Komatsu HD1500-7 Dump Truck Operation and Maintenance Manual CEAM027201

Description

• Model List:
  • HD1500-7 Dump Truck

• 1. FOREWORD
• 1.1. ALERTS PAGE
• 1.2. TABLE OF CONTENTS
• 1.3. TRUCK MODEL ILLUSTRATION
• 1.4. ABOUT THIS MANUAL
• 2. TORQUE TABLES AND CONVERSION CHARTS
• 2.1. EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values
• 2.2. STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws Class 10 Nuts
• 2.3. STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws
• 2.4. SAE Grade 9 Capscrews
• 2.4.1. Hardware Tightening Method
• 3. SAFETY
• 3.1. Safety Rules
• 3.2. Safety Features
• 3.3. Clothing And Personal Items
• 3.4. Unauthorized Modification
• 3.5. Leaving The Operators Seat
• 3.6. Mounting And Dismounting
• 3.7. Fire Prevention For Fuel And Oil
• 3.8. Precautions With High Temperature Fluids
• 3.9. Asbestos Dust Hazard Prevention
• 3.10. Prevention Of Injury By Work Equipment
• 3.11. Fire Extinguisher And First Aid Kit
• 3.12. Precautions For ROPS
• 3.13. Precautions For Attachments
• 3.14. HAUL ROADS
• 3.15. PRECAUTIONS DURING OPERATION
• 3.15.1. BEFORE STARTING THE ENGINE
• 3.15.2. OPERATING THE MACHINE
• 3.15.3. TOWING
• 3.15.4. WORKING NEAR BATTERIES
• 3.16. PRECAUTIONS FOR MAINTENANCE
• 3.16.1. BEFORE PERFORMING MAINTENANCE
• 3.16.2. DURING MAINTENANCE
• 3.16.3. TIRES
• 3.16.4. WHEN REPAIRS ARE NECESSARY
• 3.17. ADDITIONAL JOB SITE RULES
• 4. WARNINGS AND CAUTIONS
• 5. OPERATING INSTRUCTIONS
• 5.1. PREPARING FOR OPERATION
• 5.1.1. Safety Is Thinking Ahead
• 5.1.2. Walk Around Inspection
• 5.1.3. Cold Weather Heating System
• 5.2. ENGINE STARTUP
• 5.2.1. Cold Weather Starting
• 5.2.2. Jump Starting
• 5.3. EMERGENCY STEERING SYSTEM
• 5.3.1. Operation
• 5.3.2. PreOperation Testing
• 5.4. AFTER THE ENGINE HAS STARTED
• 5.5. MACHINE OPERATION SAFETY PRECAUTIONS
• 5.6. LOADING
• 5.7. HAULING
• 5.8. RETARDER OPERATION
• 5.9. ENGINE OVERSPEED
• 5.10. PASSING
• 5.11. DUMPING
• 5.11.1. Raising the Dump Body
• 5.11.2. Lowering The Dump Body
• 5.12. SAFE PARKING PROCEDURES
• 5.13. TURNING OFF THE ENGINE
• 5.14. SUDDEN LOSS OF ENGINE POWER
• 5.14.1. Emergency Steering and Secondary Braking
• 5.15. DISABLED TRUCK DUMPING PROCEDURE
• 5.15.1. Hookup
• 5.15.2. Raising the Body
• 5.15.3. Lowering the Body
• 5.16. DISABLED TRUCK STEERING AND BRAKING
• 5.17. TOWING
• 6. OPERATOR CAB AND CONTROLS
• 6.1. STEERING WHEEL AND CONTROLS
• 6.1.1. Horn Button
• 6.1.2. ARSC Set Lever
• 6.1.3. Telescoping/Tilt Wheel Lever
• 6.1.4. MultiFunction Turn Signal Lever
• 6.2. RETARDER CONTROL LEVER
• 6.3. SERVICE BRAKE PEDAL
• 6.4. ACCELERATOR PEDAL
• 6.5. INSTRUMENT PANEL
• 6.6. HEATER / AIR CONDITIONER CONTROLS
• 6.6.1. Fan Control Knob
• 6.6.2. Temperature Control Knob
• 6.6.3. Air Conditioning Heater
• 6.6.4. Air Flow Directional Knob
• 6.6.5. Heater/Air Conditioner Vents
• 6.7. RETARDING CAPACITY CHART
• 6.8. OVERHEAD PANEL
• 6.8.1. Radio Speakers
• 6.8.2. Air Cleaner Vacuum Gauges
• 6.8.3. Warning Alarm Buzzer
• 6.8.4. AM/FM RADIO / CD Player
• 6.9. CENTER CONSOLE
• 6.9.1. Hoist Control Lever
• 6.9.2. Transmission Shift Lever
• 6.9.3. Parking Brake Switch
• 6.9.4. LH Window Control Switch
• 6.9.5. RH Window Control Switch
• 6.9.6. Auxiliary Power Outlets
• 6.10. OPERATOR SEAT
• 6.10.1. Seat Belts And Tethers
• 6.11. Adjustment
• 6.12. INSTRUMENT PANEL AND INDICATORS
• 6.12.1. UPPER RH SWITCH PANEL
• 6.12.2. LOWER RH SWITCH PANEL
• 6.12.3. UPPER LH SWITCH PANEL
