Komatsu HD1500-7 Dump Truck Operation and Maintenance Manual CEAM019207

Description

• Model List:
  • HD1500-7 Dump Truck

• 1. CEAM019207.pdf
• 1.1. FOREWORD
• 1.2. ALERTS PAGE
• 1.3. TABLE OF CONTENTS
• 1.4. TABLE OF CONTENTS
• 1.5. TABLE OF CONTENTS
• 1.6. TABLE OF CONTENTS
• 1.6.1. TRUCK MODEL ILLUSTRATION
• 1.6.2. ABOUT THIS MANUAL
• 1.7. TORQUE TABLES AND CONVERSION CHARTS
• 1.7.1. EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values
• 1.7.2. STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws Class 10 Nuts
• 1.7.3. STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws
• 1.7.4. STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws
• 1.7.4.1. Hardware Tightening Method
• 1.8. SAFETY
• 1.8.1. Safety Rules
• 1.8.2. Safety Features
• 1.8.3. Clothing And Personal Items
• 1.8.4. Unauthorized Modification
• 1.8.5. Leaving The Operators Seat
• 1.8.6. Mounting And Dismounting
• 1.8.7. Fire Prevention For Fuel And Oil
• 1.8.8. Precautions With High Temperature Fluids
• 1.8.9. Asbestos Dust Hazard Prevention
• 1.8.10. Prevention Of Injury By Work Equipment
• 1.8.11. Fire Extinguisher And First Aid Kit
• 1.8.12. Precautions For ROPS
• 1.8.13. Precautions For Attachments
• 1.8.14. HAUL ROADS
• 1.8.15. PRECAUTIONS DURING OPERATION
• 1.8.15.1. BEFORE STARTING THE ENGINE
• 1.8.15.2. OPERATING THE MACHINE
• 1.8.15.3. TOWING
• 1.8.15.4. WORKING NEAR BATTERIES
• 1.8.16. PRECAUTIONS FOR MAINTENANCE
• 1.8.16.1. BEFORE PERFORMING MAINTENANCE
• 1.8.16.2. DURING MAINTENANCE
• 1.8.16.3. TIRES
• 1.8.16.4. WHEN REPAIRS ARE NECESSARY
• 1.9. ADDITIONAL JOB SITE RULES
• 1.10. WARNINGS AND CAUTIONS
• 1.11. OPERATING INSTRUCTIONS
• 1.11.1. PREPARING FOR OPERATION
• 1.11.1.1. Safety Is Thinking Ahead
• 1.11.1.2. Walk Around Inspection
• 1.11.1.3. Cold Weather Heating System
• 1.11.2. ENGINE STARTUP
• 1.11.2.1. Cold Weather Starting
• 1.11.2.2. Jump Starting
• 1.11.3. EMERGENCY STEERING SYSTEM
• 1.11.3.1. Operation
• 1.11.3.2. PreOperation Testing
• 1.11.4. AFTER THE ENGINE HAS STARTED
• 1.11.5. MACHINE OPERATION SAFETY PRECAUTIONS
• 1.11.6. LOADING
• 1.11.7. HAULING
• 1.11.8. RETARDER OPERATION
• 1.11.9. PASSING
• 1.11.10. DUMPING
• 1.11.10.1. Raising the Dump Body
• 1.11.10.2. Lowering The Dump Body
• 1.11.11. SAFE PARKING PROCEDURES
• 1.11.12. TURNING OFF THE ENGINE
• 1.11.13. SUDDEN LOSS OF ENGINE POWER
• 1.11.13.1. Emergency Steering And Braking
• 1.11.14. DISABLED TRUCK DUMPING PROCEDURE
• 1.11.14.1. Hookup
• 1.11.14.2. Raising the Body
• 1.11.14.3. Lowering the Body
• 1.11.15. DISABLED TRUCK STEERING AND BRAKING
• 1.11.16. TOWING
• 1.12. OPERATOR CAB AND CONTROLS
