Komatsu HD1500-5 Dump Truck Operation & Maintenance Manual SERIAL NUMBERS A30049-A30069 PDF

Komatsu HD1500-5 Dump Truck Operation & Maintenance Manual

Description:

• Komatsu HD1500-5 Dump Truck Operation & Maintenance Manual
• SERIAL NUMBERS A30049-A30069

This manual is written for use by the operator and/or the service technician. It is designed to help these persons learn how to operate the truck and 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 performing repairs on the truck. The front cover of this manual includes a form number. This form number should be referenced when ordering additional copies of this manual, or for any other correspondence regarding the coverage in this manual.

Table Of Contents:

• Komatsu HD1500-5 Dump Truck Operation & Maintenance Manual
• SERIAL NUMBERS A30049-A30069
• CEAM010703.pdf.................................................................................... 0 FOREWORD...................................................................................... 5 ALERTS PAGE................................................................................... 6 TABLE OF CONTENTS............................................................................. 7 TABLE OF CONTENTS............................................................................. 8 TRUCK MODEL ILLUSTRATION...................................................................... 15 ABOUT THIS MANUAL......................................................................... 16 TORQUE TABLES AND CONVERSION CHARTS........................................................... 17 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values...................... 18 STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts..................... 18 STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws........................ 19 STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws.................................... 20 Hardware Tightening Method............................................................ 28 SAFETY........................................................................................ 29 Safety Rules.............................................................................. 29 Safety Features........................................................................... 29 Clothing And Personal Items............................................................... 29 Unauthorized Modification................................................................. 29 Leaving The Operator’s Seat............................................................... 29 Mounting And Dismounting.................................................................. 30 Fire Prevention For Fuel And Oil.......................................................... 30 Precautions With High Temperature Fluids.................................................. 30 Asbestos Dust Hazard Prevention........................................................... 30 Prevention Of Injury By Work Equipment.................................................... 31 Fire Extinguisher And First Aid Kit....................................................... 31 Precautions For ROPS...................................................................... 31 Precautions For Attachments............................................................... 31 HAUL ROADS................................................................................ 32 PRECAUTIONS DURING OPERATION.............................................................. 32 BEFORE STARTING THE ENGINE............................................................ 32 Fire Prevention................................................................... 33 Preparing For Operation........................................................... 33 Ventilation In Enclosed Areas..................................................... 33 In Operator’s Cab - Before Starting The Engine.................................... 33 Mirrors, Windows, And Lights...................................................... 33 OPERATING THE MACHINE................................................................. 34 When Starting The Engine.......................................................... 34 Precautions For Starting Machine.................................................. 34 Truck Operation - General......................................................... 34 Traveling......................................................................... 35 Traveling In Reverse.............................................................. 35 Traveling On Slopes............................................................... 35 Ensure Good Visibility............................................................ 35 Operate Carefully On Snow......................................................... 36 Avoid Damage To Dump Body......................................................... 36 Driving Near High Voltage Cables.................................................. 36 When Dumping...................................................................... 36 Working On Loose Ground........................................................... 36 Loading The Body.................................................................. 36 Parking The Machine............................................................... 36 TOWING................................................................................ 37 WORKING NEAR BATTERIES................................................................ 37 Battery Hazard Prevention......................................................... 37 Starting With Booster Cables...................................................... 37 PRECAUTIONS FOR MAINTENANCE............................................................... 38 BEFORE PERFORMING MAINTENANCE......................................................... 38 Warning Tag....................................................................... 38 Proper Tools...................................................................... 38 Stopping The Engine Before Service................................................ 38 Securing The Dump Body............................................................ 38 DURING MAINTENANCE.................................................................... 40 Personnel......................................................................... 40 Attachments....................................................................... 40 Working Under The Machine......................................................... 40 Keep The Machine Clean............................................................ 40 Rules To Follow When Adding Fuel Or Oil........................................... 40 Radiator Water Level.............................................................. 40 Use Of Lighting................................................................... 40 Precautions With The Battery...................................................... 41 Handling High Pressure Hoses...................................................... 41 Precautions With High Pressure Oil................................................ 41 Precautions When Performing Maintenance Near High Temperature Or High Pressure.... 41 Rotating Fan And Belts............................................................ 41 Waste Materials................................................................... 41 TIRES................................................................................. 42 Tire Maintenance.................................................................. 42 Storing Tires After Removal....................................................... 42 WHEN REPAIRS ARE NECESSARY............................................................ 43 ADDITIONAL JOB SITE RULES..................................................................... 44 WARNINGS AND CAUTIONS......................................................................... 45 OPERATING INSTRUCTIONS........................................................................ 51 PREPARING FOR OPERATION................................................................... 51 Safety Is Thinking Ahead.............................................................. 51 At The Truck - Ground Level Walk Around Inspection.................................... 51 ENGINE START-UP SAFETY PRACTICES.......................................................... 54 EMERGENCY STEERING SYSTEM................................................................. 55 Operation............................................................................. 