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Komatsu Dump Truck HD465-7EO HD605-7EO Operation & Maintenance Manual SN 10718 and up – PDF DOWNLOAD
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Komatsu Dump Truck HD465-7EO HD605-7EO Operation & Maintenance Manual
Serial: 10718 and up
Book Code : TEN00370-03
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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 : 8.82 MB
Format : PDF
Language : English
Number of Pages : 411 Pages
Brand: Komatsu
Type of machine: Dump Truck
Type of document: Operation & Maintenance Manual
Model: HD465-7EO HD605-7EO
Serial: 10718 and up
KOMATSU DUMP TRUCK HD465-7EO HD605-7EO OPERATION & MAINTENANCE MANUAL SN 10718 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........................................................................140 OPERATIONS, CHECKS AFTER STARTING ENGINE...............................................143 STOPPING ENGINE........................................................................144 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING........................................145 SHIFTING GEAR..........................................................................151 TRAVELING DOWNHILL.....................................................................153 STEERING THE MACHINE...................................................................166 LOADING OPERATIONS.....................................................................166 DUMP OPERATIONS........................................................................167 PRECAUTIONS FOR OPERATION..............................................................169 PARKING MACHINE........................................................................170 CHECKS AFTER COMPLETION OF WORK........................................................170 CHECKS AFTER STOPPING ENGINE...........................................................171 LOCKING................................................................................171 HANDLING TIRES.........................................................................172 DETERMINING AND MAINTAINING TRAVEL ROAD....................................................176 DETERMINING TRAVEL ROAD................................................................176 MAINTAINING TRAVEL ROAD................................................................176 WORKSITE...................................................................................177 EXAMINATION AN CONFIRMATION OF WORKSITE................................................177 WORKING ON LOOSE GROUND................................................................177 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLE..................................................178 ENSURE GOOD VISIBILITY.................................................................178 CONFIRMATION OF MARK...................................................................178 TRANSPORTATION.............................................................................179 PRECAUTIONS WHEN TRANSPORTING..........................................................179 STEPS FOR TRANSPORTATION...............................................................179 METHOD OF SECURING MACHINE.............................................................180 METHOD OF LIFTING MACHINE..............................................................181 COLD WEATHER OPERATION.....................................................................184 PRECAUTIONS FOR LOW TEMPERATURE........................................................184 PRECAUTIONS AFTER COMPLETION OF WORK...................................................186 AFTER COLD WEATHER.....................................................................186 LONG-TERM STORAGE..........................................................................187 BEFORE STORAGE.........................................................................187 DURING STORAGE.........................................................................187 AFTER STORAGE..........................................................................187 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE...................................187 TROUBLESHOOTING............................................................................188 AFTER RUNNING OUT OF FUEL..............................................................188 IF TRANSMISSION HAS TROUBLE............................................................188 METHOD OF LOWERING DUMP BODY IN EMERGENCY..............................................189 METHOD OF TOWING MACHINE...............................................................190 IF BATTERY IS DISCHARGED...............................................................194 ACTION IF FIRE OCCURS..................................................................198 OTHER TROUBLE..........................................................................199 MAINTENANCE ...................................................................................206 GUIDES TO MAINTENANCE......................................................................207 SECONDARY MATERIALS FOR OPERATION..........................................................215 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................215 OUTLINE OF ELECTRIC SYSTEM.................................................................219 WEAR PARTS.................................................................................220 WEAR PARTS LIST........................................................................220 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................221 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................222 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....223 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................224 TORQUE LIST............................................................................224 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................225 SAFETY CRITICAL PARTS..................................................................225 MAINTENANCE SCHEDULE CHART.................................................................226 MAINTENANCE SCHEDULE CHART.............................................................226 SERVICE PROCEDURE..........................................................................228 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).............................228 WHEN REQUIRED..........................................................................229 CHECK BEFORE STARTING..................................................................254 EVERY 250 HOURS SERVICE................................................................255 EVERY 500 HOURS SERVICE................................................................269 EVERY 1000 HOURS SERVICE...............................................................279 EVERY 2000 HOURS SERVICE...............................................................288 EVERY 4000 HOURS SERVICE...............................................................291 EVERY 8000 HOURS SERVICE...............................................................295 EVERY 15000 HOURS SERVICE..............................................................296 SPECIFICATIONS ................................................................................298 SPECIFICATIONS.............................................................................299 ATTACHMENTS, OPTIONS ..........................................................................300 SELECTING DUMP BODY........................................................................301 HANDLING TACHOGRAPH (TCO20-90W)............................................................302 EXPLANATION OF COMPONENTS..............................................................302 METHOD OF USE..........................................................................305 HANDLING AIR SUSPENSION SEAT...............................................................309 OPERATOR'S SEAT ADJUSTMENT.............................................................309 REMOVAL AND INSTALLATION OF HEADREST...................................................313 HANDLING AUTOMATIC SPIN REGULATOR (ASR)....................................................314 EXPLANATION OF COMPONENTS..............................................................314 ACTUATION OF ASR SYSTEM................................................................315 PRECAUTION WHEN USING ASR SYSTEM.......................................................315 TROUBLESHOOTING........................................................................316 BLEEDING AIR FROM ASR CIRCUIT..........................................................317 HANDLING ANTI SKID BRAKE SYSTEM (ABS)......................................................318 EXPLANATION OF COMPONENTS..............................................................318 ABS SYSTEM CHECK AFTER STARTING ENGINE.................................................319 OPERATION OF ABS.......................................................................320 PRECAUTION WHEN USING ABS SYSTEM.......................................................320 TROUBLESHOOTING........................................................................321 HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)................................................322 OUTLINE OF SYSTEM......................................................................322 NORMAL OPERATION DISPLAY...............................................................323 EXTERNAL DISPLAY LAMPS.................................................................325 PERFORMING CALIBRATION.................................................................326 DATA STORED IN PAYLOAD METER...........................................................328 PROCEDURE WHEN DOWNLOADING.............................................................329 MACHINE ID, OPEN ID....................................................................333 PAYLOAD (CYCLE DATA ITEM)..............................................................335 SERVICE FUNCTIONS......................................................................335 OTHERS.................................................................................335 HANDLING PAYLOAD METER II (CARD TYPE)......................................................336 METHOD OF USING ACCURATELY.............................................................337 GENERAL LOCATIONS......................................................................338 CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)................................343 EXTERNAL DISPLAY LAMPS.................................................................347 DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER......................................349 OPERATION OF SWITCHES..................................................................354 PROBLEM AND WARNING DISPLAY (ERROR CODE)...............................................376 WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY)....................383 OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED..........386 USE OF REAR VIEW MONITOR...................................................................389 NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR.....................................389 SETTING OF REAR VIEW MONITOR...........................................................392 CAUTIONS WHEN USING REAR VIEW MONITOR..................................................392 EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER.................................................393 SOCKET FOR ENGINE HEATER...............................................................393 CONNECTING EXTERNAL POWER SOURCE.......................................................393 RESTARTING ENGINE......................................................................394 HANDLING EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER....................................395 HANDLING DUMPING COUNTER...................................................................401 HANDLING BATTERY ISOLATOR..................................................................402 HANDLING MACHINES EQUIPPED WITH VHMS.......................................................404 VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED..................................404 VHMS AND COMMUNICATIONS TERMINAL INSTALLED.............................................404 PROCEDURE WHEN DOWNLOADING.............................................................405 CHECK BEFORE STARTING..................................................................405 INDEX..........................................................................................408
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
