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Komatsu HD1500-7 Dump Truck Operation & Maintenance Manual - PDF
Komatsu HD1500-7 Dump Truck Operation & Maintenance Manual
Description:
Komatsu HD1500-7 Dump Truck Operation & Maintenance 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 must understand the content in this manual before operating, maintaining or performing operational checks on the truck. All safety notices, warnings and cautions must be understood before operating or repairing the truck. The first section is an introduction to the manual and contains a table of contents to locate specific areas of interest.
- Other sections include Safety, Operation, Maintenance, Specifications, and Optional Equipment. This manual shows dimensioning of metric and (U.S. standard) units throughout. All references to right, left, front, or rear are made with respect to the operator’s normal seated position, unless specifically stated otherwise. Standard torque requirements are shown in torque charts in the Introduction section and individual torques are provided in the text in bold face type, such as 135 N·m (100 ft lb).
- All torque specifications have ±10% tolerance unless otherwise specified. The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck.
- A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum Gross Vehicle Weight (GVW) rating. The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit.
- This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum GVW. GVW is the total truck weight.
- This is equal to the empty vehicle weight + the fuel & lubricants + the payload. To determine allowable payload: Service all lubricants to the proper level including the fuel tank. Weigh the empty truck This includes all accessories, body liners, tailgates, etc. Record this value and subtract from the GVW rating. The result is the allowable payload
Table of Contents:
Komatsu HD1500-7 Dump Truck Operation & Maintenance Manual \
CEAM020605.pdf.................................................................................... 0 FOREWORD...................................................................................... 5 ALERTS PAGE................................................................................... 6 TABLE OF CONTENTS............................................................................. 7 TABLE OF CONTENTS............................................................................. 8 TABLE OF CONTENTS............................................................................. 9 TABLE OF CONTENTS............................................................................. 10 TRUCK MODEL ILLUSTRATION.................................................................. 12 ABOUT THIS MANUAL......................................................................... 13 TORQUE TABLES AND CONVERSION CHARTS........................................................... 15 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values...................... 16 STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts..................... 16 STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws........................ 17 STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws.................................... 18 Hardware Tightening Method............................................................ 26 SAFETY........................................................................................ 27 Safety Rules.............................................................................. 27 Safety Features........................................................................... 27 Clothing And Personal Items............................................................... 27 Unauthorized Modification................................................................. 27 Leaving The Operator’s Seat............................................................... 27 Mounting And Dismounting.................................................................. 28 Fire Prevention For Fuel And Oil.......................................................... 28 Precautions With High Temperature Fluids.................................................. 28 Asbestos Dust Hazard Prevention........................................................... 28 Prevention Of Injury By Work Equipment.................................................... 29 Fire Extinguisher And First Aid Kit....................................................... 29 Precautions For ROPS...................................................................... 29 Precautions For Attachments............................................................... 29 HAUL ROADS................................................................................ 30 PRECAUTIONS DURING OPERATION.............................................................. 30 BEFORE STARTING THE ENGINE............................................................ 30 Fire Prevention................................................................... 31 Preparing For Operation........................................................... 31 Ventilation In Enclosed Areas..................................................... 31 In Operator’s Cab - Before Starting The Engine.................................... 31 Mirrors, Windows, And Lights...................................................... 31 OPERATING THE MACHINE................................................................. 32 When Starting The Engine.......................................................... 32 Precautions For Starting Machine.................................................. 32 Truck Operation - General......................................................... 32 Traveling......................................................................... 33 Traveling In Reverse.............................................................. 33 Traveling On Slopes............................................................... 33 Ensure Good Visibility............................................................ 33 Operate Carefully On Snow......................................................... 34 Avoid Damage To Dump Body......................................................... 34 Driving Near High Voltage Cables.................................................. 34 When Dumping...................................................................... 34 Working On Loose Ground........................................................... 34 Loading The Body.................................................................. 34 Parking The Machine............................................................... 34 TOWING................................................................................ 35 WORKING NEAR BATTERIES................................................................ 35 Battery Hazard Prevention......................................................... 35 Starting With Booster Cables...................................................... 