hd785 7 operation

OperationHD785-7

OperationOperation

HD785-7

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GENERAL VIEW

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GENERAL VIEW OF CONTROLS AND GAUGES

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CHARACTER DISPLAY

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CHARACTER DISPLAY

SERVICE METER/ODOMETEREven if the starting switch is at the OFF position, the service meter will display as long as the top part ( ) of machine monitor mode selector switch 1 is being pressed.

USER MODE

REVERSE TRAVEL ODOMETER

RESET METHOD FOR FILTER, OIL REPLACEMENT TIME

1. Press the ( 　　 ) of machine monitor mode selector switch 1, and display the reverse travel in odometer.

2. Press (>) or (<) of machine monitor mode selector switch 2 and display "MAINTENANCE MONITOR".

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CHARACTER DISPLAY

3. Press the ( 　　 ) of machine monitor mode selector switch 1.

4. Press (>) or (<) of machine monitor mode selector switch 2 and display the item to be reset.

5. Press the ( 　　 ) of machine monitor mode selector switch 1.

6. When resetting the replacement time, press (>) or (<) of machine monitor mode selector switch 2, align the cursor with “YES”, then press ( 　　 )

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CHARACTER DISPLAY

METHOD FOR SELECTING LANGUAGE1. Press the ( 　　 ) of machine monitor mode

selector switch 1 and display the reverse travel odometer.

2. Press (>) or (<) of machine monitor mode selector switch 2 and display "LANGUAGE".

3. Press the ( 　　 ) of machine monitor mode selector switch 1. The presently selected language is displayed.

4. Press (>) or (<) of machine monitor mode selector switch 2 and select the language.

5. When the ( 　　 ) of machine monitor mode selector switch 1 is pressed, the language is set and the screen returns to the previous screen.

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CHARACTER DISPLAY

INPUT METHOD FOR TELEPHONE NUMBER1. Press (>) or (<) of machine monitor mode

selector switch 2 and display "TEL".2. Press ( ) of machine monitor mode selector

switch 1. It will change to the display in the diagram on the right.

3. Up to 12 digits can be displayed for the telephone number.Input from the first digits.The cursor is displayed at the input position. Press (>) or (<) of machine monitor mode selector switch 2 and display "0 - 9 ".To leave a blank, select "*".When the input value is decided, press ( ) of machine monitor mode selector switch 1. The cursor will move to the next position.

4. Repeat the procedure in Step 4 until the last digit. At the last digit, press ( )

5. When completing the operation, press ( )

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CHARACTER DISPLAY

METHOD OF SWITCHING BETWEEN RL AND RH1. Press (>) or (<) of machine monitor mode

selector switch 2 to display "SELECT RL → RH" or "SELECT RH → RL".

2. Press ( ) of machine monitor mode selector switch 1. RL or RH is selected

3. When completing the operation, press ( )

ACTION CODE DISPLAY-During Engine Running-

When action codes E02 or E03 occur, the alarm buzzer sounds intermittently and the central warning lamp lights up.

E03: When this code is displayed, stop the machine immediately, check the failure code, and contact your Komatsu distributor for repairs.

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CHARACTER DISPLAY

E02: If overrun related information is displayed, reduce the engine speed and the speed of the machine while continuing operations.E01: If maintenance location is displayed and the maintenance caution lamp lights up, carry out inspection and maintenance of the displayed item after the completion of operations or when the shift changes.FILTER, OIL REPLACEMENT TIME DISPLAY After completion of the system check, this display (5) shows for 30 seconds the filters and oil which are near the replacement interval.The maintenance caution lamp also flashes or lights up at the same time.

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CHARACTER DISPLAY

Items for display of filter, oil replacement time

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CAUTION ITEMS

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EMERGENCY STOP ITEM

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EMERGENCY STOP ITEM

CENTRAL WARNING LAMP

ENGINE WATER TEMPERATURE CAUTION LAMP"E02 ENGINE OVERHEAT“

TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP"E02 TC OVERHEAT"

RETARDER OIL TEMPERATURE CAUTION LAMP"E02 BRAKE OVERHEAT"

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EMERGENCY STOP ITEM

BATTERY CHARGE CIRCUIT CAUTION LAMP

"E03 CHECK RIGHT NOW"

STEERING OIL TEMPERATURE CAUTION LAMP

"E02 STRG OVERHEAT“

ENGINE OIL PRESSURE CAUTION LAMP

"E03 CHECK RIGHT NOW“

BRAKE OIL PRESSURE CAUTION LAMP

"E03 CHECK RIGHT NOW"

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EMERGENCY STOP ITEM

TILT CAUTION LAMPThis monitor (8) lights up if the dump body has left its seat when therear frame of the machine has tilted beyond the safety range to theleft or right.

