Komatsu HD785-5 Manual

DUMP TRUCK
PEN00042-03
HD785 -5
SERIAL NUMBERS 4254 and up
Komatsu has Operation & Maintenance Manuals written
in some other languages. if a foreign language manual
is necessary, contact your local distributor for
availability.
NOTICE
Unsafe Use of this machine may cause serious injury or
Death.Operators and maintenance personnel must read
this manual before operating or maintaining this machine.
This manual should be kept near the machine for
reference and periodically reviewed by all personnel
who will come into contact with it .
WARNING

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FOREWORD
FOREWORD
FOREWORD
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. Most
accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of
machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when
performing operation and maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or maintenance.
Always be sure to read and understand this manual thoroughly before performing operation and maintenance.
Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you
understand them fully.
Keep this manual in the storage location for the operation and maintenance manual given below, and have all personnel read it
periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu
or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
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 or purchased from someone 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.
Place to Keep the Manual
It is located behind the operator's seat.
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FOREWORD FOREWORD
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FOREWORD
FOREWORD
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FOREWORD SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such
situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may cause
property damage.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the safety lock lever in the LOCK position.
If you accidentally touch the control levers when they are not locked, this may cause a serious injury or death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to
protect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
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FOREWORD
SAFETY INFORMATION
Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out
operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.
Example of safety label using words
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazardous
condition equivalent to the signal word. These safety pictograms
use pictures in order to let the operator or maintenance worker
understand the level and type of hazardous condition at all times.
Safety pictograms show the type of hazardous condition at the top
or left side, and the method of avoiding the hazardous condition at
the bottom or right side. In addition, the type of hazardous condition
is displayed inside a triangle and the method of avoiding the
hazardous condition is shown inside a circle.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility
to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1-> (1))
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FOREWORD INTENDED USE
INTENDED USE
DIRECTIONS OF MACHINE
In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the
operator's seat in the direction of travel (front) of the machine.
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FOREWORD
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND
DISTRIBUTOR
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
It is located on the left front end of the frame.
The design of the nameplate differs according to the territory.
ENGINE SERIAL NO. PLATE POSITION
The engine serial number plate is on the upper right side of (viewed
from the fan) the cylinder block (on the intake manifold cover).
SERVICE METER POSITION
It is located on the right side of the meter section.
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FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Product identification number (PIN)
Distributor name
Address
Service Personnel
Phone/Fax
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FOREWORD
CONTENTS
CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 5
