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Komatsu HD465-7, HD605-7 GALEO Dump Truck Operation & Maintenance Manual SN 7001 and up – DOWNLOAD
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Komatsu HD465-7, HD605-7 GALEO Dump Truck Operation & Maintenance Manual
SERIAL NUMBERS:
HD465-7001 and up
HD605-7001 and up
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Description
Komatsu HD465-7, HD605-7 GALEO Dump Truck Operation & Maintenance Manual
FILE DETAILS:
Komatsu HD465-7, HD605-7 GALEO Dump Truck Operation & Maintenance Manual
Model Specification: KOMATSU HD465-7, HD605-7 DUMP TRUCK
Language: English
File Format: PDF
Total Pages: 364
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES
KOMATSU HD465-7, HD605-7 GALEO DUMP TRUCK OPERATION & MAINTENANCE MANUAL SN 7001 AND UP – DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu HD465-7, HD605-7 GALEO 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 forthe operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
TABLE OF CONTENTS:
Komatsu HD465-7, HD605-7 GALEO 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................................................................ 9 SERVICE METER POSITION................................................................. 10 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................................. 10 CONTENTS....................................................................................... 11 SAFETY......................................................................................... 15 SAFETY INFORMATION......................................................................... 16 SAFETY LABELS.............................................................................. 18 POSITION FOR ATTACHING SAFETY LABELS................................................... 19 SAFETY LABELS.......................................................................... 20 GENERAL PRECAUTIONS........................................................................ 24 SAFETY RULES........................................................................... 24 IF PROBLEMS ARE FOUND.................................................................. 24 CLOTHING AND PERSONAL PROTECTIVE ITEMS................................................. 24 FIRE EXTINGUISHER AND FIRST AID KIT.................................................... 24 SAFETY FEATURES........................................................................ 24 KEEP MACHINE CLEAN..................................................................... 25 INSIDE OPERATOR'S COMPARTMENT.......................................................... 25 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT......................................... 25 HANDRAILS AND STEPS.................................................................... 26 MOUNTING AND DISMOUNTING............................................................... 26 CRUSHING OR CUTTING PREVENTION......................................................... 26 PREVENTION OF BURNS.................................................................... 27 FIRE PREVENTION........................................................................ 27 ACTION IF FIRE OCCURS.................................................................. 28 WINDOW WASHER LIQUID................................................................... 28 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)........................... 29 PRECAUTIONS FOR ATTACHMENTS, OPTIONS................................................... 29 UNAUTHORIZED MODIFICATION.............................................................. 29 SAFETY AT WORKSITE..................................................................... 29 WORKING ON LOOSE GROUND................................................................ 30 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................................................. 30 ENSURE GOOD VISIBILITY................................................................. 30 PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS...................................... 31 CHECKING SIGNALMAN'S SIGNALS AND SIGNS................................................. 31 EMERGENCY ESCAPE FROM OPERATOR'S CAB................................................... 31 ASBESTOS DUST HAZARD PREVENTION........................................................ 31 PRECAUTIONS DURING OPERATION............................................................... 32 STARTING ENGINE........................................................................ 32 CHECKS BEFORE STARTING ENGINE, ADJUST.............................................. 32 PRECAUTIONS WHEN STARTING.......................................................... 32 PRECAUTIONS IN COLD AREAS.......................................................... 33 OPERATION.............................................................................. 34 CHECKS BEFORE STARTING OPERATION................................................... 34 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE................................... 34 PRECAUTIONS WHEN TRAVELING......................................................... 34 PRECAUTIONS WHEN TRAVELING ON SLOPES............................................... 35 PRECAUTIONS WHEN OPERATING DUMP BODY............................................... 35 PRECAUTIONS WHEN OPERATING......................................................... 35 PRECAUTIONS FOR ACCUMULATED SNOW, ICE.............................................. 35 PARKING MACHINE.................................................................... 36 TRANSPORTATION......................................................................... 37 LOADING AND UNLOADING.............................................................. 37 SHIPPING........................................................................... 37 BATTERY................................................................................ 38 BATTERY HAZARD PREVENTION.......................................................... 38 STARTING WITH BOOSTER CABLES....................................................... 39 TOWING................................................................................. 40 WHEN TOWING........................................................................ 40 PRECAUTIONS FOR MAINTENANCE................................................................ 41 WARNING TAG............................................................................ 41 KEEP WORK PLACE CLEAN AND TIDY......................................................... 41 APPOINT LEADER WHEN WORKING WITH OTHERS................................................ 41 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE............................. 42 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING..................................... 43 PROPER TOOLS........................................................................... 43 HANDLING SUSPENSION CYLINDER, ACCUMULATOR.............................................. 44 PERSONNEL.............................................................................. 44 WORK UNDER THE MACHINE................................................................. 44 NOISE.................................................................................. 44 PRECAUTIONS WHEN USING HAMMER.......................................................... 44 REPAIR WELDING......................................................................... 44 REMOVING BATTERY TERMINAL.............................................................. 45 PRECAUTIONS WITH HIGH-PRESSURE OIL..................................................... 45 HANDLING HIGH-PRESSURE HOSES, PIPING................................................... 46 WASTE MATERIALS........................................................................ 46 MAINTENANCE OF AIR CONDITIONER......................................................... 46 COMPRESSED AIR......................................................................... 46 PERIODIC REPLACEMENT OF SAFETY-CRITICAL 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 OTHER FUNCTIONS OF MACHINE MONITOR..................................................... 