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KOMATSU HD465-7E0 HD605-7E0 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:10739 & UP) – PDF DOWNLOAD
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- KOMATSU HD465-7E0 HD605-7E0 DUMP TRUCK OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:10739 & UP
- PUBLICATION NUMBER:TEN00439-07
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Description
KOMATSU HD465-7E0 HD605-7E0 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:10739 & UP)
KOMATSU HD465-7E0 HD605-7E0 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:10739 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU HD465-7E0 HD605-7E0 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:10739 & UP)
- 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. Storage location for the Operation and Maintenance Manual: On inside of left door 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)) 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 HD465-7E0 HD605-7E0 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:10739 & UP)
COVER.......................................................................................... 1 FOREWORD....................................................................................... 2 BEFORE READING THIS MANUAL................................................................. 3 SAFETY INFORMATION......................................................................... 4 INTENDED USE............................................................................... 5 USE OF MACHINE......................................................................... 5 GENERAL VIEW AND DIRECTIONS OF MACHINE................................................. 5 VISIBILITY FROM OPERATOR'S SEAT........................................................ 6 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................. 7 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........................... 7 EPA REGULATIONS, ENGINE NUMBER PLATE................................................... 7 SERVICE METER POSITION................................................................. 8 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................................. 8 CONTENTS................................................................................... 9 SAFETY......................................................................................... 14 IMPORTANT SAFETY INFORMATION............................................................... 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 DASHBOARD.............................................................................. 57 EXPLANATION OF COMPONENTS.................................................................. 58 GENERAL VIEW OF MACHINE................................................................ 58 OPERATOR'S CAB......................................................................... 61 CONTROL LEVERS AND PEDALS.............................................................. 63 MACHINE MONITOR........................................................................ 69 DISPLAY OF CHARACTER DISPLAY........................................................... 82 OTHER FUNCTIONS OF CHARACTER DISPLAY................................................... 86 SWITCHES............................................................................... 90 BODY PIVOT PIN.........................................................................100 LOCATION OF FIRE EXTINGUISHER..........................................................101 DUST INDICATOR.........................................................................101 FUSES..................................................................................102 CAR RADIO..............................................................................105 CAR STEREO.............................................................................107 AIR CONDITIONER........................................................................112 OPERATION..................................................................................117 CHECK BEFORE STARTING ENGINE...........................................................117 STARTING ENGINE........................................................................144 OPERATIONS, CHECKS AFTER STARTING ENGINE...............................................147 STOPPING ENGINE........................................................................148 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING........................................149 SHIFTING GEAR..........................................................................155 TRAVELING DOWNHILL.....................................................................157 STEERING THE MACHINE...................................................................170 LOADING OPERATIONS.....................................................................170 DUMP OPERATIONS........................................................................171 PRECAUTIONS FOR OPERATION..............................................................173 PARKING MACHINE........................................................................174 CHECKS AFTER COMPLETION OF WORK........................................................174 CHECKS AFTER STOPPING ENGINE...........................................................175 LOCKING................................................................................175 HANDLING TIRES.........................................................................176 DETERMINING AND MAINTAINING TRAVEL ROAD....................................................180 DETERMINING TRAVEL ROAD................................................................180 MAINTAINING TRAVEL ROAD................................................................180 WORKSITE...................................................................................181 EXAMINATION AN CONFIRMATION OF WORKSITE................................................181 WORKING ON LOOSE GROUND................................................................181 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLE..................................................182 ENSURE GOOD VISIBILITY.................................................................182 CONFIRMATION OF MARK...................................................................182 TRANSPORTATION.............................................................................183 PRECAUTIONS WHEN TRANSPORTING..........................................................183 STEPS FOR TRANSPORTATION...............................................................183 METHOD OF SECURING MACHINE.............................................................184 METHOD OF LIFTING MACHINE..............................................................185 COLD WEATHER OPERATION.....................................................................188 PRECAUTIONS FOR LOW TEMPERATURE........................................................188 PRECAUTIONS AFTER COMPLETION OF WORK...................................................190 AFTER COLD WEATHER.....................................................................190 LONG-TERM STORAGE..........................................................................191 BEFORE STORAGE.........................................................................191 DURING STORAGE.........................................................................191 AFTER STORAGE..........................................................................191 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE...................................191 TROUBLESHOOTING............................................................................192 AFTER RUNNING OUT OF FUEL..............................................................192 IF TRANSMISSION HAS TROUBLE............................................................192 METHOD OF LOWERING DUMP BODY IN EMERGENCY..............................................193 METHOD OF TOWING MACHINE...............................................................194 