KOMATSU HD785-5 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:4085 & UP) KOMATSU HD785-5
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KOMATSU HD785-5 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:4085 & UP) KOMATSU HD785-5
- This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor.
- if you sell the machine, be sure to give this manual to the new owners.
- Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.
- This manual may contain attachments and optional equipment that are not available in your area. Consult Komatsu or your Komatsu distributor for those items you may require.
TABLE OF CONTENTS:
KOMATSU HD785-5 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:4085 & UP) KOMATSU HD785-5
COVER........................................................................................... 1 1.FOREWORD...................................................................................... 2 2.SAFETY INFORMATION............................................................................ 5 3.INTRODUCTION.................................................................................. 6 3.1 FEATURES................................................................................ 6 3.2 BREAKING IN THE MACHINE................................................................. 6 4.LOCATION OF PLATES,TABLE TO ENTER SERIAL NUMBER AND DISTRIBUTOR............................... 7 4.1 MACHINE SERIAL NO.PLATE POSITION........................................................ 7 4.2 ENGINE SERIAL NO.PLATE POSITION......................................................... 7 4.3 TABEL TO ENTER SERIAL NO.AND DISTRIBUTOR................................................ 7 5.CONTENTS...................................................................................... 8 SAFETY.......................................................................................... 12 6.GENERAL PRECAUTIONS....................................................................... 13 7.PRECAUTIONS DURING OPERATION.............................................................. 19 7.1 BEFORE STARTING ENGINE.............................................................. 19 7.2 AFTER STARTING ENGINE............................................................... 21 7.3 SHIPPING............................................................................ 29 7.4 BATTERY............................................................................. 30 7.5 TOWING.............................................................................. 32 8.PRECAUTIONS FOR MAINTENANCE............................................................... 33 8.1 BEFORE CARRYING OUT MAINTENANCE..................................................... 33 8.2 DURING MAINTENANCE.................................................................. 39 8.3 TIRES............................................................................... 46 9.POSITION FOR ATTACHING SAFETY LABELS...................................................... 48 9.1 POSITION FOR ATTACHING SAFETY LABELS................................................ 48 OPERATION....................................................................................... 52 10.GENERAL VIEW............................................................................. 53 10.1 GENERAL VIEW OF MACHINE............................................................ 53 10.2 GENERAL VIEW OF CONTROLS AND GAUGES................................................ 54 11.EXPLANATION OF COMPONENTS................................................................ 55 11.1 MACHINE MONITOR.................................................................... 55 11.2 SWITCHES........................................................................... 69 11.3 CONTROL LEVERS AND PEDALS.......................................................... 76 11.4 MECHATRONICS EQUIPMENT CONTROLLER.................................................. 80 11.5 SAFETY PIN......................................................................... 80 11.6 DUST INDICATOR..................................................................... 81 11.7 FUSES.............................................................................. 81 11.8 LOCATION OF MANUAL BOX............................................................. 82 11.9 CAR STEREO......................................................................... 83 11.10 AIR CONDITIONER................................................................... 89 11.11 CAR HEATER........................................................................ 93 11.12 LOCATION OF FIRE EXTINGUISHER..................................................... 94 11.13 LOCATION OF FIRST AID BOX......................................................... 94 12.OPERATION................................................................................ 95 12.1 CHECK BEFORE STARTING ENGINE....................................................... 95 12.2 STARTING ENGINE....................................................................112 12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE........................................114 12.4 MOVING MACHINE OFF.................................................................115 12.5 SHIFTING GEAR......................................................................117 12.6 TRAVELING DOWNHILL.................................................................118 12.7 TRAVELING IN REVERSE...............................................................124 12.8 STEERING THE MACHINE...............................................................125 12.9 STOPPING THE MACHINE...............................................................126 12.10 OPERATING DUMP BODY...............................................................128 12.11 PRECAUTIONS FOR OPERATION.........................................................130 12.12 PARKING MACHINE...................................................................131 12.13 CHECKS AFTER COMPLETION OF WORK...................................................132 12.14 STOPPING ENGINE...................................................................132 12.15 CHECKS AFTER STOPPING ENGINE......................................................132 12.16 LOCKING...........................................................................133 12.17 HANDLING TIRES....................................................................134 13.DETERMINING AND MAINTAINING TRAVEL ROAD..................................................137 13.1 DETERMINING TRAVEL ROAD............................................................137 13.2 MAINTAINING TRAVEL ROAD............................................................138 14.COLD WEATHER