Komatsu HD1500-7 Operation & Maintenance Manual
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Komatsu HD1500-7 Operation & Maintenance Manual

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

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  • Page 1 CEAM020605 Operation & Maintenance Manual DUMP TRUCK A30049-A30055, A30058-A30064, A30067-A30070, A30073-A30075, SERIAL NUMBERS A30078-A30080, A30085-A30090, A30095-A30108 With SDA12V160 Engine ®...
  • Page 3 This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or disclosed except in accordance with written autho- rization from KAC. It is the policy of the Company to improve prod- ucts whenever it is possible and practical to do so.
  • Page 4 Komatsu is also aware of repair companies that will rework or modify an OEM part for reuse in critical systems. Komatsu does not generally authorize such repairs or modifications for the same reasons as noted above.
  • Page 5 OM1048 03/13 Introduction - Section 10 Page 10-1 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 must understand the content in this manual before operating, maintain- ing or performing operational checks on the truck.

  • Page 6: Alerts Page

    Introduction - Section 10 03/13 OM1048 Page 10-2 ALERTS PAGE...

  • Page 7: Table Of Contents

    OM1048 03/13 Introduction - Section 10 Page 10-3 TABLE OF CONTENTS SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION / PAGE FOREWARD .

  • Page 8: Table Of Contents

    Introduction - Section 10 03/13 OM1048 Page 10-4 TABLE OF CONTENTS SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION / PAGE HAULING .
  • Page 9 OM1048 03/13 Introduction - Section 10 Page 10-5 TABLE OF CONTENTS SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION / PAGE Seat Belts .
  • Page 10 Introduction - Section 10 03/13 OM1048 Page 10-6 TABLE OF CONTENTS SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION / PAGE Deck Mounted Backup Lights .
  • Page 11 OM1048 03/13 Introduction - Section 10 Page 10-7 TABLE OF CONTENTS SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION / PAGE SYSTEM PRIMING .

  • Page 12: Truck Model Illustration

    Introduction - Section 10 03/13 OM1048 Page 10-8 TRUCK MODEL ILLUSTRATION KOMATSU HD1500 DUMP TRUCK...

  • Page 13: About This Manual

    The front cover of this manual includes a form number. This form number 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: Komatsu America Corp. Peoria Technical Publications P.O. Box 240...
  • Page 14 Introduction - Section 10 03/13 OM1048 Page 10-10 NOTES...
  • Page 15 OM1201 9/11 Torque Tables And Conversion Charts - Section 12 Page 12-1 TORQUE TABLES AND CONVERSION CHARTS This manual provides dual dimensioning for many specifications. Metric units are specified first, with References throughout the manual to standard U.S. standard units in parentheses. When torque val- torques or other standard values will be to one of ues are not specified in the assembly instructions the following tables.
  • Page 16 Torque Size N•m ft lb kg•m NOTE: This list represents the current engineering 1.35 approved sources for use in Komatsu manufacture. It is not exclusive. Other products may meet the same specifications of this list. 11.5 18.0 28.5 39.0 56.0 76.0...
  • Page 17 OM1201 9/11 Torque Tables And Conversion Charts - Section 12 Page 12-3 STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws The following specifications apply to required assem- • The maximum torque tolerance shall be ±10% of bly torques for all grade 5 and grade 8 cap screws.
  • Page 18 Torque Tables And Conversion Charts- Section 12 9/11 OM1201 Page 12-4 STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws The following specifications apply to required assem- bly torques for all 12-point, grade 9 (170,000 psi min- imum tensile), cap screws. •...
  • Page 19 OM1201 9/11 Torque Tables And Conversion Charts - Section 12 Page 12-5 TABLE 4. Tightening Torque For T-Bolt Type Hose Clamp (SAE J1508 Type TB) Newton meters Inch Pounds Thread Size Band Width (N·m) (in. lb) 0.25-28 UNF 19.05 mm (0.75 in.) 8.5 ±...
  • Page 20 Torque Tables And Conversion Charts- Section 12 9/11 OM1201 Page 12-6 TABLE 7. Torque Chart For JIC 37° Swivel NutS With Or Without O-ring Seals Size Tube Size Threads UNF-2B Newton meters Foot Pounds Code (OD) (N·m) (ft lb) – 2 0.125 0.312 –...
  • Page 21 OM1201 9/11 Torque Tables And Conversion Charts - Section 12 Page 12-7 TABLE 9. Torque Chart For O-ring Boss Fittings Foot Pounds Newton meters Size Tube Size (OD) Threads UNF-2B (ft lb) (N·m) Code – 2 0.125 0.312 – 24 4 ±...
  • Page 22 Torque Tables And Conversion Charts- Section 12 9/11 OM1201 Page 12-8 TABLE11. Common Conversion Multipliers Metric To English Multiply To Convert From millimeter (mm) inch (in.) 0.0394 centimeter (cm) inch (in.) 0.3937 meter (m) foot (ft) 3.2808 meter (m) yard (yd) 1.0936 kilometer (km) mile (mi)
  • Page 23 OM1201 9/11 Torque Tables And Conversion Charts - Section 12 Page 12-9 TABLE 12. Common Conversion Multipliers English to Metric To Convert Multiply From 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)
  • Page 24 Torque Tables And Conversion Charts- Section 12 9/11 OM1201 Page 12-10 TABLE 13. Temperature Conversions Formula: F° - 32 ÷ 1.8 = C° or C° x 1.8 + 32 = F° Celsius Fahrenheit Celsius Fahrenheit Celsius Fahrenheit C° F° C° F°...
  • Page 25 Used for protecting battery electrode terminals from corrosion. * NOTE: The part numbers in this column are not Komatsu numbers. These are vendor designations. (1) Used for threaded areas (for example, plug, nipple, elbow etc.) which are removable, and a pressure of 1965 kPa (285 psi) or less.
  • Page 26 Torque Tables And Conversion Charts- Section 12 9/11 OM1201 Page 12-12 Hardware Tightening Method Mark cap screws and nuts with paint or ink before tightening to the specified torque. This method provides verification that the hardware has been properly tightened. 1.