IF BATTERY IS DISCHARGED...............................................................198 ACTION IF FIRE OCCURS..................................................................202 OTHER TROUBLE..........................................................................203 MAINTENANCE....................................................................................210 GUIDES TO MAINTENANCE......................................................................211 SECONDARY MATERIALS FOR OPERATION..........................................................219 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................219 OUTLINE OF ELECTRIC SYSTEM.................................................................223 WEAR PARTS.................................................................................224 WEAR PARTS LIST........................................................................224 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................225 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................226 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....227 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................228 TORQUE LIST............................................................................228 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................229 SAFETY CRITICAL PARTS..................................................................229 MAINTENANCE SCHEDULE CHART.................................................................230 MAINTENANCE SCHEDULE CHART.............................................................230 SERVICE PROCEDURE..........................................................................232 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).............................232 WHEN REQUIRED..........................................................................233 CHECK BEFORE STARTING..................................................................258 EVERY 250 HOURS SERVICE................................................................259 EVERY 500 HOURS SERVICE................................................................272 EVERY 1000 HOURS SERVICE...............................................................282 EVERY 2000 HOURS SERVICE...............................................................291 EVERY 4000 HOURS SERVICE...............................................................295 EVERY 8000 HOURS SERVICE...............................................................299 EVERY 15000 HOURS SERVICE..............................................................300 SPECIFICATIONS.................................................................................302 SPECIFICATIONS.............................................................................303 ATTACHMENTS, OPTIONS...........................................................................306 SELECTING DUMP BODY........................................................................307 HANDLING TACHOGRAPH (TCO20-90W)............................................................308 EXPLANATION OF COMPONENTS..............................................................308 METHOD OF USE..........................................................................310 HANDLING AIR SUSPENSION SEAT...............................................................314 OPERATOR'S SEAT ADJUSTMENT.............................................................314 REMOVAL AND INSTALLATION OF HEADREST...................................................318 HANDLING AUTOMATIC SPIN REGULATOR (ASR)....................................................319 EXPLANATION OF COMPONENTS..............................................................319 ACTUATION OF ASR SYSTEM................................................................320 PRECAUTION WHEN USING ASR SYSTEM.......................................................320 TROUBLESHOOTING........................................................................321 BLEEDING AIR FROM ASR CIRCUIT..........................................................322 HANDLING ANTI SKID BRAKE SYSTEM (ABS)......................................................323 EXPLANATION OF COMPONENTS..............................................................323 ABS SYSTEM CHECK AFTER STARTING ENGINE.................................................324 OPERATION OF ABS.......................................................................325 PRECAUTION WHEN USING ABS SYSTEM.......................................................325 TROUBLESHOOTING........................................................................326 HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE)........................................327 OUTLINE OF SYSTEM......................................................................327 NORMAL OPERATION DISPLAY...............................................................328 EXTERNAL DISPLAY LAMPS.................................................................330 PERFORMING CALIBRATION.................................................................331 DATA STORED IN PAYLOAD METER...........................................................332 PROCEDURE WHEN DOWNLOADING.............................................................334 MACHINE ID, OPEN ID....................................................................338 PAYLOAD (CYCLE DATA ITEM)..............................................................340 SERVICE FUNCTIONS......................................................................340 OTHERS.................................................................................340 HANDLING PAYLOAD METER II (CARD TYPE)......................................................341 METHOD OF USING ACCURATELY.............................................................342 GENERAL LOCATIONS......................................................................343 CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)................................348 EXTERNAL DISPLAY LAMPS.................................................................352 DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER......................................354 OPERATION OF SWITCHES..................................................................359 PROBLEM AND WARNING DISPLAY (ERROR CODE)...............................................380 WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY)....................387 OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED...........390 USE OF REAR VIEW MONITOR...................................................................393 NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR.....................................393 SETTING OF REAR VIEW MONITOR...........................................................396 CAUTIONS WHEN USING REAR VIEW MONITOR..................................................396 EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER.................................................397 SOCKET FOR ENGINE HEATER...............................................................397 CONNECTING EXTERNAL POWER SOURCE.......................................................397 RESTARTING ENGINE......................................................................398 HANDLING DUMPING COUNTER...................................................................405 HANDLING BATTERY ISOLATOR..................................................................406 HANDLING MACHINES EQUIPPED WITH KOMTRAX Plus...............................................408 KOMTRAX Plus INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED..........................408 KOMTRAX Plus AND COMMUNICATIONS TERMINAL INSTALLED.....................................408 PROCEDURE WHEN DOWNLOADING.............................................................409 CHECK BEFORE STARTING..................................................................410 INDEX..........................................................................................414
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