Komatsu HD1500-5 Operation & Maintenance Manual
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Komatsu HD1500-5 Operation & Maintenance Manual

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CEAM013603
Operation & Maintenance
Manual
DUMP TRUCK
A30072-A30076
SERIAL NUMBERS
®

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  • Page 1 CEAM013603 Operation & Maintenance Manual DUMP TRUCK A30072-A30076 SERIAL NUMBERS ®...
  • Page 3 This manual should be kept in or near the machine for reference, and periodically reviewed by all personnel who will come into contact with it. This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or dis- closed except in accordance with written authorization from KAC.
  • Page 4 Komatsu is also aware of repair companies that will rework or modify an OEM part for reuse in critical systems. Komatsu does not generally authorize such repairs or modifications for the same reasons as noted above.
  • Page 5 OM1042 03/13 Introduction - Section 10 Page 10-1 FOREWORD 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, maintain- ing or performing operational checks on the truck.
  • Page 6 Introduction - Section 10 03/13 OM1042 Page 10-2 ALERTS PAGE This “ALERT” symbol is used with the signal words, “CAUTION”, “DANGER”, and “WARNING” in this manual to alert the reader to hazards arising from improper oper- ating and maintenance practices. “DANGER”...

  • Page 7: Table Of Contents

    OM1042 03/13 Introduction - Section 10 Page 10-3 TABLE OF CONTENTS SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION / PAGE FOREWARD .

  • Page 8: Table Of Contents

    Introduction - Section 10 03/13 OM1042 Page 10-4 TABLE OF CONTENTS SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION / PAGE Driving Near High Voltage Cables .
  • Page 9 OM1042 03/13 Introduction - Section 10 Page 10-5 TABLE OF CONTENTS SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION / PAGE OPERATING INSTRUCTIONS .
  • Page 10 Introduction - Section 10 03/13 OM1042 Page 10-6 TABLE OF CONTENTS SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION / PAGE Fan Control Knob .
  • Page 11 OM1042 03/13 Introduction - Section 10 Page 10-7 TABLE OF CONTENTS SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION / PAGE Air Conditioner &...
  • Page 12 Introduction - Section 10 03/13 OM1042 Page 10-8 TABLE OF CONTENTS SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION / PAGE Transmission Oil Temperature .
  • Page 13 OM1042 03/13 Introduction - Section 10 Page 10-9 TABLE OF CONTENTS SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION / PAGE Removal .
  • Page 14 Introduction - Section 10 03/13 OM1042 Page 10-10 TABLE OF CONTENTS SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION / PAGE SETTING THE TIME .

  • Page 15: Truck Model Illustration

    OM1042 03/13 Introduction - Section 10 Page 10-11 TRUCK MODEL ILLUSTRATION KOMATSU HD1500 DUMP TRUCK...

  • Page 16: About This Manual

    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. Direct all inquiries to: Komatsu America Corp. Peoria Technical Publications P.O. Box 240...
  • Page 17 OM1201 9/11 Torque Tables And Conversion Charts - Section 12 Page 12-1 TORQUE TABLES AND CONVERSION CHARTS This manual provides dual dimensioning for many specifications. Metric units are specified first, with References throughout the manual to standard U.S. standard units in parentheses. When torque val- torques or other standard values will be to one of ues are not specified in the assembly instructions the following tables.
  • Page 18 Torque Size N•m ft lb kg•m NOTE: This list represents the current engineering 1.35 approved sources for use in Komatsu manufacture. It is not exclusive. Other products may meet the same specifications of this list. 11.5 18.0 28.5 39.0 56.0 76.0...
  • Page 19 OM1201 9/11 Torque Tables And Conversion Charts - Section 12 Page 12-3 STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws The following specifications apply to required assem- • The maximum torque tolerance shall be ±10% of bly torques for all grade 5 and grade 8 cap screws.
  • Page 20 Torque Tables And Conversion Charts- Section 12 9/11 OM1201 Page 12-4 STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws The following specifications apply to required assem- bly torques for all 12-point, grade 9 (170,000 psi min- imum tensile), cap screws. •...
  • Page 21 OM1201 9/11 Torque Tables And Conversion Charts - Section 12 Page 12-5 TABLE 4. Tightening Torque For T-Bolt Type Hose Clamp (SAE J1508 Type TB) Newton meters Inch Pounds Thread Size Band Width (N·m) (in. lb) 0.25-28 UNF 19.05 mm (0.75 in.) 8.5 ±...
  • Page 22 Torque Tables And Conversion Charts- Section 12 9/11 OM1201 Page 12-6 TABLE 7. Torque Chart For JIC 37° Swivel NutS With Or Without O-ring Seals Size Tube Size Threads UNF-2B Newton meters Foot Pounds Code (OD) (N·m) (ft lb) – 2 0.125 0.312 –...
  • Page 23 OM1201 9/11 Torque Tables And Conversion Charts - Section 12 Page 12-7 TABLE 9. Torque Chart For O-ring Boss Fittings Foot Pounds Newton meters Size Tube Size (OD) Threads UNF-2B (ft lb) (N·m) Code – 2 0.125 0.312 – 24 4 ±...
  • Page 24 Torque Tables And Conversion Charts- Section 12 9/11 OM1201 Page 12-8 TABLE11. Common Conversion Multipliers Metric To English Multiply To Convert From millimeter (mm) inch (in.) 0.0394 centimeter (cm) inch (in.) 0.3937 meter (m) foot (ft) 3.2808 meter (m) yard (yd) 1.0936 kilometer (km) mile (mi)
  • Page 25 OM1201 9/11 Torque Tables And Conversion Charts - Section 12 Page 12-9 TABLE 12. Common Conversion Multipliers English to Metric To Convert Multiply From inch (in.) millimeter (mm) 25.40 inch (in.) centimeter (cm) 2.54 foot (ft) meter (m) 0.3048 yard (yd) meter (m) 0.914 mile (mi)
  • Page 26 Torque Tables And Conversion Charts- Section 12 9/11 OM1201 Page 12-10 TABLE 13. Temperature Conversions Formula: F° - 32 ÷ 1.8 = C° or C° x 1.8 + 32 = F° Celsius Fahrenheit Celsius Fahrenheit Celsius Fahrenheit C° F° C° F°...
  • Page 27 Used for protecting battery electrode terminals from corrosion. * NOTE: The part numbers in this column are not Komatsu numbers. These are vendor designations. (1) Used for threaded areas (for example, plug, nipple, elbow etc.) which are removable, and a pressure of 1965 kPa (285 psi) or less.
  • Page 28 Torque Tables And Conversion Charts- Section 12 9/11 OM1201 Page 12-12 Hardware Tightening Method Mark cap screws and nuts with paint or ink before tightening to the specified torque. This method provides verification that the hardware has been properly tightened. 1.

