Komatsu HD405 Manuals

Manuals and User Guides for Komatsu HD405. We have 1 Komatsu HD405 manual available for free PDF download: Operation & Maintenance Manual

Komatsu HD405 Operation & Maintenance Manual

Komatsu HD405 Operation & Maintenance Manual (361 pages)

DUMP TRUCK

Brand: Komatsu | Category: Trucks | Size: 8 MB

Table of Contents

Table of Contents

10
- Before Reading this Manual
  3
- Safety Information
  6
- Intended Use
  7
- Use of Machine
  7
  - Directions of Machine
    7
- Visibility from Operator's Seat
  7
- Product Identification Number (Pin)/Machine Serial No. Plate
  8
- Epa Regulations, Engine Number Plate
  8
- Location of Plates, Table to Enter Serial No. and Distributor
  8
- Service Meter Position
  9
  - Table of Contents
    10
- Safety
  15
- Safety Labels
  18
- Safety Labels
  20
- Understanding the Machine
  25
- Precautions Regarding Safety-Related Equipment
  25
- Wear Well-Fitting Clothes and Protective Equipment
  25
- Ensuring Safe Operation
  25
- General Precautions Common to Operation and Maintenance
  25
- Preparations for Safe Operation
  25
- Inspecting Machine
  25
- Precautions before Starting Operation
  25
- Keep Machine Clean
  26
- Precautions Inside Operator's Compartment
  26
- Provide Fire Extinguisher and First Aid Kit
  26
- If any Problem Is Found
  26
- Fire Prevention
  27
- Precautions to Prevent Fire
  27
- Action if Fire Occurs
  27
- Precautions When Getting on or off Machine
  28
- Use Handrails and Steps When Getting on or off Machine
  28
- No Jumping on or off Machine
  28
- No People on Dump Body
  28
- Precautions When Standing up from Operator's Seat
  29
- Precautions When Leaving Machine
  29
- Emergency Exit from Operator's Cab
  29
- Unauthorized Modification
  30
- Precautions Related to Protective Structures
  30
  - Roll-Over Protective Structure
    30
- Do Not Get Caught in Dump Body
  30
- Precautions When Running Engine Inside Building
  31
- Precautions Related to Attachments and Options
  31
- Precautions for Operation
  32
- Precautions for Jobsite
  32
- Investigate and Confirm Jobsite Conditions
  32
- Working on Loose Ground
  32
- Do Not Go Close to High-Voltage Cables
  32
- Ensure Good Visibility
  33
- Checking Signs and Signalman's Signals
  33
- Beware of Asbestos Dust
  33
- Starting Engine
  34
- Use Warning Tags
  34
- Checks before Starting Engine
  34
- Starting with Booster Cables
  35
- Precautions in Cold Areas
  35
- Precautions When Starting Engine
  35
- Operation
  36
- Checks before Operation
  36
- Precautions When Traveling in Forward or Reverse
  36
- Precautions When Traveling
  37
- Traveling on Slopes
  37
- Precautions When Operating
  37
- Precautions When Loading Dump Body
  38
- Precautions When Operating Dump Body
  38
- Traveling on Snow-Covered or Frozen Surfaces
  38
- Parking Machine
  39
- Transportation
  40
- Loading and Unloading
  40
- Towing
  41
- When Towing
  41
- Select Suitable Place for Inspection and Maintenance
  42
- Only Authorized Personnel
  42
- Appoint Leader When Working with Others
  42
- Keep Workplace Clean and Tidy
  42
- Precautions for Maintenance
  42
- Precautions before Starting Inspection and Maintenance
  42
- Display Warning Tag During Inspection and Maintenance
  42
- Stop Engine before Carrying out Inspection and Maintenance
  43
- Two Workers for Maintenance When Engine Is Running
  44
- Proper Tools
  45
- Installing, Removing, or Storing Attachments
  45
- Precautions When Working under Machine
  45
- Precautions When Working at High Places
  45
- Precautions for Inspection and Maintenance
  46
- Precautions When Welding
  46
- Handling Battery
  46
- Precautions with High-Temperature Coolant
  47
- Precautions with High-Temperature Oil
  47
- Precautions When Using Hammer
  47
- Precautions with High-Pressure Oil
  48
- Precautions with High-Pressure Fuel
  48
- Handling High-Pressure Hoses and Piping
  48
- Noise
  48
- Disposing of Waste Materials
  49
- Method of Selecting Window Washer Fluid
  49
- Precautions with Compressed Air
  49
- Maintenance of Air Conditioner
