Komatsu Dump Truck HD465-7E0, HD605-7E0 Repair Service Manual + Operation & Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Dump Truck HD465-7E0, HD605-7E0, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Dump Truck HD465-7E0, HD605-7E0 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 3,390 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEN01081-18 - Dump Truck HD465-7E0, HD605-7E0 Shop Manual.pdf
GEN00046-04 - Dump Truck HD465-7E0, HD605-7E0 Field Assembly Instruction.pdf
TEN00138-08 - Dump Truck HD465-7E0, HD605-7E0 Operation & Maintenance Manual.pdf
TEN00332-00 - Dump Truck HD465-7E0, HD605-7E0 Operation & Maintenance Manual.pdf
TEN00370-03 - Dump Truck HD465-7E0, HD605-7E0 Operation & Maintenance Manual.pdf
TEN00439-07 - Dump Truck HD465-7E0, HD605-7E0 Operation & Maintenance Manual.pdf
MAIN SECTIONS
Composition of shop manual
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accordingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN01081-18
00 Index and foreword
Index
Foreword and general information SEN01082-18
SEN01083-18 q
SEN01084-06
01 Specification
Specification and technical data SEN01085-04
SEN01086-04 q
10 Structure, function and maintenance standard
Engine and cooling system
Power train, Part 1
Power train, Part 2
Steering system
Brake system
Undercarriage and frame
Hydraulic system
Work equipment (Body)
Cab and its attachments
Electrical system, Part 1
Electrical system, Part 2
Electrical system, Part 3
Electrical system, Part 4 SEN01087-10
SEN01088-02
SEN01089-04
SEN01090-01
SEN01091-01
SEN01092-02
SEN01093-03
SEN01094-03
SEN04679-00
SEN01095-02
SEN01096-04
SEN01097-04
SEN01098-02
SEN01099-05
20 Standard value table
Standard service value table SEN01100-03
SEN01649-03
30 Testing and adjusting
Testing and adjusting, Part 1
Testing and adjusting, Part 2
Testing and adjusting, Part 3
Testing and adjusting, Part 4
Testing and adjusting, Part 5 SEN01101-06
SEN01650-05
SEN01651-05
SEN01652-04
SEN01653-02
SEN01654-04
SEN01660-04
40 Troubleshooting
Failure code table and fuse locations SEN01102-07
HD465-7E0, HD605-7E000 Index and foreword
General information on troubleshooting
Troubleshooting by failure code, Part 1
Troubleshooting by failure code, Part 2
Troubleshooting by failure code, Part 3
Troubleshooting by failure code, Part 4
Troubleshooting by failure code, Part 5
Troubleshooting by failure code, Part 6
Troubleshooting by failure code, Part 7
Troubleshooting by failure code, Part 8
Troubleshooting by failure code, Part 9
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)
SEN01083-18
SEN01661-05
SEN01662-03
SEN01663-04
SEN01664-04
SEN01665-04
SEN01666-05
SEN01667-05
SEN01668-03
SEN01669-02
SEN01670-03
SEN01671-03
SEN01672-01
SEN01673-03
50 Disassembly and assembly
General information on disassembly and assembly
Engine and cooling system
Power train, Part 1
Power train, Part 2
Steering system
Brake system
Undercarriage and frame
Hydraulic system
Body
Cab and its attachments
Electrical system SEN01103-04
SEN02483-03
SEN02484-03
SEN02485-01
SEN02486-01
SEN02487-01
SEN02488-01
SEN02489-02
SEN02490-01
SEN02491-02
SEN02492-03
SEN02493-01
90 Diagrams and drawings
Hydraulic diagrams and drawings
Electrical diagrams and drawings SEN01104-10
SEN01105-03
SEN01106-08
COVER...1
FOREWORD...2
BEFORE READING THIS MANUAL...3
SAFETY INFORMATION...6
INTENDED USE...7
USE OF MACHINE...7
GENERAL VIEW AND DIRECTIONS OF MACHINE...7
VISIBILITY FROM OPERATOR'S SEAT...7
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...8
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...8
EPA REGULATIONS, ENGINE NUMBER PLATE...8
SERVICE METER POSITION...9
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...9
CONTENTS...10
SAFETY...14
IMPORTANT SAFETY INFORMATION...15
SAFETY LABELS...18
POSITION FOR ATTACHING SAFETY LABELS...19
SAFETY LABELS...20
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE...25
PRECAUTIONS BEFORE STARTING OPERATION...25
PREPARATIONS FOR SAFE OPERATION...25
FIRE PREVENTION...27
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE...28
DO NOT GET CAUGHT IN DUMP BODY...30
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...30
UNAUTHORIZED MODIFICATION...30
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS...31
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING...31
PRECAUTIONS FOR OPERATION...32
PRECAUTIONS FOR JOBSITE...32
STARTING ENGINE...34
OPERATION...36
TRANSPORTATION...40
TOWING...41
PRECAUTIONS FOR MAINTENANCE...42
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE...42
PRECAUTIONS FOR INSPECTION AND MAINTENANCE...46
TIRES...51
OPERATION...54
GENERAL VIEW...55
GENERAL VIEW OF MACHINE...55
GENERAL VIEW OF CONTROLS AND GAUGES...56
DASHBOARD...57
EXPLANATION OF COMPONENTS...58
