Komatsu HD465-8 HD605-8 Dump Truck Operation & Maintenance Manual EENAM03552 – PDF DOWNLOAD

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Komatsu HD465-8 HD605-8 Dump Truck Operation & Maintenance Manual EENAM03552 – PDF DOWNLOAD

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Komatsu HD465-8 HD605-8 Dump Truck Operation & Maintenance Manual EENAM03552 – PDF DOWNLOAD

SERIAL NUMBERS
HD465-8 – 30001 and up
HD605-8 – 30001 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 HD465-8 HD605-8 Dump Truck Operation & Maintenance Manual EENAM03552 – PDF DOWNLOAD

FOREWORD 3
READ THIS MANUAL 4
KOMATSU MACHINE OPERATOR PRIVACY POLICY 5
SAFETY INFORMATION 8
NOISE 9
VIBRATION – OPERATING CONDITION 9
GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE 9
VIBRATION LEVEL 11
INTRODUCTION 12
MAIN USE OF MACHINE 12
DIRECTIONS OF MACHINE 12
VISIBILITY FROM OPERATOR’S SEAT 12
PRODUCT INFORMATION 14
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO PLATE 14
LOCATION OF ENGINE NUMBER PLATE 14
FLUORINATED GREENHOUSE GASES 15
SERVICE METER LOCATION 15
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 15
SERIAL PLATE 16
DECLARATION OF CONFORMITY 17
TABLE OF CONTENTS 18
SAFETY 21
SAFETY LABELS 22
LOCATION OF SAFETY LABELS 23
CONTENTS OF SAFETY LABELS 26
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 33
PRECAUTIONS BEFORE STARTING OPERATION 33
ENSURE SAFE OPERATION 33
UNDERSTAND THE MACHINE 33
PREPARATIONS FOR SAFE OPERATION 33
PRECAUTIONS FOR SAFETY-RELATED EQUIPMENT 33
INSPECT MACHINE 33
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT 33
KEEP MACHINE CLEAN 33
PRECAUTIONS FOR INSIDE OPERATOR’S COMPARTMENT 34
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 34
IF ANY PROBLEM IS FOUND 34
PRECAUTIONS TO PREVENT FIRE 34
ACTIONS IF FIRE OCCURS 34
PREVENT FIRE 35
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 36
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE 36
NO JUMPING ON OR OFF MACHINE 37
LIFTING OF PERSONNEL PROHIBITED 37
PEOPLE ON DUMP BODY 37
WHEN STANDING UP FROM OPERATOR’S SEAT 37
PRECAUTIONS WHEN LEAVING MACHINE 37
EMERGENCY EXIT FROM OPERATOR’S CAB 38
ELECTROMAGNETIC INTERFERENCE 38
DO NOT GET CAUGHT IN WORK EQUIPMENT 38
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 38
UNAUTHORIZED MODIFICATION 39
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 39
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 39
PRECAUTIONS FOR OPERATION 40
PRECAUTIONS FOR JOBSITE 40
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 40
PRECAUTIONS WHEN WORKING ON LOOSE GROUND 40
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 40
ENSURE GOOD VISIBILITY 41
CHECK SIGNS AND SIGNALMAN’S SIGNALS 41
BEWARE OF ASBESTOS DUST 41
START ENGINE 42
USE WARNING TAGS 42
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE 42
PRECAUTIONS WHEN STARTING ENGINE 43
IN COLD AREAS 43
START ENGINE WITH JUMPER CABLES 43
PRECAUTIONS FOR OPERATION 43
CHECKS BEFORE OPERATION 43
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 44
WHEN TRAVELING 44
PRECAUTIONS WHEN TRAVELING ON SLOPES 45
PRECAUTIONS WHEN OPERATING MACHINE 45
WHEN LOADING ON DUMP BODY 45
WHEN DUMPING 45
WHEN OPERATING ON SNOW OR FROZEN SURFACES 45
