Komatsu HD1500-5 Dump Truck Operation & Maintenance Manual PDF DOWNLOAD

Komatsu HD1500-5 Dump Truck Operation & Maintenance Manual

Description:

Komatsu HD1500-5 Dump Truck Operation & Maintenance Manual

• This Manual is written for use by the operator and/or the service technician and is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently.
• All operators and maintenance personnel should read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when operating or accomplishing repairs on the truck.
• The first section is an Introduction to the manual and contains a Table of Contents to locate specific areas of interest. Other sections include Safety, Operation, Maintenance, Specifications, and Optional Equipment.
• The illustrations used in this manual are TYPICAL of the component shown and may not be an exact reproduction of what is found on the truck.
• This manual shows dimensioning of metric and (U.S. standard) units throughout. All references to “Right”, “Left”, “Front”, or “Rear” aremadewith respect to the operator’s normal seated position, unless specifically stated otherwise.
• Standard torque requirements are shown in torque charts in the Introduction section and individual torques are provided in the text in bold face type, such as 723 kg.m (100 ft.lbs.) torque. All torque specifications have ± 10% tolerance unless otherwise specified.

Table Of Contents:

Komatsu HD1500-5 Dump Truck Operation & Maintenance Manual

MAIN MENU........................................................................................  0
COVER............................................................................................  1
INTRODUCTION.....................................................................................  7
	FORWARD......................................................................................  7
	ALERTS PAGE-A DESCRIPTION OF THE DANGER, WARNING, AND CAUTION SYMBOLS USED IN THIS MANUAL....  8
	TABLE OF CONTENTS............................................................................  9
	TRUCK MODEL ILLUSTRATION..................................................................... 12
	ABOUT THIS MANUAL............................................................................ 13
	STANDARD CHARTS AND TABLES................................................................... 15
SAFETY........................................................................................... 23
	GENERAL SAFETY............................................................................... 23
	PRECAUTIONS DURING OPERATION................................................................. 27
		OPERATING MACHINE........................................................................ 29
		BATTERY.................................................................................. 32
		TOWING................................................................................... 33
	PRECAUTIONS FOR MAINTENANCE.................................................................. 34
		BEFORE CARRYING OUT MAINTENANCE.......................................................... 34
		DURING MAINTENANCE....................................................................... 35
		TIRES.................................................................................... 38
		WHEN REPAIRS ARE NECESSARY............................................................... 39
		ADDITIONAL JOB SITE RULES................................................................ 40
	WARNING, CAUTION AND INSTRUCTION PLATES/DECALS............................................... 41
OPERATION........................................................................................ 47
	OPERATING INSTRUCTIONS....................................................................... 47
		PREPARING FOR OPERATION.................................................................. 47
		SAFETY IS THINKING AHEAD................................................................. 47
		AT THE TRUCK -GROUND LEVEL WALK -AROUND INSPECTION....................................... 47
	ENGINE START-UP SAFETY PRACTICES............................................................. 50
	AFTER ENGINE HAS STARTED..................................................................... 51
	MACHINE OPERATION SAFETY PRECAUTIONS......................................................... 53
	LOADING...................................................................................... 53
	HAULING...................................................................................... 54
		RETARDER OPERATION....................................................................... 54
	PASSING...................................................................................... 55
	DUMPING...................................................................................... 56
	SAFE PARKING PROCEDURES...................................................................... 57
	SHUTDOWN PROCEDURE........................................................................... 57
	TOWING....................................................................................... 58
	OPERATOR CAB AND CONTROLS.................................................................... 59
		STEERING WHEEL AND CONTROLS.............................................................. 60
		RETARDER CONTROL LEVER................................................................... 61
		SERVICE BRAKE PEDAL...................................................................... 61
		THROTTLE PEDAL........................................................................... 61
		INSTRUMENT PANEL......................................................................... 61
		HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS.......................................... 62
		RETARDING CAPACITY CHART................................................................. 63
		RADIO SPEAKERS........................................................................... 64
		"MOM" DISPLAY SCREEN..................................................................... 64
		WARNING ALARM BUZZER..................................................................... 64
		CAB RADIO................................................................................ 64
		AIR CLEANER VACUUM GAUGES................................................................ 64
		PAYLOAD METER............................................................................ 64
