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Komatsu HD465-7 HD605-7 Dump Truck Full Service Repair Manual

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🏷️ Basic Information Identification Make: Komatsu Model: HD465-7 / HD605-7 Type: Dump Truck / Articulated Dump Truck Generation Series: 7 Series Codes Chassis Code Hd465: HD465-7 Chassis Code Hd605: HD605-7 👋 Introduction Market Position Segment: Heavy-duty construction and mining equipment Application: Off-highway haulage, mining, quarrying, construction site material transport Competitive Analysis Key Competitors: Caterpillar (700 series), Volvo (A-series ADTs), John Deere (E-series ADTs), Bell Equipment Key Features Durability: Built for harsh operating conditions, robust construction Performance: High payload capacity, efficient power-to-weight ratio, excellent traction Operator Comfort: Ergonomic cab design, advanced suspension for ride comfort Articulation: Articulated steering for superior maneuverability 📋 Manual Details Coverage Areas Primary Coverage: Full Service Repair and Maintenance Component Coverage: Engine, Transmission, Drivetrain, Hydraulics, Brakes, Electrical System, Chassis, Bodywork, Operator's Cab Page Count Estimated Pages: Extensive (Exact number not specified, but described as 'very detailed') Manual Type Type: Full Service Repair Manual Purpose: Repair, Maintenance, Overhaul, Troubleshooting Language Language: English Format Format: Digital (likely PDF, implied by online sales) 📖 Manual Coverage Systems Covered Powertrain: Engine (disassembly, assembly, troubleshooting), Transmission (operation, repair, adjustment), Final Drives, Differentials Hydraulic System: Steering, Hoist, Braking hydraulics, pump and valve repair, cylinder overhaul Electrical System: Wiring diagrams, component testing, diagnostic procedures, starter, alternator, battery system Chassis And Suspension: Frame, steering linkage, suspension components, wheel hubs, bearings Braking System: Air brake system components, service brakes, parking brake, retarder system (if applicable) Operator Interface: Cabin systems, controls, instrumentation, HVAC (Heating, Ventilation, Air Conditioning) Procedures Included Maintenance: Scheduled maintenance tasks, fluid change intervals, filter replacement, lubrication points Troubleshooting: Diagnostic charts, common fault diagnosis, symptom-based troubleshooting guides Repair And Overhaul: Step-by-step disassembly and reassembly procedures for major components Adjustment And Calibration: Procedures for adjusting brakes, transmission, and other systems Specification Data: Torque specifications, clearances, fluid capacities, pressure readings Technical Depth Depth: Comprehensive - Suitable for certified mechanics and advanced DIY users Detail Level: Detailed diagrams, exploded views, component identification, and overhaul instructions 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Searchable text content Print Quality Resolution: High-resolution for clear viewing of diagrams and text Diagrams: Clear, legible schematics and illustrations Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Hd465 Engine Manufacturer: Komatsu Engine Model: S6D140E-3 Engine Type: Turbocharged, Aftercooled, Direct Injection, Diesel Displacement: 15.24 L (930 cu. in.) Bore X Stroke: 140 mm x 152 mm (5.51 in x 5.98 in) Rated Power Net Iso: 331 kW (444 HP) @ 2000 RPM Maximum Torque Net: 1853 Nm (1366 lb-ft) @ 1400 RPM Emission Certification: EPA Tier 3 / EU Stage IIIA Compliant Primary Engine Hd605 Engine Manufacturer: Cummins Engine Model: QSM11 Engine Type: Turbocharged, Aftercooled, High Pressure Common Rail, Diesel Displacement: 10.8 L (660 cu. in.) Rated Power Net Iso: 260 kW (349 HP) @ 2100 RPM Maximum Torque Net: 1444 Nm (1065 lb-ft) @ 1400 RPM Emission Certification: EPA Tier 3 / EU Stage IIIA Compliant Fuel System Fuel Type: Diesel Fuel Tank Capacity: Approximately 400-450 Liters (105-119 Gallons) Fuel Filter Type: High-efficiency diesel particulate filter (DPF) with regeneration system (if applicable for later models/regions) 🔧 Transmission Standard Transmission Type: Planetary Gear Type, Electronically Controlled Full Automatic Transmission Number Of Speeds: 6 Forward / 1 Reverse (typically) Transmission Control: Komatsu Traction Control System (KTCS) integrated Transmission Fluid Type: Komatsu genuine oil or equivalent (e.g., SAE 80W-90 gear oil or specific ATF depending on type) Features Kickdown Prevention: Automatic downshift prevention for enhanced safety and component protection Automatic Mode: Selectable auto shift modes (e.g., Power, Economy) or