Komatsu HD1500-5 Dump Truck Operation & Maintenance Manual SERIAL NUMBERS A30079-A30160 PDF DOWNLOAD

Komatsu HD1500-5 Dump Truck Operation & Maintenance Manual

Description:

• Komatsu HD1500-5 Dump Truck Operation & Maintenance Manual 
• SERIAL NUMBERS A30079-A30160
• 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 must understand the content in this manual before operating, maintaining or performing operational checks on the truck. All safety notices, warnings and cautions must be understood before operating or repairing 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. This manual shows dimensioning of metric and (U.S. standard) units throughout.
• All references to right, left, front, or rear are made with 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 135 N·m (100 ft lbs). All torque specifications have ±10% tolerance unless otherwise specified.
• 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. A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum Gross Vehicle Weight (GVW) rating.
• The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
• The GVW is what determines the load on the drive train, frame, tires, and other components.
• The vehicle design and application guidelines are sensitive to the total maximum GVW. GVW is the total truck weight. This is equal to the empty vehicle weight + the fuel & lubricants + the payload.
• To determine allowable payload: Service all lubricants to the proper level including the fuel tank. Weigh the empty truck This includes all accessories, body liners, tailgates, etc. Record this value and subtract from the GVW rating. The result is the allowable payload.

Table Of Contents:

• Komatsu HD1500-5 Dump Truck Operation & Maintenance Manual 
• SERIAL NUMBERS A30079-A30160
• CEAM014503.pdf.................................................................................... 0 FOREWORD...................................................................................... 5 ALERTS PAGE................................................................................... 6 TABLE OF CONTENTS............................................................................. 7 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........................................................................ 53 PREPARING FOR OPERATION................................................................... 53 Safety Is Thinking Ahead.............................................................. 53 At The Truck - Ground Level Walk Around Inspection.................................... 53 ENGINE START-UP SAFETY PRACTICES.......................................................... 56 EMERGENCY STEERING SYSTEM................................................................. 57 Operation............................................................................. 57 Pre-Operation Testing................................................................. 57 AFTER THE ENGINE HAS STARTED.............................................................. 58 MACHINE OPERATION SAFETY PRECAUTIONS...................................................... 61 LOADING................................................................................... 61 HAULING................................................................................... 62 RETARDER OPERATION........................................................................ 62 PASSING................................................................................... 63 DUMPING................................................................................... 63 Raising the Dump Body................................................................. 64 Lowering The Dump Body................................................................ 65 SAFE PARKING.............................................................................. 65 SHUTDOWN PROCEDURE........................................................................ 65 SUDDEN LOSS OF ENGINE POWER............................................................... 66 Emergency Steering And Braking........................................................ 66 DISABLED TRUCK DUMPING.................................................................... 66 Hookup................................................................................ 66 Raising the Body...................................................................... 66 Lowering the Body..................................................................... 67 DISABLED TRUCK STEERING AND BRAKING....................................................... 68 TOWING.................................................................................... 70 OPERATOR CAB AND CONTROLS..................................................................... 73 STEERING WHEEL AND CONTROLS............................................................... 74 Horn Button........................................................................... 74 Telescope Lock Ring................................................................... 74 Tilt Wheel Lever...................................................................... 74 Turn Signal / Headlight Dimmer........................................................ 74 Windshield Wiper / Washer Control..................................................... 75 RETARDER CONTROL LEVER.................................................................... 75 SERVICE BRAKE PEDAL....................................................................... 75 ACCELERATOR (THROTTLE) PEDAL.............................................................. 76 INSTRUMENT PANEL.......................................................................... 76 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS......................................... 76 Defroster Vent Control Switch......................................................... 76 Heat Vent Control Switch.............................................................. 76 Fan Control Knob...................................................................... 76 Temperature Control Knob.............................................................. 76 Air Conditioner Control Switch........................................................ 77 Heater/Air Conditioner Vents.......................................................... 77 RETARDING CAPACITY CHART.................................................................. 77 Radio Speakers........................................................................ 78 MOM Display Screen.................................................................... 78 MOM Dimmer Switch..................................................................... 78 Warning Alarm Buzzer.................................................................. 78 Cab Radio............................................................................. 78 PMC Interface Connector............................................................... 78 Air Cleaner Vacuum Gauges............................................................. 78 Payload Meter......................................................................... 