Komatsu HD785-5 Dump Truck Operation & Maintenance Manual (4188 and up) - SEAM028205P

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the Komatsu Dump Truck HD785-5 (SN: 4188 and up). It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Komatsu HD785-5 Dump Truck
Serial Numbers : H0785-4188 and up


TABLE OF CONTENTS :

COVER
FOREWORD
- FOREWORD
- SAFETY INFORMATION
- INTENDED USE
- LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
CONTENTS
SAFETY
- SAFETY INFORMATION
- SAFETY LABLES
- GENERAL PRECAUTIONS
- PRECAUTIONS DURING OPERATION
- PRECAUTIONS FOR MAINTENANCE
- PRECAUTIONS WITH TIRES
OPERATION
- GENERAL VIEW
- EXPLANATION OF COMPONENTS
- OPERATION
- DETERMINING AND MAINTAINING TRAVEL ROAD
- COLD WEATHER OPERATION
- LONG-TERM STORAGE
- TROUBLESHOOTING
MAINTENANCE
- GUIDES TO MAINTENANCE
- OUTLINES OF SERVICE
- WEAR PARTS
- USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
- STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
- PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
- MAINTENANCE SCHEDULE CHART
- SERVICE PROCEDURE
SPECIFICATIONS
ATTACHMENTS,OPTIONS
- HANDLING PAYLOAD METER
- TACHOGRAPH(TCO 15-6)
- REVO TACHOGRAPH(TCO 15-7)
- USING DIFFERENTIAL LOCK
- OPERATION OF ABS AND ABS/ASR
- ARSC (AUTOMATIC RETARDER SPEED CONTROL)
- PMC (POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR OPERATION AND MAINTENANCE)
- ASR-Ⅱ (AUTOMATIC SPIN REGULATOR Ⅱ)
HIGH ALTITUDE SPECIFICATIONS
- EXPLANATION OF COMPONENTS
- SERVICE PROCEDURE
INDEX


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEAM028205P
Total Pages : 272


This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance.

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COVER
FOREWORD
- FOREWORD
- SAFETY INFORMATION
- INTENDED USE
- - DIRECTIONS OF MACHINE
- LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
- - MACHINE SERIAL NO.PLATE POSITION
- - ENGINE SERIAL NO.PLATE POSITION
- - SERVICE METER POSITION
- - TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

CONTENTS

SAFETY
- SAFETY INFORMATION
- SAFETY LABLES
- - POSITION FOR ATTACHING SAFETY LABELS
- - SAFETY LABELS
- GENERAL PRECAUTIONS
- - SAFETY RULES
- - IF ABNORMALITIES ARE FOUND
- - CLOTHING AND PERSONAL PROTECTIVE ITEMS
- - FIRE EXTINGUISHER AND FIRST AID KIT
- - SAFETY FEATURES
- - KEEP MACHINE CLEAN
- - INSIDE OPERATOR'S COMPARTMENT
- - ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT
- - HANDRAILS AND STEPS
- - MOUNTING AND DISMOUNTING
- - PREVENTION OF BURNS
- - FIRE PREVENTION
- - ACTION IF FIRE OCCURS
- - WINDOW WASHER LIQUID
- - PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)
- - PRECAUTIONS FOR ATTACHMENTS
- - UNAUTHORIZED MODIFICATION
- - SAFETY AT WORKSITE
- - WORKING ON LOOSE GROUND
- - DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES
- - ENSURE GOOD VISIBILITY
- - PRECAUTIONS ON INDOOR VENTILATION
- - CHECKING SIGNALMAN'S SIGNALS AND SIGNS
- - ASBESTOS DUST HAZARD PREVENTION
- PRECAUTIONS DURING OPERATION
- - BEFORE STARTING ENGINE
- - - CHECKS BEFORE STARTING ENGINE, ADJUST
- - - PRECAUTIONS WHEN STARTING ENGINE
- - - PRECAUTIONS IN COLD AREAS
- - AFTER STARTING ENGINE
- - - CHECK AFTRE STARTING ENGINE
- - - PRECAUTIONS WHEN TRAVELING FORWARD OR REVERSE
- - - PRECAUTIONS DURING OPERATION
- - - PRECAUTIONS WHEN TRAVELING ON THE SLOPES
- - - PRECAUTIONS WHEN OPERATING DUMP BODY
- - - PRECAUTIONS FOR OPERATION
- - - METHOD OF USING BRAKES
- - - PRECAUTIONS UNDER THE SNOWING AND FREEZING CONDITION
- - - PRECAUTIONS FOR PARKING
- - BATTERY
- - - BATTERY HAZARD PREVENTION
- - - STARTING WITH BOOSTER CABLES
- - TOWING
- - - WHEN TOWING
- PRECAUTIONS FOR MAINTENANCE
- - WARNING TAG
- - KEEP WORK PLACE CLEAN AND TIDY
- - APPOINT LEADER WHEN WORKING WITH OTHERS
- - STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE
- - TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING
- - PROPER TOOLS
- - HANDLING SUSPENTION CYLINDER
- - PERSONNEL
- - WORK UNDER THE MACHINE
- - NOISE
- - PRECAUTIONS WHEN USING HAMMER
- - REPAIR WELDING
- - REMOVING BATTERY TERMINAL
- - PRECAUTIONS WITH HIGH-PRESSURE OIL
- - HANDLING HIGH-PRESSURE HOSES, PIPING
- - WASTE MATERIALS
- - MAINTENANCE OF AIR CONDITIONER
- - COMPRESSED AIR
- - PERIODIC REPLACEMENT OF SAFETY-CIRTICAL PARTS
- PRECAUTIONS WITH TIRES
- - HANDLING TIRES
- - PRECAUTIONS WHEN STORING TIRE

