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Komatsu Dump Truck HM325-7 HD405-7 Operation & Maintenance Manual TEN00137-09 – PDF DOWNLOAD
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Komatsu Dump Truck HM325-7 HD405-7 Operation & Maintenance Manual
Book Code : TEN00137-09
SERIAL NUMBERS:
HD325-7001-7025
HD325-7101 and up
HD405-3001-3035
HD405-7101 and up
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Description
Komatsu Dump Truck HM325-7 HD405-7 Operation & Maintenance Manual
FILE DETAILS:
Komatsu Dump Truck HM325-7 HD405-7 Operation & Maintenance Manual
Size : 8.28 MB
Format : PDF
Language : English
Number of Pages : 361 Pages
Brand: Komatsu
Type of machine: Dump Truck
Type of document: Operation & Maintenance Manual
Model: HM325-7 HD405-7
Serial: 7001-7025 3001-3035 and up
KOMATSU DUMP TRUCK HM325-7 HD405-7 OPERATION & MAINTENANCE MANUAL TEN00137-09 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Dump Truck HM325-7 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 HM325-7 HD405-7 Operation & Maintenance Manual
COVER.......................................................................................... 1 FOREWORD....................................................................................... 2 BEFORE READING THIS MANUAL................................................................. 3 SAFETY INFORMATION......................................................................... 6 INTENDED USE............................................................................... 7 USE OF MACHINE......................................................................... 7 DIRECTIONS OF MACHINE.................................................................. 7 VISIBILITY FROM OPERATOR'S SEAT........................................................ 7 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................. 8 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........................... 8 EPA REGULATIONS, ENGINE NUMBER PLATE................................................... 8 SERVICE METER POSITION................................................................. 9 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................................. 9 CONTENTS................................................................................... 10 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........................................................................141 OPERATIONS, CHECKS AFTER STARTING ENGINE...............................................143 STOPPING ENGINE........................................................................144 CHECKS AFTER STOPPING ENGINE...........................................................144 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING........................................145 SHIFTING GEAR..........................................................................150 TRAVELING DOWNHILL.....................................................................152 STEERING THE MACHINE...................................................................161 LOADING OPERATIONS.....................................................................161 DUMP OPERATIONS........................................................................162 PRECAUTIONS FOR OPERATION..............................................................163 PARKING MACHINE........................................................................164 CHECKS AFTER COMPLETION OF WORK........................................................165 LOCKING................................................................................165 HANDLING TIRES.........................................................................166 DETERMINING AND MAINTAINING TRAVEL ROAD....................................................169 DETERMINING TRAVEL ROAD................................................................169 MAINTAINING TRAVEL ROAD................................................................169 TRANSPORTATION.............................................................................170 PRECAUTIONS WHEN TRANSPORTING..........................................................170 STEPS FOR TRANSPORTATION...............................................................170 METHOD OF SECURING MACHINE.............................................................170 METHOD OF LIFTING MACHINE..............................................................171 COLD WEATHER OPERATION.....................................................................174 PRECAUTIONS FOR LOW TEMPERATURE........................................................174 PRECAUTIONS AFTER COMPLETION OF WORK...................................................175 AFTER COLD WEATHER.....................................................................176 LONG-TERM STORAGE..........................................................................177 BEFORE STORAGE.........................................................................177 DURING STORAGE.........................................................................177 AFTER STORAGE..........................................................................177 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE...................................177 TROUBLESHOOTING............................................................................178 AFTER RUNNING OUT OF FUEL..............................................................178 IF TRANSMISSION HAS TROUBLE............................................................179 METHOD OF LOWERING DUMP BODY IN EMERGENCY..............................................180 METHOD OF TOWING MACHINE...............................................................182 IF BATTERY IS DISCHARGED...............................................................186 OTHER TROUBLE..........................................................................189 MAINTENANCE....................................................................................196 GUIDES TO MAINTENANCE......................................................................197 OUTLINE OF SERVICE.........................................................................200 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................200 OUTLINE OF ELECTRIC SYSTEM.............................................................204 WEAR PARTS.................................................................................205 WEAR PARTS LIST........................................................................205 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................206 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................207 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....208 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................209 TORQUE LIST............................................................................209 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................210 SAFETY CRITICAL PARTS..................................................................211 MAINTENANCE SCHEDULE CHART.................................................................212 MAINTENANCE SCHEDULE CHART.............................................................212 SERVICE PROCEDURE..........................................................................215 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).............................215 WHEN REQUIRED..........................................................................216 CHECK BEFORE STARTING..................................................................237 EVERY 250 HOURS SERVICE................................................................238 EVERY 500 HOURS SERVICE................................................................250 EVERY 1000 HOURS SERVICE...............................................................256 EVERY 2000 HOURS SERVICE...............................................................268 EVERY 4000 HOURS SERVICE...............................................................272 EVERY 8000 HOURS SERVICE...............................................................275 EVERY 15000 HOURS SERVICE..............................................................276 SPECIFICATIONS.................................................................................278 SPECIFICATIONS.............................................................................279 ATTACHMENTS, OPTIONS...........................................................................280 SELECTING DUMP BODY........................................................................281 HANDLING AIR SUSPENSION SEAT...............................................................282 SEAT ADJUSTMENT........................................................................282 REMOVAL AND INSTALLATION OF HEADREST...................................................284 HANDLING AUTOMATIC SPIN REGULATOR (ASR)....................................................285 EXPLANATION OF COMPONENTS..............................................................285 ACTUATION OF ASR SYSTEM................................................................286 PRECAUTIONS WHEN USING.................................................................286 BLEEDING AIR FROM ASR CIRCUIT..........................................................287 HANDLING ABS...............................................................................288 EXPLANATION OF COMPONENTS..............................................................288 ABS SYSTEM CHECK AFTER STARTING ENGINE.................................................290 OPERATION OF ABS.......................................................................290 PRECAUTIONS WHEN USING.................................................................291 HANDLING PAYLOAD METER II (CARD TYPE)......................................................292 METHOD OF USING ACCURATELY.............................................................293 GENERAL LOCATIONS......................................................................294 CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)................................299 EXTERNAL DISPLAY LAMPS.................................................................303 DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER......................................305 OPERATION OF SWITCHES..................................................................310 PROBLEM AND WARNING DISPLAY (ERROR CODE)...............................................332 WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY)....................339 OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED...........342 ARSC (AUTOMATIC RETARDER SPEED CONTROL)....................................................345 EXPLANATION OF COMPONENTS..............................................................346 METHOD OF OPERATION....................................................................349 USE OF REAR VIEW MONITOR...................................................................352 NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR.....................................352 SETTING OF REAR VIEW MONITOR...........................................................355 CAUTIONS WHEN USING REAR VIEW MONITOR..................................................355 HANDLING DUMPING COUNTER...................................................................356 HANDLING MACHINES EQUIPPED WITH KOMTRAX....................................................357 BASIC PRECAUTIONS......................................................................357 INDEX..........................................................................................358
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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