		WINSHIELD WIPERS......................................................................... 64
		CENTER CONSOLE STRUCTURE................................................................. 65
			TRANSMISSION RANGE SELECTOR.......................................................... 66
			CONTROL SWITCHES..................................................................... 66
			SHIFT LIMITER SWITCH................................................................. 66
			F1 START SWITCH...................................................................... 66
			HOIST CONTROL SWITCH................................................................. 66
			PARKING BRAKE SWITCH................................................................. 67
			BRAKE LOCK SWITCH.................................................................... 67
			L.H. WINDOW CONTROL SWITCH........................................................... 67
			R.H. WINDOW CONTROL SWITCH........................................................... 67
			ASH TRAY............................................................................. 67
			LIGHTER.............................................................................. 67
			PASSENGER SEAT W/SAFETY BELT......................................................... 67
		OPERATOR SEAT............................................................................ 68
	INSTRUMENT PANEL AND INDICATORS.............................................................. 69
		KEYSWITCH................................................................................ 70
		EMERGENCY BRAKE SWITCH................................................................... 70
		R.H. CONTROL/INDICATOR PANEL (POD)....................................................... 71
		CENTER DISPLAY PANEL..................................................................... 71
		L.H. CONTROL/INDICATOR PANEL (POD)....................................................... 71
		LADDER LIGHT SWITCH...................................................................... 71
		HEADLIGHT SWITCH......................................................................... 71
		BACK UP/DECK LIGHTS SWITCH............................................................... 71
		ELECTRONIC DISPLAY SWITCHES.............................................................. 71
	R.H. CONTROL/INDICTOR PANEL (FIGURE 3-7)..................................................... 72
		DISCUSSION OF ITEMS 1-10, FIGURE 3-7..................................................... 73
	CENTER DISPLAY PANEL (FIGURE 3-8)............................................................ 74
		DISCUSSION OF ITEMS 1-29, FIGURE 3-8..................................................... 75
	L.H. CONTROL/INDICATOR PANEL (POD) (FIGURE 3-8).............................................. 77
		DISCUSSION OF ITEMS 1-21 FIGURE 3-9...................................................... 78
	REAR OF OPERATOR CAB......................................................................... 80
	CUMMINS ENGINE CENTRY FUEL SYSTEM DIAGNOSTICS................................................ 82
		DETERMINING "FAULT" CODES................................................................ 82
		EXITING THE DIAGNOSTICS MODE............................................................. 83
	MESSAGES FOR OPERATION AND MAINTENANCE ("MOM")............................................... 85
		DISCUSSION OF SCREEN DISPLAYS............................................................ 85
	CENTER ELECTRONIC DISPLAY PANEL.............................................................. 89
		DISCUSSION OF SCREEN DISPLAYS............................................................ 90
MAINTENANCE...................................................................................... 91
	LUBRICATION AND SERVICE...................................................................... 91
		LUBRICATION CHART........................................................................ 92
		10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS....................................... 93
		250 HOUR LUBRICATION MAINTENANCE CHECKS.................................................. 95
		500 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................. 97
		1000 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................. 98
		2000 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................. 99
		5000 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................100
	HYDRAULIC TANK SERVICE.......................................................................101
		STEERING CIRCUIT FILTERS.................................................................102
		HYDRAULIC TANK BREATHER SERVICE..........................................................103
	LINCOLN AUTOMATIC LUBRICATION SYSTEM.........................................................105
		SYSTEM COMPONTENTS.......................................................................105
		SYSTEM OPERATION.........................................................................108
		SYSTEM PRIMING ..........................................................................109
		SYSTEM CHECKOUT..........................................................................109
		PRESSURE REDUCER AJUSTMENTS..............................................................109
		24VDC SOLID STATE TIMER CHECK............................................................110
			24VDC SOLID STATE ADJUSTMENT.........................................................110
		INJECTORS & ADJUSTMENT...................................................................111
		TROUBLESHOOTING CHART....................................................................114
		PUMP CYCLE TIMER.........................................................................112
		PREVENTIVE MAINTENANCE PROCEDURES........................................................117
SPECIFICATIONS...................................................................................119
	MAJOR COMPONENT DESCRIPTIONS.................................................................119
	SPECIFICATIONS...............................................................................121
OPTIONAL EQUIPMENT...............................................................................123
	PAYLOAD METER II (REFER TO SEPARATE PAYLOAD METER II INDEX)..................................123
		PAYLOAD METER II ON BOARD WEIGHTING SYSTEM (OBWS)........................................125
