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Komatsu HD325-6 HD405-6 Dump Truck Operation & Maintenance Manual SN 6001, 2001 and up – PDF DOWNLOAD
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Komatsu HD325-6 HD405-6 Dump Truck Operation & Maintenance Manual
Book Code: SEAM000817T
SERIAL NUMBERS:
- HD325-6001 and up
- HD405-2001 and up
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Description
Komatsu HD325-6 HD405-6 Dump Truck Operation & Maintenance Manual
FILE DETAILS:
Komatsu HD325-6 HD405-6 Dump Truck Operation & Maintenance Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Operation & Maintenance Manual
Machine Model: HD325-6, HD405-6
Serial Number: 6001, 2001 and up
Language: English
Book Code: SEAM000817T
Pages: 300
File Format: Portable Document Format (PDF)
KOMATSU HD325-6 HD405-6 DUMP TRUCK OPERATION & MAINTENANCE MANUAL SN 6001, 2001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu HD325-6 HD405-6 Dump Truck Operation & Maintenance Manual
FOREWORD:
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
TABLE OF CONTENTS:
Komatsu HD325-6 HD405-6 Dump Truck Operation & Maintenance Manual
COVER.................................................................................. 1 FOREWORD............................................................................... 2 FOREWORD........................................................................... 3 SAFETY INFORMATION................................................................. 6 INTENDED USE....................................................................... 8 DIRECTIONS OF MACHINE.......................................................... 8 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...................... 9 PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE.................. 9 ENGINE SERIAL NO. PLATE POSITION............................................... 9 SERVICE METER POSITION......................................................... 10 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...................................... 10 CONTENTS............................................................................... 11 SAFETY................................................................................. 14 SAFETY INFORMATION................................................................. 15 SAFETY LABLES...................................................................... 17 POSITION FOR ATTACHING SAFETY LABELS........................................... 17 SAFETY LABELS.................................................................. 18 GENERAL PRECAUTIONS................................................................ 23 SAFETY RULES................................................................... 23 IF ABNORMALITIES ARE FOUND..................................................... 23 CLOTHING AND PERSONAL PROTECTIVE ITEMS......................................... 23 FIRE EXTINGUISHER AND FIRST AID KIT............................................ 23 SAFETY FEATURES................................................................ 24 KEEP MACHINE CLEAN............................................................. 24 INSIDE OPERATOR'S COMPARTMENT.................................................. 24 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT................................. 24 HANDRAILS AND STEPS............................................................ 25 MOUNTING AND DISMOUNTING....................................................... 25 CRUSHING OR CUTTING PREVENTION................................................. 25 PREVENTION OF BURNS............................................................ 26 FIRE PREVENTION................................................................ 26 ACTION IF FIRE OCCURS.......................................................... 27 WINDOW WASHER LIQUID........................................................... 27 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)................... 28 PRECAUTIONS FOR ATTACHMENTS.................................................... 28 UNAUTHORIZED MODIFICATION...................................................... 28 SAFETY AT WORKSITE............................................................. 28 WORKING ON LOOSE GROUND........................................................ 29 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES......................................... 29 ENSURE GOOD VISIBILITY......................................................... 29 PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS.............................. 30 CHECKING SIGNALMAN'S SIGNALS AND SIGNS......................................... 30 EMERGENCY ESCAPE FROM OPERATOR'S CAB........................................... 30 ASBESTOS DUST HAZARD PREVENTION................................................ 30 PRECAUTIONS DURING OPERATION....................................................... 31 STARING ENGINE................................................................. 31 CHECKS BEFORE STARTING ENGINE, ADJUST...................................... 31 PRECAUTIONS WHEN STARTING.................................................. 31 PRECAUTIONS IN COLD AREAS.................................................. 32 OPERATION...................................................................... 33 CHECKS BEFORE STARTING OPERATION........................................... 33 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE........................... 33 PRECAUTIONS WHEN TRAVELING................................................. 33 PRECAUTIONS WHEN TRAVELING ON SLOPS........................................ 34 PRECAUTIONS WHEN OPERATING DUMP BODY....................................... 34 PRECAUTIONS WHEN OPERATING................................................. 34 PRECAUTIONS FOR ACCUMULATED SNOW, ICE...................................... 34 PARKING MACHINE............................................................ 35 TRANSPORTATION................................................................. 36 SHIPPING................................................................... 