• 1.12.1. STEERING WHEEL AND CONTROLS
• 1.12.1.1. Horn Button
• 1.12.1.2. ARSC Set Lever
• 1.12.1.3. Telescoping/Tilt Wheel Lever
• 1.12.1.4. MultiFunction Turn Signal Lever
• 1.12.2. RETARDER CONTROL LEVER
• 1.12.3. SERVICE BRAKE PEDAL
• 1.12.4. ACCELERATOR PEDAL
• 1.12.5. INSTRUMENT PANEL
• 1.12.6. HEATER / AIR CONDITIONER CONTROLS
• 1.12.6.1. Fan Control Knob
• 1.12.6.2. Temperature Control Knob
• 1.12.6.3. Air Conditioning Heater
• 1.12.6.4. Air Flow Directional Knob
• 1.12.6.5. Heater/Air Conditioner Vents
• 1.12.7. RETARDING CAPACITY CHART
• 1.12.8. RADIO SPEAKERS
• 1.12.9. AIR CLEANER VACUUM GAUGES
• 1.12.10. WARNING ALARM BUZZER
• 1.12.11. AM/FM RADIO / CD PLAYER
• 1.12.12. CENTER CONSOLE
• 1.12.12.1. Hoist Control Lever
• 1.12.12.2. Transmission Shift Lever
• 1.12.12.3. Parking Brake Switch
• 1.12.12.4. LH Window Control Switch
• 1.12.12.5. RH Window Control Switch
• 1.12.12.6. Auxiliary Power Outlets
• 1.12.13. OPERATOR SEAT
• 1.12.13.1. Seat Belts
• 1.12.13.2. Seat Adjustment
• 1.12.14. INSTRUMENT PANEL AND INDICATORS
• 1.12.14.1. UPPER RH SWITCH PANEL
• 1.12.14.2. LOWER RH SWITCH PANEL
• 1.12.14.3. UPPER LH SWITCH PANEL
• 1.12.14.4. LOWER LH SWITCH PANEL
• 1.12.15. ELECTRONIC DISPLAY PANEL
• 1.12.15.1. PILOT DISPLAY ITEMS
• 1.12.15.2. METER DISPLAYS
• 1.12.15.3. CAUTION ITEMS
• 1.12.15.4. EMERGENCY STOP ITEMS
• 1.12.15.5. CHARACTER DISPLAY
• 1.12.15.6. ACTION CODE DISPLAYS
• 1.12.15.7. CHECKING FAILURE CODES
• 1.12.15.8. CHARACTER DISPLAY FLOW CHART
• 1.12.16. REAR ELECTRICAL COMPARTMENT
• 1.12.17. AUTOMATIC RETARD SPEED CONTROL (ARSC)
• 1.12.18. AUTOMATIC SPIN REGULATOR (ASR)
• 1.13. EXTERIOR LIGHTING AND SWITCHES
• 1.13.1. DECK LIGHTING
• 1.13.1.1. High Beam Headlights
• 1.13.1.2. Forward Warning Horns
• 1.13.1.3. Clearance/Turn Signal Lights
• 1.13.1.4. Deck Mounted Backup Lights
• 1.13.1.5. Payload Indicator Lights
• 1.13.2. UPRIGHTS
• 1.13.2.1. Ladder Lights
• 1.13.2.2. Low Beam Headlights
• 1.13.2.3. Ground Level Download Box
• 1.13.2.4. Ground Level Engine Shutdown Switch
• 1.13.2.5. Remote Grease Fill Port
• 1.13.2.6. Engine Service Lights
• 1.13.3. REAR AXLE LIGHT BAR
• 1.13.3.1. Backup Lights
• 1.13.3.2. Backup Alarm
• 1.13.3.3. Turn Signal Lights
• 1.13.3.4. Retard/Clearance Lights
• 1.13.3.5. Brake Light
• 1.14. LUBRICATION AND SERVICE
• 1.14.1. COOLANT SPECIFICATIONS
• 1.14.1.1. Unacceptable Practices
• 1.14.2. RADIATOR FILL PROCEDURE
• 1.14.3. HYDRAULIC TANK SERVICE
• 1.14.3.1. Filling Instructions
• 1.14.4. TRANSMISSION OIL LEVEL CHECK
• 1.14.5. QUICK FILL SERVICE CENTER
• 1.14.6. PERIODIC REPLACEMENT OF CRITICAL PARTS
