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HD405-6
Komatsu HD405-6 User Manual
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MAINTENANCE
RECOMMENDED FUEL, COOLANT, AND LUBRICANT
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL
When
using
commercially
available
oils
other
than
Komatsu
genuine
oil,
or
when
checking
the
latest
specifications,
refer
to
the
Komatsu
web
page
or
consult
your
Komatsu
distributor.
4 - 15
195
197
Table of Contents
Table of Contents
11
Foreword
3
Safety Information
6
Intended Use
8
Directions of Machine
8
Location of Plates, Table to Enter Serial No. and Distributor
9
Engine Serial No. Plate Position
9
Service Meter Position
10
Table of Contents
11
Safety
17
Safety Labels
19
Position for Attaching Safety Labels
19
Safety Labels
20
General Precautions
25
Safety Rules
25
Clothing and Personal Protective Items
25
Fire Extinguisher and First Aid Kit
25
Safety Features
26
Keep Machine Clean
26
Inside Operator's Compartment
26
Always Apply Lock When Leaving Operator's Seat
26
Handrails and Steps
27
Mounting and Dismounting
27
Crushing or Cutting Prevention
27
Prevention of Burns
28
Fire Prevention
28
Action if Fire Occurs
29
Window Washer Liquid
29
PRECAUTIONS WHEN USING ROPS (Roll over Protective Structure)
29
Precautions for Attachments, Options
30
Unauthorized Modification
30
Safety at Worksite
30
Working on Loose Ground
30
Do Not Go Close to High-Voltage Cables
31
Ensure Good Visibility
31
Precautions Related to Ventilation of Exhaust Gas
32
Checking Signalman's Signals and Signs
32
Emergency Escape from Operator's Cab
32
Asbestos Dust Hazard Prevention
32
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
Every 4000 Hours Service
257
Check Water Pump
257
Check Air Compressor
257
Check Fan Pulley and Tension Pulley
257
Check Vibration Damper
257
Check Injector (All Areas Except EPA Exhaust Gas Regulation Areas)
257
Replace Injector Assembly ( EPA Exhaust Gas Regulation Areas Only)
257
Checking for Looseness of High-Pressure Clamp, Hardening of Rubber
257
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
Every 8000 Hours Service
259
Replace Injector Nozzle Tip (All Areas Except EPA Exhaust Gas Regulation Areas)
259
Replace High-Pressure Piping Clamp
259
Replace Fuel Spray Prevention Cap
259
Every 15000 Hours Service
260
Check, Replace Steering a Arm Mounting Bolt
260
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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Komatsu HD405-6 Specifications
General
Brand
Komatsu
Model
HD405-6
Category
Trucks
Language
English
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