Operation HD785-7

Operation
HD785-7
Page 2/51 Operation HD785-7
GENERAL VIEW
Page 3/51 Operation HD785-7
GENERAL VIEW OF CONTROLS AND GAUGES

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CHARACTER DISPLAY
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CHARACTER DISPLAY
SERVICE METER/ODOMETER
Even 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 LANGUAGE
1. 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.

Page 8/51 Operation HD785-7
CHARACTER DISPLAY
INPUT METHOD FOR TELEPHONE NUMBER
1. 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 ( )


Page 9/51 Operation HD785-7
CHARACTER DISPLAY
METHOD OF SWITCHING BETWEEN RL AND RH
1. 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.
Page 10/51 Operation HD785-7
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 LAMP
This monitor (8) lights up if the dump body has
left its seat when the
rear frame of the machine has tilted beyond the
safety range to the
left 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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PILOT DISPLAY PORTION
ENGINE PRE-HEATING PILOT LAMP
When the starting switch is turned to the ON position
in cold weather.

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

LOCKUP PILOT LAMP
Lights up when the torque converter lockup is
engaged and the transmission is shifted to direct drive.

HEAD LAMP HIGH BEAM PILOT LAMP
lights up when the head lamps are set to high beam.
TURN SIGNAL PILOT LAMP
Flashes at the same time as the turn signal lamp
flashes.
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PILOT DISPLAY PORTION
SHIFT INDICATOR
Shows the transmission shift range (speed range).
SHIFT LEVER POSITION PILOT LAMP
Displays the position of the shift lever.
The letter or number for the speed range selected
by the shift lever
lights up.

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

AUTO SUSPENSION MODE PILOT LAMP
(If equipped)
H : Hard mode
M : Medium mode
S : Soft mode
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PILOT DISPLAY PORTION
AUTO RETARDER SET SPEED INDICATOR
Displays the set travel speed for the auto
retarder speed control (ARSC).



AUTO RETARDER READY PILOT LAMP
Shows 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 SWITCH
Turn the starting switch ON, press this switch (3) and check for any
blown bulbs.
POWER MODE SELECTOR SWITCH
When the switch is pressed, the mode switches to high power
mode and the high power mode pilot lamp on the machine monitor
lights up.
If the switch is pressed again, the mode returns to the economy
mode and the power mode pilot lamp on the machine monitor goes
out.
When the engine is started, the economy mode is selected
automatically.
High power mode
Operates at maximum output.
Economy mode (general operations)
Use this for operations under general standard conditions.

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SWITCHES
EMERGENCY STEERING SWITCH
When the switch is pressed, the emergency pump is actuated to
make it possible to operate the steering.
When the switch is ON, the pilot lamp (red) inside the switch and
the pilot lamp on the machine monitor light up.
The emergency steering pump can be used for a maximum of 90
seconds.
When the emergency steering is being used, keep the travel speed
to a maximum of 5 km/h (3.1 MPH).
On machines equipped with auto emergency steering, the auto
emergency steering is actuated automatically in the
following cases.
When the steering hydraulic pump fails
When the engine has stopped during operation
When 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, 2
This switch (16) is used to operate the character display.
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CONTROL LEVERS AND PEDALS
Page 27/51 Operation HD785-7
CONTROL LEVERS AND PEDALS
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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CONTROL LEVERS AND PEDALS
DUMP LEVER
A) RAISE
B) 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 PEDAL
It 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.
Page 29/51 Operation HD785-7
CHECK BEFORE STARTING

1. CHECK COOLANT LEVEL, ADD COOLANT










2. CHECK DUST INDICATOR




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CHECK BEFORE STARTING
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
Page 31/51 Operation HD785-7
CHECK BEFORE STARTING
6. CHECK OIL LEVEL IN BRAKE SUB-TANK,
ADD OIL






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



8. DRAIN WATER, SEDIMENT FROM FUEL
TANK
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CHECK BEFORE STARTING
9. DRAIN WATER FROM FUEL PRE-FILTER





10. CHECK WATER SEPARATOR, DRAIN
WATER AND SEDIMENT

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







12. CHECK WHEEL HUB NUTS, TIGHTEN
Tightening torque: 1519 to 1852 Nm
{155 to 189kgfm, 1121 to 1367 lbft}


13. CHECK CENTRAL WARNING LAMP, ALARM
BUZZER, MONITOR LAMPS AND METERS
Press machine monitor check switch (1)
Page 34/51 Operation HD785-7
CHECK BEFORE STARTING
14. CHECK BRAKING CAPACITY OF SECONDARY
BRAKE
Check 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 STEERING
CHECK 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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CHECK BEFORE STARTING
16. CHECK BACKUP ALARM
1. 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 TIRES
Measure 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 FUEL
1. 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).

Page 38/51 Operation HD785-7
TROUBLESHOOTING
Emergency Disposal
IF TRANSMISSION HAS TROUBLE
1. 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.
Page 39/51 Operation HD785-7
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).

Page 40/51 Operation HD785-7
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 EMERGENCY
1. 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
Page 41/51 Operation HD785-7
WHEN PARKING BRAKE HAS BEEN ACTUATED IN
EMERGENCY [No.1]

Rear
18M16 bolts (distance under head:85 to 95 mmthread pitch:2 mm
18M16 washers
Front
16M16 bolts (distance under head:80 to 90 mmthread pitch:2 mm
16M16 washers









REMARK
There 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
Page 42/51 Operation HD785-7
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

Page 44/51 Operation HD785-7
HANDLING AUTOMATIC SPIN REGULATOR (ASR) (OPTION)
ASR is a function to prevent slipping of the drive wheels caused by excessive
torque. Accordingly, the machine can
start and travel normally even on a bad or frozen road surface.
EXPLANATION OF COMPONENTS










ASR SWITCH
This switch (1) turn to the ASR system ON/OFF.
(A): ASR system ON
(B): ASR system OFF
Page 45/51 Operation HD785-7
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.
Page 46/51 Operation HD785-7
HD785-7 Main Different & Cautioning Points of
Maintenance compared with HD785-5
Every 500H Service
1. Fuel Pre Filter Cartridge Replacement

Every 1000H Service
1. Change oil in Brake Sub Tank
2. Replace Fuel Main Filter Cartridge - It is prohibited to fill
in Fuel in Main Fuel Filter with Hands (Use Priming
Pump)

Every 2000H Service
1. Check Accumulator Gas Check (Cut In and Cut Out
Pressure Check)

Every 8000H
1. Replace Fuel Spray Prevention Cap

Every 15000H Service
Check Replace Steering A Arm Mounting Bolts and Lock
Plate
Check, replace steering a
arm mounting bolt
Page 47/51 Operation HD785-7
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 applied
suddenly or are applied on snow-covered roads or other slippery road surfaces.
EXPLANATION OF COMPONENTS









ABS MAIN SWITCH
The switch (1) is used to turn the ABS system ON/OFF.
(A): ABS system ON
(B): ABS system OFF
Page 48/51 Operation HD785-7
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)
Page 49/51 Operation HD785-7
EXTERNAL DISPLAY LAMPS (OPTION)
The external lamps display the payload as follows.
Page 50/51 Operation HD785-7
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. The
word CALIBRATION flashes two or three times,
and then the display on the right is given.
(1) ( )
(2) ( > )
Page 51/51 Operation HD785-7
END OF
Operation