Komatsu D465-7 (-40C Spec) Galeo Dump Truck Operation & Maintenance Manual (7001 and up)

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the Komatsu Galeo Dump Truck HD465-7 (-40C Spec) (7001 and up). It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Komatsu HD465-7 Galeo Dump Truck (-40C Spec)
Serial Numbers : H0465-7001 and up


TABLE OF CONTENTS :

COVER
FOREWORD
- FOREWORD
- SAFETY INFORMATION
- INTENDED USE
- LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
CONTENTS
SAFETY
- SAFETY INFORMATION
- SAFETY LABELS
- GENERAL PRECAUTIONS
- PRECAUTIONS DURING OPERATION
- PRECAUTIONS FOR MAINTENANCE
- PRECAUTIONS WITH TIRES
OPERATION
- GENERAL VIEW
- EXPLANATION OF COMPONENTS
- OPERATION
- DETERMINING AND MAINTAINING TRAVEL ROAD
- TRANSPORTATION
- COLD WEATHER OPERATION
- LONG-TERM STORAGE
- TROUBLESHOOTING
MAINTENANCE
- GUIDES TO MAINTENANCE
- OUTLINE OF SERVICE
- WEAR PARTS
- RECOMMENDED FUEL, COOLANT, AND LUBRICANT
- STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
- PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
- MAINTENANCE SCHEDULE CHART
- SERVICE PROCEDURE
SPECIFICATIONS
INDEX


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : PEN00111-00
Total Pages : 258


This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance.

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COVER
FOREWORD
- FOREWORD
- SAFETY INFORMATION
- INTENDED USE
- - DIRECTIONS OF MACHINE
- LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
- - PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
- - ENGINE SERIAL NO. PLATE
- - SERVICE METER POSITION
- - TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

CONTENTS

SAFETY
- SAFETY INFORMATION
- SAFETY LABELS
- - POSITION FOR ATTACHING SAFETY LABELS
- - SAFETY LABELS
- GENERAL PRECAUTIONS
- - SAFETY RULES
- - IF PROBLEMS ARE FOUND
- - CLOTHING AND PERSONAL PROTECTIVE ITEMS
- - FIRE EXTINGUISHER AND FIRST AID KIT
- - SAFETY FEATURES
- - KEEP MACHINE CLEAN
- - INSIDE OPERATOR'S COMPARTMENT
- - ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT
- - HANDRAILS AND STEPS
- - MOUNTING AND DISMOUNTING
- - CRUSHING OR CUTTING PREVENTION
- - PREVENTION OF BURNS
- - FIRE PREVENTION
- - ACTION IF FIRE OCCURS
- - WINDOW WASHER LIQUID
- - PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)
- - PRECAUTIONS FOR ATTACHMENTS, OPTIONS
- - UNAUTHORIZED MODIFICATION
- - SAFETY AT WORKSITE
- - WORKING ON LOOSE GROUND
- - DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES
- - ENSURE GOOD VISIBILITY
- - PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS
- - CHECKING SIGNALMAN'S SIGNALS AND SIGNS
- - EMERGENCY ESCAPE FROM OPERATOR'S CAB
- - ASBESTOS DUST HAZARD PREVENTION
- PRECAUTIONS DURING OPERATION
- - STARTING ENGINE
- - - CHECKS BEFORE STARTING ENGINE, ADJUST
- - - PRECAUTIONS WHEN STARTING
- - - PRECAUTIONS IN COLD AREAS
- - OPERATION
- - - CHECKS BEFORE STARTING OPERATION
- - - PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE
- - - PRECAUTIONS WHEN TRAVELING
- - - PRECAUTIONS WHEN TRAVELING ON SLOPES
- - - PRECAUTIONS WHEN OPERATING DUMP BODY
- - - PRECAUTIONS WHEN OPERATING
- - - PRECAUTIONS FOR ACCUMULATED SNOW, ICE
- - - PARKING MACHINE
- - TRANSPORTATION
- - - LOADING AND UNLOADING
- - - SHIPPING
- - BATTERY
- - - BATTERY HAZARD PREVENTION
- - - STARTING WITH BOOSTER CABLES
- - TOWING
- - - WHEN TOWING
- PRECAUTIONS FOR MAINTENANCE
- - WARNING TAG
- - KEEP WORK PLACE CLEAN AND TIDY
- - APPOINT LEADER WHEN WORKING WITH OTHERS
- - STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE
- - TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING
- - PROPER TOOLS
- - HANDLING SUSPENSION CYLINDER, ACCUMULATOR
- - PERSONNEL
- - WORK UNDER THE MACHINE
- - NOISE
- - PRECAUTIONS WHEN USING HAMMER
- - REPAIR WELDING
- - REMOVING BATTERY TERMINAL
- - PRECAUTIONS WITH HIGH-PRESSURE OIL
- - HANDLING HIGH-PRESSURE HOSES, PIPING
- - WASTE MATERIALS
- - MAINTENANCE OF AIR CONDITIONER
- - COMPRESSED AIR
- - PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS
- PRECAUTIONS WITH TIRES
- - HANDLING TIRES
- - PRECAUTIONS WHEN STORING TIRE

