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Komatsu HD1500-7 User Manual

Komatsu HD1500-7
172 pages
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CEAM020605
Operation
&
Maintenance
Manual
DUMP TRUCK
SERIAL NUMBERS
A30049-A30055, A30058-A30064,
A30067-A30070, A30073-A30075,
A30078-A30080, A30085-A30090,
A30095-A30108
With SDA12V160 Engine
®

Table of Contents

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Komatsu HD1500-7 Specifications

General IconGeneral
BrandKomatsu
ModelHD1500-7
CategoryTrucks
LanguageEnglish

Summary

Non-OEM Parts in Critical Systems

Foreword

Alerts Page

Torque Tables and Conversion Charts

Standard Tightening Torques (Class 10.9)

Assembly torque specifications for metric class 10.9 cap screws.

Hardware Tightening Method

Method for verifying proper hardware tightening using paint marks.

Safety

Clothing And Personal Items

Guidelines for appropriate attire and personal items for operator safety.

Unauthorized Modification

Warnings against vehicle modifications without authorization.

Operating the Machine

When Starting The Engine

Procedures and safety precautions for starting the engine.

Truck Operation - General

General safety rules and practices for operating the truck.

Towing

Working Near Batteries

Safety precautions when working near vehicle batteries.

Precautions for Maintenance

Before Performing Maintenance

Essential steps and warnings before commencing maintenance tasks.

Tires

Tire Maintenance

Procedures for maintaining tires to ensure safety and prevent damage.

Warnings and Cautions

Lubrication Chart

Operating Instructions

Preparing for Operation

Steps to ensure the truck is properly prepared for safe operation.

Walk Around Inspection

Systematic inspection procedure before starting the engine.

Engine Start-Up

Cold Weather Starting

Specific procedures for starting the engine in cold weather conditions.

Emergency Steering System

Operation

How the emergency steering system functions and its limitations.

Steering

Machine Operation Safety Precautions

Hauling

Raising the Dump Body

Safe Parking Procedures

Disabled Truck Dumping Procedure

Hookup

Steps for connecting a "good" truck to dump a disabled one.

Towing

Operator Cab and Controls

Steering Wheel and Controls

Overview of steering wheel adjustments and control levers.

Instrument Panel

Heater / Air Conditioner Controls

Fan Speed Control Knob

How to adjust fan speed for climate control.

Retarding Capacity Chart

Transmission Shift Lever

Operator Seat

Seat Adjustment

How to adjust the operator's seat for comfort and ergonomics.

Upper RH Switch Panel

Brake Lock Switch

How to use the brake lock for stationary holding.

Lower RH Switch Panel

Key Switch

Operation of the ignition key switch.

Auxiliary Brake Switch

How to manually activate the auxiliary braking system.

Lower LH Switch Panel

Head Light Switch

How to control headlights, clearance lights, and panel lights.

Electronic Display Panel

Meter Displays

Speedometer

Indicates the travel speed of the truck.

Engine Tachometer

Displays the engine speed and warns of over-speed conditions.

Caution Items

Maintenance Caution Lamp

Indicates when maintenance is required for various systems.

Emergency Stop Items

Character Display

Filter And Oil Change Display

Resetting The Filter/Oil Replacement Meter

Action Code Displays

E03 Codes

Actions required for E03 action codes indicating critical failures.

Rear Electrical Compartment

Vehicle Health Monitoring System (VHMS)

Overview of the machine management system and its data collection.

Automatic Spin Regulator (ASR)

Exterior Lighting and Switches

Deck Lighting

Covers various lights on the truck deck.

Lubrication and Service

Coolant Specifications

Recommended coolant types and mixtures for different climates.

Radiator Fill Procedure

Hydraulic Tank Service

Filling Instructions

Procedures for filling the hydraulic tank and ensuring proper level.

Periodic Replacement of Critical Parts

10 Hour (Daily) Inspection

250 Hour Inspection

Every 250 Hours Service

Recurring maintenance tasks performed every 250 hours.

Automatic Lubrication System

General Description

Overview of the automatic lubrication system's function.

System Components

Details on filters, pumps, injectors, and other system parts.

System Operation

Injector Operation

Lubricant Pump

Pump Pressure Control

How hydraulic pressure is controlled and monitored for the pump.

Injectors (SL-1 Series “H”)

Injector Adjustment

How to adjust the lubricant output volume of the injectors.

System Priming

System Check

Lubrication Controller Adjustment

Factory settings for dip switches and rotary switch.

System Troubleshooting Chart

Preventative Maintenance

Daily Lubrication System Inspection

Daily checks to ensure proper operation of the lubrication system.

Major Components and Specifications

Engine

Specifications for the Komatsu SDA12V160 diesel engine.

Transmission

Details on the torqflow transmission, shift control, and lockup clutch.

Brake System

Information on the hydraulic service and retarder brakes.

Specifications

Service Capacities

Fluid capacities for engine, cooling, hydraulic, and other systems.

Hydraulic System

Details on hydraulic pumps, valves, and cylinders.

Vehicle Health Monitoring System (VHMS)

VHMS Downloading

Steps for downloading VHMS data from the ground level download box.

Payload Meter

Normal Operation Display

Calibrating PLM

PLM Downloading

Downloading From Inside Of The Cab

Steps for downloading PLM data from inside the cab.

Setting the Machine ID and Open ID

Payload - Cycle Data Item

Confirming recorded payload:

Methods for confirming the haul payload.

AM/FM Radio / CD Player

General Radio Receiver Functions

Features of the radio receiver.

Adjusting the Receiver Settings

Using the Alarm

Setting the Alarm

How to set the alarm time and activate it.

Troubleshooting

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