Galeo HD785-7 DUMP TRUCK. Operation and Maintenance Manual (2006) - page 10

MAINTENANCE

SERVICE PROCEDURE

CHECK ALTERNATOR

When carrying out the EVERY 2000 HOURS SERVICE or EVERY YEAR SERVICE, remove the belt and check that
the alternator rotates smoothly. If it does not rotate smoothly, please ask your Komatsu distributor to carry out
inspection and repair.

CHECK, ADJUST ENGINE VALVE CLEARANCE

Special tools are needed for the inspection and maintenance, so please contact your Komatsu distributor to have
this work carried out.

CHECK ACCUMULATOR GAS PRESSURE

When carrying out the EVERY 2000 HOURS SERVICE or EVERY YEAR SERVICE or when making periodic
replacement of the critical safety parts, please ask your Komatsu distributor to check the accumulator gas pressure.

4 - 86

MAINTENANCE

SERVICE PROCEDURE

EVERY 4000 HOURS SERVICE

Maintenance for every 250, 500, 1000, and 2000 hours should be performed at the same time.

CHANGE OIL IN STEERING, HOIST OIL TANK

WARNING

The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the
temperature to go down before starting the work.
When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

Refill capacity: 122 liters (32.2 US gal)

1. Lower the dump body and stop the engine.
2. Turn the cap of oil filler (F) to release the internal pressure

before removing the cap.

3. Remove drain plug (1), then loosen drain plug (2) slowly to

avoid getting oil on yourself, and drain the oil.

4. Pour in the specified amount of engine oil from oil filler (F).
5. After adding oil, check that the oil is at the specified level. See

CHECK OIL LEVEL IN STEERING AND HOIST OIL TANK,
ADD OIL (PAGE 3-79).

LUBRICATE DRIVE SHAFT

(4 points)
Carry out greasing every 4000 hours or every two years (whichever comes sooner).

1. Using a grease pump, pump in grease through the grease

fittings marked by the arrows.

2. Grease the spider portion until grease comes out from the cap

seal.

3. For the spline portion, continue greasing until grease comes

out from the vent.

4. After greasing, wipe off any old grease that was pushed out.

4 - 87

MAINTENANCE

SERVICE PROCEDURE

CHECK VIBRATION DAMPER

Check that there are no cracks or peeling in the outside surface of the rubber.
If any cracks or peeling are found, contact your Komatsu distributor to have the parts replaced.

CHECK STARTING MOTOR

The brush may be worn or have no grease on the bearing, so contact your Komatsu distributor for inspection or
repair.
If the engine is started frequently, carry out inspection every 1000 hours.

CHECK WATER PUMP

Check around the water pump for water leakage. If any part is leaking, ask your Komatsu distributor for
inspection/repair.

CHECK FAN PULLEY AND TENSION PULLEY

Check for play of the pulley and leakage of grease. If any problem is found, please contact your Komatsu distributor.

4 - 88

MAINTENANCE

SERVICE PROCEDURE

CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER

Check visually and touch by hand to check that there are no loose mounting bolts for high-pressure piping clamps
(1) - (34) in the diagram and no hardening of any rubber parts. If any problem is found, the part must be replaced.
In this case, please ask your Komatsu distributor to carry out the replacement.

NOTICE
If the engine continues to be used when there are loose bolts, hardened rubber, or missing parts, there is danger of damage or
breakage occurring due to vibration and wear at the connections of high-pressure piping. Always check that the proper
high-pressure piping clamps are correctly installed.

4 - 89

MAINTENANCE

SERVICE PROCEDURE

CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER

Fuel spray prevention caps (1) - (32) are protective parts installed to prevent fire caused by fuel leaking and spraying
out on to high temperature parts of the engine. Check visually that there are no missing caps or loose bolts, and feel
with your finger to check that the rubber has not hardened. If there is any problem, the problem part must be
replaced. Contact your Komatsu distributor for part replacement.

4 - 90

MAINTENANCE

SERVICE PROCEDURE

EVERY 8000 HOURS SERVICE

Maintenance for every 250, 500, 1000, 2000, and 4000 hours of service should be performed at the same time.

REPLACE HIGH-PRESSURE PIPING CLAMP

Ask your Komatsu distributor to carry out this work.

REPLACE FUEL SPRAY PREVENTION CAP

Ask your Komatsu distributor to carry out this work.

