TRAINER:

HD785-5
OPERATOR
FAMILIARIZATION
SPECIFICATIONS

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

M01i)2) P0+o03 -5 -$ To44es

P0+o03 -. 87 To44es (576&&-7- T+res/

E4"i4e )o3e 8o)0#s2 SA$5V$7&

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

N2)<er o= C+i43ers $5

E4"i4e Dis*0ce)e4# .&678 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 the
triangles, there is a strong
chance of extinguishing the
fire
Instant emergency shutting
down of the engine is
required, as this stops the
fuel supply, oxygen and
heat source
Correct extinguisher
selection is critical
FIRE E>TING?ISHERS
Know the location of all
the extinguishers
nderstand the colour
coding of the
extinguishers
nderstand the
operation of each
extinguisher
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 A E>IT
%a&or cause of soft tissue
damage 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 STIC8
A FILL
PASSENGERS SIDE ENGINE @AB ALTERNATOR A
FAN @ELTS
ENGINE
FILTERS
ENGINE @AB
LOO8ING FROM THE TOP DEC8
Chec' sec2ri#+ o= *i4s%
s#eeri4" 0r)s A h+3r02ic
r0)s% A "re0se i4es
SPOT THE HAZARDC
Poor s#0430r3 o=
90'0ro243
Po#e4#i0 )0Dor
i4ci3e4#
T0" o2# 043 s#043
3o94
Re*or# #o +o2r
s2*erEisor
@RA8E
COOLING
OIL
TAN8
HBDRA?LIC
A
STEERING
OIL
TAN8
TRANSMISSION
OIL 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 TAN8
CAPACITB $55& Li#res
G02"e
F0s# Fi
FRONT @RA8ES
Dr+ 3isc 9i#h 5 c0i*ers *er 9hee
O*er0#e3 Ei0 =oo# *e30% o4+ #o <e 2se =or so9 s*ee3
)04oe2Eri4" or i4 0 e)er"e4c+% 9i o4+ 0**+ i= #he
=ro4# <r0'e s9i#ch is #2r4e3 o46
@r0'e 3iscs h0Ee 0)*e <r0'i4" c0*0<ii#+ #o co4#ro Eehice s*ee3
043 si4ce #he+ 0re oi-cooe3% *osi#iEe <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 E0Ee 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
co4Eer#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'
5/ P2)*
./ Re#0r3er
7/ Oi cooer
5/ Fi#er
,/ T04'
@r0'e 3isc
Re#0r3er
FOOT @RA8E (SERVICE @RA8E/

THE SERVICE @RA8ES !ILL APPLB THE FRONT AND

REAR @RA8ES IF :
THE FRONT @RA8E C?T OFF S!ITCH IS NOT ON
I= #he <2##o4 is *2she3 i4 o4+ #he REAR <r0'es 9i
0**+ 0# $&&F *ress2re6
The serEice <r0'e 0so h0s 0 r0#io E0Ee =i##e3% re0r <r0'es
0**+ =irs# % #he4 0=#er $:5 *e30 #r0Ee <o#h =ro4# 043 re0r
<r0'es o*er0#e 0# #he s0)e *ress2res (D0sh 5 o4+/6

THE SERVICE @RA8ES 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&F 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 oEerhe0#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# 5&&& r*) 24#i #he re#0r3er oi #e)*er0#2re
is i4 #he "ree4 r04"e

I= #he E4"i4e RPM E1cee3s 5,&& r*) #he re#0r3er 9i 0**+6

A43 9i ree0se 0# 5.&& r*) #o *reEe4# #he e4"i4e =ro)
oEers*ee3i4"
RETARDER OPERATION
!0r4i4":
!he4 *0r'i4" or e0Ei4" #he #r2c'% 3o4G# e0Ee #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 serEice <r0'e #o co4#ro
#he #r2c'6 A**+ 043 ree0se #he re#0r3er seEer0 #i)es #o
co4=ir) o*er0#io46
/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 @RA8ES (RETARDER/
OPERATED VIA RETARDER LEVER
Re#0r3er
eEer
RETARDER OPERATION

Whilst getting loaded and tipping

A90+s 0**+ the retarder

The retarder c04 h043e the shock

impact of loading and tipping *also
the retarder oil is cooled or can "e
cooled 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 the

Komatsu operator and maintenance
manual *dash 3 # 4 trucks,
PAR8 @RA8E

The P0r' <r0'e is #he o4+ FAIL SAFE <r0'e o4 #he #r2c'%
#his )e04s #h0# i# is SPRING 0**ie3 043 AIR *ress2re ree0se3

!he4 *0r'i4" #he #r2c'% =ii4" #he #r2c' 0# #he s#043 *i*e or
e0Ei4" #he se0# #he PAR8 @RA8E M?ST <e 0**ie3
S9i#ch o4 ce4#re
co4soe
P0r' <r0'e
PAR8 @RA8E
EMERGENCB @RA8ES