  • Page 27: Safety

    Komatsu America Corp. can possibly create hazards. • Before making any modification, consult the Safety Features authorized regional Komatsu America Corp. distributor. Komatsu will not be responsible for • Ensure all guards and covers are in their proper injury damage caused position.
  • Page 28 Safety - Section 20 03/13 OM2032 Page 20-2 Mounting And Dismounting Precautions With High Temperature Fluids • Never jump on or off the machine. Never climb on • Immediately after machine operation, fluids are at or off a machine while it is moving. high temperatures and are pressurized.
  • Page 29 • DO NOT use attachments that are not authorized by Komatsu America Corp., or the authorized regional Komatsu distributor. Fire Extinguisher And First Aid Kit...

  • Page 30: Haul Roads

    • When creating haul roads, orient the road so the maintain a Komatsu machine. loaded truck passes on the side closest to the hill face. Keep the road as straight as possible. If...
  • Page 31 OM2032 03/13 Safety - Section 20 Page 20-5 Fire Prevention In Operator’s Cab - Before Starting The Engine • Thoroughly remove wood • DO NOT leave tools or spare parts lying around chips, leaves, paper and other or allow trash to accumulate in the cab of the flammable items accumulated truck.

  • Page 32: Operating The Machine

    Safety - Section 20 03/13 OM2032 Page 20-6 OPERATING THE MACHINE • Check for flat tires periodically during a shift. If When Starting The Engine the truck has been operating on a flat tire, DO • Never start the engine if a warning tag is attached NOT park the machine inside of a building until to the controls.
  • Page 33 OM2032 03/13 Safety - Section 20 Page 20-7 Traveling • When operating in areas that may be hazardous • Lower the dump body and set the dump lever to or have poor visibility, designate a person to the FLOAT position before traveling. direct work site traffic.
  • Page 34 Safety - Section 20 03/13 OM2032 Page 20-8 Operate Carefully On Snow When Dumping • When working on snowy or icy roads, there is • Before dumping, check that there is no person or danger that the machine may slip to the side on objects behind the machine.

  • Page 35: Towing

    OM2032 03/13 Safety - Section 20 Page 20-9 TOWING • Improper towing methods may lead to serious • If acid is accidentally ingested, drink a large personal injury and/or damage. quantity of water, milk, beaten eggs or vegetable oil. Call a doctor or poison prevention center •...

