komatsu hd785-5 - familiarization presentation

7/22/2019 Komatsu HD785-5 - FAMILIARIZATION Presentation

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TRAINER:

HD785-5

OPERATOR

FAMILIARIZATION



SPECIFICATIONS

• Gross Vehice !ei"h# $58%&$& '" (E)*#+ ,,%.&'"/

• M01i)2) P0+o03 -5 $ To44es

P0+o03 -. 87 To44es (76&&- T+res/

• E4"i4e )o3e o)0#s2 SA$V$&

• E4"i4e Horse*o9er $&5& h* 78. '9 ; &&& r*)

• N2)<er o= C+i43ers $

• E4"i4e Dis*0ce)e4# .&68 i#res



ISOLATION POINT

• The isolation switch is

located on the right

hand side of the ladder

way• Turn the switch to off,

then fit your personal

Danger lock or tag



FIRE TETRAHEDRON• Which means that if you

suppress one of thetriangles, there is a strongchance of extinguishing thefire

• Instant emergency shutting

down of the engine isrequired, as this stops thefuel supply, oxygen andheat source

• Correct extinguisherselection is critical



FIRE E>TING?ISHERS

• Dry powder extinguishers

are located at ground le!el

at the "oarding ladder # on the top deck a"o!e the

radiator

• $lways check the charge

indicator, and for any sign

of damage



SAFE @OARDING E>IT

• %a&or cause of soft tissuedamage in the work place

• 'igh risk of trip, slip and

fall accidents

• (our duty of care

• $lways maintain three points of contact



!or'sho*Asse)<+

Per#h



ENGINE @AB LEFT SIDE ENGINE DIP STIC

FILL



PASSENGERS SIDE ENGINE @AB ALTERNATOR

FAN @ELTS

ENGINEFILTERS



ENGINE @AB

LOOING FROM THE TOP DEC



Chec' sec2ri#+ o= *i4s%

s#eeri4" 0r)s h+3r02icr0)s% "re0se i4es



SPOT THE HAZARD

• Poor s#0430r3 o=90'0ro243

• Po#e4#i0 )0ori4ci3e4#

• T0" o2# 043 s#043

3o94• Re*or# #o +o2r

s2*erisor



@RAE

COOLING

OIL

TAN

HBDRA?LIC

STEERING

OILTAN

TRANSMISSIONOIL FILL



STOPPED

R?NNING

TRANSMISSION OIL LEVEL

D0sh 5 Tr2c's



D0sh . Tr2c's

STOPPED

R?NNING

TRANSMISSION OIL LEVEL



Tr04s)issio4

F2e

T04'

H+3r02ic

T04'

P0r' @r0'e

E)er"e4c+

s#eeri4"*2)*



REAR S?SPENSION

Re#0r3er

<r0'e

Re#0r3er

<r0'e



F?EL TAN

CAPACITB $5& Li#res

G02"eF0s# Fi



FRONT @RAES

Dr+ 3isc 9i#h c0i*ers *er 9hee

O*er0#e3 i0 =oo# *e30% o4+ #o <e 2se =or so9 s*ee3

)04oe2ri4" or i4 0 e)er"e4c+% 9i o4+ 0**+ i= #he

=ro4# <r0'e s9i#ch is #2r4e3 o46

M #i Di @ '



@r0'e 3iscs h0e 0)*e <r0'i4" c0*0<ii#+ #o co4#ro ehice s*ee3

043 si4ce #he+ 0re oi-cooe3% *osi#ie <r0'i4" *er=or)04ce is

o<#0i40<e 0# 0 #i)es6 H+3r02ic0+ 0c#20#e3 <r0'es re32ce o*er0#or

<r0'i4" e==or#s6 !he4 #he <r0'e *e30 is 3e*resse3 <+ #he o*er0#or%#he <r0'e 0e i4#erco44ec#e3 9i#h #he <r0'e *e30 o*e4s 043 =ee3s

co)*resse3 0ir #o #he <r0'e ch0)<ers% 9here<+ 0ir *ress2re is

co4er#e3 i4#o h+3r02ic *ress2re #o 0c#20#e #he *is#o4s o= #he 9hee

<r0'e c+i43ers6 These *is#o4s #he4 #eesco*e #o 0**+ #he <r0'e 3iscs6

M2#i*e-Disc @r0'es

Re#0r3er



Re#0r3er @r0'e O*er0#io4

• %ulti pack "rake operation• )teel and friction discs *+rake

linings

• )teel discs locked to the outer

fixed hu"

