Komatsu HD465-8E0 HD605-8E0 Dump Truck Operation & Maintenance Manual EENAM03870 – PDF DOWNLOAD

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Komatsu HD465-8E0 HD605-8E0 Dump Truck Operation & Maintenance Manual EENAM03870 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu HD465-8E0 HD605-8E0 Dump Truck Operation & Maintenance Manual EENAM03870 – PDF DOWNLOAD

SERIAL NUMBERS
HD465-8E0 – 35001 and up
HD605-8E0 – 35001 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 HD465-8E0 HD605-8E0 Dump Truck Operation & Maintenance Manual EENAM03870 – PDF DOWNLOAD

FOREWORD 1-1
READ THIS MANUAL 1-6
KOMATSU MACHINE OPERATOR PRIVACY POLICY 1-7
SAFETY INFORMATION 1-10
VIBRATION LEVEL 1-11
INTRODUCTION 1-12
MAIN USE OF MACHINE 1-12
DIRECTIONS OF MACHINE 1-12
VISIBILITY FROM OPERATOR’S SEAT 1-13
PRODUCT INFORMATION 1-14
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO PLATE 1-14
LOCATION OF ENGINE NUMBER PLATE 1-14
FLUORINATED GREENHOUSE GASES 1-15
SERVICE METER LOCATION 1-15
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1-15
SERIAL PLATE 1-16
DECLARATION OF CONFORMITY 1-16
ABBREVIATION LIST 1-17
SAFETY 2-1
SAFETY LABELS 2-2
LOCATION OF SAFETY LABELS 2-3
CONTENTS OF SAFETY LABELS 2-6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2-13
PRECAUTIONS BEFORE STARTING OPERATION 2-13
PREPARATIONS FOR SAFE OPERATION 2-13
PRECAUTIONS TO PREVENT FIRE 2-15
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2-17
DO NOT GET CAUGHT IN WORK EQUIPMENT 2-19
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2-19
UNAUTHORIZED MODIFICATION 2-19
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2-20
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2-20
PRECAUTIONS FOR OPERATION 2-21
PRECAUTIONS FOR JOBSITE 2-21
START ENGINE 2-24
PRECAUTIONS FOR OPERATION 2-26
TRANSPORTATION 2-30
TOWING AND BEING TOWED 2-31
PRECAUTIONS FOR MAINTENANCE 2-32
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2-32
PRECAUTIONS FOR CHECK AND MAINTENANCE 2-38
TIRES 2-43
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 3-10
EXPLANATION OF MACHINE MONITOR EQUIPMENT 3-10
SWITCHES 3-115
CONTROL LEVERS AND PEDALS 3-128
OTHER EQUIPMENT 3-133
MACHINE OPERATIONS AND CONTROLS 3-167
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE 3-167
METHOD FOR STARTING ENGINE 3-205
METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE 3-209
METHOD FOR STOPPING ENGINE 3-212
METHOD FOR CHECKING AFTER STOPPING ENGINE 3-213
METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MACHINE
3-214
METHOD FOR SHIFTING GEARS 3-220
METHOD FOR TRAVELING DOWNHILL 3-222
METHOD FOR TURNING MACHINE 3-237
HANDLE OVERLOAD SPEED LIMIT FUNCTION 3-238
METHOD FOR LOADING 3-241
HANDLING PAYLOAD METER 3-242
METHOD FOR DUMPING 3-261
PRECAUTIONS FOR OPERATION 3-263
METHOD FOR PARKING MACHINE 3-264
METHOD FOR CHECKING AFTER FINISHING WORK 3-265
LOCK 3-266
HANDLE TIRE 3-272
HANDLE AIR CONDITIONER 3-275
EXPLANATION OF AIR CONDITIONER EQUIPMENT 3-276
METHOD FOR OPERATING AIR CONDITIONER 3-283
HANDLE RADIO 3-290
EXPLANATION OF RADIO EQUIPMENT 3-290
METHOD FOR CONTROLLING RADIO 3-292
DUMP BODY HEATING SPECIFICATIONS 3-295
DETERMINE AND MAINTAIN TRAVEL ROAD 3-296
TRANSPORTATION 3-297
PRECAUTIONS FOR TRANSPORTATION 3-297
SELECT TRANSPORTATION METHOD 3-297
METHOD FOR SECURING MACHINE 3-297
PRECAUTIONS FOR LIFTING MACHINE 3-298
COLD WEATHER OPERATION 3-301
