KOMATSU HD785-7 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:8378 & UP) KOMATSU HD785-7 – PDF DOWNLOAD

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KOMATSU HD785-7 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:8378 & UP) KOMATSU HD785-7

KOMATSU HD785-7 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:8378 & UP) KOMATSU HD785-7 – PDF DOWNLOAD:

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KOMATSU HD785-7 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:8378 & 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 inyour 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:8378 & UP) KOMATSU HD785-7

FOREWORD 1- 1
BEFORE READING THIS MANUAL 1- 2
SAFETY INFORMATION 1- 3
INTENDED USE 1- 4
USE OF MACHINE 1- 4
DIRECTIONS OF MACHINE 1- 4
VISIBILITY FROM OPERATOR’S SEAT 1- 5
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 6
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 6
EPA REGULATIONS, ENGINE NUMBER PLATE 1- 6
SERVICE METER POSITION 1- 7
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 7
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 5
POSITION FOR ATTACHING SAFETY LABELS 2- 6
SAFETY LABELS 2- 7
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 12
PRECAUTIONS BEFORE STARTING OPERATION 2- 12
PREPARATIONS FOR SAFE OPERATION 2- 12
FIRE PREVENTION 2- 14
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2- 15
DO NOT GET CAUGHT IN DUMP BODY 2- 17
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2- 17
UNAUTHORIZED MODIFICATION 2- 17
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2- 18
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2- 18
PRECAUTIONS FOR OPERATION 2- 19
PRECAUTIONS FOR JOBSITE 2- 19
STARTING ENGINE 2- 21
OPERATION 2- 23
TRANSPORTATION 2- 27
TOWING 2- 28
PRECAUTIONS FOR MAINTENANCE 2- 29
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 29
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2- 33
TIRES 2- 38
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
GENERAL VIEW OF CONTROLS AND GAUGES 3- 3
EXPLANATION OF COMPONENTS 3- 5
MACHINE MONITOR 3- 5
OTHER FUNCTIONS OF MACHINE MONITOR 3- 27
SWITCHES 3- 32
CONTROL LEVERS AND PEDALS 3- 42
BODY PIVOT PIN 3- 48
LOCATION OF FIRE EXTINGUISHER 3- 48
DUST INDICATOR 3- 49
FUSES 3- 50
CAR RADIO 3- 54
CAR STEREO 3- 60
AIR CONDITIONER 3- 69
HANDLING MACHINES EQUIPPED WITH KOMTRAX Plus 3- 74
OPERATION 3- 77
CHECK BEFORE STARTING ENGINE 3- 77
STARTING ENGINE 3-101
BREAKING-IN THE MACHINE 3-103
OPERATIONS, CHECKS AFTER STARTING ENGINE 3-103
STOPPING ENGINE 3-104
CHECKS AFTER STOPPING ENGINE 3-104
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING 3-105
SHIFTING GEAR 3-110
TRAVELING DOWNHILL 3-112
STEERING THE MACHINE 3-126
LOADING OPERATIONS 3-126
DUMP OPERATIONS 3-127
PRECAUTIONS FOR OPERATION 3-129
PARKING MACHINE 3-130
CHECKS AFTER COMPLETION OF WORK 3-131
LOCKING 3-131
HANDLING TIRES 3-132
DETERMINING AND MAINTAINING TRAVEL ROAD 3-135
DETERMINING TRAVEL ROAD 3-135
MAINTAINING TRAVEL ROAD 3-135
TRANSPORTATION 3-136
PRECAUTIONS WHEN TRANSPORTING 3-136
STEPS FOR TRANSPORTATION 3-136
METHOD OF SECURING MACHINE 3-136
METHOD OF LIFTING MACHINE 3-138
COLD WEATHER OPERATION 3-141
PRECAUTIONS FOR LOW TEMPERATURE 3-141
PRECAUTIONS AFTER COMPLETION OF WORK 3-142
AFTER COLD WEATHER 3-143
LONG-TERM STORAGE 3-144
BEFORE STORAGE 3-144
DURING STORAGE 3-144
AFTER STORAGE 3-144
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE 3-144
TROUBLESHOOTING 3-145
AFTER RUNNING OUT OF FUEL 3-145
IF TRANSMISSION HAS TROUBLE 3-146
METHOD OF LOWERING DUMP BODY IN EMERGENCY 3-146
METHOD OF TOWING MACHINE 3-147
IF BATTERY IS DISCHARGED 3-151
OTHER TROUBLE 3-155
MAINTENANCE 4- 1
GUIDES TO MAINTENANCE 4- 2
OUTLINE OF SERVICE 4- 6
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 7