• -riction discs locked to the inner

hu"

• $s the retarder is applied the disc

are squee.ed together, thus the

whole assem"ly is slowed*"raking



$/ T04'

/ P2)*

./ Re#0r3er

/ Oi cooer

5/ Fi#er

,/ T04'



@r0'e 3isc

Re#0r3er



FOOT @RAE (SERVICE @RAE/

• THE SERVICE @RAES !ILL APPLB THE FRONT AND

REAR @RAES IF :

THE FRONT @RAE C?T OFF S!ITCH IS NOT ON

I= #he <2##o4 is *2she3 i4 o4+ #he REAR <r0'es 9i

0**+ 0# $&& *ress2re6

The serice <r0'e 0so h0s 0 r0#io 0e =i##e3% re0r <r0'es

0**+ =irs# % #he4 0=#er $ *e30 #r0e <o#h =ro4# 043 re0r

<r0'es o*er0#e 0# #he s0)e *ress2res (D0sh 5 o4+/6

• THE SERVICE @RAES ARE TO @E ?SED FOR SLO! SPEED MANOE?VRING AND IN AN EMERGENCB



RETARDER OPERATION

• Re#0r3er o*er0#es o4+ #he re0r <r0'es

• Re#0r3er 0**ies o4+ 8& o= <r0'i4" c0*0ci#+

• !his# re#0r3i4" #he e4"i4e s*ee3 sho23 <e 0# e0s# $8&& r*)

#o 0i3 i4 #he cooi4" o= #he re#0r3er oi

• I= #he re#0r3er oi #e)*er0#2re oerhe0#s% <ri4" #he #r2c' #o 0

s0=e s#o*6 A**+ #he re#0r3er 9i#h #he #r04s)issio4 i4 4e2#r0

043 r24 #he e4"i4e 0# &&& r*) 24#i #he re#0r3er oi #e)*er0#2re

is i4 #he "ree4 r04"e

• I= #he E4"i4e RPM E1cee3s ,&& r*) #he re#0r3er 9i 0**+6

A43 9i ree0se 0# .&& r*) #o *ree4# #he e4"i4e =ro)

oers*ee3i4"



RETARDER OPERATION

!0r4i4":

!he4 *0r'i4" or e0i4" #he #r2c'% 3o4# e0e #he re#0r3er

0**ie3 0s #his )0+ c02se #he re#0r3er #o <ee3 3o946

The res2# 9i <e #h0# 0=#er s#0r# 2*% #he =irs# 0**ic0#io4 o=#he re#0r3er )0+ <e o= 4o e==ec#6 ?se #he serice <r0'e #o co4#ro

#he #r2c'6 A**+ 043 ree0se #he re#0r3er seer0 #i)es #o

co4=ir) o*er0#io46

/ ki ith th 0 t d i t l D d t



/arking with the 0etarder is not only Dangerous due to

possi"le air loss # "rakes releasing, "ut can also cause a

"rake o!erstroke in the "rake master cylinder, which is

also dangerous1

$ir from

"rake #retarder

controls

2il to

"rake packs

REAR @RAES (RETARDER/



REAR @RAES (RETARDER/

OPERATED VIA RETARDER LEVER

Re#0r3ereer



RETARDER OPERATION

• Whilst getting loaded and tipping

• A90+s 0**+ the retarder • The retarder c04 h043e the shock

impact of loading and tipping *alsothe retarder oil is cooled or can "ecooled at the loading or tipping

area• The park "rake 9i 4o# h043e the

shock impact and will "e damaged*o!er time

• These instructions are as per theKomatsu operator and maintenancemanual *dash 3 # 4 trucks



EMERGENCB @RAES



EMERGENCB @RAES

• I4 04 E)er"e4c+ 0**ic0#io4 0 =ie (5/ <r0'es 0**+ :