  • Page 29: Safety

    Komatsu America Corp. can possibly create hazards. • Before making any modification, consult the Safety Features authorized regional Komatsu America Corp. distributor. Komatsu will not be responsible for • Ensure all guards and covers are in their proper injury damage caused position.

  • Page 30: Mounting And Dismounting

    Safety - Section 20 03/13 OM2032 Page 20-2 Mounting And Dismounting Precautions With High Temperature Fluids • Never jump on or off the machine. Never climb on • Immediately after machine operation, fluids are at or off a machine while it is moving. high temperatures and are pressurized.

  • Page 31: Prevention Of Injury By Work Equipment

    • DO NOT use attachments that are not authorized by Komatsu America Corp., or the authorized regional Komatsu distributor. Fire Extinguisher And First Aid Kit...

  • Page 32: Haul Roads

    • When creating haul roads, orient the road so the maintain a Komatsu machine. loaded truck passes on the side closest to the hill face. Keep the road as straight as possible. If...

  • Page 33: Fire Prevention

    OM2032 03/13 Safety - Section 20 Page 20-5 Fire Prevention In Operator’s Cab - Before Starting The Engine • Thoroughly remove wood • DO NOT leave tools or spare parts lying around chips, leaves, paper and other or allow trash to accumulate in the cab of the flammable items accumulated truck.

  • Page 34: Operating The Machine

    Safety - Section 20 03/13 OM2032 Page 20-6 OPERATING THE MACHINE • Check for flat tires periodically during a shift. If When Starting The Engine the truck has been operating on a flat tire, DO • Never start the engine if a warning tag is attached NOT park the machine inside of a building until to the controls.

  • Page 35: Traveling

    OM2032 03/13 Safety - Section 20 Page 20-7 Traveling • When operating in areas that may be hazardous • Lower the dump body and set the dump lever to or have poor visibility, designate a person to the FLOAT position before traveling. direct work site traffic.

  • Page 36: Operate Carefully On Snow

    Safety - Section 20 03/13 OM2032 Page 20-8 Operate Carefully On Snow When Dumping • When working on snowy or icy roads, there is • Before dumping, check that there is no person or danger that the machine may slip to the side on objects behind the machine.

  • Page 37: Towing

    OM2032 03/13 Safety - Section 20 Page 20-9 TOWING • Improper towing methods may lead to serious • If acid is accidentally ingested, drink a large personal injury and/or damage. quantity of water, milk, beaten eggs or vegetable oil. Call a doctor or poison prevention center •...

  • Page 38: Precautions For Maintenance

    The Komatsu body-up retention cable can only be used with a Komatsu body. Non-OEM dump bodies may not accommodate the Komatsu body-up retention cable. The end user must ensure that a proper cable/sling is used.
  • Page 39 OM2032 03/13 Safety - Section 20 Page 20-11 2. Remove cable (2) from its stored position on the 4. Move the hoist lever to the FLOAT position to body and install between dump body (1) and slowly lower the body until the cable is support- the axle housing ear.

  • Page 40: During Maintenance

    Safety - Section 20 03/13 OM2032 Page 20-12 DURING MAINTENANCE Rules To Follow When Adding Fuel Or Oil • Spilled fuel and oil may cause slipping. Always Personnel clean up spills, immediately. Failure to clean up • Only authorized personnel may service and fuel or oil spills may lead to fires.

  • Page 41: Precautions With The Battery

    OM2032 03/13 Safety - Section 20 Page 20-13 Precautions With The Battery Precautions When Performing Maintenance Near High Temperature Or High Pressure • When repairing electrical system or when • Immediately after stopping performing electrical operation, engine coolant and welding, remove operating oils are at high negative (-) terminal of...

  • Page 42: Tires

    If the proper maintenance procedures are not used, the tire may burst and cause serious injury or dam- age. When performing tire/wheel maintenance, con- sult your authorized regional Komatsu distributor, or the tire manufacturer for questions regarding tire safety. Mounted tires stored as spares must be inflated to the minimum inflation pressure necessary to keep the tire beads properly seated.

  • Page 43: When Repairs Are Necessary

    OM2032 03/13 Safety - Section 20 Page 20-15 WHEN REPAIRS ARE NECESSARY 9. If the truck is to be towed for any reason, 1. Only qualified maintenance personnel, who always consider any special precautions. Refer understand the systems being repaired, may to Section 30, Operating Instructions - Towing, attempt repairs.

  • Page 44: Additional Job Site Rules

    Safety - Section 20 03/13 OM2032 Page 20-16 ADDITIONAL JOB SITE RULES • Use this space to add any additional job site rules not covered in any of the previous discussions. • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ •...

  • Page 45: Warnings And Cautions

    OM2205 Warnings and Cautions - Section 22 Page 22-1 WARNINGS AND CAUTIONS The following pages give an explanation of the Warning, Caution, and Service Instruction plates and decals attached to the truck. The plates and decals listed here are typical of this truck model, but because of customer options, individual trucks may have plates and decals that are different from those shown here.
  • Page 46 Object Protective Structure (FOPS) meets various SAE performance requirements. ! WARNING ! Do not make modifications to this structure, or attempt to repair damage without written approval from Komatsu. Unauthorized repairs will void certification. Danger plates are mounted on each suspension and accumulator cylinder.
  • Page 47 OM2205 Warnings and Cautions - Section 22 Page 22-3 A plate is mounted on the left hand side of the trans- mission oil pan to provide instructions for proper transmission oil level check. Warning plates are mounted on the truck frame in front of and to the rear of both front tires to alert all persons to stay clear when the truck is being steered.
  • Page 48 Warnings and Cautions - Section 22 OM2205 Page 22-4 A plate on the side of the hydraulic tank furnishes instructions for filling the hydraulic tank. Keep the system open to the atmosphere only as long as absolutely necessary to lessen chances of system contamination.
  • Page 49 OM2205 Warnings and Cautions - Section 22 Page 22-5 A plate is located next to filler cap on fuel cap which specifies diesel fuel only. Refer to the Engine Opera- tion and Maintenance Manual. Attached to the interior of battery box lid is a danger plate.
  • Page 50 Warnings and Cautions - Section 22 OM2205 Page 22-6 A product identification plate is located on the right hand frame rail near the front bumper. This lists the vehicle model number, maximum G.V.W. and Product Identification Number. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit.

