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KOMATSU HD785-7 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:8085 & UP) KOMATSU HD785-7 – PDF DOWNLOAD
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- KOMATSU HD785-7 DUMP TRUCK OPERATION & MAINTENANCE MANUAL
- Serial Number:8085 & UP
- PUBLICATION NUMBER:TEN00371-03
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Description
KOMATSU HD785-7 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:8085 & UP) KOMATSU HD785-7
KOMATSU HD785-7 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:8085 & UP) KOMATSU HD785-7 – PDF DOWNLOAD:
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KOMATSU HD785-7 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:8085 & 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 carry out 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 your distributor immediately to arrange for its replacement. For details regarding the machine serial No. you will need to provide your Komatsu distributor, see “TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR (PAGE 1-7)”.
- This manual uses the international units (SI) for units of measurement. For reference, units that have been used in the past are given in ( ). The explanations, values, and illustrations in this manual have been prepared based on the latest information available as of the date of its publication. Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual.
- Consult Komatsu or your Komatsu distributor for the latest available information concerning your machine or with questions regarding information contained in this manual. The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example:1 → (1)) 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, 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 HD785-7 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:8085 & 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.........................................................................100 LOCATION OF FIRE EXTINGUISHER..........................................................100 DUST INDICATOR.........................................................................101 FUSES..................................................................................102 CAR RADIO..............................................................................106 CAR STEREO.............................................................................112 AIR CONDITIONER........................................................................121 HANDLING MACHINES EQUIPPED WITH VHMS...................................................126 OPERATION..................................................................................128 CHECK BEFORE STARTING ENGINE...........................................................128 STARTING ENGINE........................................................................151 BREAKING-IN THE MACHINE................................................................153 OPERATIONS, CHECKS AFTER STARTING ENGINE...............................................153 STOPPING ENGINE........................................................................154 CHECKS AFTER STOPPING ENGINE...........................................................154 MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING........................................155 SHIFTING GEAR..........................................................................160 TRAVELING DOWNHILL.....................................................................162 STEERING THE MACHINE...................................................................176 LOADING OPERATIONS.....................................................................176 DUMP OPERATIONS........................................................................177 PRECAUTIONS FOR OPERATION..............................................................179 PARKING MACHINE........................................................................180 CHECKS AFTER COMPLETION OF WORK........................................................181 LOCKING................................................................................181 HANDLING TIRES.........................................................................182 DETERMINING AND MAINTAINING TRAVEL ROAD....................................................185 DETERMINING TRAVEL ROAD................................................................185 MAINTAINING TRAVEL ROAD................................................................185 TRANSPORTATION.............................................................................186 PRECAUTIONS WHEN TRANSPORTING..........................................................186 STEPS FOR TRANSPORTATION...............................................................186 METHOD OF SECURING MACHINE.............................................................186 METHOD OF LIFTING MACHINE..............................................................188 COLD WEATHER OPERATION.....................................................................191 PRECAUTIONS FOR LOW TEMPERATURE........................................................191 PRECAUTIONS AFTER COMPLETION OF WORK...................................................192 AFTER COLD WEATHER.....................................................................193 LONG-TERM STORAGE..........................................................................194 BEFORE STORAGE.........................................................................194 DURING STORAGE.........................................................................194 AFTER STORAGE..........................................................................194 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE...................................194 TROUBLESHOOTING............................................................................195 AFTER RUNNING OUT OF FUEL..............................................................195 IF TRANSMISSION HAS TROUBLE............................................................196 METHOD OF LOWERING DUMP BODY IN EMERGENCY..............................................196 METHOD OF TOWING MACHINE...............................................................197 IF BATTERY IS DISCHARGED...............................................................201 OTHER TROUBLE..........................................................................205 MAINTENANCE ...................................................................................212 GUIDES TO MAINTENANCE......................................................................213 OUTLINE OF SERVICE.........................................................................217 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................218 OUTLINE OF ELECTRIC SYSTEM.............................................................221 WEAR PARTS.................................................................................222 WEAR PARTS