KOMATSU HD785-5 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:4254 & UP) KOMATSU HD785-5
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KOMATSU HD785-5 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:4254 & UP) KOMATSU HD785-5
- Operators and maintenance personnel must always do as follows before beginning operation or maintenance.
- Always be sure to read and understand this manual thoroughly before performing operation and maintenance.
- Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you understand them fully.
- Keep this manual in the storage location for the operation and maintenance manual given below, and have all personnel read it periodically.
- If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor.
- If you sell the machine, be sure to give this manual to the new owners together with the machine.
- Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.
TABLE OF CONTENTS:
KOMATSU HD785-5 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:4254 & UP) KOMATSU HD785-5
COVER ......................................................................................... 1 FOREWORD ...................................................................................... 2 FOREWORD................................................................................... 3 SAFETY INFORMATION......................................................................... 6 INTENDED USE............................................................................... 8 DIRECTIONS OF MACHINE.................................................................. 8 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................. 9 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........................... 9 ENGINE SERIAL NO. PLATE POSITION....................................................... 9 SERVICE METER POSITION................................................................. 9 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................................. 10 CONTENTS................................................................................... 11 SAFETY ........................................................................................ 16 SAFETY..................................................................................... 17 SAFETY LABELS.............................................................................. 19 POSITION FOR ATTACHING SAFETY LABELS................................................... 20 SAFETY LABELS.......................................................................... 21 GENERAL PRECAUTIONS........................................................................ 26 PRECAUTIONS DURING OPERATION............................................................... 34 BEFORE STARTING ENGINE................................................................. 34 AFTER STARTING ENGINE.................................................................. 36 BATTERY................................................................................ 39 TOWING................................................................................. 41 PRECAUTIONS FOR MAINTENANCE................................................................ 42 PRECAUTIONS WITH TIRES..................................................................... 48 OPERATION ..................................................................................... 50 GENERAL VIEW............................................................................... 51 GENERAL VIEW OF MACHINE................................................................ 51 GENERAL VIEW OF CONTROLS AND GAUGES.................................................... 52 EXPLANATION OF COMPONENTS.................................................................. 54 MACHINE MONITOR........................................................................ 54 SWITCHES............................................................................... 71 CONTROL LEVERS AND PEDALS.............................................................. 79 MECHATRONICS EQUIPMENT CONTROLLER...................................................... 83 BODY PIVOT PIN......................................................................... 84 DUST INDICATOR......................................................................... 84 FUSES.................................................................................. 85 CAR STEREO............................................................................. 87 AIR CONDITIONER........................................................................ 96 CAR HEATER.............................................................................101 LOCATION OF FIRE EXTINGUISHER..........................................................102 LOCATION OF FIRST AID KIT..............................................................102 OPERATION..................................................................................103 CHECK BEFORE STARTING ENGINE...........................................................103 STARTING ENGINE........................................................................119 OPERATIONS, CHECKS AFTER STARTING ENGINE...............................................122 STOPPING ENGINE........................................................................123 CHECKS AFTER STOPPING ENGINE...........................................................123 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING........................................124 SHIFTING GEAR..........................................................................129 TRAVELING DOWNHILL.....................................................................130 STEERING THE MACHINE...................................................................136 LOADING OPERATIONS.....................................................................136 DUMP OPERATIONS........................................................................137 PRECAUTIONS FOR OPERATION..............................................................138 PARKING MACHINE........................................................................139 CHECKS AFTER COMPLETION OF WORK........................................................140 DRAIN WATER FROM AIR TANK..............................................................140 LOCKING................................................................................141 HANDLING TIRES.........................................................................142 DETERMINING AND MAINTAINING TRAVEL ROAD....................................................144 DETERMINING TRAVEL ROAD................................................................144 MAINTAINING TRAVEL ROAD................................................................144 TRANSPORTATION.............................................................................145 PRECAUTIONS WHEN TRANSPORTING..........................................................145 STEPS FOR TRANSPORTATION...............................................................145 METHOD OF SECURING MACHINE.............................................................146 METHOD OF LIFTING MACHINE..............................................................147 COLD WEATHER OPERATION.....................................................................149 PRECAUTIONS FOR LOW TEMPERATURE........................................................149 PRECAUTIONS AFTER COMPLETION OF WORK...................................................150 AFTER COLD WEATHER.....................................................................151 LONG-TERM STORAGE..........................................................................152 BEFORE