MACHINE MONITOR, OPTION SYSTEM CAUTION LAMP"E03 CHECK RIGHT NOW"

ENGINE SYSTEM CAUTION LAMP"E03 CHECK RIGHT NOW"

TRANSMISSION SYSTEM CAUTION LAMP"E03 CHECK RIGHT NOW"

RETARDER SYSTEM CAUTION LAMP"E03 CHECK RIGHT NOW"

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PILOT DISPLAY PORTION

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ENGINE PRE-HEATING PILOT LAMP

When the starting switch is turned to the ON position in cold weather.

RETARDER PILOT LAMPLights up when the retarder control lever is pulled and the retarder is actuated.

LOCKUP PILOT LAMPLights up when the torque converter lockup isengaged and the transmission is shifted to direct drive.

HEAD LAMP HIGH BEAM PILOT LAMPlights up when the head lamps are set to high beam. TURN SIGNAL PILOT LAMPFlashes at the same time as the turn signal lampflashes.

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SHIFT INDICATOR

Shows the transmission shift range (speed range).

SHIFT LEVER POSITION PILOT LAMPDisplays the position of the shift lever.The letter or number for the speed range selected by the shift leverlights up.

POWER MODE PILOT LAMPDisplays the power mode.This monitor lights up when the high power mode is used.

AUTO SUSPENSION MODE PILOT LAMP(If equipped)H : Hard modeM : Medium modeS : Soft mode

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AUTO RETARDER SET SPEED INDICATORDisplays the set travel speed for the auto retarder speed control (ARSC).

AUTO RETARDER READY PILOT LAMPShows that the auto retarder speed control can be actuated at the set travel speed.

EXHAUST BRAKE PILOT LAMP(If equipped)Lights up when the exhaust brake is applied.

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METERS

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SWITCHES

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SWITCHES

MACHINE MONITOR BULB CHECK SWITCHTurn the starting switch ON, press this switch (3) and check for anyblown bulbs.POWER MODE SELECTOR SWITCH When the switch is pressed, the mode switches to high powermode and the high power mode pilot lamp on the machine monitorlights up.If the switch is pressed again, the mode returns to the economymode and the power mode pilot lamp on the machine monitor goesout.When the engine is started, the economy mode is selectedautomatically.High power modeOperates at maximum output.Economy mode (general operations)Use this for operations under general standard conditions.

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SWITCHES

EMERGENCY STEERING SWITCHWhen the switch is pressed, the emergency pump is actuated tomake it possible to operate the steering.When the switch is ON, the pilot lamp (red) inside the switch andthe pilot lamp on the machine monitor light up.The emergency steering pump can be used for a maximum of 90seconds.When the emergency steering is being used, keep the travel speedto a maximum of 5 km/h (3.1 MPH).On machines equipped with auto emergency steering, the auto emergency steering is actuated automatically in thefollowing cases.When the steering hydraulic pump failsWhen the engine has stopped during operationWhen the emergency steering is actuated, stop the machine promptly and perform inspection.If the starting switch is at the ON position and the parking brake switch is at the TRAVEL position when the machine is stopped, the automatic emergency steering is actuated after 1 second, so set the parking brake switch to the PARKING position.

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SWITCHES

MACHINE MONITOR MODE SELECTOR SWITCH 1, 2This switch (16) is used to operate the character display.

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CONTROL LEVERS AND PEDALS

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GEAR SHIFT LEVER

R position:

RL: Select this when high rimpull is needed.RH: Select this when travel speed is needed.

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DUMP LEVERA) RAISEB) HOLD: The dump body stops and is held in

position.C) FLOAT: The dump body moves freely under

external force.D) LOWER

RETARDER CONTROL LEVER

DUMP LEVER LOCK KNOB

SECONDARY BRAKE PEDALIt is possible to apply the parking brake with this pedal.Use this brake pedal if the brake pedal is damaged or there is any other problem and the wheel brakes do not work.As a emergency brake.

