Safety Operator Training

HD785
 ----- INDEX -----
Page
1. For Safety Operation
… check before sitting down 3
2. … check after sitting down 4–5
3. … Starting 6
4. … Traveling flat road 7
5. … Traveling downhill 8 – 10
6. … Traveling uphill 11
7. … Loading area 12
8. … Dumping area 13
9. … Common 14 – 15
10. … Operation guide (HD785-5, 7) 16 – 17
11. … Facility, Environment 18
12. … Leveling the Road Surface 19
1. For safety operation … check before sitting down
(1) Do not operate the machine if you are
in poor physical condition or under the
influence of alcohol.
(2) Wear working clothes and personal
protective items correctly.
(3) Walk-around the machine and check if
there is abnormal condition. (Crack,
tire damage, oil and water leakage etc.)
(4) Check that there are no persons or
obstacles in surrounding area. Pointing confirmation
(5) Check the oil level of engine and
power train. Strap Hard
hat
(6) Check the water level of radiator.
(7) Clean the windows and mirror.

Safety
shoes

Wear and safety protector

3
2. For safety operation … check after sitting down
Pointing confirmation
(1) Fasten seat belt.
(2) Check the mirror position is Fasten seat belt &
correct. readjust seat position
(3) Recheck mode of each switch.
(4) Sound the horn before starting the
engine.
(5) Check if the function of panel is
normal.
(6) Warming up the machine.
(7) Check the safety by mirror: front
and rear, left and right hand side,
forward-down side

Instrument panel & Warming check! Forward-down side

Left Right
Warming
hand hand
-up
side side
OK!

4
2-1. For safety operation … check after sitting down
When you turn the starting switch ON before starting engine, system will do self check
in 3 seconds.
Please check the centralized caution lamps, caution buzzer, monitor lamps and meters.

☆After starting engine – warming up

Normal function Normal function

by warming up by warming up

Selected mode No error code,

should display No abnormal The warning buzzer
user code not be sounding.
display
Caution
- If any warning or abnormal problem found, carry out repairs immediately.
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3. For safety operation … Starting

(1) Apply brake pedal and release parking brake.

RAISE
(2) Set dump lever in FLOAT position. HOLD
(3) Sound horn 2 times as a sign of starting. FLOAT
After sounding, do not start the machine LOWER
immediately, start it after some time.

(4) Put shift lever from N to R or other position

which you selected.
(5) Apply accelerator pedal slowly after
confirmed engage of T/M clutch by operating
shift lever and release brake pedal.
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4. For safety operation … Traveling flat road
(1) Keep the speed within maximum.
(2) Stop slowly at the decided stop position.
(3) About the condition of passing each other
☆Mountain and Valley: Valley side has priority
(Priority is bad condition of road shoulder)
☆Loaded and Empty: Loaded has priority
☆Shelter place: Shelter side should wait,
other side has priority.
(4) Sleeping operation and looking-away operation
is extremely prohibited.
(5) Wet road surface and steel plate is dangerous
to slipping. Reduce speed before and go slowly.

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5. For safety operation … Traveling downhill
(1) Keep strictly decided speed.
(2) Condition of passing each other
☆Uphill and downhill: Uphill has priority, downhill
should slow down or stop
(3) Return the accelerator pedal and reduce speed
by retarder brake before downhill condition.
☆Sudden braking by foot brake become cause of
slipping.
HD785-5: Front brake is caliper disc
(4) Adjust retarder to avoid red range of engine
rpm during retarder operation. Pull the retarder
lever gradually in case of caution lights up with
above the permission maximum speed.
(5) In downhill operation, adjust retarder for the retarder oil temp.
gauge display to become within the white range.
☆ Brake oil does overheating when engine rpm is low.
☆ Engine rpm is required more than 1500rpm. Keep around 2000rpm!!
☆ When retarder oil temp. caution is on, please make 1 shift down.
If the caution is not off, stop machine. And cool the oil temp. with N lever
position and rotate engine at middle with 1800rpm.
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5-1. For safety operation … Traveling downhill
(6) Please operate retarder lever with the
middle finger and ring finger. The thumb
and forefinger are light touch with the
handle, and fix and operate.
☆ The one hand operation is dangerous in
case of sudden handle operation.
☆ When grasping retarder strongly, the
operation posture isn't stable and becomes
the cause of stiff neck.
☆ Put the thumb as fulcrum, retarder
operation becomes easy.
(7) In downhill operation, both legs separate
from the pedal and put them on the floor.
☆ If you put a leg on accelerator pedal and
brake pedal, auto retarder is released in
case of vibrate and so on and is dangerous.
☆ When not fixing the right leg, the upper
part of body moves. It is bad influences the
minute operation of retarder lever and so
on.
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5-2. For safety operation … Traveling downhill
ARSC (Automatic Retarder Speed Control)

When you want to reduce speed at downhill or flat

condition, ARSC switch ON and leave foot from
accelerator pedal, then retarder will functioning
automatically depend on the shift and engine rpm.