35 PRECAUTIONS FOR MAINTENANCE............................................................... 36 BEFORE PERFORMING MAINTENANCE......................................................... 36 Warning Tag....................................................................... 36 Proper Tools...................................................................... 36 Stopping The Engine Before Service................................................ 36 Securing The Dump Body............................................................ 36 DURING MAINTENANCE.................................................................... 38 Personnel......................................................................... 38 Attachments....................................................................... 38 Working Under The Machine......................................................... 38 Keep The Machine Clean............................................................ 38 Rules To Follow When Adding Fuel Or Oil........................................... 38 Radiator Water Level.............................................................. 38 Use Of Lighting................................................................... 38 Precautions With The Battery...................................................... 39 Handling High Pressure Hoses...................................................... 39 Precautions With High Pressure Oil................................................ 39 Precautions When Performing Maintenance Near High Temperature Or High Pressure.... 39 Rotating Fan And Belts............................................................ 39 Waste Materials................................................................... 39 TIRES................................................................................. 40 Tire Maintenance.................................................................. 40 Storing Tires After Removal....................................................... 40 WHEN REPAIRS ARE NECESSARY............................................................ 41 ADDITIONAL JOB SITE RULES..................................................................... 42 WARNINGS AND CAUTIONS......................................................................... 43 OPERATING INSTRUCTIONS........................................................................ 49 PREPARING FOR OPERATION................................................................... 49 Safety Is Thinking Ahead.............................................................. 49 Walk Around Inspection................................................................ 49 Cold Weather Heating System........................................................... 52 ENGINE START-UP........................................................................... 53 Cold Weather Starting................................................................. 53 Jump Starting......................................................................... 54 EMERGENCY STEERING SYSTEM................................................................. 54 Operation............................................................................. 54 Pre-Operation Testing................................................................. 54 AFTER THE ENGINE HAS STARTED.............................................................. 55 MACHINE OPERATION SAFETY PRECAUTIONS...................................................... 58 LOADING................................................................................... 59 HAULING................................................................................... 60 RETARDER OPERATION........................................................................ 60 PASSING................................................................................... 61 DUMPING................................................................................... 61 Raising the Dump Body................................................................. 62 Lowering The Dump Body................................................................ 62 SAFE PARKING PROCEDURES................................................................... 63 TURNING OFF THE ENGINE.................................................................... 63 SUDDEN LOSS OF ENGINE POWER............................................................... 64 Emergency Steering And Braking........................................................ 64 DISABLED TRUCK DUMPING PROCEDURE.......................................................... 65 Hookup................................................................................ 65 Raising the Body...................................................................... 66 Lowering the Body..................................................................... 66 DISABLED TRUCK STEERING AND BRAKING....................................................... 67 TOWING.................................................................................... 69 OPERATOR CAB AND CONTROLS..................................................................... 71 STEERING WHEEL AND CONTROLS............................................................... 72 Horn Button........................................................................... 72 ARSC Set Lever........................................................................ 72 Telescoping/Tilt Wheel Lever.......................................................... 72 Multi-Function Turn Signal Lever...................................................... 72 RETARDER CONTROL LEVER.................................................................... 73 SERVICE BRAKE PEDAL....................................................................... 74 ACCELERATOR PEDAL......................................................................... 74 INSTRUMENT PANEL.......................................................................... 74 HEATER / AIR CONDITIONER CONTROLS......................................................... 75 Fan Speed Control Knob................................................................ 75 Temperature Control Knob.............................................................. 75 Air Flow Directional Knob............................................................. 75 Heater/Air Conditioner Vents.......................................................... 75 RETARDING CAPACITY CHART.................................................................. 76 RADIO SPEAKERS............................................................................ 76 AIR CLEANER VACUUM GAUGES................................................................. 76 WARNING ALARM BUZZER...................................................................... 76 AM/FM RADIO / CD PLAYER................................................................... 76 CENTER CONSOLE............................................................................ 