OVERHAUL STARTING MOTOR AND ALTERNATOR

Ask your Komatsu distributor to carry out this work.

4 - 91

MAINTENANCE

SERVICE PROCEDURE

EVERY 15000 HOURS SERVICE

Maintenance for every 250, 500, 1000, 2000, 4000 and 8000 hours of service should be performed at the same time.

CHECK, REPLACE STEERING A ARM MOUNTING BOLT

Check and replace the A arm mounting bolts, lock plate, and
holder.
Please consult your Komatsu distributor when checking and
replacing.

(1) A arm
(2) Front suspension
(3) Lock plate
(4) Bolt
(5) Holder

4 - 92

5 - 1

SPECIFICATIONS

Item

Unit

HD785-7

Overall weight (unladen weight + max. payload
+ 1 operator (80kg (176 lb))

kg (lb)

163080 (359591)

Unladen weight

kg (lb)

72000 (158760)

Max. payload

kg (lb)

91000 (200655)

Dump body capacity

Struck

(cu.yd)

40 (53.32)

Heaped (2 : 1)

(cu.yd)

60 (78.48)

Dumping speed (at 2100 rpm) (raised)

sec

Engine type

Komatsu SAA12V140E-3

Flywheel horsepower of engine (ISO 9249)

kW(HP)/rpm

Power mode

Economy mode

879(1178)/1900

734(984)/1900

Max. torque

m(kgf

m)/rpm

5076(518)/1350

A Overall length

mm (ft in)

10290 (33' 9")

B Overall height

mm (ft in)

5050 (16' 7")

C Overall height at dumping

mm (ft in)

10080 (33' 1")

D Overall width

mm (ft in)

6885 (22' 7")

E Min. ground clearance (bottom of frame)

mm (ft in)

775 (2' 7")

Min. turning radius

mm (ft in)

10100 (33' 2")

Power mode

Economy mode

Travel speed

Forward

1st

km/h (MPH)

10.5 (6.5)

9.5 (5.9)

2nd

km/h (MPH)

15.0 (9.3)

13.5 (8.4)

3rd

km/h (MPH)

20.0 (12.4)

18.5 (11.5)

4th

km/h (MPH)

27.0 (16.8)

25.0 (15.5)

5th

km/h (MPH)

36.0 (22.4)

33.5 (20.8)

6th

km/h (MPH)

48.5 (30.1)

46.0 (28.6)

7th

km/h (MPH)

65.0 (40.4)

60.5 (37.6)

Reverse

km/h (MPH)

9.5 (5.9)

9.0 (5.6)

km/h (MPH)

11.5 (7.1)

Temperature range when using

-20 to 45

C (-4 to 113

5 - 2

SPECIFICATIONS

5 - 3

6 - 1

ATTACHMENTS, OPTIONS

SELECTING DUMP BODY

Select the dump body from the following table.

6 - 2

ATTACHMENTS, OPTIONS

HANDLING AIR SUSPENSION SEAT

SEAT ADJUSTMENT

WARNING

Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat.
Adjust the seat before starting operations or when changing operators.
Adjust the position of the operator's seat so that you can depress the brake pedal fully with your back against the seat backrest.

Adjustments (E), (J), and (K) use the air compressor built into the seat, so turn the engine starting switch to the ON
position when carrying out the adjustment.

(A) Fore-and-aft adjustment
Pull lever (1) up, set the seat to the desired position, then release
the lever.
Amount of adjustment: 180 mm (7.1 in)

(10 mm (0.4 in) x 18 stages)

(B) Adjusting seat angle
Move lever (2) up and apply your weight to the rear of the seat. The
seat will tilt to the rear.
Move lever (3) up and apply your weight to the front of the seat.
The seat will tilt to the front.
Amount of adjustment: 24 degrees (front and rear tilt: 3 stages
each)

(C) Adjusting height of seat
Move levers (2) and (3) up and move the seat up or down to the
desired position.
These levers are also used for adjusting the seat angle, so adjust
the seat angle to set the seat to the desired height.
Amount of adjustment: 65 mm (2.6 in)

(D) Adjusting fore-and-aft position of seat cushion
Push in lever (4), set the seat cushion to the desired position, then release the lever.
Amount of adjustment: 60 mm (2.4 in)

