PDF Operation & Maintenance Manual Komatsu HD465-7EO HD605-7EO Dump Truck - 1 MB
This is the official Operation & Maintenance Manual for Komatsu HD465-7EO and HD605-7EO dump trucks with serial numbers 10694 and up.
This guide is crucial for operators and maintenance staff, providing detailed instructions on safe operation, daily checks, and scheduled maintenance tasks.
Following this manual helps to ensure the longevity and reliability of these massive haul trucks.
It's the primary resource for keeping your equipment in top condition.
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TEN00332-00
DUMP TRUCK HD465 -7E0
HD605 -7E0
HD465-10694
SERIAL NUMBERS and up
HD605-10694
WARNING
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 near the machine for
reference and periodically reviewed by all personnel who
will come into contact with it.
NOTICE
Komatsu has Operation & Maintenance Manuals
written in some other languages. If a foreign language
manual is necessary, contact your local distributor for
availability.
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CONTENTS FOREWORD
HANDLING ANTI SKID BRAKE SYSTEM (ABS) 6- 19
EXPLANATION OF COMPONENTS 6- 19
ABS SYSTEM CHECK AFTER STARTING ENGINE 6- 20
OPERATION OF ABS 6- 21
PRECAUTION WHEN USING ABS SYSTEM 6- 21
TROUBLESHOOTING 6- 22
HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE) 6- 23
OUTLINE OF SYSTEM 6- 23
NORMAL OPERATION DISPLAY 6- 24
EXTERNAL DISPLAY LAMPS 6- 26
PERFORMING CALIBRATION 6- 27
DATA STORED IN PAYLOAD METER 6- 29
PROCEDURE WHEN DOWNLOADING 6- 30
MACHINE ID, OPEN ID 6- 34
PAYLOAD (CYCLE DATA ITEM) 6- 36
SERVICE FUNCTIONS 6- 36
OTHERS 6- 36
HANDLING PAYLOAD METER II (CARD TYPE) 6- 37
METHOD OF USING ACCURATELY 6- 38
GENERAL LOCATIONS 6- 39
CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS) 6- 44
EXTERNAL DISPLAY LAMPS 6- 48
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER 6- 50
OPERATION OF SWITCHES 6- 55
PROBLEM AND WARNING DISPLAY (ERROR CODE) 6- 77
WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY) 6- 84
OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN
REPLACED 6- 87
USE OF REAR VIEW MONITOR 6- 90
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR 6- 90
SETTING OF REAR VIEW MONITOR 6- 93
CAUTIONS WHEN USING REAR VIEW MONITOR 6- 93
HANDLING DUMPING COUNTER 6- 94
HANDLING BATTERY ISOLATOR 6- 95
HANDLING MACHINES EQUIPPED WITH VHMS 6- 97
VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED 6- 97
VHMS AND COMMUNICATIONS TERMINAL INSTALLED 6- 97
PROCEDURE WHEN DOWNLOADING 6- 98
CHECK BEFORE STARTING 6- 98
INDEX 7- 1
1 - 10
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SAFETY LABELS SAFETY
(9) Caution when handling battery cable (09808-03000)
(10) Exhaust pipe is hot! (09817-K088B)
(11) Caution for avoiding falling down (09805-13000)
2 - 10
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PRECAUTIONS FOR OPERATION SAFETY
ENSURE GOOD VISIBILITY
This machine is equipped with mirrors to ensure good visibility, but even then there are places that cannot be seen
from the operator's seat, so be careful when operating.
When traveling or carrying out operations in places with poor visibility, it is impossible to check for obstacles in the
area around the machine and to check the condition of the jobsite. This leads to danger of serious personal injury
or death. When traveling or carrying out operations in places with poor visibility, always observe the following.
Position a signalman if there are areas where the visibility is not good.
Only one signalman should give signals.
When working in dark places, turn on the working lamp and front lamps installed to the machine, and set up
additional lighting in the work area if necessary.
Stop operations if the visibility is poor, such as in mist, snow, rain, or dust.