  49
- Handling Suspension Cylinder, Accumulator, Gas Spring
  49
- Periodic Replacement of Safety Critical Parts
  50
- Tires
  51
- Handling Tires
  51
- Precautions When Storing Tires
  52
- Operation
  55
- General View
  55
- General View of Machine
  55
- General View of Controls and Gauges
  56
- Explanation of Components
  58
- Machine Monitor
  58
  - Character Display
    60
  - Caution Items
    65
  - Meter Display Portion
    72
  - Shift Indicator
    74
  - Engine Tachometer
    76
  - Fuel Gauge
    77
  - Central Warning Lamp
    78
- Other Functions of Machine Monitor
  79
- Switches
  83
  - Starting Switch
    84
  - Lamp Switch
    84
  - Turn Signal Lever
    84
  - Dimmer Switch
    85
  - Hazard Lamp Switch
    85
  - Parking Brake Switch
    87
  - Cigarette Lighter
    90
  - Horn Button
    91
- Control Levers and Pedals
  92
  - Brake Pedal
    92
  - Accelerator Pedal
    93
  - Gear Shift Lever
    93
- Body Pivot Pin
  97
- Location of Fire Extinguisher
  97
- Dust Indicator
  98
- Fuses
  99
- Car Radio
  102
  - Power Switch/Volume
    102
  - Preset Switch
    104
  - Method of Operation
    105
  - Listening to Radio
    105
  - Adjusting Time
    107
  - Precautions for Use
    107
- Car Stereo
  108
  - Preset Buttons
    111
- Air Conditioner
  117
  - On/Off Switch
    117
  - Fan Switch
    117
  - Air Conditioner Switch
    117
  - Mode Selector Switch
    118
  - Temperature Control Switch
    119
  - Inspection and Maintenance
    121
- Operation
  122
- Check before Starting Engine
  122
  - Walk-Around Check
    122
  - Adjustment before Operation
    134
- Starting Engine
  141
- Operations, Checks after Starting Engine
  143
  - Breaking-In the Machine
    143
  - Warming-Up Operation
    143
- Stopping Engine
  144
- Checks after Stopping Engine
  144
- Moving Machine off (Forward, Reverse), Stopping
  145
  - Forward and Reverse
    147
  - Stopping Machine
    148
  - Normal Stopping
    148
- Shifting Gear
  150
  - Skip Shift
    151
- Traveling Downhill
  152
- Steering the Machine
  161
- Loading Operations
  161
- Dump Operations
  162
- Precautions for Operation
  163
- Parking Machine
  164
- Checks after Completion of Work
  165
- Locking
  165
- Handling Tires
  166
- Determining and Maintaining Travel Road
  169
- Determining Travel Road
  169
- Maintaining Travel Road
  169
- Method of Securing Machine
  170
- Steps for Transportation
  170
- Precautions When Transporting
  170
- Transportation
  170
- Method of Lifting Machine
  171
  - Lifting Procedure
    173
- Cold Weather Operation
  174
- Precautions for Low Temperature
  174
  - Fuel and Lubricants
    174
- Precautions after Completion of Work
  175
- After Cold Weather
  176
- Precautions before Traveling after Long-Term Storage
  177
- After Storage
  177
- Before Storage
  177
- During Storage
  177
- Long-Term Storage
  177
- Troubleshooting
  178
- After Running out of Fuel
  178
- If Transmission Has Trouble
  179
- Method of Lowering Dump Body in Emergency
  180
- Method of Towing Machine
  182
- If Battery Is Discharged
  186
  - Removal and Installation of Battery
    186
  - Starting Engine with Booster Cable
    187
  - Starting the Engine
    188
- Other Trouble
  189
  - Hours Service
    190
  - Action Code
    194
- Maintenance
  197
- Guides to Maintenance
  197
- Outline of Service
  200
- Handling Oil, Fuel, Coolant, and Performing Oil Clinic
  200
  - Coolant and Water for Dilution
    201
  - CARRYING out KOWA (Komatsu Oil Wear Analysis)
    203
  - Oil Sampling
    203
  - Storing Oil and Fuel
    204
- Outline of Electric System
  204
- Wear Parts
  205
- Wear Parts List
  205
- Recommended Fuel, Coolant, and Lubricant
  206
- Use of Fuel, Coolant and Lubricants According to Ambient Temperature
  207
- Recommended Brands, Recommended Quality for Products Other than Komatsu Genuine Oil
  208
- Standard Tightening Torques for Bolts and Nuts
  209
- Torque List
  209
- Periodic Replacement of Safety Critical Parts
  210
- Safety Critical Parts
  211
Maintenance Schedule Chart

