Komatsu HD785-7 Dump Truck Operation and Maintenance Manual TEN00598-02

Description

• Model List:
  • HD785-7 Dump Truck

• 1. COVER
• 2. FOREWORD
• 2.1. BEFORE READING THIS MANUAL
• 2.2. SAFETY INFORMATION
• 2.3. INTENDED USE
• 2.3.1. USE OF MACHINE
• 2.3.2. DIRECTIONS OF MACHINE
• 2.3.3. VISIBILITY FROM OPERATORS SEAT
• 2.4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
• 2.4.1. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
• 2.4.2. EPA REGULATIONS, ENGINE NUMBER PLATE
• 2.4.3. SERVICE METER POSITION
• 2.4.4. TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
• 2.5. CONTENTS
• 3. SAFETY
• 3.1. SAFETY
• 3.2. SAFETY LABELS
• 3.2.1. POSITION FOR ATTACHING SAFETY LABELS
• 3.2.2. SAFETY LABELS
• 3.3. GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
• 3.3.1. PRECAUTIONS BEFORE STARTING OPERATION
• 3.3.2. PREPARATIONS FOR SAFE OPERATION
• 3.3.3. FIRE PREVENTION
• 3.3.4. PRECAUTIONS WHEN GETTING ON OR OFF MACHINE
• 3.3.5. DO NOT GET CAUGHT IN DUMP BODY
• 3.3.6. PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES
• 3.3.7. UNAUTHORIZED MODIFICATION
• 3.3.8. PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS
• 3.3.9. PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING
• 3.4. PRECAUTIONS FOR OPERATION
• 3.4.1. PRECAUTIONS FOR JOBSITE
• 3.4.2. STARTING ENGINE
• 3.4.3. OPERATION
• 3.4.4. TRANSPORTATION
• 3.4.5. TOWING
• 3.5. PRECAUTIONS FOR MAINTENANCE
• 3.5.1. PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE
• 3.5.2. PRECAUTIONS FOR INSPECTION AND MAINTENANCE
• 3.5.3. TIRES
• 4. OPERATION
• 4.1. GENERAL VIEW
• 4.1.1. GENERAL VIEW OF MACHINE
• 4.1.2. GENERAL VIEW OF CONTROLS AND GAUGES
• 4.2. EXPLANATION OF COMPONENTS
• 4.2.1. MACHINE MONITOR
• 4.2.2. OTHER FUNCTIONS OF MACHINE MONITOR
• 4.2.3. SWITCHES
• 4.2.4. CONTROL LEVERS AND PEDALS
• 4.2.5. BODY PIVOT PIN
• 4.2.6. LOCATION OF FIRE EXTINGUISHER
• 4.2.7. DUST INDICATOR
• 4.2.8. FUSES
• 4.2.9. CAR RADIO
• 4.2.10. AIR CONDITIONER
• 4.2.11. HANDLING MACHINES EQUIPPED WITH KOMTRAX Plus
• 4.3. OPERATION
• 4.3.1. CHECK BEFORE STARTING ENGINE
• 4.3.2. STARTING ENGINE
• 4.3.3. BREAKINGIN THE MACHINE
• 4.3.4. OPERATIONS, CHECKS AFTER STARTING ENGINE
• 4.3.5. STOPPING ENGINE
• 4.3.6. CHECKS AFTER STOPPING ENGINE
• 4.3.7. MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING
• 4.3.8. SHIFTING GEAR
• 4.3.9. TRAVELING DOWNHILL
• 4.3.10. STEERING THE MACHINE
• 4.3.11. LOADING OPERATIONS
• 4.3.12. DUMP OPERATIONS
• 4.3.13. PRECAUTIONS FOR OPERATION
• 4.3.14. PARKING MACHINE
• 4.3.15. CHECKS AFTER COMPLETION OF WORK
• 4.3.16. LOCKING
• 4.3.17. HANDLING TIRES