COLD WEATHER OPERATION INFORMATION 3-301
PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER 3-302
AFTER COLD WEATHER SEASON 3-303
PRECAUTIONS FOR LONG-TERM STORAGE 3-304
PREPARATION FOR LONG-TERM STORAGE 3-304
MAINTENANCE DURING LONG-TERM STORAGE 3-304
STARTING MACHINE AFTER LONG-TERM STORAGE 3-304
PREPARATION BEFORE TRAVELING AFTER LONG-TERM STORAGE 3-305
TROUBLES AND ACTIONS 3-306
ACTIONS WHEN RUNNING OUT OF FUEL 3-306
ACTIONS IF TRANSMISSION HAS TROUBLE 3-306
METHOD FOR LOWERING DUMP BODY IF TROUBLES OCCUR 3-307
PRECAUTIONS FOR TOWING MACHINE 3-308
PRECAUTIONS FOR DISCHARGED BATTERY 3-312
OTHER TROUBLE 3-317
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 WELDING 4-2
DO NOT DROP THINGS INSIDE MACHINE 4-2
PRECAUTIONS FOR KDPF 4-3
DUSTY JOBSITES 4-3
AVOID MIXING OIL 4-3
LOCK INSPECTION COVERS 4-3
BLEED AIR FROM HYDRAULIC CIRCUIT 4-3
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES 4-3
CHECKS AFTER INSPECTION AND MAINTENANCE 4-4
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE 4-4
CLOSE ENGINE SIDE COVER SECURELY 4-4
PRECAUTIONS FOR JACK-UP 4-5
OUTLINE OF MAINTENANCE 4-6
HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4-6
HANDLE ELECTRICAL COMPONENTS 4-10
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS 4-11
MAINTENANCE SCHEDULE 4-13
MAINTENANCE SCHEDULE TABLE 4-13
MAINTENANCE PROCEDURE 4-15
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) 4-15
WHEN REQUIRED 4-16
CHECKS BEFORE STARTING 4-44
EVERY 250 HOURS MAINTENANCE 4-45
EVERY 500 HOURS MAINTENANCE 4-59
EVERY 1000 HOURS MAINTENANCE 4-67
EVERY 2000 HOURS MAINTENANCE 4-81
EVERY 4000 HOURS MAINTENANCE 4-89
EVERY 4500 HOURS MAINTENANCE 4-93
EVERY 8000 HOURS MAINTENANCE 4-94
EVERY 9000 HOURS MAINTENANCE 4-95
EVERY 15000 HOURS MAINTENANCE 4-96
SPECIFICATIONS 5-1
SPECIFICATIONS 5-2
SPECIFICATIONS: HD465-8E0 5-2
SPECIFICATIONS: HD605-8E0 5-4
ATTACHMENTS AND OPTIONS 6-1
BODY SELECTION 6-2
HANDLE ENGINE ROOM LAMP 6-3
METHOD FOR USING ENGINE ROOM LAMP 6-3
HANDLE EXTERNAL POWER SUPPLY ENGINE PREHEATER 6-4
EXPLANATION OF COMPONENTS 6-4
INSTALLATION PROCEDURES FOR EXTERNAL POWER SUPPLY SYSTEM FOR EXTERNAL
POWER SUPPLY ENGINE PREHEATER 6-6
FABRICATE EXTERNAL POWER SUPPLY CABLE 6-8
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 Antilock Brake System (ABS) 6-16
EXPLANATION OF COMPONENTS 6-16
ABS SETTING 6-18
ABS CHECK 6-19
PRECAUTIONS FOR USING ABS 6-21
TROUBLES AND ACTIONS 6-22
HANDLE MACHINE LOCKOUT 6-24
EXPLANATION OF COMPONENTS 6-24
OPERATE MACHINE LOCKOUT 6-27
HANDLE SPEED LIMIT FUNCTION 6-32
OPERATION OF SPEED LIMIT FUNCTION 6-33
OPERATION IF TROUBLES ON SYSTEM OCCUR 6-34
HANDLE AUTO-GREASING SYSTEM 6-35
METHOD FOR OPERATING AUTO-GREASING SYSTEM 6-35
METHOD FOR SETTING TIMER 6-36
METHOD FOR BLEEDING AIR FROM GREASING CIRCUIT 6-38
METHOD FOR ADJUSTING INJECTOR DISCHARGED VOLUME 6-39
METHOD FOR CHECKING INJECTOR OPERATION 6-39
METHOD FOR FILLING GREASE 6-40
SERVICE CENTER 6-41
VALVE POSITIONS OF REFILLING PIPING AND DISCHARGING PIPING 6-41
REPLACEMENT PARTS 7-1
PERIODIC REPLACEMENT OF 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 7-5
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
7-7
RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS 7-8
INDEX 8-1

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• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
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