LIST........................................................................222 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................223 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................224 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....228 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................229 TORQUE LIST............................................................................229 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................230 SAFETY CRITICAL PARTS..................................................................231 MAINTENANCE SCHEDULE CHART.................................................................238 MAINTENANCE SCHEDULE CHART.............................................................238 SERVICE PROCEDURE..........................................................................240 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).............................240 WHEN REQUIRED..........................................................................241 CHECK BEFORE STARTING..................................................................268 EVERY 250 HOURS SERVICE................................................................269 EVERY 500 HOURS SERVICE................................................................283 EVERY 1000 HOURS SERVICE...............................................................287 EVERY 2000 HOURS SERVICE...............................................................301 EVERY 4000 HOURS SERVICE...............................................................304 EVERY 8000 HOURS SERVICE...............................................................308 EVERY 15000 HOURS SERVICE..............................................................309 SPECIFICATIONS ................................................................................310 SPECIFICATIONS.............................................................................311 ATTACHMENTS, OPTIONS ..........................................................................312 SELECTING DUMP BODY........................................................................313 HANDLING AIR SUSPENSION SEAT...............................................................314 SEAT ADJUSTMENT........................................................................314 REMOVAL AND INSTALLATION OF HEADREST...................................................316 HANDLING AUTOMATIC SPIN REGULATOR (ASR)....................................................317 EXPLANATION OF COMPONENTS..............................................................317 ACTUATION OF ASR SYSTEM................................................................318 PRECAUTIONS WHEN USING.................................................................318 TROUBLESHOOTING........................................................................319 BLEEDING AIR FROM ASR CIRCUIT..........................................................320 HANDLING ABS...............................................................................321 EXPLANATION OF COMPONENTS..............................................................321 ABS SYSTEM CHECK AFTER STARTING ENGINE.................................................323 OPERATION OF ABS.......................................................................323 PRECAUTIONS WHEN USING.................................................................324 TROUBLESHOOTING........................................................................325 HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)................................................327 OUTLINE OF SYSTEM......................................................................327 NORMAL OPERATION DISPLAY...............................................................329 EXTERNAL DISPLAY LAMPS.................................................................330 PERFORMING CALIBRATION.................................................................331 DATA STORED IN PAYLOAD METER...........................................................333 PROCEDURE WHEN DOWNLOADING.............................................................333 METHOD OF SETTING MACHINE ID, OPEN ID..................................................337 PAYLOAD (CYCLE DATA ITEM)..............................................................339 SERVICE FUNCTIONS......................................................................339 OTHERS.................................................................................339 HANDLING AUTO-GREASING SYSTEM..............................................................340 METHOD OF OPERATING AUTO-GREASING SYSTEM...............................................340 METHOD OF SETTING TIMER................................................................341 BLEEDING AIR FROM GREASE CIRCUIT.......................................................342 METHOD OF ADJUSTING DISCHARGE FROM INJECTOR............................................342 CHECKING OPERATION OF INJECTOR.........................................................343 METHOD OF CHARGING WITH GREASE.........................................................344 USE OF REAR VIEW MONITOR...................................................................345 NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR.....................................345 SETTING OF REAR VIEW MONITOR...........................................................348 CAUTIONS WHEN USING REAR VIEW MONITOR..................................................348 EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER.................................................349 SOCKET FOR ENGINE HEATER...............................................................349 SOCKET FOR ENGINE, TRANSMISSION, HYDRAULIC TANK AND BRAKE SUB-TANK HEATER..............349 CONNECTING EXTERNAL POWER SOURCE.......................................................350 RESTARTING ENGINE......................................................................351 HANDLING EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER....................................353 HANDLING PRELUBE SYSTEM....................................................................360 EXPLANATION OF COMPONENTS..............................................................360 OPERATION..............................................................................362 TROUBLESHOOTING........................................................................365 HANDLING DUMPING COUNTER...................................................................367 HANDLING BATTERY ISOLATOR..................................................................368 HANDLING HIGH-ALTITUDE SETTING SELECTOR FUNCTION (FOR PLACES AT HIGH ALTITUDE).............370 PRECAUTIONS WHEN USING.................................................................370 INDEX..........................................................................................372
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