Unsafe use of this machine may cause serious injury or death.

Operators and
maintenance personnel must read and understand this manual before operating
or maintaining this machine.
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 Mining Systems, Inc. and is not to be reproduced, used, or disclosed except
in accordance with written authorization from Komatsu Mining Systems, Inc.
It is the policy of the Company to improve products whenever it is possible and practical to do so. The Company
reserves the right to make changes or add improvements at any time without incurring any obligation to install
such changes on products sold previously.
Because of continuous research and development, periodic revisions may be made to this publication. Customers
should contact their local distributor for information on the latest revision.

CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust, some of its constituents, and certain vehicle
components contain or emit chemicals known to the State of
California to cause cancer, birth defects or other reproductive harm.

CALIFORNIA
Proposition 65 Warning
Battery posts, terminals and related accessories contain lead and
lead compounds, chemicals known to the State of California to
cause cancer and birth defects or other reproductive harm.
Wash hands after handling.
 EMISSION CONTROL WARRANTY

EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)

1. Products Warranted

Komatsu America International Company, Komatsu Mining Systems Inc. and Komatsu Utility Corporation (collectively “Komatsu”) produce and/or
market products under brand names of Komatsu, Dresser, Dressta, Haulpak and Galion. This emissions warranty applies to new engines bearing the
Komatsu name installed in these products and used in Canada in machines designed for industrial off-highway use. This warranty applies only to
these engines produced on or after January 1, 2000. This warranty will be administered by Komatsu distribution in Canada.

2. Coverage

Komatsu warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform, at the
time of sale by Komatsu, with all U.S. Federal emission regulations applicable at the time of manufacture and that it is free from defects in
workmanship or material which would cause it not to meet these regulations within five years or 3,000 hours of operation, whichever occurs first, as
measured from the date of delivery of the engine to the ultimate purchaser.

3. Limitations

Failures, other than those resulting from defects in materials or workmanship, are not covered by this warranty. Komatsu is not responsible for
failures or damage resulting from what Komatsu determines to be abuse or neglect, including, but not limited to: operation without adequate coolant
or lubricants; over fueling; over speeding; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in
or shutdown practices; unauthorized modifications of the engine. Komatsu is also not responsible for failures caused by incorrect fuel or by water,
dirt or other contaminants in the fuel. Komatsu is not responsible for non-engine repairs, “downtime” expense, related damage, fines, all business
costs or other losses resulting from a warrantable failure.

KOMATSU IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

This warranty, together with the express commercial warranties, are the sole warranties of Komatsu. THERE ARE NO OTHER
WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICUALR PURPOSE.

GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS

ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS (APPLICABLE AU CANADA SEULEMENT):

1. Produits garantis:
Komatsu America International Company, Komatsu Mining Systems Inc. et Komatsu Utility Corporation (collectivement Komatsu) produisent et/ou font la
mise en marché de produits portant les noms de marque Komatsu, Dresser, Dressta, Haulpak et Galion. Cette garantie sur les émissions s’applique à tous les
nouveaux moteurs portant le nom Komatsu, installés dans ces produits et utilisés au Canada dans des machines conçues pour utilisation industrielle non-
routière. Cette garantie s’applique seulement sur les moteurs produits à partir du 1er Janvier 2000. Cette garantie sera administrée par la distribution de
Komatsu au Canada .

2. Couverture:
Komatsu garantit à l’acheteur ultime et chaque acheteur subséquent que le moteur est conçu, construit et équipé en toute conformité, au moment de la vente
par Komatsu, avec toutes les Réglementations fédérales américaines sur les émissions applicables au moment de la fabrication et qu’il est exempt de défauts
de construction ou de matériaux qui auraient pour effet de contrevenir à ces réglementations en dedans de 5 ans ou 3000 heures d’opération, mesuré à partir
de la date de livraison du moteur au client ultime.

3. Limitations:
Les bris, autres que ceux résultant de défauts de matériaux ou de construction, ne sont pas couverts par cette Garantie. Komatsu n’est pas responsable pour
bris ou dommages résultant de ce que Komatsu détermine comme étant de l’abus ou négligence, incluant mais ne se limitant pas à: l’opération sans
lubrifiants ou agent refroidissants adéquats; la suralimentation d’essence; la survitesse; le manque d’entretien des systèmes de lubrification, de
refroidissement ou d’entrée; de pratiques non-propices d’entreposage, de mise en marche, de réchauffement, de conditionnement ou d’arrêt; les
modifications non-autorisées du moteur. De plus, Komatsu n’est pas responsable de bris causés par de l’essence inadéquate ou de l’eau, des saletés ou autres
contaminants dans l’essence. Komatsu n’est pas responsable des réparations non-reliées au moteur, des dépenses encourues suite aux temps d’arrêts, des
dommages relatifs, amendes, et de tout autre coût d’affaires ou autres pertes résultant d’un bris couvert par la garantie.

KOMATSU N’EST PAS RESPONSABLE DES INCIDENTS OU DOMMAGES CONSÉQUENTS.

Cette garantie, ainsi que les garanties expresses commerciales, sont les seules garanties de Komatsu. IL N’Y A AUCUNE AUTRE
GARANTIE, EXPRESSE OU SOUS -ENTENDUE, MARCHANDABLE OU PROPICE A UNE UTILISATION PARTICULIÈRE.

CEHQ000700 - Komatsu America International Company 12/99

 INFORMATION IMPORTANTE SUR LE MOTEUR AVERTISSEMENT
CE MOTEUR EST CONFORME AUX NORMES AMÉRICAINES DEL’EPA (ANNÉE DU DES BLESSURES PEUVENT RÉSULTER ET LA GARANTIE
MODÈLE) ET DE LA CALIFORNIE POUR LES MOTEURS LARGES NON-ROUTIERS A IGNI- S’ANNULER SI LES RPM DU TAUX D’ESSENCE OU L’ALTITUDE
TION PAR COMPRESSION. CE MOTEUR EST CERTIFIÉ POUR OPERATION À ESSENCE EXCÈDENT LES VALEURS MAXIMALES PUBLIÉES POUR CE
DIÉSEL. MODÈLE ET SON APPLICATION.

IMPORTANT ENGINE INFORMATION

THIS ENGINE CONFORMS TO YYYY MODEL YEAR U.S. EPA REGULATION AND THE CALIFORNIA
REGULATIONS LARGE NON ROAD COMPRESSION IGNITION ENGINES. THIS ENGINE IS CERTI-
FIED TO OPERATE ON DIESEL FUEL.
MODÈLE DU MOTEUR WARNING NO. SÉRIE
INJURY MAY RESULT AND WARRANTY IS VOIDED IF FUEL RATE RPM OR ALTITUDES EXCEED
PUBLISHED MAXIMUM VALUES FOR THIS MODEL AND APPLICATION.
FAMILLE DU MOTEUR ENGINE MODEL SERIAL NO. DÉPLACEMENT

SYSTÈME DE ENGINE FAMILY DISPLACEMENT LITERS

CONTROLE DES
ÉMISSIONS D’ÉCHAPPEMENT EXHAUST EMISSION
FIRING ORDER 1-5-3-6-2-4 LITRES
CONTROL SYSTEM
ADV. LOAD OUTPUT Kw ( HP) RPM
CHARGE DE SORTIE ADV. SÉQUENCE DE MISE À FEU
VALVE LASH IN. EX. FUEL RATE mm3/STROKE mm3/BATTEMENT
PORTÉE DE VALVE À FROID COLD (mm) AT ADV.
(mm) TAUX D’ESSENCE À ADV.

VITESSE STATIQUE IDLE SPEED RPM FAMILY EMISSION LIMIT

INITIAL INJECTION DEG. BTDC DATE OF MANUFACTURE LIMITE D’ÉMISSION DE
TIMING LA FAMILLE

RÉGLAGE DE L’ALLUMAGE - _____________________________________________ KOMATSU LTD.

INJECTION INITIALE MADE IN JAPAN DATE
DE FABRICATION

DEG. BTDC
KOMATSU LTÉE
FABRIQUÉ AU JAPON

ENGINE DATAPLATE - ENGLISH / FRENCH

OM1021.1 8/00 Introduction - Section 1
Page 1-1

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 should read and understand the materials in this manual before operating
the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions
should be understood and followed when operating or accomplishing repairs on 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.
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.
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 723 kg.m (100 ft.lbs.) torque. All torque specifications have ± 10%
tolerance unless otherwise specified.

A Product Identification plate is normally located on the truck frame upright in front of the left side front wheel and
designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W.
(Gross Vehicle Weight) 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 Gross Vehicle Weight (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 Gross Vehicle Weight (GVW) and
this means the TOTAL WEIGHT: the Empty Vehicle Weight + the fuel & lubricants + the payload.
To determine allowable payload:
Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories, body liners,
tailgates, etc.) and then weigh truck.
Record this value and subtract from the GVW rating. The result is the allowable payload.
NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable payload. To
maximize payload and to keep from exceeding the GVW rating, these accumulations should be removed as often as
practical.

Exceeding the allowable payload will reduce expected life of truck components.
Introduction - Section 1 OM1021.1 8/00
Page 1-2

This “ALERT” symbol is used with the signal words,

“CAUTION”, “DANGER”, and “WARNING” in this man-
ual to alert the reader to hazards arising from
improper operating and maintenance practices.

“DANGER” identifies a specific potential hazard

WHICH WILL RESULT
in either INJURY OR DEATH
if proper precautions are not taken.

“WARNING” identifies a specific potential hazard

WHICH MAY RESULT
in either INJURY OR DEATH
if proper precautions are not taken.

“CAUTION” is used for general reminders

of proper safety practices
OR
to direct the reader’s attention to avoid unsafe
or improper practices which may result
in damage to the equipment.
OM1021.1 8/00 Introduction - Section 1
Page 1-3

TABLE OF CONTENTS

SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION / PAGE

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 1
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
ALERTS Page - a description of the DANGER, WARNING, and CAUTION symbols used in this manual. . . . 1-2
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Truck Model Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
STANDARD CHARTS and TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2
Safety records of most organizations will show that the greatest percentage of accidents are caused by unsafe acts
of persons. The remainder are caused by unsafe mechanical or physical conditions. Report all unsafe conditions to
the proper authority. These safety rules are provided as a guide for the operator. However, local conditions and
regulations may add many more to this list.
GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Operating Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
PRECAUTIONS FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Before Carrying Out Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
WHEN REPAIRS ARE NECESSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Additional Job Site Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
WARNING, CAUTION, and Instruction Plates / Decals . . . . . . . . . . . . . . . . . . . . . 2-19 through 2-24

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3
This portion of the manual covers Identification, location,and operation of the controls, switches, and indicators in the
Operator’s Cab and use / function of these controls, switches, and indicators.
OPERATING INSTRUCTIONS
Preparing For Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Safety Is Thinking Ahead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
At The Truck - Ground Level Walk-Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
ENGINE START-UP SAFETY PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
AFTER ENGINE HAS STARTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
MACHINE OPERATION SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
HAULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Retarder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
PASSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
DUMPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
SAFE PARKING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Introduction - Section 1 OM1021.1 8/00
Page 1-4

TABLE OF CONTENTS (Continued)

SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION / PAGE
OPERATION (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3
OPERATOR CAB and CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
STEERING WHEEL AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
RETARDER CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
SERVICE BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
THROTTLE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS . . . . . . . . . . . . . . . . . . . . 3-16
RETARDING CAPACITY CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
RADIO SPEAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
“MOM” DISPLAY SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
WARNING ALARM BUZZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
CAB RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
AIR CLEANER VACUUM GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
PAYLOAD METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
WINDSHIELD WIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
CENTER CONSOLE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Transmission Range Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Shift Limiter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
F1 Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Hoist Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Brake Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
L.H. Window Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
R.H. Window Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Ash Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Passenger Seat w/Safety Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
INSTRUMENT PANEL AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Keyswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Emergency Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
R. H. Control/Indicator Panel (Pod) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Center Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
L. H. Control/Indicator Panel (Pod) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Ladder Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Back Up/Deck Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Electronic Display Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
R. H. CONTROL/INDICATOR PANEL (Figure 3-7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Discussion of items 1 - 10, Figure 3-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 — 27
CENTER DISPLAY PANEL (Figure 3-8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Discussion of items 1 - 29, Figure 3-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28— 30
L. H. CONTROL/INDICATOR PANEL (POD) (Figure 3-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Discussion of items 1 - 21, Figure 3-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31—3-34
REAR OF OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
CUMMINS ENGINE CENTRY FUEL SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . 3-36
Determining “FAULT” Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Exiting The Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
OM1021.1 8/00 Introduction - Section 1
Page 1-5

TABLE OF CONTENTS (Continued)

SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION / PAGE

OPERATION (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3

MESSAGES FOR OPERATION AND MAINTENANCE (“MOM”) . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Discussion of Screen Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 – 3-43
CENTER ELECTRONIC DISPLAY PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Discussion of Screen Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 – 3-44

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4
This portion of the manual pertains mainly to the periodic Lubrication and Service required to keep the truck operating
at its design potential. Routine lubrication and maintenance procedures are provided in this section. For major repairs,
refer to the appropriate section in the Truck Service Manual.
Refer to the engine manufacturer’s service manual when servicing the engine.

LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
10 HOUR (SHIFT) Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
250 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
500 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
1000 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
2000 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
5000 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
HYDRAULIC TANK SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
STEERING CIRCUIT FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
HYDRAULIC TANK BREATHER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
LINCOLN AUTOMATIC LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
System Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Pressure Reducer Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
24VDC Solid State Timer Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
24VDC Solid State Timer Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Injectors & Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Pump Cycle Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Preventive Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5
This portion of the manual covers major component descriptions and truck specifications.
Major Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6

This portion of the manual covers operation/maintenance of OPTIONAL EQUIPMENT.

PAYLOAD METER II (Refer to separate PAYLOAD METER II Index) . . . . . . . . . . . . . . . . . . . . . TC6-1

PAYLOAD METER II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 — 6-34
RADIO, AM/FM STEREO CASSETTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Introduction - Section 1 OM1021.1 8/00
Page 1-6

KOMATSU HD1500-5LC Truck

OM1021.1 8/00 Introduction - Section 1
Page 1-7

About This Manual

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 should read and understand the materials in this manual before operating the
truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions
should be understood and followed when operating or accomplishing repairs on the truck.

The front cover of this manual includes a Form Number. This Form No. 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:
DataKom
P.O. Box 240
Peoria, IL 61650-0240
(309)-672-7072 – FAX

This 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.

When searching for a specific area of interest, go first to the Table of Contents to locate the Section in which the
subject might generally be included. Then, go to that Section of the Table of Contents to find a Subject description
that most closely describes the specific area of interest to find a page number and go to that page.
Section Numbers and Page Numbers are located at the top, outside corner of the page.

At the top, inside corner of the page is a document (module) number. If there is ever a question regarding the
information in a particular Section, refer to the document (module) number, the manual Form No., and use the address
shown above to correspond. If there is a date (month/year) behind the document (module) number, that indicates the
latest revision date of that page.

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.

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.

When assembly instructions are provided without references to torque values, standard torque values should be
assumed. Standard torque requirements are shown in torque charts on the following pages of this section, and in the
General Information section of the truck service manual. Individual torques when provided in the text are in bold face
type, such as 723 kg.m (100 ft.lbs.) torque. All torque specifications have ± 10% tolerance unless otherwise specified.
Introduction - Section 1 OM1021.1 8/00
Page 1-8

NOTES
OM1021.2 Introduction - Section 1
Standard Charts and Tables Page 1-9

STANDARD TABLES
This manual provides dual dimensioning for many specifications. Metric units are specified first, with U.S. standard
units in parentheses. References throughout the manual to standard torques or other standard values will be to one
of the following Tables.
For values not shown in any of the charts or tables, standard conversion factors for most commonly used
measurements are provided in TABLES I and .
NOTE: Portions of this truck may be assembled with SAE (U.S.) hardware.
BE SURE TO REFER TO THE CORRECT TABLE!

INDEX OF TABLES
TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
TABLE I . . . . . . . COMMON CONVERSIONS TABLE I – COMMON CONVERSIONS
METRIC -to- ENGLISH . . . . . 1-9 METRIC -to- ENGLISH
TO CONVERT
MULTIPLY BY
TABLE II STANDARD TIGHTENING TORQUE FROM TO
. . . . . . . . For Capscrews and Nuts 1-10 millimeter (mm) inch – in. 0.0394
centimeter (cm) inch – in. 0.3937
TABLE III STANDARD TIGHTENING TORQUE
meter (m) foot – ft. 3.2808
. . . . . . . . . . . For Split Flange Bolts 1-10
meter (m) yard – yd. 1.0936
TABLE IV . . . . . . TIGHTENING TORQUE FOR kilometer (km) mile – mi. 0.6210
. . . Flared Tube And Hose Fittings 1-10 sq. centimeters (cm 2) sq. in. – in.2 0.1550
2
sq. centimeters (cm ) sq. ft. – ft.2 0.001
TABLE V . . TEMPERATURE CONVERSIONS 1-11 cu. centimeters (cm 3) cu. in. – in.3 0.061
TABLE VI . . . . . . . . TORQUE CONVERSIONS liters (l) cu. in. – in.3 61.02
3
. . . kilogram.meters To foot pounds 1-11 cu. meters (m ) cu. ft. – ft.3 35.314
liters (l) cu. ft. – ft.3 0.0353
TABLE VII . . . . . . . . TORQUE CONVERSIONS grams (g) ounce – oz. 0.0353
kilogram.meters To Newton.meters 1-11 milliliter (ml) fluid ounce – fl. oz. 0.0338
TABLE VIII . . . . . . PRESSURE CONVERSIONS kilogram (kg) pound (mass) 2.2046
. . . . . . . . . . . . kg/cm2 To (psi) 1-12 Newton (N) pound (force) – lbs. 0.2248
Newton.meters (N.m) kilogram.meters (kg.m) 0.102
TABLE IX . . . . . . PRESSURE CONVERSIONS Newton.meters (N.m) ft. lbs. (force) 0.7376
. . . . . . . . . . . . . kg/cm2 To kPa 1-12 kilogram.meters (kg.m) ft. lbs. (force) 7.2329
kilogram.meters (kg.m) Newton.meters (N.m) 9.807
TABLE X . . . . . PRESSURE CONVERSIONS
kilopascals (kPa) psi (pressure) 0.1450
. . . . . . . . . . . . . . . . . . psi To kPa 1-12
megapascals (MPa) psi (pressure) 145.038
SEALANTS AND ADHESIVES . . . . . . . . . . . . . 1-13 kilograms/cm 2 (kg/cm 2) psi (pressure) 14.2231
kilograms/cm 2 (kg/cm 2) kilopascals (kPa) 98.068
TABLE XI STANDARD TIGHTENING TORQUE
kilogram (kg) ton (short) 0.0011
. . . . For SAE Capscrews and Nuts 1-14
metric ton ton (short) 1.1023
TABLE XII . . . STANDARD ASSEMBLY TORQUE liters (l) quart – qt. 1.0567
. 12-Pt, Grade 9, Capscrews (SAE) 1-14 liters (l) gallon – gal. 0.2642
Watts HP (horsepower) 0.00134
TABLE XIII JIC Swivel Nuts Torque Chart (SAE) 1-15 kilowatts (kW) HP (horsepower) 1.3410
TABLE XIV . . . Pipe Thread Torque Chart (SAE) 1-15
TABLE XV . . . O-Ring Boss Torque Chart (SAE) 1-15
TABLE XVI O-Ring Face Seal Torque Cht (SAE) 1-15
TABLE XVII . . . . . . COMMON CONVERSIONS
ENGLISH -to- METRIC 1-16
Introduction - Section 1 OM1021.2
Page 1-10 Standard Charts and Tables

TABLE I
STANDARD TIGHTENING TORQUE FOR
METRIC HEX HEAD CAPSCREW AND NUT ASSEMBLY

Capscrew Thread Width Kilogram.meters Newton.meters Foot Pounds

Diameter Across Flat (kg.m) (N.m) (ft.lbs.)
(mm) (mm) Tolerances ± 10% Tolerances ± 10% Tolerances ± 10%
6 10 1.35 13.2 10
8 13 3.2 31.4 23
10 17 6.7 65.7 48
12 19 11.5 112 83
14 22 18.0 177 130
16 24 28.5 279 206
18 27 39.0 383 282
20 30 56.0 549 405
22 32 76.0 745 550
24 36 94.5 927 684
27 41 135 1320 975
30 46 175 1720 1266
33 50 225 2210 1630
36 55 280 2750 2025
39 60 335 3280 2420
This Table represents standard values only.
Do not use these values to replace torque values which are specified in the Service Manual instructions.

TABLE III
TIGHTENING TORQUE FOR SPLIT FLANGE BOLTS

Capscrew Thread Width Kilogram.meters Newton.meters Foot Pounds

Diameter Across Flat (kg.m) (N.m) (ft.lbs.)
(mm) (mm) Tolerances ± 10% Tolerances ± 10% Tolerances ± 10%
10 14 6.7 65.7 48
12 17 11.5 112 83
16 22 28.5 279 206
This Table represents standard values only.
Do not use these values to replace torque values which are specified in the Service Manual instructions.

TABLE IV
TIGHTENING TORQUE FOR FLARED TUBE AND HOSE FITTINGS

Thread Diameter Width Kilogram.meters Newton.meters Foot Pounds

of Nut Across Flat (kg.m) (N.m) (ft.lbs.)
(mm) (mm) Tolerances ± 10% Tolerances ± 10% Tolerances ± 10%
14 19 2.5 25 18
18 24 5 50 36
22 27 8 80 58
24 32 14 140 101
30 36 18 175 130
33 41 20 195 145
36 46 25 245 180
42 55 30 295 215
OM1021.2 Introduction - Section 1
Standard Charts and Tables Page 1-11

TABLE V TEMPERATURE CONVERSIONS

FORMULA: F° – 32 ÷ 1.8 = C° C° x 1.8 + 32 = F°
CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT
C° F° C° F° C° F°
121 250 482 63 145 293 4 40 104
118 245 473 60 140 284 2 35 95
116 240 464 57 135 275 –1 30 86
113 235 455 54 130 266 –4 25 77
110 230 446 52 125 257 –7 20 68
107 225 437 49 120 248 –9 15 59
104 220 428 46 115 239 – 12 10 50
102 215 419 43 110 230 – 15 5 41
99 210 410 41 105 221 – 18 0 32
96 205 401 38 100 212 – 21 –5 23
93 200 392 35 95 293 – 23 – 10 14
91 195 383 32 90 194 – 26 – 15 5
88 190 374 29 85 185 – 29 – 20 –4
85 185 365 27 80 176 – 32 – 25 – 13
82 180 356 24 75 167 – 34 – 30 – 22
79 175 347 21 70 158 – 37 – 35 – 31
77 170 338 18 65 149 – 40 – 40 – 40
74 165 329 15 60 140 – 43 – 45 – 49
71 160 320 13 55 131 – 46 – 50 – 58
68 155 311 10 50 122 – 48 – 55 – 67
66 150 302 7 45 113 – 51 – 60 – 76
NOTE: The numbers in the unmarked columns refer to temperature in either degrees Celsius (C°) or Fahrenheit, F°. Select a number in
this unmarked column and read to the left to convert to degrees Celsius (C°) or read to the right to convert to degrees Fahrenheit, F°.
If starting with a known temperature (either C° or F°), find that temperature in the marked column and read the converted temperature in
the center, unmarked column.

TABLE VI TORQUE CONVERSIONS

kilogram.meter - kg.m To Foot Pounds – (ft.lbs.)
1 kg.m = 7.233 ft.lbs.
kg.m 0 1 2 3 4 5 6 7 8 9
0 (ft. lbs.) 7.23 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.5 303.8 311.0 318.2 325.5 332.7 339.9 347.2 354.4
50 361.6 368.9 376.1 383.3 390.6 397.8 405.0 412.3 419.5 426.7
60 434.0 441.2 448.4 455.7 462.9 470.1 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

TABLE VII TORQUE CONVERSIONS

kilogram.meter - kg.m To Newton.meters (N.m)
1 kg.m = 9.807 N.m
kg.m 0 1 2 3 4 5 6 7 8 9
0 (N.m) 9.8 19.6 29.4 39.2 49.0 58.8 68.6 78.5 88.3
10 98.1 107.9 117.7 127.5 137.3 147.1 156.9 166.7 176.5 186.3
20 196.1 205.9 215.8 225.6 235.4 245.2 255.0 264.8 274.6 284.4
30 294.2 304.0 313.8 323.6 333.4 343.2 353.1 362.9 372.7 382.5
40 392.3 402.1 411.9 421.7 431.5 441.3 451.1 460.9 470.7 480.5
50 490.4 500.2 510.0 519.8 529.6 539.4 549.2 559.0 568.8 578.6
60 588.4 598.2 608.0 617.8 627.6 637.5 647.3 657.1 666.9 676.7
70 686.5 696.3 706.1 716.0 725.7 735.5 745.3 755.1 764.9 774.8
80 784.6 794.4 804.2 814.0 823.8 833.6 843.4 853.2 863.0 872.8
90 882.6 892.4 902.2 912.1 921.9 931.7 941.5 951.3 961.1 970.9
Introduction - Section 1 OM1021.2
Page 1-12 Standard Charts and Tables

TABLE VIII PRESSURE CONVERSIONS

kilograms/cm2 (kg/cm2) To pounds per sq. in. (psi)
1 kg/cm2 = 14.2231 psi
kg/cm2 0 1 2 3 4 5 6 7 8 9
0 (psi) 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 185.0 199.1 213.3 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.2 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.1 597.4 611.6 625.8 640.0 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.0 782.3 796.5 810.7 824.9 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 952.9 967.2 981.4
70 995.6 1009.8 1024.1 1038.3 1052.5 1066.7 1081.0 1095.2 1109.4 1123.6
80 1137.8 1152.1 1166.3 1180.5 1194.7 1209.0 1223.2 1237.4 1251.6 1265.9
90 1280.1 1294.3 1308.5 1322.7 1337.0 1351.2 1365.4 1379.6 1393.9 1408.1

TABLE IX PRESSURE CONVERSIONS

kilograms/cm2 (kg/cm2) To kilopascals (kPa)
1 kg/cm2 = 9.8068 kPa
kg/cm2 0 1 2 3 4 5 6 7 8 9
0 (kPa) 9.81 19.6 29.4 39.2 49.0 58.8 68.6 78.5 88.3
10 98.1 107.9 117.7 127.5 137.3 147.1 156.9 166.7 176.5 186.3
20 196.1 205.9 215.7 225.6 235.4 245,2 255.0 264.8 274.6 284.4
30 294.2 304.0 313.8 323.6 333.4 343.2 353.0 362.9 372.7 382.5
40 392.3 402.1 411.9 421.7 431.5 441.3 451.1 460.9 470.7 480.5
50 490.3 500.1 510.0 519.8 529.6 539.4 549.2 559.0 568.8 578.6
60 588.4 598.2 608.0 617.8 627.6 637.4 647.2 657.1 666.9 676.7
70 686.5 696.3 706.1 715.9 725.7 735.5 745.3 755.1 764.9 774.7
80 784.5 794.4 804.2 814.0 823.8 833.6 843.4 853.2 863.0 872.8
90 882.6 892.4 902.2 912.0 921.8 931.6 941.5 951.3 961.1 970.9

TABLE X PRESSURE CONVERSIONS

Pounds/sq. in. [psi] To kilopascals (kPa)
Formula: psi x 6.895 = kPa
PSI 0 1 2 3 4 5 6 7 8 9
0 (kPa) 6.895 13.79 20.68 27.58 34.47 41.37 48.26 55.16 62.05
10 68.95 75.84 82.74 89.63 96.53 103.42 110.32 117.21 124.1 131.0
20 137.9 144.8 151.7 158.6 165.5 172.4 179.3 186.2 193.1 200.0
30 206.8 213.7 220.6 227.5 234.4 241.3 248.2 255.1 262.0 268.9
40 275.8 282.7 289.6 296.5 303.4 310.3 317.2 324.1 331.0 337.9
50 344.7 351.6 358.5 365.4 372.3 379.2 386.1 393.0 399.9 406.8
60 413.7 420.6 427.5 434.4 441.3 448.2 455.1 462.0 468.9 475.8
70 482.6 489.5 496.4 503.3 510.2 517.1 524.0 530.9 537.8 544.7
80 551.6 558.5 565.4 572.3 579.2 586.1 593.0 599.9 606.8 613.7
90 620.5 627.4 634.3 641.2 648.1 655.0 661.9 668.8 675.7 682.6

NOTE: Tables such as Table VI, VII, VIII, IX, and X may be used as in the following example:
Example: Convert 955 kg.m to foot pounds (ft.lbs.).

1. Select Table VI. 4. Go to kg.m row 0, column 5; read 36.2

5 kg.m = 36.2 ft.lbs. Add to step 3.
2. Go to kg.m row 90, column 5; read 687.1
95 kg.m = 687.1 ft.lbs. 5. 950 + 5 kg.m = 6871 + 36.2 = 6907.2 ft.lbs.
955 kg.m = 6907.2 ft.lbs.
3. Multiply by 10:
950 kg.m = 6871 ft.lbs.
OM1021.2 Introduction - Section 1
Standard Charts and Tables Page 1-13

SEALANTS AND ADHESIVES

Nomenclature Code Three Bond Applications
LT-1A TB1521 Used to apply rubber pads, rubber gaskets and cork plugs.
Used to apply resin, rubber, metallic and non-metallic
LT-1B 1000B - 1000W
parts when a fast, strong seal is needed.
LT-2 TB1374 Preventing bolts, nuts and plugs from loosening and leaking oil.
Adhesives
LT-2A TB2411 Preventing bolts, nuts and plugs from loosening and leaking oil. (1)
LT-2B TB2403 Preventing bolts, nuts and plugs from loosening and leaking oil. (2)
LT-2C TB2430 or TB2440 Preventing bolts, nuts and plugs from loosening and leaking oil. (2)
LT-3 Main bond TB2001
Provides an airtight, electrically insulating seal. Used for aluminum surfaces.
Hardening agent TB2105
LG-1 TB1108B Used with gaskets and packings to increase sealing effect.
LG-3 TB1107 Heat-resistant gasket for precombustion chambers and exhaust piping.
Liquid Gasket Used by itself on mounting surfaces on the final drive and transmission
LG-4 TB1104
cases. Thickness after tightening: 0.07-0.08 mm (0.0027-0.0032 in)
Used by itself to seal grease fittings, tapered screw fittings and tapered
LG-5 TB1110
screw fittings in hydraulic circuits of less than 50 mm (2 in ) in diameter.
Antifriction Applied to bearings and taper shafts to facilitate press-fitting
LM-P —
compound and to prevent sticking, burning or rusting.
Applied to bearings, sliding parts and oil seals for lubrication,
Grease G2-LI —
rust prevention and facilitation of assembling work.
Vaseline — — Used for protecting battery electrode terminals from corrosion.

(1) Used for threaded areas (for example, plug, nipple, elbow etc.) which are removable and a pressure of 20 kg/cm2
(285 psi) or less.
(2) Used for threaded areas (for example, stud, etc.) which are not removable and a pressure of 20 kg/cm2 (285 psi)
or less.
NOTE:
These sealants and adhesives are manufactured and sold by Three Bond U.S.A., Inc.

For information, call or write to: PART NUMBERS

Three Bond U.S.A., Inc. Three Bond Komatsu
6184 Schumacher Park Drive TB1374 09940-00030
West Chester, OH 45069 TB1521 790-129-9030
Telephone: (513) 779-7300 TB1104 790-129-9020
Fax: (513) 779-7375 TB1108B 790-129-9010
Introduction - Section 1 OM1021.2
Page 1-14 Standard Charts and Tables

TABLE XI
STANDARD TORQUE CHART
SAE HEX HEAD CAPSCREW AND NUT ASSEMBLY
(LUBRICATED THREADS)
TOLERANCES ± 10%
GRADE 5 GRADE 8
CAPSCREW TORQUE – GRADE 5 TORQUE – GRADE 8 CAPSCREW TORQUE – GRADE 5 TORQUE – GRADE 8
THREAD THREAD
SIZE ft. lbs. kg.m N.m ft. lbs. kg.m N.m SIZE ft. lbs. kg.m N.m ft. lbs. kg.m N.m

1/4–20 7 0.97 9.5 10 1.38 13.6 3/4–16 235 32.5 319 335 46.3 454
1/4–28 8 1.11 10.8 11 1.52 14.9 7/8–9 350 48.4 475 500 69.2 678
5/16–18 15 2.07 20.3 21 2.90 28 7/8–14 375 51.9 508 530 73.3 719
5/16–24 16 2.21 22 22 3.04 30 1.0–8 525 72.6 712 750 103.7 1017
3/8–16 25 3.46 34 35 4.84 47 1.0–12 560 77.4 759 790 109.3 1071
3/8–24 30 4.15 41 40 5.5 54 1.0–14 570 78.8 773 800 110.6 1085
7/16–14 40 5.5 54 58 8.0 79 1 1/8–7 650 89.9 881 1050 145 1424
7/16–20 45 6.2 61 62 8.57 84 1 1/8–12 700 96.8 949 1140 158 1546
1/2–13 65 9 88 90 12.4 122 1 1/4–7 910 125.9 1234 1480 205 2007
1/2–20 70 9.7 95 95 13.1 129 1 1/4–12 975 134.8 1322 1580 219 2142
9/16–12 90 12.4 122 125 17.3 169 1 3/8–6 1200 166 1627 1940 268 2630
9/16–18 95 13.1 129 135 18.7 183 1 3/8–12 1310 181 1776 2120 293 2874
5/8–11 125 17.3 169 175 24.2 237 1 1/2–6 1580 219 2142 2560 354 3471
5/8–18 135 18.7 183 190 26.2 258 1 1/2–12 1700 235 2305 2770 383 3756
3/4–10 220 30.4 298 310 42.8 420
1 ft. lbs. = 0.138 kg.m = 1.356 N.m

TABLE XII – Standard Assembly TABLE XII - STANDARD ASSEMBLY TORQUE

for 12-Point, Grade 9, Capscrews
Torques For 12-Point, Grade 9,
CAPSCREW TORQUE TORQUE TORQUE
Capscrews (SAE) SIZE* ft. lbs. N.m kg.m
The following specifications appy to required assembly 0.250 - 20 12 16 1.7
0.312 - 18 24 33 3.3
torques for all 12-Point, Grade 9 (170,000 psi minimum
0.375 - 16 42 57 5.8
tensile), Capscrews.
0.438 - 14 70 95 9.7
• Capscrew threads and seats SHALL be lubricated 0.500 - 13 105 142 14.5
when assembled. 0.562 - 12 150 203 20.7
0.625 - 11 205 278 28.3
Unless instructions specifically recommend oth-
0.750 - 10 360 488 49.7
erwise, these standard torque values are to be
0.875 - 9 575 780 79.4
used with simple lithium base chassis grease
1.000 - 8 860 1166 119
(multi-purpose EP NLGI) or a rust- preventive 1.000 - 12 915 1240 126
grease (see list, this page) on the threads. 1.125 - 7 1230 1670 170
1.125 - 12 1330 1800 184
• Torques are calculated to give a clamping force 1.250 - 7 1715 2325 237
of approximately 75% of proof load. 1.250 - 12 1840 2495 254
• The maximum torque tolerance shall be ± 10% of 1.375 - 6 2270 3080 313
the torque value shown. 1.375 - 12 2475 3355 342
1.500 - 6 2980 4040 411
1.500 - 12 3225 4375 445
* Shank Diameter (in.) - Threads per in.
This Table represents standard values only.
Do not use these values to replace torque values which are
specified in assembly instructions.
OM1021.2 Introduction - Section 1
Standard Charts and Tables Page 1-15

TABLE XIII TABLE XV

TORQUE CHART FOR JIC 37° SWIVEL NUTS TORQUE CHART FOR
WITH OR WITHOUT O-RING SEAL O-RING BOSS FITTINGS
SIZE TUBE SIZE THREADS TORQUE SIZE TUBE SIZE THREADS TORQUE
CODE (O.D.) UNF – 2B FT. LBS. CODE (O.D.) UNF – 2B FT. LBS.
–2 0.125 0.312–24 4± 1 –2 0.125 0.312–24 4± 2
–3 0.188 0.375–24 8± 3 –3 0.188 0.375–24 5± 2
–4 0.250 0.438–20 12 ± 3 –4 0.250 0.438–20 8± 3
–5 0.312 0.500–20 15 ± 3 –5 0.312 0.500–20 10 ± 3
–6 0.375 0.562–18 18 ± 5 –6 0.375 0.562–18 13 ± 3
–8 0.500 0.750–16 30 ± 5 –8 0.500 0.750–16 24 ± 5
– 10 0.625 0.875–14 40 ± 5 – 10 0.625 0.875–14 32 ± 5
– 12 0.750 1.062–12 55 ± 5 – 12 0.750 1.062–12 48 ± 5
– 14 0.875 1.188–12 65 ± 5 – 14 0.875 1.188–12 54 ± 5
– 16 1.000 1.312–12 80 ± 5 – 16 1.000 1.312–12 72 ± 5
– 20 1.250 1.625–12 100 ± 10 – 20 1.250 1.625–12 80 ± 5
– 24 1.500 1.875–12 120 ± 10 – 24 1.500 1.875–12 80 ± 5
– 32 2.000 2.500–12 230 ± 20 – 32 2.000 2.500–12 96 ± 10

TABLE XIV TABLE XVI

TORQUE CHART FOR TORQUE CHART FOR
PIPE THREAD FITTINGS O-RING FACE SEAL FITTINGS
WITH WITHOUT SIZE TUBE SIZE THREADS TORQUE
SIZE PIPE THREAD
SEALANT SEALANT CODE (O.D.) UNF – 2B FT. LBS.
CODE SIZE
FT. LBS. FT. LBS. –4 0.250 0.438–20 11 ± 1
–2 0.125–27 15 ± 3 20 ± 5 –6 0.375 0.562–18 18 ± 2
–4 0.250–18 20 ± 5 25 ± 5 –8 0.500 0.750–16 35 ± 4
–6 0.375–18 25 ± 5 35 ± 5 – 10 0.625 0.875–14 51 ± 5
–8 0.500–14 35 ± 5 45 ± 5 – 12 0.750 1.062–12 71 ± 7
– 12 0.750–14 45 ± 5 55 ± 5 – 16 1.000 1.312–12 98 ± 6
– 16 1.000–11.50 55 ± 5 65 ± 5 – 20 1.250 1.625–12 132 ± 7
– 20 1.250–11.50 70 ± 5 80 ± 5 – 24 1.500 1.875–12 165 ± 15
– 24 1.500–11.50 80 ± 5 95 ± 10
– 32 2.000–11.50 95 ± 10 120 ± 10
Introduction - Section 1 OM1021.2
Page 1-16 Standard Charts and Tables

TABLE XVII – COMMON CONVERSIONS

ENGLISH -to- METRIC
TO CONVERT MULTIPLY
FROM TO BY
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. kilometer (km) 1.61
sq. in. – in.2 sq. centimeters (cm 2) 6.45
sq. ft. – ft.2 sq. centimeters (cm 2) 929
3
cu. in. – in. cu. centimeters (cm 3) 16.39
cu. in. – in.3 liters (l) 0.016
cu. ft. – ft.3 cu. meters (m 3) 0.028
cu. ft. – ft.3 liters (l) 28.3
ounce – oz. kilogram (kg) 0.028
fluid ounce – fl. oz. milliliter (ml) 29.573
pound (mass) kilogram (kg) 0.454
pound (force) – lbs. Newton (N) 4.448
in. lbs. (force) Newton.meters (N.m) 0.113
ft. lbs. (force) Newton.meters (N.m) 1.356
ft. lbs. (force) kilogram.meters (kg.m) 0.138
kilogram.meters (kg.m) Newton.meters (N.m) 9.807
psi (pressure) kilopascals (kPa) 6.895
psi (pressure) megapascals (MPa) 0.007
psi (pressure) kilograms/cm 2 (kg/cm 2) 0.0704
ton (short) kilogram (kg) 907.2
ton (short) metric ton 0.907
quart – qt. liters (l) 0.946
gallon – gal. liters (l) 3.785
HP (horsepower) Watts 745.7
HP (horsepower) kilowatts (kW) 0.745
OM2022.1 8/00 Safety - Section 2
General Safety Page 2-1

GENERAL SAFETY

This safety section also contains precautions for optional equipment and attachments.