When checking the mirrors installed to the machine, remove all dirt and adjust the angle of the mirror to ensure
good visibility.
If the machine is equipped with cameras, clean off any dirt from the lens and make sure that the camera gives
a clear view.
CHECKING SIGNS AND SIGNALMAN'S SIGNALS
Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if
necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.
Only one signalman should give signals.
Make sure that all workers understand the meaning of all signals and signs before starting work.
BEWARE OF ASBESTOS DUST
Asbestos dust in the air can cause lung cancer if it is inhaled. There is danger of inhaling asbestos when working
on jobsites handling demolition work or work handling industrial waste. Always observe the following.
Spray water to keep down the dust.
Do not use compressed air.
If there is danger that there may be asbestos dust in the air,
always operate the machine from an upwind position, and make
sure that all workers operate on the upwind side.
All workers should use anti-dust masks.
Do not allow other persons to approach during the operation.
Always observe the rules and regulations for the work site and
environmental standards.
This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use
genuine Komatsu parts.
2 - 20
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PRECAUTIONS FOR MAINTENANCE SAFETY
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE
Always stop the machine before performing any inspection and
maintenance.
Lower the dump body completely, set dump lever (1) to the
HOLD position, lock with dump lever lock knob (2), then stop the
engine.
Set parking brake switch (3) to the PARKING position to apply
the parking brake, then put blocks in front of and behind the tires
to prevent the machine from moving.
2 - 30
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EXPLANATION OF COMPONENTS OPERATION
CONTROL LEVERS AND PEDALS
(1) Steering wheel (6) Brake pedal
(2) Retarder control lever (7) Secondary brake pedal
(3) Auto retarder (ARSC) set lever (8) Dump lever lock knob
(4) Gear shift lever (9) Dump lever
(5) Accelerator pedal
STEERING WHEEL
NOTICE
When the steering wheel is turned fully to the right or left, do not apply force to try to turn it further. The temperature of the steering
hydraulic circuit will rise and cause overheating, and this will lead to damage of steering related components.
Use this steering wheel (1) to steer the machine when traveling. When it is turned to the right, the machine turns to
the right; when it is turned to the left, the machine turns to the left.
REMARK
The steering for this machine is operated by hydraulic cylinders. When the steering wheel is turned, pressurized oil
proportional to the amount of the steering wheel is turned flows from the hydraulic equipment on the steering shaft
to the steering hydraulic cylinder, and moves the steering.
3 - 10
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EXPLANATION OF COMPONENTS OPERATION
AUTO SUSPENSION MODE PILOT LAMP
(If equipped)
This auto suspension pilot lamp (11) shows the suspension mode
being used.
With this machine, an automatic suspension system is available as
an option. This system automatically selects the hardness of the
suspension according to the condition of the machine load and the
operating condition of the brakes, steering, and dump control.
H (hard mode): When the machine is loaded, if the machine is
used under hard conditions, the suspension
becomes harder.
M (medium mode):For normal operations when the machine is
loaded, this mode is used and the suspension
is set to medium strength.
S (soft mode):When the machine is not loaded, the suspension
become softer.
AUTO RETARDER READY PILOT LAMP
This auto retarder ready pilot lamp (12) shows the auto retarder
setting. If the auto retarder (ARSC) is being actuated, the lamp
lights up to show that the auto retarder speed control is being
actuated. When the auto retarder speed control setting is
cancelled, the lamp goes out.
SPEEDOMETER
This speedometer (13) shows the travel speed of the machine.
3 - 20
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EXPLANATION OF COMPONENTS OPERATION
FILTER,OIL REPLACEMENT TIME DISPLAY
This display appears after completion of the system check. The top
line shows the ID number and the filter or oil that is approaching
time for replacement. The bottom line shows the remaining time.
The display is given for 30 seconds. At the same time, the
maintenance caution lamp flashes or lights up.
After replacing the filter or changing the oil, reset the replacement
interval. For details, see "RESET METHOD FOR FILTER,OIL
REPLACEMENT TIME (PAGE 3-33)".