☆ Use manual mode (OFF position) at slippery

road condition.

ON

OFF

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6. For safety operation … Traveling uphill
(1) The slight inclination uphill or empty load operation recommend D shift, an
economy E mode.
☆ When the Lock-Up lamp (green) disappears in the starting of loaded uphill and
the 2nd shift, drop a shift step on 5th shift (It drop till 1st shift).
Press a power mode according to need.
(2) Pay attention to the Torque Converter oil temperature gauge.
☆ It will be affected by payload, haul road angle and outside temperature.

Torque Converter oil temperature gauge

Lock-Up lamp Shift position display
OFF
Economy Mode

ON
Power Mode

Power Mode

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7. For safety operation … Loading area

(1) Keep a distance between the front dump truck.

(2) Put shift lever in “N” and use parking brake at
safe place.
(3) Confirm that payload is not on a side.
☆ If felt about side loading in either side by the
inclination of dump truck. Check the loading
condition, ask loader operator to correct it by radio
or a gesture. Or ask to change the shape of loading
condition.
(4) After loading finished, check the safety condition
of surround area with both side mirror, then start
by D-range slowly.

D-range

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8. For safety operation … Dumping area
(1) Before dump operation, confirm that there are not a
person and an obstacle, a high-voltage cable behind.
(2) Put a shift lever in “N” position then put parking brake
at safe place.
(3) Set a dump lever in raise position, and increase engine
rpm gradually and dump. Soft landing
☆ Keep engine turn around 1700rpm during body raising.
☆ Loose accelerator when body reached near the maximum angle, and
suppress load spilling from the impact on hoist cylinder and body side.
☆ Make speed slow when dumping a big rock.
(4) Confirm the dumping completed.
☆Remaining soil of the body can be checked from the space between
differential case and dump body through the rear window from inside cabin.
(5) Put dump lever in lower and float position after
checked there is no soil on the body, then release
accelerator and the body down by itself.
When the body down to the half position,
put dump lever float and it makes sit down.
(6) Run after the body puts on and sits down.
☆If body raised continuously, speed is fixed on 1st shift.
Sudden start causes wear and cut of tire.
Step slowly to accelerate by D shift. 13
9. For safety operation … Common
(1) Caution of reversing
Hazard Lamp
☆ Decide a way of signal or radio for reversing.

Machine Action Way of signal

Reversing
Reversing Stop slowly with foot brake.
machine
Apply parking brake.
Hazard Lamp
Repeat R shift and N.
Shift Position
Machine at
Signal of wait Hazard Lamp
behind

Stay shelter Horn

Accepting
Passing
signal of
reversing

Hazard Lamp Horn Passing

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9-1. For safety operation … Common
(1) It is dangerous to stop and park the machine on slope.
Do not stop and park at slope. chock!

☆ If you need to stop and park at slope, being always

perpendicular to the road surface.
Apply parking brake and retarder brake.
Put chock on the side of descent of the tire.

(2) After washing and backwater running, check the effect Brake check!
of brake at low speed.
Brake
Effect of the brake becomes low when the brake disc OK!
has splashed by water.
Until the effect of brake recovers, runs at low speed,
step on brake pedal lightly several times and dry it.
☆ HD785-5 is front caliper disc

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9-2. For safety operation … Common
PARKING MACHINE
o Avoid stopping suddenly. Give yourself ample room
when stopping.
o Park the machine on firm, horizontal ground.
Do not park the machine on a slope.
If it is unavoidably necessary to park the machine on a
slope, put blocks under the tires to prevent the
machine from moving.
o If the gear shift lever is touched by mistake, the
machine may move suddenly, and this may lead to a
serious injury or death. Before standing up from the
operator's seat, always set the parking brake switch
securely to the PARKING position.
CAUTION
To prevent damage to the parking brake, apply the
parking
brake only when parking the machine.
1. Release accelerator pedal (1), then depress brake
pedal
(2) to stop the machine.
2. Move gear shift lever (3) to the N position, then set
parking
brake switch (4) to the PARKING position to apply the
parking
brake.