(E) Setting seat for weight
Sit on the seat, raise your body slightly, then operate switch (5) to adjust the strength of the suspension.
Amount of adjustment: 50 - 130 kg (110 - 287 lb)(target)
When + is pressed: Suspension becomes stronger
When - is pressed: Suspension becomes weaker

(F) Adjusting reclining angle
Move lever (6) up and move the backrest to the front or rear.
Push your back against the backrest when carrying out this adjustment. If your back is not pressing against the
backrest, the backrest may suddenly spring forward.
Amount of adjustment: Front tilt: Free
Rear tilt: 40 degrees (2 degrees x 20 stages)

6 - 3

ATTACHMENTS, OPTIONS

HANDLING AIR SUSPENSION SEAT

(G) Adjusting headrest angle
Rotate the headrest to the front or rear.
Amount of adjustment:
Front tilt: 13 degrees
Rear tilt: 13 degrees

(H) Adjusting headrest height
Move the headrest up or down.
Amount of adjustment: 80 mm (3.2 in)

(I) Adjusting armrest angle
Rotate the knob (7) and adjust the angle of the armrest. (Left side only)
Amount of adjustment: 73 degrees (front: 54 degrees; rear: 19 degrees)
If the arm rest is turned, it will spring up. (Both left and right sides)

(J) Lumbar support
Operate switch (8) to give a suitable tension to the lower lumbar region.
Operate switch (9) to give a suitable tension to the upper lumbar region.
When + is pressed: Tension becomes stronger
When - is pressed: Tension becomes weaker

(K) Side support
Operate switch (10) to give a suitable tension to the left and right lumbar region.
When + is pressed: Tension becomes stronger
When - is pressed: Tension becomes weaker

6 - 4

ATTACHMENTS, OPTIONS

HANDLING AIR SUSPENSION SEAT

REMOVAL AND INSTALLATION OF HEADREST

REMOVAL

If the headrest is not needed, remove it as follows.

1. Pull up the headrest to the position where it stops.
2. From the top of the seat back, turn stopper (1) (under the

material at the top of the seat) of the headrest bar on one side
in the direction of the arrow, and pull up the headrest.
When stopper (1) is turned, it will come out of groove (2).

3. Turn stopper (1) on the other side in the direction of the arrow,

and pull up the headrest.
When both stoppers (1) come out of groove (2), the headrest
can be removed.

INSTALLATION

1. Insert the bars into the holes in the top of the seat and push

down.

6 - 5

ATTACHMENTS, OPTIONS

HANDLING AUTOMATIC SPIN REGULATOR (ASR)

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

(1)
(2)
(3)

ASR switch
ASR actuation lamp
Retarder control lever

(4)
(5)
(6)

Accelerator pedal
Brake pedal
Character display

ASR SWITCH

This switch (1) turn to the ASR system ON/OFF.

(A): ASR system ON
(B): ASR system OFF

6 - 6

ATTACHMENTS, OPTIONS

HANDLING AUTOMATIC SPIN REGULATOR (ASR)

ASR ACTUATION LAMP

When the ASR switch is ON, this lamp (2) lights up if the system detects slipping from the rear wheels and actuates
the ASR.

RETARDER CONTROL LEVER

When the ASR is actuated and this lever (3) is used to actuate the retarder, the actuation of the ASR system is
canceled.

ACCELERATOR PEDAL

The ASR system is actuated only when this pedal (4) is being depressed and the travel speed is 0 to 30 km/h (0 to
18.6 MPH). If the pedal is released while the ASR is being actuated, the actuation of the ASR system is canceled.

BRAKE PEDAL

If this pedal (5) is depressed while the ASR is being actuated, the actuation of the ASR system is canceled.

CHARACTER DISPLAY

If any problem occurs in the ASR system, an action code is shown on this display (6).

ACTUATION OF ASR SYSTEM

The ASR system can be actuated when the ASR switch is ON.
When the system detects slipping of the rear wheels and the ASR is actuated, the ASR actuation lamp lights up.

PRECAUTIONS WHEN USING

WARNING

The ASR system is actuated when the ASR switch is at the ON position.
If any problem occurs in the system and it cannot carry out proper control, an action code is shown on the character display
on the machine monitor, and the ASR system is canceled.
Drive the machine immediately to a safe place, stop the machine, and turn the ASR switch OFF.
On road surfaces with an extremely low wear coefficient (icy road surfaces, etc.) or on steep slopes, it may be impossible to
drive safely even when the ASR is actuated.