OPERATION
- GENERAL VIEW
- - GENERAL VIEW OF MACHINE
- - GENERAL VIEW OF CONTROLS AND GAUGES
- EXPLANATION OF COMPONENTS
- - MACHINE MONITOR
- - SWITCHES
- - CONTROL LEVERS AND PEDALS
- - MECHATRONICS EQUIPMENT CONTROLLER
- - SAFETY PIN
- - DUST INDICATOR
- - FUSES
- - CAR RADIO
- - AIR CONDITIONER
- - CAR HEATER
- - LOCATION OF FIRE EXTINGUISHER
- - LOCATION OF FIRST AID KIT
- OPERATION
- - CHECK BEFORE STARTING ENGINE
- - STARTING ENGINE
- - OPERATIONS, CHECKS AFTER STARTING ENGINE
- - STOPPING ENGINE
- - CHECKS AFTER STOPPING ENGINE
- - MOVING MACHINE OFF(FORWARD, REVERSE), STOPPING
- - SHIFTING GEAR
- - TRAVELING DOWNHILL
- - STEERING THE MACHINE
- - LOADING OPERATIONS
- - DUMP OPERATIONS
- - PRECAUTIONS FOR OPERATION
- - PARKING MACHINE
- - CHECKS AFTER COMPLETION OF WORK
- - DRAIN WATER FROM TANK
- - LOCKING
- - HANDLING TIRES
- DETERMINING AND MAINTAINING TRAVEL ROAD
- - DETERMINING TRAVEL ROAD
- - MAINTAINING TRAVEL ROAD
- COLD WEATHER OPERATION
- - PRECAUTIONS FOR LOW TEMPERATURE
- - PRECAUTIONS AFTER COMPLETION OF WORK
- - AFTER COLD WEATHER
- LONG-TERM STORAGE
- - BEFOR STORAGE
- - DURING STORAGE
- - AFTER STORAGE
- - PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE
- TROUBLESHOOTING
- - AFTER RUNNING OUT OF FUEL
- - TOWING THE MACHINE
- - IF BATTERY IS DISCHARGED
- - OTHER TROUBLE