  • Page 51: Operating Instructions

    Be familiar with use and care of the safety equipment equipment for external damage from rocks or on the Komatsu HD1500-5 truck. Only qualified oper- misuse. Make sure lenses are clean and are not ators or technicians should attempt to operate or cracked or broken.
  • Page 52 Operating Instructions - Section 30 03/13 OM3040 Page 30-2 KOMATSU HD1500-5 TRUCK...
  • Page 53 OM3040 03/13 Operating Instructions - Section 30 Page 30-3 8. Move to the side of the hydraulic tank and 18. Move in front of the right dual tires. Inspect the check the hydraulic fluid level for both the hoist cylinder as was done on the left side. hydraulic tank and brake cooling oil.

  • Page 54: Engine Start-Up Safety Practices

    Operating Instructions - Section 30 03/13 OM3040 Page 30-4 27. Checking the coolant in the radiator using the 2. Ensure the transmission range selector is in coolant level sight gauge. NEUTRAL and the parking brake is applied before starting. 3. Do not attempt to start the engine while the cold weather starting heater (if equipped) is operat- ing.

  • Page 55: Emergency Steering System

    1. Park the empty truck on flat, level ground. Lower the dump body onto the frame and stop NOTE: HD1500-5 trucks are equipped with four 12 the engine. Verify that the key switch is in the volt batteries connected in series and parallel to OFF position.

  • Page 56: After The Engine Has Started

    Operating Instructions - Section 30 03/13 OM3040 Page 30-6 AFTER THE ENGINE HAS STARTED 4. Turn the key switch to the ON position, but do not start the engine. After the engine has been started, operate at approx- a. Steering system pressure: Verify that the low imately 1000 rpm, until the coolant temperature steering pressure...
  • Page 57 OM3040 03/13 Operating Instructions - Section 30 Page 30-7 Service Brake c. Move transmission range selector to the D position and gradually increase engine 2. With the truck on flat ground, check for normal speed to 1550 rpm. (Placing the range selec- operation of the service (foot) brake: tor in D ensures that the transmission will a.
  • Page 58 Operating Instructions - Section 30 03/13 OM3040 Page 30-8 FIGURE 30-1. BRAKE SYSTEM CONTROLS 1. Service Brake 4. Service Brake Lamp 2. Retarder Lever 5. Parking Brake Lamp FIGURE 30-2. CONSOLE CONTROLS 3. Auxiliary Brake Switch 6. Central Warning Lamp 1.

  • Page 59: Machine Operation Safety Precautions

    OM3040 03/13 Operating Instructions - Section 30 Page 30-9 MACHINE OPERATION SAFETY PRECAUTIONS 7. Apply the brake lock switch at the shovel and dump areas. After the truck engine is started and all systems are 8. Proceed slowly on rough terrain to avoid deep functioning properly, the operator must follow all local ruts or large obstacles.

  • Page 60: Hauling

    Operating Instructions - Section 30 03/13 OM3040 Page 30-10 HAULING RETARDER OPERATION 1. Always stay alert! Drive with extreme caution Two lists are provided on the retarding capacity especially when in unfamiliar areas. decal. One a continuous rating, and the second a short-length rating.

  • Page 61: Passing

    OM3040 03/13 Operating Instructions - Section 30 Page 30-11 If the operator observes that either the maximum 13. Report adverse haul road conditions, immedi- engine speed of 2100 rpm or the brake oil tempera- ately. Muddy or icy roads, pot holes or other ture of 120°C (248°F) are about to be exceeded, the obstructions can present hazards.

  • Page 62: Raising The Dump Body

    Operating Instructions - Section 30 03/13 OM3040 Page 30-12 Raising the Dump Body When dumping very large rocks or sticky mate- rial, the material may exit the body too fast. This may cause a violent jolt to the dump body and cause possible injury to the operator.

  • Page 63: Lowering The Dump Body

    OM3040 03/13 Operating Instructions - Section 30 Page 30-13 SAFE PARKING Lowering The Dump Body 7. After the load clears the body, lower the body to The operator must continue the use of safety precau- the frame by moving the hoist control lever for- tions when preparing for parking and engine shut- ward to the DOWN position.

  • Page 64: Sudden Loss Of Engine Power

    6. Adjust the power down relief setting on the good truck to the maximum setting. On HD1500-5 trucks, the power down relief valve (1, Figure 30- 4) is located on pilot valve (2) which is inside of the brake cabinet on the lower RH side.

  • Page 65: Lowering The Body

    Increase engine speed as necessary. this procedure.) The power down relief valve on a HD1500-5 machine should be set at 10 342 kPa (1500 psi). Do Not move the hoist control from the POWER DOWN position until full extension is reached.

  • Page 66: Disabled Truck Steering And Braking

    Figure 30-7 illustrates a typical hookup with another NOTE: Each braking application and release on HD1500-5. Figure 30-6 shows the location of the the disabled truck transfers the release oil from quick disconnects on the bleeddown manifold.
  • Page 67 OM3040 03/13 Operating Instructions - Section 30 Page 30-17...

  • Page 68: Towing

    (Refer to Section G, • For the HD1500-5, wire rope capable of towing Final Drive, in the shop manual for more 77 110 kg (170,000 lb) is required. information.) •...
  • Page 69 • Minimize the tow angle at all times - Never exceed 10° in any direction, vertically or horizontally. The towed truck must be steered in the direction of the wire rope. Consult your area Komatsu service representative for any questions or concerns about towing a dis- abled truck.
  • Page 70 Operating Instructions - Section 30 03/13 OM3040 Page 30-20 NOTES...

  • Page 71: Operator Cab And Controls

    OM3211 08/11 Operator Cab and Controls - Section 32 Page 32-1 OPERATOR CAB AND CONTROLS FIGURE 32-1. CAB INTERIOR - OPERATOR VIEW 1. Steering Wheel 7. Heater/Air Conditioner Vents 13. PMC Interface Connector 2. Retarder Control Lever 8. Retarding Capacity Chart 14.

  • Page 72: Steering Wheel And Controls

    Operator Cab and Controls - Section 32 08/11 OM3211 Page 32-2 STEERING WHEEL AND CONTROLS An indicator in the top, center of the instrument dis- Steering wheel (1, Figure 32-2) will telescope "in" play panel will illuminate to indicate the turning direc- and "out"...

  • Page 73: Windshield Wiper / Washer Control

    OM3211 08/11 Operator Cab and Controls - Section 32 Page 32-3 Windshield Wiper / Washer Control b. When the lever is rotated "downward" (clock- The windshield wiper control is used to activate the wise), it is in the ON/RETARD position. The wiper blades and washer system.

  • Page 74: Accelerator (Throttle) Pedal

    Operator Cab and Controls - Section 32 08/11 OM3211 Page 32-4 ACCELERATOR (THROTTLE) PEDAL HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS Accelerator (throttle) pedal (4, Figure 32-1) is a foot- operated pedal which allows the operator to control The heater/air conditioner compartment contains engine rpm, depending on pedal depression.

