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Komatsu Dump Truck HD465-7EO HD605-7EO Operation & Maintenance Manual SN 10694 and up – PDF DOWNLOAD
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Komatsu Dump Truck HD465-7EO HD605-7EO Operation & Maintenance Manual
Book Code : TEN00332-00
SERIAL NUMBERS:
HD465-10694 and up
HD605-10694 and up
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Description
Komatsu Dump Truck HD465-7EO HD605-7EO Operation & Maintenance Manual
FILE DETAILS:
Komatsu Dump Truck HD465-7EO HD605-7EO Operation & Maintenance Manual
Size : 9.14 MB
Format : PDF
Language : English
Number of Pages : 401 Pages
Brand: Komatsu
Type of machine: Dump Truck
Type of document: Operation & Maintenance Manual
Model: HD465-7EO HD605-7EO
Serial: 10694 and up
KOMATSU DUMP TRUCK HD465-7EO HD605-7EO OPERATION & MAINTENANCE MANUAL SN 10694 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Dump Truck HD465-7EO HD605-7EO 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 HD465-7EO HD605-7EO Operation & Maintenance Manual
COVER.......................................................................................... 1 FOREWORD....................................................................................... 2 BEFORE READING THIS MANUAL................................................................. 3 SAFETY INFORMATION......................................................................... 4 INTENDED USE............................................................................... 5 USE OF MACHINE......................................................................... 5 GENERAL VIEW AND 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 IMPORTANT SAFETY INFORMATION............................................................... 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 DASHBOARD.............................................................................. 55 EXPLANATION OF COMPONENTS.................................................................. 56 GENERAL VIEW OF MACHINE................................................................ 56 OPERATOR'S CAB......................................................................... 59 CONTROL LEVERS AND PEDALS.............................................................. 61 MACHINE MONITOR........................................................................ 66 DISPLAY OF CHARACTER DISPLAY........................................................... 79 OTHER FUNCTIONS OF CHARACTER DISPLAY................................................... 83 SWITCHES............................................................................... 87 BODY PIVOT PIN......................................................................... 97 LOCATION OF FIRE EXTINGUISHER.......................................................... 98 DUST INDICATOR......................................................................... 98 FUSES.................................................................................. 99 CAR RADIO..............................................................................102 CAR STEREO.............................................................................104 AIR CONDITIONER........................................................................109 OPERATION..................................................................................114 CHECK BEFORE STARTING ENGINE...........................................................114 STARTING ENGINE........................................................................139 OPERATIONS, CHECKS AFTER STARTING ENGINE...............................................142 STOPPING ENGINE........................................................................142 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING........................................143 SHIFTING GEAR..........................................................................149 TRAVELING DOWNHILL.....................................................................151 STEERING THE MACHINE...................................................................164 LOADING OPERATIONS.....................................................................164 DUMP OPERATIONS........................................................................165 PRECAUTIONS FOR OPERATION..............................................................167 PARKING MACHINE........................................................................168 CHECKS AFTER COMPLETION OF WORK........................................................168 CHECKS AFTER STOPPING ENGINE...........................................................169 LOCKING................................................................................169 HANDLING TIRES.........................................................................170 DETERMINING AND MAINTAINING TRAVEL ROAD....................................................174 DETERMINING TRAVEL ROAD................................................................174 MAINTAINING TRAVEL ROAD................................................................174 WORKSITE...................................................................................175 EXAMINATION AN CONFIRMATION OF WORKSITE................................................175 WORKING ON LOOSE GROUND................................................................175 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLE..................................................176 ENSURE GOOD VISIBILITY.................................................................176 CONFIRMATION OF MARK...................................................................176 TRANSPORTATION.............................................................................177 PRECAUTIONS WHEN TRANSPORTING..........................................................177 STEPS FOR TRANSPORTATION...............................................................177 METHOD OF SECURING MACHINE.............................................................178 METHOD OF LIFTING MACHINE..............................................................179 COLD WEATHER OPERATION.....................................................................182 PRECAUTIONS FOR LOW TEMPERATURE........................................................182 PRECAUTIONS AFTER COMPLETION OF WORK...................................................184 AFTER COLD WEATHER.....................................................................184 LONG-TERM STORAGE..........................................................................185 BEFORE STORAGE.........................................................................185 DURING STORAGE.........................................................................185 AFTER STORAGE..........................................................................185 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE...................................185 TROUBLESHOOTING............................................................................186 AFTER RUNNING OUT OF FUEL..............................................................186 IF TRANSMISSION HAS TROUBLE............................................................186 METHOD OF LOWERING DUMP BODY IN EMERGENCY..............................................187 METHOD OF TOWING MACHINE...............................................................188 IF BATTERY IS DISCHARGED...............................................................192 ACTION IF FIRE OCCURS..................................................................196 