On road surfaces where it is possible to carry out normal travel even when the ASR switch is turned OFF, if the
road surface is slippery, be extremely careful not to let the machine slip to the side.
If both rear wheels slip at the same speed, the ASR will not function. In this case, adjust the engine output with
the accelerator pedal.

6 - 7

ATTACHMENTS, OPTIONS

HANDLING AUTOMATIC SPIN REGULATOR (ASR)

TROUBLESHOOTING

WHEN A PROBLEM OCCURS IN THE SYSTEM

This system is equipped with a self-diagnostic function and displays an action code on the character display of the
machine monitor. If an action code is displayed, check the code. For details, see "ACTION CODE (PAGE 3-155)".

Failure code

Type of failure

Action

DLt3

Disconnection in transmission output shaft speed sensor

ASR canceled

Dk11

Failure in accelerator sensor system

ASR canceled

DX18

Failure in ASR electromagnetic proportional pressure reducing
valve (left) (valve is not actuated)

ASR canceled

DX18

Failure in ASR electromagnetic proportional pressure reducing
valve (left) (valve remains actuated)

ASR canceled

DX17

Failure in ASR electromagnetic proportional pressure reducing
valve (right) (valve is not actuated)

ASR canceled

DX17

Failure in ASR electromagnetic proportional pressure reducing
valve (right) (valve remains actuated)

ASR canceled

DX18

Disconnection in output wiring of ASR electromagnetic proportional
pressure reducing valve (left)

ASR canceled

DX18

Short circuit in output wiring of ASR electromagnetic proportional
pressure reducing valve (left)

ASR canceled

DX18

Short circuit with chassis ground in output wiring of ASR
electromagnetic proportional pressure reducing valve (left)

ASR canceled

DX17

Disconnection in output wiring of ASR electromagnetic proportional
pressure reducing valve (right)

ASR canceled

DX17

Short circuit in output wiring of ASR electromagnetic proportional
pressure reducing valve (right)

ASR canceled

DX17

Short circuit with chassis ground in output wiring of ASR
electromagnetic proportional pressure reducing valve (right)

ASR canceled

DLF9

Disconnection in wheel speed sensor (RL)

ASR canceled

DLF8

Disconnection in wheel speed sensor (RR)

ASR canceled

DLF9

Failure in wheel speed sensor (RL) system

ASR canceled

DLF8

Failure in wheel speed sensor (RR) system

ASR canceled

DLF3

Failure in transmission output shaft sensor

ASR canceled

DDDA

Disconnection in ASR system switch

ASR canceled

DDDA

Short circuit with chassis ground in ASR system switch

ASR canceled

DK30

Failure in steering angle potentiometer

Recognizes steering
angle as 20

and

continues ASR control

DWNB

Disconnection in shut-off valve output wiring

ASR canceled

DWNB

Short circuit in shut-off valve output wiring

ASR canceled

DWNB

Short circuit with chassis ground in shut-off valve output wiring

ASR canceled

DWNB

Failure in shut-off valve (valve is not actuated)

ASR canceled

DWNB

Failure in shut-off valve (valve remains actuated)

ASR canceled

6 - 8

ATTACHMENTS, OPTIONS

HANDLING AUTOMATIC SPIN REGULATOR (ASR)

BLEEDING AIR FROM ASR CIRCUIT

If the piping or valves in the ASR circuit have been replaced, bleed the air from the ASR circuit as follows.

1. Start the engine, check that the oil in the transmission case is the specified level, and check if the brake oil

pressure caution lamp is out.

2. Turn the ASR switch ON, remove the cover behind the

operator's seat, and connect connector TEST (1). The valve
opens and oil pressure is applied to the ASR circuit.

3. Bleed the air from the rear brakes. For details, see

MAINTENANCE, "BLEED AIR FROM REAR BRAKE (PAGE
4-38)".

4. 4. After completing the air-bleeding operation, remove

connector TEST (1) and install the cover.

6 - 9

ATTACHMENTS, OPTIONS

HANDLING ABS

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

(1)
(2)
(3)
(4)

ABS main switch
ABS operation lamp
ABS system check switch
Retarder control lever

(5)
(6)
(7)

Brake pedal
Accelerator pedal
Character display

ABS MAIN SWITCH

The switch (1) is used to turn the ABS system ON/OFF.