78 Windshield Wipers..................................................................... 78 CENTER CONSOLE............................................................................ 79 Transmission Range Selector........................................................... 80 Control Switches...................................................................... 81 Shift Limiter Switch.................................................................. 81 F1 Start Switch....................................................................... 81 Hoist Control Lever................................................................... 81 Parking Brake Switch.................................................................. 81 Brake Lock Switch..................................................................... 82 LH Window Control Switch.............................................................. 82 RH Window Control Switch.............................................................. 82 Ash Tray.............................................................................. 82 Lighter............................................................................... 82 Passenger Seat w/Safety Belt.......................................................... 82 OPERATOR SEAT............................................................................. 82 Seat Belts............................................................................ 82 Adjustment............................................................................ 83 INSTRUMENT PANEL AND INDICATORS............................................................... 84 Keyswitch................................................................................. 85 Auxiliary Brake Switch.................................................................... 85 RH Control/Indicator Panel (Pod).......................................................... 86 Center Display Panel...................................................................... 86 LH Control/Indicator Panel (Pod).......................................................... 86 Ladder Light Switch....................................................................... 86 Head Light Switch......................................................................... 86 BackUp/Deck Light Switch.................................................................. 86 RH Control/Indicator Panel (Pod).......................................................... 86 Cold Weather Starting Aid (Ether Injection) Switch........................................ 86 Hazard Warning Lights Switch.............................................................. 87 Automatic Idle Selector Switch (AISS)..................................................... 87 Air Conditioner & Heater Vent............................................................. 88 ASR Cut (Traction Control) Switch (Option)................................................ 88 Center Display Panel...................................................................... 88 Air Pressure Monitor (Not Used)........................................................... 88 Air Pressure Gauge (Not Used)............................................................. 88 Coolant Temperature Monitor............................................................... 88 Engine Cooling Water Temperature Gauge.................................................... 90 Torque Converter Oil Temperature Monitor.................................................. 90 Torque Converter Oil Temperature Gauge.................................................... 90 Retarder Oil Temperature Monitor.......................................................... 90 Retarder Oil Temperature Gauge............................................................ 90 Left Turn Signal Pilot Lamp............................................................... 90 High Beam Pilot Lamp...................................................................... 90 Right Turn Signal Pilot Lamp.............................................................. 90 Speedometer............................................................................... 90 Tachometer................................................................................ 91 Lock-up Pilot Lamp........................................................................ 91 Shift Limiter Pilot Lamp.................................................................. 91 Shift Indicator........................................................................... 91 Transmission Shift Position Pilot Lamp.................................................... 91 Engine Controller Monitor................................................................. 91 Automatic Transmission Mechatronics Monitor............................................... 91 Other Mechatronics Monitor (Optional)..................................................... 91 Fuel Level Monitor........................................................................ 91 Fuel Gauge................................................................................ 92 Engine Power Derate Monitor............................................................... 92 F1 Start Monitor.......................................................................... 92 Auto Cruise Control (Not Used)............................................................ 92 ASR Monitor (Optional).................................................................... 92 ABS Monitor (Not Used).................................................................... 92 Service Meter............................................................................. 92 Odometer.................................................................................. 92 LH Control/Indicator Panel (Pod).......................................................... 93 LH Panel/Pod Assembly..................................................................... 93 Engine Oil Temperature.................................................................... 93 Engine Coolant Level...................................................................... 93 Low Steering Pressure..................................................................... 93 Accumulator Pre-Charge.................................................................... 93 Battery Charge Amps....................................................................... 94 Check Engine.............................................................................. 94 Parking Brake............................................................................. 94 Body Float................................................................................ 94 Transmission Oil Temperature.............................................................. 94 Service Brakes Applied.................................................................... 94 Maintenance Monitor....................................................................... 94 Transmission Oil Filters.................................................................. 94 Lamp Test................................................................................. 95 Low Brake Pressure........................................................................ 