55 Pre-Operation Testing................................................................. 55 AFTER THE ENGINE HAS STARTED.............................................................. 56 MACHINE OPERATION SAFETY PRECAUTIONS...................................................... 59 LOADING................................................................................... 59 HAULING................................................................................... 60 RETARDER OPERATION........................................................................ 60 PASSING................................................................................... 61 DUMPING................................................................................... 61 Raising the Dump Body................................................................. 62 Lowering The Dump Body................................................................ 63 SAFE PARKING.............................................................................. 63 SHUTDOWN PROCEDURE........................................................................ 63 SUDDEN LOSS OF ENGINE POWER............................................................... 64 Emergency Steering And Braking........................................................ 64 DISABLED TRUCK DUMPING.................................................................... 64 Hookup................................................................................ 64 Raising the Body...................................................................... 64 Lowering the Body..................................................................... 65 DISABLED TRUCK STEERING AND BRAKING....................................................... 66 TOWING.................................................................................... 68 OPERATOR CAB AND CONTROLS..................................................................... 71 STEERING WHEEL AND CONTROLS............................................................... 72 Horn Button........................................................................... 72 Telescope Lock Ring................................................................... 72 Tilt Wheel Lever...................................................................... 72 Turn Signal / Headlight Dimmer........................................................ 72 Windshield Wiper / Washer Control..................................................... 73 RETARDER CONTROL LEVER.................................................................... 73 SERVICE BRAKE PEDAL....................................................................... 73 ACCELERATOR (THROTTLE) PEDAL.............................................................. 74 INSTRUMENT PANEL.......................................................................... 74 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS......................................... 74 Defroster Vent Control Switch......................................................... 74 Outside/Inside Air Control Switch..................................................... 74 Heat Vent Control Switch.............................................................. 74 Fan Control Knob...................................................................... 74 Temperature Control Knob.............................................................. 75 Air Conditioner Control Switch........................................................ 75 Heater/Air Conditioner Vents.......................................................... 75 RETARDING CAPACITY CHART.................................................................. 75 Radio Speakers........................................................................ 76 MOM Display Screen.................................................................... 76 MOM Dimmer Switch..................................................................... 76 Warning Alarm Buzzer.................................................................. 76 Cab Radio............................................................................. 76 PMC Interface Connector............................................................... 76 Air Cleaner Vacuum Gauges............................................................. 76 Payload Meter......................................................................... 76 Windshield Wipers..................................................................... 76 CENTER CONSOLE............................................................................ 77 Transmission Range Selector........................................................... 78 Control Switches...................................................................... 79 Shift Limiter Switch.................................................................. 79 F1 Start Switch....................................................................... 79 Hoist Control Lever................................................................... 79 Parking Brake Switch.................................................................. 79 Brake Lock Switch..................................................................... 80 LH Window Control Switch.............................................................. 80 RH Window Control Switch.............................................................. 80 Ash Tray.............................................................................. 80 Lighter............................................................................... 80 Passenger Seat w/Safety Belt.......................................................... 80 OPERATOR SEAT............................................................................. 80 Seat Belts............................................................................ 80 Adjustment............................................................................ 81 INSTRUMENT PANEL AND INDICATORS............................................................... 82 Keyswitch................................................................................. 83 Auxiliary Brake Switch.................................................................... 83 RH Control/Indicator Panel (Pod).......................................................... 84 Center Display Panel...................................................................... 84 LH Control/Indicator Panel (Pod).......................................................... 84 Ladder Light Switch....................................................................... 84 Head Light Switch......................................................................... 84 BackUp/Deck Lights Switch................................................................. 84 RH Control/Indicator Panel (Pod).......................................................... 84 Cold Weather Starting Aid (Ether Injection) Switch........................................ 84 Hazard Warning Lights Switch.............................................................. 85 Automatic Idle Selector Switch (AISS)..................................................... 85 Air Conditioner & Heater Vent............................................................. 86 ASR Cut (Traction Control) Switch (Option)................................................ 86 Center Display Panel...................................................................... 86 Air Pressure Monitor (Not Used)........................................................... 86 Air Pressure Gauge (Not Used)............................................................. 86 Coolant Temperature Monitor............................................................... 86 Engine Cooling Water Temperature Gauge.................................................... 88 Torque Converter Oil Temperature Monitor.................................................. 88 Torque Converter Oil Temperature Gauge.................................................... 88 Retarder Oil Temperature Monitor.......................................................... 88 Retarder Oil Temperature Gauge............................................................ 88 Left Turn Signal Pilot Lamp............................................................... 88 High Beam Pilot Lamp...................................................................... 88 Right Turn Signal Pilot Lamp.............................................................. 88 Speedometer............................................................................... 