WHEN PARKING MACHINE 46
TRANSPORTATION 46
PRECAUTIONS WHEN LOADING AND UNLOADING 47
TOWING AND BEING TOWED 47
PRECAUTIONS FOR TOWING AND BEING TOWED 47
PRECAUTIONS FOR MAINTENANCE 48
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 48
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE 48
KEEP WORK PLACE CLEAN AND TIDY 48
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE 48
ONLY AUTHORIZED PERSONNEL 48
APPOINT LEADER WHEN WORKING WITH OTHERS 48
STABILITY 48
GUARDS 49
END OF SERVICE LIFE 49
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 49
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 50
PRECAUTIONS WHEN INSTALLING, REMOVING, OR STORING ATTACHMENTS 50
PRECAUTIONS FOR WORKING AT HIGH PLACES 51
PRECAUTIONS WHEN WORKING ON MACHINE 51
PRECAUTIONS WHEN WORKING UNDER MACHINE 51
USE PROPER TOOLS 52
PRECAUTIONS FOR CHECK AND MAINTENANCE 52
TURN BATTERY DISCONNECT SWITCH TO OFF POSITION 52
PRECAUTIONS FOR WELDING 52
HANDLE BATTERY 52
WHEN USING HAMMER 53
PRECAUTIONS FOR HIGH-TEMPERATURE COOLANT 53
PRECAUTIONS FOR HIGH-TEMPERATURE OIL 54
PRECAUTIONS FOR HIGH-TEMPERATURE PARTS 54
PRECAUTIONS FOR HIGH-PRESSURE OIL 54
PRECAUTIONS FOR HIGH-PRESSURE FUEL 54
HANDLE HIGH-PRESSURE HOSES AND PIPING 54
PRECAUTIONS FOR HIGH VOLTAGE 55
PRECAUTIONS FOR NOISE 55
HANDLE SUSPENSION CYLINDERS, ACCUMULATOR AND GAS SPRINGS 55
PRECAUTIONS FOR COMPRESSED AIR 55
MAINTENANCE OF AIR CONDITIONER 55
CHEMICAL HAZARD 55
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 55
METHOD FOR SELECTING WINDOW WASHER FLUID 56
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 56
TIRES 56
HANDLE TIRES 56
PRECAUTIONS FOR STORING TIRES 57
OPERATION 59
GENERAL VIEW 60
MACHINE EQUIPMENT NAME 60
CONTROLS AND GAUGES NAMES 61
MACHINE MONITOR EQUIPMENT NAME 63
OTHER EQUIPMENT NAME 65
EXPLANATION OF COMPONENTS 67
EXPLANATION OF MACHINE MONITOR EQUIPMENT 67
BASIC OPERATION OF MACHINE MONITOR 68
WARNING DISPLAY 73
ACTION LEVEL DISPLAY 74
ENGINE COOLANT TEMPERATURE CAUTION LAMP 77
TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP 78
RETARDER OIL TEMPERATURE CAUTION LAMP 78
FUEL LEVEL CAUTION LAMP 78
BRAKE OIL PRESSURE CAUTION LAMP 78
SEATBELT CAUTION LAMP 79
STEERING SYSTEM CAUTION LAMP 79
STEERING OIL PRESSURE CAUTION LAMP 79
STEERING OIL TEMPERATURE CAUTION LAMP 80
SECONDARY STEERING SYSTEM CAUTION LAMP 80
SECONDARY STEERING MOTOR CAUTION LAMP 80
HOIST CONTROL SYSTEM CAUTION LAMP 80
BODY FLOAT CAUTION LAMP 81
INCLINATION CAUTION LAMP 81
SYSTEM CAUTION LAMP 81
KDPF SYSTEM CAUTION LAMP 82
KDPF SOOT ACCUMULATION CAUTION LAMP 82
TRANSMISSION SYSTEM CAUTION LAMP 82
TRANSMISSION OIL FILTER CLOGGING CAUTION LAMP 83
RETARDER SYSTEM CAUTION LAMP 83
ENGINE SYSTEM CAUTION LAMP 83
PARKING BRAKE SYSTEM CAUTION LAMP 84
KTCS SYSTEM CAUTION LAMP 84
ENGINE OIL PRESSURE CAUTION LAMP 84
ENGINE OIL LEVEL CAUTION LAMP 85
ENGINE OVERRUN CAUTION LAMP 85
RADIATOR COOLANT LEVEL CAUTION LAMP 85
CHARGE LEVEL CAUTION LAMP 85
AIR CLEANER CLOGGING CAUTION LAMP 86
FAN CONTROL SYSTEM CAUTION LAMP 86
FAN-REVERSE OPERATION CAUTION LAMP 86
AIR CONDITIONER SYSTEM CAUTION LAMP 86
ARSC SYSTEM CAUTION LAMP 87
ARSC OVERHEAT NOTICE CAUTION LAMP 87