INTENDED USE 1- 7
DIRECTIONS OF MACHINE 1- 7
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 8
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 8
ENGINE SERIAL NO. PLATE POSITION 1- 8
SERVICE METER POSITION 1- 8
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 9
SAFETY 2- 1
SAFETY INFORMATION 2- 2
SAFETY LABELS 2- 4
POSITION FOR ATTACHING SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
GENERAL PRECAUTIONS 2- 10
PRECAUTIONS DURING OPERATION 2- 18
BEFORE STARTING ENGINE 2- 18
AFTER STARTING ENGINE 2- 20
BATTERY 2- 23
TOWING 2- 25
PRECAUTIONS FOR MAINTENANCE 2- 26
PRECAUTIONS WITH TIRES 2- 32
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
SWITCHES 3- 22
CONTROL LEVERS AND PEDALS 3- 30
MECHATRONICS EQUIPMENT CONTROLLER 3- 34
SAFETY PIN 3- 35
DUST INDICATOR 3- 35
FUSES 3- 36
CAR STEREO 3- 38
AIR CONDITIONER 3- 47
CAR HEATER 3- 52
LOCATION OF FIRE EXTINGUISHER 3- 53
LOCATION OF FIRST AID KIT 3- 53
OPERATION 3- 54
CHECK BEFORE STARTING ENGINE 3- 54
STARTING ENGINE 3- 70
OPERATIONS, CHECKS AFTER STARTING ENGINE 3- 73
STOPPING ENGINE 3- 74
CHECKS AFTER STOPPING ENGINE 3- 74
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING 3- 75
SHIFTING GEAR 3- 80
TRAVELING DOWNHILL 3- 81
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FOREWORD CONTENTS
STEERING THE MACHINE 3- 87
LOADING OPERATIONS 3- 87
DUMP OPERATIONS 3- 88
PRECAUTIONS FOR OPERATION 3- 89
PARKING MACHINE 3- 90
CHECKS AFTER COMPLETION OF WORK 3- 91
DRAIN WATER FROM AIR TANK 3- 91
LOCKING 3- 92
HANDLING TIRES 3- 93
DETERMINING AND MAINTAINING TRAVEL ROAD 3- 95
DETERMINING TRAVEL ROAD 3- 95
MAINTAINING TRAVEL ROAD 3- 95
TRANSPORTATION 3- 96
PRECAUTIONS WHEN TRANSPORTING 3- 96
STEPS FOR TRANSPORTATION 3- 96
METHOD OF SECURING MACHINE 3- 97
METHOD OF LIFTING MACHINE 3- 98
COLD WEATHER OPERATION 3-100
PRECAUTIONS FOR LOW TEMPERATURE 3-100
PRECAUTIONS AFTER COMPLETION OF WORK 3-101
AFTER COLD WEATHER 3-102
LONG-TERM STORAGE 3-103
BEFORE STORAGE 3-103
DURING STORAGE 3-103
AFTER STORAGE 3-103
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE 3-103
TROUBLESHOOTING 3-104
AFTER RUNNING OUT OF FUEL 3-104
METHOD OF TOWING MACHINE 3-104
IF BATTERY IS DISCHARGED 3-109
OTHER TROUBLE 3-113
MAINTENANCE 4- 1
GUIDES TO MAINTENANCE 4- 2
OUTLINE OF SERVICE 4- 4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 4
OUTLINE OF ELECTRIC SYSTEM 4- 7
WEAR PARTS 4- 8
WEAR PARTS LIST 4- 8
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 9
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 10
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL 4- 11
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 12
TORQUE LIST 4- 12
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 13
SAFETY CRITICAL PARTS 4- 14
MAINTENANCE SCHEDULE CHART 4- 15
MAINTENANCE SCHEDULE CHART 4- 15
SERVICE PROCEDURE 4- 18
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) 4- 18
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FOREWORD
CONTENTS
WHEN REQUIRED 4- 19
CHECK BEFORE STARTING 4- 36
EVERY 100 HOURS SERVICE 4- 37
EVERY 250 HOURS SERVICE 4- 38
EVERY 500 HOURS SERVICE 4- 53
EVERY 1000 HOURS SERVICE 4- 58
EVERY 2000 HOURS SERVICE 4- 63
EVERY 4000 HOURS SERVICE 4- 69
EVERY 15000 HOURS SERVICE 4- 71
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
HANDLING PAYLOAD METER 6- 2
NAME OF PARTS 6- 2
EXTERNAL DISPLAY LAMPS 6- 3
OPERATING PAYLOAD METER 6- 5
TACHOGRAPH (TCO 15-6) 6- 13
EXPLANATION OF COMPONENTS 6- 13
METHOD OF USING KEY 6- 15
METHOD OF USE 6- 15
REVO TACHOGRAPH (TCO 15-7) 6- 17
EXPLANATION OF COMPONENTS 6- 17
METHOD OF USE 6- 19
USING DIFFERENTIAL LOCK 6- 21
DIFFERENTIAL LOCK PEDAL 6- 21
PRECAUTIONS AND METHOD OF USE 6- 22
OPERATION OF ABS AND ABS/ASR 6- 23
EXPLANATION OF COMPONENTS 6- 23
OPERATION METHOD 6- 25
PRECAUTIONS FOR USE 6- 26
TROUBLESHOOTING 6- 26
ARSC (AUTOMATIC RETARDER SPEED CONTROL) 6- 27
EXPLANATION OF COMPONENTS 6- 28
METHOD OF OPERATION 6- 30
TROUBLESHOOTING 6- 32
PMC (POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR
OPERATION AND MAINTENANCE) 6- 35
CHECK BEFORE STARTING 6- 35
ABNORMALITY DISPLAYED DURING OPERATION 6- 35
HOW TO DOWNLOAD THE STORED DATA IN PMC AND OTHER CONTROLLERS 6- 35
MESSAGE FOR OPERATION AND MAINTENANCE (MOM) 6- 36