Items for display of filter, oil replacement time
Replacement
Item Character display ID number
interval
Fuel prefilter 500 FUEL P FILT 41
Fuel main filter 500 FUEL FILT 03
Engine oil filter 500 ENG FILT 02
Engine oil 500 ENG OIL 01
Transmission oil filter 500 TM FILT 13
Corrosion resistor 1000 CORR RES 06
Torque converter, transmission and rear
1000 TC/TM/BKOIL 24
brake cooling oil
Brake oil filter 1000 BK OIL FILT 14
Brake cooling oil filter 1000 BK C FILT 16
Steering, hoist oil filter 2000 HYD FILT 04
Differential case oil 2000 DIFF OIL 11
Final drive oil 2000 FNL OIL 08
Steering, hoist oil 4000 HYD OIL 10
REMARK
1) Displays related to filter and oil replacement time
The top line shows the ID number and name of the item to be replaced; the bottom line displays in turn the time
remaining before replacement and the total number of times that replacement has been carried out.
The display is given for 30 seconds. When the starting switch is turned again to the ON position, the display does
not appear.
If an action code is being displayed, the message in the illustration above does not appear on the character
display.
If two or more items are displayed, each one is displayed for 3 seconds in turn.
If there are more than 10 items, all the items are displayed once each.
The display appears 30 hours before the filter or oil replacement time.
When the replacement time approaches, the maintenance caution lamp flashes; when the replacement time is
exceeded, it lights up.
3 - 30
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EXPLANATION OF COMPONENTS OPERATION
STARTING SWITCH
Use this starting switch (9) to start or stop the engine.
When the key is inserted in the starting switch, it can be turned to
the following positions.
OFF position:
In this position, the key can be inserted or removed. When it is
turned to the OFF position, all the electrical systems on the
machine are turned off and the engine stops.
ON position:
When the key is at the ON position, electricity flows in the charging
circuit and lamp circuits. Keep the key at the ON position when the
engine is running.
When turning the starting switch key to the ON and OFF positions, if the key is held between the ON and OFF
positions, the controller may detect a problem. If this happens, turn the switch to the OFF position, then turn it again
to the ON position in the same way as for normal operations.
In cold weather, if the key is turned to the ON position, depending on the engine water temperature, the engine
preheater may be actuated and the machine monitor preheating pilot lamp may light up. After completion of
preheating, the preheating pilot lamp will go out. When it goes out, turn the key to the START position to start the
engine.
START position:
Turn the key to this position to start the engine. When the key is turned to the START position, the starting motor
is actuated and starts cranking. When the engine starts, release the key. The key will return automatically to the ON
position.
POWER MODE SELECTOR SWITCH
Use this power mode selector switch (10) to set the travel system
to the most economical travel setting to match the operating
conditions.
There are two power modes.
(A): Economy mode (operations on level ground)
Use this position when operating on level ground where high
output power is not needed and when the emphasis is on
reducing fuel consumption.
(B): High power mode (general operations)
Use this position for normal operating conditions.
When portion (A) of the switch is pressed, the mode switches to the economy mode, the economy mode pilot lamp
on the machine monitor lights up, and the monitor lamp inside the switch also lights up.
When portion (B) of the switch is pressed, the mode switches to the high power mode, the power mode pilot lamp
on the machine monitor lights up, and the monitor lamp inside the switch goes out.
When the head lamps are turned on, the icon inside portion (B) of the power mode selector switch lights up.
3 - 40
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EXPLANATION OF COMPONENTS OPERATION
Fuse box BT4
No. Capacity Name of circuit
(41) 10A Room lamp
(42) 10A Engine preheat power
(43) 20A Yellow rotating lamp (if equipped)
(44) 20A Side lamp (if equipped)
Electric operator's seat heater (if equipped),
(45) 20A
Air suspension seat (if equipped)
(46) 10A Payload external display lamp (if equipped)
(47) 10A Tachograph (if equipped), cigarette lighter
(48) 20A Air conditioner
(49) 20A Spare
(50) 20A Front wiper
Fuse box V (Inside battery box)
No. Capacity Name of circuit
(51) 10A Power source for emergency system
(52) 120A Power source for engine heater
3 - 50
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EXPLANATION OF COMPONENTS OPERATION
TEMPERATURE CONTROL SWITCH
Use this switch (7) to adjust the temperature of the air blowing out from the vents. The adjustment can be made to
8 levels from low temperature to high temperature.