  • Page 75: Air Conditioner Control Switch

    OM3211 08/11 Operator Cab and Controls - Section 32 Page 32-5 Air Conditioner Control Switch Heater/Air Conditioner Vents Air Conditioner control switch (5, Heater/air conditioner vents (6, Figure 32-3) may be Figure 32-3) is a three position rotated 360°. There are three vents in the heater/air switch that controls the air condi- conditioner compartment (shown in Figure 32-3), four tioner to cool the cab air.

  • Page 76: Radio Speakers

    Operator Cab and Controls - Section 32 08/11 OM3211 Page 32-6 Customer specified options may cause this decal to Cab Radio change: Always refer to the retarding capacity chart This panel will normally contain an AM/FM stereo in the operator's cab, and follow the recommenda- radio (12, Figure 32-1).

  • Page 77: Center Console

    OM3211 08/11 Operator Cab and Controls - Section 32 Page 32-7 CENTER CONSOLE The housing below the passenger seat provides an Center console (1, Figure 32-4) located to the right of easy access to various control components (relays, the operator seat, is a housing structure which pro- solenoids, valves, etc.) for the service technician.

  • Page 78: Transmission Range Selector

    Operator Cab and Controls - Section 32 08/11 OM3211 Page 32-8 Transmission Range Selector Transmission range selector (2, Figure 32-4) is L - LOW position - Use this range position when mounted to the right of the operator's seat. maneuvering in tight spaces and when pulling through mud or deep snow.

  • Page 79: Control Switches

    OM3211 08/11 Operator Cab and Controls - Section 32 Page 32-9 Control Switches Hoist Control Lever Control switches (3, 4, 6, & 7, Figure 32-4) are simple Hoist control lever (5, Figure 32-4) is a four-function, rocker type switches which turn functions on and off. three-position, hand-operated lever located between the operator seat and the center console.

  • Page 80: Brake Lock Switch

    Operator Cab and Controls - Section 32 08/11 OM3211 Page 32-10 Brake Lock Switch Ash Tray Moving brake lock switch (7, Figure 32- Ash tray (10, Figure 32-4) is used for extinguishing 4) to the ON position, applies the brake and depositing smoking materials.

  • Page 81: Adjustment

    OM3211 08/11 Operator Cab and Controls - Section 32 Page 32-11 Adjustment The following adjustments must be made while sitting in the seat. 1. Headrest: (1, Figure 32-5) will move up, down, fore, or aft by moving the headrest to the desired position.

  • Page 82: Instrument Panel And Indicators

    Operator Cab and Controls - Section 32 08/11 OM3211 Page 32-12 INSTRUMENT PANEL AND INDICATORS FIGURE 32-6. INSTRUMENT PANEL 1. Keyswitch 4. Center Display Panel 7. Headlight Switch 2. Auxiliary Brake Switch 5. LH Panel (Pod) 8. Backup/Deck Lights 3. RH Panel (Pod) 6.

  • Page 83: Keyswitch

    OM3211 08/11 Operator Cab and Controls - Section 32 Page 32-13 Keyswitch Keyswitch (1, Figure 32-6) is a three position (OFF, RUN, START) switch. Starting fluid is extremely volatile and flammable! Use with extreme care. If the truck is equipped with an engine starting aid for cold weather starting, and ambient temperature is below -5°C (23°F), push the engine starting aid switch “in”...

  • Page 84: Rh Control/Indicator Panel (Pod)

    Operator Cab and Controls - Section 32 08/11 OM3211 Page 32-14 RH Control/Indicator Panel (Pod) These are rocker type switches. The OFF and ON positions are RH control/indicator panel (3, Figure 32-6), located to marked with these symbols. the right of the steering wheel, provides an array of switches and controls.

  • Page 85: Rh Control/Indicator Panel (Pod)

    OM3211 08/11 Operator Cab and Controls - Section 32 Page 32-15 Hazard Warning Lights Switch Automatic Idle Selector Switch (AISS) Hazard warning light switch (2, Figure AISS switch (3, Figure 32-7) controls 32-7) causes all turn signal lights to the idle speed of the engine (released flash, simultaneously.
  • Page 86 Operator Cab and Controls - Section 32 08/11 OM3211 Page 32-16 Air Conditioner & Heater Vent Center Display Panel Air conditioner/heater vent (4, Figure 32-7) swivels Center display panel (4, Figure 32-6) consists of a on a vertical axis to direct air toward or away from the gauge and monitor module (1 - 27, Figure 32-8), with operator.
  • Page 87 OM3211 08/11 Operator Cab and Controls - Section 32 Page 32-17 FIGURE 32-8. CENTER DISPLAY PANEL 1. Air Pressure Monitor (Not Used) 16. Shift Indicator 2. Air Pressure Gauge (Not Used) 17. Transmission Shift Position Pilot Lamp 3. Coolant Temperature Monitor 18.
  • Page 88 Operator Cab and Controls - Section 32 08/11 OM3211 Page 32-18 Engine Cooling Water Temperature Gauge Retarder Oil Temperature Gauge Engine cooling water temperature gauge (4, Figure Retarder oil temperature gauge (8, Figure 32-8) indi- 32-8) indicates the temperature of the cooling water. cates the temperature of the retarder cooling oil.
  • Page 89 OM3211 08/11 Operator Cab and Controls - Section 32 Page 32-19 Tachometer Engine Controller Monitor Tachometer (13, Figure 32- Engine control monitor (18, Figure 32- 8) indicates 0-2500 rpm 8) flashes (red) whenever any abnor- engine speed. Each bar mality occurs in any of the engine con- represents 100 rpm.
  • Page 90 Operator Cab and Controls - Section 32 08/11 OM3211 Page 32-20 Fuel Gauge ASR Monitor (Optional) Fuel gauge (22, Figure 32-8) indicates This indicator (26, Figure 32-8) illumi- the amount of fuel in the fuel tank. If nates whenever the optional traction there is more than 150 liters (40 gal.) control system (if installed) is acti- of fuel in the tank while the engine is...
  • Page 91 OM3211 08/11 Operator Cab and Controls - Section 32 Page 32-21 LH Control/Indicator Panel (Pod) Engine Oil Temperature LH control/indicator panel (5, Figure 32-6), located to Engine oil temperature monitor light (2, the left of the steering wheel, contains the following: Figure 32-9) will illuminate if the engine oil temperature exceeds 121°C (250°F) for a continuous period of 5...

  • Page 92: Transmission Oil Temperature

    Operator Cab and Controls - Section 32 08/11 OM3211 Page 32-22 Battery Charge Amps Service Brakes Applied Battery charge amps monitor light (6, Service brakes applied monitor light Figure 32-9) will illuminate if the trans- (11, Figure 32-9) will illuminate mission controller detects low battery (amber), if the transmission controller current at the "R"...