77 Hoist Control Lever................................................................... 78 Transmission Shift Lever.............................................................. 78 Parking Brake Switch.................................................................. 79 LH Window Control Switch.............................................................. 79 RH Window Control Switch.............................................................. 79 Auxiliary Power Outlets............................................................... 79 OPERATOR SEAT............................................................................. 80 Seat Belts............................................................................ 80 Seat Adjustment....................................................................... 80 INSTRUMENT PANEL AND INDICATORS........................................................... 81 UPPER RH SWITCH PANEL..................................................................... 82 Brake Lock Switch..................................................................... 82 F1 Start Switch....................................................................... 82 Hazard Warning Lights Switch.......................................................... 82 LOWER RH SWITCH PANEL..................................................................... 83 Key Switch............................................................................ 83 Ether Starting Aid Switch............................................................. 84 ASR Cut Switch........................................................................ 84 ARSC Switch........................................................................... 84 Automatic Idle Selector Switch (AISS)................................................. 84 Auxiliary Brake Switch................................................................ 85 UPPER LH SWITCH PANEL..................................................................... 86 Automatic Lubrication System Indicator................................................ 86 LOWER LH SWITCH PANEL..................................................................... 87 Head Light Switch..................................................................... 87 Ladder Light Switch................................................................... 87 BackUp/Deck Light Switch.............................................................. 87 Fog Light Switch...................................................................... 88 Mode Select Switches 1 & 2............................................................ 88 Panel Light Dimmer Switch............................................................. 88 ELECTRONIC DISPLAY PANEL.................................................................. 89 PILOT DISPLAY ITEMS....................................................................... 90 METER DISPLAYS............................................................................ 92 CAUTION ITEMS............................................................................. 94 EMERGENCY STOP ITEMS...................................................................... 96 CHARACTER DISPLAY......................................................................... 99 ACTION CODE DISPLAYS......................................................................104 CHECKING FAILURE CODES....................................................................105 CHARACTER DISPLAY FLOW CHART..............................................................106 REAR ELECTRICAL COMPARTMENT...............................................................107 AUTOMATIC RETARD SPEED CONTROL (ARSC).....................................................110 AUTOMATIC SPIN REGULATOR (ASR)............................................................113 EXTERIOR LIGHTING AND SWITCHES................................................................115 DECK LIGHTING.............................................................................115 High Beam Headlights..................................................................115 Forward Warning Horns.................................................................115 Clearance/Turn Signal Lights..........................................................116 Deck Mounted Backup Lights............................................................116 Payload Indicator Lights..............................................................116 UPRIGHTS..................................................................................117 Ladder Lights.........................................................................117 Low Beam Headlights...................................................................117 Ground Level Download Box.............................................................117 Ground Level Engine Shutdown Switch...................................................117 Remote Grease Fill Port...............................................................117 Engine Service Lights.................................................................118 REAR AXLE LIGHT BAR.......................................................................118 Backup Lights.........................................................................118 Backup Alarm..........................................................................118 Turn Signal Lights....................................................................118 Retard/Clearance Lights...............................................................119 Brake Light...........................................................................119 LUBRICATION AND SERVICE.......................................................................121 COOLANT SPECIFICATIONS....................................................................121 Unacceptable Practices................................................................121 RADIATOR FILL PROCEDURE...................................................................121 HYDRAULIC TANK SERVICE....................................................................122 Filling Instructions..................................................................122 TRANSMISSION OIL LEVEL CHECK..............................................................122 QUICK FILL SERVICE CENTER.................................................................123 PERIODIC REPLACEMENT OF CRITICAL PARTS....................................................123 10 HOUR (DAILY) INSPECTION................................................................125 10 HOUR (DAILY) INSPECTION (continued)....................................................126 250 HOUR INSPECTION.......................................................................127 250 HOUR INSPECTION (continued)...........................................................128 250 HOUR INSPECTION (continued)...........................................................129 500 HOUR INSPECTION.......................................................................130 