		GENERAL INFORMATION......................................................................125
		LIGHTS, SWITCHES, AND COMPONENTS.........................................................126
		TIPS FOR OPERATION.......................................................................127
		EXTERNAL DISPLAY LIGHTS..................................................................127
		THEORY OF OPERATION......................................................................128
			LINKAGE FACTOR.......................................................................128
			BRAKE LOCK...........................................................................129
			CALCULATION METHOD...................................................................129
			SOURCES OF ERROR.....................................................................129
			TYPICAL DATA FROM SERVICE CHECK MODE.................................................129
			EXAMPLE CALCULATION OF PAYLOAD.......................................................130
			CALCULATION OF THE CALIBRATION LOAD..................................................130
		TYPES OF DATA STORED.....................................................................131
			CYCLE DATA...........................................................................131
			ENGINE ON/OFF DATA...................................................................132
			FAULT CODES AND WARNING DATA.........................................................132
			ENGINE OPERATION.....................................................................133
			TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES.............................................133
			OTHER DATA...........................................................................133
		OPERATOR FUNCTIONS.......................................................................134
			USING THE OPERATOR LOAD COUNTER......................................................134
				DESCRIPTION......................................................................134
				VIEWING THE OPERATIOR LOAD COUTER................................................134
				CLEARING THE OPERATOR LOAD COUNTER...............................................134
			DIMMING THE LIGHTS ON THE DISPLAY....................................................134
		INITIAL SETUP OF PAYLOAD METER...........................................................135
			SWITCH SETTINGS......................................................................135
			CHECKING THE OPERATOR CHECK MODE.....................................................135
			CHECKING THE SERVICE CHECK MODE......................................................136
				SETTING THE "UP:00"..............................................................136
				SETTING THE "PL:00"..............................................................136
			CHECKING THE GT SETTING..............................................................136
			CHECKING THE INCLINOMETER SETTINGS...................................................136
			CALIBRATING A TRUCK..................................................................137
		DISPLAYS AT START-UP.....................................................................138
		SETUP AND MAINTENANCE....................................................................139
			SETTING THE SPEED LIMIT..............................................................139
			SETTING THE OPTION CODE..............................................................139
			SETTING THE MACHINE I.D. CODE........................................................139
			SETTING THE OPERATOR I.D. CODE.......................................................140
			SETTING THE TIME AND DATE............................................................140
		DOWNLOAD OF INFORMATION..................................................................140
		DISPLAY OF FAULT CODES...................................................................141
		CHARTS OF ERROR CODES AND OTHER INFORMATION..............................................142
		SERVICE CHECK MODE.......................................................................144
			MONITORING INPUT SIGNALS.............................................................144
			UP FACTOR - PAYLOAD CALCULATION GAIN.................................................145
			PL MODE - LOAD CALCULATION TIMING....................................................145
		FINAL GEAR RATIO SELECTION...............................................................146
		BATTERY REPLACEMENT PROCEDURE............................................................147
			REPLACING THE BATTERY................................................................147
			AFTER REPLACING THE BATTERY..........................................................148
		SUSPENSION PRESSURE SENSOR...............................................................148
			REMOVAL..............................................................................148
			INSTALLATION.........................................................................149
		INCLINOMETER.............................................................................149
			REMOVAL..............................................................................149
			INSTALLATION.........................................................................149
		SCOREBOARD...............................................................................150
			DESCRIPTION..........................................................................150
			MAKING CONNECTIONS...................................................................150
			WIRING DIAGRAM.......................................................................151
			NORMAL OPERATION OF THE SCOREBOARD...................................................152
		PAYLOAD METER BACK PANEL.................................................................152
			AMP PIN IDENTIFICATION...............................................................153
		PAYLOAD CIRCUIT NUMBERS..................................................................154
		PALOAD METER II RE-INITIALIZATION PROCEDURE..............................................155
	PAYLOAD METER II.............................................................................125
	RADIO, AM/FM STERO CASSETTE..................................................................157

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