73 SWITCHES............................................................................... 76 CONTROL LEVERS AND PEDALS.............................................................. 85 MECHATRONICS EQUIPMENT CONTROLLER...................................................... 90 SAFETY PIN............................................................................. 91 DUST INDICATOR......................................................................... 91 FUSES.................................................................................. 92 CAR RADIO.............................................................................. 97 CAR STEREO.............................................................................103 AIR CONDITIONER........................................................................111 OPERATION..................................................................................115 CHECK BEFORE STARTING ENGINE...........................................................115 STARTING ENGINE........................................................................129 OPERATIONS, CHECKS AFTER STARTING ENGINE...............................................132 STOPPING ENGINE........................................................................133 CHECKS AFTER STOPPING ENGINE...........................................................133 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING........................................134 SHIFTING GEAR..........................................................................139 TRAVELING DOWNHILL.....................................................................141 STEERING THE MACHINE...................................................................155 LOADING OPERATIONS.....................................................................155 DUMP OPERATIONS........................................................................156 PRECAUTIONS FOR OPERATION..............................................................157 PARKING MACHINE........................................................................158 CHECKS AFTER COMPLETION OF WORK........................................................159 LOCKING................................................................................159 HANDLING TIRES.........................................................................160 DETERMINING AND MAINTAINING TRAVEL ROAD....................................................163 DETERMINING TRAVEL ROAD................................................................163 MAINTAINING TRAVEL ROAD................................................................163 TRANSPORTATION.............................................................................164 PRECAUTIONS WHEN TRANSPORTING..........................................................164 STEPS FOR TRANSPORTATION...............................................................164 METHOD OF SECURING MACHINE.............................................................165 METHOD OF LIFTING MACHINE..............................................................166 COLD WEATHER OPERATION.....................................................................168 PRECAUTIONS FOR LOW TEMPERATURE........................................................168 PRECAUTIONS AFTER COMPLETION OF WORK...................................................169 AFTER COLD WEATHER.....................................................................170 LONG-TERM STORAGE..........................................................................171 BEFORE STORAGE.........................................................................171 AFTER STORAGE..........................................................................171 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE...................................171 TROUBLESHOOTING............................................................................172 AFTER RUNNING OUT OF FUEL..............................................................172 METHOD OF TOWING MACHINE...............................................................172 IF BATTERY IS DISCHARGED...............................................................176 OTHER TROUBLE..........................................................................180 MAINTENANCE....................................................................................186 GUIDES TO MAINTENANCE......................................................................187 OUTLINE OF SERVICE.........................................................................189 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................189 OUTLINE OF ELECTRIC SYSTEM.............................................................192 WEAR PARTS.................................................................................193 WEAR PARTS LIST........................................................................193 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................194 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................195 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....197 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................198 TORQUE LIST............................................................................198 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................200 SAFETY CRITICAL PARTS..................................................................200 MAINTENANCE SCHEDULE CHART.................................................................201 MAINTENANCE SCHEDULE CHART.............................................................201 SERVICE PROCEDURE..........................................................................203 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).............................203 INITIAL 2000 HOURS SERVICE (ONLY AFTER THE FIRST 2000 HOURS)...........................203 CHECK INJECTOR SETTING LOAD, ADJUST................................................203 WHEN REQUIRED..........................................................................204 CHECK, CLEAN OR REPLACE AIR CLEANER................................................204 CLEAN INSIDE OF COOLING SYSTEM.....................................................210 CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID......................................213 CLEAN AIR CONDITIONER AIR FILTER...................................................213 CHECK REFRIGERANT (GAS) LEVEL......................................................214 CHECK DUMP BODY....................................................................214 CHECK ELECTRIC INTAKE AIR HEATER...................................................214 CHECK LENGTH OF SUSPENSION CYLINDER, CHECK OIL LEVEL...............................215 BLEED AIR FROM REAR BRAKE..........................................................217 BLEED AIR FROM FRONT BRAKE.........................................................218 BLEED AIR FROM PARKING BRAKE.......................................................219 CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS...................................220 CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT......................................220 SELECTION AND INSPECTION OF TIRES..................................................221 CHECK BEFORE STARTING..................................................................224 EVERY 250 HOURS SERVICE................................................................225 CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL......................................225 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.......................................225 LUBRICATION........................................................................226 CHECK DRIVE SHAFT..................................................................227 CHECK LEVEL OF BATTERY ELECTROLYTE.................................................228 CHECK ALTERNATOR BELT TENSION, ADJUST..............................................230 