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Komatsu Dump Truck HD325-7 HD405-7 Operation & Maintenance Manual SN 7611 and up – PDF DOWNLOAD
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Komatsu Dump Truck HD325-7 HD405-7 Operation & Maintenance Manual
SERIAL NUMBERS:
- HD325-7611 and up
- HD405-7611 and up
Book Code : TEN00425-07
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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 : 8.61 MB
Format : PDF
Language : English
Number of Pages : 373 Pages
Brand: Komatsu
Type of machine: Dump Truck
Type of document: Operation & Maintenance Manual
Model: HD325-7 HD405-7
Serial: 7611 and up
KOMATSU DUMP TRUCK HD325-7 HD405-7 OPERATION & MAINTENANCE MANUAL SN 7611 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........................................................ 6 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................. 7 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........................... 7 EPA REGULATIONS, ENGINE NUMBER PLATE................................................... 7 SERVICE METER POSITION................................................................. 8 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................................. 8 CONTENTS................................................................................... 9 SAFETY......................................................................................... 14 SAFETY..................................................................................... 15 SAFETY LABELS.............................................................................. 18 POSITION FOR ATTACHING SAFETY LABELS................................................... 19 SAFETY LABELS.......................................................................... 20 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE.................................... 25 PRECAUTIONS BEFORE STARTING OPERATION.................................................. 25 PREPARATIONS FOR SAFE OPERATION........................................................ 25 FIRE PREVENTION........................................................................ 27 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE............................................. 28 DO NOT GET CAUGHT IN DUMP BODY......................................................... 30 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES........................................... 30 UNAUTHORIZED MODIFICATION.............................................................. 30 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS......................................... 31 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING........................................ 31 PRECAUTIONS FOR OPERATION.................................................................. 32 PRECAUTIONS FOR JOBSITE................................................................ 32 STARTING ENGINE........................................................................ 34 OPERATION.............................................................................. 36 TRANSPORTATION......................................................................... 40 TOWING................................................................................. 41 PRECAUTIONS FOR MAINTENANCE................................................................ 42 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE................................. 42 PRECAUTIONS FOR INSPECTION AND MAINTENANCE............................................. 46 TIRES.................................................................................. 51 OPERATION...................................................................................... 54 GENERAL VIEW............................................................................... 55 GENERAL VIEW OF MACHINE................................................................ 55 GENERAL VIEW OF CONTROLS AND GAUGES.................................................... 56 EXPLANATION OF COMPONENTS.................................................................. 58 MACHINE MONITOR........................................................................ 58 OTHER FUNCTIONS OF MACHINE MONITOR..................................................... 79 SWITCHES............................................................................... 83 CONTROL LEVERS AND PEDALS.............................................................. 92 BODY PIVOT PIN......................................................................... 97 LOCATION OF FIRE EXTINGUISHER.......................................................... 97 DUST INDICATOR......................................................................... 98 FUSES.................................................................................. 99 CAR RADIO..............................................................................102 CAR STEREO.............................................................................108 AIR CONDITIONER........................................................................117 OPERATION..................................................................................122 CHECK BEFORE STARTING ENGINE...........................................................122 STARTING ENGINE........................................................................142 OPERATIONS, CHECKS AFTER STARTING ENGINE...............................................144 STOPPING ENGINE........................................................................145 CHECKS AFTER STOPPING ENGINE...........................................................145 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING........................................146 SHIFTING GEAR..........................................................................151 TRAVELING DOWNHILL.....................................................................153 STEERING THE MACHINE...................................................................162 LOADING OPERATIONS.....................................................................162 DUMP OPERATIONS........................................................................163 PRECAUTIONS FOR OPERATION..............................................................164 PARKING MACHINE........................................................................165 CHECKS AFTER COMPLETION OF WORK........................................................166 LOCKING................................................................................166 HANDLING TIRES.........................................................................167 DETERMINING AND MAINTAINING TRAVEL ROAD....................................................170 DETERMINING TRAVEL ROAD................................................................170 MAINTAINING TRAVEL ROAD................................................................170 TRANSPORTATION.............................................................................171 PRECAUTIONS WHEN TRANSPORTING..........................................................171 STEPS FOR TRANSPORTATION...............................................................171 METHOD OF SECURING MACHINE.............................................................171 METHOD OF LIFTING MACHINE..............................................................172 COLD WEATHER OPERATION.....................................................................175 PRECAUTIONS FOR LOW TEMPERATURE........................................................175 PRECAUTIONS