  • Page 93: Lamp Test

    OM3211 08/11 Operator Cab and Controls - Section 32 Page 32-23 Lamp Test Panel Dimmer Switch Lamp test switch (14, Figure 32-9) is a Panel dimmer switch (18, Figure 32-9) three position, two function switch. The is used to adjust the brightness of the switch is spring loaded to the middle, lighting inside the monitor panel.

  • Page 94: Ac/Heater Vent

    Shop Manual for specific information regarding this device. 7. ATC - Automatic Transmission Controller This panel controls and monitors the Komatsu fully automatic transmission. It controls the shift schedules and lock-up clutch modulation and monitors numerous other sensor inputs. Refer to the Shop Manual for specific information regarding this device.
  • Page 95 OM3211 08/11 Operator Cab and Controls - Section 32 Page 32-25 FIGURE 32-10. REAR WALL OF OPERATOR CAB 1. Circuit Breaker Panel 6. ASC - Automatic Suspension Controller 2. Relay Board (Optional) 3. Relay Board 7. ATC - Automatic Transmission Controller 4.
  • Page 96 Operator Cab and Controls - Section 32 08/11 OM3211 Page 32-26 CIRCUIT BREAKER CHART CIRCUIT BREAKER IDENTIFICATION CIRCUIT NUMBER CONTROL DESCRIPTION AMPS VOLTS LOCATION: BATTERY BOX CB24V 24 Volt Control Power (To Power Bus #3 on Cab Rear Wall) CB12V 12 Volt Control Power (To Power Bus #4 on Cab Rear Wall) LOCATION: CAB REAR WALL CB01...

  • Page 97: Quantum™ Fuel System Diagnostics

    OM3211 08/11 Operator Cab and Controls - Section 32 Page 32-27 QUANTUM™ FUEL SYSTEM Determining Fault Codes DIAGNOSTICS Quantum™ fault codes consist of three numerical digits. Each digit is indicated with up to five light Check engine monitor light (7, Figure 32-9) monitors flashes (check engine monitor light) per each digit.

  • Page 98: Exiting The Diagnostics Mode

    Operator Cab and Controls - Section 32 08/11 OM3211 Page 32-28 4. Pressing the lamp test switch to the bottom ("√") Exiting The Diagnostics Mode again will advance to the next fault code (if Starting the engine or turning the keyswitch to the more than one code is present).

  • Page 99: Message For Operation And Maintenance ("Mom")

    OM3211 08/11 Operator Cab and Controls - Section 32 Page 32-29 MESSAGE FOR OPERATION AND MAINTENANCE ("MOM") "MOM" (Message for Operation and Maintenance) is the message display screen located in the upper 1. Screen i1, Initial Message panel just above the operator’s head. It is used to display messages to the operator and service per- sonnel.
  • Page 100 Operator Cab and Controls - Section 32 08/11 OM3211 Page 32-30 This screen is displayed after i1 and before engine is If "MOM" judges that departure is not acceptable, started. It is used to inform the operator whether the "DEPARTURE WAIT" is indicated on the screen. conditions are acceptable to start the engine.
  • Page 101 OM3211 08/11 Operator Cab and Controls - Section 32 Page 32-31 The payload meter is the source of the information 5. Screen i6, Warning Message Display regarding payload data. "MOM" is unable to indicate this data until it is sent by the payload meter. The payload meter will send this information to "MOM"...
  • Page 102 Operator Cab and Controls - Section 32 08/11 OM3211 Page 32-32 The possible action codes are as follows: 6. Screen i7, Back Light Off Code Description Notify maintenance at shift change Notify maintenance right now Reduce engine / machine speed Stop safely now / shut off engine Stop with engine at mid speed Start engine and keep at low idle...

  • Page 103: Transmission Response With Fault Codes

    OM3211 08/11 Operator Cab and Controls - Section 32 Page 32-33 Transmission Response With Fault Codes Fault Description Remarks When the transmission controller detects any of the Code severe fault that are listed below while the engine is Speed running, the transmission will shift to the neutral gear Signal Lost _ - : 0 : Engine b01_...

  • Page 104: Idle Validation Feature

    Operator Cab and Controls - Section 32 08/11 OM3211 Page 32-34 CENTER ELECTRONIC DISPLAY PANEL 1. Bring the truck to a stop in a safe location. Apply the parking brake and move the range Action Code Display selector to the neutral position. 2.

  • Page 105: Cancellation Of Action Code

    OM3211 08/11 Operator Cab and Controls - Section 32 Page 32-35 These two displays will alternate every second. The Cancellation of Action Code other displays, gauges and pilots will function as nor- If either of the following requirements is satisfied then mal.
  • Page 106 Operator Cab and Controls - Section 32 08/11 OM3211 Page 32-36 NOTES...

  • Page 107: Lubrication And Service

    Refer to the engine service manual when servicing • Use of Treated Water coolant. the engine or any of its components. • Use of coolants with less than 40 percent antifreeze. HD1500-5 SERVICE CAPACITIES QUICK FILL SERVICE CENTER Liters Crankcase: Gallons...
  • Page 108 Lubrication and Service - Section 40 08/11 OM4041 Page 40-2 Refer to the following table for the maximum recom- mended fill pressures for the service center. MAXIMUM FIll PRESSURES Fill System Engine Crankcase Hydraulic Tank Coolant Grease 10 342 1,500...

  • Page 109: 10 Hour (Daily) Inspection

    OM4041 08/11 Lubrication and Service - Section 40 Page 40-3 10 HOUR (DAILY) INSPECTION Prior to each operating shift, a "walk around" inspection should be performed. Check the truck for general condi- tion. Look for evidence of hydraulic leaks; check all lights and mirrors for clean and unbroken lenses; check opera- tor's cab for clean and unbroken glass;...
  • Page 110 Lubrication and Service - Section 40 08/11 OM4041 Page 40-4 10 HOUR (DAILY) INSPECTION (continued) Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 3. AIR CLEANERS Check air cleaner vacuum gauges. Clean or replace filter elements if restriction reaches 6.2 kPa (25 in.

  • Page 111: 250 Hour Inspection

    OM4041 08/11 Lubrication and Service - Section 40 Page 40-5 250 HOUR INSPECTION Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS INITIAL 250 HOUR SERVICE 1. Perform the following maintenance after running the machine for the first 250 hours.
  • Page 112 Lubrication and Service - Section 40 08/11 OM4041 Page 40-6 250 HOUR INSPECTION (continued) Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 3 ALTERNATOR BELT - Check the alternator belt for cracks, glazing or cuts. Check for proper tension. Repair or adjust as necessary.
  • Page 113 OM4041 08/11 Lubrication and Service - Section 40 Page 40-7 500 HOUR INSPECTION In addition to the 250 hour lubrication and inspection schedule, perform the following: Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 1 RADIATOR - Check for clogged or damaged fins.