OUTLINE OF ELECTRIC SYSTEM 4- 10
WEAR PARTS 4- 11
WEAR PARTS LIST 4- 11
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 12
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 13
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL 4- 17
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 18
TORQUE LIST 4- 18
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 19
SAFETY CRITICAL PARTS 4- 20
MAINTENANCE SCHEDULE CHART 4- 27
MAINTENANCE SCHEDULE CHART 4- 27
SERVICE PROCEDURE 4- 29
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) 4- 29
WHEN REQUIRED 4- 30
CHECK BEFORE STARTING 4- 57
EVERY 250 HOURS SERVICE 4- 58
EVERY 500 HOURS SERVICE 4- 72
EVERY 1000 HOURS SERVICE 4- 76
EVERY 2000 HOURS SERVICE 4- 90
EVERY 4000 HOURS SERVICE 4- 94
EVERY 8000 HOURS SERVICE 4- 98
EVERY 15000 HOURS SERVICE 4- 99
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
SELECTING DUMP BODY 6- 2
HANDLING AIR SUSPENSION SEAT 6- 3
SEAT ADJUSTMENT 6- 3
REMOVAL AND INSTALLATION OF HEADREST 6- 5
HANDLING AUTOMATIC SPIN REGULATOR (ASR) 6- 6
EXPLANATION OF COMPONENTS 6- 6
ACTUATION OF ASR SYSTEM 6- 7
PRECAUTIONS WHEN USING 6- 7
TROUBLESHOOTING 6- 8
BLEEDING AIR FROM ASR CIRCUIT 6- 9
HANDLING ABS 6- 10
EXPLANATION OF COMPONENTS 6- 10
ABS SYSTEM CHECK AFTER STARTING ENGINE 6- 12
OPERATION OF ABS 6- 12
PRECAUTIONS WHEN USING 6- 13
TROUBLESHOOTING 6- 14
HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE) 6- 16
OUTLINE OF SYSTEM 6- 16
NORMAL OPERATION DISPLAY 6- 18
EXTERNAL DISPLAY LAMPS 6- 19
PERFORMING CALIBRATION 6- 20
DATA STORED IN PAYLOAD METER 6- 22
PROCEDURE WHEN DOWNLOADING 6- 22
METHOD OF SETTING MACHINE ID, OPEN ID 6- 26
PAYLOAD (CYCLE DATA ITEM) 6- 28
SERVICE FUNCTIONS 6- 28
OTHERS 6- 28
HANDLING AUTO-GREASING SYSTEM 6- 29
METHOD OF OPERATING AUTO-GREASING SYSTEM 6- 29
METHOD OF SETTING TIMER 6- 30
BLEEDING AIR FROM GREASE CIRCUIT 6- 31
METHOD OF ADJUSTING DISCHARGE FROM INJECTOR 6- 31
CHECKING OPERATION OF INJECTOR 6- 32
METHOD OF CHARGING WITH GREASE 6- 33
USE OF REAR VIEW MONITOR 6- 34
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR 6- 34
SETTING OF REAR VIEW MONITOR 6- 37
CAUTIONS WHEN USING REAR VIEW MONITOR 6- 37
EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER 6- 38
SOCKET FOR ENGINE HEATER 6- 38
SOCKET FOR ENGINE, TRANSMISSION, HYDRAULIC TANK AND BRAKE SUB-TANK
HEATER 6- 38
CONNECTING EXTERNAL POWER SOURCE 6- 39
RESTARTING ENGINE 6- 40
HANDLING EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER 6- 42
HANDLING PRELUBE SYSTEM 6- 49
EXPLANATION OF COMPONENTS 6- 49
OPERATION 6- 51
TROUBLESHOOTING 6- 54
HANDLING DUMPING COUNTER 6- 56
EMERGENCY ENGINE STOP SWITCH 6- 57
HANDLING BATTERY ISOLATOR 6- 59
HANDLING HIGH-ALTITUDE SETTING SELECTOR FUNCTION (FOR PLACES AT HIGH
ALTITUDE) 6- 61
PRECAUTIONS WHEN USING 6- 61
HANDLING VEHICLE SPEED LIMIT 6- 62
EXPLANATION OF COMPONENTS 6- 62
OPERATION OF VEHICLE SPEED LIMIT 6- 64
TROUBLESHOOTING 6- 65
HANDLING OF SPEED LIMIT CONTROL FUNCTION IN OVERLOAD STATE 6- 66
EXPLANATION OF COMPONENTS 6- 66
OPERATION OF SPEED LIMIT CONTROL FUNCTION IN OVERLOAD STATE 6- 67
TROUBLESHOOTING 6- 68
AUTO-GREASING REFILLING SYSTEM 6- 69
SYSTEM EXPLANATION 6- 69
OPERATING PROCEDURE OF THE REFILLING SYSTEM 6- 70
HANDLING POWER LADDER 6- 71
EXPLANATION OF COMPONENTS 6- 72
OPERATION OF POWER LADDER 6- 74
OPERATING THE LADDER WHEN THE STARTING SWITCH IS TURNED OFF 6- 77
POWER LADDER RELATED FUNCTIONS 6- 77
MAINTENANCE OF POWER LADDER 6- 78
SAFETY CRITICAL PARTS FOR PERIODIC REPLACEMENT 6- 82
PROCEDURES WHEN MACHINE BECOMES IMMOVABLE BECAUSE PARKING BRAKE
CANNOT BE RELEASED 6- 83
PROCEDURES WHEN THE LADDER BECOMES IMMOVABLE 6- 84
TROUBLESHOOTING 6- 86
INDEX 7- 1

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