T9o (/ =ro4#% T9o (/ re0r 043 #he P0r' <r0'e 5 <r0'es

• I= #he #r2c' h0s o4+ $& o= 0ir *ress2re re)0i4i4"% 0 <r0'es

9i 0**+6 O4ce #he e)er"e4c+ <r0'e 0ir #04's h0e <ee3

3o94% #he *0r' <r0'e 9i re)0i4 0**ie3 i0 s*ri4" 0**ic0#io4

EMERGENCB @RAE

LEVER LOCATED ON

THE CENTRE CONSOLE

• I4 #he E)er"e4c+ 0**ic0#io4% ee4 i= #he Fro4# @r0'e S9i#ch

is #2r4e3 o== #he Fro4# @r0'es 9i 0**+



@RAE TESTING 0s MACA S6O6P

• A #es# 0re #o <e co432c#e3 o4 ee "ro243% 9i#h 0

=2+ ch0r"e3 0ir s+s#e) 0=#er 0 co)*e#e 90'0ro243i4s*ec#io4

• A #es#s 0re #o <e co432c#e3 i4 Drie (D/ 9hich is 43"e0r

• PAR @RAE $75& RPM

• RETARDER $$5&& RPM

• FOOT @RAE $8&& RPM

• EMERGENCB @RAE F?LL THROTTLE



#h e0r 7' h

REAR S?SPENSION



REAR S?SPENSION

Air Dr0i4

E)er"e4c+ #04'

@ATTERIES RADIATOR FRONT



@ATTERIES% RADIATOR FRONT

@RAE FL?ID

R03i0#or He03er

T04'

Fro4# @r0'e

F2i3

Loc0#io4 #o* 3ec'



-ront +rake oil

0adiator Water'eader Tank

Loc0#io4 #o* 3ec'

AIR TAN DRAINS



AIR TAN DRAINS

GREASE SBSTEM



GREASE SBSTEM

• %ounted on the top deck, fully

automatic

• 5rease controller located on the

dash in front of the passenger

• The controller has four

functions6

70un light

7-ault light

7Test "utton

78ow le!el li ht

AIR CLEANERS



AIR CLEANERS



ACTION CODES

& /ark the machine at a safe location and contact your super!isor

& Carry out an E)er"e4c+ S#o*, s#o* the E4"i4e and contact your

super!isor

&$ Carry out checks and maintenance according to the operators manual

&. 2perate the machine keeping the engine at low re!olutions and low

tra!el speed

&5 S#o* the machine1 0un the engine at mid9range speed under no load

&, 0estart the engine1 Idle the engine for a while

&7 Do not raise the "ody

ACTION CODES



ACTION CODES

A=#er <ri4" #he #he #r2c' #o 0 s0=e co4#roe3 s#o*:

To access the )er!ice Code -ault :um"er, press the T;)T +utton*yellow until the $larm +u..er has sounded three *3 times or more

This will then "ring up the )er!ice Code *type of fault eg6

Ac#io4 Co3e &5Serice co3e <OE

Lo9 @r0'e Air Press2re

Ac#io4 Co3e &

Serice Co3e COLo9 e4"i4e oi *ress2re

Ac#io4 Co3e &5

Serice Co3e <o3

Tor2e Co4er#er Oi Te)*er0#2re Oerhe0#

G S S



!EIGHT SBSTEM

• <=>> maximum limit

for cycle data

• %easures out ?@> mts,after mo!ing off

• -ault codes displayed

• Dash 4 A =? Tonnes

• Dash 3 A B Tonnes

P ' @ ' Shi=# i i#



P0r' @r0'e Shi=# i)i#

Po9er Mo3es

EMERGENCB @RAE

EMERGENCB

STEERING

E)er"e4c+ s#o* oc0#io4



EMERGENCB ENGINE STOP

REAR OF CENTRE CONSOLE



GEAR H?NTING

• When hauling uphill, lock the transmission in ?st gear

• If the transmission is allowed to repeatedly upshift and

downshift "etween gears, extreme pressures ar placed on the dri!eline and power train components1 )elec

