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KOMATSU HD785-7 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:30001 and up) KOMATSU HD785-7 – PDF DOWNLOAD
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- KOMATSU HD785-7 DUMP TRUCK OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:30001 and up
- PUBLICATION NUMBER:TEN00598-02
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Description
KOMATSU HD785-7 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:30001 and up) KOMATSU HD785-7
KOMATSU HD785-7 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:30001 AND UP) KOMATSU HD785-7 – PDF DOWNLOAD:
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TABLE OF CONTENTS:
KOMATSU HD785-7 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:30001 and up) KOMATSU HD785-7
COVER.......................................................................................... 1 FOREWORD....................................................................................... 2 BEFORE READING THIS MANUAL................................................................. 3 SAFETY INFORMATION......................................................................... 4 INTENDED USE............................................................................... 5 USE OF MACHINE......................................................................... 5 DIRECTIONS OF MACHINE.................................................................. 5 VISIBILITY FROM OPERATOR'S SEAT........................................................ 6 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................. 7 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........................... 7 EPA REGULATIONS, ENGINE NUMBER PLATE................................................... 7 SERVICE METER POSITION................................................................. 8 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................................. 8 CONTENTS................................................................................... 9 SAFETY......................................................................................... 14 SAFETY..................................................................................... 15 SAFETY LABELS.............................................................................. 18 POSITION FOR ATTACHING SAFETY LABELS................................................... 19 SAFETY LABELS.......................................................................... 20 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE.................................... 25 PRECAUTIONS BEFORE STARTING OPERATION.................................................. 25 PREPARATIONS FOR SAFE OPERATION........................................................ 25 FIRE PREVENTION........................................................................ 27 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE............................................. 28 DO NOT GET CAUGHT IN DUMP BODY......................................................... 30 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES........................................... 30 UNAUTHORIZED MODIFICATION.............................................................. 30 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS......................................... 31 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING........................................ 31 PRECAUTIONS FOR OPERATION.................................................................. 32 PRECAUTIONS FOR JOBSITE................................................................ 32 STARTING ENGINE........................................................................ 34 OPERATION.............................................................................. 36 TRANSPORTATION......................................................................... 40 TOWING................................................................................. 41 PRECAUTIONS FOR MAINTENANCE................................................................ 42 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE................................. 42 PRECAUTIONS FOR INSPECTION AND MAINTENANCE............................................. 46 TIRES.................................................................................. 51 OPERATION...................................................................................... 54 GENERAL VIEW............................................................................... 55 GENERAL VIEW OF MACHINE................................................................ 55 GENERAL VIEW OF CONTROLS AND GAUGES.................................................... 56 EXPLANATION OF COMPONENTS.................................................................. 58 MACHINE MONITOR........................................................................ 58 OTHER FUNCTIONS OF MACHINE MONITOR..................................................... 80 SWITCHES............................................................................... 85 CONTROL LEVERS AND PEDALS.............................................................. 95 BODY PIVOT PIN.........................................................................101 LOCATION OF FIRE EXTINGUISHER..........................................................101 DUST INDICATOR.........................................................................102 FUSES..................................................................................103 CAR RADIO..............................................................................107 AIR CONDITIONER........................................................................111 HANDLING MACHINES EQUIPPED WITH KOMTRAX Plus...........................................116 OPERATION..................................................................................119 CHECK BEFORE STARTING ENGINE...........................................................119 STARTING ENGINE........................................................................144 BREAKING-IN THE MACHINE................................................................146 OPERATIONS, CHECKS AFTER STARTING ENGINE...............................................146 STOPPING ENGINE........................................................................147 CHECKS AFTER STOPPING ENGINE...........................................................147 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING........................................148 SHIFTING GEAR..........................................................................153 TRAVELING DOWNHILL.....................................................................155 STEERING THE MACHINE...................................................................169 LOADING OPERATIONS.....................................................................169 DUMP OPERATIONS........................................................................170 PRECAUTIONS FOR OPERATION..............................................................172 PARKING MACHINE........................................................................173 CHECKS AFTER