(A): ABS system ON
(B): ABS system OFF

6 - 10

ATTACHMENTS, OPTIONS

HANDLING ABS

ABS OPERATION LAMP

When the ABS main switch is ON and a tendency for the tires to lock is detected, the ABS is actuated and lamp (2)
lights up.

ABS SYSTEM CHECK SWITCH

This switch (3) is used to check the ABS system after the engine
is started.

RETARDER CONTROL LEVER

When the retarder is being actuated with this lever (4), the ABS is actuated if there is a tendency for the tires to lock.

BRAKE PEDAL

When the wheel brakes are being applied with this pedal (5), the ABS is actuated if there is a tendency for the tires
to lock.

ACCELERATOR PEDAL

If this pedal (6) is depressed when the ABS is being actuated, the ABS is canceled.

CHARACTER DISPLAY

If any problem occurs in the ABS system, the action code is displayed on this display (7).

6 - 11

ATTACHMENTS, OPTIONS

HANDLING ABS

ABS SYSTEM CHECK AFTER STARTING ENGINE

After starting the engine, check the ABS system.

1. Set the machine in the following condition. If the machine is not in the following condition, the ABS system

cannot be checked.

Parking brake applied
Brake oil pressure normal
ABS main switch ON
No problem in ABS system

2. Keep the brake pedal depressed until the ABS system check is completed.
3. Keep the ABS system check switch pressed for approx. 1 second.

The ABS operation lamp flashes and the ABS check system starts.

REMARK

The ABS system checks the ABS control valve, ABS cut valve, oil pressure switch, and oil pressure sensor. This
check is completed in approx. 12 seconds.

4. When the flashing of the ABS operation lamp stops, the check is completed. Release the brake pedal.

OPERATION OF ABS

The ABS can be actuated only when the ABS main switch is ON.
If the retarder control lever is operated or the brake pedal is depressed, the ABS is actuated.
If there is a tendency for the wheels to lock, the ABS system is actuated and the ABS operation lamp lights up.

6 - 12

ATTACHMENTS, OPTIONS

HANDLING ABS

PRECAUTIONS WHEN USING

WARNING

When the ABS is actuated on a slippery road surface, the stopping distance will become slightly longer.
In addition, when traveling at extremely low speed, the wheels may lock, so be very careful when driving.
When traveling on roads with an extremely low friction coefficient (icy roads, etc.) or when traveling up or down a steep hill,
it may not be possible to ensure safe travel even with the ABS installed.
In such cases, carry out maintenance on the road surface before traveling on it.
When the ARSC is being used, even if there is a tendency for the wheels to lock, the ABS is not actuated.
The ABS is actuated when the retarder control lever or brake pedal are operated.
After turning the ABS main switch ON, it takes a short time for the preparation of the ABS operation, so the ABS is not actuated
for 2 seconds. Turn the ABS main switch ON beforehand if it is to be actuated.

It is possible to carry out normal travel even when the ABS main switch is OFF. However, be extremely careful
about the machine slipping to the side when traveling on slippery road surfaces.

Even if there is a failure in the ABS system, it is possible to carry out normal travel. However, be extremely careful
about the machine slipping to the side when traveling on slippery road surfaces.
If any problem occurs in the ABS system, the system is automatically turned OFF, so the condition becomes the
same as for a machine which does not have the ABS installed.

Even when the ABS system is installed, the secondary brake function is maintained, but when the secondary
brake is actuated, even if the wheels lock, the ABS is not actuated.

When equipping the machine with a wireless system, install it as far as possible from the system equipment and
wiring.
In addition, when equipping the machine with a wireless system, check carefully that the wireless and operating
system do not break any laws regulating use of the airwaves.

6 - 13

ATTACHMENTS, OPTIONS

HANDLING ABS

TROUBLESHOOTING

This system has a self-diagnosis function. If any problem occurs in the system, the action code is displayed on the
character display of the machine monitor.
If an action code is displayed, stop the machine at a safe place and apply the parking brake. Check the failure code
in "ACTION CODE (PAGE 3-155)", and ask your Komatsu distributor to carry out repairs.