• 6.12.4. LOWER LH SWITCH PANEL
• 6.13. ELECTRONIC DISPLAY PANEL
• 6.13.1. PILOT DISPLAY ITEMS
• 6.13.2. METER DISPLAYS
• 6.13.3. CAUTION ITEMS
• 6.13.4. EMERGENCY STOP ITEMS
• 6.13.5. CHARACTER DISPLAY
• 6.13.6. ACTION CODE DISPLAYS
• 6.13.7. CHECKING FAILURE CODES
• 6.13.8. CHARACTER DISPLAY FLOW CHART
• 6.14. REAR ELECTRICAL COMPARTMENT
• 6.15. AUTOMATIC RETARD SPEED CONTROL (ARSC)
• 6.16. AUTOMATIC SPIN REGULATOR (ASR)
• 7. EXTERIOR LIGHTING AND SWITCHES
• 7.1. DECK LIGHTING
• 7.1.1. High Beam Headlights
• 7.1.2. Forward Warning Horns
• 7.1.3. Clearance/Turn Signal Lights
• 7.1.4. Deck Mounted Backup Lights
• 7.1.5. Payload Indicator Lights
• 7.2. UPRIGHTS
• 7.2.1. Ladder Lights
• 7.2.2. Low Beam Headlights
• 7.2.3. Ground Level Download Box
• 7.2.4. Ground Level Engine Shutdown Switch
• 7.2.5. Remote Grease Fill Port
• 7.2.6. Engine Service Lights
• 7.3. REAR AXLE LIGHT BAR
• 7.3.1. Backup Lights
• 7.3.2. Backup Alarm
• 7.3.3. Turn Signal Lights
• 7.3.4. Retard/Clearance Lights
• 7.3.5. Brake Light
• 8. LUBRICATION AND SERVICE
• 8.1. COOLANT SPECIFICATIONS
• 8.1.1. Unacceptable Practices
• 8.2. RADIATOR FILL PROCEDURE
• 8.3. HYDRAULIC TANK SERVICE
• 8.3.1. Filling Instructions
• 8.4. TRANSMISSION OIL LEVEL CHECK
• 8.5. FUEL SYSTEM SERVICE
• 8.5.1. Fuel Tank Cleaning
• 8.5.2. Fuel Filter Service
• 8.6. CAB AIR FILTER SERVICE
• 8.7. HVAC RECIRCULATION FILTER
• 8.8. CAB AIR FILTER
• 8.9. AIR INTAKE CLEANER SERVICE
• 8.10. QUICK FILL SERVICE CENTER
• 8.11. PERIODIC REPLACEMENT OF CRITICAL PARTS
• 8.12. HOUR (DAILY) INSPECTION
• 8.13. HOUR (DAILY) INSPECTION (continued)
• 8.14. HOUR INSPECTION
• 8.15. HOUR INSPECTION (continued)
• 8.16. HOUR INSPECTION (continued)
• 8.17. HOUR INSPECTION
• 8.18. HOUR INSPECTION
• 8.19. HOUR INSPECTION
• 8.20. HOUR INSPECTION
• 8.21. ,000 HOUR INSPECTION
• 9. AUTOMATIC LUBRICATION SYSTEM
• 9.1. GENERAL DESCRIPTION
• 9.2. SYSTEM COMPONENTS
• 9.3. SYSTEM OPERATION
• 9.4. INJECTOR OPERATION
• 9.5. LUBRICANT PUMP
• 9.5.1. Pump Housing Oil Level
• 9.5.2. Pump Pressure Control
• 9.6. INJECTORS (SL1 Series H))
• 9.6.1. Injector Specifications
• 9.6.2. Injector Adjustment
• 9.7. SYSTEM PRIMING
• 9.7.1. Filter Assembly
• 9.8. SYSTEM CHECK
• 9.8.1. Lubrication Controller Check
• 9.8.2. Lubrication Controller Operation
• 9.8.3. Lubrication Controller Components
• 9.8.4. Lubrication Controller Adjustment
• 9.9. SYSTEM TROUBLESHOOTING CHART
• 9.10. PREVENTATIVE MAINTENANCE
• 9.10.1. Daily Lubrication System Inspection
• 9.10.2. Hour Inspection
• 9.10.3. Hour Inspection
• 10. MAJOR COMPONENTS AND SPECIFICATIONS
• 10.1. ENGINE
• 10.2. TRANSMISSION
• 10.3. SPECIFICATIONS
• 11. KOMTRAX Plus
• 11.1. KOMTRAX Plus DOWNLOADING
• 11.2. PAYLOAD METER
• 11.2.1. NORMAL OPERATION DISPLAY
• 11.2.2. EXTERNAL DISPLAY LAMPS
• 11.2.3. PREDICTED LOAD DISPLAY
• 11.2.4. CALIBRATING PLM
• 11.2.5. DATA STORED IN PAYLOAD METER
• 11.2.6. PLM DOWNLOADING
• 11.2.7. SETTING THE MACHINE ID AND OPEN ID
• 11.2.8. PAYLOAD CYCLE DATA ITEM
• 11.2.9. ADDITIONAL FUNCTIONS
• 12. AM/FM RADIO / CD / MP3 / USB / iPOD / AUX PLAYER
• 12.1. OPERATING INSTRUCTIONS
• 12.1.1. GENERAL RADIO RECEIVER FUNCTIONS
• 12.1.2. USING THE RADIO
• 12.1.3. USING THE CLOCK
• 12.1.4. USING THE ALARM
• 12.1.5. USING THE WEATHERBAND (USA Only)
• 12.1.6. USING THE COMPACT DISC PLAYER/USB
• 12.1.7. PLAYING AN MP3 DISC/USB
• 12.1.8. PLAYING MP3 FILES
• 12.1.9. USING AN iPOD
• 12.1.10. OPERATING TIPS
• 12.1.11. TROUBLESHOOTING