Komatsu HD785-5 Manuals

Komatsu HD785-5 Manuals

Manuals and User Guides for Komatsu HD785-5. We have 1 Komatsu HD785-5 manual available for free PDF download: Operation & Maintenance Manual

Komatsu HD785-5 Operation & Maintenance Manual

Komatsu HD785-5 Operation & Maintenance Manual (307 pages)

DUMP TRUCK

Brand: Komatsu | Category: Trucks | Size: 5.93 MB

Table of Contents

Table of Contents

11
- Foreword
  12
  - Safety Information
    16
- Safety
  17
  - Safety Labels
    18
- 2 Position for Attaching Safety Labels
  
  19
  - Safety Labels
    20
  - General Precautions
    24
    
    Clothing and Personal Protective Items
    24
    
    Fire Extinguisher and First Aid Kit
    24
    
    Safety Features
    24
    
    Safety Rules
    24
    
    Always Apply Lock When Leaving Operator's Seat
    25
    
    Inside Operator's Compartment
    25
    
    Keep Machine Clean
    25
    
    Handrails and Steps
    26
    
    Mounting and Dismountin
    26
    
    Fire Prevention
    27
    
    Prevention of Burns
    27
    
    Action if Fire Occurs
    28
    
    Window Washer Liquid
    28
    
    Precautions for Attachments
    29
    
    PRECAUTIONS WHEN USING ROPS (Roll over Protective Structure)
    29
    
    Safety at Worksite
    29
    
    Unauthorized Modification
    29
    
    Do Not Go Close to High-Voltage Cables
    30
    
    Ensure Good Visibility
    30
    
    Working on Loose Ground
    30
    
    Asbestos Dust Hazard Prevention
    31
    
    Checking Signalman's Signals and Signs
    31
    
    Precautions on Indoor Ventilation
    31
  - Precautions During Operation
    32
    
    Before Starting Engine
    32
    
    Checks before Starting Engine, Adjust
    32
    
    Precautions When Starting Engine
    32
    
    Precautions in Cold Areas
    33
    
    After Starting Engine
    34
    
    Check after Starting Engine
    34
    
    Precautions When Traveling Forward or Reverse
    34
    
    Method of Using Brakes
    35
    
    Precautions During Operation
    35
    
    Precautions for Operation
    35
    
    Precautions When Operating Dump Body
    35
    
    Precautions When Traveling on the Slopes
    35
    
    Precautions for Parking
    36
    
    Precautions under the Snowing and Freezing Condition
    36
    
    Battery
    37
    
    Battery Hazard Prevention
    37
    
    Starting with Booster Cables
    38
    
    Towing
    39
    
    When Towing
    39
  - Precautions for Maintenance
    40
    
    Appoint Leader When Working with Others
    40
    
    Keep Work Place Clean and Tidy
    40
    
    Warning Tag
    40
    
    Stop Engine before Carrying out Inspection and Maintenance
    41
    
    Proper Tools
    42
    
    Two Workers for Maintenance When Engine Is Running
    42
    
    Handling Suspention Cylinder
    43
    
    Noise
    43
    
    Personnel
    43
    
    Precautions When Usin Hammer
    43
    
    Repair Welding
    43
    
    Work under the Machine
    43
    
    Handling High-Pressure Hoses, Piping
    44
    
    Maintenance of Air Conditioner
    44
    
    Precautions with High-Pressure Oil
    44
    
    Removing Battery Terminal
    44
    
    Waste Materials
    44
    
    Compressed Air
    45
    
    Periodic Replacement of Safety-Critical Parts
    45
  - Precautions with Tires
    46
  - Operation
    46
    
