Komatsu Hd465-8 Manual

HD465

-8

HD605

-8

SERIAL NUMBERS

HD465-8 - 30001 and up

HD605-8 - 30001 and up

DUMP TRUCK

Unsafe use of this machine may cause serious injury or

death. Operators and maintenance personnel must read

this manual before operating or maintaining this

machine. This manual should be kept inside the cab for

reference and periodically reviewed by all personnel who

will come into contact with the machine.

Operation &

Maintenance Manual

EENAM03550

WARNING

ORIGINAL INSTRUCTIONS

FOREWORD

Komatsu recommends that any service parts used for maintenance, repair or

replacement of emission control systems be genuine new Komatsu or Ko-

matsu approved rebuilt parts or assemblies or others parts of equivalent

quality, and that the engine be serviced by an authorized Komatsu distribu-

tor. Failure to follow these recommendations could result in ineffective serv-

ice, damage to the product or safety risks (including personal injury or

death).

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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 funda-

mental 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 precau-

tions.

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 im-

proper 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.

Keep it in the pocket behind the operator's seat.

If this manual is lost, damaged, or unreadable, contact Komatsu or your Komatsu distributor and tell them about

the machine model name and the serial No. immediately to arrange for its replacement.

For the machine model name and the serial No., see the machine serial No. plate. In order to arrange the prop-

er Operation and Maintenance Manual, you will need to provide the machine model name and the serial No.

This manual uses the International System of 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. If there is any question or suggestion, consult your Ko-

matsu distributor.

The numbers in the illustrations correspond to the numbers in ( ) in the text. (Example: 1 → (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 your Komatsu distributor before

operating the machine.

READ THIS MANUAL FOREWORD

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SAFETY INFORMATION

To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by-

standers, the precautions and warnings included in this manual and the safety signs attached to the machine

must always be observed.

To identify important safety messages in the manual and on the machine labels, the following signal words are

used.

The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When

you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety mes-

sage.

This signal word indicates an imminently hazardous situation which, if not avoided, will result

in death or serious injury.

This signal word indicates a potentially hazardous situation which, if not avoided, could result

in death or serious injury.

This signal word indicates a potentially hazardous situation which, if not avoided, may result

in minor or moderate injury. It may also be used to alert against unsafe practices that may

cause property damage.

The following signal words are used to alert you to information that must be followed to avoid damage to the

machine.

If precautions described are not observed, the machine may be damaged or the service life

may be reduced.

This word is used for information that is useful to know.

FOREWORD SAFETY INFORMATION

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NOISE

Sound pressure level at the operator’s station, measured according to ISO 6396 (Dynamic test method, simulat-

ed working cycle).

The maximum value of the standard deviation of the measured

time-averaged A-weighted emission sound pressure level at the

operator’s position is 2.5dB, in accordance with ISO 11201

VIBRATION - OPERATING CONDITION

(Rigid/Articulate dumper:) Work cycle (including waiting, travelling, loading, travelling with load, unloading and

travelling without load)

GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE

The following guides can help an operator of this machine to reduce the whole body vibration levels:

1. Use the correct equipment and attachments.

2. Maintain the machine according to this manual

• Tire pressures (for wheeled machines), tension of crawler (for crawler machines)

• Brake and steering systems

• Controls, hydraulic system and linkages

3. Keep the terrain where the machine is working and travelling in good condition

• Remove any large rocks or obstacles

• Fill any ditches and holes

• Site manager should provide machine operators with machine and schedule time to maintain terrain

conditions

4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted

• Adjust the seat and suspension for the weight and size of the operator

• Wear seat belt

• Inspect and maintain the seat suspension and adjustment mechanisms

5. Steer, brake, accelerate, shift gears (for wheeled machines), and move the attachment levers and pedals

slowly so that the machine moves smoothly

6. Adjust the machine speed and travel path to minimize the vibration level

• When pushing with bucket or blade, avoid sudden loading; load gradually

• Drive around obstacles and rough terrain conditions

• Slow down when it is necessary to go over rough terrain

• Make the curve radius of travelling path as large as possible

NOISE FOREWORD

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• Travel at low speed when travelling around sharp curves

7. Minimize vibrations for long work cycle or long distance travelling

• Reduce speed to prevent bounce

• Transport machines long distances between worksites

8. The following guidelines can be effective to minimize risks of low back pain

• Operate the machine only when you are in good health

• Provide breaks to reduce long periods of sitting in the same posture

• Do not jump down from the cab or machine

• Do not repeatedly handle and lift loads

FOREWORD NOISE

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VIBRATION LEVEL

When used for its intended purpose, levels of vibration for the earth moving-machine transmitted from the oper-

ator’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with

ISO 7096.