  • Page 114: 1000 Hour Inspection

    Lubrication and Service - Section 40 08/11 OM4041 Page 40-8 1000 HOUR INSPECTION In addition to the 250 and 500 hour lubrication and inspection schedules, perform the following: Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS...

  • Page 115: 2000 Hour Inspection

    OM4041 08/11 Lubrication and Service - Section 40 Page 40-9 2000 HOUR INSPECTION Maintenance for every 250, 500 and 1000 hours should also be performed at this time. Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS...

  • Page 116: 5000 Hour Inspection

    Lubrication and Service - Section 40 08/11 OM4041 Page 40-10 5000 HOUR INSPECTION Maintenance for every 250, 500, 1000 and 2000 hours should also be performed at this time. Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS...

  • Page 117: Radiator Fill Procedure

    OM4041 08/11 Lubrication and Service - Section 40 Page 40-11 RADIATOR FILL PROCEDURE Check oil level again, as described below, when transmission oil reaches operating temperature. 2. Engine Running: The cooling system is pressurized due to thermal The oil level must be visible in lower part of expansion of coolant.

  • Page 118: Hydraulic Tank Service

    Lubrication and Service - Section 40 08/11 OM4041 Page 40-12 Hydraulic Tank Service When servicing the hydraulic tank, always follow the Filling Instructions described above to relieve any internal tank pressure before opening tank. 1. When checking oil level, or any other service, inspect the breather (3, Figure 40-3) to be cer- tain that it is open to atmosphere.

  • Page 119: Steering Circuit Filter

    OM4041 08/11 Lubrication and Service - Section 40 Page 40-13 STEERING CIRCUIT FILTER Removal The brake and steering circuit filter is located on the left frame rail, forward of the hydraulic tank. Relieve pressure before disconnecting hydraulic and other lines. Tighten all connections before applying pressure.

  • Page 120: Hydraulic Tank Breather

    Lubrication and Service - Section 40 08/11 OM4041 Page 40-14 HYDRAULIC TANK BREATHER Cleaning 1. Shut down the engine and open hydraulic tank filler caps slowly to relieve any internal pres- sure. 1. Hydraulic tank may be pressurized! Depress relief valve (2, Figure 40-2) and release hydraulic tank filler cap slowly to remove any internal pressure.

  • Page 121: Lincoln Automatic Lubrication System

    The system is controlled by an electric timer which signals solenoid valves to cause operation of a hydraulically operated grease pump. For the HD1500-5, these components (valves, pump, and reservoir/canister) are mounted on the right deck structure to the right of the hydraulic cabinet just above the right front suspension.
  • Page 122 Automatic Lubrication System - Section 42 OM4202 Page 42-2 Solenoid valve SV2 (8) directs the hydraulic fluid to the hydraulic cylinder which operates the grease pump. Figure 42-2. LUBE INJECTOR GROUPS • Pressure reducing valve (10) lowers hydraulic Lube # of fluid pressure to the operating range of the hydraulic pump cylinder.
  • Page 123 OM4202 Automatic Lubrication System - Section 42 Page 42-3 FIGURE 42-2. HD1500-5 AUTOMATIC LUBRICATION SYSTEM ARRANGEMENT Group Lube Location "A" Contains 3 Injectors 1. Grease Pump/Cylinder Group Lube Location "B" Contains 3 Injectors 2. Cylinder Pressure Gauge Group Lube Location "C"...

  • Page 124: System Operation

    Automatic Lubrication System - Section 42 OM4202 Page 42-4 Pump Cycle Timer Safety Unloader Relief Valve [Also called a "flasher" timer, because it contains an Safety unloader relief valve (not shown) is located on LED that illuminates when there is power going to the back of vent valve (11, Figure 42-1).

  • Page 125: System Priming

    OM4202 Automatic Lubrication System - Section 42 Page 42-5 With the vent valve closed, the pump cycles until lubricant pressure reaches maximum pump output This equipment generates very high grease pres- pressure* (pump stalls). As the grease supply line sure. Extreme caution should be used when comes to maximum pressure, the injectors meter operating this equipment as material leaks from grease to the points of lubrication.

  • Page 126: System Checkout

    Automatic Lubrication System - Section 42 OM4202 Page 42-6 4. Repeat Step 3 until all lines are full and all plugs Pressure Reducer Adjustment replaced. NOTE: Steering accumulator pressure is necessary NOTE: Fill each feed line with grease before to power the lube system for this procedure. connecting lines to the injector outlets and bearings.

  • Page 127: 24 Vdc Solid State Timer Check

    OM4202 Automatic Lubrication System - Section 42 Page 42-7 6. Observe the 35 MPa (5000 psi) pressure test 24 VDC Solid State Timer Check gauge in the grease supply line. The pressure To check the solid state timer operation without wait- should be 17.2 - 20.7 MPa (2500 - 3000 psi).

  • Page 128: 24 Vdc Solid State Timer Adjustment

    Automatic Lubrication System - Section 42 OM4202 Page 42-8 24 VDC Solid State Timer Adjustment Injector Adjustment The timer is factory set for a nominal 2.5 minute (off The injectors may be adjusted to supply from 0.13 cc time) interval. Dwell time is approximately 1 minute, to 1.31 cc (0.008 in to 0.08 in ) of lubricant per injec-...

  • Page 129: Pump Cycle Timer (Flasher Timer)

    OM4202 Automatic Lubrication System - Section 42 Page 42-9 When the injector is not pressurized, maximum injec- Pump Cycle Timer (Flasher Timer) Adjustment: tor delivery volume is attained by turning adjusting The pump cycle timer is factory set at 1 second ON screw (2) fully counterclockwise until indicating pin and 1 second OFF for 30 cycles/minute.
  • Page 130 Automatic Lubrication System - Section 42 OM4202 Page 42-10 FIGURE 42-6. SYSTEM HYDRAULIC SCHEMATIC 1. Grease Pump Cylinder 6. Solenoid (SV2) 12. Hydraulic Supply 2. Grease Pump 7. Pressure Reducer 13. Hydraulic Tank (Return) 3. Grease Reservoir 8. Solenoid (SV1) 14.

  • Page 131: System Troubleshooting Chart

    OM4202 Automatic Lubrication System - Section 42 Page 42-11 SYSTEM TROUBLESHOOTING CHART If the following procedures do not correct the problem, contact a factory authorized service center. POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Pump Does Not Operate Lube system not grounded. Correct grounding connections to pump assembly and truck chassis.
  • Page 132 Automatic Lubrication System - Section 42 OM4202 Page 42-12 POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Pressure Gauge Does Not Register Pressure No system pressure to the pump. Determine problem in hydraulic system. No 24 VDC signal at solenoids SV1 and Determine problem in 24 VDC electric system.