    Handling Tires
    46
    
    Precautions When Storing Tire
    46
    
    General View
    48
    
    General View of Machine
    48
    
    General View of Controls and Gauges
    49
    
    Explanation of Components
    51
    
    Machine Monitor
    51
    
    Switches
    68
    
    Control Levers and Pedals
    76
    
    Mechatronics Equipment Controller
    80
    
    Dust Indicator
    81
    
    Safety Pin
    81
    
    Fuses
    82
    
    Car Stereo
    84
    
    Air Conditioner
    93
    
    Car Heater
    98
    
    Location of Fire Extinguisher
    99
    
    Location of First Aid Kit
    99
    
    Operation
    100
- 3 Check before Starting Engine
  
  100
  - Starting Engine
    116
  - Operations, Checks after Starting Engine
    119
  - Stopping Engine
    120
  - Checks after Stopping Engine
    120
  - Moving Machine off (Forward, Reverse), Stopping
    121
  - Shifting Gear
    126
  - Traveling Downhill
    127
  - Steering the Machine
    133
  - Loading Operations
    133
  - Dump Operations
    134
  - Precautions for Operation
    135
  - Parking Machine
    136
  - Checks after Completion of Work
    137
  - Drain Water from Air Tank
    137
  - Locking
    138
  - Handling Tires
    139
  - Determining and Maintaining Travel Road
    141
    
    Determining Travel Road
    141
    
    Maintaining Travel Road
    141
  - Transportation
    142
    
    Precautions When Transporting
    142
    
    Steps for Transportation
    142
    
    Method of Securing Machine
    143
    
    Method of Lifting Machine
    144
  - Cold Weather Operation
    146
    
    Precautions for Low Temperature
    146
    
    Precautions after Completion of Work
    147
    
    After Cold Weather
    148
  - Long-Term Storage
    149
    
    After Storage
    149
    
    Before Storage
    149
    
    During Storage
    149
    
    Precautions before Traveling after Long-Term Storage
    149
  - Troubleshooting
    150
    
    After Running out of Fuel
    150
    
    Method of Towing Machine
    150
    
    If Battery Is Discharged
    155
    
    Other Trouble
    159
  - Maintenance
    167
    
    Guides to Maintenance
    167
    
    Handling Oil, Fuel, Coolant, and Performing Oil Clinic
    169
    
    Outline of Service
    169
    
    Outline of Electric System
    172
    
    Wear Parts
    173
    
    Wear Parts List
    173
    
    Recommended Fuel, Coolant, and Lubricant
    174
    
    Use of Fuel, Coolant and Lubricants According to Ambient Temperature
    175
    
    Recommended Brands, Recommended Quality for Products Other than Komatsu Genuine Oil
    176
    