212
- Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge
  215
- Change Oil in Transmission Case, Brake Sub Tank
  215
- Clean Hydraulic Tank Strainer
  215
- Initial 250 Hours Service (Only after the First 250 Hours)
  215
- Replace Brake Oil Filter Element
  215
- Replace Fuel Prefilter Cartridge
  215
- Replace Steering, Hoist Oil Tank Filter Element
  215
- Replace Transmission and Rear Brake Cooling Oil Filter Element
  215
- Replace Transmission Oil Filter Element (Pump Outlet Port)
  215
- Service Procedure
  215
- Check, Clean or Replace Air Cleaner
  216
- When Required
  216
- Clean Inside of Cooling System
  222
- Check Level of Window Washer Fluid, Add Fluid
  224
- Clean Air Conditioner Air Filter
  225
- Check Dump Body
  226
- Check Refrigerant (Gas) Level
  226
- Check Length of Suspension Cylinder, Check Oil Level
  227
- Bleed Air from Rear Brake
  229
- Bleed Air from Front Brake
  230
- Adjust Parking Brake
  231
- Clean, Check Radiator Fins and after Cooler Fins
  232
- Check Play of Output Coupling of Output Shaft
  233
- Selection and Inspection of Tires
  234
- Check before Starting
  237
- Check Oil Level in Differential Case, Add Oil
  238
- Check Oil Level in Final Drive Case, Add Oil
  238
- Every 250 Hours Service
  238
- Lubrication
  239
- Check Drive Shaft
  240
- Lubrication Drive Shaft (*)
  240
- Check Level of Battery Electrolyte
  241
- Check Alternator Belt Tension, Adjust
  243
- Check Air Conditioner Compressor Belt Tension, Adjust
  244
- Clean Breathers
  245
- Check Braking Capacity of Foot Brake
  246
- Check Frame
  246
- Check Braking Capacity of Parking Brake
  247
- Check Braking Capacity of Retarder Brake
  247
- Check, Clean Automatic Suspension
  248
- Check of Accumulator Gas Pressure
  249
- Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge
  250
- Every 500 Hours Service
  250
- Replace Fuel Prefilter Cartridge
  251
- Replace Transmission Oil Filter Element (Pump Outlet Port)
  253
- Check Wear of Front Disc Brake Pads
  254
- Check Fan Belt Tension, Adjust
  255
- Every 1000 Hours Service
  256
- Replace Fuel Main Filter Cartridge
  256
- Replace Corrosion Resistor Cartridge
  258
- Change Oil in Transmission Case, Brake Sub Tank, Wash Strainer
  259
- Replace Transmission and Rear Brake Cooling Oil Filter Element
  262
- Replace Brake Oil Filter Element
  263
- Lubrication
  264
- Check Wear of Rear Brake Disc
  265
- Recover Oil Leaking from Floating Seal
  266
- Check of Engine Air Intake Piping Clamps for Looseness
  267
- Every 2000 Hours Service
  268
- Replace Steering, Hoist Oil Tank Filter Element
  268
- Change Oil in Final Drive Case
  269
- Clean Hydraulic Tank Strainer
  269
- Change Oil in Differential Case
  270
- Clean Differential Case Breather
  270
- Check Accumulator Gas Pressure
  271
- Check Alternator
  271
- Check Vibration Damper
  271
- Check, Adjust Engine Valve Clearance
  271
- Change Oil in Steering, Hoist Oil Tank
  272
- Every 4000 Hours Service
  272
- Grease Extended Greasing Interval Drive Shaft (*)
  272
- Check Accumulator
  273
- Check Fan Pulley and Tension Pulley
  273
- Check Starting Motor
  273
- Check Water Pump
  273
- Checking for Looseness of High-Pressure Clamp, Hardening of Rubber
  273
- Checking for Missing Fuel Spray Prevention Cap, Hardening of Rubber
  274
- Every 8000 Hours Service
  275
- Overhaul Starting Motor and Alternator
  275
- Replace Fuel Spray Prevention Cap
  275
- Replace High-Pressure Piping Clamp
  275
- Check, Replace Steering a Arm Mounting Bolt
  276
- Every 15000 Hours Service
  276
- Specifications
  279
- Attachments, Options
  281
- Selecting Dump Body
  281
- Handling Air Suspension Seat
  282
- Seat Adjustment
  282
- Removal and Installation of Headrest
  284
- Explanation of Components
  285
- Handling Automatic Spin Regulator (Asr)
  285
- Actuation of Asr System
  286
- Precautions When Using
  286
- Bleeding Air from Asr Circuit
  287
- Explanation of Components
  288
  - Brake Pedal
    289
  - Accelerator Pedal
    289
- Handling Abs
  288
- Abs System Check after Starting Engine
  290
- Operation of Abs
  290
- Precautions When Using
  291
- Handling Payload Meter II (Card Type)
  292
- Method of Using Accurately
  293
- General Locations
  294
- Content of Display (Controller, External Display Lamps)
  299
  - When the Power Is on
    299
- External Display Lamps
  303
- Details of Data Stored in Memory of Payload Meter
  305
  - Cycle Data
    306
  - Other Data
    309
- Operation of Switches
  310
  - Carrying out Calibration
    311
  - Method of Operation
    316
- Problem and Warning Display (Error Code)
  332
- When Error Code F-09 Is Displayed (Procedure for Replacing Battery)
  339
- Operation When Error Code F.cal Is Displayed or Controller Has Been Replaced
  342
- Arsc (Automatic Retarder Speed Control)
  345
- Explanation of Components
  346
- Method of Operation
  349
- Name and Functon of each Part of Rear View Monitor
  352
  - Auto Switch
    352
  - Manual Switch
    353
- Use of Rear View Monitor
  352
- Cautions When Using Rear View Monitor
  355
- Setting of Rear View Monitor
  355
- Handling Dumping Counter
  356
- Basic Precautions
  357
- Handling Machines Equipped with Komtrax
  357
- Index
  358

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