Komatsu HD405-6 Rigid Dump Truck Manuals

Manuals and User Guides for Komatsu HD405-6 Rigid Dump Truck. We have 1 Komatsu HD405-6 Rigid Dump Truck manual available for free PDF download: Operation & Maintenance Manual

Komatsu HD405-6 Operation & Maintenance Manual

Komatsu HD405-6 Operation & Maintenance Manual (317 pages)

Dump Truck

Brand: Komatsu | Category: Trucks | Size: 6 MB

Table of Contents

Table of Contents

11
Safety

17
- Safety Labels
  19
  - Position for Attaching Safety Labels
    19
  - Safety Labels
    20
- General Precautions
  25
- Precautions During Operation
  33
  - Starting Engine
    33
    
    Checks before Starting Engine, Adjust
    33
    
    Precautions When Starting
    33
    
    Precautions in Cold Areas
    34
  - Operation
    35
    
    Checks before Starting Operation
    35
    
    Precautions When Traveling in Forward or Reverse
    35
    
    Precautions When Traveling
    36
    
    Precautions When Traveling on Slopes
    36
    
    Precautions When Operating Dump Body
    36
    
    Precautions When Operating
    36
    
    Precautions for Accumulated Snow, Ice
    37
    
    Parking Machine
    37
  - Transportation
    38
    
    Loading and Unloading
    38
    
    Shipping
    38
  - Battery
    39
    
    Battery Hazard Prevention
    39
    
    Starting with Booster Cables
    40
  - Towing
    41
    
    When Towing
    41
- Precautions for Maintenance
  42
  - Warning Tag
    42
  - Keep Work Place Clean and Tidy
    42
  - Appoint Leader When Working with Others
    42
  - Stop Engine before Carrying out Inspection and Maintenance
    43
  - Two Workers for Maintenance When Engine Is Running
    44
  - Proper Tools
    44
  - Handling Suspention Cylinder
    45
  - Personnel
    45
  - Work under the Machine
    45
  - Noise
    45
  - Precautions When Using Hammer
    45
  - Repair Welding
    45
  - Removing Battery Terminal
    46
  - Precautions with High-Pressure Oil
    46
  - Precautions for High-Pressure Fuel
    46
  - Handling High-Pressure Hoses, Piping
    46
  - Precautions for High Voltage
    47
  - Waste Materials
    47
  - Maintenance of Air Conditioner
    47
  - Compressed Air
    47
  - Periodic Replacement of Safety-Critical Parts
    47
- Operation
  48
  - Handling Tires
    48
    
    Precautions When Storing Tire
    48
  - General View
    51
    
    General View of Machine
    51
    
    General View of Controls and Gauges
    52
  - Explanation of Components
    54
    
    Machine Monitor
    54
    
    Switches
    72
    
    Control Levers and Pedals
    81
    
    Mechatronics Equipment Controller
    85
    
    Body Pivot Pin
    86
    
    Dust Indicator
    86
    
    Location of Fire Extinguisher
    87
    
    Location of First Aid Kit
    87
    
    Fuses
    87
    
    Car Radio
    90
    
    Car Stereo
    96
    
    Air Conditioner
    104
  - Operation
    109
    
    Check before Starting Engine
    109
    
    Starting Engine
    125
    
    Operations, Checks after Starting Engine
    129
    
    Stopping Engine
    130
    
    Checks after Stopping Engine
    130
    
    Moving Machine off (Forward, Reverse), Stopping
    131
    
    Shifting Gear
    136
  - Traveling Downhill
    137
  - Steering the Machine
    146
  - Loading Operations
    146
  - Dump Operations
    147
  - Precautions for Operation
    148
  - Parking Machine
    149
  - Checks after Completion of Work
    150
  - Drain Water from Air Tank
    150
  - Locking
    150
  - Handling Tires
    151
  - Determining and Maintaining Travel Road
    155
  - Determining Travel Road
    155
- Precautions with Tires
  48
- Maintaining Travel Road
  155
- Transportation
  156
  - Precautions When Transporting
    156
  - Steps for Transportation
    156
  - Method of Securing Machine
    156
  - Method of Lifting Machine
    157
- Cold Weather Operation
  159
  - Precautions for Low Temperature
    159
  - Precautions after Completion of Work
    160
  - After Cold Weather
    161
- Long-Term Storage
  162
  - Before Storage
    162
  - During Storage
    162
  - After Storage
    162
  - Precautions before Traveling after Long-Term Storage
    162
- Troubleshooting
  163
  - After Running out of Fuel
    163
  - Method of Towing Machine
    165
  - If Battery Is Discharged
    170
  - Other Trouble
    174
- Guides to Maintenance
  183
- Maintenance
  183
- Outline of Service
  185
  - Handling Oil, Fuel, Coolant, and Performing Oil Clinic
    185
  - Outline of Electric System
    189
- Wear Parts
  190
  - Wear Parts List
    190
- Recommended Fuel, Coolant, and Lubricant
  191
  - Use of Fuel, Coolant and Lubricants According to Ambient Temperature
    192
  - Recommended Brands, Recommended Quality for Products Other than Komatsu Genuine Oil
    196
- Standard Tightening Torques for Bolts and Nuts
  197
  - Torque List
    197
- Periodic Replacement of Safety Critical Parts
  198
  - Safety Critical Parts
    198
Maintenance Schedule Chart

