Komatsu HD1500-5 (SN: A30070-30071; A30077-30077) Rigid Dump Trucks (USA) Operate and Maintenance manual (CEAM012803)

Illustrated factory Operate and Maintenance manual for Komatsu Rigid Dump Trucks Models HD1500-5.

This manual will assist you in operating, and maintaining for your rigid dump truck.
You can use a Windows, Mac, or Android device to view this manual. You only need to have a PDF reader installed.

Covered Models (USA):
   HD1500-5 (SN: A30070-30071; A30077-30077)

Format: PDF, 178 pages
Language: English
Table of Contents:
   Truck Model Illustration
   ABOUT THIS MANUAL
   STANDARD CHARTS AND TABLES
   SAFETY
   Safety Rules
   Safety Features
   Clothing And Personal Items
   Unauthorized Modification
   Leaving The Operators Seat
   Mounting And Dismounting
   Fire Prevention For Fuel And Oil
   Precautions With High Temperature Fluids
   Asbestos Dust Hazard Prevention
   Prevention Of Injury By Work Equipment
   Fire Extinguisher And First Aid Kit
   Precautions For ROPS
   Precautions For Attachments
   HAUL ROADS
   BEFORE STARTING THE ENGINE
   Fire Prevention
   Preparing For Operation
   Ventilation In Enclosed Areas
   In Operators Cab - Before Starting The Engine
   Mirrors, Windows, And Lights
   OPERATING THE MACHINE
   When Starting The Engine
   Precautions For Starting Machine
   Truck Operation - General
   Traveling
   Traveling In Reverse
   Traveling On Slopes
   Ensure Good Visibility
   Operate Carefully On Snow
   Avoid Damage To Dump Body
   TABLE OF CONTENTS
   Driving Near High Voltage Cables
   When Dumping
   Working On Loose Ground
   Loading The Body
   Parking The Machine
   TOWING
   WORKING NEAR BATTERIES
   Battery Hazard Prevention
   Starting With Booster Cables
   PRECAUTIONS FOR MAINTENANCE
   BEFORE PERFORMING MAINTENANCE
   Warning Tag
   Proper Tools
   Stopping The Engine Before Service
   Securing The Dump Body
   DURING MAINTENANCE
   Personnel
   Attachments
   Working Under The Machine
   Keep The Machine Clean
   Rules To Follow When Adding Fuel Or Oil
   Radiator Water Level
   Use Of Lighting
   Precautions With The Battery
   Handling High Pressure Hoses
   Precautions With High PressureOil
   Precautions When Performing Maintenance Near High Temperature Or High Pressure
   Rotating Fan And Belts
   Waste Materials
   TIRES
   Handling Tires
   Storing Tires After Removal
   WHEN REPAIRS ARE NECESSARY
   ADDITIONAL JOB SITE RULES
   WARNINGS AND CAUTIONS
   OPERATING INSTRUCTIONS
   PREPARING FOR OPERATION
   Safety Is Thinking Ahead
   At The Truck - Ground Level Walk Around Inspection
   ENGINE START-UP SAFETY PRACTICES
   EMERGENCY STEERING SYSTEM
   Operation
   Pre-Operation Testing
   AFTER THE ENGINE HAS STARTED
   MACHINE OPERATION SAFETY PRECAUTIONS
   LOADING
   HAULING
   RETARDER OPERATION
   PASSING
   DUMPING
   Raising the Dump Body
   Lowering The Dump Body
   SAFE PARKING
   SHUTDOWN PROCEDURE
   SUDDEN LOSS OF ENGINE POWER
   Emergency Steering And Braking
   DISABLED TRUCK DUMPING
   Hookup
   Raising the Body
   Lowering the Body
   DISABLED TRUCK STEERING AND BRAKING
   TOWING
   OPERATOR CAB AND CONTROLS
   STEERING WHEEL AND CONTROLS
   Horn Button
   Telescope Lock Ring
   Tilt Wheel Lever
   Turn Signal / Headlight Dimmer
   Windshield Wiper / Washer Control
   RETARDER CONTROL LEVER
   SERVICE BRAKE PEDAL
   ACCELERATOR (THROTTLE) PEDAL
   INSTRUMENT PANEL
   HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS
   Defroster Vent Control Switch
   Heat Vent Control Switch
   Fan Control Knob
   Temperature Control Knob
   Air Conditioner Control Switch
   Heater/Air Conditioner Vents
   RETARDING CAPACITY CHART
   Radio Speakers
   MOM Display Screen
   MOM Dimmer Switch
   Warning Alarm Buzzer
   Cab Radio
   PMC Interface Connector
   Air Cleaner Vacuum Gauges
   Payload Meter
   Windshield Wipers
   CENTER CONSOLE
   Transmission Range Selector
   Control Switches
   Shift Limiter Switch
   F1 Start Switch