Read and follow all safety precautions. Failure to do so may

result in serious injury or death.

SAFETY RULES
• ONLY trained and authorized personnel can operate and maintain the machine.
• Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.
• When working with another operator or a person on worksite traffic duty, be sure all personnel understand all
hand signals that are to be used.

SAFETY FEATURES
• Be sure all guards and covers are in their proper position. Have guards and covers repaired if damaged.
(See Walk-Around Inspection, Operating Instructions - Section 3)
• Learn the proper use of safety features such as safety locks, safety pins, and seat belts, and use these safety
features properly.
• NEVER remove any safety features. ALWAYS keep them in good operating condition.
• Improper use of safety features could result in serious bodily injury or death.

CLOTHING AND PERSONAL PROTECTIVE ITEMS

• Avoid loose clothing, jewelry, and loose long hair. They can catch on controls or in moving parts and cause
serious injury or death. Also, do not wear oily clothes because they are
flammable.
• Wear a hard hat, safety glasses, safety shoes, mask or gloves when
operating or maintaining the machine. Always wear safety goggles, hard
hat and heavy gloves if your job involves scattering metal chips or minute
materials— this is so particularly when driving pins with a hammer and
when cleaning the air cleaner element with compressed air. Check also
that there is no one near the machine.

UNAUTHORIZED MODIFICATION
• Any modification made without authorization from Komatsu can create hazards.
• Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injury
or damage caused by any unauthorized modification.
Safety - Section 2 OM2022.1 8/00
Page 2-2 General Safety

STANDING UP FROM THE SEAT

• To prevent any accident occurring if you should touch any control lever that is not locked, always carry out the
following before standing up from the operator’s seat.
• Place the gear shift lever at neutral and set the parking lever to the PARKING position.
• Lower the dump body, set the dump lever to the HOLD position, then apply the lock.
• Stop the engine. When leaving the machine, always lock everything. Always remember to take the key with you.
If the machine should suddenly move or move in an unexpected way, this may result in serious bodily injury or
death.

MOUNTING AND DISMOUNTING

• NEVER jump on or off the machine. NEVER get on or off a moving machine.
• When getting on or off the machine, face the machine and use the handhold and steps.
• Never hold any control levers when getting on or off the machine.
• Always maintain three-point contact with the handholds and steps to ensure that you support yourself.
• When bringing tools to the operator’s compartment, always pass them by hand or pull them up by rope.
• If there is any oil, grease, or mud on the handholds or steps, wipe it off immediately. Always keep these parts
clean. Repair any damage and tighten any loose bolts.
• Use the handrails and steps marked by arrows in the diagram below when getting on or off the machine.
A: For use when getting on or off the machine from the left door.
B: For use when getting on or off the machine from the engine hood or right door.

FIRE PREVENTION FOR FUEL AND OIL

Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly FLAMMABLE and can be HAZARDOUS.
• Keep flame away from flammable fluids.
• Stop the engine and do not smoke when refueling.
• Tighten all fuel and oil tank caps securely.
• Refueling and oiling should be made in well ventilated areas.
• Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.
OM2022.1 8/00 Safety - Section 2
General Safety Page 2-3

PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES

• Immediately after operations, the engine cooling water, engine oil, differential and final drive case oil, and
hydraulic oil are at high temperature and are under pressure. If the cap is removed or the oil or water is drained
or the filters are replaced, there is danger of serious burns. Always wait for the temperature to go down, and carry
out the operation according to the specified procedure.
• To prevent hot water from spurting out:
1) Stop the engine.
2) Wait for the water temperature to go down.
3) Turn the cap slowly to release the pressure before removing the cap.
• To prevent hot oil from spurting out:
1) Stop the engine.
2) Wait for the oil temperature to go down.
3) Turn the cap slowly to release the pressure before removing the cap.

ASBESTOS DUST HAZARD PREVENTION

Asbestos dust can be HAZARDOUS to your health if it is inhaled.
If you handle materials containing asbestos fibers, follow these guidelines as given
below:
• NEVER use compressed air for cleaning.
• Use water for cleaning to keep down the dust.
• Operate the machine with the wind to your back, whenever possible.
• Use an approved respirator if necessary.

PREVENTION OF INJURY BY WORK EQUIPMENT

• Never enter or put your hand or arm or any other part of your body between movable parts such as the dump
body and chassis or cylinders. If the work equipment is operated, the clearance will change and this may lead
to serious bodily injury or death.

FIRE EXTINGUISHER AND FIRST AID KIT

• Be sure fire extinguishers have been provided and know how to use them.

• Provide a first aid kit at the storage point.

• Know what to do in the event of a fire.
• Be sure you know the phone numbers of persons you should contact in case of
an emergency.
Safety - Section 2 OM2022.1 8/00
Page 2-4 General Safety

PRECAUTIONS WHEN USING ROPS

• If ROPS is installed, the ROPS must never be removed when operating the machine.
• The ROPS is installed to protect the operator if the machine should roll over. If is designed not only to support
the load if the machine should roll over, but also to absorb the impact energy.
• The Komatsu ROPS fulfills all of the regulations and standards for all countries, but if it is rebuilt without
authorization or is damaged when the machine rolls over, the strength will drop and it will not be able to fulfill its
function properly. It can only display its performance if it is repaired or modified in the specified way.
• When modifying or repairing the ROPS, always contact your Komatsu distributor.
• Even if the ROPS is installed, it cannot show its full effect if the operator does not fasten the seat belt properly.
Always fasten the seat belt when operating.

PRECAUTIONS FOR ATTACHMENTS

• When installing and using an optional attachment, read the instruction manual for the attachment and the
information related to attachments in this manual.
• Do not use attachments that are not authorized by Komatsu or your Komatsu distributor. Use of unauthorized
attachments could create a safety problem and adversely affect the proper operation and useful life of the
machine.
• Any injuries, accidents, and product failures resulting from the use of unauthorized attachments will not be the
responsibility of Komatsu.
OM2022.1 8/00 Safety - Section 2
General Safety Page 2-5

PRECAUTIONS DURING OPERATION

BEFORE STARTING ENGINE

SAFETY AT WORKSITE
• Before starting the engine, thoroughly check the area for any unusual conditions that could be dangerous.
• Examine the road surface in the jobsite and determine the best and safest method of operation.
• Choose an area where the ground is as horizontal and firm as possible before carrying out the operation.
• If you need to operate on a road, protect pedestrians and cars by designating a person for worksite traffic duty
or by installing fences around the worksite.
• Check the river bed condition, and depth and flow of water before crossing shallow parts of river. NEVER be in
water which is in excess of the permissible water depth.
• The operator must check personally the work position, roads to be used, and existence of obstacles before starting
operations.
• Always determine the travel roads in the worksite and maintain them so that it is always safe for the machines
to travel.

FIRE PREVENTION
• Thoroughly remove wood chips, leaves, paper and other flammable things accumulated in the engine compart-
ment. They could cause a fire.

• Check fuel, lubrication, and hydraulic systems for leaks. Have any leaks
repaired. Wipe up any excess oil, fuel or other flammable fluids.
• Be sure a fire extinguisher is present and working.
• Do not operate the machine near any flame.

IN OPERATOR’S CAB
• Do not leave tools or spare parts lying around in the operator’s compartment. They may damage or break the
control levers or switches. Always put them in the tool box on the right side of the machine.
• Keep the cab floor, controls, steps and handrails free of oil, grease, snow, and excess dirt.
• Check the seat belt, buckle and hardware for damage or wear. Replace any worn or damaged parts. Always use
seat belts when operating your machine.

VENTILATION FOR ENCLOSED AREAS

• If it is necessary to start the engine within an enclosed area, provide adequate ventilation.
Exhaust fumes from the engine can KILL.
Safety - Section 2 OM2022.1 8/00
Page 2-6 General Safety

KEEP MIRRORS, WINDOWS, AND LIGHTS CLEAN

• Remove any dirt from the surface of the windows or lights to ensure good visibility.
• Adjust the rear view mirror to a position where the operator can see best from the operator’s seat, and keep the
surface of the mirror clean. If any glass should break, replace it with a new part.
• Check that the machine is equipped with the head lamps and working lamps needed for the operating conditions.
Check that all the lamps light up properly.
OM2022.1 8/00 Safety - Section 2
General Safety Page 2-7

OPERATING MACHINE

WHEN STARTING ENGINE

• Walk around your machine again just before mounting it, checking for people and objects that might be in the
way.
• NEVER start the engine if a warning tag has been attached to the control.
• When starting the engine, sound the horn as an alert.
• Start and operate the machine only while seated.
• Do not allow any person other than the operator in the operator’s compartment or any other place on the machine.
• For machines equipped with a back-up alarm buzzer, check that the alarm buzzer works properly.

CHECK WHEN TRAVELING IN REVERSE

Before operating the machine or work equipment, do as follows:
• Sound the horn to warn people in the area.
• Check that there is no one near the machine. Be particularly careful to check
behind the machine.
• If necessary, designate a person to check the safety. This is particularly
necessary when traveling in reverse.
• When operating in areas that may be hazardous or have poor visibility,
designate a person to direct worksite traffic.
• Do not allow any one to enter the line of travel of the machine. This rule must
be strictly observed even on machines equipped with a back-up alarm or rear view mirror.

TRAVELING
• When traveling on rough ground, travel at low speed. When changing direction, avoid turning suddenly.
• Lower the dump body and set the dump lever to the FLOAT position when traveling.
• If the engine should stop when the machine is traveling, the steering wheel will not work, and it will be dangerous
to drive the machine. Apply the brakes immediately and stop the machine.

TRAVELING ON SLOPES
• Traveling on slopes could result in the machine tipping over or slipping.
• Do not change direction on slopes. To ensure safety, go down to level ground before turning.
• Do not travel up and down on grass, fallen leaves, or wet steel plates. These materials may make the machine
slip on even the slightest slope. Take all possible steps to avoid traveling sideways, and always keep the travel
speed low.
• When traveling downhill, use the retarder brake to reduce speed. Do not turn the steering wheel suddenly. Do
not use the foot brake except in an emergency.
• If the engine should stop on a slope, apply the brakes fully and apply the parking brake, also, to stop the machine.
Safety - Section 2 OM2022.1 8/00
Page 2-8 General Safety

ENSURE GOOD VISIBILITY

• When working in dark places, install working lamps and head lamps, and set up lighting in the work area if
necessary.
• Stop operations if the visibility is poor, such as in mist, snow, or rain, and wait for the weather to improve to a
condition that allows the operation to be carried out safely.

OPERATE CAREFULLY ON SNOW

• When working on snowy or icy roads, there is danger that the machine may slip to the side on even the slightest
slope, so always travel slowly and avoid sudden starting, turning, or stopping.
• Be extremely careful when carrying out snow-clearing operations. The road shoulder and other objects are buried
in the snow and cannot be seen.
• When traveling on snow-covered roads, always install tire chains.

AVOID DAMAGE TO DUMP BODY

• When working in tunnels, on bridges, under electric cables, or when entering a parking place or any other place
where there are height limits, always drive extremely carefully and lower the dump body completely before driving
the machine.

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

• Going close to high-voltage cables can cause electric shock. Always maintain the safe distance given below
between the machine and the electric cable.

Voltage Min. Safety Distance

6.6 kV 3m 10 ft
33.0 kV 4m 14 ft
66.0 kV 5m 17 ft
154.0 kV 8m 27 ft
275.0 kV 10 m 33 ft

• The following actions are effective in preventing accidents:

1) Wear shoes with rubber or leather soles.
2) Use a signalman to give warning if the machine approaches too close to the electric cable.
• If the work equipment should touch the electric cable, the operator should not leave the operator’s compartment.
• When carrying out operations near high voltage cables, do not let anyone come close to the machine.
• Check with the electricity company about the voltage of the cables before starting operations.
OM2022.1 8/00 Safety - Section 2
General Safety Page 2-9

WHEN DUMPING
• Before starting the dumping operation, check that there is no person or object behind the machine.
• Stop the machine in the correct position, and check again that there is no person or object behind the machine.
Give the determined signal, then slowly operate the dump body. If necessary, use blocks for the wheels or position
a flagman.
• When carrying out dumping operations on slopes, the machine stability will become poor and there is danger
that it may tip over. Always carry out such operations extremely carefully.
• Do not travel with the dump body raised.

WORKING ON LOOSE GROUND

• Avoid operating your machine too close to the edge of cliffs, overhangs, and deep ditches. If these areas collapse,
your machine could fall or tip over and result in serious injury or death. Remember that the soil after heavy rain
or blasting is weakened in these areas.
• Earth laid on the ground and the soil near ditches are loose. They can collapse under the weight or vibration of
your machine.
• When operating in places where there is danger of falling rocks or danger of the machine turning over, always
install ROPS and a seat belt.

WHEN LOADING
• Check that the surrounding area is safe, stop the machine in the correct loading position, then load the body
uniformly.
• Do not leave the operator’s seat during the loading operation.

PARKING THE MACHINE

• Choose a horizontal road surface to park the machine. If the machine has to be parked on a slope, always put
blocks under all the wheels to prevent the machine from moving.
• When parking on public roads, provide fences and signs, such as flags or lights, on the machine to warn
pedestrians and other vehicles. Be sure that the machine, flags, or lights do not obstruct the traffic.
• Before leaving the machine, lower the dump body fully, set the parking lever to the PARKING position, stop the
engine, then lock everything. Always take the key with you.
Safety - Section 2 OM2022.1 8/00
Page 2-10 General Safety

BATTERY

BATTERY HAZARD PREVENTION

• Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid
on yourself, immediately flush the area with water.
• Battery acid could cause blindness if splashed into the eyes. If acid gets into the eyes, flush them immediately
with large quantities of water and see a doctor at once.
• If you accidentally drink acid, drink a large quantity of water or milk, beaten egg or vegetable oil. Call a doctor or
poison prevention center immediately.
• When working with batteries ALWAYS wear safety glasses or goggles.
• Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited with a small spark of
flame.
• Before working with batteries, stop the engine and turn the starting switch to the OFF position.
• Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as tools, across
the terminals.
• When removing or installing, check which is the positive (+) terminal and negative (-) terminal.
• Tighten the battery cap securely.
• Tighten the battery terminals securely. Loosened terminals can generate sparks and lead to an explosion.

STARTING WITH BOOSTER CABLES

• ALWAYS wear safety glasses or goggles when starting the machine with booster cables.
• When starting from another machine, do not allow the two machines to touch.
• Be sure to connect the positive (+) cable first when installing the booster cables. Disconnect the ground or negative
(-) cable first when removing them.
• If any tool touches between the positive (+) terminal and the chassis, it will cause sparks. This is dangerous, so
be sure to work carefully.
• Connect the batteries in parallel: positive to positive and negative to negative.
• When connecting the ground cable to the frame of the machine to be started, be sure to connect it as far as
possible from the battery.
OM2022.1 8/00 Safety - Section 2
General Safety Page 2-11

TOWING

WHEN TOWING, FIX WIRE TO HOOK

• Towing in the wrong way may lead to serious personal injury or damage.
• When using another machine to tow this machine, use a wire rope with ample strength for the weight of this
machine.
• Never tow a machine on a slope.
• Do not use any towing rope that has kinks or is twisted.

• Do not stand astride the towing cable or wire rope.

• When connecting a machine that is to be towed, do not let any one come
between the towing machine and the machine that is being towed.
• Set the coupling of the machine being towed in a straight line with the towing
portion of the machine, and secure it in position.

(For towing method, see Section 3, “Operating Instructions”, page 3-12.)

Safety - Section 2 OM2022.1 8/00
Page 2-12 General Safety

PRECAUTIONS FOR MAINTENANCE

BEFORE CARRYING OUT MAINTENANCE

WARNING TAG
• If others start the engine or operate the controls while you are performing service or lubrication, you could suffer
serious injury or death.
• ALWAYS attach the WARNING TAG to the control lever in the operator’s cab to alert others that you are working
on the machine. Attach additional warning tags around the machine, if necessary.
• These tags are available from your Komatsu distributor. (Part No. 09963-03000)

PROPER TOOLS
• Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools
could cause personal injury.

PERIODIC REPLACEMENT OF CRITICAL PARTS

• Periodically replace parts used to insure safety or prevent accident. (See “PERIODIC REPLACEMENT OF
COMPONENT PARTS FOR SAFETY DEVICES”, Section 4.)
• Replace these components periodically with new ones, regardless of whether or not they appear to be defective.
These components deteriorate over time.
• Replace or repair any such components if any defect is found, even though they have not reached the time
specified.

STOPPING THE ENGINE BEFORE SERVICE

• When carrying out inspection or maintenance, always stop the machine on firm flat ground, lower the dump body,
then stop the engine.
• If the engine must be run during service, such as when cleaning the radiator, always set the transmission lever
to the neutral position and the parking brake lever to the PARKING position. Always carry out the work with two
people. One person should sit on the operator’s seat so that he can stop the engine if necessary. NEVER move
any controls you do not need to operate.
• When servicing the machine, be careful not to touch any moving part or get your clothes caught.
• Put blocks under the wheels.
• When carrying out service with the dump body raised, always place the dump lever at the HOLD position, apply
the lock, and insert the safety pins securely.
OM2022.1 8/00 Safety - Section 2
General Safety Page 2-13

DURING MAINTENANCE

PERSONNEL
• Only authorized personnel can service and repair the machine. Extra precaution should be used when grinding,
welding, and using a sledge-hammer.

ATTACHMENTS
• Place attachments that have been removed from the machine in a safe place so that they
do not fall. If they fall on you or others, serious injury could result.

WORK UNDER THE MACHINE

• Always lower all movable work equipment to the ground or to their lowest position before
performing service or repairs under the machine.
• Always block the tires of the machine securely.
• Never work under the machine if the machine is poorly supported.

KEEP THE MACHINE CLEAN

• Spilled oil or grease, or scattered tools or broken pieces are dangerous because
they may cause you to slip or trip.
Always keep your machine clean and tidy.
• If water gets into the electrical system, there is danger that the machine may not
move or may move unexpectedly.
Do not use water or steam to clean the sensors, connectors, or the inside of the
operator’s compartment.

RULES TO FOLLOW WHEN ADDING FUEL OR OIL

• Spilled fuel and oil may cause you to slip, so always wipe it up immediately.
• Always tighten the cap of the fuel and oil fillers securely.
• Never use fuel for washing any parts.
• Always add fuel and oil in a well-ventilated place.
Safety - Section 2 OM2022.1 8/00
Page 2-14 General Safety

RADIATOR WATER LEVEL

• If it is necessary to add water to the radiator, stop the engine and allow the engine
and radiator to cool down before adding the water.
• Slowly loosen the cap to relieve pressure before removing the cap.

USE OF LIGHTING

When checking fuel, oil, coolant, or battery electrolyte, always use lighting with
anti-explosion specifications. If such lighting equipment is not used, there is
danger or explosion.

PRECAUTIONS WITH BATTERY

• When repairing the electrical system or when carrying out electrical welding,
remove the negative (-) terminal of the battery to stop the flow of current.

HANDLING HIGH-PRESSURE HOSES

• Do not bend high-pressure hoses or hit them with hard objects. Do not use any bent or cracked piping, tubes or
hoses. They may burst during use.
• Always repair any loose or broken fuel hoses or oil hoses. If fuel or oil leaks, it may cause a fire.

PRECAUTIONS WITH HIGH PRESSURE OIL

• Do not forget that the work equipment circuits are always under pressure.
• Do not add oil, drain oil, or carry out maintenance or inspection before completely releasing the internal pressure.
• If oil is leaking under high pressure from small holes, it is dangerous if the jet of high-pressure oil hits your skin
or enters your eyes. Always wear safety glasses and thick gloves, and use a piece of cardboard or a sheet of
wood to check for oil leakage.
• If you are hit by a jet of high-pressure oil, consult a doctor immediately for medical attention.
OM2022.1 8/00 Safety - Section 2
General Safety Page 2-15

PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE

• Immediately after stopping operations, the engine cooling water and oil at all parts
are at high temperature and under high pressure.
In this condition, if the cap is removed, or the oil or water are drained, or the filters
are replaced, it may result in burns or other injury. Wait for the temperature to go
down, then carry out the inspection and maintenance in accordance with the
procedures given in this manual.

ROTATING FAN AND BELT

• Keep away from rotating parts and be careful not to let anything get caught in them.
• If your body or tools touch the fan blades or fan belt, they may be cut off or sent flying,
so never touch any rotating parts.

WASTE MATERIALS

• Never dump waste oil in a sewer system, rivers, etc.

• Always put oil drained from your machine in containers. Never drain oil directly
on the ground.
• Obey appropriate laws and regulations when disposing of harmful objects such
as oil, fuel, coolant, solvent, filters, batteries, and others.
Safety - Section 2 OM2022.1 8/00
Page 2-16 General Safety

TIRES

HANDLING TIRES
If tires are not used under the specified conditions, they may overheat and burst or be cut and burst by sharp stones
on rough road surfaces. This may lead to serious injury or damage.
To maintain safety, always keep to the following conditions:
• Inflate the tires to the specified pressure. Abnormal heat is generated particularly when the inflation pressure is
too low.
• Use the specified tires.

The values given in this manual for the tire inflation pressure and permissible speed are general values. The actual
values may differ depending on the type of tire and the condition under which they are used. For details, please
contact your Komatsu distributor or tire maker.
If the tires become hot, a flammable gas is produced, and this may ignite. It is particularly dangerous if the tires
become overheated when the tires are under pressure. If the gas generated inside the tire ignites, the internal pressure
will suddenly rise, and the tire will explode, and this may lead to serious personal injury. Explosions differ from
punctures or tire bursts, because the destructive force is extremely large. Therefore, the
following operations are strictly prohibited when the tire is under high internal pressure:
• Welding the rim
• Building fires or carrying out welding near the wheel or tire.

If you do not understand the proper procedure for carrying out maintenance or replacement of the wheel or tire, and
you use the wrong method, the wheel or tire may burst and cause serious injury or damage. When carrying out such
maintenance, please consult your Komatsu distributor or tire maker.

STORING TIRES AFTER REMOVAL

• As a basic rule, store the tires in a warehouse which unauthorized persons cannot enter. If the tires are stored
outside, always erect a fence around the tires and put up “No Entry” and other warning signs that even young
children can understand.
• Stand the tire on level ground, and block it securely so that it cannot roll or fall over.
• If the tire should fall over, get out of the way quickly. The tires for construction equipment are extremely heavy,
so trying to hold the tire may lead to serious injury.
OM2022.1 8/00 Safety - Section 2
General Safety Page 2-17

WHEN REPAIRS ARE NECESSARY

1. Only qualified maintenance personnel who understand the systems being repaired should accomplish repairs.
2. Many components on the truck are large and heavy. Insure that lifting equipment - hoists, slings, chains, lifting
eyes - are of adequate capacity to handle the lift.
3. DO NOT WORK under a suspended load. Do not work under raised body unless body safety cables, props, or
pins are in place to hold the body in up position.
4. Do not repair or service truck while engine is running, except when adjustments can only be made under such
conditions. Keep a safe distance from moving parts.
5. When servicing any air conditioning system with refrigerant, wear a face shield and cold resistant gloves for
protection against freezing. Be certain to follow all current regulations for handling and recycling refrigerants.
6. Follow package directions carefully when using cleaning solvents.
7. If an auxiliary battery assist is needed, first use one cable to connect the 24V positive (+) post of the disabled
truck batteries to the 24V positive (+) post of the auxiliary assist. Use second cable to connect the 24V negative
(-) post of the auxililary assist battery to a frame ground (-) on the disabled truck away from the battery.
8. Always disconnect the positive and negative battery cables of the vehicle before doing any welding on the unit.
Failure to do so may seriously damage the battery and electrical equipment. Disconnect battery charging
alternator lead wire and isolate transmission electronic control components before making welding repairs.
Always fasten the welding machine ground (-) lead to the piece being welded; grounding clamp MUST BE
ATTACHED AS NEAR AS POSSIBLE to the weld area. Never allow welding current to pass through ball
bearings, roller bearings, suspensions, or hydraulic cylinders. Always avoid laying welding cables over or near
the vehicle electrical harnesses. Welding voltage could be induced into the electrical harness and possibly cause
damage to components.
9. If truck is to be towed for any reason, use a rigid tow bar. Check truck cab for decal recommending special towing
precautions. (Also refer to Towing Procedure in OPERATING INSTRUCTIONS.)
10. Drain, clean and ventilate fuel tanks and/or hydraulic tanks before making any welding repairs.
Any operating fluid, such as hydraulic oil or brake fluid escaping under pres-
sure, can have sufficient force to enter a person’s body by penetrating the skin.
Serious injury and possibly death may result if proper medical treatment by a
physician familiar with this injury is not received immediately.

11. Relieve pressure in lines or hoses before making any disconnects.

12. After adjustments or repairs, replace all shields, screens and clamps.
13. Tire Care:
Do not stand in front of rim and locking ring when inflating tire mounted on the
machine. Observers should not be permitted in the area and should be kept
away from the side of such tires.

Do not weld or apply heat on the rim assembly with the tire mounted on the rim. Resulting gases inside the
tire may ignite, causing explosion of tire and rim.

14. Only a qualified operator or experienced maintenance personnel who are also qualified in operation should move
the truck under its own power in the repair facility or during road testing after repairs are complete.
Safety - Section 2 OM2022.1 8/00
Page 2-18 General Safety

ADDITIONAL JOB SITE RULES

Use this space to add any ADDITIONAL Job Site Rules not covered in any of the previous discussions.
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OM2022.2 8/00 Safety - Section 2
Warnings and Cautions Page 2-19

WARNINGS AND CAUTIONS

The following pages give an explanation of the Warning, Caution, and Service Instruction plates and decals attached
to the HD1500-5 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.
The plates and decals must be kept clean and legible. If any decal or plate becomes unable to be read or damaged,
it should be replaced with a new one.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A warning decal is located at the lower right side of the A Grade/Speed plate showing Retarding Capacities is
instrument panel and below the key switch. located on the left front post of the operator’s cab and
The warning stresses the importance of reading the provides the recommended MAXIMUM speeds to be
operator’s manual before operation. used when descending various grades with a loaded
truck.

. . . . . . . . . . . . . . . . . . . . . .
A warning decal is located to the far right of the
instrument panel and below the Auxiliary Brake switch.

Depress the center button to apply the auxiliary brake.

The RED lamp will illuminate.
Depress the button again to release the auxiliary
brake; the light will turn “Off”.

Refer to OPERATING INSTRUCTIONS, Section 3,

Hauling/Retarder Operation, for complete details re-
garding the use of the information on this chart.
Always refer to the decal in operator’s cab. This decal
may change with OPTIONAL truck equipment such as:
tire sizes, etc.

When the auxiliary brake switch is activated, full,

unmodulated hydraulic brake pressure is applied
to all wheels. The parking brake is also applied.
Never apply the auxiliary brake switch when the
truck is moving, except as an emergency measure.
Safety - Section 2 OM2022.2 8/00
Page 2-20 Warnings and Cautions

A plate attached to the right rear corner of the cab states the Rollover Protective Structure and Falling Object Protective
Structure meets various SAE performance requirements.

! WARNING ! Do not make modifications to this structure, or attempt to repair damage without
written approval from the Manufacturer.
Unauthorized repairs will void certification.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DANGER plates are mounted on each suspension and

accumulator cylinder. These plates warn that the sus-
pensions and accumulators are charged with high
pressure nitrogen. No servicing of any kind should be
attempted until the service manual has been refer-
enced and proper and safe procedures are followed.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning plates are attached to both the hydraulic tank

and fuel tank to alert technicians not to work on the
truck with the body in the raised position unless
body-up retention device (pins or cable) is in position.
OM2022.2 8/00 Safety - Section 2
Warnings and Cautions Page 2-21

A plate is mounted on the left hand side of the trans-

mission oil pan to provide instructions for proper trans-
mission oil level check.
1. Engine Stopped:
• Oil level must be visible in upper part of sight gauge
(STOP) between “H” and “L” to be sure there is
sufficient oil to safely operate transmission when
engine is stopped, or if transmission oil is cold
(engine has been stopped for 8 hours or more).
Check oil level again, as described below, when
transmission oil reaches operating temperature.
2. Engine Running:
• Oil level must be visible in lower part of sight gauge
(turtle) between “H” and “L”.
Check transmission oil level with:
• truck parked on level surface,
• engine running at low idle,
• transmission in neutral, “N”, and
• transmission oil at normal operating temperature:
Add clean oil as required through transmission oil
filler tube at left rear of transmission.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A warning plate is mounted on top of the radiator surge

tank cover near the radiator cap.
The engine cooling system is pressurized. Always
turn the key switch off and allow the engine to cool
before removing radiator cap. Unless the pressure
is first released, removing the radiator cap after the
engine has been running for a time will result in the hot
coolant being expelled from the radiator.
Serious scalding and burning can result.
Service personnel should use caution when serv-
icing radiator. The system is pressurized because
of thermal expansion of coolant. “DO NOT” re-
move radiator cap while engine is hot. Severe
burns may result.
Safety - Section 2 OM2022.2 8/00
Page 2-22 Warnings and Cautions

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. Service the tank with clean Type C-4
hydraulic oil. All oil being put into the hydraulic tank
should be filtered through 3 micron filters.

A CAUTION decal is attached below the hydraulic tank

oil level sight gauge. Check level with body down,
engine stopped, and key switch “Off” (to assure pres-
sure has been relieved from system) before removing
fillercap.
Add oil per filling instructions, if oil level is below top of
sight glass.

A warning plate is attached to the frame above the

hydraulic system (APU) quick disconnect fittings to
alert technicians that high pressure hydraulic oil is
present during operation. Care must be taken when it
is necessary to open the hydraulic system. There is
always a chance of residual pressure being present.
Open fittings slowly to allow any pressure to bleed off
before removing any connections.
Any operating fluid, such as hydraulic oil, escap-
ing under pressure can have sufficient force to
enter a person’s body by penetrating the skin.
Serious injury and possibly death may result if
proper medical treatment by a physician familiar
with this injury is not received immediately.
OM2022.2 8/00 Safety - Section 2
Warnings and Cautions Page 2-23

A plate is located next to filler cap on fuel cap which

specifies Diesel Fuel Only. Care should be taken to
open cap slowly and bleed off pressure that may be in
tank when removing filler cap.
Operation and Maintenance Manual refered to is from
Engine Manufacturer.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attached to the interior of battery box lid is a DANGER
plate. This plate stresses the need to keep from mak-
ing any sparks near the battery. When another battery
or 24VDC power source is used for auxiliary power, all
switches must be “Off” prior to making any connec-
tions. When connecting auxiliary power cables, posi-
tively maintain correct polarity; connect the positive (+)
leads together and then connect the negative (-) lead
of the auxiliary power cable to a good frame ground.
Do not connect to the negative post of the truck battery
or near the battery box. This hookup completes the
circuit but minimizes danger of sparks near the batter-
ies.
Sulfuric acid is corrosive and toxic. Use proper safety
gear, goggles, rubber gloves and rubber apron when
handling and servicing batteries. Avoid contact with
skin, eyes or clothing. In event of accident, immedi-
ately flush with plenty of water and call a physician.
KEEP OUT OR REACH OF CHILDREN!
These decals are placed on the top of the battery box
and near the battery disconnect switches to indicate
that the battery system (24VDC) is a NEGATIVE (-)
GROUND system.
This decal is placed above the battery disconnect
switches on the right side of the battery box to indicate
“Off” and “On” positions of the switches.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A caution plate is located on the side of the battery box.

These instructions must be followed when welding is
done on the truck to avoid damage to the electronic
components.
Safety - Section 2 OM2022.2 8/00
Page 2-24 Warnings and Cautions

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. This complete
number will be necessary for the proper ordering of many service parts and/or warranty consideration.