PAYLOAD METER SYSTEM CAUTION LAMP 87
OVERLOAD CAUTION LAMP 87
BRAKE COOLING OIL FILTER CLOGGING CAUTION LAMP 88
HYDRAULIC OIL FILTER CLOGGING CAUTION LAMP 88
AUTO SUSPENSION SYSTEM CAUTION LAMP 88
OVERSPEED CAUTION LAMP 88
MAINTENANCE TIME CAUTION LAMP 89
CENTRALIZED WARNING LAMP 89
PILOT DISPLAY AND METER DISPLAY 91
USER MENU 107
SWITCHES 157
STARTING SWITCH 158
CIGARETTE LIGHTER 159
LAMP SWITCH 159
DIMMER SWITCH 160
TURN SIGNAL LEVER 160
WIPER, WINDOW WASHER SWITCH 160
HORN BUTTON 161
MONITOR BRIGHTNESS SELECTOR SWITCH 161
SWITCH FOR MIRROR WITH HEATED WIRE 161
HAZARD LAMP SWITCH 161
SECONDARY STEERING SWITCH 162
REARVIEW MONITOR BRIGHTNESS ADJUSTMENT SWITCH 162
AISS LOW SWITCH 162
FRONT BRAKE OFF SWITCH 163
PARKING BRAKE SWITCH 163
FOG LAMP SWITCH 164
POWER WINDOW SWITCH 164
SIDE LAMP SWITCH 165
ROOM LAMP1 SWITCH 165
ROOM LAMP2 SWITCH 165
ENGINE SHUTDOWN SECONDARY SWITCH 166
STAIRCASE LIGHTING SWITCH 166
CONTROL LEVERS AND PEDALS 167
BRAKE PEDAL 168
SECONDARY BRAKE PEDAL 168
ACCELERATOR PEDAL 168
GEAR SHIFT LEVER 168
RETARDER CONTROL LEVER 170
ARSC TRAVEL SPEED SET LEVER 170
DUMP LEVER 171
DUMP LEVER LOCK KNOB 171
OTHER EQUIPMENT 172
CAB DOOR 172
DRINK BOX 173
LUNCH BOX TRAY 173
MAGAZINE BOX 173
CUP HOLDER 174
ASHTRAY 174
POWER SUPPLY OUTLET 174
FUSE 175
TOOL BOX 178
GREASE PUMP HOLDER 178
BATTERY DISCONNECT SWITCH 178
SYSTEM OPERATING LAMP 179
CIRCUIT BREAKER 180
DUST INDICATOR 181
BODY PIVOT PINS 181
HANDLE REAR VIEW MONITOR 182
HANDLE Komatsu Diesel Particulate Filter (KDPF) 184
Komatsu Closed Crankcase Ventilation (KCCV) 194
KOMTRAX Plus 195
MACHINE OPERATIONS AND CONTROLS 196
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE 196
METHOD FOR WALK-AROUND CHECK 196
METHOD FOR CHECKING BEFORE STARTING 199
ADJUST BEFORE OPERATION 210
METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE 223
METHOD FOR STARTING ENGINE 226
METHOD FOR MANUAL PREHEATING WHEN STARTING ENGINE 228
TURBOCHARGER PROTECTION FUNCTION 229
METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE 229
METHOD FOR CANCELING TO HOLD DUMP BODY 230
METHOD FOR CHECKING STARTING CONDITION AND UNUSUAL NOISE OF ENGINE 230
METHOD FOR CHECKING LOW-SPEED RUN AND ACCELERATION OF ENGINE 230
METHOD FOR RUNNING-IN THE NEW MACHINE 230
METHOD FOR WARM-UP OPERATION 231
METHOD FOR STOPPING ENGINE 231
METHOD FOR CHECKING AFTER STOPPING ENGINE 233
METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MACHINE 233
METHOD FOR MOVING MACHINE 233
METHOD FOR TRAVELING REVERSE 235
METHOD FOR STOPPING MACHINE 236
METHOD FOR SHIFTING GEARS 238
METHOD FOR TRAVELING DOWNHILL 239
HANDLE Automatic Retarder Speed Control (ARSC) 242
BRAKE PERFORMANCE CURVE 245
METHOD FOR TURNING MACHINE 252
HANDLE OVERLOAD SPEED LIMIT FUNCTION 253
OPERATION OF OVERLOAD SPEED LIMIT FUNCTION 253
OPERATION IF TROUBLES ON SYSTEM OCCUR 254
METHOD FOR LOADING 255
HANDLING PAYLOAD METER 255
OUTLINE OF SYSTEM 255
PAYLOAD DISPLAY 257
EXTERNAL DISPLAY LAMP 258
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER 259
METHOD FOR DOWNLOADING DATA FROM CONNECTOR FOR DOWNLOAD 260
DISPLAY TOTAL PAYLOAD AND NUMBER OF CYCLES 263
DISPLAY FUEL CONSUMPTION RECORD 265
SETTING MACHINE ID AND OPEN ID 266