OTHER TROUBLE..........................................................................197 MAINTENANCE....................................................................................204 GUIDES TO MAINTENANCE......................................................................205 SECONDARY MATERIALS FOR OPERATION..........................................................213 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................213 OUTLINE OF ELECTRIC SYSTEM.................................................................217 WEAR PARTS.................................................................................218 WEAR PARTS LIST........................................................................218 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................219 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................220 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....221 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................222 TORQUE LIST............................................................................222 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................223 SAFETY CRITICAL PARTS..................................................................223 MAINTENANCE SCHEDULE CHART.................................................................224 MAINTENANCE SCHEDULE CHART.............................................................224 SERVICE PROCEDURE..........................................................................226 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).............................226 WHEN REQUIRED..........................................................................227 CHECK BEFORE STARTING..................................................................252 EVERY 250 HOURS SERVICE................................................................253 EVERY 500 HOURS SERVICE................................................................267 EVERY 1000 HOURS SERVICE...............................................................277 EVERY 2000 HOURS SERVICE...............................................................287 EVERY 4000 HOURS SERVICE...............................................................290 EVERY 8000 HOURS SERVICE...............................................................294 EVERY 15000 HOURS SERVICE..............................................................295 SPECIFICATIONS.................................................................................296 SPECIFICATIONS.............................................................................297 ATTACHMENTS, OPTIONS...........................................................................298 SELECTING DUMP BODY........................................................................299 HANDLING TACHOGRAPH (TCO20-90W)............................................................300 EXPLANATION OF COMPONENTS..............................................................300 METHOD OF USE..........................................................................303 HANDLING AIR SUSPENSION SEAT...............................................................307 OPERATOR'S SEAT ADJUSTMENT.............................................................307 REMOVAL AND INSTALLATION OF HEADREST...................................................311 HANDLING AUTOMATIC SPIN REGULATOR (ASR)....................................................312 EXPLANATION OF COMPONENTS..............................................................312 ACTUATION OF ASR SYSTEM................................................................313 PRECAUTION WHEN USING ASR SYSTEM.......................................................313 TROUBLESHOOTING........................................................................314 BLEEDING AIR FROM ASR CIRCUIT..........................................................315 HANDLING ANTI SKID BRAKE SYSTEM (ABS)......................................................316 EXPLANATION OF COMPONENTS..............................................................316 ABS SYSTEM CHECK AFTER STARTING ENGINE.................................................317 OPERATION OF ABS.......................................................................318 PRECAUTION WHEN USING ABS SYSTEM.......................................................318 TROUBLESHOOTING........................................................................319 HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)................................................320 OUTLINE OF SYSTEM......................................................................320 NORMAL OPERATION DISPLAY...............................................................321 EXTERNAL DISPLAY LAMPS.................................................................323 PERFORMING CALIBRATION.................................................................324 DATA STORED IN PAYLOAD METER...........................................................326 PROCEDURE WHEN DOWNLOADING.............................................................327 MACHINE ID, OPEN ID....................................................................331 PAYLOAD (CYCLE DATA ITEM)..............................................................333 SERVICE FUNCTIONS......................................................................333 OTHERS.................................................................................333 HANDLING PAYLOAD METER II (CARD TYPE)......................................................334 METHOD OF USING ACCURATELY.............................................................335 GENERAL LOCATIONS......................................................................336 CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)................................341 EXTERNAL DISPLAY LAMPS.................................................................345 DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER......................................347 OPERATION OF SWITCHES..................................................................352 PROBLEM AND WARNING DISPLAY (ERROR CODE)...............................................374 WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY)....................381 OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED...........384 USE OF REAR VIEW MONITOR...................................................................387 NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR.....................................387 SETTING OF REAR VIEW MONITOR...........................................................390 CAUTIONS WHEN USING REAR VIEW MONITOR..................................................390 HANDLING DUMPING COUNTER...................................................................391 HANDLING BATTERY ISOLATOR..................................................................392 HANDLING MACHINES EQUIPPED WITH VHMS.......................................................394 VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED..................................394 VHMS AND COMMUNICATIONS TERMINAL INSTALLED.............................................394 PROCEDURE WHEN DOWNLOADING.............................................................395 CHECK BEFORE STARTING..................................................................395 INDEX..........................................................................................398
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