The lubrication chart is located on the left hand front fender behind the ladder.
Refer to Maintenance - Section 4, “Lubrication and Service”, for more complete lubrication instructions.
OM3024.1 8/00 Operation - Section 3
Operating Instructions Page 3-1

OPERATING INSTRUCTIONS

PREPARING FOR OPERATION

The safest trucks are those which have been properly Local work practices may prevent an operator from
prepared for operation. At the beginning of each shift, performing all tasks suggested here, but to the extent
a careful check of the truck should be made by the permitted, the operator should follow this or similar
operator before attempting to start the engine. routine.
1. Start at left front of truck (see illustration, next
SAFETY IS THINKING AHEAD
page). While performing the walk around inspec-
Prevention is the best safety program. Prevent a tion, visually inspect all lights and safety equip-
potential accident by knowing the employer’s safety ment for external damage from rocks or misuse.
requirements and all necessary job site regulations, as Make sure lenses are clean and unbroken.
well as use and care of the safety equipment on the
2. Move behind the front of the left front tire, inspect
KOMATSU HD1500-5 Truck.
the hub and the oil disc brake assemblies for
Only qualified operators or technicians should attempt
leaks and any abnormal conditions.
to operate or maintain the HD1500-5 Truck.
Check that all suspension attaching hardware is
Safe practices start before the operator gets to secure and inspect for evidence of wear. Verify
the equipment! suspension extension (exposed piston rod) is
correct, and there are no leaks.
• Wear the proper clothing. Loose fitting clothing,
unbuttoned sleeves and jackets, jewelry, etc., can 3. With engine stopped, check engine oil level. Verify
catch on a protrusion and cause a potential hazard. engine oil filters or oil lines to filters are not
leaking.
• Always use the personal safety equipment pro-
vided for the operator such as hard hat, safety 4. Inspect fan and air conditioner belts for correct
shoes, safety glasses or goggles. There are some tension, obvious wear, and tracking. Inspect fan
conditions when protective hearing devices should guard for security and condition.
also be worn for operator safety.
5. Move outboard of the front wheel, and inspect
• When walking to and from the truck, maintain a safe attaching lugs/wedges to be sure all are tight and
distance from all machines even if the operator is complete. Check tires for cuts, damage or “bub-
visible. bles” and that inflation appears to be correct.
6. Move behind the rear of the front wheel, inspect
for leaks at hub or brakes or any unusual condi-
At The Truck - Ground Level Walk Around
tions. Inspect suspension hardware to be sure it
Inspection
is all in place. Inspect the tie-rod pivots and
At the beginning of each shift, a careful walk around steering cylinder for proper greasing, and for se-
inspection of the truck should be made before the curity of all parts. Inspect for hydraulic leaks.
operator attempts engine start-up. A walk around in-
7. Inspect sight glass for transmission oil level.
spection is a systematic ground level inspection of the
Check pumps on front of transmission for leakage
truck and its components to insure that the truck is safe
and that all parts are secure.
to operate before entering the operator’s cab.
8. Move to the side of the hydraulic tank and check
Start at the left front corner of the truck (see illustration,
the hydraulic fluid level for both the hydraulic tank
next page), and move in a counter-clockwise direction,
and brake cooling oil. Oil should be visible in sight
front-to-rear, across the rear, and continuing forward
glass with engine stopped and body down.
up the opposite side of the truck to the original starting
point. If these steps are taken in sequence, and are 9. Move on around the hydraulic tank and in front of
repeated from the same point and in the same direction the rear dual tires. Inspect hoist cylinder for dam-
before every shift, many potential problems may be age and leaks. Inspect upper and lower hoist
avoided. cylinder pins for security and proper greasing.
If problems or potential problems are found during the 10. Before leaving this position, verify there is no
“walk-around”, be sure to notify maintenance. Vehicle leakage or any other unusual condition with trans-
breakdowns and UNSCHEDULED downtime and loss mission or drive shaft.
of production can be reduced.
Operation - Section 3 OM3024.1 8/00
Page 3-2 Operating Instructions

START HERE

KOMATSU HD1500-5 Truck

OM3024.1 8/00 Operation - Section 3
Operating Instructions Page 3-3

11. Move around the dual tires. Verify all lugs/wedges 23. Move on around to the right front of the truck.
are in place and tight. Inspect wheel for leakage
24. As you move in front of the radiator, inspect for
from inside the wheel housing that would indicate
and remove debris that might be stuck in front of
planetary leakage. Check dual tires for cuts, dam-
the radiator. Check for coolant leaks. Inspect all
age or “bubbles” and that inflation appears to be
headlamps and fog lights.
correct. If truck has been run on a “flat”, the tire
must be cooled before parking truck inside. 25. Before climbing ladder to first level, be sure
Inspect for rocks that might be lodged between ground level engine shutdown switch is “ON” (if
dual tires, and verify rock ejector is in good con- equipped).
dition and straight so that it cannot damage a tire.
26. Climb ladder to main deck. Always use grab rails
12. Inspect left rear suspension for damage, proper and ladder when mounting or dismounting from
inflation, and leaks. Inspect for proper greasing, the truck. Clean ladder and hand rails of any
and that covers over the chromed piston rod are foreign material, such as ice, snow, oil or mud.
in good condition.
13. Check final drive housing breather. Replace
breather if obstructed. Check for leakage around
final drive housing, wet disc brake housings, and Always mount and dismount ladders facing the
the hoses connected to the housings. truck. Never attempt to mount or dismount while
14. While standing behind final drive housing, look up the truck is in motion.
to see that rear lights and back up horns are in 27. When checking coolant in radiator, use coolant
good condition. Inspect linkage rods to verify all level sight gauge (if equipped) or observe coolant
locations are getting proper greasing. Also check level through opening in end of hood. If it is
both body hinge pins for greasing and any abnor- necessary to remove radiator cap, shut down
mal condition. engine (if running), and relieve coolant pressure
15. Perform the same inspection on the right rear SLOWLY before removing radiator cap.
suspension as done on the left.
16. Move to the right dual tires and inspect between
the tires for rocks, rock ejector condition. Inspect
tires for cuts, damage, and correct inflation. If engine has been running, allow coolant to cool,
17. Perform same inspection for wheel lugs/wedges before removing the fill cap or draining radiator.
and for leaks as done on the left dual wheels. Serious burns may result if coolant is not allowed
to cool.
18. Move in front of right dual tires. Inspect hoist
cylinder the same as was done on the left side. 28. Inspect battery box cover for looseness, damage.

19. Move on around the fuel tank, inspect the fuel 29. Check air cleaner indicator. If the RED area is
quantity gauge. Inspect the attaching hardware showing in the indicator, the air filter must be
for the fuel tank at the upper saddles, and then at cleaned/replaced before operating truck.
the lower back of the tank for the security and 30. Clean cab windows and mirrors; clean out cab
condition of the mounts. floor as necessary. Insure steering wheel, con-
20. Move in behind the right front wheel, and inspect trols and pedals are free of any oil, grease or mud.
the tie-rod pivots and steering cylinder for proper 31. Stow personal gear in cab so that it does not
greasing, and for security of all parts.Be sure the interfere with any operation of the truck. Dirt or
suspension protective cover is in good condition. trash buildup, specifically in the operator’s cab,
Check suspension attaching hardware and sus- should be cleared. Do not carry tools or supplies
pension extension, as well as greasing and at- in cab of truck or on the deck.
taching hardware for the steering cylinder.
32. Adjust seat and steering wheel so that it is com-
21. Move out and around the right front wheel, verify fortable for use.
all lugs/wedges are in place and tight.
33. Read and understand the OPERATOR CON-
22. Move behind the front of the right front wheel. TROLS AND INSTRUMENT PANEL discussion
Check hub and oil disc brakes for leaks or any in this section.
unusual condition. Inspect engine compartment Be familiar with all control locations and functions
for leaks or any unusual condition. Inspect fan BEFORE operating truck.
guard and belts, and for debris behind radiator.
Operation - Section 3 OM3024.1 8/00
Page 3-4 Operating Instructions

ENGINE START-UP SAFETY PRACTICES

Safety rules must be observed upon engine start-up.

Starting fluid is extremely volatile and flammable!

Insure adequate ventilation before start-up, if the Use with extreme care.
truck is in an enclosure. Exhaust fumes are dan-
gerous!
If truck is equipped with Engine Starting Aid for
1. Insure all personnel are clear of truck before cold weather starting, and ambient temperature
starting engine. Always sound the horn as a is below -5°C (23°F), push the Engine Starting Aid
warning before actuating operational controls. switch “in” for three seconds; then release. Turn
the key switch to the “start” position. If engine
2. Check and insure Transmission Range Selector
does not start, wait at least 15 sec. before repeat-
is in “Neutral” before starting.
ing the procedure.
3. Do not attempt to start engine while cold weather
Do not crank an electric starter for more than 30
starting heater (if equipped) is in operation. Dam-
seconds. Allow two minutes for starter motor
age to coolant heaters will result, due to lack of
cooling before attempting to start engine again.
circulation.
Severe damage to starter motor can result
4. The key switch is a three position (Off, Run, Start) from overheating.
switch.
5. The truck cannot be push started. Transmission
lube and control systems are inoperative when
When the key slot is in the vertical
engine is not running.
position, the electrical system is
“Off” and no electrical devices are 6. When getting a battery assist from one truck to
energized. another, all switches must be “Off” prior to making
any connections. Be certain to maintain correct
Use this key position to stop the
polarity. Connect one lead of booster cable to 24V
engine when it is running.
positive (+) post of battery needing assist, and
other lead of the booster cable to the 24V positive
(+) post of auxiliary battery. Connect one lead of
When the switch is rotated one position clock-
second booster cable to 24V negative (-) post of
wise, it is in the “Run” position and all electrical
auxiliary battery and then connect other lead of
circuits (except “Start”) are energized.
the booster cable to a good frame ground on the
With Transmission Selector disabled truck away from the battery needing
Lever in the “Neutral” position, assist. This procedure will avoid the possibility of
rotate key switch fully clockwise causing sparks near the battery where explosive
to “start” position (Transmis- gases may be present.
sion Range Selector in “Neu-
tral”) and hold this position until
engine starts (see NOTE be- NOTE: HD1500-5 Trucks are equipped with four 12
low). “Start” position is spring volt batteries connected in series and parallel to pro-
loaded to return to “run” when vide 24 volt output. Be certain to maintain correct
key is released. voltage and polarity when connecting booster cables.
Damage to electrical components may result if voltage
NOTE: The starter is equipped with an Engine
and polarity are not correct.
Prelube System; a noticeable time delay will oc-
cur (while engine lube oil passages are being
filled) before starter engagement and engine
cranking will begin. The colder the engine oil
temperature, the longer the time delay will be. In
addition, if truck is also equipped with Engine
Starting Aid for cold weather starting, the Engine
Prelube System should be engaged FIRST for
5-10 seconds, or until starter is engaged, BE-
FORE activating the Engine Starting Aid .
OM3024.1 8/00 Operation - Section 3
Operating Instructions Page 3-5

AFTER ENGINE HAS STARTED c. Reduce engine speed to low idle, move re-
tarder lever to Off position (lever up). Service
• After the engine has been started, operate at ap- brake lamp should turn off. Place range selec-
proximately 1000 rpm, until coolant temperature tor in the N position.
gauge is indicating “normal” (green) range.
• Become thoroughly familiar with steering, braking, Parking Brake
and emergency controls.
4. Check operation of the parking brake:
a. Press the parking brake switch (3, Figure 3-1)
to the ON (applied) position. Verify red parking
brake ON lamp (5) in left pod illuminates.
b. Move the transmission range selector (2, Fig-
ure 3-2) to any position other than N; verify the
During the following safety checks, if actuation or central warning lamp (6) on the left pod flashes.
release of any steering , brake or emergency con- c. Move transmission range selector to the 5
trol circuit does not appear normal, shut engine position and gradually increase engine speed
down immediately and notify maintenance person- to 1640 rpm. Truck must not move.
nel. Do not operate truck until circuit in question If truck moves, notify maintenance person-
is fully operational. nel to adjust parking brake. DO NOT oper-
Be certain area around truck is clear before test- ate truck until parking brake is fully
ing. operational.
d. Reduce engine speed to low idle. Place selec-
Steering tor lever in N position.
1. Test the truck steering in extreme right and left
directions. If the steering system is not operating
properly, shut engine down immediately. Deter-
mine the steering system problem and have re-
pairs made before resuming operation.

Service Brake
2. With the truck on flat ground, check for normal
operation of the service (foot) brake:
a. Depress foot brake pedal (1, Figure 3-1). Verify
amber service brake lamp (4) in left pod illumi-
nates.
b. Move transmission range selector (2, Figure
3-2) to the 5 position and gradually increase
engine speed to 1560 rpm. Truck must not
move.
c. Reduce engine speed to low idle, release serv-
ice brake and place range selector in the N
position. Verify service brake lamp is off.

Retarder
3. With the truck on flat ground, check retarder
operation:
a. Move the retarder lever (2, Figure 3-1) to
maximum retard position (lever down. Verify
amber service brake lamp (4) in left pod illumi-
nates.
b. Move transmission range selector to the 5
position and gradually increase engine speed
FIGURE 3-1. BRAKE SYSTEMS CONTROLS
to 1560 rpm. Truck must not move.
1. Service Brake 4. Service Brake Lamp
2. Retarder Lever 5. Parking Brake Lamp
3. Auxiliary Brake Switch 6. Central Warning Lamp
Operation - Section 3 OM3024.1 8/00
Page 3-6 Operating Instructions

Auxiliary Brake 6. Check gauges, warning lights and instruments

before moving the truck to insure proper system
5. Check operation of the auxiliary brake:
operation and proper instrument functioning.
a. Press the auxiliary brake switch (2, Figure 3-1) Give special attention to braking and steering
to select the ON (applied) position. Verify inter- circuit warning lights. If warning lights come on,
nal red lamp and service brake lamp turn on. shut down the engine immediately and determine
b. Move transmission range selector to the 5 the cause.
position and gradually increase engine speed
to full throttle. Truck must not move. 7. Insure headlights, worklights and taillights are in
proper working order. Good visibility may prevent
an accident. Check operation of windshield wiper
and washer.
8. When truck body is in dump position, do not allow
anyone beneath it, unless body-up retaining de-
If truck moves, notify maintenance personnel to vice is in place.
immediately repair brakes. DO NOT operate truck
9. Do not use the fire extinguisher for any purpose
until auxiliary brake is fully operational.
other than putting out a fire! If extinguisher is
c. Reduce engine speed to low idle. Place range discharged, report the occurrence so the used
selector lever in N position. Press auxiliary unit can be refilled or replaced.
brake switch to turn OFF. Verify red indicator 10. Do not allow unauthorized personnel to ride in the
lamp and service brake lamp are off. truck. Do not allow anyone to ride on the ladder
or on the deck of the truck.
11. Do not leave truck unattended while engine is
running. Shutdown engine before leaving cab.

FIGURE 3-2. CONSOLE CONTROLS

1. Center Console 3. Parking Brake Switch
2. Transmission Range 4. Brake Lock Switch
Selector
OM3024.1 8/00 Operation - Section 3
Operating Instructions Page 3-7

MACHINE OPERATION SAFETY LOADING

PRECAUTIONS 1. Pull into the loading area with caution. Remain at
After the truck engine is started and all systems are a safe distance while truck ahead is being loaded.
functioning properly, the operator must follow all local 2. Do not drive over unprotected power cables.
safety rules to insure safe machine operation.
3. When approaching or leaving a loading area,
watch out for other vehicles and for personnel
working in the area.
4. When pulling in under a loader or shovel, follow
If any of the red warning lights come “On” or if any “Spotter” or “Shovel Operator” signals. The truck
gauge reads in the red area during truck operation, operator may speed up loading operations by
a malfunction is indicated. Stop truck as soon as observing the location and loading cycle of the
safety permits, shut down engine if problem indi- truck being loaded ahead, then follow a similiar
cates and have problem corrected before resum- pattern.
ing truck operation.
5. Operator should remain in truck cab with engine
running while truck is being loaded.
1. Always sound the warning horn before moving the Place Transmission Range Selector in “Neutral”
truck. When backing the truck, give back-up sig- and apply the Brake Lock Switch.
nal (three blasts on horn); when starting forward,
two blasts on horn. These signals must be given
each time the truck is moved forward or back-
ward. Look to the rear before backing the truck.
Watch for and obey ground spotter’s hand signals
If operator must leave truck cab during loading,
before making any reverse movements. Spotter
engine must be shut down and parking brake ap-
should have a clear view of the total area at the
plied. DO NOT use emergency brake for parking.
rear of the truck.
Remain far enough away from truck to avoid being
2. Operate the truck only while properly seated with struck by flying material.
seat belt fastened. Keep hands and feet inside
the cab compartment while truck is in operation.
6. When truck is loaded, pull away from shovel as
Keep a firm grip on steering wheel at all times.
quickly as possible, but with extreme caution.
3. Check gauges and instruments frequently during
operation for proper readings.
4. Observe all regulations pertaining to the job site’s
traffic pattern. Be alert to any unusual traffic pat-
tern. Match the truck speed to haul road condi-
tions and slow the truck in any congested area.
Obey the spotter’s signals at shovel and dump.
5. Do not allow engine to run at “Idle” for extended
periods of time.
6. Check parking brake periodically during working
shift. Use parking brake for parking only.
Do not attempt to apply parking brake while truck
is moving!
7. Apply the Brake Lock Switch at the shovel and
dump areas.
8. Proceed slowly on rough terrain to avoid deep ruts
or large obstacles. Avoid traveling close to soft
edges and the edge of fill area.
9. Truck operation requires concentrated effort by
the driver. Avoid distractions of any kind while
operating the truck.
Operation - Section 3 OM3024.1 8/00
Page 3-8 Operating Instructions

HAULING Retarder Operation

1. Always stay alert! If unfamiliar with the road, drive Two lists are provided on the Retarding Capac-
with extreme caution. ity decal, one a continuous rating and the second
a short-length rating. Both lists are matched to the
2. Govern truck speed by the road conditions, truck at maximum Gross Vehicle Weight.
weather and visibility.
The continuous numbers on the chart indicate the
3. Operate truck so it is under control at all times. combination of speeds and grades which the
4. Use extreme caution when approaching a haul vehicle can safely negotiate for unlimited time or
road intersection. Maintain a safe distance from distance.
oncoming vehicles. The short-length numbers listed on the chart in-
5. Obey all road signs. dicate the combination of speeds and grades
which the vehicle can safely negotiate for three
6. Always dim headlights when meeting oncoming minutes. These speeds are faster than the con-
vehicles. tinuous values, reflecting the thermal capacity of
7. Maintain a safe distance when following another various system components. System compo-
vehicle. Never approach another vehicle from the nents can accept heating at a higher-than-con-
rear, in the same lane, closer than 15 m (50 ft). tinuous rate for a short period of time, beyond
When operating on a down grade, stay at least 30 which the system would become over-tempera-
m (100 ft) away. ture.
8. Before starting down a grade, maintain a speed The short-length rating (sometimes called the
that will insure safe operation and provide effec- “three-minute” limit) will successfully accommo-
tive retarding under all conditions. date most downhill loaded hauls. It is necessary
to divide haul road grade segment length by
When descending a known grade with a loaded allowable speed to determine actual time on
truck, the operator should adjust the speed of the grade. If actual time on grade exceeds the allow-
truck if necessary, to preselect a transmission able amount, the grade will need to be negotiated
gear range, so that operation can be maintained at the continuous speed. Ambient temperature,
within the speeds listed on the Retarding Capac- as well as the prior temperature of the brake
ity decal located inside the cab on the left front cooling oil can affect this number (the brake cool-
cab post (Shown below). Either the retarder con- ing oil could already be above the normal range
trol lever or the foot-operated brake pedal can be from recent operating conditions).
used to control the speed of the truck.

DO NOT exceed these recommended MAXIMUM

speeds when descending grades with a loaded
truck.
For Efficient Retarder Operation, the operator
should:
• Maintain engine RPM between 2000 — 2100
RPM, and
• When descending a grade, the operator should
apply the retarder lever/foot pedal and observe
both the Tachometer and the Brake Oil Tempera-
ture Gauge . The engine RPM must be main-
tained at 2000 – 2100 RPM and the Brake Oil
Temperature must be maintained below 248oF
(120oC).
If the operator observes that either the maximum
engine speed of 2100 RPM or the Brake Oil
Temperature of 248oF (120oC) are about to be
exceeded, the operator should immediately move
OM3024.1 8/00 Operation - Section 3
Operating Instructions Page 3-9

the transmission range selector to the next lower PASSING

range and use, either the retarder control lever,
or the foot-operated brake pedal, to apply more 1. Do not pass another truck on a hill or blind curve!
brake pressure until the truck is slowed to a speed 2. Before passing, make sure the road ahead is
which will permit the transmission to downshift to clear. If a disabled truck is blocking your lane,
the gear range selected. slow down and pass with extreme caution.
Continue this procedure to downshift to the re- 3. Use only the areas designated for passing.
quired gear range to maintain engine speed at
2000 – 2100 RPM and brake oil temperature
below 248oF (120oC). When the proper gear
range is attained, continue to use the retarder as
needed to maintain a safe, productive speed.
If brake oil temperature exceeds 248oF (120oC),
the Brake Oil Temperature Warning light will turn
on. As quickly as safety will permit, bring the
truck to a complete stop away from traffic, move
transmission range selector to “Neutral”, apply
the parking brake, and run engine at high idle.
Continue to run engine at high idle until Brake Oil
Temperature Warning light turns off and brake oil
temperature cools to below 248oF (120oC). If
temperature does not return to this range within
a few minutes, report the condition immediately
to maintenance personnel and wait for further
instructions before moving truck.
9. When operating truck in darkness or when visibil-
ity is poor, do not move truck unless headlights
are on. Do not back truck if back-up horn or lights
are inoperative.
10. When backing the truck, give back-up signal
(three blasts on horn); when starting forward, two
blasts on horn. These signals must be given each
time the truck is moved forward or backward.
11. Do not stop or park on a haul road unless unavoid-
able. If you must stop, move truck to a safe place,
apply parking brake, shut down engine, block
wheels securely and notify maintenance person-
nel for assistance.
12. If the warning light for “Low Steering Pressure”
illuminates during operation, steer the truck im-
mediately to a safe stopping area, away from
other traffic, if possible. Refer to item 11 above.
13. Report haul road conditions immediately. Muddy
or icy roads, pot holes or other obstructions can
present hazards.
14. Cab doors should remain closed at all times while
truck is in motion or unattended.
15. Check for flat tires periodically during shift. If truck
has been run on a “flat”, it must not be parked
in a building until the tire cools.
Operation - Section 3 OM3024.1 8/00
Page 3-10 Operating Instructions

DUMPING To Raise dump body:

1. Pull into dump area with extreme caution. Make

sure area is clear of persons and obstructions,
including overhead utility lines. Obey signals di-
rected by the spotter, if present.
Avoid unstable areas. Stay a safe distance from The dumping of very large rocks (10% of payload,
edge of dump area. or greater) or sticky material (loads that do not flow
Position truck on a solid, level surface before freely from the body) may allow the material to
dumping. move too fast and cause the dump body to move
RAPIDLY and SUDDENLY. This sudden movement
may jolt the truck violently and cause possible
injury to the operator, and/or damage to the hoist
cylinders, frame, and/or the dump body hinge pins.
If it is necessary to dump this kind of material, refer
As body raises, the truck Center of Gravity (CG) to the CAUTION in the following procedure:
will move. Truck must be on level surface to pre-
vent tipping / rolling!
4. Pull the Hoist Control Lever (1, Figure 3-3) back
to the “RAISE” position (4) and release lever.
2. Carefully maneuver truck into dump position. (Releasing the hoist lever anywhere during the
When backing truck into dump position, use only “Hoist Up/RAISE” operation will place the dump
the foot-operated brake pedal to stop and hold body in “HOLD” at that position.)
truck.
5. Raise engine RPM to accelerate hoist speed.
3. When in dump position, place transmission range
Refer to the CAUTION below.
selector at the “Neutral” position, and apply the
Brake Lock switch. When body is near the maximum angle, reduce
engine RPM (reduce foot pressure on the accel-
erator pedal) to reduce shock load to the hydraulic
system and hoist cylinders.

If dumping very large rocks or sticky material as

decribed in WARNING above, slowly accelerate
engine RPM to raisethe dump body.
When the material starts to move, release hoist
lever to “HOLD” position. If the material does not
continue moving and clear the dump body, repeat
this procedure until material has cleared body.

6. When the dump body rises to the desired position,

FIGURE 3-3. HOIST CONTROL VALVE
release the hoist control lever (it will return to the
1. Hoist Control Lever 4. “RAISE” Position “HOLD” position). If desired to raise the body
2. “FLOAT”/"HOLD" Position 5. Center Console further, move dump lever again to “RAISE” posi-
3. “DOWN” Position tion and dump body will rise until hoist cylinders
are fully extended.
← ARROW Points to Front of Truck (Releasing the hoist lever anywhere during the
“Hoist Up/RAISE” operation will place the dump
body in “HOLD” at that position.)
OM3024.1 8/00 Operation - Section 3
Operating Instructions Page 3-11

To Lower Body: SAFE PARKING PROCEDURES

7. After material being dumped clears body, lower The operator must continue the use of safety precau-
body to frame by moving the Hoist Control Lever tions when preparing for parking and engine shut-
forward to the “DOWN” position and the dump down.
body will start to move down.
In the event that the equipment is being worked in
8. Releasing the lever completely will automatically consecutive shifts, any questionable truck perform-
return it to the “FLOAT” position. The body will ance the operator may have noticed must be checked
then move down under its own weight. by maintenance personnel before the truck is released
to another operator.
If dumped material builds up at body tailgate and
body cannot be lowered, shift Transmission 1. The truck should be parked on level ground, if at
Range Selector to “D” (Drive), release Brake all possible. If parking must be done on a grade,
Lock switch, and drive forward to clear material. the truck should be positioned at right angles to
Stop, shift Transmission Range Selector to “N” the grade.
(Neutral), apply Brake Lock switch and lower 2. The parking brake must be applied and/or chocks
dump body. See NOTE : * below. placed fore/aft of wheels so that the truck cannot
roll. Each truck should be parked at a reasonable
distance from another.
3. Haul roads are not safe parking areas. In an
emergency, pick the safest spot most visible to
other machines in the area. If the truck becomes
The truck is not to be moved with
disabled where traffic is heavy, mark the truck
the dump body raised except for
with warning flags in daylight or with flares at
emergency moves only. Failure
night.
to lower the dump body before
moving truck may cause dam-
age to hoist cylinders, frame
and/or body hinge pins. SHUTDOWN PROCEDURE
NOTE: When traveling, always place the dump lever The following sequence of shutdown procedure is
at the FLOAT position, regardless of whether or not important and should be followed at each shutdown.
the truck is loaded.
* If the transmission range selector is moved to any
position other than “N” (neutral) when the dump lever 1. Stop truck, reduce engine RPM to low idle. Place
is not at the FLOAT position, the central warning lamp Transmission Range Selector in “Neutral” and
will flash and the alarm buzzer will sound intermittently. apply parking brake.
2. Allow engine to cool gradually by running at low
9. With body returned to frame, move Transmission idle for 3 to 5 minutes.
Range Selector to “D” (Drive), release Brake 3. Turn keyswitch to the “off” position to stop engine.
Lock switch, and leave dump area carefully.
4. Close and lock all windows, remove key from key
switch and lock cab to prevent possible unauthor-
ized truck operation.
5. Dismount truck properly.
Operation - Section 3 OM3024.1 8/00
Page 3-12 Operating Instructions

TOWING
Prior to towing a truck, many factors must be carefully 3. Determine that towing vehicle has adequate ca-
considered. Serious personal injury and/or significant pacity to both move and stop the towed truck
property damage may result if important safety prac- under all conditions.
tices, procedures, and preparation for moving heavy 4. Protect both operators in the event of tow bar
equipment are not observed. failure.
Towing a disabled truck requires a rigid tow bar capa- 5. Release disabled truck brakes and remove all
ble of towing at least 1.5 times the Gross Vehicle blocking.
Weight (GVW) of the vehicle being towed.
NEVER use cable for towing a disabled vehicle!
When towing becomes necessary, use the tow eyes
installed under the front frame/bumper and take the
Do not tow the truck any faster than 8 kph (5 MPH).
following precautions:
1. Block disabled truck to prevent movement while
6. Sudden movement may cause tow bar failure.
preparing truck for towing and attaching tow bar.
Smooth and gradual truck movement is preferred.
Inspect tow bar for capacity (it must be capable
of towing at least 1.5 times the Gross Vehicle 7. Minimize tow angle at all times -
Weight of vehicle being towed). NEVER EXCEED 30o.
The towed truck must be steered in the direction
2. Determine primary reason that vehicle is disabled.
of the tow bar.
a. If truck is disabled because of a suspected final
drive problem, both right and left planetary sun
gears/drive axles should be removed before
any towing. (Refer to Section “G”, Final Drive,
in the Shop Manual for procedure.)
Extensive secondary damage can occur to
final drive components and/or transmis-
sion, if truck is towed without first removing
sun gears/drive axles.
b. If truck is disabled because of a suspected
transmission problem, and the towing distance
surpasses 800m (2,625 ft), remove the drive
shaft between the transmission and the differ-
ential case (if final drive sun gears have not
been removed).
c. If the engine of the disabled truck is operable;
keep the engine running while towing, so that
the steering and braking can be used.
d. If the engine is NOT operable, hydraulic power
for steering and braking and transmission lubri-
cation will not be available.
Install the necessary hydraulic connections be-
tween the towing vehicle and the disabled truck
to provide hydraulic power for steering and
braking. (Refer to the decals on the truck near
the hydraulic manifold.)
Disconnect transmission as stated above.
OM3024.2 8/00 Operation - Section 3
Operator Cab and Controls Page 3-13

OPERATOR CAB AND CONTROLS

FIGURE 3-4. CAB INTERIOR - OPERATOR VIEW

1. Steering Wheel 6. Heater/Air Conditioner Controls 13. “PMC” Interface Connector
2. Retarder Control Lever 7. Heater/Air Conditioner Vents 14. Air Cleaner Vacuum Gauges
3. Service Brake Pedal 8. Retarding Capacity Chart 15. Payload Meter II
4.Throttle/Accellerator Pedal 9. Radio Speakers 16. Windshield Wipers
5.Instrument Panel, with Center 10. “MOM” Display Screen 17. Sun Visors
Electronic Display Panel, and 11. Warning Alarm Buzzer 18. "MOM" Dimmer Switch
L.H & R.H. Control/Indicator Pods 12. Radio, AM/FM Stereo, Cassette
Operation - Section 3 OM3024.2 8/00
Page 3-14 Operator Cab and Controls

STEERING WHEEL AND CONTROLS

The steering wheel (1, Figure 3-5) will telescope “in”
and “out” and adjust through a tilt angle to provide a
comfortable wheel position for most operators.

HORN BUTTON
The horn (2, Figure 3-5) is actuated by pushing the
button in the center of the steering wheel. Operation of
the horn should be verified before moving the truck.
Observe all local safety rules regarding the use of the
horn as a warning signal device before starting engine
and moving the vehicle.

TELESCOPE LOCK RING

The Telescope Lock Ring (3, Figure 3-5) around the
horn button locks/unlocks the telescoping function of
FIGURE 3-5. STEERING WHEEL AND CONTROLS
the steering column. Rotating the ring (* ) counter-
1. Steering Wheel 4. Tilt Wheel Lever
clockwise (L.H. rotation), releases the column to move
2. Horn 5. Turn Signal Lever
"in" or "out". Rotating the ring clockwise (R.H. rotation),
3. Telescope Lock Ring 6. Retarder Control Lever
locks the column in the adjusted position.
(* ) DO NOT ROTATE RING MORE THAN 90°!
Electrical ground wire may be cut! Windshield Wiper / Washer Control
The Windshield Wiper Control is used to activate the
TILT WHEEL LEVER wiper blades and washer system.
Adjust the tilt of the steering wheel by pulling the tilt This control is on the Turn Signal Lever and has three
adjustment lever (4, Figure 3-5) toward the steering wiper speed settings and a washer control:
wheel and moving the wheel to the desired angle.
Releasing the lever will lock the wheel in the desired
location.

TURN SIGNAL / HEADLIGHT DIMMER

The Turn Signal Lever (5, Figure 3-5) is used to activate
turn signal lights and to select either high or low head- Rotate the knob on the end of the lever clockwise
light beams. (from OFF position) to activate the various speed
selections.
Move the lever upward to signal a turn
to the right. OFF: Wipers are Off.

An indicator in the top, center of the instrument Wipers operate at Intermittent speed.
display panel will illuminate to indicate turn direc-
tion selected.
Refer to INSTRUMENT PANEL & INDICATOR Wipers operate at Low speed.
LIGHTS.

Move the lever downward to signal a Wipers operate at High speed.

turn to the left.

Grasp control knob and

push in (toward steering
Moving the lever toward the steering wheel will column) to spray washer
change the High/Low Headlight beam. liquid onto windshield.
When high beams are selected, the
indicator in the top, center of the instru-
ment display panel will illuminate.
OM3024.2 8/00 Operation - Section 3
Operator Cab and Controls Page 3-15

RETARDER CONTROL LEVER

The Retarder Control Lever (6, Figure 3-5) is mounted
on the right side of the steering column. It can be used
to modulate the full range of retarding/braking effort
being applied to both the front and rear oil disc brakes.
Any application of the retarder lever will cause an
indicator light to illuminate in the L.H. instrument
panel/pod (Refer to “Instrument Panel And Indicator
Lights”)
a. When the lever is rotated to full “Up” (counter-
clockwise) position, it is in the “Off/No Retard”
position.
b. When the lever is rotated to full “Down” (clock-
wise) position, it is in the full “On/Retard” position.
ACCELERATOR (THROTTLE) PEDAL
c. For long downhill hauls, the lever may be posi- The Accelerator Pedal (Throttle) Pedal (4, Figure 3-4)
tioned anywhere to provide a desired retarding is a foot-operated pedal which allows the operator to
effort, and it will remain where it is positioned. control engine RPM, depending on pedal depression.
NOTE:
The foot-operated treadle pedal contains an electronic
When retarding is completed, and acceleration is
sensor which sends signals to the Cummins Engine
resumed, be sure to return the lever to the full
Quantum  fuel control system.The movement of the
“Up” (counterclockwise/"Off/No Retard") posi-
fuel governor control arm corresponds directly to the
tion, to prevent rapid wear to brake discs and/or
travel of the treadle pedal as it is applied by the opera-
overheating of the brake cooling system.
tor. When the pedal is released, springs return the
control arm and the pedal to their “rest” position and
The Retarder Lever and foot-operated Service Brake the engine speed returns to low idle.
pedal can be used simultaneously or independently.
The Retard Control Module (RCM) will determine which
device is requesting the most retarding/braking effort
and apply that amount. INSTRUMENT PANEL
The Instrument Panel (5, Figure 3-4) includes a Center
Electronic Display Panel, and L.H & R.H. Panels/Pods
which contain a variety of switches and indicators.
SERVICE BRAKE PEDAL Refer to “INSTRUMENT PANEL AND INDICATOR
LIGHTS” later in this Section, for a detailed description
The Service Brake Pedal (3, Figure 3-4) is a single
of the function and location of each of these compo-
function, foot-operated pedal which controls and
nents.
modulates service brake pressure directly through a
hydraulic valve.
When the pedal is partially depressed, an indicator light
in the L.H. instrument panel pod (11, Figure 3-12) will
illuminate. As the pedal is further depressed, the serv-
ice brakes are actuated (a slight increase in pedal
resistance will be felt ) through a hydraulic valve, which
modulates pressure to the service brakes. Completely
depressing the pedal causes full application of both the
front and rear oil disc service brakes.
The Grade/Speed Chart (8, Figure 3-4) should always
be followed to determine MAXIMUM safe truck speeds
for descending various grades with a loaded truck.
Operation - Section 3 OM3024.2 8/00
Page 3-16 Operator Cab and Controls

HEATER / AIR CONDITIONER TEMPERATURE CONTROL KNOB

COMPARTMENT AND CONTROLS The Temperature Control Knob (5, Figure 3-6) is pro-
The heater/air conditioner compartment contains the vided for the operator to select a comfortable tempera-
heater/air conditioner controls (6, Figure 3-4) and ture.
some of the heater/air conditioner components, such Rotating the knob counter-clockwise (blue arrow)
as the blower motor assembly and the heater coils. will select cooler temperatures.
Optimum cab air climate can be selected by using the Full counter-clockwise position is the coldest air
following controls in various combinations. setting.