Failure code

Name of failure

Remedy

DBC0

Drop in power source voltage

Cancel ABS

DBC2

Failure in the solenoid power source system

Cancel ABS

DLF6

Disconnection in wheel rotation sensor (FR)

Cancel ABS

DLF7

Disconnection in wheel rotation sensor (FL)

Cancel ABS

dLF8

Disconnection in wheel rotation sensor (RR)

Cancel ABS

dLF9

Disconnection in wheel rotation sensor (RL)

Cancel ABS

DHU6

Failure in ABS control valve pressure sensor (FR)

Cancel ABS

DHU7

Failure in ABS control valve pressure sensor (FL)

Cancel ABS

DHU8

Failure in ABS control valve pressure sensor (RR)

Cancel ABS

DHU9

Failure in ABS control valve pressure sensor (RL)

Cancel ABS

dk11

Failure in accelerator sensor

Cancel ABS

DWND

Failure in ABS cut valve (F)

Cancel ABS

DWNE

Failure in ABS cut valve (R)

Cancel ABS

D1E5

Failure in ABS relay output system

Cancel ABS

DX21

Disconnection in ABS control valve (FR) output circuit

Cancel ABS

DX21

Short circuit in ABS control valve (FR) output circuit

Cancel ABS

DX21

Short circuit with ground in ABS control valve (FR) output circuit

Cancel ABS

DX22

Disconnection in ABS control valve (FL) output circuit

Cancel ABS

DX22

Short circuit in ABS control valve (FL) output circuit

Cancel ABS

DX22

Short circuit with ground in ABS control valve (FL) output circuit

Cancel ABS

DX23

Disconnection in ABS control valve (RR) output circuit

Cancel ABS

DX23

Short circuit in ABS control valve (RR) output circuit

Cancel ABS

DX23

Short circuit with ground in ABS control valve (RR) output circuit

Cancel ABS

DX24

Disconnection in ABS control valve (RL) output circuit

Cancel ABS

DX24

Short circuit in ABS control valve (RL) output circuit

Cancel ABS

DX24

Short circuit with ground in ABS control valve (RL) output circuit

Cancel ABS

DBC9

Problem in connector connection

Cancel ABS

DBC3

Drop in the battery direct power source voltage

Continue ABS control

DBC1

Drop in main power source voltage

Cancel ABS

DDD9

Disconnection in ABS system switch

Cancel ABS

DDD9

Short circuit in ABS system switch

Cancel ABS

DX21

Defective ABS control valve (FR)

Cancel ABS

DX22

Defective ABS control valve (FL)

Cancel ABS

DWND

Defective ABS cut valve (F)

Cancel ABS

DX23

Defective ABS control valve (RR)

Cancel ABS

DX24

Defective ABS control valve (RL)

Cancel ABS

DWNE

Defective ABS cut valve (R)

Cancel ABS

6 - 14

ATTACHMENTS, OPTIONS

HANDLING ABS

Failure code

Name of failure

Remedy

DX25

Defective ABS front wheel system control valve

Cancel ABS

DX26

Defective ABS rear wheel system control valve

Cancel ABS

6 - 15

ATTACHMENTS, OPTIONS

HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)

OUTLINE OF SYSTEM

The payload meter detects the signals from the pressure sensors, clinometer, body float detection, neutral
detection, and travel speed detection, and uses the microcomputer built into the controller to calculate the payload.
The calculated payload is displayed on the character display on the machine monitor; the external display lamps
also display the payload condition.
The data stored in the payload meter can be downloaded to a personal computer using the separately sold special
software.

The measurement carries out processing of the total of the signals from the pressure sensors when the machine is
traveling loaded.
Rough road surface, sudden acceleration, and sudden braking cause a deterioration in the accuracy of the
measurement. To ensure that the accuracy is good, maintain the road surface and accelerate or decelerates the
machine smoothly.

Payload display

External display lamps

Download connector inside cab
(end marked PLM)
When downloading, remove the connected cable. After
completing the download operation, do not forget to restore the
cable to its original position. If it is not restored, the download
operation cannot be carried out from outside the cab.

6 - 16

ATTACHMENTS, OPTIONS

HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)

ATTACHMENTS, OPTIONS

HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)

Download connector outside cab
(end marked PLM)

NORMAL OPERATION DISPLAY

Machine condition

Machine monitor display

External display lamps

When starting switch is ON

Light up for 30 sec

When empty

Stopped (*1)

Standard display (*2)

OFF

Traveling

Standard display

OFF

During loading

Stopped

Payload display (*3)

Payload display

Traveling

Standard display

OFF

When loaded

Stopped

Payload display

Traveling

Standard display

OFF

When dumping

Stopped

Payload display

→

standard display Payload display

→

OFF

Traveling

Standard display

OFF

(*1) "Stopped" means that the gearshift lever is at the N position and the travel speed signal is 0.
(*2) For details of the standard display on the machine monitor, see "MACHINE MONITOR (PAGE 3-5)" and

OTHER FUNCTIONS OF "OTHER FUNCTIONS OF MACHINE MONITOR (PAGE 3-27)" in the explanation for
components in the OPERATION section.