36 LOADING AND UNLOADING...................................................... 36 BATTERY........................................................................ 37 BATTERY HAZARD PREVENTION.................................................. 37 STARTING WITH BOOSTER CABLES............................................... 38 TOWING......................................................................... 39 WHEN TOWING................................................................ 39 PRECAUTIONS FOR MAINTENANCE........................................................ 40 WARNING TAG.................................................................... 40 KEEP WORK PLACE CLEAN AND TIDY................................................. 40 APPOINT LEADER WHEN WORKING WITH OTHERS........................................ 40 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE..................... 41 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING............................. 42 PROPER TOOLS................................................................... 43 HANDLING SUSPENTION CYLINDER................................................... 43 PERSONNEL...................................................................... 43 WORK UNDER THE MACHINE......................................................... 43 NOISE.......................................................................... 43 PRECAUTIONS WHEN USING HAMMER.................................................. 44 REPAIR WELDING................................................................. 44 REMOVING BATTERY TERMINAL...................................................... 44 PRECAUTIONS WITH HIGH-PRESSURE OIL............................................. 44 PRECAUTIONS FOR HIGH-PRESSURE FUEL............................................. 44 HANDLING HIGH-PRESSURE HOSES, PIPING........................................... 45 PRECAUTIONS FOR HIGH VOLTAGE................................................... 45 WASTE MATERIALS................................................................ 45 MAINTENANCE OF AIR CONDITIONER................................................. 45 COMPRESSED AIR................................................................. 45 PERIODIC REPLACEMENT OF SAFETY-CIRTICAL PARTS.................................. 46 PRECAUTIONS WITH TIRES............................................................. 47 HANDLING TIRES................................................................. 47 PRECAUTIONS WHEN STORING TIRE.................................................. 47 OPERATION.............................................................................. 48 GENERAL VIEW....................................................................... 49 GENERAL VIEW OF MACHINE........................................................ 49 GENERAL VIEW OF CONTROLS AND GAUGES............................................ 50 EXPLANATION OF COMPONENTS.......................................................... 52 MACHINE MONITOR................................................................ 52 SWITCHES....................................................................... 69 CONTROL LEVERS AND PEDALS...................................................... 78 MECHATRONICS EQUIPMENT CONTROLLER.............................................. 82 SAFETY PIN..................................................................... 83 DUST INDICATOR................................................................. 83 LOCATION OF FIRE EXTINGUISHER.................................................. 84 LOCATION OF FIRST AID KIT...................................................... 84 FUSES.......................................................................... 84 CAR RADIO...................................................................... 87 CAR STEREO..................................................................... 93 AIR CONDITIONER................................................................101 OPERATION..........................................................................106 CHECK BEFORE STARTING ENGINE...................................................106 STARTING ENGINE................................................................122 OPERATIONS, CHECKS AFTER STARTING ENGINE.......................................126 STOPPING ENGINE................................................................127 CHECKS AFTER STOPPING ENGINE...................................................127 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING................................128 SHIFTING GEAR..................................................................133 TRAVELING DOWNHILL.............................................................134 STEERING THE MACHINE...........................................................143 LOADING OPERATIONS.............................................................143 DUMP OPERATIONS................................................................144 PRECAUTIONS FOR OPERATION......................................................145 PARKING MACHINE................................................................146 CHECKS AFTER COMPLETION OF WORK................................................147 DRAIN WATER FROM AIR TANK......................................................147 LOCKING........................................................................147 HANDLING TIRES.................................................................148 DETERMINING AND MAINTAINING TRAVEL ROAD............................................151 DETERMINING TRAVEL ROAD........................................................151 MAINTAINING TRAVEL ROAD........................................................151 TRANSPORTATION.....................................................................152 PRECAUTIONS WHEN TRANSPORTING..................................................152 STEPS FOR TRANSPORTATION.......................................................152 COLD WEATHER OPERATION.............................................................153 PRECAUTIONS FOR LOW TEMPERATURE................................................153 