DEFROSTER VENT CONTROL SWITCH Rotating the knob clockwise (red arrow) will select
warmer temperatures.
The defroster control switch (1, Fig- Full clockwise position is the warmest heater set-
ure 3-6) directs heated air for wind- ting.
shield defrosting. “Down” position
of the rocker switch is OFF. “Up” AIR CONDITIONER CONTROL KNOB
position of the rocker switch is On.
The Air Conditioner rocker switch
(6, Figure 3-6) is a three position
OUTSIDE/INSIDE AIR CONTROL SWITCH switch and it controls the air condi-
tioner to cool the cab air. Pressing
The outside/inside air c ontrol the switch to the left will turn the air
switch (2, Figure 3-6) allows either conditioner "ON". When the switch
outside or inside air to be circulated is in the "Center" position, the air
through the cab heater assembly. conditionerand the heater are both
"ON". When the switch is pressed to the right side, only
the heater is "ON".
Pressing the switch “Up” directs in-
side air to be recirculated through
the heater assembly.
Pressing the switch “Down” directs
outside air to be circulated through
the heater assembly and into the
cab.

HEAT VENT CONTROL SWITCH

The heater control (3, Figure 3-6)
directs heated air to the cab floor for
heating of the cab.
“ Down” position of the rocker
switch is OFF. “Up” position of the
rocker switch is On.

FAN CONTROL KNOB

The fan control knob (4, Figure 3-6)
is provided to control the cab air fan
motor. The fan motor is a 3-speed
motor (low, medium and high).
Speeds are selected by rotating the
control knob clockwise to the de-
sired position. “Off” is full counter-
clockwise position.

FIGURE 3-6. A/C & HEATER CONTROLS

OM3024.2 8/00 Operation - Section 3
Operator Cab and Controls Page 3-17

HEATER/AIR CONDITIONER VENTS RETARDING CAPACITY CHART

The heater/air conditioner vents (7, Figure 3-6) The Retarding Capacity chart (8, Figure 3-4 & shown
may be rotated 360°. There are three in the below) provides the recommended MAXIMUM truck
Heater/Air Conditioner Compartment (shown be- speeds for descending various grades with a fully
low), four vents across the top of the panel, and loaded truck.
one each in the R.H. & L.H. instrument panel pods.
Air flow through the vents is controlled by manu-
ally opening/closing or turning the louvers.

RETARDING CAPACITY CHART

The operator should reference the Retarding Capacity
chart before descending any grade with a loaded truck.
Proper selection of road grade, truck speed, transmis-
sion gear range, and use of the retarder lever and/or
brake pedal are required to maintain a safe speed.
Refer to OPERATING INSTRUCTIONS, “Retarder Op-
eration”, previously discussed in this Section.
DO NOT exceed these recommended MAXIMUM
speeds when descending grades with a loaded
truck.
Customer specified options may cause this decal to
change: ALWAYS refer to the Retarding Capacity
chart in the operator’s cab, and follow the recommen-
dations there for safe truck operation.
Operation - Section 3 OM3024.2 8/00
Page 3-18 Operator Cab and Controls

RADIO SPEAKERS AIR CLEANER VACUUM GAUGES

Radio Speakers (9, Figure 3-4) for the AM/FM Stereo The air cleaner vacuum gauges (14,
radio are located at the far left and right of the overhead Figure 3-4) provide a continuous
panel. reading of maximum air cleaner re-
striction reached during operation.
The air cleaner(s) should be serv-
iced when the gauge(s) shows the
“MOM” DISPLAY SCREEN following maximum recommended
This panel (10, Figure 3-4) contains an electronic dis- restriction:
play to provide the operator or service technician with
important messages concerning selected truck func- Cummins Engine: . . . 25 inches of H2O Vacuum.
tions.
Refer to “ELECTRONIC DISPLAYS AND MESSAGES” NOTE: After service, push the reset pin on the face of
later in this Section, for a detailed description of the the gauge to allow the gauge to return to zero.
messages provided and the functions monitored by
this display.
PAYLOAD METER
The Payload Meter (15, Figure 3-4) is used to provide
WARNING ALARM BUZZER management with operational data such as tonnage
This alarm (11, Figure 3-4) will sound when activated hauled and cycle times. Refer to Section 5, Optional
by any one of several truck functions. Equipment, for a more complete description of the
Refer to “INSTRUMENT PANEL AND INDICATOR payload meter and its functions.
LIGHTS”, for a detailed description of functions and
indicators that will activate this alarm.
WINDSHIELD WIPERS
The windshield wipers (16, Figure 3-4) are powered by
CAB RADIO an electric motor. Refer to “TURN SIGNAL / HEAD-
This panel will normally contain an AM/FM Stereo radio LIGHT DIMMER LEVER”, for a description of the wind-
(12, Figure 3-4). shield wiper and washer controls.

Refer to Section 5, Optional Equipment, for a more

complete description of the radio and its functions.
Individual customers may use this area for other pur-
poses, such as a two-way communications radio.

PMC INTERFACE CONNECTOR

The “PMC” Interface Connector (13, Figure 3-4) is used
to communicate data between a computer and the
PMC.
Refer to the Shop Manual, Powertrain Management
Controller section, for a more complete description of
the PMC and its functions.
OM3024.2 8/00 Operation - Section 3
Operator Cab and Controls Page 3-19

CENTER CONSOLE STRUCTURE

The Center Console (1, Figure 3-7) located to the right The housing below the passenger seat provides an
of the operator seat, is a housing structure which easy access to various control components (relays,
provides a mounting surface for certain operator con- solenoids, valves, etc.) for the service technican.
trols and a passenger seat. Refer to the Shop manual for descriptions and service
for these devices.

FIGURE 3-7. CENTER CONSOLE

1. Center Console Structure 6. Parking Brake Switch 10. Ash Tray

2. Transmission Range Selector 7. Brake Lock Switch 11. Cigar/Cigarette Lighter
3. Shift Limit Switch 8. L.H. Window Control Switch 12. Passenger Seat Belt
4. “F1" Start Switch 9. R.H. Window Control Switch 13. Passenger Seat
5. Hoist Control Lever
Operation - Section 3 OM3024.2 8/00
Page 3-20 Operator Cab and Controls

Transmission Range Selector (2, Figure 3-7) Control Switches (3, 4, 6, & 7, Figure 3-7)
The Transmission Range Selector is mounted to the These switches are simple “Rocker-type” switches
right of the operator’s seat. which turn functions “On” and “Off”.
The Transmission Range Selector has seven positions "ON"
(R, N, D, 5, 4, 3, and L). When moving the range selector
lever from “N” to “R”, or from “D” to 5, press the lock
The “On” and “Off” positions are maked with
button on the end of the handle before moving the
selector lever. "OFF" these symbols.

“R” - REVERSE position - is used to move the truck

backwards. Bring truck to a complete stop before
shifting from DRIVE to REVERSE or vice-versa. The
Reverse Warning Horn is activated when REVERSE
position is selected. Shift Limiter Switch (3, Figure 3-7)
“N” - NEUTRAL position - is used when starting the
This switch is used to limit the highest
engine, during loading operations and parking the
speed range when the transmission shift
truck with engine running. The truck cannot be started
lever is in “D” or “L” Ranges.
unless the range selector is in the “N” - NEUTRAL
position.
“D” - DRIVE position - When starting from a stopped On/Off Range Range(s) Attainable
position, the transmission will shift automatically to
second gear. As the truck ground speed increases, the On “D” Range - F2 – F6
transmission will automatically upshift through each “L” Range - F1
gear to seventh gear operation. As the truck ground
Off “D” Range - F2 – F7
speed slows down, the transmission will automatically
down shift to the correct gear for grade/load/engine “L” Range - F1 – F2
conditions.
“5, 4, 3" positions - Road and load conditions some-
times make it desirable to limit the automatic up-shift- F1 Start Switch (4, Figure 3-7)
ing to a lower range. These positions provide more
effective retarding on grades. When the range selector This switch is used to electrically assure
is placed in any one of these positions, the transmis- that the transmission always starts in
sion will not shift above the highest gear range se- “F1". When this switch is ”On" and the
lected. It will also down-shift to first range when transmission range selector is moved to
required by grade/load/engine conditions. a “Forward” range position, the transmis-
sion will shift to “F1" to start, regardless
When conditions permit, select position “D” for normal of the selector position.
operation.
“L” - LOW position - Use this range position when
maneuvering in tight spaces and when pulling through
mud or deep snow. Use this range position also when Hoist Control Lever (5, Figure 3-7)
driving up and down steep grades where maximum The hoist control is a four-function, three-position,
driving power or maximum retarding is required. hand-operated lever located between the operator seat
and the Center Console.
Refer to “OPERATING INSTRUCTIONS, DUMPING”
for more complete details concerning this control.
OM3024.2 8/00 Operation - Section 3
Operator Cab and Controls Page 3-21

Parking Brake Switch (6, Figure 3-7) L.H. Window Control Switch
(8, Figure 3-7)
When this switch is in the “On” position,
the parking brake is applied. This control switch is spring-loaded to the
center, “OFF”, position. Pushing the front of
When this switch is in the “Off” position,
the switch raises the left side cab window.
the parking brake is released.
Pushing the rear of the switch lowers the
window.
The Parking Brake is spring applied and hydraulically
released. It will hold a stationary truck when the engine
is stopped and the keyswitch is in the “Off” position.
R.H. Window Control Switch
DO NOT apply the parking brake while the truck is (9, Figure 3-7)
in motion. Damage to the Park Brake components
This control switch is spring-loaded to the
may occur.
center, “OFF”, position. Pushing the front of
When the keyswitch is “On” and the Parking Brake the switch raises the right side cab window.
Switch is applied, an indicator light in the L.H. panel Pushing the rear of the switch lowers the
pod will illuminate. window.

Brake Lock Switch (7, Figure 3-7) Ash Tray (10, Figure 3-7)
When this switch is in the “On” position, The Ash Tray is used for extinguishing and depositing
the Brake Lock is applied. smoking materials. DO NOT use for flammable materi-
als, such as paper wrappers, etc.
When this switch is in the “Off” position,
Be certain that all fire ash is extinguished!
the Brake Lock is released.

The Brake Lock should be used with engine running for

Lighter (11, Figure 3-7)
dumping and loading operations only. The brake lock
switch actuates the hydraulic brake system which The LIGHTER may be used for lighting cigars/ciga-
locks the rear wheel service brakes only. rettes.
Always use CAUTION with smoking materials!.
When pulling into shovel or dump area, select a loading
area with as level a surface as possible. When truck is This socket may also be used for a 12 VDC power
completely stopped and in loading position, apply the supply.
brake lock by pressing the rocker switch toward the
“On” symbol. To release, press the rocker switch to-
ward the “Off”symbol.
Passenger Seat w/Safety Belt (12 & 13, Figure 3-7)
The Passenger Seat (13) is mounted on top of the right
hand portion of the Center Console structure.
Use at shovel and dump only to hold truck truck in
position. Any passenger riding in the truck, must use the seat
belt (12) whenever the truck is being operated.
Do not use this switch to stop truck, unless foot-
operated brake valve is inoperative. Use of this The area beneath the passenger seat provides a cabi-
switch applies rear oil disc service brakes at full, net for various 24 VDC electrical components. Consult
unmodulated pressure! the Service Manual for service involving any of these
components.
Do not use brake lock for parking. With engine
stopped, hydraulic pressure will bleed down, al-
lowing brakes to release!
Operation - Section 3 OM3024.2 8/00
Page 3-22 Operator Cab and Controls

OPERATOR SEAT

The operator’s seat provides a fully adjustable cush- Installation

ioned ride for the driver’s comfort and ease of opera-
1. Mount seat assembly to seat riser. Install cap-
tion.
screws (11, Figure 3-8), lockwashers (12), flat-
washers (13) and nuts (14). Tighten capscrews to
Adjustment
standard torque.
The following adjustments must be made while sitting
2. Fasten tether straps (10) to floor with capscrews
in the seat.
(15), flatwashers (16) and lockwashers (17).
1. Headrest: headrest (1, Figure 3-8) will move up, Tighten capscrews to standard torque.
down, fore, or aft by moving headrest to desired
position.
2. Armrests: rotate adjusting knob until armrest is in
desired position.
3. Backrest: Pull control (3) upward and hold, select
backrest angle; release control handle.
4. Front Height and Slope Adjustment of Seat
Cushion:
a. Front height and slope; lift control lever (4) and
hold.
b. Bend knees to move seat to a comfortable
position; release control lever to lock adjust-
ment.
5. Fore/Aft Location of Seat:
a. Raise adjustment lever (5).
b. Move seat to desired position; release lever.
6. Seat Height: Press rocker switch (6) on top to
increase ride height. Press on lower part of rocker
switch to lower ride height.
7 & 8. Air Lumbar Support Each rocker switch (7 or
8) controls an air pillow. Switch (7) controls the
lower air pillow and switch (8) controls the upper
air pillow. To inflate, press on top of rocker switch
and hold for desired support, then release. To
deflate, press on bottom of rocker switch and hold
for desired support, then release. Adjust each
pillow for desired support. FIGURE 3-8. OPERATOR’S SEAT
1. Headrest 9. Seat Belt
2. Armrest Adjustment 10. Seat Tether
Removal 3. Backrest Adjustment 11. Capscrew
4. Front Height and Slope 12. Lockwasher
1. Remove capscrews (11, Figure 3-8) and hardware Adjustment 13. Flatwasher
that secures the seat base to the riser. Remove 5. Fore and Aft Adjustment 14. Nut
capscrews (15) that secures tether (10) to floor. 6. Height Adjustment 15. Capscew
2. Remove seat assembly from cab to clean work 7. Lower Air Pillow Lumbar Support 16. Flatwasher
area for disassembly. 8. Upper Air Pillow Lumbar Support 17. Lockwasher
OM3024.3 8/00 Operation - Section 3
Instrument Panel and Indicators Page 3-23

INSTRUMENT PANEL AND INDICATORS

FIGURE 3-9. INSTRUMENT PANEL

1. Keyswitch 3. R.H. Panel (Pod) 6. Ladder Light Switch
2. Auxiliary Brake Switch 4. Center Display Panel 7. Head Light Switc
5. L.H. Panel (Pod) 8. BackUp/Deck Lights Switch

The instrument panel consists of a R.H. & L.H. Control/Indicator Panel (R.H. & L.H. Pods), a
Center Display Panel (gauge and monitor module, with speedometer/tachometer module, trans-
mission range indicator, service/hour meter, and odometer), and a row of control switches across
the bottom of the panel.

The gauge and monitor module and speedometer module each have a microcomputer to process
and display the signals from the sensors. Liquid crystal is used for the display area.

The monitors and gauges inside the monitor module and speedometer module are actuated by
the signal from the gauge and monitor module, and the odometer is actuated by signals from the
speedometer module.

The following pages will identify each element of the instrument panel and detail its function and
purpose for the operator.
Operation - Section 3 OM3024.3 8/00
Page 3-24 Instrument Panel and Indicators

Keyswitch
The keyswitch (1, Figure 3-9) is a three position (Off,
Run, Start) switch.
Starting fluid is extremely volatile and flammable!
Use with extreme care.

If truck is equipped with optional Engine Starting Aid

and ambient temperature is below 50oF (10oC), turn
the keyswitch to the “Start” position, and while crank-
ing engine, move the Engine Starting Aid switch to the
“On” position for three (3) seconds MAXIMUM; then
release Engine Starting Aid. If engine does not start,
wait at least fifteen (15) seconds before repeating the
procedure.
Do not crank an electric starter for more than 30
seconds.
Allow two minutes for cooling before attempting to start
engine again.
Severe damage to starter motor can result from over-
heating.

“OFF” – Auxiliary Brake Switch

Key insertion/withdrawal position –
This switch (2, Figure 3-9) applies the Auxiliary Brake.
None of the electrical circuits are
energized in this position. Depress the center button to apply the auxiliary brake.
When the switch is “On”, the RED lamp will illuminate.
Turn the switch to “OFF” to stop the
engine. Depress the button again to release the auxiliary
brake; the light will turn “Off”.
“ON” –
When the switch is rotated one position clock-
wise, it is in the “Run” position.
Lamp circuits and other electrical circuits (except
“Start”) are energized in this position.
“START” –
With Transmission Selector
Lever in the “Neutral” position,
rotate keyswitch fully clockwise to
the “Start” position and hold until
engine starts. “Start” position is
spring loaded to return to “Run” When the auxiliary brake switch is activated, full,
when key is released. unmodulated hydraulic brake pressure (or what-
ever pressure remains, if the system is failing) is
applied to all wheels.
NOTE: The engine start circuit is equipped with the In addition, the parking brake is also applied.
Cummins Engine Prelube System. A noticeable time
delay will occur (while engine lube oil passages are The operator should not apply the auxiliary brake
being filled) before starter engagement and engine switch when the truck is moving, except as an
cranking will begin. The colder the engine oil tempera- emergency measure.
ture, the longer the time delay will be. In addition, if
truck is also equipped with Engine Starting Aid for cold NOTE: This switch is for the manual activation of the
weather starting, the Engine Prelube System should auxiliary brake circuit by the operator.
be engaged FIRST for 5-10 seconds, or until starter is The auxiliary brake circiut will apply automatically, if
engaged, BEFORE activating the Engine Starting Aid. the hydraulic brake pressure decreases below a pre-
set value.
OM3024.3 8/00 Operation - Section 3
Instrument Panel and Indicators Page 3-25

R.H. Control/Indicator Panel (Pod) Ladder Light Switch

The Control/Indicator Panel (3, Figure 3-9), located to
The switch (6, Figure 3-9) turns the
the right of the steering wheel, provides an array of
ladder lights “On” or “Off” after or
switches and controls.
before using ladder. A similar
For detailed inrormation on this assembly, refer to
switch is available at ground level
“R.H. Control/Indicator Panel (Pod)” later in this sec-
to turn the lader lights “Off” or “On”.
tion.

Center Display Panel

Head Light Switch
The Center Display Panel (4, Figure 3-9) provides an
array of gauges and monitors, with an odometer mod- The instrument panel lights, clear-
ule) and a service/hour meter module. ance lights, and the headlights are
For detailed inrormation on this assembly, refer to controlled by this three position
“Center Display Panel” later in this section. rocker type switch (7, Figure 3-9).
“Off” is selected by pressing the left
side of the switch. Press the right
side of the switch until it reaches
L.H. Control/Indicator Panel (Pod) the first detent (middle) to select the panel, clearance,
The Control/Indicator Panel (5, Figure 3-9), located to and tail lights only. Press the right side of the switch
the left of the steering wheel, provides an array of again, until it reaches the second detent to select
indicator/monitor lights and three switches. headlights, as well as panel, clearance, and tail lights.
For detailed inrormation on this assembly, refer to
“L.H. Control/Indicator Panel (Pod)” later in this sec-
tion.
"OFF" T h e s e a r e “ R o c k e r - t y pe ” "ON"
switches.
The “Off” and “On” positions are
marked with these symbols.

BackUp/Deck Lights Switch

The BackUp/Deck Lights Switch (8,
Figure 3-9) allows backup lights to
be turned “On” providing added
visibility and safety when the Trans-
mission Range Selector lever (see
OPERATOR CONTROLS) is not in
“REV” position.
Operation - Section 3 OM3024.3 8/00
Page 3-26 Instrument Panel and Indicators

R.H. Control/Indicator Panel (Pod)

The Control/Indicator Panel (3, Figure 3-9), located to
the right of the steering wheel, contains the following:

Cold Weather Starting Aid (Ether Injection)

Switch
The Starting Aid Switch (1, Figure 3-10)
is an “ON-OFF” type “rocker” switch that
is spring-loaded to the “OFF” position.

When the outside temperature is below

-5°C (23°F), depress the top of this switch and
hold for 2-3 seconds before starting the engine.
The Cold Starting Aid atomizes ether into the
engine intake manifold.
Refer to KEYSWITCH, “START” for further de-
tails regarding the use of this switch.
DO NOT push ether injection switch after engine
has started!
SERIOUS DAMAGE TO ENGINE MAY OCCUR!

Hazard Warning Lights Switch

The Hazard Warning Light switch (2, Fig-

ure 3-10) causes all turn signal lights to
flash simultaneously.

The “rocker” switch is an “ON-OFF” type.

Depressing the bottom turns the switch “Off”.
Depressing the top turns the switch “On”.

FIGURE 3-10. R.H. CONTROL/INDICATOR PANEL

1. Cold Weather (Ether) 4. A/C & Heater Vent

Starting Aid Switch 5. ASR Cut (Traction
2. Hazard Flasher Control) Switch
Switch (Optional)
3. AISS Automatic
Engine Idle System
OM3024.3 8/00 Operation - Section 3
Instrument Panel and Indicators Page 3-27

Automatic Idle Selector Switch (AISS) ASR Cut (Traction Control) Switch (Option)
The AISS Switch (3, Figure 3-10) controls
The ASR cut switch (5, Figure 3-10) is
the “idle” speed of the engine (released
used to activate or de-activate the Op-
throttle pedal). With the foot-operated
tional traction control system.
throttle pedal in the released position, the
PMC (Powertrain Management Control-
ler) sends a signal to the Quantum  Fuel Control
System for a “low idle” RPM. The “rocker” switch is an “ON-OFF” type.
Depressing the bottom turns the system “Off”.
This signal may be for either:
Depressing the top turns the system “On”.
• 650 RPM - “Normal” low idle, or
When the system is On, the internal lamp in the
• 1000 RPM - High-Low idle;
switch illuminates.
depending on the following conditions:
1. Depressing the bottom of the switch selects the
“Off/AUTO” position which is used for normal When ASR is active, the system monitors individual
truck operations. When the AISS switch is in this wheel speeds and if it determines one of the rear
position, the PMC idle signal will be determined wheels is slipping (losing traction) when power is
by two conditions: applied, braking is applied to the rear wheel with the
engine coolant temperature, and higher speed.
brake application.
a. Engine Coolant Temperature -
If the engine coolant temperature is below NOTE: If both rear wheels are slipping approximately
30°C/47°F, the PMC will signal for 1000 RPM, the same amount, the system will not provide any
regardless of other conditions. braking to the wheels. In this situation, the operator
must reduce the throttle to prevent slippage.
If the engine coolant temperature is above
30°C/47°F, the PMC will signal for 650 RPM,
except as follows:
b. Brake Application -
If both the parking brake and service brake are
released (acceleration anticipated), the PMC
will signal for 1000 RPM, regardless of other
conditions.
2. Depressing the top of the switch selects the
“On/Low” position.
When the AISS switch is in this position, the PMC
will signal for 750 RPM, regardless of other con-
ditions. “On/Low position is used when fine con-
trol movements are needed, such as when
parking in confined spaces.

Air Conditioner & Heater Vent

The air conditioner/heater vent (4, Figure 3-10) swivels
on a vertical axis to direct air toward or away from the
operator. Air flow (up, down, on, off) through the vent
is controlled by manually opening/closing or turning
the louver.
Operation - Section 3 OM3024.3 8/00
Page 3-28 Instrument Panel and Indicators

Center Display Panel

The Center Display Panel (4, Figure 3-9) consists of a The monitors and gauges inside the monitor module
gauge and monitor module (1 – 27, Figure 3-11), with and speedometer module are actuated by the signal
an odometer module (29) and a service/hour meter from the gauge and monitor module, and the odometer
module (28). Liquid crystal is used for the display area. is actuated by signals from the speedometer module.

The gauge and monitor module and the speedometer The following pages will identify each element of the
module each have a microcomputer to process and Center Display Panel and detail the function and pur-
display the signals from the sensors. pose for the operator.

FIGURE 3-11. 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. Engine Controller Monitor
4. Coolant Temperature Gauge 19. Automatic Transmission Mechatronics Monitor
5. Torque Converter Oil Temperature Monitor 20. Other Controllers (OPTIONAL)
6. Torque Converter Oil Temperature Gauge 21. Fuel Level Monitor
7. Retarder Oil Temperature Monitor 22. Fuel Gauge
8. Retarder Oil Temperature Gauge 23. Engine Power Derate Monitor
9. Left Turn Signal Pilot Lamp 24. F1 Start Monitor
10. High Beam Pilot Lamp 25. Auto Cruise Control Monitor (Not Used)
11. Right Turn Signal Pilot Lamp 26. ASR Monitor
12. Speedometer 27. ABS Monitor
13. Tachometer 28. Service Meter & Indicator
14. Lock-up Pilot Lamp 29. Odometer
15. Shift Limiter Pilot Lamp
OM3024.3 8/00 Operation - Section 3
Instrument Panel and Indicators Page 3-29

Air Pressure Monitor (NOT USED) Retarder Oil Temperature Monitor

The Air Pressure Monitor (1, Figure 3-11) The Retarder Oil Temperature Monitor
is NOT USED on this truck. lamp (7, Figure 3-11) warns that the re-
tarder oil temperature has risen.

If it flashes, stop the machine, return the Transmission

Air Pressure Gauge (NOT USED)
Range Selector lever to Neutral, and run the engine
The Air Pressure Gauge (2, Figure 3-11) is NOT USED under no load at 1200-1500 RPM until the warning
on this truck. lamp goes out.

Retarder Oil Temperature Gauge

Coolant Temperature Monitor
The Retarder Oil Temperature Gauge (8, Figure 3-11)
indicates the temperature of the retarder cooling oil.
The Coolant Temperature Monitor (3, Fig-
During normal operation, a lamp in the green range
ure 3-11) indicates a rise in the cooling
should light up.
water temperature.
If the lamp in the red range lights up during operation,
the alarm buzzer will sound, the central warning lamp
When the monitor lamp flashes, run the engine with no
will flash, and the retarder oil temperature monitor
load at 1200-1500 RPM until the green range of the
lamp will flash at the same time. If this happens, stop
engine water temperature gauge lights.
the machine, return the Transmission Range Selector
lever to Neutral, and run the engine at 1200-1500
Engine Cooling Water Temperature Gauge
RPM under no load, and wait until the lamps in the
The Engine Cooling Water Temperature Gauge (4, green range light up.
Figure 3-11) indicates the temperature of the cooling
water. If the temperature is normal during operation, Left Turn Signal Pilot Lamp
the green range will light. If the red range lights during
operation, the alarm buzzer will sound, the central When the turn signal lever is moved down-
warning lamp will flash and the coolant temperature wards, the left turn signal pilot lamp (9,
monitor lamp will flash at the same time. If this occurs, Figure 3-11) flashes.
stop the machine and run the engine with no load at
1200-1500 RPM until the green range lights.
High Beam Pilot Lamp
Torque Converter Oil Temperature Monitor The High Beam Pilot Lamp (10, Figure 3-11)
lights up when the head lamps are on high
The Torque Converter Oil Temperature beam.
Monitor (5, Figure 3-11) indicates a rise in
the torque converter oil temperature.
Right Turn Signal Pilot Lamp
When the monitor lamp flashes, stop the machine and
When the turn signal lever is moved up-
run the engine with no load at 1200-1500 RPM until
wards, the right turn signal pilot lamp (11,
the green range of the temperature gauge lights.
Figure 3-11) flashes.
Torque Converter Oil Temperature Gauge
The Torque Converter Oil Temperature Gauge (6,
Speedometer
Figure 3-11) indicates the temperature of the torque
converter oil. If the temperature is normal during op- The digital Speedometer (12,
eration, the green range will light. If the red range lights Figure 3-11) indicates the
during operation, the alarm buzzer will sound, the travel speed of the truck in
central warning lamp will light up and the torque con- miles per hour, or kilometers
verter oil temperature monitor lamp will flash at the per hour.
same time. If this occurs, stop the machine and run the This figure will appear momentarily when the
engine with no load at 1200-1500 RPM until the green keyswitch is first turned “On” to demonstate that all
range lights. segments are working.
Operation - Section 3 OM3024.3 8/00
Page 3-30 Instrument Panel and Indicators

Tachometer Automatic Transmission Mechatronics Monitor

The Tachometer (13, Figure This red indicator (19, Figure 3-11)
3-11) indicates 0-2500 RPM flashes whenever any abnormality occurs
engine speed. in the mechatronics related parts of the
Each bar represents 100 transmission control system.
RPM.

Other Mechatronics Monitor (OPTIONAL)

This red indicator (20, Figure 3-11)
Lock-up Pilot Lamp
flashes whenever any abnormality occurs
in the mechatronics related parts of the
The Lock-Up Pilot Lamp (14, Figure 3-11)
PMC (Powertrain Management Control)
lights up (blue) whenever the torque con-
system, RCM (Retard Control Monitor)
verter is locked up and the transmission
system, PLM (PayLoad Meter) system, and the sus-
enters direct drive.
pension control system .

Fuel Level Monitor

Shift Limiter Pilot Lamp
This red indicator (21, Figure 3-11)
The Shift Limiter Pilot Lamp (15, Figure
flashes whenever the remaining fuel in
3-11) lights up (blue) whenever the shift
the fuel tank goes below 40 gal. (150
limiter switch (on center console) is acti-
liters).
vated.

When this indicator flashes, check the fuel level gauge

(22) and/or add fuel to the truck fuel tank.
Shift Indicator

Fuel Gauge
The Shift Indicator (16, Figure 3-11) indicates the
lever position of the transmission range selector. The Fuel Gauge (22, Figure 3-11) indi-
cates the amount of fuel in the fuel tank. If
there is more than 40 gal. (150 liters) of
fuel in the tank while the engine is operating, the green
range illuminates. If there is less than 40 gal. (150
liters) of fuel in the tank, the red range illuminates.

Engine Power Derate Monitor

Transmission Shift Position Pilot Lamp
This red indicator (23, Figure 3-11)
The Transmission Shift Position Pilot Lamp (17, flashes to alert the operator that the PMC
Figure 3-11) will indicate the specific gear range (Powertrain Management Controller) has
in which the transmission is actually operating; detected an engine fault and is signalling
R, N, 1, 2, 3, 4, 5, 6, or 7. the Quantum  Fuel Control system to
reduce power output to protect the engine.

Engine Controller Monitor

F1 Start Monitor
This red indicator (18, Figure 3-11) This blue indicator (24, Figure 3-11) illu-
flashes whenever any abnormality oc- minates whenever the F1 Shift Limit
curs in any of the engine control systems. switch (on center console) is activated.
OM3024.3 8/00 Operation - Section 3
Instrument Panel and Indicators Page 3-31

Auto Cruise Control (Not Used) L.H. Control/Indicator Panel (Pod)

This indicator (25, Figure 3-11) is cur- The Control/Indicator Panel (5, Figure 3-9), located to
rently not used. the left of the steering wheel, contains the following:

ASR Monitor (OPTIONAL)

This indicator (26, Figure 3-11) illumi-

nates whenever the OPTIONAL traction
control system (if installed) is activated.

ABS Monitor (OPTIONAL)

This indicator (27, Figure 3-11) illumi-

nates whenever the OPTIONAL Anti-Slip
Brake control system (if installed) is acti-
vated.
FIGURE 3-12. L.H. CONTROL/INDICATOR PANEL

1. L.H. Panel (Pod Assy.)11. Service Brakes Applied

2. Engine Oil Temp. 12. Maintenance Monitor
3. Engine Coolant Level 13. Transmission Oil Filters
4. Low Steering Press. 14. Lamp Test Switch
5. Accumulator 15. Low Brake Pressure
Service Meter
Pre-Charge Pressure 16. Lateral Slope Warning
The Service Meter (28, Figure 3-11) dis- 6. Battery Charge (Amps) 1
plays the total hours of operation for the 7. Check Engine 18. Panel Dimmer Switch
truck.The meter advances whenever the 8. Parking Brake 19. Engine Oil Pressure
engine is operating, even if the truck is not 9. Body Float 20. Central Warning Lamp
moving. 10. Trans. Oil Temp. 21. A/C & Heater Vent

L.H. Panel/Pod Assembly

The L.H. Panel/Pod Assy. (1, Figure 3-12) provides an
Odometer array of indicator/monitor lights and three switches.
NOTE: All the Indicator Lamps are RED in color;
The Odometer (29, Figure 3-11) indicates the total Except, #11. which is AMBER/YELLOW.
distance that the truck has traveled in miles or kilome-
ters. Engine Oil Temperature
The Engine Oil Temperature Monitor light
(2, Figure 3-12) will illuminate if the en-
gine oil temperature exceeds 250°F
(121°C) for a continuous period of 5 sec-
onds. If the lamp flashes and alarm buzz-
er sounds, stop the engine.
At the same time, a fault code will be registered in the
Quantum  System. Refer to Quantum  FUEL
SYSTEM DIAGNOSTICS later in this section.
Operation - Section 3 OM3024.3 8/00
Page 3-32 Instrument Panel and Indicators

Engine Coolant Level Parking Brake

The Engine Coolant Level Monitor light (3, The Parking Brake Monitor light (8, Fig-
Figure 3-12) will illuminate, if the engine ure 3-12) will illuminate if the transmis-
coolant level is below the sensor for a sion controller detects that the parking
continuous period of 5 seconds. At the brake is applied or that the wire between
same time, a fault code will be registered the switch and the controller is cut or
in the Quantum  System. (Refer to Quantum  broken.
FUEL SYSTEM DIAGNOSTICS later in this section.)
If this monitor lamp flashes and alarm buzzer sounds, Body Float
stop truck, shutdown engine, and add coolant as re-
quired. The Body Float Monitor light (9, Figure
3-12) will illuminate if the transmission
controller detects that the body is not
seated on the frame rail or that the wire
Low Steering Pressure
from the proximity switch and the controller is cut.
The Low Steering Pressure Monitor light When the dump body control lever is set to any position
(4, Figure 3-12) will illuminate if the steer- other than FLOAT, the Body Float Monitor lights up.
ing system pressure is below 1850 psi When traveling, always set the lever to FLOAT posi-
(12.8 MPa). The light may also indicate tion.
that the wire from the switch to the trans-
mission controller is cut or broken.
Transmission Oil Temperature
The Transmission Oil Temperature
Accumulator Pre-Charge Monitor light (10, Figure 3-12) will illumi-
nate if the transmission controller detects
The Accumulator Pre-Charge Monitor
that the oil temperature is over 248°F
light (5, Figure 3-12) will illuminate, if the
(120°C)
accumulator nitrogen pressure is below
850 psi (5 861 kPa). The light may also
indicate that the wire from the switch to
Service Brakes Applied
the transmission controller is cut or broken.
The Service Brakes Applied Monitor light
(11, Figure 3-12) will illuminate (amber),
Battery Charge Amps if the transmission controller detects that
the rear brakes have been applied, or
The Battery Charge Amps Monitor light
that the wire between the switch and the
(6, Figure 3-12) will illuminate, if the
controller is grounded.
transmission controller detects low bat-
tery current at the “R” terminal of the
Maintenance Monitor
alternator while the engine is running or
if the wire is cut. If the monitor lamp flashes, check the
The Maintenance Monitor lamp (12, Fig-
charging circuit.
ure 3-12) will illuminate if the PMC (Pow-
ertrain Management Controller), detects
any of the following faults:
Check Engine
* Low oil brake cooling oil level
The Check Engine Monitor light (7, Figure
* Low hydraulic oil level
3-12) will illuminate if a problem occurs in
* Low battery liquid level
the Quantum  engine control system.
* Front oil brake cooling filter restricted
The light is also used to display the
* Rear oil brake cooling filter restricted - Right side
trouble code.
* Rear oil brake cooling filter restricted - Left side
* Hydraulic Oil Filters Restricted
(Refer to Quantum  FUEL SYSTEM DIAGNOSTICS
* Brake Disc Wear Indication - Right Front
later in this section.)
* Brake Disc Wear Indication - Left Front
* Brake Disc Wear Indication - Right Rear
* Brake Disc Wear Indication - Left Rear
OM3024.3 8/00 Operation - Section 3
Instrument Panel and Indicators Page 3-33

Transmission Oil Filters Crankcase Pressure

The Transmission Oil Filters Monitor The Crankcase Pressure Monitor lamp
lamp (13, Figure 3-12) will illuminate if the (17, Figure 3-12) will illuminate if the en-
transmission controller detects that a gine crankcase pressure is greater than
transmission filter is restricted, or that the 14.5 in. of H2O (water) for more than 5
wire between the controller and the seconds.
switch is cut or broken. At the same time a fault code will be registered in the
If this lamp flashes and the alarm buzzer sounds, notify Quantum  System. (Refer to Quantum  FUEL
maintenance personnel, immediately. SYSTEM DIAGNOSTICS later in this section.)
As soon as practical thereafter, drain the transmission
oil, replace the transmission filters, and check for
contamination in the oil.
Panel Dimmer Switch
Lamp Test
The Panel Dimmer Switch (18, Figure
The Lamp Test switch (14, Figure 3-12) is a 3-12) is used to adjust the brightness of
three position, two function switch. The switch the lighting inside the monitor panel.
is spring loaded to the middle, “neutral” posi-
tion. If depressed on the right side and held, it
is a lamp test for all of the monitor lamps except the
Adjust as follows:
check engine lamp.
To increase brightness, turn clockwise.
If the left side of the rocker switch is depressed held
the lamp test for the check engine lamp will function. To decrease brightness, turn counter-clockwise.
When the check engine lamp is illuminated because
of a fault in the Quantum  System, depress and
release the left side of the rocker switch. Wait, and the Engine Oil Pressure
Check Engine lamp will begin flashing the fault codes.
The Engine Oil Pressure Monitor lamp
(19, Figure 3-12) will illuminate if the en-
(Refer to Quantum  FUEL SYSTEM DIAGNOSTICS
gine oil pressure falls below a certain
later in this section.)
value for a 5 second period of time. That
value is dependent on engine RPM.
At the same time a fault code will be registered in the
Low Brake Pressure Quantum  System. (Refer to Quantum  FUEL
SYSTEM DIAGNOSTICS later in this section.)
The Low Brake Pressure Monitor lamp
(15, Figure 3-12) will illuminate if the
transmission controller detects that the
brake system hydraulic pressure is below
1850 psi, or that the wire from the switch
to the controller is cut.