AFTER COMPLETION OF WORK...................................................176 AFTER COLD WEATHER.....................................................................177 LONG-TERM STORAGE..........................................................................178 BEFORE STORAGE.........................................................................178 DURING STORAGE.........................................................................178 AFTER STORAGE..........................................................................178 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE...................................178 TROUBLESHOOTING............................................................................179 AFTER RUNNING OUT OF FUEL..............................................................179 IF TRANSMISSION HAS TROUBLE............................................................180 METHOD OF LOWERING DUMP BODY IN EMERGENCY..............................................181 METHOD OF TOWING MACHINE...............................................................182 IF BATTERY IS DISCHARGED...............................................................186 OTHER TROUBLE..........................................................................189 MAINTENANCE....................................................................................196 GUIDES TO MAINTENANCE......................................................................197 OUTLINE OF SERVICE.........................................................................201 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................201 OUTLINE OF ELECTRIC SYSTEM.............................................................205 WEAR PARTS.................................................................................206 WEAR PARTS LIST........................................................................206 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................207 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................208 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....209 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................210 TORQUE LIST............................................................................210 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................211 SAFETY CRITICAL PARTS..................................................................212 MAINTENANCE SCHEDULE CHART.................................................................213 MAINTENANCE SCHEDULE CHART.............................................................213 SERVICE PROCEDURE..........................................................................216 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).............................216 WHEN REQUIRED..........................................................................217 CHECK BEFORE STARTING..................................................................237 EVERY 250 HOURS SERVICE................................................................238 EVERY 500 HOURS SERVICE................................................................250 EVERY 1000 HOURS SERVICE...............................................................256 EVERY 2000 HOURS SERVICE...............................................................269 EVERY 4000 HOURS SERVICE...............................................................274 EVERY 8000 HOURS SERVICE...............................................................277 EVERY 15000 HOURS SERVICE..............................................................278 SPECIFICATIONS.................................................................................280 SPECIFICATIONS.............................................................................281 ATTACHMENTS, OPTIONS...........................................................................284 SELECTING DUMP BODY........................................................................285 HANDLING AIR SUSPENSION SEAT...............................................................286 SEAT ADJUSTMENT........................................................................286 REMOVAL AND INSTALLATION OF HEADREST...................................................288 HANDLING AUTOMATIC SPIN REGULATOR (ASR)....................................................289 EXPLANATION OF COMPONENTS..............................................................289 ACTUATION OF ASR SYSTEM................................................................290 PRECAUTIONS WHEN USING.................................................................290 BLEEDING AIR FROM ASR CIRCUIT..........................................................291 HANDLING ABS...............................................................................292 EXPLANATION OF COMPONENTS..............................................................292 ABS SYSTEM CHECK AFTER STARTING ENGINE.................................................294 OPERATION OF ABS.......................................................................294 PRECAUTIONS WHEN USING.................................................................295 HANDLING PAYLOAD METER II (CARD TYPE)......................................................296 METHOD OF USING ACCURATELY.............................................................297 GENERAL LOCATIONS......................................................................298 CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)................................303 EXTERNAL DISPLAY LAMPS.................................................................307 DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER......................................309 OPERATION OF SWITCHES..................................................................314 PROBLEM AND WARNING DISPLAY (ERROR CODE)...............................................336 WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY)....................343 OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED...........346 ARSC (AUTOMATIC RETARDER SPEED CONTROL)....................................................349 EXPLANATION OF COMPONENTS..............................................................350 METHOD OF OPERATION....................................................................353 USE OF REAR VIEW MONITOR...................................................................356 NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR.....................................356 SETTING OF REAR VIEW MONITOR...........................................................359 CAUTIONS WHEN USING REAR VIEW MONITOR..................................................359 EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER.................................................360 SOCKET FOR ENGINE HEATER...............................................................360 CONNECTING EXTERNAL POWER SOURCE.......................................................360 RESTARTING ENGINE......................................................................361 HANDLING EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER....................................362 HANDLING DUMPING COUNTER...................................................................368 HANDLING MACHINES EQUIPPED WITH KOMTRAX....................................................369 BASIC PRECAUTIONS......................................................................369 INDEX..........................................................................................370
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