the lower of the two gears to minimi.e the stress that is

caused when gear hunting is allowed to occur

ie: 785 pushes 1010 hp through the power train every gear shift



DRIVE LINE FAIL?RE

• Dri!e line axle

• )heared off internally in

the differential

• ;mergency park up

procedure *3>> Tonnes• %achine down time

• 'igh repair cost

Tr04s)issio4



Tr04s)issio4

• 7 S*ee3 Tr04s)issio4

• I4 Drie (D/ 43 #o 7#h Ge0r

• I4 Drie (D/ 9i#h #he shi=# i)i#er o4%,#h "e0r i)i#

• I4 5#h Ge0r% $s# #o 5#h &'*h

• I4 #h Ge0r% $s# #o #h .&'*h

• I4 .r3 Ge0r% $s# #o .r3 '*h

• I4 Lo9 Ge0r% $s#

#o 43

$,65'*h

• I4 Lo9 (L/ 9i#h #he shi=# i)i#er o4%$s# "e0r oc'e3

Shi=# Li)i#@2##o4

T i i C t l



Transmission Control

• $lways lock the transmission in 8E

low gear and shift limit to pre!ent the transmission from unnecessaryup shifts

• This will aid in keeping thecon!erter F transmission oiltemperature at a cooler le!el

• 2"ser!e the con!erter lock upindicator on the dash to ensure thecon!erter is locked up, if on a long

up hill haul the con!erter was notlocked up, con!erter F transmissionoil temperature will o!erheat, thiswill cause other cooling systems torise in temperature1

Cooling The Con!erter



Cooling The Con!erter

• If the con!erter

temperature acti!ates

the warning system

• +ring the machine to a

safe controlled stop

• $pply the retarder andhigh idle the engine to

cool the con!erter oil

!ia the cooler



E)er"e4c+ S#eeri4" S+s#e)



E)er"e4c+ S#eeri4" S+s#e)

• To #es# #he A2#o)0#ic o*er0#io4 o= #he e)er"e4c+ s#eeri4"

s+s#e) +o2 )2s# h0e 0 =2+ ch0r"e3 0ir s+s#e)

• A**+ +o2r serice <r0'e (=oo# <r0'e/% #2r4 o4 #he i"4i#io4 'e+

(30sh i"h#s 2*/ 043 #he4 #2r4 o== #he *0r' <r0'e s9i#ch

• The E)er"e4c+ s#eeri4" s+s#e) sho23 0c#ie A?TOMATICALLB

0=#er $65 seco43s

• To #2r4 o==% re-0**+ #he *0r' <r0'e

• I= #he s#eeri4" 3i3 4o# 02#o)0#ic0+ 'ic' i4% #he #r2c' )2s# 4o#

"o #o 9or' re*or# #he =02# #o +o2r s2*erisor



SAE S#eeri4" Co2rse

Steering meetsSteering meets

SAE J1511 standardsSAE J1511 standards

C o r r i d o

r 1

C o r r i d o r 3

Corridor 2

Corridor 4

Finish 1

Finish 2

Start 1

Start 2

1.25 x max width over tires

5 x max width over tires25 m

4 0 m

3 0 m

2 0 m 1

0 m

C

A

B

C

A = 1.10 x the tire track circle or 14 mA = 1.10 x the tire track circle or 14 m

whichever is lar!er. whichever is lar!er.B = 1."5 x the tire track circle or 22 mB = 1."5 x the tire track circle or 22 m

whichever is lar!er. whichever is lar!er.

C = 2.00 x the maxim#m axle s$acin!C = 2.00 x the maxim#m axle s$acin! or 15 m whichever is smaller. or 15 m whichever is smaller.

REVERSE TRANSMISSION




NE?TRALIZER

• The machine is equipped

with a re!erse transmission

neutrali.er1 The re!erse

neutrali.er pre!ents

re!erse from engaging

while the "ody dump

control is in the 0$I);D position1





NE?TRALIZER

• If the dump control le!er ismo!ed to the raise position

when the transmission is in

re!erse, the transmission will

promptly go to :eutral

• To return to 0e!erse, mo!e the

dump le!er to 'old



THANK YOU FOR

YOUR ATTENTION

Any Questions

komatsu hd785-5 - familiarization presentation

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