.................................... 23 PRECAUTIONS BEFORE STARTING OPERATION.................................................. 23 PREPARATIONS FOR SAFE OPERATION........................................................ 23 FIRE PREVENTION........................................................................ 25 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE............................................. 26 DO NOT GET CAUGHT IN DUMP BODY......................................................... 28 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES........................................... 28 UNAUTHORIZED MODIFICATION.............................................................. 28 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS......................................... 29 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING........................................ 29 PRECAUTIONS FOR OPERATION.................................................................. 30 PRECAUTIONS FOR JOBSITE................................................................ 30 STARTING ENGINE........................................................................ 32 OPERATION.............................................................................. 34 TRANSPORTATION......................................................................... 38 TOWING................................................................................. 39 PRECAUTIONS FOR MAINTENANCE................................................................ 40 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE................................. 40 PRECAUTIONS FOR INSPECTION AND MAINTENANCE............................................. 44 TIRES.................................................................................. 49 OPERATION...................................................................................... 52 GENERAL VIEW............................................................................... 53 GENERAL VIEW OF MACHINE................................................................ 53 GENERAL VIEW OF CONTROLS AND GAUGES.................................................... 54 EXPLANATION OF COMPONENTS.................................................................. 56 MACHINE MONITOR........................................................................ 56 OTHER FUNCTIONS OF MACHINE MONITOR..................................................... 77 SWITCHES............................................................................... 81 CONTROL LEVERS AND PEDALS.............................................................. 90 BODY PIVOT PIN......................................................................... 95 LOCATION OF FIRE EXTINGUISHER.......................................................... 95 DUST INDICATOR......................................................................... 96 FUSES.................................................................................. 97 CAR RADIO..............................................................................100 CAR STEREO.............................................................................106 AIR CONDITIONER........................................................................115 OPERATION..................................................................................120 CHECK BEFORE STARTING ENGINE...........................................................120 STARTING ENGINE........................................................................139 OPERATIONS, CHECKS AFTER STARTING ENGINE...............................................141 STOPPING ENGINE........................................................................142 CHECKS AFTER STOPPING ENGINE...........................................................142 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING........................................143 SHIFTING GEAR..........................................................................148 TRAVELING DOWNHILL.....................................................................150 STEERING THE MACHINE...................................................................159 LOADING OPERATIONS.....................................................................159 DUMP OPERATIONS........................................................................160 PRECAUTIONS FOR OPERATION..............................................................161 PARKING MACHINE........................................................................162 CHECKS AFTER COMPLETION OF WORK........................................................163 LOCKING................................................................................163 HANDLING TIRES.........................................................................164 DETERMINING AND MAINTAINING TRAVEL ROAD....................................................167 DETERMINING TRAVEL ROAD................................................................167 MAINTAINING TRAVEL ROAD................................................................167 TRANSPORTATION.............................................................................168 PRECAUTIONS WHEN TRANSPORTING..........................................................168 STEPS FOR TRANSPORTATION...............................................................168 METHOD OF SECURING MACHINE.............................................................168 METHOD OF LIFTING MACHINE..............................................................169 COLD WEATHER OPERATION.....................................................................172 PRECAUTIONS FOR LOW TEMPERATURE........................................................172 PRECAUTIONS AFTER COMPLETION OF WORK...................................................173 AFTER COLD WEATHER.....................................................................174 LONG-TERM STORAGE..........................................................................175 BEFORE STORAGE.........................................................................175 DURING STORAGE.........................................................................175 AFTER STORAGE..........................................................................175 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE...................................175 TROUBLESHOOTING............................................................................176 AFTER RUNNING OUT OF FUEL..............................................................176 IF TRANSMISSION HAS TROUBLE............................................................177 METHOD OF LOWERING DUMP BODY IN EMERGENCY..............................................178 METHOD OF TOWING MACHINE...............................................................179 IF BATTERY IS DISCHARGED...............................................................183 OTHER TROUBLE..........................................................................186 MAINTENANCE....................................................................................192 GUIDES TO MAINTENANCE......................................................................193 OUTLINE OF SERVICE.........................................................................197 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................197 OUTLINE OF ELECTRIC SYSTEM.............................................................201 WEAR PARTS.................................................................................202 WEAR PARTS LIST........................................................................202 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................203 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................204 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....205 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................206 TORQUE LIST............................................................................206 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................207 SAFETY CRITICAL PARTS..................................................................208 MAINTENANCE SCHEDULE CHART.................................................................209 MAINTENANCE SCHEDULE CHART.............................................................209 SERVICE PROCEDURE..........................................................................212 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).............................212 WHEN REQUIRED..........................................................................213 CHECK BEFORE STARTING..................................................................234 EVERY 250 HOURS SERVICE................................................................235 EVERY 500 HOURS SERVICE................................................................247 EVERY 1000 HOURS SERVICE...............................................................253 EVERY 2000 HOURS SERVICE...............................................................266 EVERY 4000 HOURS SERVICE...............................................................270 EVERY 8000 HOURS SERVICE...............................................................273 EVERY 15000 HOURS SERVICE..............................................................274 SPECIFICATIONS.................................................................................276 SPECIFICATIONS.............................................................................277 ATTACHMENTS, OPTIONS...........................................................................278 SELECTING DUMP BODY........................................................................279 HANDLING AIR SUSPENSION SEAT...............................................................280 SEAT ADJUSTMENT........................................................................280 REMOVAL AND INSTALLATION OF HEADREST...................................................282 HANDLING AUTOMATIC SPIN REGULATOR (ASR)....................................................283 EXPLANATION OF COMPONENTS..............................................................283 ACTUATION OF ASR SYSTEM................................................................284 PRECAUTIONS WHEN USING.................................................................284 BLEEDING AIR FROM ASR CIRCUIT..........................................................285 HANDLING ABS...............................................................................286 EXPLANATION OF COMPONENTS..............................................................286 ABS SYSTEM CHECK AFTER STARTING ENGINE.................................................288 OPERATION OF ABS.......................................................................288 PRECAUTIONS WHEN USING.................................................................289 HANDLING PAYLOAD METER II (CARD TYPE)......................................................290 METHOD OF USING ACCURATELY.............................................................291 GENERAL LOCATIONS......................................................................292 CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)................................297 EXTERNAL DISPLAY LAMPS.................................................................301 DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER......................................303 OPERATION OF SWITCHES..................................................................308 PROBLEM AND WARNING DISPLAY (ERROR CODE)...............................................330 WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY)....................337 OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED...........340 ARSC (AUTOMATIC RETARDER SPEED CONTROL)....................................................343 EXPLANATION OF COMPONENTS..............................................................344 METHOD OF OPERATION....................................................................347 USE OF REAR VIEW MONITOR...................................................................350 NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR.....................................350 SETTING OF REAR VIEW MONITOR...........................................................353 CAUTIONS WHEN USING REAR VIEW MONITOR..................................................353 HANDLING DUMPING COUNTER...................................................................354 HANDLING MACHINES EQUIPPED WITH KOMTRAX....................................................355 BASIC PRECAUTIONS......................................................................355 INDEX..........................................................................................356
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
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