manual override 📐 Dimensions Exterior Hd465 Overall Length: Approximately 9.8 - 10.2 m (32.2 - 33.5 ft) Overall Width: Approximately 3.0 - 3.2 m (9.8 - 10.5 ft) Overall Height: Approximately 3.5 - 3.7 m (11.5 - 12.1 ft) Wheelbase: Approximately 4.5 - 4.7 m (14.8 - 15.4 ft) Ground Clearance: Approximately 0.5 m (1.6 ft) Exterior Hd605 Overall Length: Approximately 10.0 - 10.4 m (32.8 - 34.1 ft) Overall Width: Approximately 3.1 - 3.3 m (10.2 - 10.8 ft) Overall Height: Approximately 3.6 - 3.8 m (11.8 - 12.5 ft) Wheelbase: Approximately 4.6 - 4.8 m (15.1 - 15.7 ft) Ground Clearance: Approximately 0.5 m (1.6 ft) Cargo Body Capacity SAE Heaped Hd465: 24.2 m³ (31.7 cu. yd.) Payload Capacity Hd465: 41,000 kg (90,390 lbs) Body Capacity SAE Heaped Hd605: 27.0 m³ (35.3 cu. yd.) Payload Capacity Hd605: 45,000 kg (99,208 lbs) Weights Operating Weight Hd465: Approximately 31,000 - 33,000 kg (68,343 - 72,752 lbs) Gross Vehicle Weight Hd465: Approximately 72,000 kg (158,730 lbs) Operating Weight Hd605: Approximately 33,000 - 35,000 kg (72,752 - 77,162 lbs) Gross Vehicle Weight Hd605: Approximately 78,000 kg (171,962 lbs) 🛡️ Safety Features Ratings Rollover Protection: ROPS (Roll-Over Protective Structure) certified cab Fall Protection: FOPS (Falling Object Protective Structure) certified cab Active Features Braking System: Service Brakes: Fully hydraulic dual-circuit,...
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Komatsu HD465-7 HD605-7 Dump Truck Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Komatsu
Model:
HD465-7 / HD605-7
Type:
Dump Truck / Articulated Dump Truck
Generation
Series:
7 Series
Codes
Chassis Code Hd465:
HD465-7
Chassis Code Hd605:
HD605-7
👋 Introduction
Market Position
Segment:
Heavy-duty construction and mining equipment
Application:
Off-highway haulage, mining, quarrying, construction site material transport
Competitive Analysis
Key Competitors:
Caterpillar (700 series), Volvo (A-series ADTs), John Deere (E-series ADTs), Bell Equipment
Key Features
Durability:
Built for harsh operating conditions, robust construction
Performance:
High payload capacity, efficient power-to-weight ratio, excellent traction
Operator Comfort:
Ergonomic cab design, advanced suspension for ride comfort
Articulation:
Articulated steering for superior maneuverability
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Service Repair and Maintenance
Component Coverage:
Engine, Transmission, Drivetrain, Hydraulics, Brakes, Electrical System, Chassis, Bodywork, Operator's Cab
Page Count
Estimated Pages:
Extensive (Exact number not specified, but described as 'very detailed')
Manual Type
Type:
Full Service Repair Manual
Purpose:
Repair, Maintenance, Overhaul, Troubleshooting
Language
Language:
English
Format
Format:
Digital (likely PDF, implied by online sales)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (disassembly, assembly, troubleshooting), Transmission (operation, repair, adjustment), Final Drives, Differentials
Hydraulic System:
Steering, Hoist, Braking hydraulics, pump and valve repair, cylinder overhaul
Electrical System:
Wiring diagrams, component testing, diagnostic procedures, starter, alternator, battery system
Chassis And Suspension:
Frame, steering linkage, suspension components, wheel hubs, bearings
Braking System:
Air brake system components, service brakes, parking brake, retarder system (if applicable)
Operator Interface:
Cabin systems, controls, instrumentation, HVAC (Heating, Ventilation, Air Conditioning)
Procedures Included
Maintenance:
Scheduled maintenance tasks, fluid change intervals, filter replacement, lubrication points
Troubleshooting:
Diagnostic charts, common fault diagnosis, symptom-based troubleshooting guides
Repair And Overhaul:
Step-by-step disassembly and reassembly procedures for major components
Adjustment And Calibration:
Procedures for adjusting brakes, transmission, and other systems
Specification Data:
Torque specifications, clearances, fluid capacities, pressure readings
Technical Depth
Depth:
Comprehensive - Suitable for certified mechanics and advanced DIY users
Detail Level:
Detailed diagrams, exploded views, component identification, and overhaul instructions
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchability:
Searchable text content
Print Quality
Resolution:
High-resolution for clear viewing of diagrams and text
Diagrams:
Clear, legible schematics and illustrations
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine Hd465
Engine Manufacturer:
Komatsu
Engine Model:
S6D140E-3
Engine Type:
Turbocharged, Aftercooled, Direct Injection, Diesel
Displacement:
15.24 L (930 cu. in.)
Bore X Stroke:
140 mm x 152 mm (5.51 in x 5.98 in)
Rated Power Net Iso:
331 kW (444 HP) @ 2000 RPM
Maximum Torque Net:
1853 Nm (1366 lb-ft) @ 1400 RPM
Emission Certification:
EPA Tier 3 / EU Stage IIIA Compliant
Primary Engine Hd605
Engine Manufacturer:
Cummins
Engine Model:
QSM11
Engine Type:
Turbocharged, Aftercooled, High Pressure Common Rail, Diesel
Displacement:
10.8 L (660 cu. in.)
Rated Power Net Iso:
260 kW (349 HP) @ 2100 RPM
Maximum Torque Net:
1444 Nm (1065 lb-ft) @ 1400 RPM
Emission Certification:
EPA Tier 3 / EU Stage IIIA Compliant
Fuel System
Fuel Type:
Diesel
Fuel Tank Capacity:
Approximately 400-450 Liters (105-119 Gallons)
Fuel Filter Type:
High-efficiency diesel particulate filter (DPF) with regeneration system (if applicable for later models/regions)
🔧 Transmission
Standard
Transmission Type:
Planetary Gear Type, Electronically Controlled Full Automatic Transmission
Number Of Speeds:
6 Forward / 1 Reverse (typically)
Transmission Control:
Komatsu Traction Control System (KTCS) integrated
Transmission Fluid Type:
Komatsu genuine oil or equivalent (e.g., SAE 80W-90 gear oil or specific ATF depending on type)
Features
Kickdown Prevention:
Automatic downshift prevention for enhanced safety and component protection
Automatic Mode:
Selectable auto shift modes (e.g., Power, Economy) or manual override
📐 Dimensions
Exterior Hd465
Overall Length:
Approximately 9.8 - 10.2 m (32.2 - 33.5 ft)
Overall Width:
Approximately 3.0 - 3.2 m (9.8 - 10.5 ft)
Overall Height:
Approximately 3.5 - 3.7 m (11.5 - 12.1 ft)
Wheelbase:
Approximately 4.5 - 4.7 m (14.8 - 15.4 ft)
Ground Clearance:
Approximately 0.5 m (1.6 ft)
Exterior Hd605
Overall Length:
Approximately 10.0 - 10.4 m (32.8 - 34.1 ft)
Overall Width:
Approximately 3.1 - 3.3 m (10.2 - 10.8 ft)
Overall Height:
Approximately 3.6 - 3.8 m (11.8 - 12.5 ft)
Wheelbase:
Approximately 4.6 - 4.8 m (15.1 - 15.7 ft)
Ground Clearance:
Approximately 0.5 m (1.6 ft)
Cargo
Body Capacity SAE Heaped Hd465:
24.2 m³ (31.7 cu. yd.)
Payload Capacity Hd465:
41,000 kg (90,390 lbs)
Body Capacity SAE Heaped Hd605:
27.0 m³ (35.3 cu. yd.)