95 Lateral Slope Warning..................................................................... 95 Crankcase Pressure........................................................................ 95 Panel Dimmer Switch....................................................................... 95 Engine Oil Pressure....................................................................... 95 Central Warning Lamp...................................................................... 95 AC/Heater Vent............................................................................ 96 REAR OF OPERATOR CAB...................................................................... 96 QUANTUM™ FUEL SYSTEM DIAGNOSTICS.......................................................... 99 Determining Fault Codes............................................................... 99 Exiting The Diagnostics Mode..........................................................100 MESSAGE FOR OPERATION AND MAINTENANCE ("MOM").................................................101 Truck Condition-..........................................................................101 Production Data During Operation - (Information from the Payload Meter)...................101 Transmission Response With Fault Codes....................................................105 Idle Validation Feature...................................................................106 CENTER ELECTRONIC DISPLAY PANEL...........................................................106 Action Code Display...................................................................106 Cancellation of Action Code...........................................................107 LUBRICATION AND SERVICE.......................................................................109 COOLANT SPECIFICATIONS....................................................................109 Unacceptable Practices................................................................109 QUICK FILL SERVICE CENTER.................................................................109 10 HOUR (DAILY) INSPECTION................................................................111 250 HOUR INSPECTION.......................................................................113 500 HOUR INSPECTION.......................................................................115 1000 HOUR INSPECTION......................................................................116 2000 HOUR INSPECTION......................................................................117 5000 HOUR INSPECTION......................................................................118 RADIATOR FILL PROCEDURE...................................................................119 TRANSMISSION OIL LEVEL CHECK..............................................................119 HYDRAULIC TANK SERVICE....................................................................119 Filling Instructions..................................................................119 Hydraulic Tank Service................................................................120 STEERING CIRCUIT FILTER...................................................................121 Removal...............................................................................121 Installation..........................................................................121 HYDRAULIC TANK BREATHER...................................................................122 Cleaning..............................................................................122 LINCOLN AUTOMATIC LUBRICATION SYSTEM..........................................................123 SYSTEM COMPONENTS.........................................................................123 System Operation......................................................................126 System Priming........................................................................127 System Checkout.......................................................................128 Pressure Reducer Adjustment...........................................................128 24 VDC Solid State Timer Check........................................................129 24 VDC Solid State Timer Adjustment...................................................130 Injectors (SL-1)......................................................................130 Injector Adjustment...................................................................130 Pump Cycle Timer (Flasher Timer):.....................................................131 Pump Cycle Timer (Flasher Timer) Installation.........................................131 Pump Cycle Timer (Flasher Timer) Adjustment:..........................................131 SYSTEM TROUBLESHOOTING CHART..................................................................133 RESERVOIR FILL PROCEDURE..................................................................135 Lubricant Required for System.........................................................135 Fill Procedure........................................................................135 PREVENTIVE MAINTENANCE PROCEDURES.............................................................136 Daily Lubrication System Inspection.......................................................136 250 Hour Inspection.......................................................................136 MAJOR COMPONENTS AND SPECIFICATIONS...........................................................137 SPECIFICATIONS................................................................................139 SECTION 60....................................................................................141 PAYLOAD METER II - ON BOARD WEIGHING SYSTEM...................................................141 INDEX.........................................................................................141 GENERAL INFORMATION.......................................................................143 Haul Cycles...........................................................................143 LIGHTS, SWITCHES AND COMPONENTS...........................................................144 TIPS FOR OPERATION........................................................................145 EXTERNAL DISPLAY LIGHTS...................................................................145 THEORY OF OPERATION.......................................................................146 Basic Description.....................................................................146 Inclinometer..........................................................................146 Linkage Factor........................................................................146 Gain Factor...........................................................................147 Brake Lock............................................................................147 Sources of Error......................................................................147 Typical Data From Service Check Mode..................................................147 Example Calculation of