METHOD FOR PERFORMING CALIBRATION 267
METHOD FOR DUMPING 269
PRECAUTIONS FOR OPERATION 271
PERMISSIBLE WATER DEPTH 271
METHOD FOR PARKING MACHINE 272
METHOD FOR CHECKING AFTER FINISHING WORK 273
LOCK 273
METHOD FOR OPENING AND CLOSING FUEL FILLER PORT CAP 274
METHOD FOR OPENING AND CLOSING TRANSMISSION CASE FILLER CAP 275
METHOD FOR OPENING AND CLOSING OIL FILLER CAP OF STEERING AND HOIST OIL TANK 276
METHOD FOR OPENING AND CLOSING RADIATOR RESERVOIR TANK COOLANT FILLER PORT CAP 276
METHOD FOR OPENING AND CLOSING OPERATOR CAB DOOR 277
HANDLE TIRE 278
PRECAUTIONS WHEN HANDLING TIRES 278
T Km P H (Ton-Km-Hour-Rating) 279
TIRE T Km P H VALUE AND CONTINUOUS MAX TRAVEL SPEED 279
PRECAUTIONS FOR LONG DISTANCE TRAVEL 280
HANDLE AIR CONDITIONER 281
EXPLANATION OF AIR CONDITIONER EQUIPMENT 282
OFF SWITCH 282
FAN SWITCH 283
TEMPERATURE CONTROL SWITCH 283
VENT SELECTOR SWITCH 284
AUTO SWITCH 285
FRESH/RECIRC AIR SELECTOR SWITCH 285
AIR CONDITIONER DISPLAY 286
AIR CONDITIONER SWITCH 286
DEFROSTER SWITCH 287
METHOD FOR OPERATING AIR CONDITIONER 287
METHOD FOR AUTOMATIC OPERATION 287
METHOD FOR STOPPING AUTOMATIC OPERATION 288
METHOD FOR MANUAL OPERATION 288
METHOD FOR STOPPING MANUAL OPERATION 290
METHOD FOR OPERATING WITH COLD AIR TO FACE AND WARM AIR TO FEET 290
METHOD FOR OPERATING DEFROSTER 291
HANDLE RADIO 294
EXPLANATION OF RADIO EQUIPMENT 294
POWER BUTTON 294
BAND/AUX SELECTOR BUTTON 294
VOLUME CONTROL BUTTON 294
TUNING/TIME ADJUSTMENT BUTTON 294
PRESET BUTTON 295
DISPLAY SELECTOR BUTTON 295
SOUND CONTROL BUTTON 295
DISPLAY 295
AUX 295
METHOD FOR CONTROLLING RADIO 295
METHOD FOR ADJUSTING FREQUENCY 295
METHOD FOR ADJUSTING FREQUENCY (AUTO PRESETTING) 296
METHOD FOR CALLING PRESET 296
METHOD FOR REGISTERING PRESET 296
METHOD FOR ADJUSTING SOUND BALANCE 297
METHOD FOR ADJUSTING HIGH REGISTER RANGE (TREBLE) 297
METHOD FOR ADJUSTING LOW REGISTER RANGE (BASS) 297
METHOD FOR ADJUSTING CLOCK 297
DUMP BODY HEATING SPECIFICATIONS 299
DETERMINE AND MAINTAIN TRAVEL ROAD 300
TRANSPORTATION 301
PRECAUTIONS FOR TRANSPORTATION 301
SELECT TRANSPORTATION METHOD 301
METHOD FOR SECURING MACHINE 301
PRECAUTIONS FOR LIFTING MACHINE 301
PROCEDURE FOR LIFTING MACHINE 303
COLD WEATHER OPERATION 305
COLD WEATHER OPERATION INFORMATION 305
FUEL AND LUBRICANTS 305
COOLANT 305
BATTERY 305
PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER 306
AFTER COLD WEATHER SEASON 306
PRECAUTIONS FOR LONG-TERM STORAGE 307
PREPARATION FOR LONG-TERM STORAGE 307
MAINTENANCE DURING LONG-TERM STORAGE 307
STARTING MACHINE AFTER LONG-TERM STORAGE 307
PREPARATION BEFORE TRAVELING AFTER LONG-TERM STORAGE 308
TROUBLES AND ACTIONS 309
ACTIONS WHEN RUNNING OUT OF FUEL 309
ACTIONS IF TRANSMISSION HAS TROUBLE 309
METHOD FOR LOWERING DUMP BODY IF TROUBLES OCCUR 309
PRECAUTIONS FOR TOWING MACHINE 311
METHOD FOR RELEASING PARKING BRAKE 313
PRECAUTIONS FOR DISCHARGED BATTERY 314
PRECAUTIONS FOR REMOVING AND INSTALLING BATTERY 315
PRECAUTIONS FOR CHARGING BATTERY 316
START ENGINE WITH JUMPER CABLES 317
OTHER TROUBLE 318
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM 318
PHENOMENA AND ACTIONS FOR CHASSIS 319
PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS 321