The temperature of the air blowing out from the vents is displayed on temperature bar (D) on the monitor. The lower
the number of segments lighted up on the bar, the lower the temperature is.
Press the > switch to raise the temperature; press the < switch to lower the temperature.
Even when the starting switch is turned OFF, the settings of each mode are retained in memory. However, in the
following cases, the settings must be made again.
When there has been abnormal interference from outside
METHOD OF OPERATION
With the FACE vents, it is possible to adjust the direction of the air flow and to turn it on or off.
However, do not set to the FACE mode with the vents closed.
COOLING
1. Press ON/OFF switch (1) to turn on the air conditioner power.
2. Press fan switch (2) to set the air flow to the maximum.
3. Press temperature control switch (3) to lower the temperature.
4. Press air conditioner switch (4) to set to COOLING.
5. Press RECIRC/FRESH selector switch (5) to set to RECIRC.
6. Press mode selector switch (6) to set the vents to FACE.
7. When the temperature inside the cab goes down, set to the
desired temperature and air flow.
NOTICE
If operations are continued for a long time with the air conditioner set to the lowest temperature and minimum air flow, there is
danger that the receiver drier may freeze.
If it freezes and no cold air comes out, stop using the cooling, and set to a higher temperature and the maximum air flow. Run for
a short time under these conditions, then return to the cooling operation.
HEATING
1. Press ON/OFF switch (1) to turn on the air conditioner power.
2. Press fan switch (2) to set the air flow to the maximum.
3. Press temperature control switch (3) to raise the temperature.
4. Press RECIRC/FRESH selector switch (4) to set to FRESH.
5. Press mode selector switch (5) to set the vents to FOOT.
6. When the temperature inside the cab goes up, set to the
desired temperature and air flow.
REMARK
The heating uses the heat from the engine cooling water, so it is effective only when the cooling water is hot.
3 - 60
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OPERATION OPERATION
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
WARNING
Immediately after the engine is stopped, the oil and parts are at high temperature, so there is danger of suffering burns during the
operation. Wait for the temperature to go down before starting the operation.
Before starting the engine, check the level of the oil in the engine
oil pan with dipstick (G).
1. Take out the dipstick (G) and wipe off the oil with cloth.
2. Insert dipstick (G) fully into the dipstick guide, then pull it out
again.
When inserting the dipstick, insert it so that the "ENGINE
STOPPED" mark on the dipstick is facing the engine.
3. The oil level should be between the H and L marks on the
ENGINE STOPPED side of dipstick (G).
4. If the oil is below the "L" mark, add oil through oil filler port (F).
If the oil is above the "H" mark, set a container in position to
catch the oil, remove drain plug (1), then loosen drain valve (2)
to drain the excess oil into the container. After draining the
excess oil, check the oil level in the engine oil pan again.
REMARK
If the oil level in the engine oil pan is checked immediately after
the engine is stopped, the oil in the oil line has probably not
returned to the oil pan, so wait for at least 15 minutes before
checking the oil level.
The dipstick is marked on one side with "ENGINE STOPPED"
for checking the oil level when the engine is stopped and on the
other side with "ENGINE IDLING" for checking the oil level
when the engine is idling. However, for this check, stop the
engine and use the side with the "ENGINE STOPPED" mark.
It is also possible to carry out the check with the engine idling, but in that case, always do as follows.
Check that the engine water temperature is in the white range.
Use the ENGINE IDLING side of the dipstick.
Remove the oil filler cap before carrying out the inspection.