MAINTENANCE
- GUIDES TO MAINTENANCE
- OUTLINES OF SERVICE
- - HANDLING OIL,FUEL,COOLANT,AND PERFORMING OIL CLINIC
- - OUTLINE OF ELECTRIC SYSTEM
- WEAR PARTS
- - WEAR PARTS LIST
- USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
- STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
- - TORQUE LIST
- PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
- - SAFETY CRITICAL PARTS
- MAINTENANCE SCHEDULE CHART
- - MAINTENANCE SCHEDULE CHART
- SERVICE PROCEDURE
- - INITIAL 250 HOURS SERVICE(ONLY AFTER THE FIRST 250 HOURS)
- - WHEN REQUIRED
- - - CHECK,CLEAN OR REPLACE AIR CLEANER
- - - CLEAN INSIDE OF COOLING SYSTEM
- - - CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID
- - - CLEAN AIR CONDITIONER AIR FILTER
- - - CHECK REFRIGERANT(GAS) LEVEL
- - - CHECK DUMP BODY
- - - CHECK ELECTRIC INTAKE AIR HEATER
- - - CHECK LENGTH OF SUSPENSION CYLINDER, CHECK OIL LEVEL
- - - BLEED AIR FROM REAR BRAKE
- - - BLEED AIR FROM FRONT BRAKE
- - - ADJUST PARKING BRAKE
- - - ADJUST BODY POSITIONER
- - - REPLACE FAN BELT,ADJUST AUTO TENSIONER
- - - CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT
- - - SELECTION AND INSPECTION OF TIRES
- - CHECK BEFORE STARTING
- - EVERY 250 HOURS SERVICE
- - - CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL
- - - CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
- - - LUBRICATING
- - - CHECK LEVEL OF BATTERY ELECTROLYTE
- - - CHECK ALTERNATOR BELT, ADJUST
- - - CHECK TENSION OF AIR CONDITIONER COMPRESSOR BELT,ADJUST
- - - CLEAN BREATHERS
- - - CHECK DRIVE SHAFT
- - - CHECK FRAME
- - - CHECK BRAKING CAPACITY OF FOOT BRAKE
- - - CHECK BRAKING CAPACITY OF RETARDER BRAKE
- - - CHECK BRAKING CAPACITY OF PARKING BRAKE
- - - CHECK WEAR OF PARKING BRAKE PADS
- - - CHECK,CLEAN AUTOMATIC SUSPENSION
- - - INSPECTION OF ENGINE EMERGENCY STOP
- - EVERY 500 HOURS SERVICE
- - - CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
- - - REPLACE FUEL FILTER CARTRIDGE
- - - REPLACE TRANSMISSION OIL FILTER ELEMENT
- - - CHECK WEAR OF FRONT DISK BRAKE PADS
- - - CLEAN,CHECK RADIATOR FINS
- - - CHECK FAN BELT FOR WEAR AND REPLACE
- - EVERY 1000 HOURS SERVICE
- - - REPLACE CORROSION RESISTOR CARTRIDGE
- - - CHANGE OIL IN TRANSMISSION CASE, CLEAN TRANSMISSION CASE STRAINER
- - - REPLACE TRANSMISSION AND REAR BRAKE COOLING OIL FILTER ELEMENT
- - - LUBRICATION
- - - CHECK WEAR OF REAR BRAKE DISC
- - - CHECK TIGHTENING PARTS OF TURBOCHARGER
- - EVERY 2000 HOURS SERVICE
- - - CHANGE OIL IN STEERING,HOIST OIL TANK
- - - CHANGE OIL IN REAR BRAKE COOLING OIL TANK
- - - CHANGE OIL IN FINAL DRIVE CASE
- - - CHANGE OIL IN DIFERENTIAL CASE
- - - CLEAN DIFFERENTIAL CASE BREATHER
- - - CLEAN EMERGENCY RELAY VALVE
- - - CHECK ALTERNATOR STARTING MOTOR
- - - CHECK, ADJUST ENGINE VALVE CLEARANCE
- - - CLEAN,CHECK TURBOCHARGER
- - - CHECK PLAY OF TURBOCHARGER ROTOR
- - - LUBRICATE DUMP CONTROL LINKAGE (5 POINTS)
- - - CLEAN AIR DRYER FILTER AND DEFLECTOR (IF EQUIPPED)
- - - REPLACE PLUG WITH STRAINER FROM MAKE-UP TANK OF REAR BRAKE CHAMBER
- - EVERY 4000 HOURS SERVICE
- - - CHECK WATER PUMP
- - - CHECK AIR COMPRESSOR
- - - CHECK FAN PULLEY AND TENSION PULLEY
- - - CHECK VIBRATION DAMPER
- - - CHECK INJECTION PUMP RACK RUBBER BOOT,REPLACE
- - - REPLACE INJECTION PUMP SCREEN FILTER
- - - CLEAN INJECTION PUMP OIL INLET STRAINER
- - - ADJUST FRONT WHEEL BEARING
- - - ADJUST REAR WHEEL BEARING

SPECIFICATIONS
- SPECIFICATIONS

ATTACHMENTS,OPTIONS
- HANDLING PAYLOAD METER
- - NAME OF PARTS
- - EXTERNAL DISPLAY LAMPS
- - OPERATING PAYLOAD METER
- TACHOGRAPH(TCO 15-6)
- - EXPLANATION OF COMPONENTS
- - METHOD OF USING KEY
- - METHOD OF USE
- REVO TACHOGRAPH(TCO 15-7)
- - EXPLANATION OF COMPONENTS
- - METHOD OF USE
- USING DIFFERENTIAL LOCK
- - DIFFERENTIAL LOCK PEDAL
- - PRECAUTIONS AND METHOD OF USE
- OPERATION OF ABS AND ABS/ASR
- - EXPLANATION OF COMPONENTS
- - OPERATION METHOD
- - PRECAUTIONS FOR USE
- - TROUBLESHOOTING
- ARSC (AUTOMATIC RETARDER SPEED CONTROL)
- - EXPLANATION OF COMPONENTS
- - METHOD OF OPERATION
- - TROUBLESHOOTING
- PMC (POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR OPERATION AND MAINTENANCE)
- - CHECK BEFORE STARTING
- - ABNORMALITY DISPLAYED DURING OPERATION
- - HOW TO DOWNLOAD THE STORED DATA IN PMC AND OTHER CONTROLLERS
- - MESSAGE FOR OPERATIONAND MAINTENANCE (MOM)
- ASR-Ⅱ (AUTOMATIC SPIN REGULATOR Ⅱ)
- - EXPLANATION OF COMPONENTS
- - ACTUATION OF ASR-Ⅱ SYSTEM
- - PRECAUTIONS WHEN USING
- - TROUBLESHOOTING

HIGH ALTITUDE SPECIFICATIONS
- EXPLANATION OF COMPONENTS
- SERVICE PROCEDURE
- - CHECK BEFORE STARTING
- - EVERY 2000 HOURS SERVICE

INDEX

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