Payload........................................................148 Viewing Payload Calculation Inputs....................................................148 Checking the Gain.....................................................................149 Adjusting the Gain....................................................................149 TYPES OF DATA STORED......................................................................150 Cycle Data............................................................................150 Engine ON/OFF Data....................................................................151 Fault Codes and Warning Data..........................................................151 Engine Operation......................................................................152 Total Payload and Total Number of Cycles..............................................152 Other Data............................................................................152 OPERATOR FUNCTIONS........................................................................153 Using the Operator Load Counter.......................................................153 Viewing the Operator Load Counter.....................................................153 Clearing the Operator Load Counter....................................................153 Dimming the Lights on the Display.....................................................153 INITIAL SETUP OF PAYLOAD METER............................................................154 Switch Settings.......................................................................154 Checking the Operator Check Mode......................................................155 Checking the Service Check Mode.......................................................155 Checking the Gt setting:..............................................................156 Checking the Inclinometer Settings....................................................156 Calibrating a Truck...................................................................156 DISPLAYS AT START-UP......................................................................157 Normal Operation......................................................................157 SETUP AND MAINTENANCE.....................................................................158 Setting The Speed Limit...............................................................158 Setting the Option Code...............................................................158 Setting The Machine I.D. Code.........................................................159 Setting The Operator I.D. Code........................................................159 Setting The Time and Date.............................................................159 DOWNLOAD OF INFORMATION...................................................................160 DISPLAY OF FAULT CODES....................................................................160 Monitoring Input Signals..............................................................164 Service Check Mode....................................................................164 UP FACTOR - PAYLOAD CALCULATION GAIN......................................................165 PL MODE -LOAD CALCULATION TIMING..........................................................165 FINAL GEAR RATIO SELECTION................................................................166 BATTERY REPLACEMENT PROCEDURE.............................................................167 Replacing the Battery.................................................................167 After Replacing the Battery...........................................................168 SUSPENSION PRESSURE SENSOR................................................................168 Removal...............................................................................168 Installation..........................................................................169 INCLINOMETER..............................................................................169 Removal...............................................................................169 Installation..........................................................................169 Adjustment............................................................................169 PAYLOAD METER BACK PANEL..................................................................170 CONNECTIONS...............................................................................171 PAYLOAD CIRCUIT NUMBERS.......................................................................172 PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE.................................................173 RADIO / CASSETTE PLAYER.......................................................................175 GENERAL RECEIVER FUNCTIONS................................................................175 Turning The Power On And Off..........................................................175 Display...............................................................................175 Setting The Default Display...........................................................175 Adjusting Display Brightness..........................................................175 SETTING THE TIME..........................................................................176 OPERATING THE RADIO.......................................................................176 BAND..................................................................................176 TUNE/SEEK.............................................................................176 Manual Tuning.........................................................................176 SEEK Mode.............................................................................176 SCAN..................................................................................176 AUTO..................................................................................176 ADJUSTING THE RECEIVER SETTINGS...........................................................177 PROGRAMMING PRESET STATIONS...............................................................177 OPERATION OF THE WEATHERBAND (U.S.).......................................................177 SATELLITE RADIO...........................................................................178 Operating Satellite Radio.............................................................178 Program Type Search (PTY).............................................................178 CASSETTE PLAYER...........................................................................179 Playing A Cassette....................................................................179 Cassette Functions....................................................................179 Programmable Eject Default............................................................179 Bad Tape Detect.......................................................................180 Cleaning The Cassette Player..........................................................180

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