Komatsu HD325-8 HD405-8 Dump Truck Operation & Maintenance Manual TEN00946-03 – PDF DOWNLOAD

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Komatsu HD325-8 HD405-8 Dump Truck Operation & Maintenance Manual TEN00946-03 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu HD325-8 HD405-8 Dump Truck Operation & Maintenance Manual TEN00946-03 – PDF DOWNLOAD

SERIAL NUMBERS

HD325-50311 and up
HD405-50311 and up

READ THIS MANUAL:

• This manual gives details of the operation and methods of inspection and maintenance for this machine that
  must be observed 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. It is dangerous to perform improper
  operation and maintenance of the machine. It may cause 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 indicated location so that all relevant personnel can
  read it at any time.

TABLE OF CONTENTS:

Komatsu HD325-8 HD405-8 Dump Truck Operation & Maintenance Manual TEN00946-03 – PDF DOWNLOAD

FOREWORD 1-1
READ THIS MANUAL 1-6
SAFETY INFORMATION 1-7
INTRODUCTION 1-8
MAIN USE OF MACHINE 1-8
DIRECTIONS OF MACHINE 1-8
VISIBILITY FROM OPERATOR’S SEAT 1-8
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION 1-9
PRODUCT INFORMATION 1-10
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO PLATE 1-10
LOCATION OF ENGINE NUMBER PLATE 1-10
SERVICE METER LOCATION 1-11
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1-11
ABBREVIATION LIST 1-12
SAFETY 2-1
SAFETY LABELS 2-2
LOCATION OF SAFETY LABELS 2-3
CONTENTS OF SAFETY LABELS 2-7
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2-14
PRECAUTIONS BEFORE STARTING OPERATION 2-14
PREPARATIONS FOR SAFE OPERATION 2-14
PRECAUTIONS TO PREVENT FIRE 2-16
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2-18
DO NOT GET CAUGHT IN WORK EQUIPMENT 2-20
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2-20
UNAUTHORIZED MODIFICATION 2-20
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2-20
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2-21
PRECAUTIONS FOR OPERATION 2-22
PRECAUTIONS FOR JOBSITE 2-22
START ENGINE 2-25
PRECAUTIONS FOR OPERATION 2-27
TRANSPORTATION 2-31
TOWING AND BEING TOWED 2-32
PRECAUTIONS FOR MAINTENANCE 2-33
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2-33
PRECAUTIONS FOR CHECK AND MAINTENANCE 2-39
TIRES 2-45
PRECAUTIONS FOR DEF 2-46
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 2-46
PRECAUTIONS FOR ADDING 2-46
PRECAUTIONS FOR STORING 2-46
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 2-46
OTHER PRECAUTIONS 2-46
OPERATION 3-1
GENERAL VIEW 3-2
MACHINE EQUIPMENT NAME 3-2
CONTROLS AND GAUGES NAMES 3-3
OTHER EQUIPMENT NAME 3-8
EXPLANATION OF COMPONENTS 3-11
EXPLANATION OF MACHINE MONITOR EQUIPMENT 3-11
SWITCHES 3-116
CONTROL LEVERS AND PEDALS 3-130
OTHER EQUIPMENT 3-135
MACHINE OPERATIONS AND CONTROLS 3-176
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE 3-176
CONTENTS FOREWORD
1-2
METHOD FOR STARTING ENGINE 3-220
METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE 3-224
METHOD FOR STOPPING ENGINE 3-226
METHOD FOR CHECKING AFTER STOPPING ENGINE 3-227
METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MACHINE
3-228
METHOD FOR SHIFTING GEARS 3-234
METHOD FOR TRAVELING DOWNHILL 3-236
METHOD FOR TURNING MACHINE 3-254
METHOD FOR LOADING 3-255
HANDLING PAYLOAD METER 3-256
METHOD FOR DUMPING 3-272
PRECAUTIONS FOR OPERATION 3-274
METHOD FOR PARKING MACHINE 3-275
METHOD FOR CHECKING AFTER FINISHING WORK 3-276
LOCK 3-277
HANDLE TIRE 3-282
HANDLE AIR CONDITIONER 3-285
EXPLANATION OF AIR CONDITIONER EQUIPMENT 3-286
METHOD FOR OPERATING AIR CONDITIONER 3-293
HANDLE RADIO 3-300
EXPLANATION OF RADIO EQUIPMENT 3-300
METHOD FOR CONTROLLING RADIO 3-302