PRECAUTIONS AFTER COMPLETION OF WORK...........................................154 AFTER COLD WEATHER.............................................................155 LONG-TERM STORAGE..................................................................156 BEFOR STORAGE..................................................................156 DURING STORAGE.................................................................156 AFTER STORAGE..................................................................156 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE...........................156 TROUBLESHOOTING....................................................................157 AFTER RUNNING OUT OF FUEL......................................................157 TOWING THE MACHINE.............................................................159 IF BATTERY IS DISCHARGED.......................................................162 OTHER TROUBLE..................................................................165 MAINTENANCE............................................................................173 GUIDES TO MAINTENANCE..............................................................174 OUTLINES OF SERVICE................................................................176 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.........................176 OUTLINE OF ELECTRIC SYSTEM.....................................................178 WEAR PARTS.........................................................................179 WEAR PARTS LIST................................................................179 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...............180 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....................................187 TORQUE LIST....................................................................187 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS......................................188 SAFETY CRITICAL PARTS..........................................................188 MAINTENANCE SCHEDULE CHART.........................................................189 MAINTENANCE SCHEDULE CHART.....................................................189 ADJUST INJECTOR................................................................192 SERVICE PROCEDURE..................................................................193 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).....................193 WHEN REQUIRED..................................................................194 CHECK, CLEAN OR REPLACE AIR CLEANER .......................................194 CLEAN INSIDE OF COOLING SYSTEM.............................................196 CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID..............................199 CLEAN AIR CONDITIONER AIR FILTER...........................................199 CHECK REFRIGERANT (GAS) LEVEL..............................................200 CHECK DUMP BODY............................................................200 CHECK ELECTRIC INTAKE AIR HEATER...........................................200 CHECK LENGTH OF SUSPENSION CYLINDER, CHECK OIL LEVEL.......................201 BLEED AIR FROM REAR BRAKE..................................................202 BLEED AIR FROM FRONT BRAKE.................................................203 ADJUSTING PARKING BRAKE....................................................204 BLEED AIR FROM HYDRAULIC CIRCUIT OF FRONT DRIVE............................205 ADJUST BODY POSITIONER.....................................................206 CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT..............................207 SELECTION AND INSPECTION OF TIRES..........................................208 DRAIN WATER FROM WATER SEPARETOR...........................................210 CHECK BEFORE STARTING..........................................................211 EVERY 50 HOURS SERVICE.........................................................212 LUBRICATION................................................................212 EVERY 100 HOURS SERVICE........................................................214 CHECK ALCOHOL LEVEL IN ALCOHOL INJECTOR, ADD ALCOHOL.......................214 EVERY 250 HOURS SERVICE........................................................215 CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL ............................215 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL ..............................215 LUBRICATE DRIVE SHAFT (5 POINTS)...........................................216 CHECK DRIVE SHAFT..........................................................216 CHECK LEVEL OF BATTERY ELECTROLYTE.........................................217 CHECK ALTERNATOR BELT TENSION, ADJUST......................................219 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST......................220 CLEAN BREATHERS............................................................221 CHECK FRAME................................................................222 CHECK BRAKING CAPACITY OF FOOT BRAKE.......................................222 CHECK BRAKING CAPACITY OF RETARDER BRAKE...................................223 CHECK BRAKING CAPACITY OF PARKING BRAKE....................................223 CHECK WEAR OF PARKING BRAKE PADS...........................................223 CHECK, CLEAN AUTOMATIC SUSPENSION..........................................224 CLEAN CENTRAL BREATHER BOX AND CENTRAL BREATHER AIR CLEANER................225 EVERY 500 HOURS SERVICE........................................................226 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..........226 REPLACE FUEL FILTER CARTRIDGE .............................................227 CLEAN FUEL TANK STRAINER...................................................229 REPLACE TRANSMISSION OIL FILTER ELEMENT ...................................230 REPLACE ELEMENT OF FRONT DRIVE OIL FILTER..................................231 CHECK WEAR OF FRONT DISK BRAKE PADS........................................231 CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS...........................232 CHECK FAN