88 Tachometer................................................................................ 89 Lock-up Pilot Lamp........................................................................ 89 Shift Limiter Pilot Lamp.................................................................. 89 Shift Indicator........................................................................... 89 Transmission Shift Position Pilot Lamp.................................................... 89 Engine Controller Monitor................................................................. 89 Automatic Transmission Mechatronics Monitor............................................... 89 Other Mechatronics Monitor (Optional)..................................................... 89 Fuel Level Monitor........................................................................ 89 Fuel Gauge................................................................................ 90 Engine Power Derate Monitor............................................................... 90 F1 Start Monitor.......................................................................... 90 Auto Cruise Control (Not Used)............................................................ 90 ASR Monitor (Optional).................................................................... 90 ABS Monitor (Not Used).................................................................... 90 Service Meter............................................................................. 90 Odometer.................................................................................. 90 LH Control/Indicator Panel (Pod).......................................................... 91 LH Panel/Pod Assembly..................................................................... 91 Engine Oil Temperature.................................................................... 91 Engine Coolant Level...................................................................... 91 Low Steering Pressure..................................................................... 91 Accumulator Pre-Charge.................................................................... 91 Battery Charge Amps....................................................................... 92 Check Engine.............................................................................. 92 Parking Brake............................................................................. 92 Body Float................................................................................ 92 Transmission Oil Temperature.............................................................. 92 Service Brakes Applied.................................................................... 92 Maintenance Monitor....................................................................... 92 Transmission Oil Filters.................................................................. 92 Lamp Test................................................................................. 93 Low Brake Pressure........................................................................ 93 Lateral Slope Warning..................................................................... 93 Crankcase Pressure........................................................................ 93 Panel Dimmer Switch....................................................................... 93 Engine Oil Pressure....................................................................... 93 Central Warning Lamp...................................................................... 93 AC/Heater Vent............................................................................ 94 REAR OF OPERATOR CAB...................................................................... 94 CIRCUIT BREAKER CHART..................................................................... 96 QUANTUM™ FUEL SYSTEM DIAGNOSTICS.......................................................... 97 Determining Fault Codes............................................................... 97 Exiting The Diagnostics Mode.......................................................... 98 MESSAGE FOR OPERATION AND MAINTENANCE ("MOM")................................................. 99 Truck Condition-.......................................................................... 99 Production Data During Operation - (Information from the Payload Meter)................... 99 Transmission Response With Fault Codes....................................................103 Idle Validation Feature...................................................................104 CENTER ELECTRONIC DISPLAY PANEL...........................................................104 Action Code Display...................................................................104 Cancellation of Action Code...........................................................105 LUBRICATION AND SERVICE.......................................................................107 COOLANT SPECIFICATIONS....................................................................107 Unacceptable Practices................................................................107 QUICK FILL SERVICE CENTER.................................................................107 10 HOUR (DAILY) INSPECTION................................................................109 250 HOUR INSPECTION.......................................................................111 500 HOUR INSPECTION.......................................................................113 1000 HOUR INSPECTION......................................................................114 2000 HOUR INSPECTION......................................................................115 5000 HOUR INSPECTION......................................................................116 RADIATOR FILL PROCEDURE...................................................................117 TRANSMISSION OIL LEVEL CHECK..............................................................117 HYDRAULIC TANK SERVICE....................................................................117 Filling Instructions..................................................................117 Hydraulic Tank Service................................................................118 STEERING CIRCUIT FILTER...................................................................119 Removal...............................................................................119 Installation..........................................................................119 HYDRAULIC TANK BREATHER...................................................................120 Cleaning..............................................................................120 LINCOLN AUTOMATIC LUBRICATION SYSTEM..........................................................121 SYSTEM COMPONENTS.........................................................................121 System Operation......................................................................124 System Priming........................................................................125 System Checkout.......................................................................126 Pressure Reducer Adjustment...........................................................126 24 VDC Solid State Timer Check........................................................127 24 VDC Solid State Timer Adjustment...................................................128 Injectors (SL-1)......................................................................128 Injector Adjustment...................................................................128 Pump Cycle Timer (Flasher Timer):.....................................................129 Pump Cycle Timer (Flasher Timer) Installation.........................................129 Pump Cycle Timer (Flasher Timer) Adjustment:..........................................129 SYSTEM TROUBLESHOOTING CHART..................................................................131 RESERVOIR FILL PROCEDURE..................................................................133 Lubricant Required for System.........................................................133 Fill Procedure........................................................................133 PREVENTIVE MAINTENANCE PROCEDURES.............................................................134 Daily Lubrication System Inspection.......................................................134 250 Hour Inspection.......................................................................134 MAJOR