DETERMINE AND MAINTAIN TRAVEL ROAD 3-305
TRANSPORTATION 3-306
PRECAUTIONS FOR TRANSPORTATION 3-306
SELECT TRANSPORTATION METHOD 3-306
METHOD FOR SECURING MACHINE 3-306
PRECAUTIONS FOR LIFTING MACHINE 3-307
COLD WEATHER OPERATION 3-310
COLD WEATHER OPERATION INFORMATION 3-310
PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER 3-312
AFTER COLD WEATHER SEASON 3-312
PRECAUTIONS FOR LONG-TERM STORAGE 3-313
PREPARATION FOR LONG-TERM STORAGE 3-313
MAINTENANCE DURING LONG-TERM STORAGE 3-313
STARTING MACHINE AFTER LONG-TERM STORAGE 3-314
PREPARATION BEFORE TRAVELING AFTER LONG-TERM STORAGE 3-314
TROUBLES AND ACTIONS 3-315
ACTIONS WHEN RUNNING OUT OF FUEL 3-315
ACTIONS IF TRANSMISSION HAS TROUBLE 3-315
METHOD FOR LOWERING DUMP BODY IF TROUBLES OCCUR 3-316
PRECAUTIONS FOR TOWING MACHINE 3-317
PRECAUTIONS FOR DISCHARGED BATTERY 3-321
OTHER TROUBLE 3-326
MAINTENANCE 4-1
PRECAUTIONS FOR MAINTENANCE 4-2
CHECK SERVICE METER READING 4-2
KOMATSU GENUINE REPLACEMENT PARTS 4-2
KOMATSU GENUINE LUBRICANTS 4-2
ALWAYS USE CLEAN WASHER FLUID 4-2
FRESH AND CLEAN LUBRICANTS 4-2
CHECK DRAINED OIL AND USED FILTER 4-2
PRECAUTIONS FOR REFILLING OIL OR FUEL 4-2
PRECAUTIONS FOR ADDING DEF 4-2
PRECAUTIONS FOR WELDING 4-2
DO NOT DROP THINGS INSIDE MACHINE 4-3
PRECAUTIONS FOR KDPF 4-3
FOREWORD CONTENTS
1-3
PRECAUTIONS FOR SCR ASSEMBLY 4-3
DUSTY JOBSITES 4-4
AVOID MIXING OIL 4-4
LOCK INSPECTION COVERS 4-4
BLEED AIR FROM HYDRAULIC CIRCUIT 4-4
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES 4-4
CHECKS AFTER INSPECTION AND MAINTENANCE 4-5
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE 4-5
PRECAUTIONS FOR JACK-UP 4-6
OUTLINE OF MAINTENANCE 4-7
HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4-7
HANDLE ELECTRICAL COMPONENTS 4-15
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS 4-16
MAINTENANCE SCHEDULE 4-18
MAINTENANCE SCHEDULE TABLE 4-18
MAINTENANCE PROCEDURE 4-20
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) 4-20
WHEN REQUIRED 4-21
CHECKS BEFORE STARTING 4-51
EVERY 250 HOURS MAINTENANCE 4-52
EVERY 500 HOURS MAINTENANCE 4-67
EVERY 1000 HOURS MAINTENANCE 4-73
EVERY 2000 HOURS MAINTENANCE 4-88
EVERY 4000 HOURS MAINTENANCE 4-100
EVERY 4500 HOURS MAINTENANCE 4-104
EVERY 8000 HOURS MAINTENANCE 4-106
EVERY 9000 HOURS MAINTENANCE 4-106
SPECIFICATIONS 5-1
SPECIFICATIONS 5-2
SPECIFICATIONS: HD325-8 5-2
SPECIFICATIONS: HD405-8 5-4
ATTACHMENTS AND OPTIONS 6-1
BODY SELECTION 6-2
HANDLE EXTERNAL POWER SUPPLY ENGINE PREHEATER 6-3
EXPLANATION OF COMPONENTS 6-3
INSTALLATION PROCEDURES FOR EXTERNAL POWER SUPPLY SYSTEM FOR EXTERNAL
POWER SUPPLY ENGINE PREHEATER 6-5
FABRICATE EXTERNAL POWER SUPPLY CABLE 6-7
INSTALL EXTERNAL POWER SUPPLY SYSTEM 6-10
METHOD FOR OPERATING EXTERNAL POWER SUPPLY HEATER 6-11
CIRCUIT DIAGRAM OF EXTERNAL POWER SUPPLY ENGINE PREHEATER 6-12
HANDLE EXTERNAL POWER SUPPLY CONNECTOR FOR STARTING MOTOR 6-13
HANDLE EXTERNAL ENGINE SHUTDOWN SECONDARY SWITCH 6-14
HANDLE KOMATSU TRACTION CONTROL SYSTEM (KTCS) 6-15
OPERATION OF KTCS 6-15
METHOD FOR OPERATING MACHINE WHEN TIRES ARE STUCK IN GROUND 6-15
HANDLE SPEED LIMIT FUNCTION 6-16
OPERATION OF SPEED LIMIT FUNCTION 6-17
OPERATION IF TROUBLES ON SYSTEM OCCUR 6-18
REPLACEMENT PARTS 7-1
DEFINED LIFE PARTS 7-2
DEFINED LIFE PARTS LIST 7-2
CONSUMABLE PARTS 7-3
CONSUMABLE PARTS LIST 7-3
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 7-4
LUBRICATION CHART 7-7
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS 7-11
INDEX 8-1
FOREWORD CONTENTS

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PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
• Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted

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