Lateral Slope Warning

The Lateral Slope Warning Monitor lamp
(16, Figure 3-12) will illuminate if the
dump body is off of the frame and the
lateral slope of the truck is beyond a
pre-set safety limit.

(This is a tip-over warning device)

Operation - Section 3 OM3024.3 8/00
Page 3-34 Instrument Panel and Indicators

Central Warning Lamp (Red Convex Lens) REAR OF OPERATOR CAB

The Central Warning Lamp Monitor lamp (20, Figure The following components are located behind the op-
3-12) will illuminate if any of the monitor lamps in the erator and passenger seats across the back wall of the
L.H. pod (Figure 3-12) are activated. This lamp is also operator cab (Refer to Figure 3-13):
activated if a fault is registered on the “MOM” display.
1. Circuit Breaker Panel
This lamp flashes, and at the same time an alarm
buzzer sounds intermittently, if an abnormality has This panel contains all of the electrical circuit
occurred in any one of the following systems: breakers on the truck.

Coolant Temperature Monitor; 2 & 3. Relay Boards

Torque Converter Oil Temperature Monitor; These panels contain relays for various electrical
Retarder Oil Temperature Monitor; circuits on the truck.
Engine Oil Pressure Monitor; Refer to the Service/Shop Manual for specific
High Engine Oil Temperature; information regarding the relay boards.
High Engine Blowby Pressure;
High Transmission Lube Oil Pressure; 4. RCM - Retard Control Monitor
Battery Charging Monitor; This panel controls and monitors the fully hydrau-
Parking Brake Monitor; lic retarder system.
Body Float Monitor; Refer to the Service/Shop Manual for specific
Automatic Transmission Monitor (Mechatronics); information regarding this device.
Other Mechatronics Monitor; or
Fuel Level Monitor. 5. RCM Data Port

This lamp will also flash and the alarm buzzer will This is a connector to be used when communica-
sound, if the parking brake is applied and the range tions are required between the RCM and a per-
selector lever is not at Neutral. sonal computer.

NOTE: The warning lamp and buzzer will not actuate 6. ASC - Automatic Suspension Controller (Op-
when "MOM" detects a problem and displays the ac- tional)
tion code "01". This panel (when installed) controls and monitors
the Varible Rate Suspension units.
AC/Heater Vent Refer to the Service/Shop Manual for specific
The AC/Heater vent (21, Figure 3-12) is provided for information regarding this device.
circulation of cooled or heated air through the cab. 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 Service/Shop Manual for specific
information regarding this device.
8. PMC - Powertrain Management Controller
This panel controls, monitors, and manages all of
the other monitors and controllers listed above.
Refer to the Service/Shop Manual for specific
information regarding this device.
9. Terminal Strips - Terminals for various electrical
circuits. Refer to the Service/Shop Manual Elec-
trical Schematic for specific information.
OM3024.3 8/00 Operation - Section 3
Instrument Panel and Indicators Page 3-35

FIGURE 3-13. REAR WALL OF OPERATOR CAB

1. Circuit Breaker Panel 6. ASC - Automatic Suspension Controller (OPTIONAL)
2. Relay Board 7. ATC - Automatic Transmission Controller
3. Relay Board 8. PMC - Powertrain Management Controller
4. RCM - Retard Control Monitor 9. Terminal Strips
5. RCM Data Port
Operation - Section 3 OM3024.3 8/00
Page 3-36 Instrument Panel and Indicators

Quantum  FUEL SYSTEM above, this switch will permit determination of the kind
DIAGNOSTICS of “fault(s)” detected.
- CUMMINS Engine Only -
Determining “FAULT” Codes
The CHECK ENGINE Monitor Light (7, Figure 3-12)
Quantum  fault codes consist of three numerical
monitors the Quantum  Fuel Control system. When
digits. Each digit is indicated with up to five light flashes
the keyswitch is turned “On”, this light should illumi-
(CHECK ENGINE Monitor Light) per each digit. There
nate for about 2 seconds and then turn “Off”, if no
is a short pause between each digit of the fault code.
“faults” are detected in the system.
Once all three digits are flashed, there is a longer
pause, followed by a repeating of the same fault code
sequence.
1. To determine an active Quantum  “fault”, turn
the keyswitch to the OFF position. Be sure engine
completely stops, if it was running.
2. Turn keyswitch to ON position (engine not run-
ning) and press Lamp Test switch to the left (“√”
position) for 1 – 2 seconds, then release (switch
is spring-loaded to the middle, “OFF”, position).

If the light stays ON, or FLASHES, then active “faults”

have been detected by the system and the engine
should not be started.
Refer to DETERMINING “FAULT” CODES below.
During engine operation, if a “fault” is detected in the
system, the light will turn ON and stay on for “Warning
faults”, or it will turn “ON and FLASH” for more severe
faults that can affect engine operation and require
immediate attention.

3. If there is an active fault after releasing the switch,

there will be a short pause, followed by the first
fault code.

• “Warning” faults (light ON) are ones that require

attention in the near future, but in most conditions
will not greatly affect governing performance.
• “Severe” faults (light FLASHING) are ones that
require immediate attention, because Quantum
 governor performance could be significanly
affected, resulting in a backup mode of operation.

Active fault conditions MUST be corrected as

soon as possible.
The Lamp Test/Diagnostic Test Switch (14, Figure
3-12) may be used to activate the Quantum  Fuel
System diagnostic codes. When the Quantum  fuel
system detects a “fault” and the CHECK ENGINE
Monitor Light (7, Figure 3-12) illuminates as described
OM3024.3 8/00 Operation - Section 3
Instrument Panel and Indicators Page 3-37

Exiting The Diagnostics Mode

4. Pressing the Lamp Test switch to the bottom (“√”) Starting the engine or turning the keyswitch to the OFF
again will advance to the next fault code (if more position will EXIT the diagnostics fault flash mode.
than one code is present). Once all active fault
codes have been displayed, the fault code display
sequence will be repeated, starting from the first
fault code.

If active fault codes have been determined as de-

scribed previously, refer to the Cummins Engine
Quantum  System “Troubleshooting and Repair
Manual”, Bulletin No. 3666070, or contact an Author-
ized Repair Location.
Operation - Section 3 OM3024.3 8/00
Page 3-38 Instrument Panel and Indicators

NOTES
OM3024.4 8/00 Operation - Section 3
Electronic Displays and Messages Page 3-39

MESSAGE FOR OPERATION AND MAINTENANCE ("MOM")

"MOM" (Message for Operation and Maintenance) is 1. Screen i1, Initial Message
the message display screen located in the upper panel
just above the operator’s head. It is used to display
messages to the operator and service personnel. The
screen incorporates touch switches on its surface, to
change displays.
Data that "MOM" can display includes:

Truck Condition-
When the key switch is turned to the run position before
cranking, the display will read OK or WAIT. If the WAIT
warning is present, the reason will also displayed.
If the engine is running and the truck is ready to be
moved, the screen will indicated departure is OK or
WAIT. If the WAIT warning is present, the reason will
also be displayed. After the key switch is turned on, the initial mes-
sage (i1) is displayed for three seconds after a
Production Data During Operation - system message is displayed. The picture num-
(Information from the Payload Meter) ber, i1, the title, and the program version number
• The Current Payload are all indicated on this screen. After being dis-
played for three seconds, i1 is changed to the first
• The Total Payload initial check, Check 1, screen i2, automatically.
• The Total Number Of Cycles If any of the controllers detect a fault in their
• Fault Information At The Time Of Occurrence system, the i1 screen is changed to the display of
the warning message i6 automatically after three
• The Fault Code And Its Description seconds.
• The Action Code And Its Description 2. Screen i2, Initial Check 1
• Other Function - Clock
NOTE: The operator should follow the recommenda-
tion that is displayed on the "MOM" screen. However,
the operation of the truck is not prohibited. Even if the
screen displays WAIT the truck can still be operated if
an emergency situation exists.

This screen is displayed after i1 and before engine

is started. It is used to inform the operator whether
the conditions are acceptable to start the engine.
When "MOM" judges that engine start is accept-
able, "ENGINE START OK" is indicated on the
screen.
If "MOM" judges that engine start is not accept-
able, "ENGINE START WAIT" is indicated on the
screen.
Operation - Section 3 OM3024.4 8/00
Page 3-40 Electronic Displays and Messages

The reason why the engine start is not acceptable If any controller detects a fault, i3 is changed to
is also indicated at the same time. If the screen the warning message screen i6 automatically.
displays "PARKING BRAKE", it means the park-
4. Screen i4, Normal Display
ing brake is not applied. If the screen displays
"T/M SHIFT LEVER", it means the shift lever is not
in the neutral position.
The engine will still start even if the screen indi-
cates "PARKING BRAKE" while the shift lever
must be in the neutral position for the engine to
start. After the engine starts the i2 screen changes
to the second initial check, Check 2, screen i3
automatically.
If any controller detects a fault, i2 is changed to
the i6, Warning Message screen automatically.

This screen is displayed while the truck is running

and the range selector is in either a forward or
reverse position. Once the range selector is
changed from the neutral position the i4 screen is
displayed until the key switch is turned to the off
position, even is the range selector is returned to
the neutral position.
Time, current payload, total payload, and total
number of cycles are indicated in this display.
If during the time the i3 screen was displayed the
"DEPARTURE WAIT" was indicated because of
3. Screen i3, Initial Check 2 either "STRG." and/or "DERATE", they will remain
This screen is displayed after the engine is running on until the cause is discovered and repaired.
but, before the range selector lever is moved from The payload meter is the source of the information
the neutral position. The indication will be that regarding payload data. "MOM" is unable to indi-
departure is acceptable or not. cate this data until it is sent by the payload meter.
When "MOM" judges that departure is acceptable, The payload meter will send this information to
"DEPARTURE OK" is indicated on the screen. "MOM" when it recognizes the truck is in a loading
configuration. It will continue sending information
If "MOM" judges that departure is not acceptable, until it realizes that the loading configuration is
"DEPARTURE WAIT" is indicated on the screen. finished or the truck has changed to a dumping
The reason why departure is not acceptable is condition. After first recognizing a loading and
also indicated at the same time. Possible reasons then dumping configurations, the payload meter
could be, "STRG. PRESSURE TOO LOW" when will then sent the data of total payload and total
the steering accumulator pressure is too low, or number of cycles.
"ENG. DERATE ON" when the engine system The following situations are considered not nor-
detects some severe fault which makes the engine mal.
power derate. a. If the truck was in a loading configuration and
The tr uc k is still ab le to d ep art even is the key switch was turned off and then back on
"STRG.PRESSURE TOO LOW" or "ENG. DER- again, "MOM" will indicate no data of current
ATE ON" if in an emergency situation. When the payload, total payload, and total number of
engine is started i2 is changed to the initial check cycles.
i3 screen automatically. b. The data for total payload and total number of
If the "LIGHTS OFF" area in the i3 screen is cycles is not indicated in "MOM" until the pay-
touched, then the back light of "MOM" is turned load meter recognizes that the truck has started
off and i3 is turned to a dark display. dumping the load.
OM3024.4 8/00 Operation - Section 3
Electronic Displays and Messages Page 3-41

c. The data for current payload is not indicated After the operator has been informed of the fault
until the payload meter recognizes that the code the action that should be taken is as
truck is being loaded. follows:
d. If after the current payload has been indicated 1) Stop the truck in a safe location.
and then additional material is now added to 2) Apply the parking brake.
the load, the current payload data will not 3) Confirm the presence of the fault code and
change. the action code.
e. If data is not being recognized by "MOM", dump 4) Follow the instructions of the action code.
the load. Activate the dump cycle a second time 5) Notify a qualified technician for repairs.
and then assume normal operation.
The possible action codes are as follows:
Note: For additional information regarding the
Payload Meter, refer to the Option section of
the service manual. Code Description
If the "LIGHTS OFF" area in i4 is touched then 01 Notify maintenance at shift change
the back light of "MOM" is turned off and i4 is 02 Notify maintenance right now
changed to a dark display. 03 Reduce engine / machine speed
If any controller detects a fault, i4 is changed to 04 Stop safely now / shut off engine
the i6 warning message display automatically.
05 Stop with engine at mid speed
5. Screen i6, Warning Message Display
06 Start engine and keep at low idle
07 Keep body seated.

Two faults can be displayed at one time along

with their description and action. If three or
more code are present the "FWD" and "REV"
touch areas on the i6 screen can be used to
view the other codes. The number that is as-
signed to each code, is the order of occur-
rence. Number 1 would be the oldest code and
as the numbers increase the newer the code.
If the fault code display in MOM is not a serious
code requiring immediate action, the code can
be cleared from the screen by touching the
number of each fault located at the left side of
When a fault occurs in any of the controllers the the code number. However, this action only
operator is informed of this through the following erases the code in MOM. This is still an active
method: fault, and the electronic display panel will keep
a. MOM will display the fault code and the action indicating the action code. The central warning
code along with a description of each. lamp will also remain activated.
b. The electronic display in the instrument panel Once the fault code is erased from MOM the
will also display the action code. same code will not appear again until the code
is recovered or unless the fault occurs again.
c. The central warning lamp is turned on and off
When all of the faults are recovered or cleared
as a warning alarm. In certain cases the warn-
from MOM the screen will return to i2, i3, or i4
ing buzzer is also activated.
automatically according to the truck condition.
If the fault is with a component or system that
also has a warning lamp, this indication will also
be activated at the same time.
Operation - Section 3 OM3024.4 8/00
Page 3-42 Electronic Displays and Messages

6. Screen i7, Back Light Off With one of the previously listed failure codes the
transmission will fail to "Neutral", in order to move the
truck the following procedure should be followed.
1. Bring the truck to a stop in a safe location. Apply
the parking brake and move the range selector
lever to the neutral position.
2. Next move the range selector to either Drive,
5th, 4th, 3rd, Low or Reverse. The transmission
will then shift to F1 or F2 when either of the
forward positions was selected, Drive, 5th, 4th,
3rd, Low or Reverse when the R position was
attained.
3. The selection of F1 or F2 will be dependant on
the type of fault.
If the transmission controller detects any of the
This i7 screen shows the back light of MOM turned following severe fault codes with the engine
off and nothing indicated. Use this screen at night running, the transmission will remain in the gear
when the lighted display is too glaring. When in i3 that it was in at the time of the fault code. When
or i4, by touching "LIGHT OFF" the display will the range selector is moved to the "N" position
switch to i7. If any area of the i7 screen is touched the transmission will shift to the "N" range also.
the display will return to i2, i3, or i4 depending on
the condition of the truck. If a fault is detected
Fault
while in the i7 screen, the display will automatically Description Remarks
Code
return to the i6 screen with the back light on.
Speed
b01_ Signal Lost
_ - : 0 : Engine
_ ; 0, 1, 2, 3
_ - : 1 : T/M input
Transmission Response With Fault Codes Speed _ - : 2 : T/M intermediate shaft
Sensor _ - : 3 : T/M output
When the transmission controller detects any of the b06_
Failure
severe fault that are listed below while the engine is _ : 0, 1, 2, 3
running, the transmission will shift to the neutral gear
_ - : 1 : Lock up
position.
_ - : 2 : High
_ - : 3 : Low
Clutch
_ - : 4 : 1st
Fault b05_ ECMV
Description Remarks _ - : 5 : 2nd
Code Failure 3
_ - : 6 : 3rd
b001 Battery Voltage Low _ - : 8 : Reverse
Solenoid Voltage _ - : 9 : Intermediate
b002
Failure
b004 ROM Sum Check Fault If the truck needs to be moved with one of these fault
Clutch Engagement codes present, the following procedure is suggested:
b005
Double 1. Bring the truck to a stop in a safe location. Apply
b006 T/M Cut Relay Failure the parking brake and move the range selector
Clutch Failure to the neutral position.
b02_ - 2 : High Clutch
_: 2, 3, 9 2. Next move the range selector to either Drive,
- 3 : Low Clutch 5th, 4th, 3rd, Low or Reverse.
Clutch ECMV Failure 1 - 4 : 1st Clutch
b03_
_ : 2 to 6, 8, 9 - 5 : 2nd Clutch The transmission will then shift to F1, F2, or F3
Clutch ECMV Failure 2 - 6 : 3rd Clutch when either of the forward positions was se-
b04_ lected, Drive, 5th, 4th, 3rd, Low or Reverse
_ : 2 to 6, 8, 9 - 8 : Reverse Clutch
- 9 : Intermediate when the R position was attained.
Clutch Solenoid
b07_ Failed High Clutch 3. The selection of F1, F2, or F3 will be dependent
_ : 2 to 6, 8, 9 on the type of fault.
OM3024.4 8/00 Operation - Section 3
Electronic Displays and Messages Page 3-43

If any of the severe fault codes that are listed below CENTER ELECTRONIC DISPLAY PANEL
appear on the warning screen,
Action Code Display
Fault As previously discussed, if a fault occurs in any of the
Description Remarks
Code monitored systems, a code will be displayed on the
b024 1st Clutch Failure "MOM" screen. At the same time an action code will
b025 2nd Clutch Failure also be displayed to inform the operator of a procedure
to follow because of the fault. This "action code" is also
b026 3rd Clutch Failure displayed on the electronic display panel. The elec-
b028 Reverse Clutch Failure tronic display panel will display the action code of any
T/M Output Speed Sensor fault informed through the serial communications net-
b063 work, "S-NET," from any controller that detects a fault
Failure
. When the fault occurs, the action code of this fault will
perform the following procedure to move the truck: be displayed automatically.

1. Bring the truck to a stop in a safe location.

Apply the parking brake and move the range
selector to the neutral position.
2. Activate the limp home switch by removing and
reconnecting the single wire connector located
under the passenger seat.
3. Next move the range selector to either Drive,
5th, 4th, 3rd, Low or Reverse. The transmission
will then shift to F1 or F2 when either of the
forward positions was selected, Drive, 5th, 4th,
3rd, Low or Reverse when the R position was
attained.
4. The selection of F1 or F2 will be dependent on
the type of fault code. FIGURE 1.
5. The limp home switch will remain active until the
key switch is turned off. When displaying an "03" action code, first the "E" will
be displayed (Figure 1) and then, the "03" code (Figure
2) will be displayed.
Idle Validation Feature
If there is a problem with the throttle pedal signal, not
transmitting correctly, because of the harness, sensor,
or controller troubles, the engine speed will go to the
following settings:

Throttle Pedal Position Engine RPM

Pressed 1300 RPM
Released 650 RPM

FIGURE 2.

These two displays will alternate every second. The

other displays, gauges and pilots will function as nor-
mal. If more than two codes are present at the same
time, the highest priority action code will be displayed.
That priority is as follows: 04; 06; 05; 07; 03; 02; 01.
Operation - Section 3 OM3024.4 8/00
Page 3-44 Electronic Displays and Messages

After the operator has been informed of the fault code, Cancellation of Action Code
the action that should be taken is as follows:
If either of the following requirements is satisfied then
1. Stop the truck in a safe location. the action code will be canceled.
2. Apply the parking brake. 1. If the fault which caused the action code is no
longer present, then the action code will be can-
3. Confirm the presence of the fault code and the
celed automatically, and the same, or next priority
action code.
action code will be displayed automatically, if
4. Follow the instructions of the action code. there are any other active faults.
5. Notify a qualified technician for repairs. 2. If the fault remains, the action code can be can-
celed by a qualified technician who is trained to
monitor the system.
The possible action codes are as follows:

CODE DESCRIPTION
01 Notify maintenance at shift change
02 Notify maintenance right now
03 Reduce engine / machine speed
04 Stop safely now / shut off engine
05 Stop with engine at mid speed
06 Start engine and keep at low idle
07 Keep body seated.
OM4021.1 8/00 Maintenance - Section 4
Lubrication and Service Page 4-1

LUBRICATION AND SERVICE

Preventive Maintenance will contribute to the long life The service intervals presented here are in hours of
and dependability of the KOMATSU HD1500-5 Truck operation. These intervals are recommended in lieu
and its components. The use of proper lubricants and of an oil analysis program which may determine
the performance of checks and adjustments at recom- different intervals. However, if truck is being operated
mended intervals is most important. under extreme conditions, some or all of the intervals
may need to be shortened and the service performed
Lubrication requirements are referenced to the lube
more frequently.
key found in the Truck Lubrication Specifications
Chart. For detailed service requirements for specific
components, refer to the shop manual section for that
Refer to engine manufacturer’s service manual when
component (i.e. Section “G” for Final Drive, Section “H”
servicing the engine or any of its components.
for Suspensions, etc.).

HD1500-5 SERVICE CAPACITIES

U.S.
Liters
Gallons
Cummins QSK 45 Engine
Crankcase:
193 51
including lube oil filters.
Cooling System: 532 140.6
Hydraulic System:
Refer to “Hydraulic Tank Service”, 900 238
page 4-11.
Fuel Tank
Diesel Fuel–ASTM D975 No. 2 * 2120 560
* Below -10°C (14°F) use No. 1
TRANSMISSION OIL LEVEL CHECK
Differential Case 300 79
Final Drive Case (each planetary) 120 31.7 1. Engine Stopped:
• Oil level must be visible in upper part of sight gauge
Transmission Case:
153 40.5 (STOP) between “H” and “L” to be sure there is
including torque converter.
sufficient oil to safely operate transmission when
COOLING SYSTEM engine is stopped, or if transmission oil is cold
ANTI - FREEZE RECOMMENDATIONS (engine has been stopped for 8 hours or more).
(Ethlyene Glycol Permanent Type Anti-Freeze) Check oil level again, as described below, when
Percentage of Protection transmission oil reaches operating temperature.
Anti-Freeze To
2. Engine Running:
10 + 23°F – 5°C
20 + 16°F – 9°C • Oil level must be visible in lower part of sight gauge
25 + 11°F – 11°C (turtle) between “H” and “L”.
30 + 4°F – 16°C
35 – 3°F – 19°C Check transmission oil level with:
40 – 12°F – 24°C • truck parked on level surface,
45 – 23°F – 30°C • engine running at low idle,
50 – 34°F – 36°C • transmission in neutral, “N”, and
55 – 48°F – 44°C • transmission oil at normal operating temperature:
60 – 62°F – 52°C
Use only anti-freeze that is compatible with engine as Add clean oil as required through transmission oil
specified by engine manufacturer. filler tube at left rear of transmission.
Maintenance - Section 4 OM4021.1 8/00
Page 4-2 Lubrication and Service
OM4021.1 8/00 Maintenance - Section 4
Lubrication and Service Page 4-3

10 HOUR (DAILY) INSPECTION

Prior to each operating shift, a “walk around” inspec- Truck Serial Number ________________________
tion should be performed. Check the truck for general Site Unit Number ___________________________
condition. Look for evidence of hydraulic leaks; check
all lights and mirrors for clean and unbroken lenses; Date:____________Hour Meter________________
check operator’s cab for clean and unbroken glass; Serviceperson Name________________________
check frame, sheet metal and body for cracks. Notify
the proper maintenance authority if any discrepancies
are found. Give particular attention to the following:
COMMENTS √’d INITIALS
CHECK ALL FLUID LEVELS
a. Engine Oil-
Note: Refer to engine manufacturer service man-
ual for oil recommendations.
b. Radiator -
Check coolant level and fill with proper mixture as
shown in Cooling System Recommendation
Chart.
c. Batteries - Check electrolyte level and add water if
necessary.
d. Hydraulic Tank - Check oil level in tank, add if
necessary. Lube key “C”.
Refer to “Hydraulic Tank Service”, page 4-11.
NOTE: Check oil level with truck level, engine
STOPPED, body down, and oil warm. Oil should
be visible in sight glass. - DO NOT OVERFILL.
e. Transmission - Check oil level.
Add oil, if necessary. Lube key “C”.
Refer to “Transmission Oil Level Check”, page
4-1.

f. Fuel Tank - Fill as required.

g. Differential - Truck should be on level surface, oil

level should be even with plug hole.
Refill with oil as necessary. Lube key “B”.
Maintenance - Section 4 OM4021.1 8/00
Page 4-4 Lubrication and Service

10 HOUR (DAILY) INSPECTION

(continued)
AIR CLEANERS COMMENTS √’d INITIALS
Check air cleaner vacuum gauges. Clean or replace
filter elements if restriction reaches 25 inches H2O
vacuum. Push the reset button on the face of the gauge
to return to zero.

DRIVE BELTS
a. Check alternator and fan belts for proper tension
and condition.
b. Inspect for alignment.

ENGINE AND TURBOCHARGERS

Inspect for leaks, vibrations or odd noises.

WHEELS AND TIRES

After each wheel mounting operation, recheck
wheel mounting capscrew tightness after 4 – 5
hours of operation. Check again at the end of the
shift and then periodically until all capscrews hold
at the prescribed 225 ± 25 kg.m (1628 ± 180 ft.lbs.)
torque. This requirement is prescribed for both
front and rear wheels.

TIRES
a. Inspect for proper inflation and wear.
b. Inspect for debris embedded in cuts or tread.
OM4021.1 8/00 Maintenance - Section 4
Lubrication and Service Page 4-5

250 HOUR SERVICE

Truck Serial Number _______________________
INITIAL 250 HOUR SERVICE Site Unit Number _________________________
Perform the following maintenance after running the Date:____________Hour Meter_______________
machine for the first 250 hours. Serviceperson Name_______________________
Thereafter, these services are to be accomplished at
the 1000/2000/5000 hour interval as scheduled.
COMMENTS √’d INITIALS

a. Fuel Filter, replace cartridges.

b. Transmission - change oil and filter elements.
c. Hydraulic - change oil and filter elements.
d. Differential Case, change oil.
e. Final Drive Case, change oil.

EVERY 250 HOURS SERVICE

1. Lubrication -
Check automatic lube system to be sure ample
grease supply is reaching pins and bearings.
- Dump body hinge pin - 2 points.
- Rear suspension - 4 points.
- Axle support pins - 8 points.
- Hoist cylinder pin - 4 points.
- Front suspension assembly - 8 points.
- Steering cylinder pin - 4 points.
- Steering linkage - 5 points.
- Front transmission mount - 1 point.
Refill grease reservoir - Use lube key “D”.
(Reservoir Capacity is approximately 7.7 gal. or
60 lbs [27 kg] of grease.)

2. BATTERY - Check electrolyte level and add distilled

water if necessary to maintain proper level.
3. ENGINE - Refer to engine manufacturer’s service
manual for oil recommendations and capacity.
- change engine oil.
- change engine lube oil filter.
Maintenance - Section 4 OM4021.1 8/00
Page 4-6 Lubrication and Service

250 HOUR SERVICE (continued)

COMMENTS √’d INITIALS
4. ALTERNATOR BELT - Check condition of the 24V
alternator belt for evidence of belt slippage, loose-
ness or physical defects.
5. AIR CONDITIONER COMPRESSOR BELT -
Check for condition of belt and proper tension.
6. TRANSMISSION CASE BREATHERS -
Remove breathers, disassemble breathers, re-
move filter element, clean in solvent. Dry with air
pressure and reassemble then reinstall.
7. HYDRAULIC TANK BREATHER -
Remove breather, disassemble breather, remove
filter element.
Replace filter element, reassemble and reinstall.
8. DIFFERENTIAL CASE -
Check oil level. Use lube key “B”.
9. DIFFERENTIAL CASE BREATHER -
Remove breather. Wash to flush out the dirt from
inside. Reinstall after cleaning.
10. FINAL DRIVE CASE - Check oil level in R.H. and
L.H. case. Use lube key “B”.
11. PARKING BRAKE - Measure brake pad for proper
wear and thickness.
Refer to Shop Manual, Section “J”, Brake System,
for limits and specifications. Use lube key “D”
chart.
12. FUEL FILTER - Remove and replace fuel filter ele-
ments.
13. CORROSION RESISTOR - Remove and replace
corrosion resistor elements.
OM4021.1 8/00 Maintenance - Section 4
Lubrication and Service Page 4-7

500 HOUR SERVICE

In addition to the 250 hour lubrication and inspection Truck Serial Number ________________________
schedule, perform the following: Site Unit Number ___________________________
Date:____________Hour Meter_______________
Serviceperson Name_______________________

COMMENTS √’d INITIALS

1. FAN BELT - Check for condition of belt and proper

tension.
Refer to shop manual, Section “C”, Engine and
Cooling System.
2. RADIATOR FINS - Check for clogged or damaged
fins. Notify the proper maintenance personnel if
any discrepancies are found.
3. TRANSMISSION OIL FILTER -
Remove and replace (2) filter elements. Refer to
Shop Manual, Section “F”, Transmission.
Maintenance - Section 4 OM4021.1 8/00
Page 4-8 Lubrication and Service

1000 HOUR SERVICE

Truck Serial Number ________________________
Site Unit Number ___________________________
In addition to the 250 and 500 hour lubrication and Date:____________Hour Meter________________
inspection schedules, perform the following: Serviceperson Name________________________

1. LUBRICATION (Manual) COMMENTS √’d INITIALS

- Parking brake linkage - 6 points - Lube key “D”.
- Driveshafts - Lubricate rear driveshaft splines. If
driveshaft U-joints are equipped with grease fit-
tings, apply one or two pumps of grease from a
hand operated grease gun - (Recommended Lu-
bricant: Mobil SHC, Shell Alvania, or Lithium com-
plex soap based E.P. 2 multipurpose grease.)
Note: In extremely severe operating condi-
tions, more frequent lubrication may be re-
quired.
2. TRANSMISSION CASE
Drain oil, remove and replace element. Remove
clean, and reinstall strainer. Refill sump with oil -
Capacity, approximately 153 liters (40.5 U.S.
gal). Lube key “C”.
3. STEERING, BRAKE, HOIST, and REAR BRAKE
COOLING OIL FILTERS.

When removing tank caps, turn cap slowly at first

to relieve inner pressure. Remove cap only after
pressure has been completely relieved.
Any operating fluid, such as hydraulic oil or brake
fluid escaping under pressure, can have sufficient
force to enter a person’s body by penetrating the
skin. Serious injury and possibly death may result
if proper medical treatment by a physician familiar
with this injury is not received immediately.

Remove & replace (4) filter elements.

Refer to “Hydraulic Tank Service”, page 4-11.

4. FRONT & REAR BRAKE WEAR -

Refer to Shop Manual Section “J”, Brake System,
for proper inspection procedure.

Carry out inspection when the oil temperature is

below 60°C (140°F ).
Hot oil may cause serious personal injury.
OM4021.1 8/00 Maintenance - Section 4
Lubrication and Service Page 4-9

2000 HOUR SERVICE

Truck Serial Number ________________________
Site Unit Number ___________________________
Maintenance for every 250, 500 and 1000 hours should Date:___________Hour Meter________________
also be carried out at this time. Serviceperson Name_______________________

1. HYDRAULIC OIL TANK COMMENTS √’d INITIALS

Drain oil from tank and refill tank to specified level,
capacity 576 liters (152 U.S. gal.).
Refer to “Lubrication Chart” for type of oil to use.
Lube key “C”.
Refer to “Hydraulic Tank Service”, page 4-11.

2. FINAL DRIVE CASE

Position machine so that casting line is horizontal
and drain plug is at the bottom. Drain oil and
reinstall plug, remove fill plug at casting line and fill
to specified level. This operation is performed on
both the right and left hand final drives.
Capacity is 120 liters (31.7 U.S. gal.) each side.
Refer to “Lubrication Chart” for type of oil to use.
Lube key “B”.

3. DIFFERENTIAL CASE
Drain oil from differential and refill to the specified
level: capacity = 300 liters (79 U.S. gal.).
Refer to “Lubrication Chart” for type of oil to use.
Lube key “B”.
Maintenance - Section 4 OM4021.1 8/00
Page 4-10 Lubrication and Service

5000 HOUR SERVICE

Truck Serial Number ________________________
Site Unit Number ___________________________
Maintenance for every 250, 500, and 1000 hours should Date:___________Hour Meter________________
also be carried out at this time. Serviceperson Name_______________________

COMMENTS √’d INITIALS

1. ENGINE DRIVELINE ADAPTER
Inspect driveline adapter splines, rubber dampers
for cracks or separation on rubber surfaces, and
bearings. If any defects are noted, repair as re-
quired.
Refer to Service Manual, Section “C” for repair
procedures.

2. FRONT AND REAR DRIVESHAFTS

If truck is equipped with driveshaft universal joints
that DO NOT have grease fittings, inspect both
front and rear driveshafts for binding, wear, vibra-
tion, or damage to the driveshaft assembly. If
U-joint damage or roughness is noted, BOTH U-
joints on a given shaft should be replaced. Refer
to Service Manual, Section “F” for replacement
procedures.

3. FRONT SUSPENSIONS
Drain Front suspension oil. Inspect upper flange
internal bearing. Replace worn parts.
Refill suspensions with clean oil and recharge with
nitrogen. Refer to Service Manual, Section “H”.

4. FRONT WHEEL BEARINGS

Check front wheel bearing adjustment. Refer to
Service Manual, Section “G”, “Front Wheel Hub
Bearing Adjustment”.
Refill hydraulic tank - Refer to “Hydraulic Tank
Service”, page 4-11.
OM4021.1 8/00 Maintenance - Section 4
Lubrication and Service Page 4-11

HYDRAULIC TANK SERVICE

Filling Instructions
1. Lower the dump body, shut down the engine, and
turn the keyswitch “Off”.

Hydraulic tank may be pressurized! Depress relief

valve (2) and release hydraulic tank filler cap slowly
to remove any internal pressure.

2. Depress relief valve (2, Figure 4-1) for 30 - 45

seconds to release any internal tank pressure.
Turn the oil filler cap (4) slowly counterclockwise
to release any possible residual tank pressure.
3. Refer to “Lubrication Chart”, Lube key “C”.
Fill tank with recommended oil, until oil is visible in FIGURE 4-1. HYDRAULIC TANK
the TOP sight glass (5).
1. Hydraulic Tank 5. Hydraulic Oil Level
NOTE: If Hydraulic tank has been completely 2. Pressure Relief Valve Upper Sight Glass
drained, refill capacity is: 576 Liters (152 gal.) 3. Breather 6. Hydraulic Oil Level
4. Filler Cap Lower Sight Glass
4. Replace fill cap.
7. Hydraulic Oil Drain
5. Start the engine, and raise and lower dump body
3 times to circulate oil and fill all lines, valves,
cylinders, etc.
6. Repeat steps 1 through 5 and fill until oil level is
again in the TOP sight glass (5).
7. If oil level falls below LOWER sight glass (6) with
engine running, repeat steps 1. through 5.