  • Page 133: Reservoir Fill Procedure

    OM4202 Automatic Lubrication System - Section 42 Page 42-13 POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Timer Turns On At Intervals Two To Ten Times More Often Than Set Time Interval Electrical noise is being introduced into the power IMPORTANT: In some instances, electrical noise supply to the timer overcoming suppressor capaci- may be generated into vehicle electrical system tor causing uncontrolled turn-on of its output relay.

  • Page 134: Preventive Maintenance Procedures

    Automatic Lubrication System - Section 42 OM4202 Page 42-14 PREVENTIVE MAINTENANCE PROCEDURES The following maintenance procedures should be 4. Inspect all bearing points for a bead of lubricant used to insure proper system operation. around the bearing seal. It is good practice to manually lube each bear- Daily Lubrication System Inspection ing point at the grease fitting (filler zerk, Figure 1.
  • Page 135 Page 50-1 MAJOR COMPONENTS AND SPECIFICATIONS ENGINE POWER STEERING The Komatsu HD1500-5 dump truck is powered by a The HD1500-5 truck is equipped with a full time Komatsu SDA12V160 diesel engine. power steering system which provides positive steer- ing control with a minimum of effort by the operator.
  • Page 136 Major Components & Specifciations - Section 50 03/13 OM5033 Page 50-2 HD1500-5 MAJOR COMPONENTS...
  • Page 137 SERVICE CAPACITIES Komatsu ......SDA12V160 ......Liters . . U.S Gallons Number of Cylinders .
  • Page 138 Standard ......33.00 R51 (w/Komatsu Engine; and ..33.00 R51 Tires) Rim Size .
  • Page 139 OM6010 Payload Meter II - Section 60 Page 60-1 SECTION 60 PAYLOAD METER II - ON BOARD WEIGHING SYSTEM INDEX GENERAL INFORMATION ............60-3 Haul Cycles .
  • Page 140 Payload Meter II - Section 60 OM6010 Page 60-2 DISPLAYS AT START-UP ............60-17 Normal Operation .
  • Page 141 OM6010 Payload Meter II - Section 60 Page 60-3 PAYLOAD METER II ON BOARD WEIGHING SYSTEM (OBWS) GENERAL INFORMATION suspension and inclinometer data. After traveling 160 m (0.10 mi.) from the loading site, the PLM II™ The Payload Meter II™ (PLM II™) On Board Weigh- uses the data sampled under the shovel to calculate ing System displays and records the payload weight final payload.
  • Page 142 Payload Meter II - Section 60 OM6010 Page 60-4 LIGHTS, SWITCHES AND COMPONENTS On The Face Of The Payload Meter (Refer to Figure 60-1) 6. Calibration/Clear Switch 1. Display Panel Used to calibrate the machine when the condi- tions regulate this action. Also used with the Digital display area for the data being recorded TOTAL/SFT switch to clear total payload and in memory.
  • Page 143 • For most Komatsu Trucks: Use only the brake lock switch to hold the truck stationary at the loading and dumping area. For Komatsu 330M/HD785 Trucks ONLY: Use the park brake switch to hold the truck stationary at the loading and dumping area.
  • Page 144 Payload Meter II - Section 60 OM6010 Page 60-6 THEORY OF OPERATION Basic Description The payload meter uses the four suspension pres- sures and the inclinometer to determine the load in the truck. These inputs are critical to the calculation of the load.
  • Page 145 OM6010 Payload Meter II - Section 60 Page 60-7 Gain Factor Sources of Error Gain factor is part of the formula the payload meter Poorly charged suspensions can lead to systematic uses to calculate the payload. The gain factor is a error in the calculation of payload.
  • Page 146 Payload Meter II - Section 60 OM6010 Page 60-8 NOTE: This screen is the only place that the Viewing Payload Calculation Inputs value of the G gain potentiometer can be The PLM II™ estimates payload by monitoring sus- checked. pension pressures when the truck is loaded and compares them to truck empty pressure values.
  • Page 147 OM6010 Payload Meter II - Section 60 Page 60-9 Checking the Gain Adjusting the Gain 1. Press and hold the LIGHT/INC and Before adjusting the gain perform the following steps: MODE switches until "CHEC" is 1. Confirm the suspension oil and nitrogen flashing on the meter.
  • Page 148 Payload Meter II - Section 60 OM6010 Page 60-10 TYPES OF DATA STORED Cycle Data One cycle is considered to be from the point where a load is dumped to the point where the next load is dumped. Data between these two points is recorded in memory. Examples of the data are shown below. The maximum num- ber of cycles that can be stored in memory is 2900 cycles.
  • Page 149 OM6010 Payload Meter II - Section 60 Page 60-11 Engine ON/OFF Data When the engine is started or stopped, the following data is recorded. ITEM UNIT RANGE REMARKS Engine Operation Number Number 1 - 65535 Advances by one each time the engine is started.
  • Page 150 Payload Meter II - Section 60 OM6010 Page 60-12 Engine Operation ITEM UNIT RANGE REMARKS Every time the engine is started the Number when Canceled Number 1 - 65535 number advances by one. Last Two Digits Of Year Year 0 - 99 Month Month 1 - 12...
  • Page 151 OM6010 Payload Meter II - Section 60 Page 60-13 OPERATOR FUNCTIONS Clearing the Operator Load Counter 1. Press the TOTAL/SFT switch once. The num- Using the Operator Load Counter ber displayed is the total tons hauled since the The payload meter makes available to the operator a last time the counter was cleared.
  • Page 152 Payload Meter II - Section 60 OM6010 Page 60-14 INITIAL SETUP OF PAYLOAD METER Switch Position There are several things that must be checked and Initial Setup should be set to 1.00 - Gain programmed when a payload meter is first installed. Clockwise(-20%) CCW (+20%) 1.
  • Page 153 OM6010 Payload Meter II - Section 60 Page 60-15 Checking the Operator Check Mode Checking the Service Check Mode The Operator Check Mode is used to check and change several settings. These should be checked before the payload meter is put into service. 1.
  • Page 154 Nitrogen levels have changed. An alternative method is to use a personal computer 4. Whenever any major change to the truck has running the Komatsu Payload Download Program for been performed that would change the empty Microsoft Windows. The "Monitor Pressures" section vehicle weight.
  • Page 155 OM6010 Payload Meter II - Section 60 Page 60-17 DISPLAYS AT START-UP 6. The display will show: This function is not used. POWER ON: "SU : - -" indicates Switch 8 is up. All external display lamps (Figure 60-2) will come on and stay on for approximately 27 seconds during the "SU : oo"...
  • Page 156 Payload Meter II - Section 60 OM6010 Page 60-18 SETUP AND MAINTENANCE Setting the Option Code 1. Press and hold the MODE switch Speed Limit until "Cd:dP" is displayed. A warning can be displayed if the machine exceeds a 2. Press the MODE switch once. preset speed.
  • Page 157 OM6010 Payload Meter II - Section 60 Page 60-19 Setting The Machine I.D. Code Setting The Time and Date 1. Press and hold the MODE switch 1. Press and hold the MODE switch until "Cd:dP" is displayed. until "Cd:dP" is displayed. 2.
  • Page 158 Payload Meter II - Section 60 OM6010 Page 60-20 DOWNLOAD OF INFORMATION DISPLAY OF FAULT CODES 1. Press and hold the MODE switch Payload information and fault codes recorded should until "Cd:dP" is displayed. be downloaded to a personal computer on a regular basis.
  • Page 159 OM6010 Payload Meter II - Section 60 Page 60-21 • Condition of the Engine Oil Pressure signal. The panel will display ":C3:XX" for 3 seconds, then indicate: "C3:oo" Engine is running. "C3:- -" Engine is not running. • Condition of Alternator 'R' terminal signal. The panel will display "C4:XX"...
  • Page 160 Payload Meter II - Section 60 OM6010 Page 60-22...
  • Page 161 OM6010 Payload Meter II - Section 60 Page 60-23...
  • Page 162 Payload Meter II - Section 60 OM6010 Page 60-24 Monitoring Input Signals Service Check Mode 1. Press and hold the LIGHT/INC and MODE This procedure can be used to monitor the current switches until "CHEC" is flashing. input signals to the payload meter. 2.
  • Page 163 OM6010 Payload Meter II - Section 60 Page 60-25 UP FACTOR - PAYLOAD CALCULATION Careful consideration must be given to the use of PL:01 and PL:10. These modes divide the data GAIN transmitted by Modular Mining and the data stored in Description of UP Factor the payload meter's memory.
  • Page 164 Payload Meter II - Section 60 OM6010 Page 60-26 FINAL GEAR RATIO SELECTION For an 830E truck, the proper gear ratio has to be selected. 1. Press and hold the MODE and LIGHT/INC switches until "CHEC" is displayed. 2. Press and hold the TOTAL/SFT and LIGHT/INC switches until "S.SEL"...
  • Page 165 OM6010 Payload Meter II - Section 60 Page 60-27 BATTERY REPLACEMENT PROCEDURE 4. Remove the electrical connector. Remove the screws on the top surface and the rear face. Remove the cover (Figure 60-8). This will ERROR CODE, F-09, DISPLAYED expose the battery, its wires, and the connector. Replacing the Battery The payload meter has an internal battery used to protect the memory from being erased when the key...
  • Page 166 Payload Meter II - Section 60 OM6010 Page 60-28 9. Forcibly clear the data for the total payload and overall number of cycles. With this operation performed, all the unwanted data inside the payload meter is cleared. Except for the calibra- tion data, all the data recorded in the previous steps is also erased.
  • Page 167 OM6010 Payload Meter II - Section 60 Page 60-29 Installation Installation 1. Install a new O-ring onto sensor (4, Figure 60- 1. Install inclinometer (3, Figure 60-13) with cap- 11) and install sensor onto adapter (3). Tighten screws, nuts and lockwashers (4). the sensor to 22-29 ft.lbs.
  • Page 168 Payload Meter II - Section 60 OM6010 Page 60-30 PAYLOAD METER BACK PANEL...
  • Page 169 OM6010 Payload Meter II - Section 60 Page 60-31 CONNECTIONS CN1 - AMP MIC-MKII 13 Pins White Connector CN3 - AMP MIC-MKII 9 Pins White (RS-232C Port) Description Comments Description Power +24V (Battery) Lamp Relay 1 Lamp Relay 2 Lamp Relay 3 Lamp Relay 4 Lamp Relay 5 Speed Sensor (Signal)
  • Page 170 Payload Meter II - Section 60 OM6010 Page 60-32 PAYLOAD CIRCUIT NUMBERS Circuit Designation Circuit Description 39F, 39F1...39F5 +18 volt sensor power supply 39FA Pressure signal Right Rear 39FB Pressure signal Left Rear 39FC Pressure signal Right Front 39FD Pressure signal Left Front 39FE Inclinometer signal 39FG...
  • Page 171 OM6010 Payload Meter II - Section 60 Page 60-33 PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE 6. Start the engine. This procedure is designed to reset the Payload Meter II™ to clear repeated F.CAL errors. 7. Set the time, date, OP, PL, and UP settings. All other user settings should updated at this time.
  • Page 172 Payload Meter II - Section 60 OM6010 Page 60-34 NOTES...