OPERATION...................................................................139 14.1 PRECAUTIONS FOR LOW TEMPERATURE....................................................139 14.2 PRECAUTIONS AFTER COMPLETION OF WORK...............................................141 14.3 AFTER COLD WEATHER.................................................................141 15.LONG-TERM STORAGE........................................................................142 15.1 BEFORE STORAGE.....................................................................142 15.2 DURING STORAGE.....................................................................142 15.3 AFTER STORAGE......................................................................143 15.4 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE...............................143 16.TROUBLESHOOTING..........................................................................144 16.1 AFTER RUNNING OUT OF FUEL..........................................................144 16.2 TOWING MACHINE.....................................................................144 16.3 IF BATTERY IS DISCHARGED...........................................................147 16.4 OTHER TROBLE.......................................................................151 MAINTENANCE ....................................................................................168 17.GUIDES TO MAINTENANCE....................................................................169 18.OUTLINES OF SERVICE......................................................................172 18.1 OUTLINE OF OIL,FUEL,COOLANT........................................................172 18.2 OUTLINE OF ELECTRIC SYSTEM.........................................................175 19.WEAR PARTS LIST..........................................................................176 20.USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE......................177 21.STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...........................................181 21.1 INTRODUCTION OF NECESSARY TOOLS....................................................181 21.2 TORQUE LIST........................................................................182 22.PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................183 23.MAINTENANCE SCHEDULE CHART...............................................................185 24.SERVICE PROCEDURE........................................................................190 24.1 INITIAL 250 HOURS SERVICE..........................................................190 24.2 WHEN REQUIRED......................................................................191 24.3 CHECK BEFORE STARTING..............................................................206 24.4 EVERY 250 HOURS SERVICE............................................................216 24.5 EVERY 500 HOURS SERVICE............................................................224 24.6 EVERY 1000 HOURS SERVICE...........................................................231 24.7 EVERY 2000 HOURS SERVICE...........................................................236 24.8 EVERY 4000 HOURS SERVICE...........................................................242 24.9 EVERY 3 YEARS SERVICE..............................................................243 SPECIFICATIONS..................................................................................244 25.SPECIFICATIONS...........................................................................245 OPTIONS,ATTACHMENTS.............................................................................247 26.HANDLING PAYLOAD METER...................................................................248 26.1 NAME OF PARTS......................................................................248 26.2 EXTERNAL DISPLAY LAMPS.............................................................248 26.3 OPERATING PAYLOAD METER............................................................250 27.OPTIONS AND ATTACHMENTS..................................................................259 28.TACHOGRAPH (TCO 15-6)....................................................................260 28.1 EXPLANATION OF COMPONENTS..........................................................260 28.2 METHOD OF USING KEY................................................................262 28.3 METHOD OF USE......................................................................263 29.REVO TACHOGRAPH (TCO 15-7)...............................................................265 29.1 EXPLANATION OF COMPONENTS..........................................................265 29.2 METHOD OF USE......................................................................268 30.USING DIFFERENTIAL LOCK..................................................................270 30.1 DIFFERENTIAL LOCK PEDAL............................................................270 30.2 PRECAUTIONS AND METHOD OF USE......................................................271 31.OPERATION OF ABS AND ABS/ASR.............................................................272 31.1 EXPLANATION OF COMPONENTS..........................................................272 31.2 OPERATION METHOD...................................................................273 31.3 PRECAUTION FOR USE.................................................................274 31.4 TROUBLESHOOTING....................................................................275 32.ARSC(AUTOMATIC RETARD SPEED CONTROL).....................................................276 32.1 EXPLANATION OF COMPONENTS..........................................................276 32.2 METHOD OF OPERATION................................................................278 32.3 TROUBLESHOOTING....................................................................280 33.PMC(POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR OPERATION AND MAINTENANCE)....283 33.1 CHECK BEFORE STARTING..............................................................283 33.2 ABNORMALITY DISPLAYED DURING OPERATION.............................................283 33.3 HOW TO DOWNLOAD THE STORED DATA IN PMC AND OTHER CONTROLLERS.......................283 33.4 MESSAGE FOR OPERATION AND MAINTENANCE(MOM).........................................284 34.ASRII(AUTOMATIC SPIN REGULATOR II).......................................................289 34.1 EXPLANATION OF COMPONENTS..........................................................289 34.2 ACTUATION OF ASRII SYSTEM..........................................................290 34.3 TROUBLESHOOTING....................................................................291
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