HYDRAULIC TANK SERVICE

When servicing the hydraulic tank, always follow
the “Filling Instructions” described above to re-
lieve any internal tank pressure before opening
tank.

1. When checking oil level, or any other service,

inspect the breather (3, Figure 4-2) to be certain
that it is open to atmosphere.
Clean any excess accumulations of dirt/mud, etc.
from around the breather. FIGURE 4-2. HYDRAULIC TANK (TOP VIEW)
Clean/replace breather element as necessary. 1. Hydraulic Tank 7. Diffusers
Refer to “HYDRAULIC TANK BREATHER”. 2. Pressure Relief Valve 8. Strainers
2. Whenever oil is drained from tank, clean diffusers 3. Breather 9. Wire Mesh Strainer
(7 & 11) and strainers (8, 9, & 10). 4. Filler Cap 10. Strainer
5. Sight Glass Guard 11. Diffuser
6. Access Cover
Maintenance - Section 4 OM4021.1 8/00
Page 4-12 Lubrication and Service

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.
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by pene-
trating the skin and cause serious injury and pos-
sibly death if proper medical treatment by a
physician familiar with this injury is not received
immediately.

1. With the key switch “Off” allow at least 90 seconds

for the accumulators to bleed down.
2. Remove plug (10, Figure 4-3) and drain oil from the
housing into a suitable container.

Take care to avoid contact with hot oil if truck has

been operating. Avoid spillage and contamination!

3. Remove housing (8) and element (7).

4. Replace O-ring (4) and backup ring (5) in filter head.

Installation
1. Install new element (7). Install housing (8) and
tighten.
2. Replace drain plug (10), and O-ring (9).

NOTE :
The indicator switch (2, Figure 4-3) is preset to actuate
at 35 psid (241 kPa) and is not repairable or adjustable.
If the indicator switch is inoperative, replace the com- FIGURE 4-3. STEERING CIRCUIT FILTER
plete switch. Attempting to adjust the switch is not
recommended. 1. Head 6. Bypass Valve
2. Indicator Switch 7. Filter Element
3. O-Ring 8. Housing
4. O-Ring 9. O-Ring
5. Backup Ring 10. Plug
OM4021.1 8/00 Maintenance - Section 4
Lubrication and Service Page 4-13

HYDRAULIC TANK BREATHER

Cleaning
1. Shut down the engine and open hydraulic tank filler
caps slowly to relieve any internal pressure.
2. Clean dirt accumulation from area of breather (3,
Figure 4-2).
3. Remove the breather from the tank.
4. Remove snap ring (1, Figure 4-4), cover (2) and
filter element (3).
5. Clean breather element in solvent and blow dry.
Clean remaining parts in solvent and dry thor-
oughly.
6. Install element, cover and snap ring. FIGURE 4-4. HYDRAULIC TANK BREATHER
7. Install breather element on hydraulic tank. 1. Snap Ring 3. Element
2. Cover
Maintenance - Section 4 OM4021.1 8/00
Page 4-14 Lubrication and Service

NOTES
OM4021.2 8/00 Maintenance - Section 4
Automatic Lube System Page 4-15

LINCOLN AUTOMATIC LUBRICATION SYSTEM

The Lincoln Automatic Lubrication System is a pressur-
ized lubricant delivery system which delivers a control-
led amount of pressurized lubricant to designated lube
points. 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.

System Components
The system is comprised of these basic elements plus
the necessary hoses and lube lines:
1. Hydraulically Powered Reciprocating Cylinder
and Pump (1 & 5, Figure 4-5).
Pump Specifications:
16:1 Pressure Ratio.
NOTE: The theoretical ratio of the pump is 16:1.
Depending on application and variable internal
friction, the operational ratio is approximately
10:1.
Hydraulic Supply Pressure (Input):
300-3000 PSI (2.1 - 20.1 MPa) FIGURE 4-5. TYPICAL AUTO LUBE SYSTEM
Input Flow (when pumping): 1.0 gpm (3.8 l/min.)
Maximum Hydraulic Temperature: 210°F (98.8°C) 1. Pump Cylinder 8. Solenoid Valve, SV2
MAXIMUM Output Pressure: Not to Exceed 2. Cyl. Pressure Gauge 9. Solenoid Valve, SV1
3500 PSI (24.1 MPa) 3. Valve Body Assy. 10. Press. Reducing Valve
WARNING: Exceeding this value will damage 4. Orifice Assembly 11. Vent Valve Assy.
components and/or cause components to 5. Pump Assembly 12. Grease Return Line
rupture, resulting in possible serious injury to 6. Canister/Reservoir 13. Grease Supply Line
any nearby personnel. 7. Pump Cycle Timer 14. Fill Vent Port
15. Fill Supply Port
Output Flow: 11 cu. in./min. (180 cc/min.)
Operating Ambient Temperature: b. Pressure Reducing Valve:
-40°F to + 135°F (-40°C to + 57.7°C) The Pressure Reducing Valve (10) lowers hy-
Seals: Buna-N draulic fluid pressure to the operating range of
Filtration Required: 10 Micron (Hydraulic Supply) the hydraulic pump cylinder.
24VDC power source. It is factory set at its maximum pressure of 300
PSI (2069 kPa), but may be adjusted lower.
c. The Cylinder Pressure Gauge (2): indicates
2. Combination Valve Body (3, Figure 4-5) includes:
hydraulic fluid pressure going to the hydraulic
a. 24VDC Solenoid Valves (SV1 & SV2) are used pump cylinder after passing through the pres-
to control the hydraulically operated pump. sure reducing valve.
Solenoid Valve SVI (9) controls the supply of d. Orifice Fitting Assembly (4): meters hydraulic
hydraulic fluid to the pressure reducing valve pressure from the pressure reducing valve to
and to the vent valve. the top of the vent valve assembly (this permits
Solenoid Valve SV2 (8) directs the hydraulic even operation of the vent valve, without
fluid to the hydraulic cylinder which operates shock). This fitting is assembled to the side of
the grease pump. the Valve Body (3) and connected with a high
pressure 1/4 in. hose to the top of the Vent Valve
Assembly (11).
Maintenance - Section 4 OM4021.2 8/00
Page 4-16 Automatic Lube System

FIGURE 4-6. HD1500-5 AUTO LUBE 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” Contains 3 Injectors 3. Pressure Regulator/Solenoid Valve
Group Lube Location “D” Contains 3 Injectors 4. Electrical Harness
Group Lube Location “E” Contains 5 Injectors 5. Hydraulic Pressure Supply
Group Lube Location “F” Contains 3 Injectors 6. Hydraulic Return to Tank
Group Lube Location “G” Contains 3 Injectors 7. Reservoir / Canister
Group Lube Location “H” Contains 3 Injectors 8. Grease Supply Line
Group Lube Location “J” Contains 4 Injectors 9. Vent Valve Assy.
Group Lube Location “K” Contains 3 Injectors 10. Lube Injector
Group Lube Location “L” Contains 3 Injectors 11. Typical Lube Injector Group
OM4021.2 8/00 Maintenance - Section 4
Automatic Lube System Page 4-17

Figure 4-6. Lube Injector Groups 3. Pump Cycle Timer (7, Figure 4-5) [also called a
“Flasher” timer, because it contains an LED that
Group No. illuminates when there is power going to SV2]:
Injector Point of Lubrication
Lube of Inj. The Pump Cycle Timer mounts on SV2 solenoid
R.H. Front Suspension, Top and generates a timed pulse signal which causes
“A” 3 R.H. Front Suspension, RR “A”-Arm the solenoid valve to move, alternately. The alter-
R.H. Front Suspension, FRT “A”-Arm nating movement of the valve, changes the direc-
L.H. Front Suspension, Top tion of hydraulic fluid flow from the top of the pump
“B” 3 L.H. Front Suspension, RR “A”-Arm cylinder to the bottom, and vice versa, causing the
L.H. Front Suspension, FRT “A”-Arm grease pump piston to reciprocate, or “pump”.
R.H. Steering Cylinder, Spindle 4. Grease Reservoir: For the HD1500-5, the Canister
“C” 3 R.H. Steering Rod, Spindle or Reservoir (6, Figure 4-5) is mounted on the right
R.H. Front Suspension, BTM “A”-Arm deck structure to the right of the hydraulic cabinet
L.H. Steering Cylinder,Spindle just above the right front suspension.
“D” 3 L.H. Steering Rod, Spindle The reservoir has an approximate capacity of 7.7
L.H. Front Suspension, BTM “A”-Arm gal. or 60 lbs. (27 kg) of grease.
R.H. Steering Cylinder, FRAME 5. Vent Valve (11, Figure 4-5): When SV1 solenoid is
L.H. Steering Cylinder, FRAME energized, hydraulic pressure closes the Vent
“E” 5 L.H. Steering Rod, PIVOT Valve, and also causes the pump to cycle. The
R.H. Steering Rod, PIVOT pump cycles until SV1 solenoid is de-energized.
CENTER Steering Pivot, FRAME When this occurs, hydraulic pressure is removed,
Rear Axle, BTM L.H. BAR FRAME causing the Vent Valve to open.
“F” 3 L.H. Hoist Cylinder, FRAME The grease pressure drops to 0, and the injectors
Transmission, FRT MOUNT recharge for their next output cycle.
Rear Axle, TOP FRT BAR FRAME 6. 24 VDC Solid State System Timer (Not Shown):
“G” 3 Rear Axle, BTM R.H. BAR FRAME The Solid State System Timer sends out a 24 VDC
R.H. Hoist Cylinder, FRAME timed-interval signal to energize the solenoid
L.H. Rear Suspension, FRAME valves, causing the grease pump to operate. This
“H” 3 L.H. Hoist Cylinder, BODY timer is mounted in the cab (in the housing under
L.H. BODY PIVOT the passenger seat) to insure temperature stabil-
ity. Its operating temperature range is -20°F to
Rear Axle, TOP SWAY BAR, FRAME 131°F (-29°C to 55°C).
R.H. Rear Suspension, FRAME
“J” 4 7. Lube Injectors (10, Figure 4-6): each injector de-
R.H. Hoist Cylinder, BODY
R.H. BODY PIVOT livers a controlled amount of pressurized lubricant
to a designated lube point.
L.H. Rear Suspension, AXLE
Refer to Figure 4-6 for locations.
“K” 3 Rear Axle, TOP FRT BAR, AXLE
Rear Axle, TOP SWAY BAR, AXLE 8. Safety Unloader Relief Valve (Not Shown); is lo-
Rear Axle, BTM R.H. BAR, AXLE cated on the back of the vent valve (11, Figure
“L” 3 L.H. Rear Suspension, FRAME 4-5). The Safety Unloader Relief Valve is designed
R.H. Rear Suspension, AXLE to open if the pressure in the grease line rises to
approximately 4000 PSI (27.5 MPa)* . If this valve
opens, the grease is expelled to atmosphere.
* NOTE: This setting is not adjustable.
WARNING: Exceeding 3500 p.s.i. (24.1 MPa) will
damage components and/or cause components to
rupture, resulting in possible serious injury to any
nearby personnel.
Maintenance - Section 4 OM4021.2 8/00
Page 4-18 Automatic Lube System

System Operation:
1. During truck operation, with the pump and timer
systems in a rest state, a preset time interval (2.5
to 80 minutes) occurs.
2. The solid state system timer sends out a 24 VDC Over pressurizing of the system, modifying parts,
signal to energize SV1, and also the flasher timer using incompatible chemicals and fluids, or using
on SV2. worn or damaged parts, may result in equipment
3. As SVI opens, the hydraulic fluid pressure flows damage and/or serious personal injury.
through the pressure reducing valve and on to * DO NOT exceed the Maximum Pump Pressure
SV2. of 3500 p.s.i. (24.1 MPa).
4. The pressure reducing valve lowers hydraulic fluid * Do not alter or modify any part of this system
pressure to the operating range of the hydraulic unless approved by factory authorization.
pump [maximum pressure 300 PSI (2069 kPa)].
This pressure also signals the Vent Valve causing * Do not attempt to repair or disassemble the
it to close. equipment while the system is pressurized.

5. After the system pressure has been reduced, it * Make sure all fluid connections are securely
passes on to SV2. Each operation of SV2 moves tightened before using this equipment.
the hydraulic cylinder which operates the grease * Always read and follow the fluid manufacturer’s
pump. As SV2 turns “On” and “Off” (refer to cycle recommendations regarding fluid compatibil-
timer/flasher below), it changes the direction of ity, and the use of protective clothing and
the hydraulic cylinder movement back and forth, equipment.
thus causing a “pumping” action.
* Check all equipment regularly and repair, or
6. The cycle timer/flasher sends a pulsing signal, 1 replace, worn or damaged parts immediately.
second “On” and 1 second “Off” (adjustable), to
SV2. Solenoid valve SV2 directs the hydraulic fluid This equipment generates very high grease pres-
to the pump at 30 cycles/minute. sure. Extreme caution should be used when oper-
ating this equipment as material leaks from loose
7. With the vent valve closed, the pump cycles until or ruptured components can inject fluid through
lubricant pressure reaches maximum pump out- the skin and into the body causing serious bodily
put pressure* (pump stalls). As the grease supply injury including possible need for amputation. Ade-
line comes to maximum pressure, the injectors quate protection is recommended to prevent
meter grease to the points of lubrication. splashing of material onto the skin or into the eyes.
* WARNING: Maximum Pump Pressure Not to
Exceed 3500 PSI (24.1 MPa). Exceeding this If any fluid appears to penetrate the skin, get emer-
value will damage components and/or cause gency medical care immediately! Do not treat as a
components to rupture, resulting in possible simple cut. Tell attending physician exactly what
serious injury to any nearby personnel. fluid was injected.

8. After approximately 75 seconds, the Solid State If overpressurizing of the equipment is believed to have
System Timer returns to the rest state, which occurred, contact a factory authorized warranty and
de-energizes SV1 solenoid valve. service center for inspection of the pump. Specialized
9. As SV1 is de-energized, the hydraulic supply to the equipment and knowledge is required for repair of the
pressure reducing valve and the vent valve is shut pump or adjustments other than the maintenance
off, causing the vent valve to open. specified in this manual.

10. When the vent valve opens, the pressure in the Annual inspection by the factory authorized warranty
grease line is vented back to the grease reservoir and service center is recommended.
and the line pressure drops to zero (0), so the
injectors can recharge for their next output cycle.
11. The system is now at rest, ready for another lube
cycle and the sequence repeats itself.
OM4021.2 8/00 Maintenance - Section 4
Automatic Lube System Page 4-19

System Priming
The system must be full of grease and free of air If pressure is not correct, adjust the Pressure
pockets to function properly. After maintenance, if the Reducing Valve as necessary (refer to “Pressure
primary or secondary lubrication lines were replaced, Reducer Adjustment”).
it will be necessary to reprime the system to eject all NOTE: DO NOT EXCEED 300 PSI (2.1 MPa) on
entrapped air. the Cylinder Pressure gauge (2, Figure 4-5)

1. Fill lube reservoir with lubricant, if necessary. 6. Disconnect jumper wire. System should vent.

2. Remove plugs from all injector manifold dead ends 7. Turn Keyswitch “Off” and shut down engine to
and supply lines. de-energize system.
Remove the 5000 PSI (35 MPa) pressure test
NOTE: To run the grease pump when priming the lube gauge previously installed. Re-connect system.
system, turn keyswitch “ON” and connect a jumper
wire between the “LUBE SW” and “SOL” terminals on
the solid state timer.
3. Run grease pump until grease flows from any one Pressure Reducer Adjustment
plug opening in the system. Replace plug in this NOTE: Steering accumulator pressure is necessary to
opening. power the lube system for this procedure.
4. Repeat step 3 until all lines are full and all plugs
replaced.
NOTE: Fill each feed line with grease before connect-
ing lines to the injector outlets and bearings. This will While engine is running, and/or accumulators are
prevent having to cycle the individual injectors once charged, exercise extreme care while working in
for each 1.0 in. (25 mm) length of feed line between the vicinity of the grease pump!
the injector and bearing fitting.
Steering pressure is also available at this time.
Keep personnel away from front wheels to prevent
System Checkout crushing!
To check system operation (not including timer), pro- Stay clear of moving engine parts and do not
ceed as follows: loosen/disconnect any pressure fittings or hoses.
1. Turn Keyswitch (3, Figure 4-11) “Off” and shut
down engine to de-energize system. To set the Pressure Reducing Valve:
Install a 5000 PSI (35 MPa) pressure test gauge in
the grease supply line (13, Figure 4-5).
1. With keyswitch “Off”, engine stopped, and steer-
2. Turn Keyswitch “On” and start engine to energize ing accumulator pressure bled down, install a
system. 5000 PSI (35 MPa) pressure test gauge in the
3. Lift the passenger seat, and connect a jumper wire grease supply line (13, Figure 4-5).
between the “SOL” and “LUBE SW” terminals on 2. At the truck Hydraulic Bleeddown Manifold, dis-
the 24 VDC solid state lube timer. connect the Bleeddown Solenoid. (This will pre-
Pump should operate. vent accumulators from bleeding down when
NOTE: If terminal post identification on the solid state engine is shut down, later in step 4.)
timer is not legible, refer to Figure 4-11 for terminal 3. Start the truck engine. When steering and brake
positions. pressures have stabilized, pull the retarder lever
4. Keep jumper wire connected until the pump stalls. to the fully applied position to apply the brakes.

5. Observe the 5000 PSI (35 MPa) pressure test 4. Turn keyswitch “Off” to completely stop engine.
gauge in the grease supply line. Pressure should Then return the keyswitch to the “On” position.
be 2500 - 3000 PSI (17.2 - 20.7 MPa). 5. Lift the passenger seat, and connect a jumper wire
! WARNING !: DO NOT EXCEED Maximum Pump between the “SOL” and “LUBE SW” terminals on
Pressure of 3500 PSI (24.1 MPa). the 24 VDC solid state lube timer.
Exceeding this value will damage components Pump should operate. Keep jumper wire con-
and/or cause components to rupture, resulting in nected until the pump stalls.
possible serious injury to any nearby personnel.
Maintenance - Section 4 OM4021.2 8/00
Page 4-20 Automatic Lube System

6. Observe the 5000 PSI (35 MPa) pressure test 3. The timer should cycle in five minutes if the truck
gauge in the grease supply line. Pressure should engine is operating.
be 2500 - 3000 PSI (17.2 - 20.7 MPa).
NOTE: If the timer check is being made on a cold start,
the first cycle will be approximately double the nominal
setting. All subsequent cycles should be within the
selected time tolerance.
DO NOT EXCEED Maximum Pump Pressure of 3500
4. Voltage checks at the timer should be accom-
p.s.i. (24.1 MPa). Exceeding this value will damage
plished if the above checks do not identify the
components and/or cause components to rupture,
problem.
resulting in possible serious injury to any nearby
personnel. a. Insure timer ground connection is clean and
tight.
If pressure is not correct, adjust the Pressure
b. With the truck keyswitch on, use a Volt-Ohm
Reducing Valve until the pressure gauge (installed
meter and read the voltage between “BAT (+ )”
at step 1) indicates 2500 - 3000 PSI (17.2 - 20.7
and “BAT (-)” terminals on the solid state timer.
MPa) grease pressure.
Normal reading should be 18-26 VDC, depend-
NOTE: DO NOT EXCEED 300 PSI (2.1 MPa) on
ing upon whether or not the engine is running.
the Cylinder Pressure gauge (2, Figure 4-5).
7. While jumper wire is installed, verify that the fol- 24 VDC Solid State Timer Adjustment
lowing events occur in this order:
The timer is factory set for a nominal 2.5 minute (off
a. The pump starts stroking and the LED on the time) interval. Dwell time is approximately 1 minute, 15
flasher unit atop of SV2 flashes “On” and “Off” seconds. A longer interval (off time) is obtained by
at approximately one second intervals. turning the Selector Knob (3, Figure 4-7) desired time
b. All of the injectors stroke down. interval.
c. Pump gets to a “stalled state” with no notice-
able piston movement.
8. Turn the keyswitch “Off” and remove jumper wire
installed in step 5, then verify the following:
a. The pressure on the Cylinder Pressure gauge
(2, Figure 4-5) drops to zero (0).
b. The pressure on the grease pressure test gauge
(installed at step 1) drops to zero (0).
c. All of the injectors reset (indicator pin up).
9. Remove grease pressure test gauge (installed at
step 1).
10. At the Hydraulic Bleeddown Manifold, reconnect
the Bleeddown Solenoid (disconnected in step 4). FIGURE 4-7. TIMER ADJUSTMENT (TOP COVER OFF)
Verify that hydraulic system now bleeds down.

24 VDC Solid State Timer Check

To check the solid state timer operation without waiting NOTE: Set timer by turning the Selector Knob (3) to the
for the normal timer setting, proceed as follows: 2.5 minute setting point. Then, turn the selector knob
1. Remove timer dust cover. clockwise, one detent at a time, to the desired setting,
NOTE: The timer incorporates a liquid and dust or until the maximum limit of eighty minutes is reached.
tight cover which must be in place and secured
at all times during truck operation. The recommended setting is 20 minutes.

2. Adjust timer to 5 minute interval setting. ! CAUTION! The solid state timer is a sealed unit,
do not attempt disassembly.
OM4021.2 8/00 Maintenance - Section 4
Automatic Lube System Page 4-21

Injectors (SL-1)
a. Each lube injector services only one grease point.
b. Injectors are available in banks of two, three, four
and five as well as single replacement units.
c. Injector output is adjustable:
Maximum output = 0.08 in3 (1.31 cc).
Minimum output = 0.008 in3 (0.13 cc).
d. In case of a pump malfunction, each injector is
equipped with a covered grease fitting to allow the
use of external lubricating equipment.

Injector Adjustment
The injectors may be adjusted to supply from 0.008 in3
to 0.08 in3 (0.13 cc to 1.31 cc) of lubricant per injection
cycle. The injector piston travel distance determines
the amount of lubricant supplied. This travel is in turn
controlled by an adjusting screw in the top of the
injector housing.
Turn the adjusting screw (2, Figure 4-8) counterclock-
wise to increase lubricant amount delivered and clock-
wise to decrease the lubricant amount.
With the Solid State Timer set at 20 minutes, the
recommended setting is:
4 turns clockwise from the maximum counter-
clockwise position. This delivers approximately
0.04 in3 (.66 cc) of lube per cycle.
When the injector is not pressurized, maximum injector
delivery volume is attained by turning the adjusting
screw (2) fully counterclockwise until the indicating pin
(1) just touches the adjusting screw. At the maximum
delivery point, about 0.38 inch (9.7 mm) adjusting
screw threads should be showing. Decrease the deliv-
ered lubricant amount by turning the adjusting screw
clockwise to limit injector piston travel. FIGURE 4-8. TYPE SL-1 SERIES INJECTOR

If only half the lubricant is needed, turn the adjusting 1. Visible Indicator Stem 3. Outlet – 0.125 in. N.P.T.
screw to the point where about 0.19 inch (4.8 mm) 2. Adjusting Screw 4. Manifold
threads are showing. The injector will be set at mini-
mum delivery point with about 0.009 inch (0.22 mm)
thread showing.
NOTE: The foregoing information concerns adjust-
ment of the injector delivery volume. The timer adjust-
ment should also be changed, if overall lubricant
delivery is too little or too much. Injector output should
NOT be adjusted to less than one-fourth capacity.
Maintenance - Section 4 OM4021.2 8/00
Page 4-22 Automatic Lube System

Pump Cycle Timer (Flasher Timer): Pump Cycle Timer (Flasher Timer) Adjustment:

The Pump Cycle Timer mounts on SV2 solenoid and The Pump Cycle timer is factory set at 1 second “On”
generates a timed pulse signal to control the recipro- and 1 second “Off” for 30 cycles/minute. If adjustment
cating cycle rate of the grease pump. is necessary, refer to Figure 4-9 and the following
procedure.
Pump Cycle Timer (Flasher Timer) Installation The one adjustment screw adjusts both the “On” time
1. Connect cycle timer to SV2. Be sure to install and “Off” time equally. The adjustment range is from
gasket. 0.5 seconds (60 cycles/minute) to 5.0 seconds (6 cy-
cles/minute). The adjustment screw allows 15 turns of
2. Connect the “Sol” from the Solid State Timer to adjustment over the timing range.
the Brown wire from the Cycle Timer and one of
the wires coming from SV1. 1. The adjustment screw should be turned 20 turns
counter-clockwise to insure a minimum start
3. Connect the White wire from the Cycle Timer and point.
the other (gnd) wire coming from SV1.
NOTE: The timer cannot be adjusted below minimum
- additional turns counter-clockwise have no effect.
2. Each clockwise turn of the adjustment screw will
equal approximately 0.3 seconds.
3. Add the number of turns clockwise to reach the
approximate desired timing.
Some additional adjustment may be necessary
depending on the accuracy needed.
NOTE: Use the light on the cycle timer to help in setting
FIGURE 4-9. PUMP CYCLE TIMER the time. The light will turn On when there is power
going to SV2.
1. Adjustment Screw 2. Red LED (Indicates
Timer Has Turned On.)
OM4021.2 8/00 Maintenance - Section 4
Automatic Lube System Page 4-23

FIGURE 4-10. HYDRAULIC SCHEMATIC FOR AUTOMATIC LUBE

1. Grease Pump Cylinder 5. Combination Valve 8. Solenoid (SV1) 12. Hydraulic Supply
2. Grease Pump (Pressure Reducing & 9. Gauge (Cyl. Press.) 13. Hyd. Tank (Return)
3. Grease Reservoir Solenoid Valves) 10. Safety Unloader Valve 14. Injectors
4. Vent Valve 6. Solenoid (SV2) 11. Orifice Assembly Fitting
7. Pressure Reducer

FIGURE 4-11. TYPICAL ELECTRICAL HOOKUP FOR AUTOMATIC LUBE

1. Timer Assembly 3. Keyswitch* 5. Timer (solid State) 8. Battery (24 V)
2. Combination Valve 4. Relay 6. Solenoid (SV1) 9. Cycle Timer
(Pressure Reducing & 7. Solenoid (SV2)
Solenoid Valves)
* Keyswitch (3) must be closed (“ON”) to energize Timer (1).
Maintenance - Section 4 OM4021.2 8/00
Page 4-24 Automatic Lube System

TROUBLESHOOTING CHART
If the following procedures do not correct the problem, contact a factory authorized service center. When submitting
equipment to be repaired, be sure to state the nature of the problem and indicate if a repair cost estimate is required.
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: Pump Does Not Operate.

Lube system not grounded. Correct grounding connections to pump assembly and
truck chassis.
Electrical power loss. Locate cause of power loss and repair.
24 VDC power required. Be sure keyswitch is “ON”.
Timer malfunction. Replace timer assembly
Solenoid valve malfunctioning. Replace the solenoid valve assembly
Pump malfunction. Replace pump assembly

NOTE: On initial startup of the lube system, the timing capacitor will not contain a charge, therefore the first timing
cycle will be about double in length compared to the normal interval. Subsequent timer cycles should be as specified.

TROUBLE: Pump Will Not Prime

Low lubricant supply. Fill Reservoir.

Dirt in reservoir, pump inlet clogged. Clean pump and reservoir.
Remove source of contamination.
Pump Jammed. Repair/replace pump assembly.

TROUBLE: Pump Will Not Build Pressure

Air trapped in lubricant supply line. Prime system to remove trapped air.
Lubricant supply line leaking. Check lines and connections to repair leakage.
Vent valve leaking. Clean or replace vent valve.
Pump cylinder worn or scored. Repair or replace pump cylinder or pump assembly.
Reservoir empty. Fill Reservoir.

TROUBLE: Injector Indicator Stem Does Not Operate

NOTE: Normally, during operation, the injector indicator stem (1, Figure 4-8) will move into the body of the injector
when pressure builds properly. When the system vents (pressure release) the indicator stem will again move out into
the adjusting yoke.

Malfunctioning injector - usually indicated by the pump Replace individual injector assembly.
building pressure and then venting.
All injectors inoperative - Pump build up not sufficient to cycle injectors.
Repair/replace pump assembly. Also check pump
cylinder pressure and line pressure at pump.

Whole series of injectors inoperative - Check for broken or clogged intermediate supply line
and replace.
OM4021.2 8/00 Maintenance - Section 4
Automatic Lube System Page 4-25

POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION

TROUBLE: Cylinder 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 SV2. Determine problem in 24 VDC electric system.
Pressure reducing valve set too low. Increase setting by 1/2 turn to check operation.
Primary solenoid valve SV1 may be inoperative. Replace solenoid coil or valve.
Broken gauge. Replace gauge.
Damaged combination valve. Replace combination valve.

TROUBLE: Pump Pressure Builds Very Slowly Or Not At All.

No pulsing signal at SV2. Check Timer.

Pressure reducing valve may be set too low. Increase setting by 1/2 turn to check operation.
Grease viscosity may be too high for temperature at Replace grease with a lower viscosity lubricant.
which pump is operating.
If pressure is not building at all, secondary solenoid Replace secondary solenoid valve SV2.
valve SV2 may be inoperative.
Pump piston ball checks and inlet checks may have Remove, inspect and clean, if necessary.
foreign matter trapped causing leakage. Inspect sealing surfaces between upper and lower inlet
checks. Replace if rough or pitted.
Shovel rod is rough or pitted. Replace shovel rod and packing.
Lubricant supply line leaks or is broken. Repair lubricant supply line
Pulsing signal of cycle timer incorrect. Set flasher timer.

TROUBLE: 24VDC Timer Not Operating:

Timer BAT (-) connection is not on grounded member. Connect to good ground.
Timer BAT (+ ) connection not on circuit continuously Establish direct connection between Timer BAT (+ )
connected to BAT (+ ) terminal during operation of connection and 24 V BAT (+ ) terminal.
vehicle.
Fuse blown (circuit breaker tripped) on power connec- Replace fuse (reset circuit breaker) or repair damaged
tion on timer, or wire is otherwise damaged. wire.
Loose wire connections at any of the timer terminals. Secure wire connections.

TROUBLE: Timer Stays Timed Out:

Commutation failure in timer caused by damaged com- Replace Timer.

ponent.
Output relay contacts welded shut caused by extended Replace Timer.
short to ground.
Solenoid valve connected to “LUBE SW” terminal of Correct wiring hook-up.
timer instead of terminal marked “SOL”.
Maintenance - Section 4 OM4021.2 8/00
Page 4-26 Automatic Lube System

POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION

TROUBLE: Timer Turns On At Intervals Two (2) To Ten (10) 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 capacitor may be generated into vehicle electrical system
causing uncontrolled turn-on of its output relay. which may cause timer to turn on at random inter-
vals, independent of timer setting.
If this occurs, a 250 to 1,000 MFD capacitor rated
150 to 350 VDC should be added across BAT (+ )
and BAT (-) terminals to suppress this noise and
improve timer performance.

TROUBLE: Timer Turns On At Intervals Faster Than Allowable Tolerances Of Settings:

Timer out of adjustment or damaged component. Refer to “Timer Adjustment and re-adjust timer, or
replace timer.

Reservoir Fill Procedure

Lubricant Required for System
Refer to “Lubrication Chart”, for correct lubricant speci-
fications.
• . Above 90°F (32°C) - Use NLGI No.2 multipurpose
grease (MPG).
• . -25° to 90°F (-32° to 32°C) - Use NGLI No. 1 MPG.
• . Below -25°F (-32°C) - Refer to local supplier for
extreme cold weather lubricant requirements.

Fill Procedure
1. Remove top vent plug (14, Figure 4-12).
2. Remove bottom fill plug (15).
3. Connect line from Lubricant Delivery system to
bottom fill port (15) and fill reservoir until grease
just begins to come out of top vent hole above.
4. Disconnect line from Lubricant Delivery system
and install plugs (14 & 15) previously removed.

FIGURE 4-12. TYPICAL AUTO LUBE SYSTEM

1. Pump Cylinder 8. Solenoid Valve, SV2
2. Cyl. Pressure Gauge 9. Solenoid Valve, SV1
3. Valve Body Assy. 10. Press. Reducing Valve
4. Orifice Assembly 11. Vent Valve Assy.
5. Pump Assembly 12. Grease Return Line
6. Canister/Reservoir 13. Grease Supply Line
7. Pump Cycle Timer 14. Top Vent Plug
15. Fill Supply Port
OM4021.2 8/00 Maintenance - Section 4
Automatic Lube System Page 4-27

Preventive Maintenance Procedures

The following maintenance procedures should be used to insure proper system operation.

Daily Lubrication System Inspection

1. Check grease reservoir level. 4. Inspect all bearing points for a bead of lubricant
around the bearing seal.
Inspect grease level height after each shift of
operation. Grease usage should be consistent It is good practice to manually lube each bearing
from day-to-day operations. point at the grease fitting (Zerk, Figure 4-8) pro-
• Lack of lubricant usage would indicate an vided on each Injector. This will indicate if there
inoperative system. are any frozen or plugged bearings, and will help
flush the bearings of contaminants.
• Excessive usage would indicate a broken sup-
ply line. 5. System Checkout
2. Check all grease feed lines hoses from the SL-1 a. Remove all SL-1 injector cover caps to allow
Injectors to the lubrication points (Figure 4-6). visual inspection of the injector cycle indicator
pins during system operation.
a. Repair or replace all worn / broken feed line
hoses. b. Lift the passenger seat and connect a jumper
wire between the “SOL” terminal and the “LUBE
b. Make sure that all air is purged and all new feed
SW” terminal on the 24VDC solid state timer
line hoses are filled with grease before sending
(Figure 4-11).
the truck back into service.
c. Start engine. The hydraulic grease pump
3. Inspect key lubrication points for a bead of lubri- should operate.
cant around seal.
d. Keep the jumper wire connected until the pump
Make note of all lubrication points that look dry. stalls out at 2000 PSI.
Notify maintenance staff for repair service. e. With the pump in the stalled-out mode, check
each SL-1 injector assembly.
250 Hour Inspection The cycle indicator pin should be retracted
1. Check all grease feed line hoses from the SL-1 inside the injector body.
Injectors to the lubrication points (Figure 4-6). f. Once all of the SL-1 injectors have been in-
a. Repair or replace all worn / broken feed line spected under pressure, remove the jumper
hoses. wire between the “SOL” terminal and “LUBE
SW” terminal on the timer assembly. The pump
b. Make sure that all air is purged and all new feed
should shut off, and the system should vent
line hoses are filled with grease before sending
back to the grease reservoir, and the pressure
the truck back into service.
should drop to zero.
2. Check all grease supply line hoses from the pump g. With the system vented, check all of the SL-1
to the SL-1 injectors. injector indicator pins.
a. Repair or replace all worn / broken supply lines. All of the pins should be visible.
b. Make sure that all air is purged and all new NOTE: Refer to the system troubleshooting
supply line hoses are filled with grease before chart, if the injectors are not working properly.
sending the truck back into service. Replace or repair injectors, if defective.
3. Check grease reservoir level. h. Reinstall all injector cover caps.
a. Fill reservoir if low. i. Check timer operation.
b. Check reservoir for contaminants. With engine running, lube system should acti-
Clean, if required. vate within 5 minutes. The system should build
2000 PSI within 25-40 seconds.
c. Check that all filler plugs, covers and breather
vents on the reservoir are intact and free of j. If the system is working properly, the machine
contaminants. is ready for operation.
k.If the system is malfunctioning, refer to the trou-
bleshooting chart in the service manual.
Maintenance - Section 4 OM4021.2 8/00
Page 4-28 Automatic Lube System

NOTES
OM5021 8/00 Specifications - Section 5
Page 5-1

MAJOR COMPONENTS AND SPECIFICATIONS

ENGINE POWER STEERING

The KOMATSU HD1500-5LC Dump Truck is powered The HD1500-5LC Truck is equipped with a full time
by a Cummins diesel engine. power steering system which provides positive steer-
ing control with a minimum of effort by the operator.
The system includes nitrogen-charged accumulators
which automatically provide emergency power if the
steering hydraulic pressure is reduced below an estab-
lished minimum.
TRANSMISSION
The TORQFLOW transmission consists of a 3-ele-
ment, single-stage, two-phase torque converter and a
planetary gear, multiple disc clutch transmission which BRAKE SYSTEM
is hydraulically actuated and force-lubricated for opti-
Depressing the brake pedal, or pulling the lever on the
mum heat dissipation.
R.H. side of the steering wheel, actuates hydraulic front
The TORQFLOW transmission is capable of seven (7)
and rear service brakes. Both front and rear service
forward speeds and one (1) reverse gear. Automatic
brakes are oil-cooled, multiple-disc brakes. These
shifting is controlled by electronic shift control with
brakes are automatically activated when the engine
automatic clutch modulation in all gears. A lockup
speed exceeds the rated revolutions of the shift posi-
system consisting of a wet, double-disc clutch, is acti-
tion.
vated in F1–F7 gears for increased fuel savings.