    Standard Tightening Torques for Bolts and Nuts
    177
    
    Torque List
    177
    
    Periodic Replacement of Safety Critical Parts
    178
    
    Safety Critical Parts
    179
Maintenance Schedule Chart

180
- Change Oil in Differential Case
  183
  - When Required
    184
- Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge
  183
- Change Oil in Final Drive Case
  183
- Change Oil in Rear Brake Cooling Oil Tank
  183
- Change Oil in Transmission Case
  183
- Replace Fuel Filter Cartridge
  183
- Replace Steering, Hoist Oil Tank and Rear Brake Cooling Oil Tank Filter Element
  183
- Replace Transmission Oil Filter Element
  183
- Service Procedure
  183
  - Initial 250 Hours Service (Only after the First 250 Hours)
    183
- Clean Inside of Cooling System
  186
- Check Level of Window Washer Fluid, Add Fluid
  189
- Clean Air Conditioner Air Filter
  189
- Check Dump Body
  190
- Check Electric Intake Air Heater
  190
- Check Refrigerant (Gas) Level
  190
- Check Length of Suspension Cylinder, Check Oil Level
  191
- Bleed Air from Front Brake
  193
- Bleed Air from Rear Brake
  193
- Adjust Parking Brake
  194
- Adjust Body Positioner
  195
- Replace Fan Belt, Adjust Auto Tensioner
  197
- Check Play of Output Coupling of Output Shaft
  198
- Selection and Inspection of Tires
  199
- Check Level of Battery Electrolyte
  207
- Check Alternator Belt, Adjust
  210
- Clean Breathers
  212
- Check Drive Shaft
  213
- Check Frame
  213
- Check Braking Capacity of Foot Brake
  214
- Check Braking Capacity of Retarder Brake
  214
- Check Braking Capacity of Parking Brake
  215
- Check Wear of Parking Brake Pads
  215
- Check, Clean Automatic Suspension
  216
- Inspection of Engine Emergency Stop
  217
  - Every 500 Hours Service
    218
  - Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge
    218
- Replace Fuel Filter Cartridge
  220
- Check Fan Belt for Wear and Replace
  222
  - Every 1000 Hours Service
    223
  - Replace Corrosion Resistor Cartridge
    223
- Check Wear of Front Disc Brake Pad
  222
- Change Oil in Transmission Case, Clean Transmission Case Strainer
  224
- Replace Steering, Hoist Oil Tank and Rear Brake Cooling Oil Tank Filter Element
  225
  - Every 2000 Hours Service
    228
  - Change Oil in Steering, Hoist Oil Tank
    228
- Change Oil in Rear Brake Cooling Oil Tank
  229
- Change Oil in Differential Case
  230
- Change Oil in Final Drive Case
  230
- Check Alternator, Starting Motor
  231
- Check Play of Turbocharger Rotor
  231
- Check, Adjust Engine Valve Clearance
  231
- Clean Differential Case Breather
  231
- Clean Emergency Relay Valve
  231
- Clean, Check Turbocharger
  231
- Lubricate Dump Control Linkage (5 Points)
  232
- Clean Air Dryer Filter and Deflector (if Equipped)
  233
- Replace Plug with Strainer from Make-Up Tank of Rear Brake Chamber
  233
  - Every 4000 Hours Service
    234
  - Every 15000 Hours Service
    236
- Specifications
  238
- Attachments, Options
  241
  - Handling Payload Meter
    241
    
    Name of Parts
    241
    
    External Display Lamps
    242
    
    Operating Payload Meter
    244
  - Tachograph (Tco 15-6)
    252
    
    Explanation of Components
    252
    
    Method of Use
    254
    
    Method of Using Key
    254
  - Revo Tachograph (Tco 15-7)
    256
    
    Explanation of Components
    256
    
    Method of Use
    258
  - Using Differential Lock
    260
    
    Differential Lock Pedal
    260
    
    Precautions and Method of Use
    261
  - Operation of Abs and Abs/Asr
    262
    
    Explanation of Components
    262
    
    Operation Method
    264
    
    Precautions for Use
    265
    
    Troubleshooting
    265
  - Arsc (Automatic Retarder Speed Control)
    266
    
    Explanation of Components
    267
    
    Method of Operation
    269
    
    Troubleshooting
    271
  - Pmc (Powertrain Management Controller) and Mom (Message for Operation and Maintenance)
    274
    
    Abnormality Displayed During Operation
    274
    
    Check before Starting
    274
    
    How to Download the Stored Data in Pmc and Other Controllers
    274
    
    Message for Operation and Maintenance (Mom)
    275
  - Asr-II (Automatic Spin Regulator II)
    280
    
    Explanation of Components
    280
    
    Actuation of Asr-II System
    281
    
    Precautions When Using
    281
    
    Troubleshooting
    282
  - Handling Auto-Greasing System
    284
    
    Outline of Auto-Greasing System
    284
    
    Setting Grease Can
    285
    
    Initial Setting of Auto-Greasing System
    286
    
    Method of Operating Auto-Greasing System
    286
    
    Precautions When Handling Auto-Greasing System
    287
    
    Position of each Injector
    291
    
    Greasing Points for each Injector
    295
- High Altitude Specifications
  300
  - Explanation of Components
    300
  - Service Procedure
    301
    
    Check before Starting
    301
    
    Every 2000 Hours Service
    302
- Index
  304

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