COMPLETION OF WORK........................................................174 LOCKING................................................................................174 HANDLING TIRES.........................................................................175 DETERMINING AND MAINTAINING TRAVEL ROAD....................................................178 DETERMINING TRAVEL ROAD................................................................178 MAINTAINING TRAVEL ROAD................................................................178 TRANSPORTATION.............................................................................179 PRECAUTIONS WHEN TRANSPORTING..........................................................179 STEPS FOR TRANSPORTATION...............................................................179 METHOD OF SECURING MACHINE.............................................................179 METHOD OF LIFTING MACHINE..............................................................181 COLD WEATHER OPERATION.....................................................................184 PRECAUTIONS FOR LOW TEMPERATURE........................................................184 INSTALLATION OF RADIATOR CURTAIN.......................................................185 PRECAUTIONS AFTER COMPLETION OF WORK...................................................185 AFTER COLD WEATHER.....................................................................186 LONG-TERM STORAGE..........................................................................187 BEFORE STORAGE.........................................................................187 DURING STORAGE.........................................................................187 AFTER STORAGE..........................................................................187 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE...................................187 TROUBLESHOOTING............................................................................188 AFTER RUNNING OUT OF FUEL..............................................................188 IF TRANSMISSION HAS TROUBLE............................................................189 METHOD OF LOWERING DUMP BODY IN EMERGENCY..............................................189 METHOD OF TOWING MACHINE...............................................................190 IF BATTERY IS DISCHARGED...............................................................194 OTHER TROUBLE..........................................................................198 MAINTENANCE....................................................................................204 GUIDES TO MAINTENANCE......................................................................205 OUTLINE OF SERVICE.........................................................................209 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................210 OUTLINE OF ELECTRIC SYSTEM.............................................................213 WEAR PARTS.................................................................................214 WEAR PARTS LIST........................................................................214 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................215 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................216 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....220 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................221 TORQUE LIST............................................................................221 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................222 SAFETY CRITICAL PARTS..................................................................223 MAINTENANCE SCHEDULE CHART.................................................................230 MAINTENANCE SCHEDULE CHART.............................................................230 SERVICE PROCEDURE..........................................................................232 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).............................232 WHEN REQUIRED..........................................................................233 CHECK BEFORE STARTING..................................................................260 EVERY 250 HOURS SERVICE................................................................261 EVERY 500 HOURS SERVICE................................................................275 EVERY 1000 HOURS SERVICE...............................................................279 EVERY 2000 HOURS SERVICE...............................................................293 EVERY 4000 HOURS SERVICE...............................................................297 EVERY 8000 HOURS SERVICE...............................................................301 EVERY 15000 HOURS SERVICE..............................................................302 SPECIFICATIONS.................................................................................304 SPECIFICATIONS.............................................................................305 ATTACHMENTS, OPTIONS...........................................................................308 SELECTING DUMP BODY........................................................................309 AUXILIARY ELECTRIC POWER...................................................................310 HANDLING AIR SUSPENSION SEAT...............................................................311 SEAT ADJUSTMENT........................................................................311 REMOVAL AND INSTALLATION OF HEADREST...................................................313 HANDLING KOMATSU TRACTION CONTROL SYSTEM (KTCS)............................................314 EXPLANATION OF COMPONENTS..............................................................314 ACTUATION OF KTCS SYSTEM...............................................................315 PRECAUTIONS WHEN USING.................................................................315 TROUBLESHOOTING........................................................................316 BLEEDING AIR FROM KTCS CIRCUIT.........................................................318 HANDLING AUTOMATIC SPIN REGULATOR (ASR)....................................................319 EXPLANATION OF COMPONENTS..............................................................319 ACTUATION OF ASR SYSTEM................................................................320 PRECAUTIONS WHEN USING.................................................................320 TROUBLESHOOTING........................................................................321 BLEEDING AIR FROM ASR CIRCUIT..........................................................322 HANDLING ABS...............................................................................323 EXPLANATION OF COMPONENTS..............................................................323 ABS SYSTEM CHECK AFTER STARTING ENGINE.................................................325 OPERATION OF ABS.......................................................................325 PRECAUTIONS WHEN USING.................................................................326 