  • Page 36: Precautions For Maintenance

    The Komatsu body-up retention cable can only be used with a Komatsu body. Non-OEM dump bodies may not accommodate the Komatsu body-up retention cable. The end user must ensure that a proper cable/sling is used.
  • Page 37 OM2032 03/13 Safety - Section 20 Page 20-11 2. Remove cable (2) from its stored position on the 4. Move the hoist lever to the FLOAT position to body and install between dump body (1) and slowly lower the body until the cable is support- the axle housing ear.

  • Page 38: During Maintenance

    Safety - Section 20 03/13 OM2032 Page 20-12 DURING MAINTENANCE Rules To Follow When Adding Fuel Or Oil • Spilled fuel and oil may cause slipping. Always Personnel clean up spills, immediately. Failure to clean up • Only authorized personnel may service and fuel or oil spills may lead to fires.
  • Page 39 OM2032 03/13 Safety - Section 20 Page 20-13 Precautions With The Battery Precautions When Performing Maintenance Near High Temperature Or High Pressure • When repairing electrical system or when • Immediately after stopping performing electrical operation, engine coolant and welding, remove operating oils are at high negative (-) terminal of...

  • Page 40: Tires

    If the proper maintenance procedures are not used, the tire may burst and cause serious injury or dam- age. When performing tire/wheel maintenance, con- sult your authorized regional Komatsu distributor, or the tire manufacturer for questions regarding tire safety. Mounted tires stored as spares must be inflated to the minimum inflation pressure necessary to keep the tire beads properly seated.

  • Page 41: When Repairs Are Necessary

    OM2032 03/13 Safety - Section 20 Page 20-15 WHEN REPAIRS ARE NECESSARY 9. If the truck is to be towed for any reason, 1. Only qualified maintenance personnel, who always consider any special precautions. Refer understand the systems being repaired, may to Section 30, Operating Instructions - Towing, attempt repairs.

  • Page 42: Additional Job Site Rules

    Safety - Section 20 03/13 OM2032 Page 20-16 ADDITIONAL JOB SITE RULES • Use this space to add any additional job site rules not covered in any of the previous discussions. • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ •...

  • Page 43: Warnings And Cautions

    PIN. FC - Character positions 10 and 11 identify the Fac- tory Code (FC). The FC identifies the Komatsu fac- tory in charge of claims for the product. The FC for A product identification plate is located on the frame electric drive trucks is 61.
  • Page 44 Safety - Section 22 10/11 OM2210 Page 22-2 Warnings and Cautions When the auxiliary brake switch is activated, full, unmodulated brake pressure is applied to all wheels. The parking brake will also be applied. Never actuate the auxiliary brake when the truck is moving, except in the event of an emergency.
  • Page 45 OM2210 10/11 Safety - Section 22 Warnings and Cautions Page 22-3 A warning plate is mounted on top of the radiator surge tank cover near the radiator cap. The engine cooling system is pressurized when the engine is on Warning plates are attached to the hydraulic tank and/or when the system is hot.
  • Page 46 Safety - Section 22 10/11 OM2210 Page 22-4 Warnings and Cautions A warning plate is attached to the frame above the hydraulic system Auxiliary Power Unit (APU) quick disconnect fittings. The plate alerts technicians that high pressure hydraulic oil is present during opera- A plate on the side of the hydraulic tank provides tion.
  • Page 47 OM2210 10/11 Safety - Section 22 Warnings and Cautions Page 22-5 A warning decal is located on the rear compartment Attached to the exterior of the battery compartment is in the operator cab. Use caution when working a danger plate. This plate stresses the prevention of around or in this compartment.
  • Page 48 Safety - Section 22 10/11 OM2210 Page 22-6 Warnings and Cautions The lubrication chart is located on the LH side of the radiator. The chart specifies some of the critical maintenance items to be checked. Component loca- tion and service intervals are specified on the chart. The lube key lists the proper lubricants to be used.