• 4.4. DETERMINING AND MAINTAINING TRAVEL ROAD
• 4.4.1. DETERMINING TRAVEL ROAD
• 4.4.2. MAINTAINING TRAVEL ROAD
• 4.5. TRANSPORTATION
• 4.5.1. PRECAUTIONS WHEN TRANSPORTING
• 4.5.2. STEPS FOR TRANSPORTATION
• 4.5.3. METHOD OF SECURING MACHINE
• 4.5.4. METHOD OF LIFTING MACHINE
• 4.6. COLD WEATHER OPERATION
• 4.6.1. PRECAUTIONS FOR LOW TEMPERATURE
• 4.6.2. INSTALLATION OF RADIATOR CURTAIN
• 4.6.3. PRECAUTIONS AFTER COMPLETION OF WORK
• 4.6.4. AFTER COLD WEATHER
• 4.7. LONGTERM STORAGE
• 4.7.1. BEFORE STORAGE
• 4.7.2. DURING STORAGE
• 4.7.3. AFTER STORAGE
• 4.7.4. PRECAUTIONS BEFORE TRAVELING AFTER LONGTERM STORAGE
• 4.8. TROUBLESHOOTING
• 4.8.1. AFTER RUNNING OUT OF FUEL
• 4.8.2. IF TRANSMISSION HAS TROUBLE
• 4.8.3. METHOD OF LOWERING DUMP BODY IN EMERGENCY
• 4.8.4. METHOD OF TOWING MACHINE
• 4.8.5. IF BATTERY IS DISCHARGED
• 4.8.6. OTHER TROUBLE
• 5. MAINTENANCE
• 5.1. GUIDES TO MAINTENANCE
• 5.2. OUTLINE OF SERVICE
• 5.2.1. HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
• 5.2.2. OUTLINE OF ELECTRIC SYSTEM
• 5.3. WEAR PARTS
• 5.3.1. WEAR PARTS LIST
• 5.4. RECOMMENDED FUEL, COOLANT, AND LUBRICANT
• 5.4.1. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
• 5.4.2. RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL
• 5.5. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
• 5.5.1. TORQUE LIST
• 5.6. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
• 5.6.1. SAFETY CRITICAL PARTS
• 5.7. MAINTENANCE SCHEDULE CHART
• 5.7.1. MAINTENANCE SCHEDULE CHART
• 5.8. SERVICE PROCEDURE
• 5.8.1. INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
• 5.8.2. WHEN REQUIRED
• 5.8.3. CHECK BEFORE STARTING
• 5.8.4. EVERY 250 HOURS SERVICE
• 5.8.5. EVERY 500 HOURS SERVICE
• 5.8.6. EVERY 1000 HOURS SERVICE
• 5.8.7. EVERY 2000 HOURS SERVICE
• 5.8.8. EVERY 4000 HOURS SERVICE
• 5.8.9. EVERY 8000 HOURS SERVICE
• 5.8.10. EVERY 15000 HOURS SERVICE
• 6. SPECIFICATIONS
• 6.1. SPECIFICATIONS
• 7. ATTACHMENTS, OPTIONS
• 7.1. SELECTING DUMP BODY
• 7.2. AUXILIARY ELECTRIC POWER
• 7.3. HANDLING AIR SUSPENSION SEAT
• 7.3.1. SEAT ADJUSTMENT
• 7.3.2. REMOVAL AND INSTALLATION OF HEADREST
• 7.4. HANDLING KOMATSU TRACTION CONTROL SYSTEM (KTCS)
• 7.4.1. EXPLANATION OF COMPONENTS
• 7.4.2. ACTUATION OF KTCS SYSTEM
• 7.4.3. PRECAUTIONS WHEN USING
• 7.4.4. TROUBLESHOOTING
• 7.4.5. BLEEDING AIR FROM KTCS CIRCUIT
• 7.5. HANDLING AUTOMATIC SPIN REGULATOR (ASR)
• 7.5.1. EXPLANATION OF COMPONENTS
• 7.5.2. ACTUATION OF ASR SYSTEM
• 7.5.3. PRECAUTIONS WHEN USING
• 7.5.4. TROUBLESHOOTING
• 7.5.5. BLEEDING AIR FROM ASR CIRCUIT
• 7.6. HANDLING ABS
• 7.6.1. EXPLANATION OF COMPONENTS