  • Page 173: Setting The Default Display

    OM7004 4/05 Radio / Cassette Player - Section 70 Page 70-1 RADIO / CASSETTE PLAYER FIGURE 70-1. RADIO / CASSETTE PLAYER GENERAL RECEIVER FUNCTIONS Setting The Default Display 1. Press and hold DSPL/TM (9) for two seconds Turning The Power On And Off until the hour digits flash.
  • Page 174 Radio / Cassette Player - Section 70 OM7004 4/05 Page 70-2 SETTING THE TIME 1. Turn the key switch ON. When in satellite mode, press and release either the 2. Press and hold DSPL/TM SET (9, Figure 70-1) TUNE or the SEEK buttons to navigate to the for two seconds.
  • Page 175 OM7004 4/05 Radio / Cassette Player - Section 70 Page 70-3 ADJUSTING THE RECEIVER SETTINGS 3. Press and hold one of the six push-buttons for VOLUME: Rotate ON/AUDIO (6, Figure 70-1) knob at least two seconds. During this period, clockwise to increase the volume and counter-clock- receiver output will be muted and the push-but- wise to decrease the volume.
  • Page 176 Radio / Cassette Player - Section 70 OM7004 4/05 Page 70-4 SATELLITE RADIO Operating Satellite Radio 1. Use the BAND button to select the proper satel- To use the satellite radio function on your radio, a subscription must be ordered from a provider. There lite radio band.
  • Page 177 OM7004 4/05 Radio / Cassette Player - Section 70 Page 70-5 CASSETTE PLAYER Cassette Functions The cassette player that the radio is equipped with The 4/REV button (17) rewinds the cassette. The works best with cassettes that range from 30 to 90 cassette will continue to rewind until the button is minutes long.
  • Page 178 Radio / Cassette Player - Section 70 OM7004 4/05 Page 70-6 Bad Tape Detect Cleaning The Cassette Player If the receiver detects a bad cassette, “BAD TAPE” After 35 hours of cassette play, the display will read will appear on the display and the tape will be TP CLEAN for five seconds.

This manual is also suitable for:

Hd1500

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