TROUBLESHOOTING........................................................................327 HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE)........................................329 OUTLINE OF SYSTEM......................................................................329 NORMAL OPERATION DISPLAY...............................................................331 EXTERNAL DISPLAY LAMPS.................................................................332 PERFORMING CALIBRATION.................................................................333 DATA STORED IN PAYLOAD METER...........................................................335 PROCEDURE WHEN DOWNLOADING.............................................................335 METHOD OF SETTING MACHINE ID, OPEN ID..................................................339 PAYLOAD (CYCLE DATA ITEM)..............................................................341 SERVICE FUNCTIONS......................................................................341 OTHERS.................................................................................341 HANDLING AUTO-GREASING SYSTEM..............................................................342 METHOD OF OPERATING AUTO-GREASING SYSTEM...............................................342 METHOD OF SETTING TIMER................................................................343 BLEEDING AIR FROM GREASE CIRCUIT.......................................................344 METHOD OF ADJUSTING DISCHARGE FROM INJECTOR............................................344 CHECKING OPERATION OF INJECTOR.........................................................345 METHOD OF CHARGING WITH GREASE.........................................................346 HANDLING REAR VIEW MONITOR.................................................................347 EXPLANATION OF COMPONENTS..............................................................347 EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER.................................................348 SOCKET FOR ENGINE HEATER...............................................................348 SOCKET FOR ENGINE, TRANSMISSION, HYDRAULIC TANK AND BRAKE SUB-TANK HEATER..............348 CONNECTING EXTERNAL POWER SOURCE.......................................................349 RESTARTING ENGINE......................................................................350 HANDLING EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER....................................352 HANDLING PRELUBE SYSTEM....................................................................359 EXPLANATION OF COMPONENTS..............................................................359 OPERATION..............................................................................361 TROUBLESHOOTING........................................................................364 HANDLING DUMPING COUNTER...................................................................366 HANDLING HIGH-ALTITUDE SETTING SELECTOR FUNCTION (FOR PLACES AT HIGH ALTITUDE).............367 PRECAUTIONS WHEN USING.................................................................367 EMERGENCY ENGINE STOP SWITCH...............................................................368 HANDLING BATTERY DISCONNECTOR SWITCH.......................................................370 EXPLANATION OF COMPONENTS..............................................................370 PRECAUTIONS WHEN OPERATING.............................................................371 HANDLING VEHICLE SPEED LIMIT...............................................................372 EXPLANATION OF COMPONENTS..............................................................372 OPERATION OF VEHICLE SPEED LIMIT.......................................................373 TROUBLESHOOTING........................................................................374 HANDLING OF SPEED LIMIT CONTROL FUNCTION IN OVERLOAD STATE.................................375 EXPLANATION OF COMPONENTS..............................................................375 OPERATION OF SPEED LIMIT CONTROL FUNCTION IN OVERLOAD STATE............................376 TROUBLESHOOTING........................................................................377 AUTO-GREASING REFILLING SYSTEM.............................................................378 SYSTEM EXPLANATION.....................................................................378 OPERATING PROCEDURE OF THE REFILLING SYSTEM............................................379 HANDLING POWER LADDER......................................................................380 EXPLANATION OF COMPONENTS..............................................................381 OPERATION OF POWER LADDER..............................................................383 OPERATING THE LADDER WHEN THE STARTING SWITCH IS TURNED OFF............................385 POWER LADDER RELATED FUNCTIONS.........................................................385 MAINTENANCE OF POWER LADDER............................................................386 SAFETY CRITICAL PARTS FOR PERIODIC REPLACEMENT.........................................390 PROCEDURES WHEN MACHINE BECOMES IMMOVABLE BECAUSE PARKING BRAKE CANNOT BE RELEASED.....391 PROCEDURES WHEN THE LADDER BECOMES IMMOVABLE...........................................392 TROUBLESHOOTING........................................................................394 INDEX..........................................................................................396
DESCRIPTION:
KOMATSU HD785-7 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:30001 and up) KOMATSU HD785-7
- This manual gives details of the operation and methods of inspection and maintenance for this machine that must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Read, understand and follow all precautions and warnings in this manual and on the machine before performing operation and maintenance. Failure to do so may result in serious injury or death.
- Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used. Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions. If you perform any operation, inspection, or maintenance under conditions that are not described in this manual, understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should you or others engage in the prohibited uses or actions described in this manual.
- Improper operation and maintenance of the machine can be hazardous and could result in serious injury or death. If you sell the machine, be sure to give this manual to the new owner together with the machine. Always keep this Operation and Maintenance Manual in the location shown on the right so that all relevant personnel can read it at any time. Storage location for the Operation and Maintenance Manual: On inside of left door If this manual is lost or damaged, contact and tell your distributor about the machine model name and the serial No.
- immediately to arrange for its replacement. For details regarding the machine model name and the serial No., see the machine serial No. plate. In order to arrange the proper Operation and Maintenance Manual, you will need to provide the machine model name and the serial No. to your Komatsu distributor.
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]