• 1.14.7. HOUR (DAILY) INSPECTION
• 1.14.8. HOUR (DAILY) INSPECTION (continued)
• 1.14.9. HOUR INSPECTION
• 1.14.10. HOUR INSPECTION (continued)
• 1.14.11. HOUR INSPECTION (continued)
• 1.14.12. HOUR INSPECTION
• 1.14.13. HOUR INSPECTION
• 1.14.14. HOUR INSPECTION
• 1.14.15. HOUR INSPECTION
• 1.15. AUTOMATIC LUBRICATION SYSTEM
• 1.15.1. GENERAL DESCRIPTION
• 1.15.2. SYSTEM COMPONENTS
• 1.15.3. SYSTEM OPERATION
• 1.15.4. INJECTOR OPERATION
• 1.15.5. LUBRICANT PUMP
• 1.15.5.1. Pump Housing Oil Level
• 1.15.5.2. Pump Pressure Control
• 1.15.6. INJECTORS (SL1 Series H))
• 1.15.6.1. Injector Specifications
• 1.15.6.2. Injector Adjustment
• 1.15.7. SYSTEM PRIMING
• 1.15.7.1. Filter Assembly
• 1.15.8. SYSTEM CHECK
• 1.15.8.1. Lubrication Controller Check
• 1.15.8.2. Lubrication Controller Operation
• 1.15.8.3. Lubrication Controller Components
• 1.15.8.4. Lubrication Controller Adjustment
• 1.15.9. SYSTEM TROUBLESHOOTING CHART
• 1.15.10. PREVENTATIVE MAINTENANCE
• 1.15.10.1. Daily Lubrication System Inspection
• 1.15.10.2. Hour Inspection
• 1.15.10.3. Hour Inspection
• 1.16. MAJOR COMPONENTS AND SPECIFICATIONS
• 1.17. SPECIFICATIONS
• 1.18. VEHICLE HEALTH MONITORING SYSTEM (VHMS)
• 1.18.1. VHMS DOWNLOADING
• 1.18.2. PAYLOAD METER
• 1.18.2.1. NORMAL OPERATION DISPLAY
• 1.18.2.2. EXTERNAL DISPLAY LAMPS
• 1.18.2.3. PREDICTED LOAD DISPLAY
• 1.18.2.4. CALIBRATING PLM
• 1.18.2.5. DATA STORED IN PAYLOAD METER
• 1.18.2.6. PLM DOWNLOADING
• 1.18.2.7. SETTING THE MACHINE ID AND OPEN ID
• 1.18.2.8. PAYLOAD CYCLE DATA ITEM
• 1.18.2.9. ADDITIONAL FUNCTIONS
• 1.19. AM/FM RADIO / CD PLAYER
• 1.19.1. GENERAL RADIO RECEIVER FUNCTIONS
• 1.19.1.1. Turning On the Power
• 1.19.1.2. OneHour Timer
• 1.19.1.3. Display
• 1.19.1.4. Setting a Default Display
• 1.19.1.5. Adjusting the Brightness of the Display
• 1.19.1.6. Auxiliary Mode
• 1.19.1.7. Adjusting the Receiver Settings
• 1.19.2. USING THE CLOCK
• 1.19.2.1. Setting the Clock
• 1.19.3. USING THE ALARM
• 1.19.3.1. Setting the Alarm
• 1.19.3.2. Turning the Alarm Off
• 1.19.3.3. Activating Snooze
• 1.19.3.4. Setting Alarm Volume
• 1.19.4. USING THE RADIO
• 1.19.4.1. Finding a Station
• 1.19.4.2. Setting the Presets
• 1.19.5. USING THE WEATHERBAND
• 1.19.6. USING THE COMPACT DISC PLAYER
• 1.19.6.1. Playing a Compact Disc
• 1.19.6.2. Button Functions
• 1.19.7. PLAYING AN MP3 DISC
• 1.19.7.1. MP3 Format Compatibility
• 1.19.7.2. Root Directory
• 1.19.7.3. Empty Directory or Folder
• 1.19.7.4. No Folder
• 1.19.7.5. File Name Display
• 1.19.7.6. PreProgrammed Playlists
• 1.19.7.7. Playing MP3 Files
• 1.19.7.8. Button Functions
• 1.19.8. TROUBLESHOOTING