OPERATION
- GENERAL VIEW
- - GENERAL VIEW OF MACHINE
- - GENERAL VIEW OF CONTROLS AND GAUGES
- EXPLANATION OF COMPONENTS
- - MACHINE MONITOR
- - OTHER FUNCTIONS OF MACHINE MONITOR
- - SWITCHES
- - CONTROL LEVERS AND PEDALS
- - MECHATRONICS EQUIPMENT CONTROLLER
- - SAFETY PIN
- - DUST INDICATOR
- - EXTERNAL ELECTRICE HEATER
- - SOCKET FOR ENGINE HEATER
- - SOCKET FOR TRANSMISSION, HYDRAULIC OIL TANK, BRAKE SUB-TANK HEATER
- - FUSES
- - CAR RADIO
- - CAR STEREO
- - AIR CONDITIONER
- OPERATION
- - CHECK BEFORE STARTING ENGINE
- - STARTING ENGINE
- - OPERATIONS, CHECKS AFTER STARTING ENGINE
- - STOPPING ENGINE
- - CONNECTING EXTERNAL POWER SOURCE
- - CHECKS AFTER STOPPING ENGINE
- - RESTARTING ENGINE
- - MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING
- - SHIFTING GEAR
- - TRAVELING DOWNHILL
- - STEERING THE MACHINE
- - LOADING OPERATIONS
- - DUMP OPERATIONS
- - PRECAUTIONS FOR OPERATION
- - PARKING MACHINE
- - CHECKS AFTER COMPLETION OF WORK
- - LOCKING
- - HANDLING TIRES
- DETERMINING AND MAINTAINING TRAVEL ROAD
- - DETERMINING TRAVEL ROAD
- - MAINTAINING TRAVEL ROAD
- TRANSPORTATION
- - PRECAUTIONS WHEN TRANSPORTING
- - STEPS FOR TRANSPORTATION
- - METHOD OF SECURING MACHINE
- - METHOD OF LIFTING MACHINE
- COLD WEATHER OPERATION
- - PRECAUTIONS FOR LOW TEMPERATURE
- - PRECAUTIONS AFTER COMPLETION OF WORK
- - AFTER COLD WEATHER
- LONG-TERM STORAGE
- - BEFORE STORAGE
- - DURING STORAGE
- - AFTER STORAGE
- - PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE
- TROUBLESHOOTING
- - AFTER RUNNING OUT OF FUEL
- - METHOD OF TOWING MACHINE
- - IF BATTERY IS DISCHARGED
- - OTHER TROUBLE

