Komatsu HD325-7 HD405-7 Dump Truck Operator’s Manual PDF Download

Description

Komatsu HD325-7 HD405-7 Dump Truck Operation & Maintenance Manual TEN00807-09 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu HD325-7 HD405-7 Dump Truck Operation & Maintenance Manual TEN00807-09 – PDF DOWNLOAD

SERIAL NUMBERS

HD325-8016 and up
HD405-8016 and up

READ 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 perform 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.

TABLE OF CONTENTS:

Komatsu HD325-7 HD405-7 Dump Truck Operation & Maintenance Manual TEN00807-09 – PDF DOWNLOAD

FOREWORD 1- 1
READ THIS MANUAL 1- 2
SAFETY INFORMATION 1- 3
INTENDED USE 1- 4
USE OF MACHINE 1- 4
DIRECTIONS OF MACHINE 1- 4
VISIBILITY FROM OPERATOR’S SEAT 1- 5
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 6
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 6
ENGINE SERIAL NO. PLATE POSITION 1- 6
SERVICE METER POSITION 1- 7
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 7
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 5
POSITION FOR ATTACHING SAFETY LABELS 2- 6
SAFETY LABELS 2- 7
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 12
PRECAUTIONS BEFORE STARTING OPERATION 2- 12
PREPARATIONS FOR SAFE OPERATION 2- 12
FIRE PREVENTION 2- 14
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2- 15
DO NOT GET CAUGHT IN DUMP BODY 2- 17
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2- 17
UNAUTHORIZED MODIFICATION 2- 17
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2- 18
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2- 18
PRECAUTIONS FOR OPERATION 2- 19
PRECAUTIONS FOR JOBSITE 2- 19
STARTING ENGINE 2- 21
OPERATION 2- 23
TRANSPORTATION 2- 27
TOWING 2- 28
PRECAUTIONS FOR MAINTENANCE 2- 29
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 29
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2- 33
TIRES 2- 38
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
GENERAL VIEW OF CONTROLS AND GAUGES 3- 3
EXPLANATION OF COMPONENTS 3- 5
MACHINE MONITOR 3- 5
OTHER FUNCTIONS OF MACHINE MONITOR 3- 27
SWITCHES 3- 31
CONTROL LEVERS AND PEDALS 3- 40
BODY PIVOT PIN 3- 45
LOCATION OF FIRE EXTINGUISHER 3- 45
DUST INDICATOR 3- 46
FUSES 3- 47
CAR RADIO 3- 50
AM/FM RADIO-CASSETTE STEREO 3- 56
AIR CONDITIONER 3- 65
OPERATION 3- 70
CHECK BEFORE STARTING ENGINE 3- 70
STARTING ENGINE 3- 91
OPERATIONS, CHECKS AFTER STARTING ENGINE 3- 93
STOPPING ENGINE 3- 94
CHECKS AFTER STOPPING ENGINE 3- 94
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING 3- 95
SHIFTING GEAR 3-100
TRAVELING DOWNHILL 3-102
STEERING THE MACHINE 3-111
LOADING OPERATIONS 3-111
DUMP OPERATIONS 3-112
PRECAUTIONS FOR OPERATION 3-113
PARKING MACHINE 3-114
CHECKS AFTER COMPLETION OF WORK 3-115
LOCKING 3-115
HANDLING TIRES 3-116
DETERMINING AND MAINTAINING TRAVEL ROAD 3-119
DETERMINING TRAVEL ROAD 3-119
MAINTAINING TRAVEL ROAD 3-119
TRANSPORTATION 3-120
PRECAUTIONS WHEN TRANSPORTING 3-120
STEPS FOR TRANSPORTATION 3-120
METHOD OF SECURING MACHINE 3-120
METHOD OF LIFTING MACHINE 3-121
COLD WEATHER OPERATION 3-124
PRECAUTIONS FOR LOW TEMPERATURE 3-124
PRECAUTIONS AFTER COMPLETION OF WORK 3-125
AFTER COLD WEATHER 3-126
LONG-TERM STORAGE 3-127
BEFORE STORAGE 3-127
DURING STORAGE 3-127
AFTER STORAGE 3-127