5. If the oil level in the engine oil pan is correct, tighten the handle on the oil filler cap securely.
3 - 70
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OPERATION OPERATION
WARNING
When standing up from the operator's seat, place the gear shift lever in N position and set the parking brake switch to PARKING
position. Place the dump control lever at HOLD and lock with the lock knob, then stop the engine. If you touch the gear shift lever
or dump control lever, the machine may suddenly move and cause serious personal injury.
FORE-AND-AFT ADJUSTMENT OF OPERATOR'S SEAT
1. Pull up lever (1) and slide the operator's seat to the front or
rear.
2. Set the seat to the desired position, then release lever (1).
Fore-and-aft adjustment: 180 mm (10 mm x 18 stages)
ADJUSTING OPERATOR'S SEAT ANGLE
BACKWARD
1. Pull up lever (2) and apply your weight to the rear of the seat
cushion. The seat cushion will tilt to the rear.
2. Set the seat cushion to the desired angle, then release lever
(2).
FORWARD
1. Push down lever (2) and apply your weight to the front of the seat cushion. The seat cushion will tilt to the front.
2. Set the seat cushion to the desired angle, then release lever (2).
Amount of adjustment: 13 degrees
3 - 80
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OPERATION OPERATION
2. Turn the key of starting switch (1) to the START position.
The engine will start.
REMARK
When the engine is started, the machine monitor may flash while
the starting motor is rotating, but if it goes out after the engine
starts, there is no problem.
3. When the engine starts, release the key in starting switch (1).
The key will return automatically to the ON position.
REMARK
If the engine does not start, turn the key in starting switch (1) to
the OFF position, then turn it back to the ON position. The
preheating will automatically start again according to the engine
water temperature.
Immediately after the engine is started, the turbo protect
function is actuated to prevent the engine speed from rising
above 1000 rpm even when the accelerator pedal is depressed.
AUTOMATIC WARMING-UP OPERATION
After the engine starts, if the engine water temperature is low (below 50°C (122°F)), the warming-up operation
(engine speed: 945 rpm) is automatically carried out. When the water temperature goes above 50°C (122°F), the
warming-up operation is canceled.
3 - 90
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OPERATION OPERATION
TRAVELING DOWNHILL
WARNING
Always keep to the permitted speed when going downhill using the retarder. If the permitted speed is exceeded, the brakes will
overheat and will make it impossible to provide the braking force. This may lead to serious personal injury. For details of the
maximum permitted speed, see the brake performance graph for the downhill distance and grade.
Operate the retarder control lever slowly. If it is operated suddenly, a sudden braking force will be generated. As a result the
tires may slip and the machine may turn in one direction or tip over, and this may lead to serious personal injury.
Do not move the gear shift lever to the N position when the machine is traveling or when it is traveling down a slope. Always
place the transmission in gear before traveling.
· If the transmission is in Neutral, the engine cannot provide any braking effect and the steering wheel will become eavier.
In addition, there will be lack of cooling oil for the retarder, so there is danger that it will overheat or that the actuation of the
brake will be poor.
· There may also be damage to the transmission or other parts of the power train, and there is danger of unexpected accidents.
For the maximum permissible speed when traveling downhill using the retarder, see the brake performance graph
for the downhill distance and graph. If the machine continues to travel downhill at a speed greater than the
maximum permissible speed on the brake performance graph, there is danger that the retarder will overheat, or
even fail.
If the retarder oil temperature caution lamp on the machine monitor lights up when the retarder is being used, shift
down to travel downhill. (When this happens, the central warning lamp lights up and the alarm buzzer sounds.)
If the retarder system caution lamp does not go out even when the transmission is shifted down, stop the machine
immediately, set the shift lever to the N position, run the engine at 2000 rpm, and wait for the retarder system
caution lamp to go out.
If the retarder loses its effect when it is used for traveling downhill, do as follows.
1. Release the retarder control lever completely, then operate the retarder control lever again.
2. If the retarder has no braking effect even when the retarder control lever is operated again, release the retarder
control lever completely, depress the brake pedal, stop the machine on flat ground, put blocks under the tires,
then ask your Komatsu distributor to carry out repairs.
If the retarder control lever is operated when traveling downhill, the transmission can be shifted down sooner than
with normal deceleration. It is also possible to travel without shifting up.