(*3) The machine starts off empty and is being loaded. It is necessary to wait for the load to go above approx. 15%

of the rated payload and for the change in the load to stabilize when the machine is stopped.

Example of payload display

6 - 17

ATTACHMENTS, OPTIONS

HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)

ATTACHMENTS, OPTIONS

HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)

Example of payload display when error occurs
If an error occurs in the suspension pressure sensors or in the
clinometer sensor, it becomes impossible to calculate the
payload, so [-----] is displayed.

When the machine is stopped during loading operations and when it is loaded, the service meter is not displayed
on the character display.
If it is desired to display the service meter, keep the machine monitor inspection switch pressed. The software
version and service meter will be displayed in turn on the bottom line of the character display.
The payload at the loading point immediately after the loading operation may differ slightly from the display at the
dumping point. This is caused by the effect of the friction in the suspension, and is impossible to remove. Even
if the display value differs slightly according to the measurement point, it does not indicate any failure in the
payload meter.

6 - 18

ATTACHMENTS, OPTIONS

HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)

EXTERNAL DISPLAY LAMPS

The external lamps display the payload as follows.

Color of lamp

HD785-7

Green

45.5 tons and up

Yellow

81.9 tons and up

Red

95.6 tons and up

WARNING

If the red lamp lights up, the machine is overloaded. Do not haul a load under this condition. To prevent overloading, we
recommend loading only up to a range where the yellow lamp lights up.

PREDICTED LOAD DISPLAY

When the load changes in steps for each bucket loaded, the system estimates the total payload if one more
bucket is loaded, and flashes the appropriate lamp to prevent overloading.
The predicted load display and actual payload display are shown at the same time.
[Example: Case of HD785, expected number of bucket loads: 4]
1st bucket 22 tons
2nd bucket 22 tons (total: 44 tons)
3rd bucket 22 tons (total: 66 tons)
4th bucket 22 tons (total: 88 tons)
When the machine is loaded in this way, the external display lamps light up as shown in the chart below.

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ATTACHMENTS, OPTIONS

HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)

PERFORMING CALIBRATION

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 100
kg (221 lb)

METHOD OF PERFORMING CALIBRATION

1. Set the machine empty. When doing this, remove all the

remaining soil inside the dump body.

2. Run in the machine.
3. With the engine still running, set the gearshift lever to the N

position and stop the machine.

4. Using the following procedure, operate machine monitor mode

selector switches 1 (1) and 2 (2) and carry out the preparatory
work for calibration.

1) With the service meter/odometer value displayed on

character display (3) of the machine monitor, press the (

) of machine monitor selector switch 1 (1) to display the
value for reverse travel.
For details of the method of displaying the reverse travel
odometer, see "OTHER FUNCTIONS OF MACHINE
MONITOR (PAGE 3-27)".

2) Press the (>) of machine monitor selector switch 2 (2)

several times and display "PLM".

3) Press the (

) of machine monitor selector switch 1 (1) and

display CALIBRATION. Then, press the (

) and check

that the word CALIBRATION flashes.

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ATTACHMENTS, OPTIONS

HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)

ATTACHMENTS, OPTIONS

HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)

5. 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.

REMARK

When canceling, press the (

) of machine monitor selector switch

(1) when the display on the right is being given.

6. Continue traveling at a speed of 10 km/h (6.2 MPH), and if the

display on the right is given after approx. 30 seconds, the
calibration is completed.

REMARK

If the (

) of machine monitor selector switch (1) is kept pressed,

the display returns to the service meter/odometer display.

NOTICE

Carry out the calibration when traveling on a flat road surface.
Carry out the calibration when traveling in a straight line (distance: approx. 100 m (328 ft 1 in)). When traveling, maintain a
speed of approx. 10 km/h (6.2 MPH).
Do not carry out calibration if there is an existing error.
Lower the dump body to seat it and set the dump lever to the FLOAT position before carrying out calibration. To confirm that
the dump body is fully seated, check that the body pilot lamp is OFF.

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