Komatsu HD785-5LC Dump Truck Operation & Maintenance Manual A10316 & UP – PDF DOWNLOAD

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Komatsu HD785-5LC Dump Truck Operation & Maintenance Manual

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Komatsu HD785-5LC Dump Truck Operation & Maintenance Manual

Language : English
Pages : 176
Downloadable : Yes
File Type : PDF
Size: 2.54 MB
Book Code: CEAM014100

KOMATSU HD785-5LC DUMP TRUCK OPERATION & MAINTENANCE MANUAL A10316 & UP – PDF DOWNLOAD:

DESCRIPTION:

Komatsu HD785-5LC Dump Truck Operation & Maintenance Manual

FOREWORD:

This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing repairs on the truck.

• The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example, the disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck.
• Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck. This manual shows dimensioning of U.S. standard and metric (SI) units throughout.
• All references to “right,” “left,” “front,” or “rear” are made with respect to the operator’s normal seated position unless specifically stated otherwise. When assembly instructions are provided without references to specific torque values, standard torque values should be used.
• Standard torque values are shown in torque charts later in this section. Specific torques, when provided in the text, are in bold face type, such as 135 N·m (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified.
• A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating. The KOMATSU truck model designation consists of three numbers and one letter (i.e. 960E). The three numbers represent the basic truck model. The letter “E” designates an Electrical wheel motor drive system.
• The Product Identification Number (vehicle serial number) contains information which identifies several characteristics of this unit. For a more detailed explanation, refer to the Operation and Maintenance Manual. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components.
• The vehicle design and application guidelines are sensitive to the maximum GVW. GVW is total weight: empty vehicle weight + fuel & lubricants + payload. To determine the allowable payload, fill all lubricants to the proper level and fill the fuel tank of an empty truck (which includes all accessories, body liners, tailgates, etc.), and then weigh the truck. Record this value and subtract it from the GVW. The result is the allowable payload.

TABLE OF CONTENTS:

Komatsu HD785-5LC Dump Truck Operation & Maintenance Manual 

MAIN MENU.....................................................................................  0
COVER.........................................................................................  1
INTRODUCTION..................................................................................  7
	FOREWORD..................................................................................  7
	ALERTS PAGE...............................................................................  8
	TABLE OF CONTENTS.........................................................................  9
	TRUCK MODEL ILLUSTRATION.................................................................. 17
	ABOUT THIS MANUAL......................................................................... 18
	STANDARD CHARTS AND TABLES................................................................ 19
		INDEX OF TABLES....................................................................... 19
GENERAL SAFETY................................................................................ 25
	Safety Rules.............................................................................. 25
	Safety Features........................................................................... 25
	Clothing And Personal Protective Items.................................................... 25
	Unauthorized Modification................................................................. 25
	Leaving The Operator's Seat............................................................... 26
	Mounting And Dismounting.................................................................. 26
	Fire Prevention For Fuel And Oil.......................................................... 26
	Precautions When Handling At High Temperatures............................................ 27
	Asbestos Dust Hazard Prevention........................................................... 27
	Prevention Of Injury By Work Equipment.................................................... 27
	Fire Extinguisher And First Aid Kit....................................................... 27
	Precautions When Using ROPS............................................................... 28
	Precautions For Attachments............................................................... 28
	PRECAUTIONS DURING OPERATION.............................................................. 29
		BEFORE STARTING ENGINE................................................................ 29
			Safety At Worksite................................................................ 29
			Fire Prevention................................................................... 29
			In Operator's Cab................................................................. 29
			Ventilation For Enclosed Areas.................................................... 29
			In Operator's Cab - Before Starting Engine........................................ 30
			Keep Mirrors, Windows, And Lights Clean........................................... 30
		OPERATING THE MACHINE................................................................. 30
			When Starting Engine.............................................................. 30
			Truck Operation - General......................................................... 30
			Check When Traveling In Reverse................................................... 31
			Traveling......................................................................... 31
			Traveling On Slopes............................................................... 32
			Ensure Good Visibility............................................................ 32
			Operate Carefully On Snow......................................................... 32
			Avoid Damage To Dump Body......................................................... 32
			Do Not Go Close To High-voltage Cables............................................ 32
			When Dumping...................................................................... 33
			Working On Loose Ground........................................................... 33
			When Loading...................................................................... 33
			Parking The Machine............................................................... 33
		TOWING................................................................................ 33
			When Towing, Attach Cable To Hook................................................. 33
		BATTERY............................................................................... 34
			Battery Hazard Prevention......................................................... 34
			Starting With Booster Cables...................................................... 34
	PRECAUTIONS FOR MAINTENANCE............................................................... 35
		BEFORE CARRYING OUT MAINTENANCE....................................................... 35
			Warning Tag....................................................................... 35
			Proper Tools...................................................................... 35
			Periodic Replacement Of Critical Parts............................................ 35
			Stopping The Engine Before Service................................................ 35
			Securing The Dump Body............................................................ 36
		DURING MAINTENANCE.................................................................... 36
			Personnel......................................................................... 36
			Attachments....................................................................... 36
			Work Under The Machine............................................................ 36
			Keep The Machine Clean............................................................ 36
			Rules To Follow When Adding Fuel Or Oil........................................... 37
			Radiator Water Level.............................................................. 37
			Use Of Lighting................................................................... 37
			Precautions With Battery.......................................................... 37
			Handling High-Pressure Hoses...................................................... 37
			Precautions With High Pressure Oil................................................ 38
			Precautions When Carrying Out Maintenance At High Temperature Or High Pressure.... 38
			Rotating Fan And Belt............................................................. 38
			Waste Materials................................................................... 38
		TIRES................................................................................. 39
			Handling Tires.................................................................... 39
			Storing Tires After Removal....................................................... 39
	WARNINGS AND CAUTIONS..................................................................... 41
OPERATION..................................................................................... 51
	OPERATING INSTRUCTIONS.................................................................... 51
		PREPARING FOR OPERATION............................................................... 51
			SAFETY IS THINKING AHEAD.......................................................... 51
			At The Truck - Ground Level Walk Around Inspection................................ 51
		ENGINE START-UP SAFETY PRACTICES...................................................... 55
			Before Starting The Engine........................................................ 55
			Starting The Engine............................................................... 56
			Starting The Engine In Cold Weather............................................... 56
		AFTER ENGINE HAS STARTED.............................................................. 57
		MACHINE OPERATION SAFETY PRECAUTIONS.................................................. 58
		LOADING............................................................................... 58
		HAULING............................................................................... 59
		RETARDER OPERATION.................................................................... 59
			Engine Overspeed.................................................................. 60
		PASSING............................................................................... 61