  • Page 49: Operating Instructions

    OM3054 03/13 Operating Instructions - Section 30 Page 30-1 OPERATING INSTRUCTIONS PREPARING FOR OPERATION Walk Around Inspection At the beginning of each shift, perform a careful walk The safest trucks are those which have been prop- around inspection on the truck before engine start- erly prepared for operation.
  • Page 50 Operating Instructions - Section 30 03/13 OM3054 Page 30-2 FIGURE 30-1. MAJOR COMPONENT LOCATION 1. Radiator 7. Hydraulic Tank 13. Rear Suspension 2. Front Suspension 8. Transmission 14. Brake Cooling Filters 3. Front Wet Disc Brakes 9. Hoist Cylinders 15. Fuel Tank 4.
  • Page 51 OM3054 03/13 Operating Instructions - Section 30 Page 30-3 4. Inspect the fan and air conditioner belts for cor- 13. Check the axle housing breather. Replace the rect tension, wear, and tracking. Inspect the fan breather if obstructed. Check for leakage guard condition and secureness.

  • Page 52: Cold Weather Heating System

    Operating Instructions - Section 30 03/13 OM3054 Page 30-4 Cold Weather Heating System 24. Ensure the ground level engine shut off switch Some trucks operating in cold weather climates may is ON. be fitted with an optional cold weather heating sys- 25.

  • Page 53: Engine Start-Up

    OM3054 03/13 Operating Instructions - Section 30 Page 30-5 ENGINE START-UP NOTE: The engine is equipped with an oil prelube Safety rules must be observed upon engine start-up. system. A noticeable time delay will occur, while engine oil passages are being filled, before cranking motor engagement and engine cranking will begin.

  • Page 54: Jump Starting

    Pre-Operation Testing when connecting booster cables. Damage to electrical components may result if voltage and Komatsu recommends that operators perform this polarity are not correct. test to verify that the steering accumulator precharge pressure is adequate at the beginning of each shift before operating the truck.

  • Page 55: After The Engine Has Started

    OM3054 03/13 Operating Instructions - Section 30 Page 30-7 AFTER THE ENGINE HAS STARTED 4. Turn the key switch to the ON position, but do not start the engine. If coolant temperature is below 50º C (122º F), the a. Steering system pressure: Verify that the low engine will operate at 1000 rpm in order to reach nor- steering pressure...
  • Page 56 Operating Instructions - Section 30 03/13 OM3054 Page 30-8 Steering Parking Brake 4. Check operation of the parking brake: 1. Test the truck steering in extreme right and left directions. If the steering system is not operat- a. Apply parking brake switch (3, Figure 30-4). ing properly, shut the engine off, immediately.
  • Page 57 OM3054 03/13 Operating Instructions - Section 30 Page 30-9 Brake Lock 6. Check the operation of the brake lock: a. Depress brake lock switch (6, Figure 30-3). Verify the brake lock indicator lamp illumi- nates. b. With the F1 start switch OFF, move the transmission shift lever to D to enable the transmission to start in second gear.

  • Page 58: Machine Operation Safety Precautions

    Operating Instructions - Section 30 03/13 OM3054 Page 30-10 MACHINE OPERATION SAFETY PRECAUTIONS Follow all local safety rules to ensure safe machine operation. A malfunction exists if any of the red warning lights illuminate or if a gauge reads in the red area during truck operation.

  • Page 59: Loading

    OM3054 03/13 Operating Instructions - Section 30 Page 30-11 LOADING 7. Apply the brake lock switch at the shovel and 1. Approach the loading area with caution. dump areas. Remain at a safe distance while the truck ahead 8. Proceed slowly on rough terrain to avoid deep is being loaded.

  • Page 60: Hauling

    Operating Instructions - Section 30 03/13 OM3054 Page 30-12 HAULING RETARDER OPERATION 1. Stay alert and drive with extreme caution. Two lists are provided on the retarding capacity decal. One list is for a continuous rating. The second 2. Govern truck speed based on road conditions, list is for a short-length rating.

  • Page 61: Passing

    OM3054 03/13 Operating Instructions - Section 30 Page 30-13 DUMPING If the maximum engine speed of 2100 rpm or the 1. Approach the dump area with extreme caution. brake oil temperature of 120°C (248°F) is about to be Ensure the area is clear of personnel and exceeded, move the transmission shift lever to the obstructions such as overhead power lines.

  • Page 62: Raising The Dump Body

    Operating Instructions - Section 30 03/13 OM3054 Page 30-14 Raising the Dump Body Lowering The Dump Body 7. After the load clears the body, lower the body to the frame by moving the hoist control lever for- ward to the DOWN position. The dump body will start to move downward.