GENERAL VIEW OF MACHINE...58
OPERATOR'S CAB...61
CONTROL LEVERS AND PEDALS...63
MACHINE MONITOR...68
DISPLAY OF CHARACTER DISPLAY...81
OTHER FUNCTIONS OF CHARACTER DISPLAY...85
SWITCHES...89
BODY PIVOT PIN...99
LOCATION OF FIRE EXTINGUISHER...100
DUST INDICATOR...100
FUSES...101
CAR RADIO...104
CAR STEREO...106
AIR CONDITIONER...111
OPERATION...116
CHECK BEFORE STARTING ENGINE...116
STARTING ENGINE...141
OPERATIONS, CHECKS AFTER STARTING ENGINE...144
STOPPING ENGINE...144
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING...145
SHIFTING GEAR...151
TRAVELING DOWNHILL...153
STEERING THE MACHINE...166
LOADING OPERATIONS...166
DUMP OPERATIONS...167
PRECAUTIONS FOR OPERATION...169
PARKING MACHINE...170
CHECKS AFTER COMPLETION OF WORK...170
CHECKS AFTER STOPPING ENGINE...171
LOCKING...171
HANDLING TIRES...172
DETERMINING AND MAINTAINING TRAVEL ROAD...176
DETERMINING TRAVEL ROAD...176
MAINTAINING TRAVEL ROAD...176
WORKSITE...177
EXAMINATION AN CONFIRMATION OF WORKSITE...177
WORKING ON LOOSE GROUND...177
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLE...178
ENSURE GOOD VISIBILITY...178
CONFIRMATION OF MARK...178
TRANSPORTATION...179
PRECAUTIONS WHEN TRANSPORTING...179
STEPS FOR TRANSPORTATION...179
METHOD OF SECURING MACHINE...180
METHOD OF LIFTING MACHINE...181
COLD WEATHER OPERATION...184
PRECAUTIONS FOR LOW TEMPERATURE...184
PRECAUTIONS AFTER COMPLETION OF WORK...186
AFTER COLD WEATHER...186
LONG-TERM STORAGE...187
BEFORE STORAGE...187
DURING STORAGE...187
AFTER STORAGE...187
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE...187
TROUBLESHOOTING...188
AFTER RUNNING OUT OF FUEL...188
IF TRANSMISSION HAS TROUBLE...188
METHOD OF LOWERING DUMP BODY IN EMERGENCY...189
METHOD OF TOWING MACHINE...191
IF BATTERY IS DISCHARGED...195
ACTION IF FIRE OCCURS...199
OTHER TROUBLE...200
MAINTENANCE...206
GUIDES TO MAINTENANCE...207
SECONDARY MATERIALS FOR OPERATION...214
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...214
OUTLINE OF ELECTRIC SYSTEM...218
WEAR PARTS...219
WEAR PARTS LIST...219
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...220
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...221
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...222
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...223
TORQUE LIST...223
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...224
SAFETY CRITICAL PARTS...224
MAINTENANCE SCHEDULE CHART...225
MAINTENANCE SCHEDULE CHART...225
SERVICE PROCEDURE...227
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)...227
WHEN REQUIRED...228
CHECK BEFORE STARTING...253
EVERY 250 HOURS SERVICE...254
EVERY 500 HOURS SERVICE...268
EVERY 1000 HOURS SERVICE...278
EVERY 2000 HOURS SERVICE...288
EVERY 4000 HOURS SERVICE...291
EVERY 8000 HOURS SERVICE...295
EVERY 15000 HOURS SERVICE...296
SPECIFICATIONS...298
SPECIFICATIONS...299
ATTACHMENTS, OPTIONS...300
SELECTING DUMP BODY...301
HANDLING TACHOGRAPH (TCO20-90W)...302
EXPLANATION OF COMPONENTS...302
METHOD OF USE...305
HANDLING AIR SUSPENSION SEAT...309
OPERATOR'S SEAT ADJUSTMENT...309
REMOVAL AND INSTALLATION OF HEADREST...313
HANDLING AUTOMATIC SPIN REGULATOR (ASR)...314
EXPLANATION OF COMPONENTS...314
ACTUATION OF ASR SYSTEM...315
PRECAUTION WHEN USING ASR SYSTEM...315
TROUBLESHOOTING...316
BLEEDING AIR FROM ASR CIRCUIT...317
HANDLING ANTI SKID BRAKE SYSTEM (ABS)...318
EXPLANATION OF COMPONENTS...318
ABS SYSTEM CHECK AFTER STARTING ENGINE...319
OPERATION OF ABS...320
PRECAUTION WHEN USING ABS SYSTEM...320
TROUBLESHOOTING...321
HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)...322
OUTLINE OF SYSTEM...322
NORMAL OPERATION DISPLAY...323
EXTERNAL DISPLAY LAMPS...325
PERFORMING CALIBRATION...326
DATA STORED IN PAYLOAD METER...328
PROCEDURE WHEN DOWNLOADING...329
MACHINE ID, OPEN ID...333
PAYLOAD (CYCLE DATA ITEM)...335
SERVICE FUNCTIONS...335
OTHERS...335
HANDLING PAYLOAD METER II (CARD TYPE)...336
METHOD OF USING ACCURATELY...337
GENERAL LOCATIONS...338
CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)...343
EXTERNAL DISPLAY LAMPS...347
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER...349
OPERATION OF SWITCHES...354
PROBLEM AND WARNING DISPLAY (ERROR CODE)...376
WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY)...383
OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED...386
USE OF REAR VIEW MONITOR...389
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR...389
SETTING OF REAR VIEW MONITOR...392
CAUTIONS WHEN USING REAR VIEW MONITOR...392
HANDLING DUMPING COUNTER...393
HANDLING BATTERY ISOLATOR...394
HANDLING MACHINES EQUIPPED WITH VHMS...396
VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED...396
VHMS AND COMMUNICATIONS TERMINAL INSTALLED...396
PROCEDURE WHEN DOWNLOADING...397
CHECK BEFORE STARTING...397
INDEX...400