Payload Capacity Hd605:
45,000 kg (99,208 lbs)
Weights
Operating Weight Hd465:
Approximately 31,000 - 33,000 kg (68,343 - 72,752 lbs)
Gross Vehicle Weight Hd465:
Approximately 72,000 kg (158,730 lbs)
Operating Weight Hd605:
Approximately 33,000 - 35,000 kg (72,752 - 77,162 lbs)
Gross Vehicle Weight Hd605:
Approximately 78,000 kg (171,962 lbs)
🛡️ Safety Features
Ratings
Rollover Protection:
ROPS (Roll-Over Protective Structure) certified cab
Fall Protection:
FOPS (Falling Object Protective Structure) certified cab
Active Features
Braking System:
Service Brakes: Fully hydraulic dual-circuit, oil-immersed multiple-disc brakes on all wheels. Parking Brake: Spring-applied, hydraulically released parking brake.
Retarder:
Engine brake or hydraulic retarder for controlled downhill descent
Traction Control:
Komatsu Traction Control System (KTCS) for improved grip on slippery surfaces
Visibility:
Large cab windows, optional rearview camera system, powerful work lights
Passive Features
Operator Restraints:
Seat belt
Emergency Stop:
Emergency engine stop button
Fire Suppression:
Optional fire suppression systems available
💡 Technology Features
Infotainment
Infotainment System:
Basic operator interface; primary focus is machine function and diagnostics, not entertainment.
Driver Assistance
Telematics:
Komatsu KOMTRAX™ (Komatsu Tracking System) for remote monitoring of machine location, status, and performance data, including engine hours, fuel consumption, and diagnostic codes.
Diagnostic Tools:
Onboard diagnostics with detailed error codes and troubleshooting guidance accessible via the cab display or external diagnostic tools.
Connectivity
Machine Monitoring:
Integrated sensors and electronic control units (ECUs) for real-time monitoring of engine, transmission, hydraulic, and brake systems.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 250-500 operating hours, depending on operating conditions and oil analysis
Engine Oil Filter Change:
Replace with every engine oil change
Fuel Filter Change:
Every 500 operating hours or as recommended by oil analysis
Hydraulic Oil Filter Change:
Typically every 1000-2000 operating hours or as per Komatsu recommendations
Transmission Oil Change:
Typically every 2000-4000 operating hours or based on oil analysis
Fluid Specifications
Engine Oil Hd465:
API CI-4 or higher, SAE 15W-40 (or viscosity recommended for ambient temperature)
Hydraulic Oil:
Komatsu Genuine hydraulic oil or equivalent (e.g., ISO VG 46)
Coolant:
Komatsu Super Long Life Coolant (SLLC) or equivalent (50% ethylene glycol, 50% deionized water)
Known Issues
Common Wear Items:
Brake discs and pads, hydraulic hoses and seals, suspension bushings, engine mounts, wear plates in dump body.
Electrical Gremlins:
Sensors, wiring harness issues in harsh environments, common in many heavy equipment models.
Transmission Logic:
Potential issues with transmission control modules or solenoids requiring diagnostic attention. Early electronic control system nuances.
Cooling System:
Overheating can occur if cooling system is not properly maintained, including radiator cleaning and coolant level checks.
📚 Vehicle History
Brand Heritage
Brand:
Komatsu Ltd. is a Japanese multinational corporation that manufactures construction, mining, and industrial equipment.
Founding Year:
1921
Model Evolution
Series Introduction:
The HD465-7 and HD605-7 represent updates to Komatsu's line of large rigid frame and articulated dump trucks, respectively, incorporating advancements in engine technology, electronics, and operator ergonomics.
Previous Models:
Predecessors likely include models such as the HD400, HD450, HD600 series, and earlier iterations of their dump truck line.
Production
Production Period:
The '7' series typically corresponds to models produced from the mid-2000s to the early-mid 2010s, preceding the current '8' series (e.g., HD465-8, HD605-8).
Manufacturing Locations:
Komatsu manufactures heavy equipment globally, including North America, Europe, and Asia. Specific production sites for these models may vary.
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the HD465-7/HD605-7 models are not typically publicized in the same way as consumer vehicles, Komatsu equipment is consistently recognized for reliability, durability, and performance in the heavy industry sector.
Ratings
Reliability:
Komatsu is highly regarded for its equipment's longevity and dependability in demanding applications.
Certifications
Manufacturing Standards:
ISO 9001 and ISO 14001 certified manufacturing processes.
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