  • Page 63: Safe Parking Procedures

    OM3054 03/13 Operating Instructions - Section 30 Page 30-15 SAFE PARKING PROCEDURES TURNING OFF THE ENGINE The operator must continue to use safety precau- Follow the sequence below at the end of machine tions when parking and turning the engine off. use.

  • Page 64: Sudden Loss Of Engine Power

    Operating Instructions - Section 30 03/13 OM3054 Page 30-16 SUDDEN LOSS OF ENGINE POWER If the engine suddenly stops, stored hydraulic pres- sure in the brake and steering accumulators enables temporary usage of steering and brake functions. Because accumulator oil supply is limited, it is important to stop the truck as quickly and safely as possible after the loss of engine power.

  • Page 65: Disabled Truck Dumping Procedure

    OM3054 03/13 Operating Instructions - Section 30 Page 30-17 DISABLED TRUCK DUMPING Hookup PROCEDURE Ensure there is an adequate and safe area to dump the loaded dump body. Sometimes it is necessary to dump a load from the body of a disabled truck with an inoperable hoist sys- 1.

  • Page 66: Raising The Body

    Operating Instructions - Section 30 03/13 OM3054 Page 30-18 Raising the Body Lowering the Body 5. Move the hoist control lever on the disabled 9. After the load has been emptied from the body, truck to the HOLD position. Leave the lever in release the hoist control lever.

  • Page 67: Disabled Truck Steering And Braking

    OM3054 03/13 Operating Instructions - Section 30 Page 30-19 DISABLED TRUCK STEERING AND BRAKING 11. If no problems are evident, begin moving the machines. During towing, it may be necessary to steer and stop a disabled truck using hydraulic power from the tow Maintain a travel speed equal to normal human truck.
  • Page 68 Operating Instructions - Section 30 03/13 OM3054 Page 30-20...

  • Page 69: Towing

    OM3054 03/13 Operating Instructions - Section 30 Page 30-21 TOWING 3. Determine the primary reason that the truck is disabled. a. If the truck is being towed because of engine failure, certain precautions must observed. The loss of hydraulic power due to Prior to towing a truck, many factors must be engine failure requires the use of hydraulic carefully considered.
  • Page 70 Operating Instructions - Section 30 03/13 OM3054 Page 30-22 5. If the engine on the disabled truck is opera- 8. Remove all blocking, and release the disabled tional, start the engine before towing to release truck brakes. Begin towing the disabled truck. A the parking brake, and to enable steering and spotter must signal the operators to stop the braking.

  • Page 71: Operator Cab And Controls

    OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-1 OPERATOR CAB AND CONTROLS FIGURE 32-1. CAB INTERIOR - OPERATOR VIEW 1. Steering Wheel 7. Heater/Air Conditioner Vents 2. Retarder Control Lever 8. Retarding Capacity Chart 3. Service Brake Pedal 9.

  • Page 72: Steering Wheel And Controls

    Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-2 STEERING WHEEL AND CONTROLS Steering wheel (1, Figure 32-2) will telescope "in" and "out" and adjust at a tilt angle to provide a com- fortable wheel position for most operators. Horn Button Horn (2, Figure 32-2) is actuated by pushing the but- ton in the center of the steering wheel.

  • Page 73: Retarder Control Lever

    OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-3 RETARDER CONTROL LEVER Turn Signal Operation Retarder control lever (6, Figure 32-2) is mounted on Move the lever upward to signal the right side of the steering column. It can be used a right turn.

  • Page 74: Service Brake Pedal

    Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-4 SERVICE BRAKE PEDAL Service brake pedal (3, Figure 32-3) is a single func- The foot-operated treadle pedal contains an elec- tion, foot-operated pedal which controls and modu- tronic sensor which sends signals to the Quantum™ lates service brake pressure directly through a fuel control system.

  • Page 75: Heater / Air Conditioner Controls

    OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-5 HEATER / AIR CONDITIONER CONTROLS Heater/Air Conditioner Vents The heater/air conditioner compartment contains Heater/air conditioner vents (6, Figure 32-4) may be heater/air conditioner controls and some of the rotated 360°. There are three vents in the heater/air heater/air conditioner components, such as the conditioner compartment, four vents across the top blower motor, evaporator and heater coil.