ASR-II (AUTOMATIC SPIN REGULATOR II) 6- 41
EXPLANATION OF COMPONENTS 6- 41
ACTUATION OF ASR-II SYSTEM 6- 42
PRECAUTIONS WHEN USING 6- 42
TROUBLESHOOTING 6- 43
HANDLING AUTO-GREASING SYSTEM 6- 45
OUTLINE OF AUTO-GREASING SYSTEM 6- 45
SETTING GREASE CAN 6- 46
INITIAL SETTING OF AUTO-GREASING SYSTEM 6- 47
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FOREWORD CONTENTS
METHOD OF OPERATING AUTO-GREASING SYSTEM 6- 47
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM 6- 48
POSITION OF EACH INJECTOR 6- 52
GREASING POINTS FOR EACH INJECTOR 6- 56
HIGH ALTITUDE SPECIFICATIONS 7- 1
EXPLANATION OF COMPONENTS 7- 2
SERVICE PROCEDURE 7- 3
CHECK BEFORE STARTING 7- 3
EVERY 2000 HOURS SERVICE 7- 4
INDEX 8- 1
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SAFETY
SAFETY INFORMATION
SAFETY INFORMATION
SAFETY LABELS 2- 4
POSITION FOR ATTACHING SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
GENERAL PRECAUTIONS 2- 10
SAFETY RULES 2- 10
IF ABNORMALITIES ARE FOUND 2- 10
CLOTHING AND PERSONAL PROTECTIVE ITEMS 2- 10
FIRE EXTINGUISHER AND FIRST AID KIT 2- 10
SAFETY FEATURES 2- 10
KEEP MACHINE CLEAN 2- 11
INSIDE OPERATOR'S COMPARTMENT 2- 11
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT 2- 11
HANDRAILS AND STEPS 2- 12
MOUNTING AND DISMOUNTIN 2- 12
PREVENTION OF BURNS 2- 13
FIRE PREVENTION 2- 13
ACTION IF FIRE OCCURS 2- 14
WINDOW WASHER LIQUID 2- 14
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure) 2- 15
PRECAUTIONS FOR ATTACHMENTS 2- 15
UNAUTHORIZED MODIFICATION 2- 15
SAFETY AT WORKSITE 2- 15
WORKING ON LOOSE GROUND 2- 16
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 16
ENSURE GOOD VISIBILITY 2- 16
PRECAUTIONS ON INDOOR VENTILATION 2- 17
CHECKING SIGNALMAN'S SIGNALS AND SIGNS 2- 17
ASBESTOS DUST HAZARD PREVENTION 2- 17
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SAFETY SAFETY INFORMATION
PRECAUTIONS DURING OPERATION 2- 18
BEFORE STARTING ENGINE 2- 18
CHECKS BEFORE STARTING ENGINE, ADJUST 2- 18
PRECAUTIONS WHEN STARTING ENGINE 2- 18
PRECAUTIONS IN COLD AREAS 2- 19
AFTER STARTING ENGINE 2- 20
CHECK AFTER STARTING ENGINE 2- 20
PRECAUTIONS WHEN TRAVELING FORWARD OR REVERSE 2- 20
PRECAUTIONS DURING OPERATION 2- 21
PRECAUTIONS WHEN TRAVELING ON THE SLOPES 2- 21
PRECAUTIONS WHEN OPERATING DUMP BODY 2- 21
PRECAUTIONS FOR OPERATION 2- 21
METHOD OF USING BRAKES 2- 21
PRECAUTIONS UNDER THE SNOWING AND FREEZING CONDITION 2- 22
PRECAUTIONS FOR PARKING 2- 22
BATTERY 2- 23
BATTERY HAZARD PREVENTION 2- 23
STARTING WITH BOOSTER CABLES 2- 24
TOWING 2- 25
WHEN TOWING 2- 25
PRECAUTIONS FOR MAINTENANCE 2- 26
WARNING TAG 2- 26
KEEP WORK PLACE CLEAN AND TIDY 2- 26
APPOINT LEADER WHEN WORKING WITH OTHERS 2- 26
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 2- 27
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2- 28
PROPER TOOLS 2- 28
HANDLING SUSPENTION CYLINDER 2- 29
PERSONNEL 2- 29
WORK UNDER THE MACHINE 2- 29
NOISE 2- 29
PRECAUTIONS WHEN USIN HAMMER 2- 29
REPAIR WELDING 2- 29
REMOVING BATTERY TERMINAL 2- 30
PRECAUTIONS WITH HIGH-PRESSURE OIL 2- 30
HANDLING HIGH-PRESSURE HOSES, PIPING 2- 30
WASTE MATERIALS 2- 30
MAINTENANCE OF AIR CONDITIONER 2- 30
COMPRESSED AIR 2- 31
PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS 2- 31
PRECAUTIONS WITH TIRES 2- 32
HANDLING TIRES 2- 32
PRECAUTIONS WHEN STORING TIRE 2- 32
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SAFETY
SAFETY LABELS
SAFETY LABELS
The following warning signs and safety labels are used on this machine.
Be sure that you fully understand the correct position and content of labels.
To ensure that the content of labels can be read properly, be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to
peel off.
There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same
way.
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
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SAFETY SAFETY LABELS
POSITION FOR ATTACHING SAFETY LABELS
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SAFETY
SAFETY LABELS
SAFETY LABELS
(1) Roll-over protective structure (ROPS) (09620-30202)
(2) Caution for checking engine room (09667-A0880)
(3) Caution for opening hydraulic tank cap
Caution for opening radiator cap (09653-A0641)
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