komatsu hd785-5 - familiarization presentation
TRANSCRIPT
7/22/2019 Komatsu HD785-5 - FAMILIARIZATION Presentation
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TRAINER:
HD785-5
OPERATOR
FAMILIARIZATION
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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
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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
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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
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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
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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
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!or'sho*Asse)<+
Per#h
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ENGINE @AB LEFT SIDE ENGINE DIP STIC
FILL
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PASSENGERS SIDE ENGINE @AB ALTERNATOR
FAN @ELTS
ENGINEFILTERS
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ENGINE @AB
LOOING FROM THE TOP DEC
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Chec' sec2ri#+ o= *i4s%
s#eeri4" 0r)s h+3r02icr0)s% "re0se i4es
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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
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@RAE
COOLING
OIL
TAN
HBDRA?LIC
STEERING
OILTAN
TRANSMISSIONOIL FILL
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STOPPED
R?NNING
TRANSMISSION OIL LEVEL
D0sh 5 Tr2c's
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D0sh . Tr2c's
STOPPED
R?NNING
TRANSMISSION OIL LEVEL
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Tr04s)issio4
F2e
T04'
H+3r02ic
T04'
P0r' @r0'e
E)er"e4c+
s#eeri4"*2)*
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REAR S?SPENSION
Re#0r3er
<r0'e
Re#0r3er
<r0'e
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F?EL TAN
CAPACITB $5& Li#res
G02"eF0s# Fi
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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 @ '
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@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
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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"
• $s the retarder is applied the disc
are squee.ed together, thus the
whole assem"ly is slowed*"raking
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$/ T04'
/ P2)*
./ Re#0r3er
/ Oi cooer
5/ Fi#er
,/ T04'
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@r0'e 3isc
Re#0r3er
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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
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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"
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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
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/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/
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REAR @RAES (RETARDER/
OPERATED VIA RETARDER LEVER
Re#0r3ereer
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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
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EMERGENCB @RAES
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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**+
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@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 $8&& RPM
• EMERGENCB @RAE F?LL THROTTLE
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#h e0r 7' h
REAR S?SPENSION
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REAR S?SPENSION
Air Dr0i4
E)er"e4c+ #04'
@ATTERIES RADIATOR FRONT
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@ATTERIES% RADIATOR FRONT
@RAE FL?ID
R03i0#or He03er
T04'
Fro4# @r0'e
F2i3
Loc0#io4 #o* 3ec'
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-ront +rake oil
0adiator Water'eader Tank
Loc0#io4 #o* 3ec'
AIR TAN DRAINS
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AIR TAN DRAINS
GREASE SBSTEM
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GREASE SBSTEM
• %ounted on the top deck, fully
automatic
• 5rease controller located on the
dash in front of the passenger
• The controller has four
functions6
70un light
7-ault light
7Test "utton
78ow le!el li ht
AIR CLEANERS
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AIR CLEANERS
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ACTION CODES
& /ark the machine at a safe location and contact your super!isor
& Carry out an E)er"e4c+ S#o*, s#o* the E4"i4e and contact your
super!isor
&$ 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
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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
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!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#
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P0r' @r0'e Shi=# i)i#
Po9er Mo3es
EMERGENCB @RAE
EMERGENCB
STEERING
E)er"e4c+ s#o* oc0#io4
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EMERGENCB ENGINE STOP
REAR OF CENTRE CONSOLE
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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
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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
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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
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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
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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
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E)er"e4c+ S#eeri4" S+s#e)
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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 $65 seco43s
• To #2r4 o==% re-0**+ #he *0r' <r0'e
• I= #he s#eeri4" 3i3 4o# 02#o)0#ic0+ 'ic' i4% #he #r2c' )2s# 4o#
"o #o 9or' re*or# #he =02# #o +o2r s2*erisor
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SAE S#eeri4" Co2rse
Steering meetsSteering meets
SAE J1511 standardsSAE J1511 standards
C o r r i d o
r 1
C o r r i d o r 3
Corridor 2
Corridor 4
Finish 1
Finish 2
Start 1
Start 2
1.25 x max width over tires
5 x max width over tires25 m
4 0 m
3 0 m
2 0 m 1
0 m
C
A
B
C
A = 1.10 x the tire track circle or 14 mA = 1.10 x the tire track circle or 14 m
whichever is lar!er. whichever is lar!er.B = 1."5 x the tire track circle or 22 mB = 1."5 x the tire track circle or 22 m
whichever is lar!er. whichever is lar!er.
C = 2.00 x the maxim#m axle s$acin!C = 2.00 x the maxim#m axle s$acin! or 15 m whichever is smaller. or 15 m whichever is smaller.
REVERSE TRANSMISSION
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REVERSE TRANSMISSION
NE?TRALIZER
• The machine is equipped
with a re!erse transmission
neutrali.er1 The re!erse
neutrali.er pre!ents
re!erse from engaging
while the "ody dump
control is in the 0$I);D position1
REVERSE TRANSMISSION
7/22/2019 Komatsu HD785-5 - FAMILIARIZATION Presentation
http://slidepdf.com/reader/full/komatsu-hd785-5-familiarization-presentation 58/59
REVERSE TRANSMISSION
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