FINAL DRIVE ASSEMBLY RETARDER

The operator can manually apply both the front and
The final drive consists of a plug-in differential with
rear oil-cooled, multiple-disc brakes by moving the
planetary wheel drive.
retarder connote lever which is mounted on the steer-
ing column, or by using the foot-operated brake pedal.

OPERATOR’S CAB
SUSPENSION
The HD1500-5LC Operator’s Cab has been engineered
for operator comfort and to allow for efficient and safe Hydro-pneumatic suspension cylinders are used at
operation of the truck. each wheel to reduce shock and provide riding comfort
for the operator and machine stability.
The cab provides for wide visibility, with an integral
4-post ROPS/FOPS structure, and an advanced ana-
log operator environment. It includes a tinted safety-
glass windshield and power-operated side windows, a
deluxe interior with a fully adjustable seat with lumbar
support, a fully adjustable/tilt steering wheel, controls
mounted within easy reach of the operator, and an
electronic display/monitoring panel to keep the opera-
tor informed of the truck’s operating circuits. Audible
alarms and indicator lights warn the operator of system
malfunctions.
Specifications - Section 5 OM5021 8/00
Page 5-2

HD1500-5LC MAJOR COMPONENTS

OM5021 8/00 Specifications - Section 5
Page 5-3

SPECIFICATIONS
ENGINE SERVICE CAPACITIES
Cummins . . . . . . . . . . . . . . . . . . . QSK 45 . . . . . . . . . . . . . . Liters . U.S. Gallons
Cummins . . . . . . . . . . . 193 . . . . . . (51)
Number of Cylinders . . . . . . . . . . . . . . . 12 (Includes Lube Oil Filters)
Operating Cycle (diesel) . . . . . . . . . . 4-Stroke Cooling System . . . . . . . 532 . . . . (140.6)
Fuel Tank . . . . . . . . . . 2120 . . . . (560.0)
Rated 1108 kW (1486 SAE Brake HP) @ 1900 rpm
Transmission . . . . . . . . . 153 . . . . . (40.5)
Flywheel . . 1048 kW ( 1406 SAE HP) @ 1900 rpm And Torque Converter
Hydraulic System . . . . . . 900 . . . . . (238)
Weight (dry) . . . . . . . . . . . 5813 kg (12,815 lbs)
(Includes Retarder Cooling)
Differential . . . . . . . . . . 300 . . . . . (79.0)
Final Drive (each planetary) . 120 . . . . . (31.7)
TRANSMISSION
Automatic Electronic Shift Control
. . . with Automatic Clutch Modulation In All Gears.
HYDRAULIC SYSTEM
Hydraulic Pumps (3)
Torque Converter . . . . . 3-Element, Single-stage,
. . . . . . . . . . . . . . . . . . . . . . Two-phase Hoist (Tandem Gear)
. 805 l/min. (213 gpm) @ 18 960 kPa (2,750 psi)
Lockup Clutch . . . . . . . . . . Wet, Double-disc,
Steering (Piston Pump)
. . . . . . . . . . . . . . Activated in F1–F7 gears.
221 l/min. (58.5 gpm) @ 18 960 kPa (2,750 psi)
Transmission . . . . . 7 Forward Speeds, 1 Reverse Brakes (Tandem Gear) . . . 1512 l/min. (400 gpm)
. . . . . . . . Planetary Gear, Multiple Disc Clutch,
Hoist Control Valve . . . . . . . . . . . . Spool Type
. . . . . . Hydraulically Actuated, Force-lubricated
Positions . . . . . . Raise, Hold, Float, and Lower
Gear . . . . . . . . . . . . Km/h . . . . . MPH
1 . . . . . . . . . . . . . . . 11.0 . . . . . . 6.8 Hydraulic Cylinders
2 . . . . . . . . . . . . . . . 14.6 . . . . . . 9.1 Hoisting . . . . . . . . 3-Stage Telescoping Piston
3 . . . . . . . . . . . . . . . 19.5 . . . . . . 12.1 Steering . . . . . . . . Twin - Double Acting Piston
4 . . . . . . . . . . . . . . . 24.5 . . . . . . 15.2 Relief Valve Setting . . . . . . 18 960 kPa (2,750 psi)
5 . . . . . . . . . . . . . . . 32.6 . . . . . . 20.3
Filtration . . . . . . . . In-line Replaceable Elements
6 . . . . . . . . . . . . . . . 44.2 . . . . . . 27.5
7 . . . . . . . . . . . . . . . 58.0 . . . . . . 36.0 Suction . . . . . . . . Single, Full Flow, 100 Mesh
Rev . . . . . . . . . . . . . . 10.6 . . . . . . 6.6 Hoist & Steering . . . . . . Dual, Full Flow, In-line
. . . . . . . High Pressure. Beta 12 Rating = 200
Transmission . . . . . . . . . Dual, High Pressure
FINAL DRIVE ASSEMBLY
Final Drive . . . . . . . . . . . . Plug-in Differential SERVICE BRAKES
. . . . . . . . . . . . . with Planetary Wheel Drive
Actuation: . . . . . . . . . . . . . . . . All-Hydraulic
Reduction Ratios: Front . . . . . . . . . . Oil-Cooled, Multiple-Disc
Bevel Set . . . . . . . . . . . . . . . . . . 2.647:1 Rear . . . . . . . . . . . Oil-Cooled, Multiple-Disc
Planetary Final Drive . . . . . . . . . . . . 7.235:1 . . Both Act as both Service and Retarder Brakes
Total Reduction . . . . . . . . . . . . . . 19.151:1 Retarder Brakes:
Normally Applied . . . . . Manually By Operator.
ELECTRIC SYSTEM Automatically Actuated . . . . . . . . . . . . . .
when engine speed exceeds the rated revolutions
Batteries (series-parallel) . . . . 4 x 12V / 220 A. Hr. of the shift position for the transmission.
Parking Brake: . . . Spring-Applied, Oil Released
Alternator . . . . . . . . 24 Volt, 240 Ampere Output . Dry Caliper Disc Actuates On Rear Drive Shaft
Lighting . . . . . . . . . . . . . . . . . . . . 24 Volt Emergency Brakes:
An emergency brake valve actuates the brakes
Starters . . . . . . . . . . . One (1) - 24 Volt Electric automatically, if the hydraulic pressure drops
below a pre-set value.
Manual operation is also possible.
Specifications - Section 5 OM5021 8/00
Page 5-4

STEERING OVERALL TRUCK DIMENSIONS

Turning Circle Diameter (SAE) . . . . 24.4 m (80 ft) Loading Height . . . . . . . . . . . 4.965 m (16’ 3")
Automatic Emergency Steering . . 2 Accumulators Minimum Clearance Height . . . . . . 5.85 m (19’ 2")
Overall Length . . . . . . . . . . . . 11.37 m (37’ 4")
Maximum Width . . . . . . . . . . . . 6.62 m (21’ 9")
TIRES
Rock Service (E-3) . . . . . . . . . . . . . Tubeless WEIGHT DISTRIBUTION
Standard . . . . . . . . . . . . . . . . . . 33.00 R51 Based on SAE 2:1 Heaped . . . . 78 m3 (102 yds3)
(w/Cummins Engine; and . . . . . . 33.00 R51 Tires)
Rim Size . . . 61x 12.95 x 12.7 cm (24 x 51 x 5 in.)
Phase II Generation . . . . . . Separable Tire Rims EMPTY . . . . . . . . Kilograms . . . . Pounds
Front Axle . . . . . . . 49 025 . . . 108,082
Rear Axle . . . . . . . . 51 437 . . . 113,399
DUMP BODY CAPACITY (Standard) Total . . . . . . . . . . 100 462 . . . 221,481
Struck . . . . . . . . . . . . . . . 54 m3 (71 yds3)
Heaped @ 2:1 (SAE) . . . . . . . 78 m3 (102 yds3) LOADED (100 Ton PAYLOAD)
. . . . . . . . . . . . Kilograms . . . . Pounds
Front Axle . . . . . . . . 82 327 . . . 181,500
Rear Axle . . . . . . . 167 149 . . . 368,500
Total * . . . . . . . . . 249 475 . . . 550,000
* Not to Exceed 249 475 kg (550,000 lbs.).
Including Options, Fuel & Payload
OM6007 8/00 Optional Equipment - Section 6
Payload Meter II Page 6-1

INDEX
PAYLOAD METER II - ON BOARD WEIGHING SYSTEM (OBWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
LIGHTS, SWITCHES, and COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
TIPS FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
EXTERNAL DISPLAY LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Linkage Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Brake Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Calculation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Sources of Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Typical Data From Service Check Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Example Calculation of Payload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Calculation of the Calibration Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
TYPES OF DATA STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Cycle data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Engine ON/OFF Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Fault Codes and Warning Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Total Payload and Total Number of Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Other Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
OPERATOR FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Using the Operator Load Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Viewing the Operator Load Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Clearing the Operator Load Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Dimming the Lights on the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
INITIAL SETUP OF PAYLOAD METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Checking the Operator Check Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Checking the Service Check Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Setting "UP:00". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Setting "PL:00" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Checking the Gt Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Checking the Inclinometer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Calibrating a Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
DISPLAYS AT START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
SETUP AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Setting the Speed Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Setting the Option Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Setting The Machine I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Setting The Operator I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Setting The Time and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
DOWNLOAD OF PAYLOAD AND FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Optional Equipment - Section 6 OM6007 8/00
Page 6-2 Payload Meter II

DISPLAY OF FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

CHARTS OF ERROR CODES AND OTHER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 & 6-21
SERVICE CHECK MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Monitoring Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
UP Factor - Payload Calculation Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
PL Mode - Load Calculation Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
FINAL GEAR RATIO SELECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
BATTERY REPLACEMENT PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Replacing the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
After Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
SUSPENSION PRESSURE SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
INCLINOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
SCOREBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Making Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Normal Operation of the Scoreboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
PAYLOAD METER BACK PANEL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
AMP Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
PAYLOAD CIRCUIT NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
PAYLOAD METER II RE-INITIALIZATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
OM6007 8/00 Optional Equipment - Section 6
Payload Meter II Page 6-3

PAYLOAD METER II
ON BOARD WEIGHING SYSTEM (OBWS)
GENERAL INFORMATION The payload meter stores in memory various operating
data. This data includes:
The Payload Meter II On Board Weighing System
displays and records the payload weight along with 1) The payload, time, distance, and travel speed for
other operating information. The system consists of a each cycle.
payload meter, pressure sensors, deck mounted lights 2) The date and time that the engine was started and
and an inclinometer. stopped.
The payload meter (Figure 6-1) uses the four suspen- 3) The date and time of each fault that occurred or
sion pressures and an inclinometer to determine the was canceled.
load in the truck. The payload weight can be displayed
in short tons or metric tons. 4) The total payload and the overall number of cycles
for a specific time period.
There are three external deck-mounted lights on each
side of the truck. The lights indicate payload weight This data is retained even when the power is switched
divided into three separate stages. A forecast feature off. The stored data is backed up by an internal battery.
will flash a deck mounted light predicting the payload The data can be down loaded from the payload meter
weight if the next bucket of material is dropped into the to a personal computer when a communication cable
body. is connected to the port inside the cab.

FIGURE 6-1. PAYLOAD METER II

1. Display panel 7. Total/shift switch [TOTAL] [SFT]
2. Reception pilot lamp (Rx busy) 8. Light/increment switch [LIGHT] [INC]
3. Transmission pilot lamp (Tx busy) 9. Memory card
4. Memory card access lamp (CARD busy) 10. Cover
5. Mode switch [MODE] 11. Diagnostic/Download Port
6. Calibration/clear switch [CAL] [CLR]
WARNING - When not inserting or removing memory card (9), always keep the cover (10) closed)
Optional Equipment - Section 6 OM6007 8/00
Page 6-4 Payload Meter II

LIGHTS, SWITCHES, and COMPONENTS

On The Face Of The Payload Meter
(Refer to Figure 6-1)
1. Display Panel 7. Total/Shift Switch
Digital display area for the data being recorded in Used to display payload and overall number of
memory. This will include items such as: cycles each time the load is dumped. Will display
Payload the error codes. This switch is also used with the
CALIBRATION/CLEAR switch to clear total pay-
Date & Time
load and overall number of cycles.
Cycles
8. Light/Increment Switch
Travel Distance
Used to change the digital increments or units for
Fault Codes and Warnings the various displays. Also used to adjust the
2. Reception Pilot Lamp (Rx Busy) brightness of the lights on the monitor display.
This light will illuminate for 3 seconds when the 9. Memory Card
system is powered up. It will then be lit whenever Used to receive data from the payload meter
the computer is communicating. memory to this card which can then be used to
3. Transmission Pilot Lamp (Tx Busy) transfer the data into a personal computer. This
enables the memory to be downloaded and saved
This light will illuminate for 3 seconds when the
when a personal computer is not available.
system is powered up. It will then be lit whenever
the memory is being downloaded to a personal 10. Cover
computer. Protective cover for the Memory Card. Do not
4. Memory Card Access Lamp (CARD Busy) open or place foreign objects in slot.
This light will illuminate for 3 seconds when the 11. Diagnostic/Download Port
system is powered up. It will also be lit whenever Connector port that is used for downloading the
the memory data is being downloaded to the memory data to a personal computer.
memory card.
5. Mode Switch
This switch is used to select the mode or system
that will allow a function to be performed.
This may include:
Various settings or corrections to the display
Memory card downloading
Clearing data
Display of Abnormalities or Warnings
Setting the speed limit
Setting the date and time
6. Calibration/Clear Switch
Used to calibrate the machine when the condi-
tions regulate this action.
Also used with the TOTAL/SFT switch to clear
total payload and overall number of cycles.
OM6007 8/00 Optional Equipment - Section 6
Payload Meter II Page 6-5

TIPS FOR OPERATION EXTERNAL DISPLAY LIGHTS

To assure that the On Board Weighing System records The Payload Meter II controls three light relays. The
the most accurate and consistent data, these impor- relays operate three deck mounted lights on each side
tant steps should be followed: of the truck. There is one green light, one amber light,
and one red light. (Figure 6-3)
* For most Haulpak Trucks:
Use only the Brake Lock switch to hold the truck While the truck is stopped being loaded and the hoist
stationary at the loading and dumping area. lever is in the float position, the appropriate lights will
For 330M Haulpak Trucks ONLY: remain on according to the following schedule:
Use the Park Brake switch to hold the truck
stationary at the loading and dumping area.
Any other method will not allow the payload sys-
tem to register properly.
* Do not activate the “Lamp Test” switch during
loading. Inaccurate and inconsistent data may be
stored.
* At the loading area do not release the Brake Lock
(or Park Brake switch) until the loading is com-
plete and the load shock from the last load
dumped has settled.
* The loading area surface must be maintained as
flat and level as possible. The On Board Weighing
FIGURE 6-2. LOAD INDICATOR LIGHTS
System can compensate for slight variations in
grade and unevenness, but ruts, berms, rocks,
INDICATOR LIGHTS PAYLOAD WEIGHT
etc. will cause the system to record inaccurate
and inconsistent data. Off Off Green 50% and Greater
Off Amber Green 90% and Greater
* Regularly remove “carryback” from the dump body.
RED Amber Green 105% and Greater
* Calibrate periodically.

The shovel or loader operator can predict the payload

weight by observing these lights. During the loading
operation, a forecast feature flashes a deck mounted
light predicting the payload weight after the next bucket
of material is loaded into the body.
The logic is as follows:
1. If the measured payload is varying 3% or less of
the rated load for more than 3 seconds, the
current load is deemed a steady value.
2. If the difference between the previous steady
value and the current steady value is greater than
15% of the rated load, the difference is taken to
be the size of the current bucket.
3. The average size of previous buckets is added to
the current load. One of the deck mounted lights
will turn on, if another “average” size load is put
in the body, and will blink at one second intervals.
Optional Equipment - Section 6 OM6007 8/00
Page 6-6 Payload Meter II

THEORY OF OPERATION Linkage Factor

The linkage factor is part of the complex calculations
Basic Description performed by the payload meter to determine the load
The payload meter uses the four suspension pres- in the truck. The linkage factor is dependent on the load
sures and the inclinometer to determine the load in the on the rear suspensions.
truck. These inputs are critical to the calculation of the Figure 6-3 shows the side view of a truck. The nose
load. The other inputs to the payload meter (Body Up, pin is marked with a star and there are three arrows
Speed, Brake Lock, Alternator R Terminal, and Engine pointing to different spots of the rear tire. This figure
Oil Pressure) are used to indicate where the truck is in shows how the support under the rear tire can affect
the haul cycle. These inputs enable the payload meter the calculation of the load. The payload meter does not
to make time and distance measurements for the haul directly measure the load transferred to the frame
cycle. through the nose pin. To account for portion of the load
The suspension pressures are the key ingredients in carried by the nose pin, the linkage factor is multiplied
determining the sprung weight of the truck. These by the rear suspension force. It is assumed that the
pressures are converted into forces using the formulas truck is supported under the center of the tire. In this
shown below. These forces are combined with the case the payload meter uses L2 to help compute the
geometry of the truck to produce the load calculation. linkage factor. If, however, the truck is backed into a
It is critical that the suspension pressure sensors are berm and the rear tire is supported towards the back
functioning properly. of the tire, the actual linkage factor calculation should
use L3. Since the payload meter assumes L2 it will
overestimate the load in the truck. The opposite is true
in the case where the rear tires are supported toward
the front of the tire. The linkage factor should use L1
π 2
Sprung Weight =
4
Suspension Diameter (Psi Left + Psi Right) but the payload meter assumes L2. This change in
leverage will cause the payload meter to underesti-
Sprung Weight = Axle Weight(lbs)/2000 mate the load.

The inclinometer gives the payload meter information

regarding the pitch angle of the truck. The front and
rear incline factors are determined by the pitch angle.
These two factors account for the load transfer that
occurs when the truck is inclined nose up or nose
down.

Figure 6-3.
OM6007 8/00 Optional Equipment - Section 6
Payload Meter II Page 6-7

Brake Lock Typical Data From Service Check Mode

The Brake Lock only applies the rear brakes. This
Number Data Description
allows the front wheels to rotate slightly as the truck is
being loaded. This is important because the payload 1 13:09 Current Time
meter assumes that the front wheels can rotate freely. 2 749.4 Front Left Pressure (Psi)
As the truck is being loaded, it will begin to squat down 3 848.9 Front Right Pressure (Psi)
on the suspensions. This will change the wheel base
4 863.2 Rear Left Pressure (Psi)
dimension of the truck. This freedom of movement
prevents additional binding and friction in the front 5 1049.0 Rear Right Pressure (Psi)
suspensions. 6 106.0 Front Weight (Tons)
The incline of the grade on which the truck is loading 7 75.1 Rear Weight (Tons)
is measured by the inclinometer. This helps determine 8 -1.85 Inclinometer (Degrees)
the incline factors that are applied to the front and rear 9 0.95 Incline Factor - Front Wheels
sprung weights. The tire forces on the road surface that
10 0.984 Incline Factor - Rear Wheels
hold the truck on grade affect the suspension pres-
sures. If the front and rear brakes are locked, the effect 11 1 Link Factor - Front Wheels
on the suspension pressures cannot be determined. 12 1.539 Link Factor - Rear Wheels
If only the rear brakes are applied the effect is predict- 13 70.6 Calibration Sprung Weight (Tons)
able and the incline factors accurately account for the
14 1.000 Gain Adjustment
forces on the tires.
15 143.8 Current Load (Tons)
If the service brake or park brake is used and depend-
16 3.9 Battery Backup Voltage (Volts)
ing on the incline and other factors, the payload meter
can overestimate or underestimate the load. It is im-
Figure 6-4.
portant that only the Brake Lock be used while
loading the truck. A sample data set is shown in Figure 6-4. This data
was taken in the laboratory and is used in Figure 6-5
Sources of Error to calculate the final load. Note that the front suspen-
sion pressures were converted into the front sprung
Suspensions weight using the formulas above Figure 6-5. The front
sprung weight is then multiplied by the front incline
Poorly charged suspensions can lead to systematic
factor and the front linkage factor. The same is done
error in the calculation of payload. The error is most
with the rear sprung weight. The front and rear sprung
obvious when the oil level is low. When there is too
weights are then summed. This number is multiplied
little oil in the suspensions, the cylinder may compress
by the Gt gain potentiometer value. This value should
completely under load. The weight of the truck will be
be 1.000. The calibration load is subtracted from the
carried by the metal to metal contact within the sus-
total to produce the final load. The load displayed on
pension. Not only will the ride of the truck and the life
the meter is this final load (item #15) multiplied by the
of the tires be affected, but the pressure in the cylinder
UP gain factor.
will not truly represent the load on the truck. In the
under-charged condition the payload meter will typi- Note - This screen is the only place that the value of
cally weigh light and under report the load. the Gt gain potentiometer can be checked. THIS GAIN
SHOULD BE SET TO 1.000. ANY OTHER SETTING
CAN PRODUCE SYSTEMATIC ERRORS IN THE
PAYLOAD MEASUREMENT.
Note - There are two gain factors that can be applied
to the payload measurement. The first is the Gt gain
factor and the other is the UP gain factor. They are not
applied uniformly to all payload calculations. Both gain
factors should be set to 1.000. See the warning on
page 16 for more information.
If the Gt gain factor displayed in the Service Check
Mode is not 1.000, adjust the gain to exactly 1.000.
Optional Equipment - Section 6 OM6007 8/00
Page 6-8 Payload Meter II

In order to adjust this gain: Calculation of the Calibration Load

1. Start with the payload meter in normal operation This procedure is similar to the manual calculation of
mode. load. This calibration load is used as item #13 from the
manual calculation procedure.
2. Adjust the gain pot, left to reduce the value and
right to increase the value. 1. Press and hold the LIGHT/INC and MODE
switches until
3. Press and hold the LIGHT/INC and "CHEC" is flashing on the display.
MODE switches until "CHEC" is
flashing on the meter. 2. Press and hold the CAL/CLR
switch until "CALL0" is flashing on
4. Press and hold the LIGHT/INC the display.
switch until "ALL0" is flashing on
the display. "A.FUL" may also be displayed. 3. Press the CAL/CLR switch to cycle through the
following data. The sequence repeats.
5. Press the LIGHT/INC switch14 times. The number
displayed will be the current Gt gain. This is not a
"live" reading. Any time the potentiometer is Item and Description Units
changed, this cycle must be repeated to view the 1. Year of Calibration Last 2 digits of year
change. 2. Month:Day of Calibration XX:XX
3. Hour:Minute of Calibration XX:XX
6. Press MODE once and "CHEC" will
flash on the display. 4. Truck Model Setting
5. Pressure Front Left Psi
7. Press MODE once and the meter will return to 6. Pressure Front Right Psi
normal operation.
7. Pressure Rear Left Psi
These calculations used a 13" front suspension diame- 8. Pressure Rear Right Psi
ter and 10" rear suspension diameter.
9. Front Sprung Weight Tons
π 2
Sprung Weight =
4
Suspension Diameter (Psi Left + Psi Right) 10. Rear Sprung Weight Tons
11. Degree of Incline ±° Nose Up Positive
Sprung Weight = Axle Weight(lbs)/2000
12. Incline Factor - Front Axle
Example Calculation of Payload
13. Incline Factor - Rear Axle
Front Weight (6) 106.00 Rear Weight(7) 75.10 14. Link Factor Front Axle
X Incline Factor (9) 15.Link Factor Rear Axle
0.95 X Incline Factor (10) 0.98
100.70 73.90 16. Calibration Weight Tons

X Link Factor (11) 1.00 X Link Factor (12) 1.53

Front Weight 100.70 Rear Weight 113.70
4. Press MODE once and
Front Weight 100.70 "CHEC" will flash on the display.
Rear Weight 113.70
5. Press MODE once and the meter will return to
Total Weight 214.40
normal operation.
XGain Factor (14) 1.00
214.40
- Calibration (13) -70.60
Current Load(15) 143.80

Figure 6-5.
OM6007 8/00 Optional Equipment - Section 6
Payload Meter II Page 6-9

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
number of cycles that can be stored in memory is 2900 cycles.

ITEM UNIT RANGE REMARKS

Advances by one each time the
Engine Operation Number Number 1 - 65535
engine is started.
Month Month 1 - 12
Day Day 1 - 31
These values are stored when the
Time Hour Hour 24 Hour Clock
load is dumped.
Time Minute Minute 1 - 59
Metric tons
Payload 0 - 6553.5
Short tons
Travel Time When Empty Minute 0 - 6553.5
Travel Distance When Empty Miles/Km 0 - 25.5
Maximum Travel Speed When Empty Mph/Kmh 0 - 99
Average Travel Speed When Empty Mph/Kmh 0 - 99
Time Stopped When Empty Minute 0 - 6553.5
Time Stopped During Loading Minute 0 - 6553.5
Travel Time When Loaded Minute 0 - 6553.5
Travel Distance When Loaded Miles/Km 0 - 25.5
Maximum Travel Speed When Loaded Mph/Kmh 0 - 99
Average Travel Speed When Loaded Mph/Kmh 0 - 99
Time Stopped When Loaded Minute 0 - 6553.5
Dumping Time Minute 0 - 6553.5
Speed Limit Mph/Kmh 0 - 99
Warnings For Each Cycle The fault codes that occur during each cycle
Optional Equipment - Section 6 OM6007 8/00
Page 6-10 Payload Meter II

Engine ON/OFF Data

When the engine is started or stopped, the following data is recorded.

ITEM UNIT RANGE REMARKS

Advances by one each time the
Engine Operation Number Number 1 - 65535
engine is started.
Last Two Digits Of The Year Year 0 - 99
Month Month 1 - 12
Indicates when the engine was
Day Day 1 - 31 started.
Time Hour Hour 24 Hour Clock
Time Minute Minute 0 - 59
Last Two Digits Of The Year Year 0 - 99
Month Month 1 - 12
Indicates when the engine was
Day Day 1 - 31 shut off.
Time Hour Hour 24 Hour Clock
Time Minute Minute 0 - 59
Total payload from the time when
Metric tons
Total Payload 0 - 999900.0 the engine was started until the
Short tons
time the engine was shut off.
Totals for the time that the engine
Total Number Of Cycles Number 0 - 9999
was running.
The engine operation numbers are included in the fault and warning data.

Fault Codes and Warning Data

ITEM UNIT RANGE REMARKS

Displayed by a combination of letters and numbers representing a specific
Error Code
error code.
Engine Operation Number Every time the engine is started
Number 1 - 65535
At Time Of Occurrence the number advances by one.
Number Of Times Of Occurrence Since
Number 1 - 255
The Engine Was Switched ON
Last Two Digits Of Year Year 0 - 99
Month Month 1 - 12
Day Day 1 -31
Time Hour Hour 24 Hour Clock
Time Minute Minute 0 - 59
OM6007 8/00 Optional Equipment - Section 6
Payload Meter II Page 6-11

Engine Operation

ITEM UNIT RANGE REMARKS

Every time the engine is started
Number when Canceled Number 1 - 65535
the number advances by one.
Last Two Digits Of Year Year 0 - 99
Month Month 1 - 12
Day Day 1 - 31
Time Hour Hour 24 Hour Clock
Time Minute Minute 0 - 59
NOTE: If the engine operation number is a 0, this indicates that the problem occurred or was canceled (depends on
the operation that was performed) when the key switch was in the ON position and the engine was not running.

Total Payload and Total Number of Cycles

The total payload and overall number of cycles can be displayed using the forced display operation. Both values
start from a zero point whenever the memory has been cleared. The payload total is automatically displayed when
the load is dumped.

ITEM UNIT RANGE REMARKS

Metric Tons The total payload since the unit
Total Payload 0 - 999900.0
Short Tons was cleared.
The number of cycles since the
Total Number Of Cycles Digital Number 0 - 9999
unit was cleared.
Last Two Digits Of Year Year 0 - 99
Month Month 1 - 12
Date and time the unit was
Day Day 1 - 31 cleared.
Time Hour Hour 24 Hour Clock
Time Minute Minute 0 - 59

Other Data
CONTENT ITEM UNIT RANGE REMARKS
Set Up Data That The Speed Limit Km/MPH 0 - 99
Operator Can Check Option Code Digital Number 0 - 13 Communication Mode
Year Year 0 - 99
Month Month 1 - 12
Calibration Data Day Day 1 - 31 Date and time when calibrated.
Hour Hour 24 Hour Clock
Minute Minute 0 - 59
Optional Equipment - Section 6 OM6007 8/00
Page 6-12 Payload Meter II

OPERATOR FUNCTIONS Clearing the Operator Load Counter

1. Press the TOTAL/SFT switch once. The number
Using the Operator Load Counter displayed is the total tons hauled since the last
time the counter was cleared. The total is dis-
Description played in hundreds of tons.
The Payload Meter makes available to the operator a
Total Load Counter and Haul Cycle Counter. This
allows each operator to track the tons hauled during 2. Press and hold the CAL/CLR switch until the
their shift. The total is displayed in hundreds of tons. display flashes.
For example, if 223 is displayed, this means that
22,300 tons have been hauled since the last time the
cycle counter was cleared. 3. Press the CAL/CLR switch until "0000" is dis-
played. After 2 seconds the meter will return to
This memory location is separate from the main pay- normal operation.
load data storage. This memory is not cleared when
the Data All Clear Operation is performed. Clearing Clearing this memory does not affect the main pay-
this memory does not affect the main payload data load data storage.
storage.

Viewing the Operator Load Counter Dimming the Lights on the Display
1. Press the TOTAL/SFT switch once. There are a total of 10 brightness levels on the PLM
If there is a fault code present at this time: display.
2. The error code for that problem will be displayed.
This will be a flashing display. From the normal operation display:
3. Press the TOTAL/SFT switch again. If additional 1. Press the LIGHT/INC switch. The lighting will
faults or warnings exist, that fault code will be become one level dimmer. This will continue until
displayed as a flashing code. the lighting has reached its lowest level.
4. Repeat step #3 until no fault codes are displayed. 2. After reaching the lowest level, the display will
":" will show when no additional faults exist. The return to the brightest setting.
display will then show total tons hauled since the
last time the counter was cleared. The total is If the switch is held in the depressed position, the
displayed in hundreds of tons. brightness will change continuously.
5. Press the TOTAL/SFT switch again. The number
displayed is the number of haul cycles since the
last time the cycle counter was cleared.
6. Press the TOTAL/SFT switch again. ":" is dis-
played for 2 seconds before the display returns to
normal operations.
OM6007 8/00 Optional Equipment - Section 6
Payload Meter II Page 6-13

INITIAL SETUP OF PAYLOAD METER There are nine switches located behind the panel on
the left side of the payload meter. Figure 6-8 shows
There are several things that must be checked and the switch numbers. The following switch positions
programmed when a Payload Meter is first installed. should be confirmed before the meter is installed.
1. Check the Switch Settings on the side of the
Switch Position
meter.
1 Gt Gain - Do Not Adjust
2. Check the Operator Check Mode settings
B Buzzer Volume - Do not Adjust
3. Check the Service Check Mode settings 2 7
4. Calibrate the clean truck. 3 7
The next few pages show the steps required to perform 4* 4 - 685E
these checks. Only after all of these steps have been 5 - 630E
performed can the payload meter be released for B - 730E
service.
C - 930E
D - 530M
E - 330M
Switch Settings
F - 830E
5 DOWN
6 DOWN
7 DOWN - SHORT TONS
UP - METRIC TONS
8 UP

* Set switch 4 for the appropriate model.

Checking the Operator 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. Press and hold the MODE
switch. The display will show.

2. Press the MODE switch once.

The display will show.
Refer to "Data All Clear" on Page 17 to clear the
haul cycle data.

3. Press the MODE switch once.

The display will show.
Refer to "Display of Fault Codes" on Page 19 for
Figure 6-6. viewing fault codes.

4. Press the MODE switch once.

The display will show.
This is the truck ID number. Refer to "Setting The
Machine ID" on Page 18 to change Machine ID.
Optional Equipment - Section 6 OM6007 8/00
Page 6-14 Payload Meter II

5. Press the MODE switch once.The Setting "PL:00"

display will show. Refer to "Setting
1. Press and hold the LIGHT/INC and MODE
The Operator ID" on Page 18 to change operator.
switches. The display will show.
6. Press the MODE switch once. The
display will show."SP:62" should be
2. Press and hold the LIGHT/INC and TOTAL/SFT
displayed. The speed limit should
switches.
be set to 62 to avoid unnecessary faults and
The display will show.
warnings. Refer to "Setting The Speed Limit" on
Page 17 to make adjustments.
3. Press the CAL/CLR switch once.
7. Press the MODE switch once. The display will show.
The display will show. Refer to
"Setting The Option Code" on 4. Press the CAL/CLR switch once.
Page 17 to change the option. The display will show.
8. Press the MODE switch once.
5. Press the LIGHT/INC switch until
The current time should be dis-
" P L : 0 0" i s di s p l ay e d. ONLY
played with the minutes flashing.
"PL:00" IS RECOMMENDED.
Refer to "Setting The Time And Date" on Page 18
to change the time and date.
6. Press the MODE switch.
9. Push the MODE switch to return to normal opera-
The display will show.
tion.
7. Press MODE and the meter will return to normal
Checking the Service Check Mode operation.

Checking the GT setting

The Gt value must be set = 1.000. Refer to "Calculation
Refer to Pages 23 and 24 for additional information Method" on Page 8 for display and adjustment infor-
on UP Factor and PL Modeprior to setting these mation.
values.
Checking the Inclinometer Settings
Setting "UP:00"
Refer to "Calculation Method" for instructions to dis-
1. Press and hold the LIGHT/INC and play truck pitch angle. With truck on level ground,
MODE switches. The display will properly charged suspensions, and empty the display
show. should indicate 0.0± 1.0. Remember this is not a live
display. After adjustment, Service Check Mode must
2. Press and hold the LIGHT/INC and be entered again to obtain a new reading.
TOTAL/SFT switches. The display
will show. An alternative method is to use a Personal Computer
running the Komatsu Payload Download Program for
3. Press the CAL/CLR switch once. windows. The "Monitor Pressures" section of the pro-
The display will show. gram displays live inclinometer data. The inclinometer
can be loosened and adjusted until the live display
4. Press the LIGHT/INC switch until shows 0.0± 1.0 degrees with the truck on level ground,
"UP: 0" is displayed. ONLY "UP: properly charged suspensions, and empty.
0" IS RECOMMENDED.
Another method is to use a voltmeter to read the
voltage output of the inclinometer. With the truck on
5. Press MODE. The display will
level ground, properly charged suspensions, and
show.
empty, the output voltage should be 2.6± .1 volts.
6. Press MODE and the meter will return to normal
operation.
OM6007 8/00 Optional Equipment - Section 6
Payload Meter II Page 6-15

Calibrating a Truck
The payload meter should be calibrated whenever one
of the following occurs:
1. When a new payload meter is installed.
2. When a suspension sensor has been changed.
3. Whenever the suspensions have been serviced
or the Nitrogen levels have changed.
4. Once a month thereafter.
To calibrate the payload meter:
1. With the engine running and the truck stopped,
press and hold the CAL/CLR switch until "CAL" is
flashing on the display.
2. Drive the truck until the speed is approximately
6-10 MPH (10-15 Km/H)
3. Press the CAL/CLR switch once.
4. Drive until the display switches back to the time
of day. This will take up to 30 seconds.
5. The payload meter is now calibrated and ready
for normal operation.

Carry out this operation on flat level ground.