		DUMPING............................................................................... 61
			To Raise dump body:............................................................... 61
			To Lower Body:.................................................................... 62
		SAFE PARKING PROCEDURES............................................................... 62
		SHUTDOWN PROCEDURE.................................................................... 62
		TOWING................................................................................ 63
		BRAKE RELEASE......................................................................... 64
			Release Of Parking Brake.......................................................... 64
			Release Of Emergency Brake........................................................ 64
	OPERATOR CAB AND CONTROLS................................................................. 65
		(1) STEERING WHEEL AND CONTROLS....................................................... 65
			(2) Tilt Lever.................................................................... 65
			(3) Turn Signal Lever Switch...................................................... 65
			(4) Horn.......................................................................... 65
			(5) Windshield Wiper / Washer Switch.............................................. 65
			(6) Headlights and Dimmer Switch.................................................. 66
			(7) Retard Control Lever.......................................................... 66
		(8) BRAKE PEDAL....................................................................... 66
		(9) THROTTLE PEDAL.................................................................... 66
		(10) CENTER CONSOLE AND CONTROLS...................................................... 66
			Transmission Range Selector (1, Figure 32-2)...................................... 66
			Shift Limiter Switch (2, Figure 32-2)............................................. 68
			Economy / Power Mode Switch (3, Figure 32-2)...................................... 68
			Emergency Steering Switch (4, Figure 32-2)........................................ 68
			Emergency Brake Lever (5, Figure 32-2)............................................ 69
			Parking Brake Valve Lever (6, Figure 32-2)........................................ 69
		ENGINE ELECTRONIC CONTROL SYSTEM...................................................... 70
			Engine Shutdown Light (Stop Engine)............................................... 70
			Engine Maintenance Light (Check Engine)........................................... 70
			Engine Maintenance Light.......................................................... 70
			Fault Check Switch (11, Figure 32-2).............................................. 71
			Fault Scroll Switch (12, Figure 32-2)............................................. 71
			Determining Fault Codes........................................................... 71
		EXITING THE DIAGNOSTICS MODE.......................................................... 71
		(11) HOIST CONTROL.................................................................... 72
			SAFETY LOCK....................................................................... 72
		ASR (AUTOMATIC SPIN REGULATOR) / ARSC (Automatic Retard Speed Control) (Optional)..... 73
		ASR SYSTEM CONTROLS................................................................... 73
			System Switch (1, Figure 32-3).................................................... 74
			ASR/ARSC Caution Lamp (6, Figure 32-3)............................................ 74
			ASR Operation Lamp (8, Figure 32-3)............................................... 74
			Central Warning Lamp (12, Figure 32-3)............................................ 74
			Retarder Control Lever (10, Figure 32-3).......................................... 74
			Accelerator Pedal (5, Figure 32-3)................................................ 74
			Brake Pedal (4, Figure 32-3)...................................................... 74
		PRECAUTIONS WHEN USING THE ASR SYSTEM................................................. 74
		ARSC SYSTEM CONTROLS.................................................................. 75
			System Switch (2, Figure 32-3).................................................... 75
			ARSC Set Lever (3, Figure 32-3)................................................... 75
			Brake Pedal (4, Figure 32-3)...................................................... 75
			Accelerator Pedal (5, Figure 32-3)................................................ 75
			ASR/ARSC Caution Lamp (6, Figure 32-3)............................................ 75
			ARSC Standby Lamp (7, Figure 32-3)................................................ 75
			Set Speed Display (9, Figure 32-3)................................................ 75
			Retarder Control Lever (10, Figure 32-3).......................................... 75
			Central Warning Lamp (12, Figure 32-3)............................................ 75
		ARSC SYSTEM ACTUATION................................................................. 76
			Traveling Again At Set Speed...................................................... 76
			Relationship With Exhaust Brake................................................... 77
			Recommended Set Speed............................................................. 77
		TROUBLESHOOTING THE ASR/ARSC SYSTEM................................................... 78
			When a problem occurs in the system............................................... 78
			Model Selection, Tire Selection, And Failure Code Display......................... 78
			Failure Codes..................................................................... 78
			Clearing The Failure Code......................................................... 80
		OPERATOR SEAT......................................................................... 81
	INSTRUMENT PANEL AND INDICATORS........................................................... 82
		WARNING & CAUTION LAMPS............................................................... 83
		GAUGE AND MONITOR PANEL............................................................... 84
			1. Air Pressure Monitor........................................................... 84
			2. Air Pressure Gauge............................................................. 84
			3. Coolant Temperature Monitor.................................................... 84
			4. Engine Cooling Water Temperature Gauge......................................... 84
			5. Torque Converter Oil Temperature Monitor....................................... 85
			6. Torque Converter Oil Temperature Gauge......................................... 85
			7. Retarder Oil Temperature Monitor............................................... 85
			8. Retarder Oil Temperature Gauge................................................. 85
			9. High Beam Pilot Lamp........................................................... 85
			10. Left Turn Signal Pilot Lamp................................................... 85
			11. Right Turn Signal Pilot Lamp.................................................. 85
			12. Speedometer................................................................... 85
			13. Tachometer.................................................................... 85
			14. Shift Limiter Pilot Lamp...................................................... 85
			15. Lock-up Pilot Lamp............................................................ 86
			16. Transmission Shift Position Pilot Lamp........................................ 86
			17. Shift Indicator............................................................... 86
			18. Engine Controller Monitor..................................................... 86
			19. Automatic Transmission Mechatronics Monitor................................... 86
			20. Other Mechatronics Monitor (OPTIONAL)......................................... 86
			21. Fuel Level Monitor............................................................ 86
			22. Fuel Gauge.................................................................... 86
			26. Service Meter................................................................. 87
			27. Service Meter Indicator....................................................... 87
			28. Odometer...................................................................... 87