STORAGE.........................................................................152 DURING STORAGE.........................................................................152 AFTER STORAGE..........................................................................152 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE...................................152 TROUBLESHOOTING............................................................................153 AFTER RUNNING OUT OF FUEL..............................................................153 METHOD OF TOWING MACHINE...............................................................153 IF BATTERY IS DISCHARGED...............................................................158 OTHER TROUBLE..........................................................................162 MAINTENANCE ...................................................................................170 GUIDES TO MAINTENANCE......................................................................171 OUTLINE OF SERVICE.........................................................................173 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................173 OUTLINE OF ELECTRIC SYSTEM.............................................................176 WEAR PARTS.................................................................................177 WEAR PARTS LIST........................................................................177 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................178 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................179 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....180 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................181 TORQUE LIST............................................................................181 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................182 SAFETY CRITICAL PARTS..................................................................183 MAINTENANCE SCHEDULE CHART.................................................................184 MAINTENANCE SCHEDULE CHART.............................................................184 SERVICE PROCEDURE..........................................................................187 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).............................187 WHEN REQUIRED..........................................................................188 CHECK BEFORE STARTING..................................................................205 EVERY 100 HOURS SERVICE................................................................206 EVERY 250 HOURS SERVICE................................................................207 EVERY 500 HOURS SERVICE................................................................222 EVERY 1000 HOURS SERVICE...............................................................227 EVERY 2000 HOURS SERVICE...............................................................234 EVERY 4000 HOURS SERVICE...............................................................240 EVERY 15000 HOURS SERVICE..............................................................242 SPECIFICATIONS ................................................................................244 SPECIFICATIONS.............................................................................245 ATTACHMENTS, OPTIONS ..........................................................................248 HANDLING PAYLOAD METER.....................................................................249 NAME OF PARTS..........................................................................249 EXTERNAL DISPLAY LAMPS.................................................................250 OPERATING PAYLOAD METER................................................................252 TACHOGRAPH (TCO 15-6)......................................................................260 EXPLANATION OF COMPONENTS..............................................................260 METHOD OF USING KEY....................................................................262 METHOD OF USE..........................................................................262 REVO TACHOGRAPH (TCO 15-7).................................................................264 EXPLANATION OF COMPONENTS..............................................................264 METHOD OF USE..........................................................................266 USING DIFFERENTIAL LOCK....................................................................268 DIFFERENTIAL LOCK PEDAL................................................................268 PRECAUTIONS AND METHOD OF USE..........................................................269 OPERATION OF ABS AND ABS/ASR...............................................................270 EXPLANATION OF COMPONENTS..............................................................270 OPERATION METHOD.......................................................................272 PRECAUTIONS FOR USE....................................................................273 TROUBLESHOOTING........................................................................273 ARSC (AUTOMATIC RETARDER SPEED CONTROL)....................................................274 EXPLANATION OF COMPONENTS..............................................................275 METHOD OF OPERATION....................................................................277 TROUBLESHOOTING........................................................................279 PMC (POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR OPERATION AND MAINTENANCE).....282 ABNORMALITY DISPLAYED DURING OPERATION.................................................282 HOW TO DOWNLOAD THE STORED DATA IN PMC AND OTHER CONTROLLERS...........................282 MESSAGE FOR OPERATION AND MAINTENANCE (MOM)............................................283 ASR-II (AUTOMATIC SPIN REGULATOR II).......................................................288 EXPLANATION OF COMPONENTS..............................................................288 ACTUATION OF ASR-II SYSTEM.............................................................289 PRECAUTIONS WHEN USING.................................................................289 TROUBLESHOOTING........................................................................290 HANDLING AUTO-GREASING SYSTEM..............................................................292 OUTLINE OF AUTO-GREASING SYSTEM........................................................292 SETTING GREASE CAN.....................................................................293 INITIAL SETTING OF AUTO-GREASING SYSTEM................................................294 METHOD OF OPERATING AUTO-GREASING SYSTEM...............................................294 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM.........................................295 POSITION OF EACH INJECTOR..............................................................299 GREASING POINTS FOR EACH INJECTOR......................................................303 HIGH ATITUDE SPECIFICATIONS ...................................................................308 EXPLANATION OF COMPONENTS..................................................................309 SERVICE PROCEDURE..........................................................................310 CHECK BEFORE STARTING..................................................................310 EVERY 2000 HOURS SERVICE...............................................................311 INDEX..........................................................................................314
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