785-5 instrument familiarization & assessment

KOMATSU 785 HAUL TRUCK

By then end of this presentation all personnel should have a better understanding of the Komatsu 785 Haul Truck this will be followed

by an assessment and must have a passing of 90%. This will include operation’s of the dump truck as listed below:

• Safe operation•Understanding all dash instruments and controls •Check before starting•Operating the dump truck•Operating the dump body•Method of releasing parking brake and emergency brake

INFORMATION

SAFETY

GENERAL VIEW OF HAUL TRUCK

1. DUMP BODY2. REAR TYRE3. FRONT TYRE4. TURN

INDICATOR5. DRIVING

LIGHTS

SAFETY

WARNING

CAUTION

DANGER

1.Only trained and authorized personnel can operate and maintain the machine.

2.Do not operate machine if you are feeling unwell, if you are on medication that makes you sleepy, if you have been drinking, or suffering from emotional problems. These problems will interfere with your sense of judgment in emergencies and may cause accidents.

3.Unless authorized under no circumstances are passengers allowed.

4.When working with another operator or with another person on worksite duties, be sure all personnel know the nature of the work and understands all hand signals that are to be used.

5.Strictly observe other rules related to safety and operations of the machine

SAFETY RULES

1. When entering operators cabin always remove mud and oil from the soles of your boots, if you operate the pedals with mud or oil on you boots your foot may slip and cause a serious accident.

2. Do not stick suction pads to the windows suction pads act as a lens and may cause fire

3. Do not use mobile phones in the cabin when operating machine, there is a danger that could lead to and unexpected accident. (D.A.M.S operators are not allowed mobile phones when on duties).

4. Do not use radios or head-phones while operating machines as you may not hear mechanical failures or an emergency call and could lead to an accident.

5. When inside the cabin while operating machine do not put your head or hands outside.

6. When operating machine keep door closed at all times.

INSIDE OPERATORS CABIN

1. Avoid loose clothing and jewelry as they may catch on controls or protruding objects and cause serious injury or death.

2. Do not wear oily clothes as they are highly flammable.3. Ensure all PPE is in good condition before using it.4. Minimum PPE requirements are as followsHard hat High Visibility reflective clothing or vest

Safety glasses

Steel Capped Safety Boots

Hearing protection

CLOTHING AND PERSONEL PROTECTIVE EQUIPMENT

To prevent any accident occurring if you should touch any control lever that is not locked always carry out the following before standing up from the operators seat.

•Place the gear shift lever in the neutral position and set the parking lever to the parking position.•Set the dump body lever to the hold position then apply lock.•Stop the engine after cooling period

LEAVING OPERATORS SEAT

1. Before getting on or off the machine, if there is any oil, mud or grease on the hand rails wipe it off immediately to prevent slipping.

2. Report damage or repairs to hand rails3. Never jump on or off the machine.4. Never get on or off a moving machine as this will lead to a

serious injury5. Always use three point contact when mounting machines.6. Use the hand rails and steps marked by the arrows in the

diagram when getting on or off the machine.

A. For use when getting on or off the machine from the left doorB. For use when getting on or off the machine from the right door

MOUNTING AND DISMOUNTING

• Before moving your machine thoroughly check the area for unusual conditions that could be dangerous or cause damage.

• Always ensure the roads are maintained so machines can travel safely.

What do you think the consequence’s of this incident is?

SAFETY AT WORKSITE

D.A.M.S have procedures in place for pre-shift checks. These procedures must be obeyed at all times before, during and after

operation the machines.•Pre-start check and fault finding procedure•Tagging and Isolation procedure•Starting mobile equipment procedure•Motor shut down procedure

PRE SHIFT CHECKS

CONTROLS AND GAUGES

PRE SHIFT CHECKSCONTROLS AND GAUGES

EXPLAINATION OF COMPONENTS

MACHINE MONITOR

A.Action code display. • If any trouble occurs and check or maintenance is required this

action code will indicate the appropriate corrective action. The monitor will light up or flash, and at the same time the central warning lamp flashes.

B. Caution lamps.• If any of these monitors lights up, carry out the inspection and

then notify your supervisor so he can contact maintenance of the appropriate item as soon as possible.

C. Emergency stop items.• Stop operations and carry out the inspection, then notify your

supervisor immediately of your situation so he can contact maintenance of the appropriate item as soon as possible.

D. Meter display portion.• This consists of many items which we will go through with the

operators manual.E. Mechatronic caution lamp portion.• Trouble occurred on the mechatronic devices of the control

system the appropriate monitor will flash, if these monitors flash carry out the specified action according to the action plan.

MACHINE MONITOR

F. Central warning lampIf the machine is in the following conditions this lamp will flash.•When an abnormality has occurred in any of B caution items.If the machine is in the following conditions this lamp will flash and at the same time the alarm buzzer will sound intermittently•When an abnormality has incurred in any of C emergency stop items•When E mechatronic caution lamp portion flashes•If parking brake is applied but the shift lever is not in neutral•When the dump lever is not in the float position and the shift lever is not in neutral•When engine tachometer red range lights up

MACHINE MONITORContinued

ACTION CODE DISPLAY

.

ACTION CODE DISPLAY

CAUTIONSShould you get any of the warning lamps flashing

contact your supervisor.Your supervisor will then notify maintenance.

.

Caution items

Caution items

EMERGENCY STOP ITEM

ANY QUESTIONS?

EMERGENCY STOP ITEM

When the ignition key is at ON position these lamps will light up when the display items are functioning

METER DISPLAYS

1. Speedometer - Travelling speed of the machine

2. Engine Tachometer - Speed of the engine (RPM) while in operation if the red range lights up, simultaneously the warning buzzer sounds and the central warning lamp flashes.

3. Service meter – Shows the total hours of operation, if machine is parked but motor is still running the meter will still advance.

METER DISPLAYS

4. Odometer – Indicates the distance travelled

5. Fuel gauge – Amount of fuel in fuel tank, if the red lights up during operation it indicates less that 120 litres remaining in fuel tank

6. Air pressure gauge – If the red range lights up during operation the alarm buzzer will sound, central warning lamp and the air pressure monitor lamp will flash. NOTE If air pressure keeps on dropping the park brakes will automatically apply. Notify your supervisor.

METER DISPLAYS

7. Engine water temperature gauge - If the red range lights up during operation the alarm buzzer will sound, central warning lamp and the air pressure monitor lamp will flash. If this happens stop the truck and idle it until the green range lights up, if the green range does not light up turn the engine off. Notify your supervisor.

8.Torque converter oil temperature - If the red range lights up during operation the alarm buzzer will sound, central warning lamp and the Torque converter monitor lamp will flash. If this happens stop the truck and idle it until the green range lights up, if the green range does not light up turn the engine off. Notify your supervisor

9. Retarder oil temperature gauge - If the red range lights up during operation the alarm buzzer will sound, central warning lamp and the Retarder oil monitor lamp will flash. If this happens stop the truck and idle it until the green range lights up, if the green range does not light up turn the engine off. Notify your supervisor

METER DISPLAYS

SWITCHES

CONTROL LEVERS AND PEDALS

NOTE – Dump lever must be in float position when travelling


CODES TO REMEMBER

Now that we have gone through the instruments and some safety and

familiarization components are there any questions before the assessment?

ASSESSMENT

ASSESSMENT QUESTIONS

785-5 instrument familiarization & assessment

Documents

moving machine

machine safety ruleswhen

parking lever

serious accident

parking position

dump body lever

operators seatbefore

s operators