			29. Power Mode Indicator.......................................................... 87
		INDICATORS AND CONTROLS PANEL......................................................... 87
			Optional Equipment................................................................ 87
			30. Coolant Level Monitor......................................................... 88
			31. Engine Oil Pressure Monitor................................................... 88
			32. Charge Monitor................................................................ 88
			33. Transmission Oil Filter Monitor............................................... 88
			34. Hazard Warning Lights......................................................... 88
			35. Front Brake On/Off Switch..................................................... 88
			36. Panel Dimmer Switch........................................................... 88
			37. AISS/Auto Switch.............................................................. 89
			38. Manual Starting Aid Switch.................................................... 89
			39. Starting Switch............................................................... 89
			40. Pilot Lamp Bulb Check Switch.................................................. 89
			41. Rear Brake Pilot Lamp......................................................... 89
			42. Body Float Caution Monitor.................................................... 89
			43. Parking Brake Monitor......................................................... 90
			44. Emergency Steering Monitor.................................................... 90
			45. Exhaust Brake (Optional)...................................................... 90
			46. Cold Start.................................................................... 90
			48. Steering Oil Temperature...................................................... 90
			50. Side Slope Warning (Optional)................................................. 90
			51. Rear Brake Caution Lamp....................................................... 90
			52. Exhaust Brake Switch (Optional)............................................... 91
			53. Fog Light Switch (Optional)................................................... 91
			54. Central Warning Lamp (Red Convex Lens)........................................ 91
		HEATER/AIR CONDITIONER CONTROLS....................................................... 92
			55. Temperature Adjustment Lever.................................................. 92
			56. Blower Switch................................................................. 92
			57. Air Selector Lever............................................................ 92
			58. Vent Selector Lever........................................................... 92
			59. Air Vent...................................................................... 93
			60. Glove Box Storage Compartment................................................. 93
			61. Air Conditioner Switch........................................................ 93
			62. Correction Code Display....................................................... 93
MAINTENANCE................................................................................... 95
	LUBRICATION AND SERVICE................................................................... 95
		10 HOUR (DAILY) INSPECTION............................................................ 97
		FLUID LEVELS & OTHER CHECKS........................................................... 97
		ENGINE................................................................................ 99
		WHEELS AND TIRES...................................................................... 99
			Tires............................................................................. 99
			WHEELS............................................................................100
		OPERATIONAL CHECKS....................................................................101
		250 HOURS SERVICE.....................................................................103
		INITIAL 250 HOURS SERVICE ONLY........................................................103
		EVERY 250 HOURS SERVICE...............................................................103
		500 HOUR SERVICE......................................................................105
		1000 HOUR SERVICE.....................................................................106
		EVERY 2000 HOUR SERVICE...............................................................107
		EVERY 5000 HOUR SERVICE...............................................................108
		HYDRAULIC TANK SERVICE................................................................109
			Filling Instructions (Hoist Oil Supply)...........................................109
			Filling Instructions (Rear Brake Cooling Oil Supply)..............................109
		HYDRAULIC FILTERS.....................................................................110
			Filter Replacement................................................................110
		HYDRAULIC TANK BREATHER...............................................................110
			Cleaning..........................................................................110
		HIGH PRESSURE HYDRAULIC FILTERS.......................................................111
			Filter Assembly Removal...........................................................111
			Filter Assembly Installation......................................................111
			Filter Element Replacement........................................................112
		TRANSMISSION FILTER...................................................................113
			Service...........................................................................113
	PERIODIC REPLACEMENT OF COMPONENT PARTS FOR SAFETY DEVICES................................114
	BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT.....................................................115
		CHECKING FRONT BRAKE PAD WEAR.........................................................115
		TESTING BRAKE PRESSURE................................................................115
		CHECKING REAR BRAKE DISC WEAR.........................................................116
		BRAKE BLEEDING........................................................................117
			Rear brakes.......................................................................117
			Front brakes......................................................................117
	PARKING BRAKE.............................................................................118
		PARKING BRAKE PAD.....................................................................118
			Inspection........................................................................118
		PARKING BRAKE ADJUSTMENT..............................................................118
			Testing...........................................................................118
			Adjusting.........................................................................118
	AUTOMATIC LUBRICATION SYSTEM..............................................................121
		OPERATION.............................................................................121
		COMPONENTS............................................................................121
		COMPONENT LOCATION....................................................................122
		GENERAL INFORMATION...................................................................124
			Lubricant Required for System.....................................................124
			Air Pressure Regulator............................................................124
			Initial Reservoir Fill............................................................124
			System Priming....................................................................124
		SYSTEM CHECKOUT.......................................................................125
			24 VDC Solid State Timer Check....................................................125
			Timer Adjustment..................................................................125
		Injectors (SL-1 Series H).............................................................126
			Injector Specifications...........................................................126
			Injector Adjustment...............................................................126
		INJECTOR OPERATION....................................................................127