FOR HD465-8 :

The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s2 , the uncertainty for this

value is 0.08 m/s2 according to EN12096:1997.

The actual acceleration value for the body is less than or equal to 0.5 m/s2, the uncertainty for this value is 0.28

m/s2 according to EN12096:1997.

FOR HD605-8 :

The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s2 , the uncertainty for this

value is 0.09 m/s2 according to EN12096:1997.

The actual acceleration value for the body is less than or equal to 0.5 m/s2, the uncertainty for this value is 0.30

m/s2 according to EN12096:1997.

These values were determined using a representative machine and measured during the typical operating con-

dition indicated below according to the measurement procedures that are defined in the standards ISO 2631/1

and ISO 5349.

VIBRATION LEVEL FOREWORD

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INTRODUCTION

MAIN USE OF MACHINE

This Komatsu machine is designed to be used mainly for the following work:

Traveling with a load

DIRECTIONS OF MACHINE

(A) Front

(B) Rear

(D) Right

(E) Operator's seat

In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from

the operator's seat in the direction of travel (front) of the machine.

VISIBILITY FROM OPERATOR'S SEAT

This machine complies with the visibility standard (ISO 5006).

This machine maintains a proximity visibility of a height of 1.5 m at a point 1 m away from the outside surface of

the machine, and a visibility for a circumference of 12 m.

FOREWORD INTRODUCTION

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PRODUCT INFORMATION

When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items.

LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI-

AL NO. PLATE

It is provided on the front right of the machine.

The design of the nameplate varies according to the district.

LOCATION OF ENGINE NUMBER PLATE

It is located on the upper left side of the engine cylinder block if you look from the fan side.

PRODUCT INFORMATION FOREWORD

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FLUORINATED GREENHOUSE GASES

Product contains fluorinated greenhouse gases.

SERVICE METER LOCATION

In the initial state, it is on the left bottom of the machine moni-

tor.

YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR

Machine serial No.

Engine serial No.

Product identification number

(PIN)

Manufacturers name:

Address: KOMATSU LTD.

2-3-6 Akasaka

Minato-ku, Tokyo 107-8414

Japan

Authorised representative:

Address: KOMATSU EUROPE INT.

Mechelsesteenweg 586

B-1800 Vilvoorde

Belgium

Distributor name

Address

Service personnel

Phone/Fax

566-93-8L620

HFC-134a

GWP 1430

1.2 kg

1.72 tCO2eq.

FOREWORD PRODUCT INFORMATION

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SERIAL PLATE

EI000001

A MACHINE DESIGNATION/TYPE E ENGINE POWER

B SERIAL NUMBER F PRODUCT IDENTIFICATION NUMBER

C YEAR OF CONSTRUCTION G MANUFACTURER

D OPERATING MASS H AUTHORISED REPRESENTATIVE

SERIAL PLATE FOREWORD

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DECLARATION OF CONFORMITY

The manufacturer/Authorised representative

The manufacturer Authorised representative

KOMATSU LTD.

2-3-6 Akasaka

Minato-ku, Tokyo 107-8414

Japan

KOMATSU EUROPE INT.

Mechelsesteenweg 586

B-1800 Vilvoorde

Belgium

Declares that this machine:

HD465-8

HD605-8

Fulfils all the relevant provisions of following EC Directives:

Machinery Directive 2006/42/EC

Electro Magnetic Compatibility Directive 2014/30/EU

Radio Equipment Directive 2014/53/EU

FOREWORD DECLARATION OF CONFORMITY

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TABLE OF CONTENTS

FOREWORD.................................................................................................................................................... 1-1

READ THIS MANUAL............................................................................................................................... 1-2

SAFETY INFORMATION .......................................................................................................................... 1-3

NOISE....................................................................................................................................................... 1-4

.................................................................................................................................................................. 1-4

VIBRATION - OPERATING CONDITION ........................................................................................... 1-4

GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ................................................................ 1-4

VIBRATION LEVEL................................................................................................................................... 1-6

INTRODUCTION ...................................................................................................................................... 1-7

MAIN USE OF MACHINE .................................................................................................................. 1-7

DIRECTIONS OF MACHINE.............................................................................................................. 1-7

VISIBILITY FROM OPERATOR'S SEAT ............................................................................................ 1-7

PRODUCT INFORMATION....................................................................................................................... 1-8

LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ........ 1-8

LOCATION OF ENGINE NUMBER PLATE ........................................................................................ 1-8

FLUORINATED GREENHOUSE GASES........................................................................................... 1-9

SERVICE METER LOCATION........................................................................................................... 1-9

YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR.............................................................. 1-9

SERIAL PLATE ....................................................................................................................................... 1-10

DECLARATION OF CONFORMITY .........................................................................................................1-11

SAFETY........................................................................................................................................................... 2-1

SAFETY LABELS ..................................................................................................................................... 2-2

LOCATION OF SAFETY LABELS...................................................................................................... 2-3

CONTENTS OF SAFETY LABELS .................................................................................................... 2-5

GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE .................................... 2-12

PRECAUTIONS BEFORE STARTING OPERATION........................................................................ 2-12

PREPARATIONS FOR SAFE OPERATION ..................................................................................... 2-12

PRECAUTIONS TO PREVENT FIRE............................................................................................... 2-13

PRECAUTIONS WHEN GETTING ON OR OFF MACHINE............................................................. 2-15

DO NOT GET CAUGHT IN WORK EQUIPMENT ............................................................................ 2-17

PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES........................................................ 2-17

UNAUTHORIZED MODIFICATION .................................................................................................. 2-18

PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS .................................................... 2-18

PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING..................................................... 2-18

PRECAUTIONS FOR OPERATION ........................................................................................................ 2-19

PRECAUTIONS FOR JOBSITE....................................................................................................... 2-19

START ENGINE............................................................................................................................... 2-21

PRECAUTIONS FOR OPERATION ................................................................................................. 2-22

TRANSPORTATION......................................................................................................................... 2-25

TOWING AND BEING TOWED........................................................................................................ 2-26

PRECAUTIONS FOR MAINTENANCE................................................................................................... 2-27

PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ................................... 2-27

PRECAUTIONS FOR CHECK AND MAINTENANCE ...................................................................... 2-31

TIRES .............................................................................................................................................. 2-35

OPERATION.................................................................................................................................................... 3-1

GENERAL VIEW....................................................................................................................................... 3-2

MACHINE EQUIPMENT NAME ......................................................................................................... 3-2

CONTROLS AND GAUGES NAMES................................................................................................. 3-3

OTHER EQUIPMENT NAME............................................................................................................. 3-7

EXPLANATION OF COMPONENTS......................................................................................................... 3-9

EXPLANATION OF MACHINE MONITOR EQUIPMENT ................................................................... 3-9

SWITCHES...................................................................................................................................... 3-99

CONTROL LEVERS AND PEDALS............................................................................................... 3-109

OTHER EQUIPMENT .....................................................................................................................3-114

MACHINE OPERATIONS AND CONTROLS ........................................................................................ 3-138

CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ...................................................... 3-138

TABLE OF CONTENTS FOREWORD

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METHOD FOR STARTING ENGINE.............................................................................................. 3-168

METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE ................................. 3-171

METHOD FOR STOPPING ENGINE ............................................................................................. 3-173

METHOD FOR CHECKING AFTER STOPPING ENGINE............................................................. 3-175

METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MA-

CHINE........................................................................................................................................ 3-175

METHOD FOR SHIFTING GEARS................................................................................................ 3-180

METHOD FOR TRAVELING DOWNHILL ...................................................................................... 3-181

METHOD FOR TURNING MACHINE ............................................................................................ 3-194

HANDLE OVERLOAD SPEED LIMIT FUNCTION ......................................................................... 3-195

METHOD FOR LOADING.............................................................................................................. 3-197

HANDLING PAYLOAD METER...................................................................................................... 3-197

METHOD FOR DUMPING ..............................................................................................................3-211

PRECAUTIONS FOR OPERATION ............................................................................................... 3-213

METHOD FOR PARKING MACHINE............................................................................................. 3-214

METHOD FOR CHECKING AFTER FINISHING WORK................................................................ 3-215

LOCK............................................................................................................................................. 3-215

HANDLE TIRE ............................................................................................................................... 3-220

HANDLE AIR CONDITIONER............................................................................................................... 3-223

EXPLANATION OF AIR CONDITIONER EQUIPMENT.................................................................. 3-224

METHOD FOR OPERATING AIR CONDITIONER......................................................................... 3-229

HANDLE RADIO ................................................................................................................................... 3-236

EXPLANATION OF RADIO EQUIPMENT ...................................................................................... 3-236

METHOD FOR CONTROLLING RADIO ........................................................................................ 3-237

DUMP BODY HEATING SPECIFICATIONS.......................................................................................... 3-241

DETERMINE AND MAINTAIN TRAVEL ROAD ..................................................................................... 3-242

TRANSPORTATION.............................................................................................................................. 3-243

PRECAUTIONS FOR TRANSPORTATION.................................................................................... 3-243

SELECT TRANSPORTATION METHOD........................................................................................ 3-243