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

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

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

9i 0**+6 O4ce #he e)er"e4c+ <r0'e 0ir #04's h0Ee <ee3
3o94% #he *0r' <r0'e 9i re)0i4 0**ie3 Ei0 s*ri4" 0**ic0#io4
EMERGENCB @RA8E
LEVER LOCATED ON
THE CENTRE CONSOLE

I4 #he E)er"e4c+ 0**ic0#io4% eEe4 i= #he Fro4# @r0'e S9i#ch

is #2r4e3 o== #he Fro4# @r0'es 9i 0**+
@RA8E TESTING 0s MACA S6O6P

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

=2+ ch0r"e3 0ir s+s#e) 0=#er 0 co)*e#e 90'0ro243
i4s*ec#io4

A #es#s 0re #o <e co432c#e3 i4 DriEe (D/ 9hich is 543

"e0r

PAR8 @RA8E $75& RPM

RETARDER $5$5&& RPM

FOOT @RA8E $8&& RPM

EMERGENCB @RA8E F?LL THROTTLE

7
#h
"e0r ;57'*h
REAR S?SPENSION
Air Dr0i4
E)er"e4c+ #04'
@ATTERIES% RADIATOR A FRONT
@RA8E FL?ID
R03i0#or He03er
T04'
Fro4# @r0'e
F2i3
-ront +rake oil
0adiator Water
'eader Tank
Loc0#io4 #o* 3ec'
AIR TAN8 DRAINS
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 light
AIR CLEANERS
ACTION CODES
&5 /ark the machine at a safe location and contact your super!isor
&7 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
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 H &5
SerEice co3e H <OE-
Lo9 @r0'e Air Press2re
Ac#io4 Co3e H &7
SerEice Co3e H CO57
Lo9 e4"i4e oi *ress2re
Ac#io4 Co3e H &5
SerEice Co3e H <o35
TorI2e Co4Eer#er Oi Te)*er0#2re OEerhe0#

!EIGHT SBSTEM

<=>> maximum limit

for cycle data

%easures out ?@> mts,

after mo!ing off

-ault codes displayed

Dash 4 A =? Tonnes

Dash 3 A BC Tonnes
P0r' @r0'e Shi=# i)i#
Po9er Mo3es
EMERGENCB @RA8E
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 are
placed on the dri!eline and power train components1 )elect
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

7 S*ee3 Tr04s)issio4

I4 DriEe (D/ 5
43
#o 7
#h
Ge0r

I4 DriEe (D/ 9i#h #he shi=# i)i#er o4%

,
#h
"e0r i)i#

I4 5
#h
Ge0r% $
s#
#o 5
#h
7&'*h

I4 7
#h
Ge0r% $
s#
#o 7
#h
.&'*h

I4 .
r3
Ge0r% $
s#
#o .
r3
55'*h

I4 Lo9 Ge0r% $
s#
#o 5
43
$,65'*h

I4 Lo9 (L/ 9i#h #he shi=# i)i#er o4%

$s# "e0r oc'e3
Shi=# Li)i#
@2##o4
Transmission Control

$lways lock the transmission in D8E

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

This will aid in keeping the

con!erter F transmission oil
temperature at a cooler le!el

2"ser!e the con!erter lock up

indicator on the dash to ensure the
con!erter is locked up, if on a long
up hill haul the con!erter was not
locked up, con!erter F transmission
oil temperature will o!erheat, this
will cause other cooling systems to
rise in temperature1
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 and

high idle the engine to
cool the con!erter oil
!ia the cooler
E)er"e4c+ S#eeri4" S+s#e)

The #r2c' is =i##e3 9i#h 04 eec#ric e)er"e4c+ s#eeri4" s+s#e)

I4 #he eEe4# #h0# #he e4"i4e sh2#s 3o94 or #he h+3r02ic s#eeri4"
*2)* =0is% #he eec#ric 3riEe4 e)er"e4c+ s#eeri4" s+s#e)
A?TOMATICALLB 0c#iE0#es #o <ri4" #he #r2c' #o 0 co4#roe3
s#o*

A=#er 0 co)*e#e 90'0ro243 i4s*ec#io4 o= #he s#eeri4" s+s#e)%

+o2 )2s# M0420+ chec' #he eec#ric0+ o*er0#e3 e)er"e4c+
s#eeri4" s+s#e)6 To )0420+ #es# 9i#h #he e4"i4e sh2# 3o94%
*2sh 3o94 #he re3 e)er"e4c+ #es# <2##o46

Bo2 )2s# <e 0<e #o he0r #he eec#ric *2)*

r244i4" 043 <e 0<e #o s#eer% e=# 043 ri"h#
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# h0Ee 0 =2+ ch0r"e3 0ir s+s#e)

A**+ +o2r serEice <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#iEe 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*erEisor
SAE S#eeri4" Co2rse
Steering meets Steering meets
SAE J1511 standards SAE 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 tires
25 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 m A = 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 m B = 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
REVERSE TRANSMISSION
NE?TRALIZER

If the dump control le!er is

mo!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