KOMATSU HD785-5 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:4254 & UP) KOMATSU HD785-5 – PDF DOWNLOAD

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KOMATSU HD785-5 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:4254 & UP) KOMATSU HD785-5

KOMATSU HD785-5 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:4254 & UP) KOMATSU HD785-5 – PDF DOWNLOAD:

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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

PLEASE NOTE:

⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected] manual.