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10. For safety operation … Operation guide (HD785-5)
Condition Flat Road Uphill Downhill Loading Dumping Remark
Empty Loaded Empty Loaded Empty Loaded
F:selectable D=F2～ F5=F1～ N=Neutral
① Shift Range D D D D or F5 D D Ｎ Ｎ Lock-Up OFF -> F5
R = Retarder
② Brake R or F R or F R or F R or F R R P P F = Foot Brake
P = Parking Brake

③ Power Mode E E E E or P E E E E Lock-Up OFF -> P

Winter: ON
④ AISS OFF OFF OFF OFF OFF OFF OFF OFF Slow drive: OFF
Front Hard ON ON ON ON ON ON ON ON
⑤ Brake OFF
Soft OFF OFF OFF OFF OFF OFF OFF OFF Soft = Frozen, Snow etc.
Hard ON ON ON ON ON ON ON ON Auto Retarder
⑥ ARSC Soft OFF OFF OFF OFF OFF OFF OFF OFF
Engine 1100rpm 1100rpm 1100rpm Full 1800rpm 1800rpm 1700rpm
⑦ rpm
～1700rpm
～ ～
rpm
～ ～ Idling
1700rpm 1700rpm 2000rpm 2000rpm

⑧ Vehicle Speed
～35km/h ～35km/h － － ～15km/h ～15km/h ～10km/h ～10km/h

Normal ⑥ ⑤ ④ ③
OFF OFF
ON ON
Lo-Idle E-Mode
Auto Front
Retarder Brake

ＯＦＦ ＯＦＦ ON ON

AUTO P-Mode
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10-1. For safety operation … Operation guide (HD785-7)
Condition Flat Road Uphill Downhill Loading Dumping Remark
Empty Loaded Empty Loaded Empty Loaded
F:selectable D=F2～ F5=F1～ N=Neutral
①
Shift Range D D D D or F5 D D N N Lock-Up OFF -> F5
R = Retarder

② Brake R or F R or F R or F R or F R R P P F = Foot Brake

P = Parking Brake

③ Power
E E E E or P E E E E Lock-Up OFF -> P
Mode
Winter: ON
④ AISS OFF OFF OFF OFF OFF OFF OFF OFF Slow drive: OFF
Exhaust Hard B B B B C=OFF is possible except steep slope
⑤ A, B: selectable A, B, C: selectable
Brake Soft B B B B Soft = Frozen, Snow etc.
Hard ON ON ON ON ON ON ON ON Auto Retarder
⑥ ARSC Soft OFF OFF OFF OFF OFF OFF OFF OFF
Engine 1100rpm 1100rpm 1100rpm Full 1800rpm 1800rpm 1700rpm
⑦ rpm ～ ～ ～ ～ ～ Idling
rpm
1700rpm 1700rpm 1700rpm 2000rpm 2000rpm

⑧ Vehicle Speed
～35km/h～35km/h － － ～15km/h～15km/h～10km/h～10km/h

Normal ⑥ ⑤ ④ ③
ON A: Upper OFF OFF
Economy
Auto Retarder Accelerator Pedal OFF Lo-Idle
Mode
B: Center
OFF Retarder, Foot Brake ON ON ON
C=OFF Auto Power Mode
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11. For safety operation … Facility, Environment

(1) Road Sign

☆Max. Speed
☆Do not overtake
☆Stop
☆Sound horn

(2) Road establishment

☆Keep out
☆No overtaking

(3) Road facilities

☆Night light
☆Curve mirror

(4) Road environment

☆Sprinkle water

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12. For safety operation … Leveling the Road Surface
Road surface roughness: B
Standard for leveling the road surface Wheel Base
Road surface roughness: Level B or less
Rolling resistance: 5% or less Depth
Grade resistance: 10% or less
Rank A B C D E
(%: Rolling Resistance) Depth (cm) -2 3-7 8-16 17-34 35 -

Macadam road in good Macadam road in quite good Unpaved road where tracks of Unpaved road where large ruts
condition: 1.5% condition : 2.5 to 3.5% tire treads remain: 5.0 to 10.0% remain: 10.0 to 30.0%

(1) Remove the unevenness and excessive horizontal inclination from the road surface. Repair the collapse
of a road edge.
(2) Remove obstacles such as rocks or lumber, collapse of cliff or slope surface, and fallen rocks. Level a
rough road surface by a bulldozer or motor grader.
(3) Dust deteriorate visibility. Spray water to keep the ground appropriately moist.
(4) A puddle of water becomes larger due to digging by dump travelling. Fill or drain off water from it as
soon as you can.
(5) In case of snowfall of freezing on the road, install a tire chain immediately. Otherwise, spread a melting
agent on the surface.
(6) Mix soil cement with soft ground to enhance the ground strength. 20
 Notes
(1) This safety manual is for HD785-7 and HD785-5. Please
attention if there is difference about specification and option
in each country.
(2) This manual is only for common attention. Please refer the
operation and maintenance manual for more understanding.
(3) Please use this manual as reference because safety sign of
machine and each regulation is different each country.
(4) It may be necessary to add some attention depend on a
condition of usage and site.
(5) “X” is marked in the picture of dangerous operation. And this
is only for purpose of attention.

Komatsu Ltd.
Product Support Div.
Techno-Center
TEL: +81-558-83-2930
Aug. 2012
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