BELT TENSION, ADJUST.............................................232 LUBRICATE TENSION PULLEY (1 POINT).........................................233 REPLACE ADDITIONAL FUEL FILTER CARTRIDGE (IF EQUIPPED).....................234 EVERY 1000 HOURS SERVICE.......................................................236 REPLACE CORROSION RESISTOR CARTRIDGE.......................................236 CHANGE OIL IN TRANSMISSION CASE, CLEAN TRANSMISSION CASE STRAINER..........237 CHANGE OIL IN FRONT FINAL DRIVE............................................238 CHANGE OIL IN FRONT DRIVE OIL TANK, CLEAN FRONT DRIVE OIL TANK STRAINER....239 REPLACE HYDRAULIC FILTER ELEMENT ..........................................240 LUBRICATION................................................................241 CHECK WEAR OF REAR BRAKE DISC..............................................242 CHECK TIGHTENING PARTS FOR TURBOCHARGER....................................242 REPLACE FUEL FILTER CARTRIDGE..............................................242 EVERY 2000 HOURS SERVICE.......................................................243 CHANGE OIL IN HYDRAULIC TANK...............................................243 CAHNGE OIL IN FINAL DRIVE CASE.............................................244 CHANGE OIL IN DIFFERENTIAL CASE............................................244 CLEAN DIFFERENTIAL CASE BREATHER...........................................245 CLEAN ENGINE BREATHER ELEMENT .............................................245 CLEAN AIR DRYER FILTER AND DEFLECTOR (IF EQUIPPED).........................246 CLEAN EMERGENCY RALAY VALVE................................................246 CHECK ALTERNATOR, STARTING MOTOR...........................................246 CHECK, ADJUST ENGINE VALVE CLEARANCE.......................................246 CHECK INJECTOR.............................................................246 CLEAN, CHECK TURBOCHARGER .................................................247 CHECK PLAY OF TURBOCHARGER ROTOR...........................................247 EVERY 4000 HOURS SERVICE.......................................................248 CHECK WATER PUMP...........................................................248 CHECK AIR COMPRESSOR.......................................................248 CHECK FAN PULLEY AND TENSION PULLEY........................................248 CHECK VIBRATION DAMPER.....................................................248 CHECK INJECTOR.............................................................248 REPLACE INJECTOR ASSEMBLY..................................................248 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HANDENING OF RUBBER.........248 CHEKCING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER........249 EVERY 8000 HOURS SERVICE.......................................................250 REPLACE INJECTOR NOZZLE TIP................................................250 REPLACE HIGH-PRESSURE PIPING CLAMP.........................................250 REPLACE FUEL SPRAY PREVENTION CAP..........................................250 SPECIFICATIONS.........................................................................251 SPECIFICATIONS.....................................................................252 ATTACHMENTS, OPTIONS...................................................................253 HANDLING PAYLOAD METER.............................................................254 NAME OF PARTS..................................................................254 EXTERNAL DISPLAY LAMPS.........................................................255 OPERATING PAYLOAD METER........................................................258 SELECTING DUMP BODY................................................................266 TACHOGRAPH (TCO 15-6)..............................................................267 EXPLANATION OF COMPONENTS......................................................267 METHOD OF USING KEY............................................................269 METHOD OF USE..................................................................269 REVO TACHOGRAPH (TCO 15-7).........................................................271 EXPLANATION OF COMPONENTS......................................................271 METHOD OF USE..................................................................273 USING DIFFERENTIAL LOCK............................................................275 DIFFERENTIAL LOCK PEDAL........................................................275 PRECAUTIONS AND METHOD OF USE..................................................276 OPERATION OF ABS AND ABS/ASR.......................................................277 EXPLANATION OF COMPONENTS .....................................................277 OPERATION METHOD ..............................................................279 PRECAUTIONS FOR USE............................................................280 TROUBLESHOOTING................................................................280 HANDLING AUTO-GREASING SYSTEM......................................................281 METHOD OF OPERATING AUTO-GREASING SYSTEM.......................................281 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM.................................287 TROUBLESHOOTING................................................................287 ARSC (AUTOMATIC RETARDER SPEED CONTROL)............................................288 EXPLANATION OF COMPONENTS......................................................289 METHOD OF OPERATION............................................................291 TROUBLESHOOTING................................................................293 HANDLING OIL FILTER CUATION .......................................................296 METHOD OF USE..................................................................296 INDEX..................................................................................298
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- This is the SAME exact manual used by your dealers to fix your vehicle.
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