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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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