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CHECK BEFORE STARTING

1. CHECK COOLANT LEVEL, ADD COOLANT

2. CHECK DUST INDICATOR

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3. CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL

4. CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL

5. CHECK OIL LEVEL IN STEERING AND HOIST OIL TANK, ADD OIL

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6. CHECK OIL LEVEL IN BRAKE SUB-TANK, ADD OIL

7. CHECK FOR LEAKAGE OF OIL FROM BRAKE OIL RECOVERY TANKFront & Rear

8. DRAIN WATER, SEDIMENT FROM FUEL TANK

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9. DRAIN WATER FROM FUEL PRE-FILTER

10.CHECK WATER SEPARATOR, DRAIN WATER AND SEDIMENT

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11.CHECK FUEL LEVEL, ADD FUELFuel tank capacity: 1300 liters (343.46 US gal)

12.CHECK WHEEL HUB NUTS, TIGHTENTightening torque: 1519 to 1852 N·m

{155 to 189kgf·m, 1121 to 1367 lbft}

13.CHECK CENTRAL WARNING LAMP, ALARM BUZZER, MONITOR LAMPS AND METERSPress machine monitor check switch (1)

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14.CHECK BRAKING CAPACITY OF SECONDARY BRAKECheck the braking capacity of the secondary brake as follows.

1. Stop the machine on flat ground, raise the oil pressure to the maximum, set the parking brake to TRAVEL, then depress secondary brake pedal (1). ( emergency brake )

2. Set gear shift lever (2) to the D position, gradually raise the engine speed, and check that the machine does not move even when the engine reaches full speed. If the machine does not move, it is normal.

15.CHECK EMERGENCY STEERINGCHECK EMERGENCY STEERING

1. Turn starting switch key to the ON position.2. Turn emergency steering switch (1) ON, and check

that the steering wheel can be operated.If the steering wheel cannot be operated, please contact your Komatsu distributor.

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16.CHECK BACKUP ALARM17.Turn the engine starting switch to the ON position.2. Place the gear shift lever in the R position and check

that the backup alarm is working.

17.CHECK ELECTRIC WIRING

18.CHECK INFLATION PRESSURE OF TIRESMeasure the inflation pressure with a tire pressure gauge, while the tires are cool, before starting work.Check for damage or wear to the tires and the rims.Check for loose wheel hub bolts.

Front wheel and rear wheel

19.DOES BODY POSITIONER OPERATE NORMALLY?

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ARCS (Automatic Retarder Speed Controller)

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TROUBLESHOOTING

AFTER RUNNING OUT OF FUEL1. Fill the fuel tank with fuel.2. Loosen air bleeding plug (2) at the fuel main

filter head.3. Loosen wing bolt (4) which is fixing lever (5)

of priming pump (3). Move lever (5) up and down to let fuel flow out of air bleeding plug (2) until bubbles do not come out any more.

4. Tighten air bleeding plug (1) and then tighten wing bolt (3) of priming pump (2) securely to lock lever (4).

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TROUBLESHOOTING

Emergency Disposal

IF TRANSMISSION HAS TROUBLE1. Decelerate the machine with the brake and

stop it on a safe place.2. Set the shift lever to the N position, then set

the parking brake switch to the PARKING position.

3. In some trouble modes, the gear is not shifted even if the shift lever is operated.In this case, perform the following procedure.

1) Remove emergency escape connector (1) (No. A-1F, A-M, white 1-pin connector), then insert it again.

2) Set the parking brake switch to the TRAVEL position.

3) Operate the shift lever to move the machine to a safe place without depressing the accelerator pedal.

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TROUBLESHOOTING

Emergency Disposal

METHOD OF LOWERING DUMP BODY IN EMERGENCY

1. Remove hydraulic tank cap (F) and release the remaining pressure in the hoist circuit

2. Loosen locknut (2) of manual lower valve (1).

3. Turn grip (3) of valve (1) counterclockwise. The oil in the hoist cylinder is drained into the hydraulic tank and the dump body lowers.

4. Tighten grip (3) and locknut (2).

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TROUBLESHOOTING

Emergency Disposal WHEN PARKING BRAKE HAS BEEN ACTUATED IN EMERGENCY

If the pressure in the hydraulic circuit goes down abnormally because of oil leakage or some other cause, the parking brake is automatically applied.It is necessary to tow or move the machine, the parking brake must be released. Release the parking brake as follows.

METHOD OF RELEASING PARKING BRAKE IN EMERGENCY1. When releasing the parking brake manually, prepare 34 M16 (80-95mm (3.2 -

3.7 in) below head, pitch 2.0mm (0.079 in) (flat)) bolts and M16 washers each.2. Prepare a container to catch the oil.3. Stop the engine.4. Put blocks under the wheels.5. Set the container to catch the oil under

the brake portion.6. Remove plug (1) from the rear axle brake portion.