IF MACHINE MONITOR SHOWS WARNING DISPLAY 323
MAINTENANCE 325
PRECAUTIONS FOR MAINTENANCE 326
CHECK SERVICE METER READING 326
KOMATSU GENUINE REPLACEMENT PARTS 326
KOMATSU GENUINE LUBRICANTS 326
ALWAYS USE CLEAN WASHER FLUID 326
FRESH AND CLEAN LUBRICANTS 326
CHECK DRAINED OIL AND USED FILTER 326
PRECAUTIONS FOR REFILLING OIL OR FUEL 326
PRECAUTIONS FOR WELDING 326
DO NOT DROP THINGS INSIDE MACHINE 326
PRECAUTIONS FOR KDPF 326
DUSTY JOBSITES 326
AVOID MIXING OIL 327
LOCK INSPECTION COVERS 327
BLEED AIR FROM HYDRAULIC CIRCUIT 327
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES 327
CHECKS AFTER INSPECTION AND MAINTENANCE 327
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE 327
CLOSE ENGINE SIDE COVER SECURELY 327
PRECAUTIONS FOR JACK-UP 327
OUTLINE OF MAINTENANCE 329
HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 329
OIL 329
FUEL 329
COOLANT AND WATER FOR DILUTION 330
GREASE 330
PERFORM KOWA (Komatsu Oil Wear Analysis) 331
STORE OIL AND FUEL 331
FILTER 332
HANDLE ELECTRICAL COMPONENTS 332
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS 333
MAINTENANCE SCHEDULE 335
MAINTENANCE SCHEDULE TABLE 335
MAINTENANCE PROCEDURE 337
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) 337
WHEN REQUIRED 337
METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER 337
METHOD FOR CLEANING INSIDE OF COOLING SYSTEM 341
METHOD FOR CLEANING RADIATOR FINS, AFTERCOOLER FINS, OIL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS 345
METHOD FOR CLEANING FINS BY ROTATING COOLING FAN IN REVERSE 345
METHOD FOR ROTATING FAN IN REVERSE 345
METHOD FOR CLEANING FIN WITH COMPRESSED AIR 347
METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL, ADDING FLUID 348
METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER 348
METHOD FOR CHECKING DUMP BODY 349
METHOD FOR CHECKING LENGTH OF SUSPENSION CYLINDER 349
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT 351
METHOD FOR BLEEDING AIR FROM FUEL CIRCUIT 353
METHOD FOR CHECKING PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT 354
SELECT AND CHECK TIRES 355
CHECKS BEFORE STARTING 357
EVERY 250 HOURS MAINTENANCE 357
METHOD FOR LUBRICATING 357
METHOD FOR CHECKING AND ADDING OIL IN DIFFERENTIAL CASE 359
METHOD FOR CHECKING OIL LEVEL IN FINAL DRIVE CASE, ADDING OIL 360
METHOD FOR CHECKING DRIVE SHAFT 360
METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL 360
METHOD FOR CLEANING TRANSMISSION CASE BREATHER 362
METHOD FOR CLEANING STEERING AND HOIST OIL TANK BREATHER 363
METHOD FOR CHECKING FRAME 364
METHOD FOR CHECKING FOOT BRAKE PERFORMANCE 364
METHOD FOR CHECKING RETARDER BRAKE PERFORMANCE 365
METHOD FOR CHECKING PARKING BRAKE PERFORMANCE 365
METHOD FOR CHECKING AND CLEANING AUTOMATIC SUSPENSION 366
METHOD FOR CHECKING FUNCTION OF ACCUMULATOR 367
EVERY 500 HOURS MAINTENANCE 368
METHOD FOR CHANGING OIL IN ENGINE OIL PAN, REPLACING ENGINE OIL FILTER CARTRIDGE 368
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE 370
METHOD FOR REPLACING TRANSMISSION OIL FILTER ELEMENT 372
METHOD FOR CHECKING WEAR OF FRONT DISC BRAKE PADS 372
METHOD FOR CHECKING AND REPLACING ALTERNATOR AND AIR CONDITIONER COMPRESSOR DRIVE BELT 373
EVERY 1000 HOURS MAINTENANCE 375
