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