METHOD FOR SECURING MACHINE.......................................................................................... 3-243

PRECAUTIONS FOR LIFTING MACHINE..................................................................................... 3-243

COLD WEATHER OPERATION............................................................................................................ 3-247

COLD WEATHER OPERATION INFORMATION ........................................................................... 3-247

PRECAUTIONS AFTER DAILY WORK COMPLETION ................................................................. 3-248

AFTER COLD WEATHER SEASON .............................................................................................. 3-248

PRECAUTIONS FOR LONG-TERM STORAGE ................................................................................... 3-249

PREPARATION FOR LONG-TERM STORAGE............................................................................. 3-249

MAINTENANCE DURING LONG-TERM STORAGE...................................................................... 3-249

STARTING MACHINE AFTER LONG-TERM STORAGE............................................................... 3-249

PREPARATION BEFORE TRAVELING AFTER LONG-TERM STORAGE..................................... 3-250

TROUBLES AND ACTIONS ................................................................................................................. 3-251

ACTIONS WHEN RUNNING OUT OF FUEL ................................................................................. 3-251

ACTIONS IF TRANSMISSION HAS TROUBLE............................................................................. 3-251

METHOD FOR LOWERING DUMP BODY IF TROUBLES OCCUR .............................................. 3-251

PRECAUTIONS FOR TOWING MACHINE.................................................................................... 3-253

PRECAUTIONS FOR DISCHARGED BATTERY ........................................................................... 3-256

OTHER TROUBLE......................................................................................................................... 3-260

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

FOREWORD TABLE OF CONTENTS

1-13

PRECAUTIONS FOR KDPF .............................................................................................................. 4-2

DUSTY JOBSITES............................................................................................................................. 4-2

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...................................................................... 4-3

FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE........................................... 4-3

CLOSE ENGINE SIDE COVER SECURELY...................................................................................... 4-3

PRECAUTIONS FOR JACK-UP......................................................................................................... 4-3

OUTLINE OF MAINTENANCE.................................................................................................................. 4-5

HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC .................................................. 4-5

HANDLE ELECTRICAL COMPONENTS ........................................................................................... 4-8

STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS................................................................ 4-9

MAINTENANCE SCHEDULE...................................................................................................................4-11

MAINTENANCE SCHEDULE TABLE................................................................................................4-11

MAINTENANCE PROCEDURE .............................................................................................................. 4-13

INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ............................ 4-13

WHEN REQUIRED .......................................................................................................................... 4-13

CHECKS BEFORE STARTING........................................................................................................ 4-33

EVERY 250 HOURS MAINTENANCE ............................................................................................. 4-33

EVERY 500 HOURS MAINTENANCE ............................................................................................. 4-44

EVERY 1000 HOURS MAINTENANCE ........................................................................................... 4-51

EVERY 2000 HOURS MAINTENANCE ........................................................................................... 4-62

EVERY 4000 HOURS MAINTENANCE ........................................................................................... 4-69

EVERY 4500 HOURS MAINTENANCE ........................................................................................... 4-72

EVERY 8000 HOURS MAINTENANCE ........................................................................................... 4-72

EVERY 9000 HOURS MAINTENANCE ........................................................................................... 4-73

EVERY 15000 HOURS MAINTENANCE ......................................................................................... 4-73

SPECIFICATIONS ........................................................................................................................................... 5-1

SPECIFICATIONS .................................................................................................................................... 5-2

SPECIFICATIONS: HD465-8 ............................................................................................................. 5-2

SPECIFICATIONS: HD605-8 ............................................................................................................. 5-3

ATTACHMENTS AND OPTIONS ..................................................................................................................... 6-1

BODY SELECTION................................................................................................................................... 6-2

HANDLE ENGINE ROOM LAMP .............................................................................................................. 6-3

METHOD FOR USING ENGINE ROOM LAMP.................................................................................. 6-3

HANDLE KOMATSU TRACTION CONTROL SYSTEM (KTCS)................................................................ 6-4

OPERATION OF KTCS...................................................................................................................... 6-4

METHOD FOR OPERATING MACHINE WHEN TIRES ARE STUCK IN GROUND........................... 6-4

HANDLE SPEED LIMIT FUNCTION ......................................................................................................... 6-5

OPERATION OF SPEED LIMIT FUNCTION...................................................................................... 6-5

OPERATION IF TROUBLES ON SYSTEM OCCUR .......................................................................... 6-6

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...................................................................................................................... 7-4

METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA-

TURE ............................................................................................................................................. 7-6

RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS .............. 7-8

INDEX.............................................................................................................................................................. 8-1

TABLE OF CONTENTS FOREWORD

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