METHOD FOR CHANGING OIL IN TRANSMISSION CASE AND BRAKE SUB-TANK, CLEANING STRAINER 375
METHOD FOR REPLACING TRANSMISSION AND REAR BRAKE COOLING OIL FILTER ELEMENT 378
METHOD FOR REPLACING BRAKE OIL FILTER ELEMENT 379
METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE 380
METHOD FOR REPLACING FUEL TANK BREATHER ELEMENT 381
METHOD FOR LUBRICATING 382
METHOD FOR CHECKING REAR BRAKE DISC WEAR AMOUNT 383
METHOD FOR COLLECTING LEAKED OIL FROM FLOATING SEAL 383
METHOD FOR CHECKING AND LUBRICATING ALTERNATOR AND AIR CONDITIONER COMPRESSOR DRIVE BELT 384
METHOD FOR CHECKING FOR LOOSENESS OF ENGINE INTAKE PIPE CLAMP 385
EVERY 2000 HOURS MAINTENANCE 386
METHOD FOR REPLACING STEERING AND HOIST OIL FILTER ELEMENT 386
METHOD FOR CHANGING OIL IN FINAL DRIVE CASE 387
METHOD FOR CHANGING OIL IN DEFERENTIAL CASE 388
METHOD FOR CLEANING DIFFERENTIAL CASE BREATHER 388
METHOD FOR CLEANING HYDRAULIC TANK STRAINER 389
METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT 389
METHOD FOR CHECKING ACCUMULATOR GAS PRESSURE 390
METHOD FOR CHECKING ALTERNATOR 390
METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE 390
METHOD FOR REPLACING KCCV FILTER ELEMENT 390
EVERY 4000 HOURS MAINTENANCE 393
REPLACE DEFINED LIFE PARTS 393
METHOD FOR CHANGING OIL IN STEERING AND HOIST OIL TANK 393
METHOD FOR LUBRICATING DRIVE SHAFT 394
METHOD FOR CHECKING WATER PUMP 394
METHOD FOR CHECKING STARTING MOTOR 394
METHOD FOR CHECKING FOR LOOSENESS OF ENGINE HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER 394
METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER 395
EVERY 4500 HOURS MAINTENANCE 396
METHOD FOR CLEANING KDPF 396
METHOD FOR CLEANING FUEL DOSER 396
METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP ON FUEL DOSER PIPING, HARDENING OF RUBBER 396
EVERY 8000 HOURS MAINTENANCE 396
METHOD FOR REPLACING ENGINE HIGH-PRESSURE PIPING CLAMP 396
METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP 396
METHOD FOR OVERHAULING STARTING MOTOR AND ALTERNATOR 397
EVERY 9000 HOURS MAINTENANCE 397
METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP ON FUEL DOSER PIPING 397
END OF SERVICE LIFE 397
EVERY 15000 HOURS MAINTENANCE 397
METHOD FOR CHECKING AND REPLACING STEERING-A ARM MOUNTING BOLT 397
SPECIFICATIONS 399
SPECIFICATIONS 400
SPECIFICATIONS: HD465-8 400
SPECIFICATIONS: HD605-8 401
ATTACHMENTS AND OPTIONS 403
BODY SELECTION 404
HANDLE ENGINE ROOM LAMP 405
METHOD FOR USING ENGINE ROOM LAMP 405
HANDLE KOMATSU TRACTION CONTROL SYSTEM (KTCS) 406
OPERATION OF KTCS 406
METHOD FOR OPERATING MACHINE WHEN TIRES ARE STUCK IN GROUND 406
HANDLE SPEED LIMIT FUNCTION 407
OPERATION OF SPEED LIMIT FUNCTION 407
OPERATION IF TROUBLES ON SYSTEM OCCUR 408
REPLACEMENT PARTS 409
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 410
DEFINED LIFE PARTS LIST 410
CONSUMABLE PARTS 411
CONSUMABLE PARTS LIST 411
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 412
LUBRICATION CHART 412
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 414
RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS 416
INDEX 417

Questions? Email us: [email protected]

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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