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..............................231 CLEAN BREATHERS....................................................................232 CHECK FRAME........................................................................233 CHECK BRAKING CAPACITY OF FOOT BRAKE...............................................233 CHECK BRAKING CAPACITY OF RETARDER BRAKE...........................................234 CHECK BRAKING CAPACITY OF PARKING BRAKE............................................234 CHECK, CLEAN AUTOMATIC SUSPENSION..................................................235 EVERY 500 HOURS SERVICE................................................................236 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................236 REPLACE FUEL FILTER CARTRIDGE......................................................237 CLEAN FUEL TANK STRAINER...........................................................239 REPLACE TRANSMISSION OIL FILTER ELEMENT............................................240 CHECK WEAR OF FRONT DISC BRAKE PADS................................................241 CHECK FAN BELT FOR WEAR AND REPLACE................................................242 EVERY 1000 HOURS SERVICE...............................................................243 REPLACE CORROSION RESISTOR CARTRIDGE...............................................243 CHANGE OIL IN TRANSMISSION CASE, CLEAN TRANSMISSION CASE STRAINER..................244 REPLACE TRANSMISSION AND REAR BRAKE COOLING OIL FILTER ELEMENT.....................246 REPLACE BRAKE OIL FILTER ELEMENT...................................................247 LUBRICATION........................................................................248 CHECK WEAR OF REAR BRAKE DISC......................................................249 CHECK TIGHTENING PARTS OF TURBOCHARGER.............................................249 CHECK PLAY OF TURBOCHARGER ROTOR...................................................249 EVERY 2000 HOURS SERVICE...............................................................250 REPLACE STEERING, HOIST OIL TANK FILTER ELEMENT....................................250 CLEAN HYDRAULIC TANK STRAINER......................................................251 CHANGE OIL IN FINAL DRIVE CASE.....................................................252 CHANGE OIL IN DIFFERENTIAL CASE....................................................252 CLEAN DIFFERENTIAL CASE BREATHER...................................................253 CLEAN ENGINE BREATHER ELEMENT......................................................253 CHECK ALTERNATOR, STARTING MOTOR...................................................254 CHECK, ADJUST ENGINE VALVE CLEARANCE...............................................254 CLEAN, CHECK TURBOCHARGER..........................................................254 CHECK ACCUMULATOR GAS PRESSURE.....................................................254 EVERY 4000 HOURS SERVICE...............................................................255 CHANGE OIL IN STEERING, HOIST OIL TANK.............................................255 LUBRICATE DRIVE SHAFT..............................................................255 CHECK WATER PUMP...................................................................255 CHECK FAN PULLEY AND TENSION PULLEY................................................255 CHECK VIBRATION DAMPER.............................................................255 EVERY 15000 HOURS SERVICE..............................................................256 CHECK, REPLACE STEERING A ARM MOUNTING BOLT........................................256 SPECIFICATIONS.................................................................................257 SPECIFICATIONS.............................................................................258 ATTACHMENTS, OPTIONS...........................................................................259 SELECTING DUMP BODY........................................................................260 HANDLING TACHOGRAPH (TCO20-90W)............................................................261 EXPLANATION OF COMPONENTS..............................................................261 METHOD OF USE..........................................................................263 HANDLING AIR SUSPENSION SEAT...............................................................267 SEAT ADJUSTMENT........................................................................267 REMOVAL AND INSTALLATION OF HEADREST...................................................269 HANDLING VEHICLE HEALTH MONITORING SYSTEM (VHMS)...........................................270 OUTLINE OF SYSTEM......................................................................270 BASIC PRECAUTIONS......................................................................271 CHECK BEFORE STARTING..................................................................271 PROCEDURE WHEN DOWNLOADING.............................................................274 OTHER PRECAUTIONS......................................................................274 HANDLING AUTOMATIC SPIN REGULATOR (ASR)....................................................275 EXPLANATION OF COMPONENTS..............................................................275 ACTUATION OF ASR SYSTEM................................................................276 PRECAUTIONS WHEN USING.................................................................276 TROUBLESHOOTING........................................................................277 BLEEDING AIR FROM ASR CIRCUIT..........................................................278 HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)................................................279 OUTLINE OF SYSTEM......................................................................279 NORMAL OPERATION DISPLAY...............................................................280 EXTERNAL DISPLAY LAMPS.................................................................282 PERFORMING CALIBRATION.................................................................283 DATA STORED IN PAYLOAD METER...........................................................285 PROCEDURE WHEN DOWNLOADING.............................................................285 MACHINE ID, OPEN ID....................................................................289 PAYLOAD (CYCLE DATA ITEM)..............................................................291 SERVICE FUNCTIONS......................................................................291 OTHERS.................................................................................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)...............................................333 WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY)....................340 OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED...........343 HANDLING BATTERY ISOLATOR..................................................................346 HANDLING AUTO-GREASING SYSTEM..............................................................347 METHOD OF OPERATING AUTO-GREASING SYSTEM...............................................347 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM.........................................354 TROUBLESHOOTING........................................................................354 HANDLING ABS...............................................................................355 EXPLANATION OF COMPONENTS..............................................................355 ABS SYSTEM CHECK AFTER STARTING ENGINE.................................................357 OPERATION OF ABS.......................................................................357 PRECAUTIONS WHEN USING.................................................................358 TROUBLESHOOTING........................................................................359 INDEX..........................................................................................361
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