Remove plug (2) from the axle brake portion.There are 9 plugs on the right side and 9 plugs on the left side.

REAR

FRONT

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WHEN PARKING BRAKE HAS BEEN ACTUATED IN EMERGENCY [No.1]

Rear18×M16 bolts (distance under head:85 to 95 mm ； thread pitch:2 mm18×M16 washersFront16×M16 bolts (distance under head:80 to 90 mm ； thread pitch:2 mm16×M16 washers

REMARKThere are 9 plugs on the right and left side. (Rear)There are 8 plugs on the right and left side. (Front)

REAR FRONT

Releasing of Parking Brake Manually

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WHEN PARKING BRAKE HAS BEEN ACTUATED IN EMERGENCY [No.2]

Rear Pull up parking brake piston

Parking Brake Piston

Service Brake Piston

Front Pull up parking brake piston

Service Brake Piston

Parking Brake Piston

(ref.HD465-7)Pull up Foot brake piston

Service brake piston Parking brake piston

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EXPLANATION OF COMPONENTS

SPECIFICATIONS

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HANDLING AUTOMATIC SPIN REGULATOR (ASR) (OPTION)

ASR is a function to prevent slipping of the drive wheels caused by excessive torque. Accordingly, the machine canstart and travel normally even on a bad or frozen road surface.EXPLANATION OF COMPONENTS

ASR SWITCHThis switch (1) turn to the ASR system ON/OFF.(A): ASR system ON(B): ASR system OFF

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HD785-7 Main Different & Cautioning Points of Maintenance compared with HD785-5

1. Initial 250H Engine Oil Change become no need

2. Suspention Oil : More heat resistance type [ HO-MVK ]

3. Initial 250H Service Additiononal Items when replacing T/M, Brake Oil Sub tank at

Initial 250H

3-1: Bleed Air from Front and Rear Brake and Parking Brake,

Every 250H

1. Check Brake Accumulator Function

Check the drop of accumulator Pressure of Service Brake, Emergency Brake,

Retarder Brake Procedure

A: Start the Engine and run it at midium Speed for 1 (one) minute, and then Stop it.

B: Turn the startion switch to the ON position and depress Brake Pedal 4 (four times),

If the Brake pressure caution lamp lights up, the Gas pressure may be low.

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HD785-7 Main Different & Cautioning Points of Maintenance compared with HD785-5Every 500H Service1. Fuel Pre Filter Cartridge Replacement Every 1000H Service1. Change oil in Brake Sub Tank2. Replace Fuel Main Filter Cartridge - It is prohibited to fill

in Fuel in Main Fuel Filter with Hands (Use Priming Pump)

Every 2000H Service1. Check Accumulator Gas Check (Cut In and Cut Out

Pressure Check) Every 8000H1. Replace Fuel Spray Prevention Cap Every 15000H ServiceCheck Replace Steering A Arm Mounting Bolts and Lock Plate

Check, replace steering a arm mounting bolt

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HANDLING ABS (OPTION)

The ABS (anti-skid brake system) is a brake system that ensures the steering ability and stable machine posture.It works by automatically suppressing the skidding caused by the wheels locking when the brakes are appliedsuddenly or are applied on snow-covered roads or other slippery road surfaces.EXPLANATION OF COMPONENTS

ABS MAIN SWITCHThe switch (1) is used to turn the ABS system ON/OFF.(A): ABS system ON(B): ABS system OFF

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HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE) (OPTION)

•Payload display

•External display lamps•There is display lamps at Left side also.

•Download connector inside cab(end marked PLM)

•Download connector outside cab(end marked PLM)

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EXTERNAL DISPLAY LAMPS (OPTION)

•The external lamps display the payload as follows.

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PERFORMING CALIBRATION (OPTION)

Carry out calibration at the following occasions.•When the machine or payload meter are received•Once every month•When the suspension cylinder gas pressure and oil amount have been adjusted (when the suspension has been adjusted)•When the suspension pressure sensor has been replaced•When the machine has been modified and the weight of the machine when empty has changed more than 100kg (221 lb)•Drive the machine at a speed of 10 km/h (6.2 MPH). When the travel speed becomes stable, press the ( ) of machine monitor selector switch 1 (1) and display CALIBRATION. Theword CALIBRATION flashes two or three times, and then the display on the right is given.

(1) ( )(2) ( > )

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END OF END OF OperationOperation

hd785 7 operation

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