199
- Adjust Injector
  202
- Change Oil in Differential Case
  203
  - When Required
    204
- Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge
  203
- Change Oil in Final Drive Case
  203
- Change Oil in Hydraulic Tank
  203
- Change Oil in Transmission Case
  203
- Replace Fuel Filter Cartridge
  203
- Replace Hydraulic Filter Element
  203
- Replace Transmission Oil Filter Element (Valve Inlet Side, Return Side)
  203
- Service Procedure
  203
  - Initial 250 Hours Service (Only after the First 250 Hours)
    203
- Check, Clean or Replace Air Cleaner
  204
- Clean Inside of Cooling System
  206
- Check Level of Window Washer Fluid, Add Fluid
  209
- Clean Air Conditioner Air Filter
  209
- Check Dump Body
  210
- Check Electric Intake Air Heater
  210
- Check Refrigerant (Gas) Level
  210
- Check Length of Suspension Cylinder, Check Oil Level
  211
- Bleed Air from Rear Brake
  212
- Bleed Air from Front Brake
  213
- Adjust Parking Brake
  214
- Bleed Air from Hydraulic Circuit of Front Drive
  215
- Adjust Body Positioner
  216
- Check Play of Output Coupling of Output Shaft
  217
- Selection and Inspection of Tires
  218
- Drain Water from Water Separator
  220
  - Check before Starting
    221
  - Every 50 Hours Service
    222
  - Lubrication
    222
    
    Every 100 Hours Service
    224
  - Check Alcohol Level in Alcohol Injector, Add Alcohol
    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
- Check Drive Shaft
  226
- Lubricate Drive Shaft (5 Places)
  226
- Check Level of Battery Electrolyte
  227
- Check Alternator Belt Tension, Adjust
  229
- Check Air Conditioner Compressor Belt Tension, Adjust
  230
- Clean Breathers
  231
- Check Braking Capacity of Foot Brake
  232
- Check Frame
  232
- Check Braking Capacity of Parking Brake
  233
- Check Braking Capacity of Retarder Brake
  233
- Check Wear of Parking Brake Pads
  233
- Check, Clean Automatic Suspension
  234
- Clean Central Breather Box and Central Breather Air Cleaner
  235
  - Every 500 Hours Service
    236
  - Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge
    236
- Replace Additional Fuel Filter Cartridge
  237
- Clean Fuel Tank Strainer
  238
- Replace Transmission Oil Filter Element (Valve Inlet Side, Return Side)
  239
- Check Wear of Front Disc Brake Pads
  240
- Replace Element of Front Drive Oil Filter
  240
- Check Fan Belt Tension, Adjust
  241
- Clean, Check Radiator Fins and after Cooler Fins
  241
- Lubricate Tension Pulley (1 Place)
  242
  - Every 1000 Hours Service
    243
  - Replace Fuel Filter Cartridge
    243
- Replace Corrosion Resistor Cartridge
  245
- Change Oil in Transmission Case, Clean Transmission Case Strainer
  246
- Change Oil in Front Final Drive
  247
- Change Oil in Front Drive Oil Tank, Clean Front Drive Oil Tank Strainer
  248
- Replace Hydraulic Filter Element
  249
- Lubrication
  250
- Check Tightening Parts of Turbocharger
  251
  - Every 2000 Hours Service
    252
  - Change Oil in Hydraulic Tank
    252
- Check Wear of Rear Brake Disc
  251
- Change Oil in Differential Case
  253
- Change Oil in Final Drive Case
  253
- Clean Differential Case Breather
  254
- Clean Engine Breather Element
  254
- Clean Air Dryer Filter and Deflector (if Equipped)
  255
- Check Alternator, Starting Motor
  256
- Check Injector (EPA Exhaust Gas Regulation Areas Only)
  256
- Check Play of Turbocharger Rotor
  256
- Check, Adjust Engine Valve Clearance
  256
- Clean Emergency Relay Valve
  256
- Clean, Check Turbocharger
  256
- Checking for Missing Fuel Spray Prevention Cap, Hardening of Rubber
  258
- Specifications
  263
- Attachments, Options
  265
  - Handling Payload Meter
    265
    
    Name of Parts
    265
    
    External Display Lamps
    266
    
    Operating Payload Meter
    269
  - Selecting Dump Body
    277
  - Tachograph (Tco 15-6)
    278
    
    Explanation of Components
    278
    
    Method of Using Key
    280
    
    Method of Use
    281
  - Revo Tachograph (Tco 15-7)
    283
    
    Explanation of Components
    283
    
    Method of Use
    286
  - Using Differential Lock
    288
    
    Differential Lock Pedal
    288
    
    Precautions and Method of Use
    289
  - Operation of Abs and Abs/Asr
    290
    
    Explanation of Components
    290
    
    Operation Method
    292
    
    Precautions for Use
    293
    
    Troubleshooting
    293
  - Handling Auto-Greasing System
    294
    
    Method of Operating Auto-Greasing System
    294
    
    Precautions When Handling Auto-Greasing System
    300
    
    Troubleshooting
    300
  - Arsc (Automatic Retarder Speed Control)
    301
    
    Explanation of Components
    301
    
    Method of Operation
    303
    
    Troubleshooting
    305
  - Asr-II (Automatic Spin Regulator II)
    308
    
    Explanation of Components
    308
    
    Actuation of Asr-II System
    309
    
    Precautions When Using
    309
    
    Troubleshooting
    310
  - Handling Oil Filter Caution
    312

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