  • Page 76: Retarding Capacity Chart

    Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-6 RETARDING CAPACITY CHART RADIO SPEAKERS Retarding capacity chart (8, Figure 32-1 & shown Radio speakers (9, Figure 32-1) for the AM/FM ste- below) provides the recommended maximum truck reo radio are located at the far left and right of the speeds for descending various grades with a fully overhead panel.

  • Page 77: Center Console

    OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-7 CENTER CONSOLE Center console (1, Figure 32-5) located to the right of the operator seat, is a housing which provides a mounting surface for certain operator controls. The passenger seat is located directly to the right of the console.

  • Page 78: Hoist Control Lever

    Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-8 Hoist Control Lever Hoist control lever (3, Figure 32-5) is a four-function, 6, 5, 4, 3, 2 positions - Road and load conditions three-position, hand-operated lever located between sometimes make it desirable to limit the automatic the operator seat and the center console.

  • Page 79: Parking Brake Switch

    OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-9 Parking Brake Switch When parking brake switch (6, Figure 32-5) is in the ON position, the parking brake is applied. When this switch is in the OFF position, the parking brake is released.

  • Page 80: Operator's Seat

    Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-10 OPERATOR SEAT The operator's seat provides a fully adjustable cush- 9. Fore/Aft Location of Seat: Lift lever (9) and ioned ride for driver comfort and easy operation. hold. Bend knees to move seat to a comfortable position: release control lever to lock adjust- Seat Belts ment.

  • Page 81: Instrument Panel And Indicators

    OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-11 INSTRUMENT PANEL AND INDICATORS FIGURE 32-7. INSTRUMENT PANEL 1. Upper LH Switch Panel 4. Lower LH Switch Panel 2. Center Electronic Display Panel (EDP) 5. Key Switch 3. Upper RH Switch Panel 6.

  • Page 82: Upper Rh Switch Panel

    Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-12 UPPER RH SWITCH PANEL Use the brake lock function only while at the shovel or dump. The brake lock is to be used to hold the truck stationary. Do not use this switch to stop the truck. Use of this switch applies the rear brakes at full, unmod- ulated pressure! Do not use the brake lock in place of the parking...

  • Page 83: Lower Rh Switch Panel

    OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-13 LOWER RH SWITCH PANEL FIGURE 32-9. LOWER RH SWITCH PANEL 1. Key Switch 4. ARSC Switch 2. Ether Starting Aid Switch (Optional) 5. AISS Switch 3. ASR Cut Switch 6.

  • Page 84: Ether Starting Aid Switch

    Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-14 ASR Cut Switch ASR (Automatic Spin Regulator) cut switch (3, Figure 32-9) is used to activate or de-activate the trac- tion control system. Starting fluid is extremely volatile and flammable! Use with extreme care.

  • Page 85: Auxiliary Brake Switch

    OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-15 1. Depressing the top of the Auxiliary Brake Switch switch selects OFF/ Auxiliary brake switch (6, Figure 32-9) is used to AUTO position which is used apply the auxiliary braking system. for enhanced truck operation.

  • Page 86: Upper Lh Switch Panel

    Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-16 UPPER LH SWITCH PANEL FIGURE 32-10. UPPER LH SWITCH PANEL 1. Automatic Lubrication System Indicator Upper LH switch panel (1, Figure 32-7), located to the left of the steering wheel, currently does not con- tain any switches (standard or optional).

  • Page 87: Lower Lh Switch Panel

    OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-17 LOWER LH SWITCH PANEL FIGURE 32-11. LH CONTROL/INDICATOR PANEL 1. Head Light Switch 5. Mode Select Switch # 1 2. Ladder Light Switch 6. Mode Select Switch # 2 3.

  • Page 88: Fog Light Switch

    Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-18 Fog Light Switch Fog light switch (4, Figure 32-11) controls the fog lights. The fog lights are optional and for use in foggy conditions and heavy rain. Pressing the bottom of the rocker switch turns the lights on.

  • Page 89: Electronic Display Panel

    30 seconds. The following system • If the lamps do not work, a failure in the circuit checks occur: has occurred. Contact your Komatsu distributor for inspection. • The central warning lamp illuminates for two seconds, and then turns off.