Travel in a straight line.
Maintain a steady speed, 6-10 MPH (10-15 Km/H)
Optional Equipment - Section 6 OM6007 8/00
Page 6-16 Payload Meter II

DISPLAYS AT START-UP 7. The display will show:

POWER ON: This display indicates the Machine ID code where

“xxx” indicates a value between 0 and 200.
ALL external display lamps (Figure 6-2) will come on
and stay on for approximately 27 seconds during the
8. The display will show:
“Power-up Process”.
The “Power-up Process” will display the PLM settings. This display indicates the Operator ID code where
Each display will occur for approximately 3 seconds: “xxx” indicates a value between 0 and 200.

9. The display will show:

1. The display will show: This display indicates the Speed Limit setting
In addition, a buzzer will sound and the following where “xx” indicates a value between 0 and 99
lamps will light for 3 seconds: km/h.

•Reception Pilot Lamp (2, Figure 6-1) 10. The display will show:
•Transmission Pilot Lamp (3, Figure 6-1)
This display indicates the Option code setting.
•Memory Card Pilot Lamp (4, Figure 6-1)
Refer to “Operator Check Mode, Setting the Op-
2. The display will show: tion Code” and to “Method of Operation” for more
information on this function.
The “xx” indicates the Truck Model. Refer to
"Initial Setup of Payload Meter" for code defini-
tions.

3. The display will show:

This display indicates the status of
the Memory Card where: NORMAL OPERATION
“Cd : - -” indicates Card Not Used, and If the truck engine is started before the preceding
“Cd : oo” indicates Card Is Used. “Power-up Process” is completed, the display will shift
4. The display will show: to normal operation.
This display indicates the status of
the Inclinometer for the PLM,
where If the engine is running when the payload meter starts
up, only "o:XXX" and "d:XXX" will display before
“CL : - -” indicates Inclinometer Not Used, and switching to normal operations.
“CL : oo” indicates Inclinometer Is Used.

5. The display will show:

This display indicates method of
measurement where:

"US : - -" indicates METRIC Tons.

"US : oo" indicates U.S. Tons.

6. The display will show:

This function is not used.
"SU : - -" indicates Switch 8 is up.
"SU : oo" indicates Switch 8 is down.
OM6007 8/00 Optional Equipment - Section 6
Payload Meter II Page 6-17

SETUP AND MAINTENANCE 7. Press the LIGHT/INC switch to change the “tens
digit” to the desired number.
8.Press the MODE switch to return to normal opera-
Speed Limit tion.
A warning can be displayed if the machine exceeds a 9. The Option Code selects the PLM communication
preset speed. mode as follows:
The available range is: 10 - 99 km/h (6 - 62 mph). It is
recommended to set the speed limit to 99 km/h (62 Option
mph). COMMUNICATION MODE
Code

Setting The Speed Limit 0 Stand Alone

10 PMC Mode (530M only)
1. Press and hold the MODE switch
until "Cd:dP" is flashing. Modular Mining Mode, Scoreboard
12
and User Data Commmunication Mode
2. Press the MODE switch once.
The display will show:
NOTES:
3. Press the MODE switch once. 1. The Option Code is set to “0" for trucks not
The display will show: equipped with Modular Mining System (MMS)
(Except 530M).
4. Press the MODE switch repeatedly
until "SP.XX" is displayed. 2. The 530M with Powertrain Management Control
(PMC) system uses “10" as the setting for the
5. Press the LIGHT/INC switch to change the “unit Option Code.
digit” to the desired number. 3. For trucks with Modular Mining System (MMS) or
6. Press the TOTAL/SFT switch Scoreboard, the Option Code is “12".
and the display will then indicate:
Setting The Machine I.D. Code
7. Press the LIGHT/INC switch to change the “tens 1. Press and hold the MODE switch
digit” to the desired number. until "Cd:dP" is displayed.
8.Press the MODE switch to return to normal opera-
tion. 2. Press the MODE switch once.
The display will show:
Setting the Option Code
3. Press the MODE switch once.
1. Press and hold the MODE switch The display will show:
until "Cd:dP" is displayed.
4. Press the MODE switch once.
2. Press the MODE switch once. "d.XXX" is displayed.
The display will show:
5. Press the LIGHT/INC switch to change the last
3. Press the MODE switch once. digit to the desired number.
The display will show: 6. Press the TOTAL/SFT switch
and the display will show:
4. Press the MODE switch repeatedly
until "OP.XX" is displayed. 7. Press the LIGHT/INC switch to change the middle
digit to the desired number.
5. Press the LIGHT/INC switch to change the “unit
digit” to the desired number. 8. Press the TOTAL/SFT switch
and the display will show:
6. Press the TOTAL/SFT switch
and the display will then indicate:
Optional Equipment - Section 6 OM6007 8/00
Page 6-18 Payload Meter II

9. Press the LIGHT/INC switch to change the first 7. Press the LIGHT/INC switch to change the hours.
digit to the desired number. The clock is a 24 hour clock.
10. Press the MODE switch to return to normal op- 8. Press the TOTAL/SFT switch and
eration. the display will then indicate:

Setting The Operator I.D. Code 9. Press the LIGHT/INC switch to change the day.
1. Press and hold the MODE switch 10. Press the TOTAL/SFT switch and
until "Cd:dP" is displayed. the display will then indicate:

2. Press the MODE switch once. The 11. Press the LIGHT/INC switch to change the month.
display will show:
12. Press the TOTAL/SFT switch and
the display will then indicate:
3. Press the MODE switch once. The
display will show:
13. Press the LIGHT/INC switch to change the year.
4. Press the MODE switch repeatedly 14.Press the MODE switch to return to normal opera-
until "o.XXX" is displayed. tion.

5. Press the LIGHT/INC switch to change the last DOWNLOAD OF INFORMATION

digit to the desired number.
Payload information and fault codes recorded should
6. Press the TOTAL/SFT switch and be downloaded to a personal computer on a regular
the display will then indicate: basis. The software required is available under part
number AK4094. Detailed instructions for installing the
7. Press the LIGHT/INC switch to change the middle software and downloading the data is provided with
digit to the desired number. AK4094 PLM II download software.
8. Press the TOTAL/SFT switch and
the display will show: Data All Clear
This function will erase all of the cycle data, engine
9. Press the LIGHT/INC switch to change the first ON/OFF data, and fault/warning data. Total payload
digit to the desired number. and the overall number of cycles will not be cleared.
10. Press the MODE switch to return to normal op- IMPORTANT - Before clearing the data, download
eration. the data to a personal computer.

Setting The Time and Date To begin, the shift lever should be in the “N”
position, the brake lock set, the hoist control lever
1. Press and hold the MODE switch should be in the “FLOAT” position and the body in
until "Cd:dP" is displayed. the down position.

2. Press the MODE switch once. The 1. Press and hold the MODE switch
display will show: until "Cd:dP" is displayed.

3. Press the MODE switch once. The 2. Press the MODE switch once. The
display will show: display will show:

4. Press the MODE switch repeatedly 3. Press and hold the CAL/CLR
until "XX:XX" is displayed. switch until "A.CLE" is flashing.

5. Press the LIGHT/INC switch to change the min- 4. Press the CAL/CLR switch again and the memory
utes. will be cleared. The meter will then return to
normal operation.
6. Press the TOTAL/SFT switch and
the display will then indicate: This does not clear the Operator Load Counter.
OM6007 8/00 Optional Equipment - Section 6
Payload Meter II Page 6-19

DISPLAY OF FAULT CODES • Condition of the Engine Oil Pressure signal.

1. Press and hold the MODE switch The panel will display “ :C3:XX” for 3 seconds,
until "Cd:dP" is displayed. then indicate:
“ C3:oo” Engine is running.
2. Press the MODE switch once. The
display will show: “ C3:– –” Engine is not running.
• Condition of Alternator ’R’ terminal signal.
3. Press the MODE switch once. The
display will show: The panel will display “ C4:XX” for 3 seconds,
then indicate:
4. Press the TOTAL/SFT switch. “ C4:oo” Engine is running.
If there are no faults or warnings, “ C4:– –” Engine is not running.
the display will show for 6 seconds.
• Condition of the Spare Analog Input 1 signal.
If there are current faults or warnings, the codes The panel will display “ C5:XX” for 3 seconds
will be displayed in order of their priority, the with XX: as an input signal (V).
highest priority first. Each code will flash for 6
seconds. • Condition of the Spare Analog Input 2 signal.
5. After the current codes have been displayed, past The panel will display “ C6:XX” for 3 seconds
history codes that have been reset will be dis- with XX: as an input signal (V).
played. Each code will flash for 3 seconds. • Condition of the Spare Digital Input 1 signal.
If there are no history codes or
The panel will display “ C7:XX” for 3 seconds,
after all history codes have been
then:
shown , the display will show for 3
seconds: “ C7:oo” High.
The system will then proceed to the following “ C7:– –” Low.
displays: Refer to Page 22 for details.
• Condition of the Spare Digital Input 2 signal.
• Condition of the shift selector on mechanical trucks
or brake lock on electric trucks. The panel will display “ C8:XX” for 3 seconds,
then:
The panel will display: “ C1:XX” for 3 seconds,
then indicate: “ C8:oo” High.

Mechanical trucks “ C8:– –” Low.

“ C1:oo” Shift selector is in "N". 4. Press the TOTAL/SFT switch to view faults again
or press the MODE switch to return to normal
“ C1:– –” Shift selector is not in "N’. operation.
Electric trucks
“ C1:oo” Brake lock is on.
“ C1:– –” Brake lock is off.
• Condition of the Body Up Switch signal.
The panel will display: “ C2:XX” for 3 seconds,
then indicate:
“ C2:oo” Body up switch is in up position.
“ C2:– –” Body up switch is in down position.
Optional Equipment - Section 6 OM6007 8/00
Page 6-20 Payload Meter II
OM6007 8/00 Optional Equipment - Section 6
Payload Meter II Page 6-21
Optional Equipment - Section 6 OM6007 8/00
Page 6-22 Payload Meter II

Monitoring Input Signals Service Check Mode

This procedure can be used to monitor the current 1. Press and hold the LIGHT/INC and MODE
input signals to the payload meter. switches until "CHEC" is flashing.
1. Press and hold the LIGHT/INC and MODE 2. Press and hold the LIGHT/INC switch until "ALL0"
switches until "CHEC" is flashing. is flashing. "A.FUL" may also be displayed.
2. Press and hold the CAL/CLR and TOTAL/SFT 3. Press the LIGHT/INC switch to cycle through the
switches until "S.CHE" is flashing. following data. The sequence repeats.
3. Press the CAL/CLR switch to cycle through the Item and Description Units
following information :
1. Current Time Hours:Minutes
C1:oo - Shift Selector in "N" 2. Pressure Front Left Psi
C1 Mechanical Trucks C1:-- - Shift Selector 3. Pressure Front Right Psi
not in "N"
4. Pressure Rear Left Psi
C1:oo - Brake Lock On
C1 Electric Trucks 5. Pressure Rear Right Psi
C1:-- - Brake Lock Off
6. Front Weight Tons
C2:oo - Body Down
C2 Body Up 7. Rear Weight Tons
C2:-- - Body Up
C3:oo - Engine Run ± ° No s e Up
C3 Engine Oil Pressure 8. Degree of Incline
C3:-- - Engine Stopped Positive
C4:oo -Alternator Charging 9. Incline Factor - Front Axle
C4 Alternator R Terminal
C4:-- - Alternator Stopped 10. Incline Factor - Rear Axle
C5 Analog 1 - Not Used 11. Link Factor - Front Axle
C6 Analog 2 - Not Used 12. Link Factor - Rear Axle
C7 Digital 1 - Not Used 13. Calibration Weight Tons
C8 Digital 2 - Not Used 14. Gt - Trimmer Gain
C9 Speed Vehicle Speed 15. Current Load Tons
Travel Distance - 16. Backup Battery Voltage Volts
C10 under the c urrent xx.xx Miles
loaded or empty state
03:01 - Empty Stopped 4. Press MODE once and "CHEC" will flash on the
Current Status 01:02 - Empty Traveling display.
Note: 06:03 - Loading 5. Press MODE once and the meter will return to
C11
Sample values are 02:04 - Loaded Traveling normal operation.
shown. 04:05 - Loaded Stopped
05:06 - Dumping
C12(a)* Time Empty Travel S1:xx - Minutes*10
C12(b) Time Empty Stopped S2:xx - Minutes*10
C12(c) Time Loaded Travel S3:xx - Minutes*10
C12(d) Time Loaded Stop S4:xx - Minutes*10
C12(e) Time Dumping S5:xx - Minutes*10
C12(f) Time Loading S6:xx - Minutes*10
* After 9.9 minutes, "S1:--" will be displayed.

4. Press the MODE switch once and "CHEC" will

flash.
5. Press the MODE switch once and the meter will
return to normal operation.
OM6007 8/00 Optional Equipment - Section 6
Payload Meter II Page 6-23

UP Factor - Payload Calculation Gain Careful consideration must be given to the use of
PL:01 and PL:10. These modes divide the data trans-
Description of UP Factor mitted by Modular Mining and the data stored in the
payload meter’s memory. Additionally, each mode
The payload calculation gain, or UP factor is multiplied handles the UP factor differently and can calculate
to the actual calculated load. From the example shown different loads for the same haul cycle. For these
in Figure XX, the calculated load is 143.8 tons. If the reasons it is recommended that the payload meter
UP factor is set to +5% the displayed load will be 143.8 be set to use PL:00 in all cases.
x 1.05 = 151 tons. This factor can be used to minimize
the effects of systematic error for a particular truck. The PL:00
UP factor is not applied uniformly to all load calcula-
tions. There are three operating modes for the payload Modular Mining Transmission - The data is captured
meter and the UP factor is applied differently to each at the last transition from 0 to 1 MPH prior to traveling
mode. Therefore, it is recommended that this percent- 160 meters from the shovel. The captured data is
age be set to 0. There are significant differences in final transmitted when the truck travels 160m from the
calculated load that can be introduced by adjusting this shovel. This load calculation will use the UP factor
gain. percentage.

Payload meters sent from the factory are typically set Memory Storage - Same as above, the data is cap-
to "UP: 5" indicating a +5% gain in final load. tured at the last transition from 0 to 1 MPH prior to
traveling 160 meters from the shovel. The captured
This should be checked on all new meters and data is stored into memory when the body rises at the
changed to "UP: 0". dump. This load calculation will use the UP factor
percentage.
PL Mode - Load Calculation Timing
PL:01
Load Calculation Timing
Modular Mining Transmission - The data is captured
The PL mode controls when the payload meter takes at the last transition from 0 to 1 MPH prior to traveling
a sample of the data and calculates the load. There 160 meters from the shovel. The captured data is
are three modes available. There are two sets of data transmitted when the truck travels 160m from the
that are affected by the PL mode setting. shovel. This load calculation will use the UP factor
percentage.
• Modular Mining Transmission
Memory Storage - The data is captured and stored
• Memory Storage when the body rises from the frame. This calculation
will not use the UP factor percentage.

PL:10
The PL mode setting can have a significant impact on Modular Mining Transmission - The data is captured
the perceived accuracy of the payload meter. and transmitted when the truck travels 160 meters
from the shovel. This calculation will not use the UP
PL:00 is the only recommended setting. factor percentage.
Use of settings other than PL:00 Memory Storage - The data is captured and stored
is NOT recommended. when the body rises from the frame. This calculation
will not use the UP factor percentage.
Optional Equipment - Section 6 OM6007 8/00
Page 6-24 Payload Meter II

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”
is displayed.

3. Press the CAL/CLR switch repeatedly

until “A.XX” is displayed, where
“XX” is one of the following:

“XX” Gear Ratio Remarks

00 31.875 Original
01 36.400 High Traction
02 28.125 Standard
03 26.625 High Speed

NOTE: The Payload Meter is originally set to “00".

4. Press the TOTAL/SFT switch and "XX" will flash.

5. Press theLIGHT/INC switch to select the desired
gear ratio.
6. Press the MODE switch
and "CHEC" will be displayed.

7. Press the MODE switch and the meter will return

to normal operation.
OM6007 8/00 Optional Equipment - Section 6
Payload Meter II Page 6-25

BATTERY REPLACEMENT PROCEDURE 4. Remove the electrical connector. Remove the

ERROR CODE, F-09, DISPLAYED screws on the top surface and the rear face.
Remove the cover (Figure 6-8). This will expose
Replacing the Battery the battery, its wires, and the connector.

The payload meter has an internal battery used to

protect the memory from being erased when the key
switch is turned to the OFF position. Battery life is
approximately 2 years. The capacity of the battery is
monitored by the payload meter. When the voltage of
the memory battery does drop, error code, F-09, will
be displayed.
When the F-09 error code appears, download the data
within 48 hours; otherwise, the data may be lost. The
Haul Cycle data may not be recorded properly while
F-09 is displayed.
At this time it will be necessary to replace the battery.
This should be performed when the truck is in an
unloaded condition. The data stored in the payload FIGURE 6-8. ACCESS TO BATTERY
meter should be downloaded to a personal computer
or carry out the memory card dump operation. If this is 5. Grasp the wires coming from the battery and pull
not done, when the battery is disconnected all data will out. By pulling perpendicular from the board, it will
be lost. disconnect the connector from the board and pull
All that is required is a phillips-head screwdriver and a the battery out of its holder all at the same time
new battery (P/N 581-86-55710) (Figure 6-9).

1. Keyswitch in the ON position, download the data

stored in the payload memory, or carry out the
memory card dump operation.
2. Turn the keyswitch to the OFF position.
3. Remove the four mounting screws holding the
payload meter in position and then pull the pay-
load meter out, away from the instrument panel
(Figure 6-7).
NOTICE - Be careful not to let dirt, metal or spare parts
to drop inside the controller at any time.

FIGURE 6-9. BATTERY INSTALLATION

6. Insert the connector of the new battery directly into

the connector on the board (Figure 6-10). Place
the battery in the battery holder, and pass the
wiring through the notch. When doing this, insert
the wiring into the bottom of the holder and pass
it through the notch.
FIGURE 6-7. REMOVING PAYLOAD METER 7. Install the controller cover, replace the electrical
connector, and install the payload meter control-
ler back into the instrument panel.
Optional Equipment - Section 6 OM6007 8/00
Page 6-26 Payload Meter II

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 calibration data, all the data recorded in
the previous steps is also erased.
10. After this procedure has been performed the
system is ready for normal function.

SUSPENSION PRESSURE SENSOR

The pressure sensors are mounted on top of each
suspension. The sensors produce a voltage signal
FIGURE 6-10. BATTERY CONNECTION from 1 – 5 volts output.
The pressure sensor is mounted to the suspension
After Replacing the Battery
cylinder using a Schrader Valve assembly, adapter
While replacing the battery, the backup power source and sensor. The sensor can be replaced without re-
for the memory inside the payload meter is momentar- leasing the pressure in the suspension by removing
ily disconnected. the sensor with the adapter.
This can allow unwanted data (garbage) to enter the
memory and affect the meter’s recognition proce- Removal
dures. The following will remove this unwanted data.
1. Turn the keyswitch to the ON position.
may flash. Make certain the adapter and sensor are removed
together from the valve assembly. Removing the
complete valve assembly or just the sensor may
2. Using the Operator Check Mode, set the speed result in the component being forced out of the
limit option code, time and date. (These were suspension by the gas pressure inside.
erased from memory when the battery was dis-
connected). 1. Disconnect sensor from truck wiring harness.
Note: The Schrader valve in the valve assembly
3. Without turning the keyswitch to the OFF position
will prevent gas from escaping when adapter
advance to the start position. With the engine
and sensor are removed together. If entire
running, the display: may flash.
valve assembly is turned allowing nitrogen gas to
escape, recharging of the suspension will be
required.
4. Perform the Calibration procedure.
Refer to Page 15. 2. Hold valve (2, Figure 6-11) with wrench while
removing the adapter/sensor assembly (3 & 4).
5. Load the truck to the rated payload, or close to it.
Dump the load. 3. Remove sensor (4) from adapter (3).
6. Move the truck to a safe area, wait at least 5
seconds after dumping the load, then shut the
truck down.
7. Turn the keyswitch back to the ON position but do
not start the engine.
8. Perform the Data All Clear in the Operator Check
mode.

FIGURE 6-11. PRESSURE SENSOR.

1. Schrader Valve 3. Adapter
2. Valve Assembly 4. Sensor
OM6007 8/00 Optional Equipment - Section 6
Payload Meter II Page 6-27

Installation Installation
1. Install new O-ring on sensor (4, Figure 6-11) and 1. Install inclinometer (3, Figure 6-13) with cap-
install sensor into adapter (3). Tighten sensor to screws, nuts and lockwashers (4).
22–29 ft.lbs. (30–39 N.m) torque.
2. Install new O-ring on adapter (3) and install com-
plete adapter/sensor assembly into valve (2).
Hold valve body and tighten adapter/sensor as-
sembly to 103 ft.lbs. (176 N.m) torque.
3. Connect sensor wiring to truck wiring harness.
The sensors have three wires. Be sure that wires
are connected correctly. (Figure 6-12)

FIGURE 6-13. INCLINOMETER

FIGURE 6-12. SENSOR SIDE CONNECTOR VIEW 1. Operator’s Center 3. Inclinometer
Console Frame 4. Capscrew, Nut and
Pin Number Wire Color Wire Function 2. Bracket Lockwasher
1 Black Ground (GND)
2 Red + Power 2. Connect inclinometer wiring to the truck wiring
3 White Signal harness. (Figure 6-14)
Be sure that wires are connected correctly.

INCLINOMETER
As the truck is tilted fore or aft, the weight distribution
between the front and rear axles changes. To compen- FIGURE 6-14. INCLINOMETER SIDE
sate for this, the inclinometer measures the ground CONNECTOR VIEW
angle at which the truck rests. This data is then sent
to the payload meter so it can calculate the correct Pin Number Wire Color Wire Function
payload weight. The inclinometer is located below the
operator’s center console (passenger seat structure). 1 Black Ground (GND)
2 White Signal
Removal 3 Red + Power
1. Disconnect inclinometer wire lead from harness.
Adjustment
2. Remove the three capscrews, nuts and lockwash-
ers (4, Figure 6-13) and inclinometer (3). 1. Park the truck on a 0% grade.
2. Loosen the three Inclinometer mounting cap-
screws (4, Figure 6-13) and rotate the Inclinome-
ter until a voltage range of 2.6 ±0.1 Volts can be
measured (using aVolt/Ohm Meter) at pins 1 and
2 of the inclinometer electrical harness connector.
3. Tighten all capscrews (4, Figure 6-13) to standard
torque, after adjustment.
Optional Equipment - Section 6 OM6007 8/00
Page 6-28 Payload Meter II

SCOREBOARD
Description
The Scoreboard from Komatsu Mining Systems uses
information from the Payload Meter to display the
current load. It uses ultra-high-brightness LED tech-
nology to form 3 digits. The sign is fully sunlight read-
able and housed in a rugged steel enclosure.
The Scoreboard displays each swing pass as the truck
is being loaded. As the truck drives away, the sign will
display the last swing pass until the final load calcula-
tion is made. It will then switch to display the final load
calculation and hold it until the truck dumps. The sign
will then clear for the empty ride back to the shovel.

Making Connections
The Scoreboard connects to the RS232 port on the
Payload Meter. It must share this connection with other
dispatch systems like Modular Mining as well as the
PC download connection. This sharing of the single
port creates special circumstances when using a Per- Figure 6-15. Scoreboard
sonal Computer or dispatch system.
The Scoreboard is in constant communications with
The harness for the Scoreboard supplies two extra
the Payload Meter and must acknowledge every mes-
connections in the overhead compartment of the cab.
sage from the meter. In addition, the Scoreboard must
One is for the existing PC port and the other is for
also signal the Payload Meter that it is ready to receive
Modular Mining.
messages by supplying a 5vdc signal over the CTS
line. Installations that include Modular Mining or other When two Scoreboards are installed, the first sign
dispatch systems must take over the responsibility for transmits load information and power to the second
acknowledging messages from the Payload Meter. To sign. Note that the communications wire from the first
do this, the return communications line and the CTS sign connects to terminal 35L7. This is the retransmit
line from the Scoreboard must be cut and taped back. terminal. This wire then connects to the 35L4 terminal
When this is done, the Scoreboard simply monitors in the second sign. This is the receive terminal of the
communications between the Payload Meter and second sign.
Modular Mining. The Modular Mining system acknow-
The Payload Meter must be set to use OP12. Refer
ledges each message from the meter.
to "Setting the Option Code" for instructions.
Sharing this RS232 port with the Personal Computer
Once in this mode, the Payload Meter will look for the
for downloading can also create problems with com-
Scoreboard and attempt to communicate with it.
munications. The Payload Meter can confuse mes-
If there are communications problems, the Payload
sages from the PersonalComputer and Scoreboard.
Meter may indicate a communications port error. Refer
To eliminate this problem, the Scoreboard must be
to "Fault Codes" for additional information.
turned off during downloading of the Payload Me-
ter. Using the circuit breaker to turn off the main power
to the Scoreboard is the best way to accomplish this.
The power to the Scoreboard must be turned off before
communications between a Personal Computer and
the Payload Meter can start. Once the download proc-
ess is finished, the power needs to be restored to the
Scoreboard to keep from receiving F99 or F93 error
codes.
OM6007 8/00 Optional Equipment - Section 6
Payload Meter II Page 6-29
Optional Equipment - Section 6 OM6007 8/00
Page 6-30 Payload Meter II

Normal Operation of the Scoreboard

On power up, the Scoreboard will display "888" and
then display the current software version, "10". The
sign will then go blank until the Payload Meter begins
sending load information. There is also a small light
that blinks once per second in the center of the top
portion of the last digit that is visible by close inspec-
tion. This light indicates that the sign is powered and
operating normally.
During the typical loading cycle there is a short delay
from when a bucket load of material is dumped into the
body and when the Scoreboard indicates the weight.
This delay is caused by the Payload Meter waiting for
the oscillations in the suspensions to settle out before
calculating a current load. The Scoreboard will display
the current load calculated by the Payload Meter after
each swingload.
If the truck operator releases the brake lock and begins
to drive before the last swingload calculation is made,
the Scoreboard will never display the last swingload.
The Scoreboard will display the last load calculation
made during the loading process until the final load
calculation is made approximately 160 meters from the
shovel. At this point the final load will be displayed.
This number will remain until the truck dumps the load.
There will typically be a difference between the last
swingload and final load calculations.

PAYLOAD METER BACK PANEL

OM6007 8/00 Optional Equipment - Section 6
Payload Meter II Page 6-31

CONNECTIONS

CN1 - AMP MIC-MKII 13 Pins White Connector CN3 - AMP MIC-MKII 9 Pins
No. Description Comments White (RS-232C Port)

1 Power +24V (Battery) No. Description

2 Lamp Relay 1 1 RTS
3 Lamp Relay 2 2 SG
4 Lamp Relay 3 3 RD
5 Lamp Relay 4 4 TX
6 Lamp Relay 5 5 CTS
7 Speed Sensor (Signal) 6 DTR
8 Speed Sensor (GND) 7 DSR
Running - 28VDC 8
9 Alternator R Terminal (Charge Signal)
Off - 0VDC
10 Key Switch ACC Terminal (ACC Signal)
11
12
13 GND (Power GND)

CN2 - AMP 040 12 Pins Black Connector CN4 - AMP 040 8 Pins Black
(Optional Input, Reserved)
No. Description Comments
Running Open No. Description
1 Engine Oil Pressure Switch
Off - Closed 1 Optional Input GND
2 Sensor Power Out +18V 2 Analog Input 1
3 Sensor GND 3 Analog Input 2
4 Left FrontSuspension Pressure Sensor 1-5VDC Normal 4 Digital Input 1
Right Front Suspension PressureSensor 5 Digital Input 2
5 1-5VDC Normal
6
6 Left Rear Suspension Pressure Sensor 1-5VDC Normal 7
7 Right Rear Suspension Pressure Sensor 1-5VDC Normal
8 Inclinometer
Body Down - Open
9 Body Rise Signal
Body Up - Gnd
Lock Off - Open
10 Break Lock Signal/Neutral Signal
Lock On - Gnd
11
12
Optional Equipment - Section 6 OM6007 8/00
Page 6-32 Payload Meter II

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 Sensor ground
39A PLM lamp output - green
39B PLM lamp output - amber
39C PLM lamp output - red
39D PLM lamp output - unused
39E PLM lamp output - unused
39G +24 volt PLM power
39AA Load light - green
39BA Load light - amber
39CA Load light - red
73FSL TCI 100% load signal - 930E only
73MSL TCI 70% load signal - 930E only
714A Speed signal
714AT Speed signal
63L Body up (gnd = up, open = down)
39H Brake lock (gnd = release, open = lock)
35L1 PLM RS232 RTS (request to send)
35L2 PLM RS232 signal ground
35L3 PLM RS232 receive
35L4 PLM RS232 transmit
35L5 PLM RS232 CTS (clear to send)
35L6
35L7/35L4 Scoreboard 1 to scoreboard 2
35L8 PLM chan 2 TxD
35L9 PLM chan 2 RxD
21C Engine oil pressure (gnd = off, open = run)
21D Alternator R-Terminal (open = off,+24V = run)
OM6007 8/00 Optional Equipment - Section 6
Payload Meter II Page 6-33

PAYLOAD METER II RE-INITIALIZATION PROCEDURE

This procedure is designed to reset the Payload Meter II to clear repeated F.CAL errors.

This procedure is necessary to fix a rare condition in 7. Set the time, date, OP, PL, and UP settings. All
the operation of the meter. Indication for this procedure other user settings should updated at this time.
is a repeated display of F.CAL on the meter despite
8. Calibrate the Payload Meter by holding the CAL
repeated calibration. If possible, download the Pay-
button until CAL flashes.
load Meter before performing this procedure. This
procedure will erase all memory and user settings. 9. Release the Brake Lock (Park Brake for 330M)
and begin driving 5-8 MPH on level ground and
NOTE:
press CAL.
This procedure should be performed before any
CAL should display until the meter finishes its
Payload Meter is returned for warranty or repair.
calibration.
10. Load the truck to rated load and drive through one
Before performing this procedure, be sure that the
haul cycle.
engine inputs into the payload meter can be manipu-
lated to indicate engine running and engine stopped. 11. After dumping the load, wait at least 15 seconds
Some payload meter installations have hard-wired and drive the truck to a safe location.
these inputs. These inputs must be accessible and
12. Stop the truck and shut down the engine.
able to produce the following input conditions:
13. Turn on the Payload Meter but leave the engine
off.
21C 21D
14. Hold MODE and LIGHT until CHEC flashes.
Condition Engine Oil Alternator "R"
Pressure Terminal 15. Hold LIGHT and CAL until A:CLE flashes.
Engine Running Open 24VDC 16. Press CAL to clear the service memory.
Engine Stopped Ground Open
17. When CHEC is displayed, press MODE to return
to normal operation.
1. Turn off all systems. 18. Clear the Haul Cycle Memory by holding MODE
until Cd:dP is displayed.
2. Turn on the Payload Meter but leave the engine
off. 19. Press MODE and A.CLE will be displayed.
3. Hold MODE and LIGHT until CHEC flashes. 20. Hold CAL until A.CLE flashed.
4. Hold the CAL, TOTAL and LIGHT buttons until 21. Press CAL once more to clear the haul cycle
00:00 is displayed. memory.
5. Press CAL for 2 seconds. 00 00 will flash and the 22. Clear the operator load counter by pressing the
meter will erase its memory and reset to its factory TOTAL button until ":" is displayed.
settings. This includes and OP, UP, PL, P.SEL,
23. Hold the CAL button until the display flashes.
and E.SEL settings.
The meter will restart and display F.CAL. 24. Hold the CAL button until 0000 is displayed to
clear the memory.
6. Start the engine.
25. The payload meter should now function normally.
Optional Equipment - Section 6 OM6007 8/00
Page 6-34 Payload Meter II

NOTES

PORTIONS OF THIS PRODUCT RELATING TO PAYLOAD MEASURING SYSTEMS ARE

MANUFACTURED UNDER LICENSE FROM

L. G. HAGENBUCH holder of
U.S. Patent Numbers 4,831,539 and 4,839,835
OM6007.1 8/00 Optional Equipment - Section 6
Cab Radio Page 6-35

CAB RADIO

To operate the Radio 7. Clock - If time-of-day is not on the display, press

RCL (7).
1. Rotate the ON-OFF control (1) clockwise to turn
the radio ON; rotate CCW (counter-clockwise) to Press and hold SET button and at the same
turn radio OFF. Rotate VOL control clockwise to time press and hold TUNE ∨ until the correct
increase volume. Rotate VOL control CCW to de- hour appears.
crease volume. Press and hold SET button and at the same
time, press and hold TUNE ∧ until the correct
2. AM/FM or WX - Press BAND switch (2) to select
minute appears. (Seconds will set to 00 when
desired band. (AM/FM or optional WX* , will be
adjusting minutes.)
displayed depending on band choice.)
Frequency - If radio is turned on and time is being
NOTE: The last station heard on each band will be
displayed, press RCL to display frequency.
stored in memory. When switching back to that
band, it will automatically return. Stereo - The radio will automatically switch to
* WX not available on all models. stereo when tuned to an FM station broadcasting
stereo, and the stereo indicator light ST will be
3. SEEK - Press SEEK ∧ / ∨ (3) to automatically
displayed.
search for the next higher / lower listenable station
and stay there. It will find another station each time 8. Balance - The left-right stereo balance is adjusted
that the button is pressed. by rotating the BALance (8) control in the corre-
sponding direction from the detent position.
4. Manual Tuning - Press and hold TUNE ∧ button
(4) to increase frequency. 9. Fade - Using the tab behind the BAL control, adjust
Release as the desired frequency is approached. the FADE control (9) to the right to FADE toward
Press TUNE ∨ to decrease frequency. the rear speakers. Adjust it to the left to FADE
toward the front speakers.
5. Pushbuttons - Press one of the five pushbuttons
(5) to recall a preset station. NOTE: BALance (8) and FADE (9) controls have a
detent position at the center for a balance of front
6. The following procedure will set-up pushbuttons:
to rear and left to right.
Locate a favorite station by using SEEK ∧ / ∨ or
10. & 11. Tone
the TUNE ∧ / ∨ buttons.
Rotate TRE control (10) towards left to decrease
Press SET pushbutton (6). The station frequency
treble; rotate TRE control towards right to increase
will flash 5 seconds or until set.
treble.
Press the button that is desired to be established
Rotate BAS control (11) to the right to increase
for that station.
bass; rotate BAS control to the left to decrease
The radio will now return to that frequency each
bass.
time that button is pressed and released.
NOTE: Both controls have a detent position at the
NOTE: A total of fifteen stations can be preset - 5
center for a balance of treble and bass.
AM, 5 FM, and 5 WX.
Optional Equipment - Section 6 OM6007.1 8/00
Page 6-36 Cab Radio

To Operate The Tape Player

12. Insert tape into door marked AUTO REVERSE. NOAA - Weather Radio is a service of the “Voice of the
Raised portion of cassette cartridge should be to National Weather Service.” It provides continuous
the right. broadcasts of the latest weather information directly
from National Weather Service offices. Taped weather
NOTE: The arrow points in the direction of tape
messages are repeated every four to six minutes and
direction.
are routinely revised every one to three hours, or more
13. Program - Press both direction buttons (13) simul- frequnetly if need be.
taneously. The direction arrow will change in the Most of the stations operate 24 hours daily.
graphic display and the player will change tracks.
Fast Forward - Viewing the arrow in the display,
press button with arrow pointing in the same
dirction to activate fast forward; press other button
lightly to cancel and return to playing speed.
Fast Reverse - Viewing the arrow in the display,
press button with arrow pointing in the opposite
direction to activate fast reverse; press other but-
ton lightly to cancel and return to speed.
14. Eject - Press EJT button (14) firmly to eject a tape.
NOTE: When tape is ejected, the radio becomes
operative. It is not necessary to eject a tape when
leaving the vehicle; a solenoid removes internal
pressure automatically.
Komatsu Mining Systems, Inc.
Peoria Operations
2300 N. E. Adams Street
Peoria, IL 61639
Printed in U.S.A. 083000