When traveling downhill, do not use the foot brake except in an emergency. Using the foot brake will cause
overheating of the front brake and reduce the life.
REMARK
Do not accelerate or shift up when using the retarder. The engine speed will rise and this may cause the alarm
buzzer to sound and the central warning lamp to flash.
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OPERATION OPERATION
Brake performance
[Downhill distance: 450 m (1,476 ft)]
(Tire size: 24.00R35aa)
Brake performance
[Downhill distance: 600 m (1,968 ft)]
(Tire size: 24.00R35aa)
3 - 110
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OPERATION OPERATION
TIRE T.Km.P.H.AND MAXIMUM SPEED FOR CONTINUOUS TRAVEL (REFERENCE)
HD465-7
Tire T.Km.P.H.for Max.speed for continuous travel
ambient temperature for ambient temperature (km/h)
16°C 27°C 38°C 49°C 16°C 27°C 38°C 49°C
Size 24.00-35-36PR When empty
(standard) 37 35 33 30
(front wheel standard)
structure CR 335 313 292 270
Code No. E3 When loaded
23 22 20 19
(TRA) (rear wheel standard)
Size 24.00R35aa When empty
35.1 31.4 27.8 25.9
(if equipped) (front wheel standard)
structure CR 396 355 314 293
Code No. E4 When loaded
21.5 19.3 17.0 15.9
(VRLSA) (rear wheel standard)
HD605-7
Tire T.Km.P.H.for Max.speed for continuous travel
ambient temperature for ambient temperature (km/h)
16°C 27°C 38°C 49°C 16°C 27°C 38°C 49°C
Size 24.00R35aa When empty
35.1 31.4 27.8 25.9
(standard) (front wheel standard)
structure CR 396 355 314 293
Code No. E4 When loaded
21.5 19.3 17.0 15.9
(VRLSA) (rear wheel standard)
Size 24.00-35-48PR When empty
(if equipped) 37 35 33 30
(front wheel standard)
structure CR 335 313 292 270
Code No. E3 When loaded
23 22 20 19
(TRA) (rear wheel standard)
3 - 120
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TRANSPORTATION OPERATION
LIFTING PROCEDURE
Lifting work can be carried out only with machines displaying a lifting mark.
When carrying out the lifting operation, stop the machine on firm level ground, and do as follows.
1. Start the engine, set the dump lever to the FLOAT position, and
check that the body pilot lamp goes out.
2. Stop the engine.
3. Set the parking brake switch to the PARKING position to apply
the parking brake, and check that the area around the
operator's compartment is safe.
CAUTION
Always wear leather gloves when handling lifting equipment. You will
suffer injury to your hands if you carry out the operation with bare hands.
4. Use wire rope, slings, and spreader bars to match the weight
of the machine, and fit the wire rope to the lifting points.
REMARK
The lifting positions for the machine differs according to the conditions.
Machine with body:Positions (1) and (3)
Total:4 places (2 at front, 2 at rear)
Machine without body:Positions (1) and (2)
Total:4 places (2 at front, 2 at rear)
5. Fit protector blocks at the contact points between the lifting equipment and the body to prevent damage to the
King equipment.
6. When the machine comes off the ground (raised 10 - 20 cm), stop and check carefully that the machine is
balanced and that the wire rope is not loose.
7. Raise the machine slowly, then lower it to the target point.
3 - 130
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TROUBLESHOOTING OPERATION
WHEN PARKING BRAKE HAS BEEN ACTUATED IN EMERGENCY
If the pressure in the hydraulic circuit goes down abnormally because of oil leakage or some other problem, the
parking brake is automatically applied.
If it is necessary to use the towing machine to move the failed machine, and the parking brake must be released,
use the following method to release the brake.
After moving the machine, please ask your Komatsu distributor to carry out repairs.
METHOD OF RELEASING PARKING BRAKE IN EMERGENCY
WARNING
Before releasing the parking brake, always put blocks under the tires. If the tires are not blocked, the machine may suddenly move