1000 HOUR INSPECTION......................................................................131 2000 HOUR INSPECTION......................................................................132 5000 HOUR INSPECTION......................................................................133 AUTOMATIC LUBRICATION SYSTEM..................................................................135 GENERAL DESCRIPTION.......................................................................135 SYSTEM COMPONENTS.........................................................................138 SYSTEM OPERATION..........................................................................140 INJECTOR OPERATION........................................................................141 LUBRICANT PUMP............................................................................142 Pump Housing Oil Level................................................................142 Pump Pressure Control.................................................................142 INJECTORS (SL-1 Series “H”))..............................................................143 Injector Specifications...............................................................143 Injector Adjustment...................................................................143 SYSTEM PRIMING............................................................................144 Filter Assembly.......................................................................144 SYSTEM CHECK..............................................................................145 Lubrication Controller Check..........................................................145 Lubrication Controller Operation......................................................145 Lubrication Controller Components.....................................................145 Lubrication Controller Adjustment.....................................................145 SYSTEM TROUBLESHOOTING CHART..............................................................147 PREVENTATIVE MAINTENANCE..................................................................149 Daily Lubrication System Inspection...................................................149 250 Hour Inspection...................................................................149 1000 Hour Inspection..................................................................150 MAJOR COMPONENTS AND SPECIFICATIONS...........................................................151 SPECIFICATIONS................................................................................153 VEHICLE HEALTH MONITORING SYSTEM (VHMS).......................................................155 VHMS DOWNLOADING..........................................................................156 PAYLOAD METER.............................................................................157 NORMAL OPERATION DISPLAY..............................................................158 EXTERNAL DISPLAY LAMPS................................................................159 PREDICTED LOAD DISPLAY................................................................159 CALIBRATING PLM.......................................................................160 DATA STORED IN PAYLOAD METER..........................................................161 PLM DOWNLOADING.......................................................................162 Downloading From Inside Of The Cab................................................162 Downloading From Ground Level Box.................................................162 SETTING THE MACHINE ID AND OPEN ID....................................................163 PAYLOAD - CYCLE DATA ITEM.............................................................164 ADDITIONAL FUNCTIONS..................................................................164 Other Settings....................................................................164 AM/FM RADIO / CD PLAYER.......................................................................165 GENERAL RADIO RECEIVER FUNCTIONS..........................................................165 Turning On the Power..................................................................165 One-Hour Timer........................................................................165 Display...............................................................................166 Setting a Default Display.............................................................166 Adjusting the Brightness of the Display...............................................166 Auxiliary Mode........................................................................166 Adjusting the Receiver Settings.......................................................166 USING THE CLOCK...........................................................................167 Setting the Clock.....................................................................167 USING THE ALARM...........................................................................167 Setting the Alarm.....................................................................167 Turning the Alarm Off.................................................................167 Activating Snooze.....................................................................167 Setting Alarm Volume..................................................................167 USING THE RADIO...........................................................................168 Finding a Station.....................................................................168 Setting the Presets...................................................................168 USING THE WEATHERBAND.....................................................................169 USING THE COMPACT DISC PLAYER.............................................................169 Playing a Compact Disc................................................................169 Button Functions......................................................................169 PLAYING AN MP3 DISC.......................................................................170 MP3 Format Compatibility..............................................................170 Root Directory........................................................................170 Empty Directory or Folder.............................................................170 No Folder.............................................................................170 File Name Display.....................................................................170 Pre-Programmed Playlists..............................................................171 Playing MP3 Files.....................................................................171 Button Functions......................................................................171 TROUBLESHOOTING...........................................................................172
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