MAINTENANCE
- GUIDES TO MAINTENANCE
- OUTLINE OF SERVICE
- - HANDLING OIL, FUEL, COOLANT, AND PREFORMING OIL CLINIC
- - OUTLINE OF ELECTRIC SYSTEM
- WEAR PARTS
- - WEAR PARTS LIST
- RECOMMENDED FUEL, COOLANT, AND LUBRICANT
- - USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
- - RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL
- STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
- - TORQUE LIST
- PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
- - SAFETY CRITICAL PARTS
- MAINTENANCE SCHEDULE CHART
- - MAINTENANCE SCHEDULE CHART
- SERVICE PROCEDURE
- - INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
- - INITIAL 2000 HOURS SERVICE (ONLY AFTER THE FIRST 2000 HOURS)
- - WHEN REQUIRED
- - - CHECK, CLEAN OR REPLACE AIR CLEANER
- - - CLEAN INSIDE OF COOLING SYSTEM
- - - CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID
- - - CLEAN AIR CONDITIONER AIR FILTER
- - - CHECK REFRIGERANT (GAS) LEVEL
- - - CHECK DUMP BODY
- - - CHECK ELECTRIC INTAKE AIR HEATER
- - - CHECK LENGTH OF SUSPENSION CYLINDER, CHECK OIL LEVEL
- - - BLEED AIR FROM REAR BRAKE
- - - BLEED AIR FROM FRONT BRAKE
- - - BLEED AIR FROM PARKING BRAKE
- - - CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS
- - - CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT
- - - SELECTION AND INSPECTION OF TIRES
- - CHECK BEFORE STARTING
- - EVERY 250 HOURS SERVICE
- - - CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL
- - - CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
- - - LUBRICATION
- - - CHECK DRIVE SHAFT
- - - CHECK LEVEL OF BATTERY ELECTROLYTE
- - - CHECK ALTERNATOR BELT TENSION, ADJUST
- - - CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST
- - - CLEAN BREATHERS
- - - CHECK FRAME
- - - CHECK BRAKING CAPACITY OF FOOT BRAKE
- - - CHECK BRAKING CAPACITY OF RETARDER BRAKE
- - - CHECK BRAKING CAPACITY OF PARKING BRAKE
- - - CHECK, CLEAN AUTOMATIC SUSPENSION
- - EVERY 500 HOURS SERVICE
- - - CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
- - - REPLACE FUEL FILTER CARTRIDGE
- - - CLEAN FUEL TANK STRAINER
- - - REPLACE TRANSMISSION OIL FILTER ELEMENT
- - - CHECK WEAR OF FRONT DISC BRAKE PADS
- - - CHECK FAN BELT FOR WEAR AND REPLACE
- - EVERY 1000 HOURS SERVICE
- - - REPLACE CORROSION RESISTOR CARTRIDGE
- - - CHANGE OIL IN TRANSMISSION CASE, CLEAN TRANSMISSION CASE STRAINER
- - - REPLACE TRANSMISSION AND REAR BRAKE COOLING OIL FILTER ELEMENT
- - - CHANGE OIL IN BRAKE CONTROL OIL TANK
- - - REPLACE BRAKE OIL FILTER ELEMENT
- - - LUBRICATION
- - - CHECK WEAR OF REAR BRAKE DISC
- - - CHECK TIGHTENING PARTS OF TURBOCHARGER
- - - CHECK PLAY OF TUBOCHARGER ROTOR
- - EVERY 2000 HOURS SERVICE
- - - REPLACE STEERING, HOIST OIL TANK FILTER ELEMENT
- - - CLEAN HYDRAULIC TANK STRAINER
- - - CHANGE OIL IN FINAL DRIVE CASE
- - - CHANGE OIL IN DIFFERENTIAL CASE
- - - CLEAN DIFFERENTIAL CASE BREATHER
- - - CLEAN ENGINE BREATHER ELEMENT
- - - CHECK ALTERNATOR, STARTING MOTOR
- - - CHECK, ADJUST ENGINE VALVE CLEARANCE
- - - CLEAN, CHECK TURBOCHARGER
- - - CHECK ACCUMULATOR GAS PRESSURE
- - EVERY 4000 HOURS SERVICE
- - - CHANGE OIL IN STEERING, HOIST OIL TANK
- - - LUBRICATE DRIVE SHAFT
- - - CHECK WATER PUMP
- - - CHECK FAN PULLEY AND TENSION PULLEY
- - - CHECK VIBRATION DAMPER

SPECIFICATIONS
- SPECIFICATIONS

INDEX

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