• 7.6.2. ABS SYSTEM CHECK AFTER STARTING ENGINE
• 7.6.3. OPERATION OF ABS
• 7.6.4. PRECAUTIONS WHEN USING
• 7.6.5. TROUBLESHOOTING
• 7.7. HANDLING PAYLOAD METER (KOMTRAX Plus BUILTIN TYPE)
• 7.7.1. OUTLINE OF SYSTEM
• 7.7.2. NORMAL OPERATION DISPLAY
• 7.7.3. EXTERNAL DISPLAY LAMPS
• 7.7.4. PERFORMING CALIBRATION
• 7.7.5. DATA STORED IN PAYLOAD METER
• 7.7.6. PROCEDURE WHEN DOWNLOADING
• 7.7.7. METHOD OF SETTING MACHINE ID, OPEN ID
• 7.7.8. PAYLOAD (CYCLE DATA ITEM)
• 7.7.9. SERVICE FUNCTIONS
• 7.7.10. OTHERS
• 7.8. HANDLING AUTOGREASING SYSTEM
• 7.8.1. METHOD OF OPERATING AUTOGREASING SYSTEM
• 7.8.2. METHOD OF SETTING TIMER
• 7.8.3. BLEEDING AIR FROM GREASE CIRCUIT
• 7.8.4. METHOD OF ADJUSTING DISCHARGE FROM INJECTOR
• 7.8.5. CHECKING OPERATION OF INJECTOR
• 7.8.6. METHOD OF CHARGING WITH GREASE
• 7.9. HANDLING REAR VIEW MONITOR
• 7.9.1. EXPLANATION OF COMPONENTS
• 7.10. EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER
• 7.10.1. SOCKET FOR ENGINE HEATER
• 7.10.2. SOCKET FOR ENGINE, TRANSMISSION, HYDRAULIC TANK AND BRAKE SUBTANK HEATER
• 7.10.3. CONNECTING EXTERNAL POWER SOURCE
• 7.10.4. RESTARTING ENGINE
• 7.10.5. HANDLING EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER
• 7.11. HANDLING PRELUBE SYSTEM
• 7.11.1. EXPLANATION OF COMPONENTS
• 7.11.2. OPERATION
• 7.11.3. TROUBLESHOOTING
• 7.12. HANDLING DUMPING COUNTER
• 7.13. HANDLING HIGHALTITUDE SETTING SELECTOR FUNCTION (FOR PLACES AT HIGH ALTITUDE)
• 7.13.1. PRECAUTIONS WHEN USING
• 7.14. EMERGENCY ENGINE STOP SWITCH
• 7.15. HANDLING BATTERY DISCONNECTOR SWITCH
• 7.15.1. EXPLANATION OF COMPONENTS
• 7.15.2. PRECAUTIONS WHEN OPERATING
• 7.16. HANDLING VEHICLE SPEED LIMIT
• 7.16.1. EXPLANATION OF COMPONENTS
• 7.16.2. OPERATION OF VEHICLE SPEED LIMIT
• 7.16.3. TROUBLESHOOTING
• 7.17. HANDLING OF SPEED LIMIT CONTROL FUNCTION IN OVERLOAD STATE
• 7.17.1. EXPLANATION OF COMPONENTS
• 7.17.2. OPERATION OF SPEED LIMIT CONTROL FUNCTION IN OVERLOAD STATE
• 7.17.3. TROUBLESHOOTING
• 7.18. AUTOGREASING REFILLING SYSTEM
• 7.18.1. SYSTEM EXPLANATION
• 7.18.2. OPERATING PROCEDURE OF THE REFILLING SYSTEM
• 7.19. HANDLING POWER LADDER
• 7.19.1. EXPLANATION OF COMPONENTS
• 7.19.2. OPERATION OF POWER LADDER
• 7.19.3. OPERATING THE LADDER WHEN THE STARTING SWITCH IS TURNED OFF
• 7.19.4. POWER LADDER RELATED FUNCTIONS
• 7.19.5. MAINTENANCE OF POWER LADDER
• 7.19.6. SAFETY CRITICAL PARTS FOR PERIODIC REPLACEMENT
• 7.19.7. PROCEDURES WHEN MACHINE BECOMES IMMOVABLE BECAUSE PARKING BRAKE CANNOT BE RELEASED
• 7.19.8. PROCEDURES WHEN THE LADDER BECOMES IMMOVABLE
• 7.19.9. TROUBLESHOOTING
• 8. INDEX