   Hoist Control Lever
   Parking Brake Switch
   Brake Lock Switch
   LH Window Control Switch
   RH Window Control Switch
   Ash Tray
   Lighter
   Passenger Seat w/Safety Belt
   OPERATOR SEAT
   Adjustment
   INSTRUMENT PANEL AND INDICATORS
   Keyswitch
   Auxiliary Brake Switch
   RH Control/Indicator Panel (Pod)
   Center Display Panel
   LH Control/Indicator Panel (Pod)
   Ladder Light Switch
   Head Light Switch
   BackUp/Deck Light Switch
   RH Control/Indicator Panel (Pod)
   Cold Weather Starting Aid (Ether Injection) Switch
   Hazard Warning Lights Switch
   Automatic Idle Selector Switch (AISS)
   Air Conditioner and Heater Vent
   ASR Cut (Traction Control) Switch (Option)
   Center Display Panel
   Air Pressure Monitor (Not Used)
   Air Pressure Gauge (Not Used)
   Coolant Temperature Monitor
   Engine Cooling Water Temperature Gauge
   Torque Converter Oil Temperature Monitor
   Torque Converter Oil Temperature Gauge
   Retarder Oil Temperature Monitor
   Retarder Oil Temperature Gauge
   Left Turn Signal Pilot Lamp
   High Beam Pilot Lamp
   Right Turn Signal Pilot Lamp
   Speedometer
   Tachometer
   Lock-up Pilot Lamp
   Shift Limiter Pilot Lamp
   Shift Indicator
   Transmission Shift Position Pilot Lamp
   Engine Controller Monitor
   Automatic Transmission Mechatronics Monitor
   Other Mechatronics Monitor (Optional)
   Fuel Level Monitor
   Fuel Gauge
   Engine Power Derate Monitor
   F1 Start Monitor
   Auto Cruise Control (Not Used)
   ASR Monitor (Optional)
   ABS Monitor (Not Used)
   Service Meter
   Odometer
   LH Control/Indicator Panel (Pod)
   LH Panel/Pod Assembly
   Engine Oil Temperature
   Engine Coolant Level
   Low Steering Pressure
   Accumulator Pre-Charge
   Battery Charge Amps
   Check Engine
   Parking Brake
   Body Float
   Transmission Oil Temperature
   Service Brakes Applied
   Maintenance Monitor
   Transmission Oil Filters
   Lamp Test
   Low Brake Pressure
   Lateral Slope Warning
   Crankcase Pressure
   Panel Dimmer Switch
   Engine Oil Pressure
   Central Warning Lamp
   AC/Heater Vent
   REAR OF OPERATOR CAB
   QUANTUM FUEL SYSTEM DIAGNOSTICS
   Determining Fault Codes
   Exiting The Diagnostics Mode
   MESSAGE FOR OPERATION AND MAINTENANCE ("MOM")
   Truck Condition
   Production Data During Operation - (Information from the Payload Meter)
   Transmission Response With Fault Codes
   Idle Validation Feature
   CENTER ELECTRONIC DISPLAY PANEL
   Action Code Display
   Cancellation of Action Code
   LUBRICATION AND SERVICE
   COOLANT SPECIFICATIONS
   Unacceptable Practices
   QUICK FILL SERVICE CENTER
   HOUR (DAILY) INSPECTION
   HOUR INSPECTION
   HOUR INSPECTION
   HOUR INSPECTION
   HOUR INSPECTION
   HOUR INSPECTION
   RADIATOR FILL PROCEDURE
   TRANSMISSION OIL LEVEL CHECK
   HYDRAULIC TANK SERVICE
   Filling Instructions
   Hydraulic Tank Service
   STEERING CIRCUIT FILTER
   Removal
   Installation
   HYDRAULIC TANK BREATHER
   Cleaning
   LINCOLN AUTOMATIC LUBRICATION SYSTEM
   SYSTEM COMPONENTS
   System Operation
   System Priming
   System Checkout
   Pressure Reducer Adjustment
   VDC Solid State Timer Check
   VDC Solid State Timer Adjustment
   Injectors (SL-1)
   Injector Adjustment
   Pump Cycle Timer (Flasher Timer):
   Pump Cycle Timer (Flasher Timer) Installation
   Pump Cycle Timer (Flasher Timer) Adjustment:
   SYSTEM TROUBLESHOOTING CHART
   RESERVOIR FILL PROCEDURE
   Lubricant Required for System
   Fill Procedure
   PREVENTIVE MAINTENANCE PROCEDURES
   Daily Lubrication System Inspection
   Hour Inspection
   MAJOR COMPONENT DESCRIPTION
   PAYLOAD METER III
   RADIO, AM / FM STEREO CASSETTE
   SETTING THE TIME
   GENERAL RECEIVER FUNCTIONS
   Turning The Power On And Off
   Display
   Setting The Default Display
   Adjusting Display Brightness
   OPERATING THE RADIO
   BAND
   TUNE/SEEK
   Manual Tuning
   SEEK Mode
   SCAN
   AUTO
   ADJUSTING THE RECEIVER SETTINGS
   PROGRAMMING PRESET STATIONS
   OPERATION OF THE WEATHERBAND (U.S.)