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE 3-127
TROUBLESHOOTING 3-128
AFTER RUNNING OUT OF FUEL 3-128
IF TRANSMISSION HAS TROUBLE 3-129
METHOD OF LOWERING DUMP BODY IN EMERGENCY 3-130
METHOD OF TOWING MACHINE 3-131
IF BATTERY IS DISCHARGED 3-135
OTHER TROUBLE 3-139
MAINTENANCE 4- 1
GUIDES TO MAINTENANCE 4- 2
OUTLINE OF SERVICE 4- 6
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 6
OUTLINE OF ELECTRIC SYSTEM 4- 10
WEAR PARTS 4- 11
WEAR PARTS LIST 4- 11
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 12
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 13
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL 4- 15
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 16
TORQUE LIST 4- 16
DEFINED LIFE PARTS 4- 17
DEFINED LIFE PARTS LIST 4- 18
MAINTENANCE SCHEDULE CHART 4- 19
MAINTENANCE SCHEDULE CHART 4- 19
MAINTENANCE INTERVAL WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS USED 4- 22
SERVICE PROCEDURE 4- 23
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) 4- 23
WHEN REQUIRED 4- 24
CHECK BEFORE STARTING 4- 44
EVERY 250 HOURS SERVICE 4- 45
EVERY 500 HOURS SERVICE 4- 57
EVERY 1000 HOURS SERVICE 4- 63
EVERY 2000 HOURS SERVICE 4- 76
EVERY 4000 HOURS SERVICE 4- 80
EVERY 8000 HOURS SERVICE 4- 84
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
SELECTING DUMP BODY 6- 2
HANDLING AIR SUSPENSION SEAT 6- 3
SEAT ADJUSTMENT 6- 3
HANDLING AUTOMATIC SPIN REGULATOR (ASR) 6- 6
EXPLANATION OF COMPONENTS 6- 6
ACTUATION OF ASR SYSTEM 6- 7
PRECAUTIONS WHEN USING 6- 7
BLEEDING AIR FROM ASR CIRCUIT 6- 8
HANDLING ABS 6- 9
EXPLANATION OF COMPONENTS 6- 9
ABS SYSTEM CHECK AFTER STARTING ENGINE 6- 11
OPERATION OF ABS 6- 11
PRECAUTIONS WHEN USING 6- 12
HANDLING PAYLOAD METER 2.5 6- 13
OUTLINE OF SYSTEM 6- 13
NORMAL OPERATION DISPLAY 6- 15
EXTERNAL DISPLAY LAMPS 6- 17
PERFORMING CALIBRATION 6- 19
DATA STORED IN PAYLOAD METER 6- 21
PROCEDURE WHEN DOWNLOADING 6- 21
DOWNLOAD SOFTWARE 6- 22
MACHINE ID, OPEN ID 6- 24
PAYLOAD (CYCLE DATA ITEM) 6- 26
SERVICE FUNCTIONS 6- 26
OTHERS 6- 26
HANDLING PAYLOAD METER II (CARD TYPE) 6- 27
METHOD OF USING ACCURATELY 6- 28
GENERAL LOCATIONS 6- 29
CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS) 6- 34
EXTERNAL DISPLAY LAMPS 6- 38
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER 6- 40
OPERATION OF SWITCHES 6- 45
PROBLEM AND WARNING DISPLAY (ERROR CODE) 6- 67
WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY) 6- 74
OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN
REPLACED 6- 77
ARSC (AUTOMATIC RETARDER SPEED CONTROL) 6- 80
EXPLANATION OF COMPONENTS 6- 81
METHOD OF OPERATION 6- 84
HANDLING REAR VIEW MONITOR 6- 87
EXPLANATION OF COMPONENTS 6- 87
EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER 6- 89
SOCKET FOR ENGINE HEATER 6- 89
CONNECTING EXTERNAL POWER SOURCE 6- 89
RESTARTING ENGINE 6- 90
HANDLING EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER 6- 91
HANDLING DUMPING COUNTER 6- 97
KOMTRAX 6- 98
POWER SUPPLY FOR KOMTRAX 6- 98
HANDLING VEHICLE SPEED LIMIT 6- 99
EXPLANATION OF COMPONENTS 6- 99
OPERATION OF VEHICLE SPEED LIMIT 6-100
TROUBLESHOOTING 6-101
INDEX 7-

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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.

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