COMPONENTS AND SPECIFICATIONS...........................................................135 SPECIFICATIONS................................................................................137 SECTION 60....................................................................................139 PAYLOAD METER II - ON BOARD WEIGHING SYSTEM...................................................139 INDEX.........................................................................................139 GENERAL INFORMATION.......................................................................141 Haul Cycles...........................................................................141 LIGHTS, SWITCHES AND COMPONENTS...........................................................142 TIPS FOR OPERATION........................................................................143 EXTERNAL DISPLAY LIGHTS...................................................................143 THEORY OF OPERATION.......................................................................144 Basic Description.....................................................................144 Inclinometer..........................................................................144 Linkage Factor........................................................................144 Gain Factor...........................................................................145 Brake Lock............................................................................145 Sources of Error......................................................................145 Typical Data From Service Check Mode..................................................145 Example Calculation of Payload........................................................146 Viewing Payload Calculation Inputs....................................................146 Checking the Gain.....................................................................147 Adjusting the Gain....................................................................147 TYPES OF DATA STORED......................................................................148 Cycle Data............................................................................148 Engine ON/OFF Data....................................................................149 Fault Codes and Warning Data..........................................................149 Engine Operation......................................................................150 Total Payload and Total Number of Cycles..............................................150 Other Data............................................................................150 OPERATOR FUNCTIONS........................................................................151 Using the Operator Load Counter.......................................................151 Viewing the Operator Load Counter.....................................................151 Clearing the Operator Load Counter....................................................151 Dimming the Lights on the Display.....................................................151 INITIAL SETUP OF PAYLOAD METER............................................................152 Switch Settings.......................................................................152 Checking the Operator Check Mode......................................................153 Checking the Service Check Mode.......................................................153 Checking the Gt setting:..............................................................154 Checking the Inclinometer Settings....................................................154 Calibrating a Truck...................................................................154 DISPLAYS AT START-UP......................................................................155 Normal Operation......................................................................155 SETUP AND MAINTENANCE.....................................................................156 Setting The Speed Limit...............................................................156 Setting the Option Code...............................................................156 Setting The Machine I.D. Code.........................................................157 Setting The Operator I.D. Code........................................................157 Setting The Time and Date.............................................................157 DOWNLOAD OF INFORMATION...................................................................158 DISPLAY OF FAULT CODES....................................................................158 Monitoring Input Signals..............................................................162 Service Check Mode....................................................................162 UP FACTOR - PAYLOAD CALCULATION GAIN......................................................163 PL MODE -LOAD CALCULATION TIMING..........................................................163 FINAL GEAR RATIO SELECTION................................................................164 BATTERY REPLACEMENT PROCEDURE.............................................................165 Replacing the Battery.................................................................165 After Replacing the Battery...........................................................166 SUSPENSION PRESSURE SENSOR................................................................166 Removal...............................................................................166 Installation..........................................................................167 INCLINOMETER..............................................................................167 Removal...............................................................................167 Installation..........................................................................167 Adjustment............................................................................167 PAYLOAD METER BACK PANEL..................................................................168 CONNECTIONS...............................................................................169 PAYLOAD CIRCUIT NUMBERS.......................................................................170 PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE.................................................171 RADIO, AM / FM STEREO CASSETTE................................................................173 SETTING THE TIME..........................................................................173 GENERAL RECEIVER FUNCTIONS................................................................173 Turning The Power On And Off..........................................................173 Display...............................................................................173 Setting The Default Display...........................................................174 Adjusting Display Brightness..........................................................174 OPERATING THE RADIO.......................................................................174 BAND..................................................................................174 TUNE/SEEK.............................................................................174 Manual Tuning.........................................................................174 SEEK Mode.............................................................................174 SCAN..................................................................................174 AUTO..................................................................................174 PROGRAMMING PRESET STATIONS...............................................................175 OPERATION OF THE WEATHERBAND (U.S.).......................................................175 ADJUSTING THE RECEIVER SETTINGS...........................................................175 PROGRAMMABLE EJECT DEFAULT................................................................176 CASSETTE PLAYER...........................................................................176 Playing A Cassette....................................................................176 Cassette Functions....................................................................176 Bad Tape Detect.......................................................................177 CASSETTE PLAYER CLEANING..................................................................177

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