			STAGE 3...........................................................................127
			STAGE 4...........................................................................127
		TROUBLESHOOTING CHART.................................................................128
MAJOR COMPONENTS AND SPECIFICATIONS...........................................................131
OPTIONAL EQUIPMENT............................................................................135
	PAYLOAD METER II™.........................................................................135
		PAYLOAD METER II ON BOARD WEIGHING SYSTEM (OBWS)......................................138
			GENERAL INFORMATION...............................................................138
				Haul Cycles...................................................................138
			LIGHTS, SWITCHES, and COMPONENTS..................................................139
			TIPS FOR OPERATION................................................................140
			EXTERNAL DISPLAY LIGHTS...........................................................140
			THEORY OF OPERATION...............................................................141
				Basic Description.............................................................141
				Inclinometer..................................................................141
				Linkage Factor................................................................141
				Gain Factor...................................................................142
				Brake Lock....................................................................142
				Sources of Error..............................................................142
				Typical Data From Service Check Mode..........................................142
				Example Calculation of Payload................................................143
				Viewing Payload Calculation Inputs............................................143
				Checking the Gain.............................................................144
				Adjusting the Gain............................................................144
			TYPES OF DATA STORED..............................................................145
				Cycle Data....................................................................145
				Engine ON/OFF Data............................................................146
				Fault Codes and Warning Data..................................................146
				Engine Operation..............................................................147
				Total Payload and Total Number of Cycles......................................147
				Other Data....................................................................147
			OPERATOR FUNCTIONS................................................................148
				Using the Operator Load Counter...............................................148
				Viewing the Operator Load Counter.............................................148
				Clearing the Operator Load Counter............................................148
				Dimming the Lights on the Display.............................................148
			INITIAL SETUP OF PAYLOAD METER....................................................149
				Switch Settings...............................................................149
				Checking the Operator Check Mode..............................................150
				Checking the Service Check Mode...............................................150
				Checking the Gt setting:......................................................151
				Checking the Inclinometer Settings............................................151
				Calibrating a Truck...........................................................151
				DISPLAYS AT START-UP..........................................................152
				NORMAL OPERATION..............................................................152
			SETUP AND MAINTENANCE.............................................................153
				Setting The Speed Limit.......................................................153
				Setting the Option Code.......................................................153
				Setting The Machine I.D. Code.................................................154
				Setting The Operator I.D. Code................................................154
				Setting The Time and Date.....................................................154
			DOWNLOAD OF INFORMATION...........................................................155
			DISPLAY OF FAULT CODES............................................................155
				Monitoring Input Signals......................................................159
				Service Check Mode............................................................159
			UP Factor - Payload Calculation Gain..............................................160
			PL Mode - Load Calculation Timing.................................................160
			FINAL GEAR RATIO SELECTION........................................................161
			BATTERY REPLACEMENT PROCEDURE.....................................................162
				Replacing the Battery.........................................................162
				After Replacing the Battery...................................................163
			SUSPENSION PRESSURE SENSOR........................................................163
				Removal.......................................................................163
				Installation..................................................................164
			INCLINOMETER......................................................................164
				Removal.......................................................................164
				Installation..................................................................164
				Adjustment....................................................................164
			PAYLOAD METER BACK PANEL..........................................................165
			CONNECTIONS.......................................................................166
			PAYLOAD METER 2 RE-INITIALIZATION PROCEDURE.......................................167
			PAYLOAD CIRCUIT NUMBERS...........................................................168
	RADIO, AM/FM STEREO CASSETTE..............................................................169
		RECEIVER CONTROLS.....................................................................169
		BASIC OPERATION.......................................................................170
			Power ON/OFF and Selecting a Source...............................................170
			To Listen To The Radio............................................................170
			Storing and Recalling Broadcast Frequencies.......................................170
			Tuning Strong Signals.............................................................170
			Storing the Strongest Broadcast Frequencies.......................................170
			Playing a Cassette Tape...........................................................171
			Radio Intercept...................................................................171
		AUDIO ADJUSTMENTS.....................................................................171
			Accessing Audio Controls..........................................................171
			Audio Controls Description and Adjustment.........................................171
			BTB (bass treble booster) Adjustment..............................................171
			Loudness Adjustment...............................................................172
			Source Level Adjustment...........................................................172
		SETTING THE CLOCK.....................................................................172
			Turning Clock Display on or off...................................................172
		XM SATELLITE RECEIVER OPERATION.......................................................172
			Switching the XM Channel Select Setting...........................................172
		LIGHTER & ASH TRAY....................................................................173
			Lighter...........................................................................173
			Ash Tray..........................................................................173

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