   SATELLITE RADIO
   Operating Satellite Radio
   Program Type Search (PTY)
   CASSETTE PLAYER
   Playing A Cassette
   Cassette Functions
   PROGRAMMABLE EJECT DEFAULT
   Bad Tape Detect
   CASSETTE PLAYER CLEANING
   TRUCK MODEL ILLUSTRATION
   TORQUE TABLES AND CONVERSION CHARTS
   SAFETY
   ADDITIONAL JOB SITE RULES
   WARNINGS AND CAUTIONS
   OPERATING INSTRUCTIONS
   OPERATOR CAB AND CONTROLS
   INSTRUMENT PANEL AND INDICATORS
   MESSAGE FOR OPERATION AND MAINTENANCE ("MOM")
   LUBRICATION AND SERVICE
   LINCOLN AUTOMATIC LUBRICATION SYSTEM
   SYSTEM TROUBLESHOOTING CHART
   PREVENTIVE MAINTENANCE PROCEDURES
   MAJOR COMPONENTS AND SPECIFICATIONS
   SPECIFICATIONS
   PAYLOAD METER II - ON BOARD WEIGHING SYSTEM
   INDEX
   GENERAL INFORMATION
   Haul Cycles
   LIGHTS, SWITCHES AND COMPONENTS
   TIPS FOR OPERATION
   EXTERNAL DISPLAY LIGHTS
   THEORY OF OPERATION
   Basic Description
   Inclinometer
   Linkage Factor
   Gain Factor
   Brake Lock
   Sources of Error
   Typical Data From Service Check Mode
   Example Calculation of Payload
   Viewing Payload Calculation Inputs
   Checking the Gain
   Adjusting the Gain
   TYPES OF DATA STORED
   Cycle Data
   Engine ON/OFF Data
   Fault Codes and Warning Data
   Engine Operation
   Total Payload and Total Number of Cycles
   Other Data
   OPERATOR FUNCTIONS
   Using the Operator Load Counter
   Viewing the Operator Load Counter
   Clearing the Operator Load Counter
   Dimming the Lights on the Display
   INITIAL SETUP OF PAYLOAD METER
   Switch Settings
   Checking the Operator Check Mode
   Checking the Service Check Mode
   Checking the Gt setting:
   Checking the Inclinometer Settings
   Calibrating a Truck
   DISPLAYS AT START-UP
   Normal Operation
   SETUP AND MAINTENANCE
   Setting The Speed Limit
   Setting the Option Code
   Setting The Machine I.D. Code
   Setting The Operator I.D. Code
   Setting The Time and Date
   DOWNLOAD OF INFORMATION
   DISPLAY OF FAULT CODES
   Monitoring Input Signals
   Service Check Mode
   UP FACTOR - PAYLOAD CALCULATION GAIN
   PL MODE -LOAD CALCULATION TIMING
   FINAL GEAR RATIO SELECTION
   BATTERY REPLACEMENT PROCEDURE
   Replacing the Battery
   After Replacing the Battery
   SUSPENSION PRESSURE SENSOR
   Removal
   Installation
   INCLINOMETER
   Removal
   Installation
   Adjustment
   PAYLOAD METER BACK PANEL
   CONNECTIONS
   PAYLOAD CIRCUIT NUMBERS
   PAYLOAD METER II RE-INITIALIZATION PROCEDURE
   PAYLOAD CIRCUIT NUMBERS
   PAYLOAD METER II RE-INITIALIZATION PROCEDURE
   RADIO, AM / FM STEREO CASSETTE