Komatsu HD1500-5 Dump Truck Operation and Maintenance Manual CEAM006100

Description

• Model List:
  • HD1500-5 Dump Truck

• 1. MAIN MENU
• 2. COVER
• 3. INTRODUCTION
• 3.1. FORWARD
• 3.2. ALERTS PAGEA DESCRIPTION OF THE DANGER, WARNING, AND CAUTION SYMBOLS USED IN THIS MANUAL
• 3.3. TABLE OF CONTENTS
• 3.4. TRUCK MODEL ILLUSTRATION
• 3.5. ABOUT THIS MANUAL
• 3.6. STANDARD CHARTS AND TABLES
• 4. SAFETY
• 4.1. GENERAL SAFETY
• 4.2. PRECAUTIONS DURING OPERATION
• 4.2.1. OPERATING MACHINE
• 4.2.2. BATTERY
• 4.2.3. TOWING
• 4.3. PRECAUTIONS FOR MAINTENANCE
• 4.3.1. BEFORE CARRYING OUT MAINTENANCE
• 4.3.2. DURING MAINTENANCE
• 4.3.3. TIRES
• 4.3.4. WHEN REPAIRS ARE NECESSARY
• 4.3.5. ADDITIONAL JOB SITE RULES
• 4.4. WARNING, CAUTION AND INSTRUCTION PLATES/DECALS
• 5. OPERATION
• 5.1. OPERATING INSTRUCTIONS
• 5.1.1. PREPARING FOR OPERATION
• 5.1.2. SAFETY IS THINKING AHEAD
• 5.1.3. AT THE TRUCK GROUND LEVEL WALK AROUND INSPECTION
• 5.2. ENGINE STARTUP SAFETY PRACTICES
• 5.3. AFTER ENGINE HAS STARTED
• 5.4. MACHINE OPERATION SAFETY PRECAUTIONS
• 5.5. LOADING
• 5.6. HAULING
• 5.6.1. RETARDER OPERATION
• 5.7. PASSING
• 5.8. DUMPING
• 5.9. SAFE PARKING PROCEDURES
• 5.10. SHUTDOWN PROCEDURE
• 5.11. TOWING
• 5.12. OPERATOR CAB AND CONTROLS
• 5.12.1. STEERING WHEEL AND CONTROLS
• 5.12.2. RETARDER CONTROL LEVER
• 5.12.3. SERVICE BRAKE PEDAL
• 5.12.4. THROTTLE PEDAL
• 5.12.5. INSTRUMENT PANEL
• 5.12.6. HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS
• 5.12.7. RETARDING CAPACITY CHART
• 5.12.8. RADIO SPEAKERS
• 5.12.9. MOM DISPLAY SCREEN
• 5.12.10. WARNING ALARM BUZZER
• 5.12.11. CAB RADIO
• 5.12.12. AIR CLEANER VACUUM GAUGES
• 5.12.13. PAYLOAD METER
• 5.12.14. WINSHIELD WIPERS
• 5.12.15. CENTER CONSOLE STRUCTURE
• 5.12.15.1. TRANSMISSION RANGE SELECTOR
• 5.12.15.2. CONTROL SWITCHES
• 5.12.15.3. SHIFT LIMITER SWITCH
• 5.12.15.4. F1 START SWITCH
• 5.12.15.5. HOIST CONTROL SWITCH
• 5.12.15.6. PARKING BRAKE SWITCH
• 5.12.15.7. BRAKE LOCK SWITCH
• 5.12.15.8. WINDOW CONTROL SWITCH
• 5.12.15.9. WINDOW CONTROL SWITCH
• 5.12.15.10. ASH TRAY
• 5.12.15.11. LIGHTER
• 5.12.15.12. PASSENGER SEAT W/SAFETY BELT
• 5.12.16. OPERATOR SEAT
• 5.13. INSTRUMENT PANEL AND INDICATORS
• 5.13.1. KEYSWITCH
• 5.13.2. EMERGENCY BRAKE SWITCH
• 5.13.3. CONTROL/INDICATOR PANEL (POD)
• 5.13.4. CENTER DISPLAY PANEL
• 5.13.5. CONTROL/INDICATOR PANEL (POD)
• 5.13.6. LADDER LIGHT SWITCH
• 5.13.7. HEADLIGHT SWITCH
• 5.13.8. BACK UP/DECK LIGHTS SWITCH
• 5.13.9. ELECTRONIC DISPLAY SWITCHES
• 5.14. CONTROL/INDICTOR PANEL (FIGURE 37)
• 5.14.1. DISCUSSION OF ITEMS 110, FIGURE 37
• 5.15. CENTER DISPLAY PANEL (FIGURE 38)
• 5.15.1. DISCUSSION OF ITEMS 129, FIGURE 38
• 5.16. CONTROL/INDICATOR PANEL (POD) (FIGURE 38)
• 5.16.1. DISCUSSION OF ITEMS 121 FIGURE 39
• 5.17. REAR OF OPERATOR CAB
• 5.18. CUMMINS ENGINE CENTRY FUEL SYSTEM DIAGNOSTICS
• 5.18.1. DETERMINING FAULT CODES
• 5.18.2. EXITING THE DIAGNOSTICS MODE
• 5.19. MESSAGES FOR OPERATION AND MAINTENANCE (MOM)
• 5.19.1. DISCUSSION OF SCREEN DISPLAYS
• 5.20. CENTER ELECTRONIC DISPLAY PANEL
• 5.20.1. DISCUSSION OF SCREEN DISPLAYS
• 6. MAINTENANCE
• 6.1. LUBRICATION AND SERVICE
• 6.1.1. LUBRICATION CHART
• 6.1.2. HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS
• 6.1.3. HOUR LUBRICATION MAINTENANCE CHECKS
• 6.1.4. HOUR LUBRICATION AND MAINTENANCE CHECKS
• 6.1.5. HOUR LUBRICATION AND MAINTENANCE CHECKS
• 6.1.6. HOUR LUBRICATION AND MAINTENANCE CHECKS
• 6.1.7. HOUR LUBRICATION AND MAINTENANCE CHECKS
• 6.2. HYDRAULIC TANK SERVICE
• 6.2.1. STEERING CIRCUIT FILTERS
• 6.2.2. HYDRAULIC TANK BREATHER SERVICE
• 6.3. LINCOLN AUTOMATIC LUBRICATION SYSTEM
• 6.3.1. SYSTEM COMPONTENTS
• 6.3.2. SYSTEM OPERATION
• 6.3.3. SYSTEM PRIMING
• 6.3.4. SYSTEM CHECKOUT
• 6.3.5. PRESSURE REDUCER AJUSTMENTS
• 6.3.6. DC SOLID STATE TIMER CHECK
• 6.3.6.1. DC SOLID STATE ADJUSTMENT
• 6.3.7. INJECTORS ADJUSTMENT
• 6.3.8. TROUBLESHOOTING CHART
• 6.3.9. PUMP CYCLE TIMER
• 6.3.10. PREVENTIVE MAINTENANCE PROCEDURES
• 7. SPECIFICATIONS
• 7.1. MAJOR COMPONENT DESCRIPTIONS
• 7.2. SPECIFICATIONS
• 8. OPTIONAL EQUIPMENT
• 8.1. PAYLOAD METER II (REFER TO SEPARATE PAYLOAD METER II INDEX)
• 8.1.1. PAYLOAD METER II ON BOARD WEIGHTING SYSTEM (OBWS)
• 8.1.2. GENERAL INFORMATION
• 8.1.3. LIGHTS, SWITCHES, AND COMPONENTS
• 8.1.4. TIPS FOR OPERATION
• 8.1.5. EXTERNAL DISPLAY LIGHTS
• 8.1.6. THEORY OF OPERATION
• 8.1.6.1. LINKAGE FACTOR
• 8.1.6.2. BRAKE LOCK
• 8.1.6.3. CALCULATION METHOD
• 8.1.6.4. SOURCES OF ERROR
• 8.1.6.5. TYPICAL DATA FROM SERVICE CHECK MODE
• 8.1.6.6. EXAMPLE CALCULATION OF PAYLOAD
• 8.1.6.7. CALCULATION OF THE CALIBRATION LOAD
• 8.1.7. TYPES OF DATA STORED
• 8.1.7.1. CYCLE DATA
• 8.1.7.2. ENGINE ON/OFF DATA
• 8.1.7.3. FAULT CODES AND WARNING DATA
• 8.1.7.4. ENGINE OPERATION
• 8.1.7.5. TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES
• 8.1.7.6. OTHER DATA
• 8.1.8. OPERATOR FUNCTIONS
• 8.1.8.1. USING THE OPERATOR LOAD COUNTER
• 8.1.8.1.1. DESCRIPTION
• 8.1.8.1.2. VIEWING THE OPERATIOR LOAD COUTER
• 8.1.8.1.3. CLEARING THE OPERATOR LOAD COUNTER
• 8.1.8.2. DIMMING THE LIGHTS ON THE DISPLAY
• 8.1.9. INITIAL SETUP OF PAYLOAD METER
• 8.1.9.1. SWITCH SETTINGS
• 8.1.9.2. CHECKING THE OPERATOR CHECK MODE
• 8.1.9.3. CHECKING THE SERVICE CHECK MODE
• 8.1.9.3.1. SETTING THE UP00
• 8.1.9.3.2. SETTING THE PL00
• 8.1.9.4. CHECKING THE GT SETTING
• 8.1.9.5. CHECKING THE INCLINOMETER SETTINGS
• 8.1.9.6. CALIBRATING A TRUCK
• 8.1.10. DISPLAYS AT STARTUP
• 8.1.11. SETUP AND MAINTENANCE
• 8.1.11.1. SETTING THE SPEED LIMIT
• 8.1.11.2. SETTING THE OPTION CODE
• 8.1.11.3. SETTING THE MACHINE I.D. CODE
• 8.1.11.4. SETTING THE OPERATOR I.D. CODE
• 8.1.11.5. SETTING THE TIME AND DATE
• 8.1.12. DOWNLOAD OF INFORMATION
• 8.1.13. DISPLAY OF FAULT CODES
• 8.1.14. CHARTS OF ERROR CODES AND OTHER INFORMATION
• 8.1.15. SERVICE CHECK MODE
• 8.1.15.1. MONITORING INPUT SIGNALS
• 8.1.15.2. UP FACTOR PAYLOAD CALCULATION GAIN
• 8.1.15.3. PL MODE LOAD CALCULATION TIMING
• 8.1.16. FINAL GEAR RATIO SELECTION
• 8.1.17. BATTERY REPLACEMENT PROCEDURE
• 8.1.17.1. REPLACING THE BATTERY
• 8.1.17.2. AFTER REPLACING THE BATTERY
• 8.1.18. SUSPENSION PRESSURE SENSOR
• 8.1.18.1. MAKING CONNECTIONS
• 8.1.18.2. WIRING DIAGRAM
• 8.1.18.3. NORMAL OPERATION OF THE SCOREBOARD
• 8.1.19. PAYLOAD METER BACK PANEL
• 8.1.19.1. AMP PIN IDENTIFICATION
• 8.1.20. PAYLOAD CIRCUIT NUMBERS
• 8.1.21. PALOAD METER II REINITIALIZATION PROCEDURE
• 8.2. PAYLOAD METER II
• 8.3. RADIO, AM/FM STERO CASSETTE