  • Page 90: Pilot Display Items

    Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-20 PILOT DISPLAY ITEMS When the key switch is in the ON position, controls that have been activated will illuminate the corre- sponding pilot display lamps. FIGURE 32-13. EDP - PILOT DISPLAY ITEMS 1.
  • Page 91 OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-21 Head Lamp High Beam Pilot Lamp ASR Actuation Lamp The high beam pilot lamp will illu- When the ASR system is active, this minate when the head lamps are lamp will illuminate when slipping from set to high beam using the multi- the rear wheels is detected.

  • Page 92: Meter Displays

    Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-22 METER DISPLAYS FIGURE 32-14. EDP - METERS 1. Torque Converter Oil Temperature Gauge 4. Speedometer 2. Engine Water Temperature Gauge 5. Retarder Oil Temperature Gauge 3. Engine tachometer 6. Fuel Gauge Speedometer Engine Tachometer The engine tachometer displays the engine speed.
  • Page 93 OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-23 Fuel Gauge Torque Converter Oil Temperature Gauge The torque converter oil temperature gauge displays The fuel gauge displays the amount of fuel remaining the torque converter oil temperature. in the fuel tank. The fuel level caution lamp will illumi- nate when the fuel level drops to 140 liters (37.0 US The white range indicates normal operating tempera- gal).

  • Page 94: Caution Items

    Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-24 CAUTION ITEMS If a caution indicator icon illuminates during machine operation, quickly assess the problem to determine the necessary reaction. FIGURE 32-15. EDP CAUTION LAMPS 1. Maintenance Caution Lamp 5.
  • Page 95 OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-25 When the maintenance caution lamp illuminates, Accumulator Charge Pressure Lamp action code E01 is simultaneously displayed on the The accumulator charge pressure lamp character display. Service the truck at the next avail- will illuminate if steering accumulator able opportunity.

  • Page 96: Emergency Stop Items

    Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-26 EMERGENCY STOP ITEMS If a fault occurs with an emergency stop item, the alarm buzzer will sound intermittently and the lamp for that item will illuminate. The central warning lamp will illuminate simultaneously.
  • Page 97 OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-27 Coolant Temperature Caution Lamp Brake Oil Pressure Caution Lamp The coolant temperature caution The brake oil pressure caution lamp will lamp will illuminate when the illuminate if accumulator oil pressure coolant temperature has risen to fails to reach the specified value 30 sec- a critical level.
  • Page 98 Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-28 Retarder System Caution Lamp Engine System Caution Lamp The retarder system caution lamp will The red engine system caution lamp will illuminate when an abnormality has illuminate when an abnormality has been detected by the RCM.

  • Page 99: Character Display

    OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-29 CHARACTER DISPLAY FIGURE 32-17. Electronic Display Panel 1. Electronic Display Panel 2. Character Display Normally, the service meter/odometer is displayed on the character display. Operator mode If the machine experiences a failure or if it is neces- Service meter, odometer display (default) * sary to perform maintenance, an action code is dis- Operation Information...
  • Page 100 NOTE: If the service meter/odometer stays on while the key switch in the OFF position, a failure has occurred. Contact your Komatsu distributor for Reverse Travel Odometer inspection. This meter indicates the total distance traveled in reverse.

  • Page 101: Transmission

    OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-31 2. Press (>) or (<) on mode select switch 2 to After replacing the filter or changing the oil, reset the scroll to the reverse odometer display. replacement interval. Refer to Resetting The Filter/ Oil Replacement Meter.
  • Page 102 Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-32 Resetting The Filter/Oil Replacement Meter The filter and oil replacement time is displayed on the character display for items needing maintenance. If a filter and/or oil have been replaced, reset the filter and oil change time.
  • Page 103 OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-33 3. Press () on mode select switch 1. This will change to the telephone input display. Up to 12 digits can be displayed for the telephone num- ber. Input from the first digits. 3.

  • Page 104: Action Code Displays

    CALL. If the telephone number has not been set, the spaces will be blank. Refer to Character Display - Inputting Telephone Numbers. If MAINTENANCE is displayed, check the failure code and contact your Komatsu distributor for repairs.

  • Page 105: Checking Failure Codes

    OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-35 CHECKING FAILURE CODES If an action code is present on the character display, check the failure codes as follows: 1. Press (>) on mode select switch 2 to display the failure code.

  • Page 106: Character Display Flow Chart

    Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-36 CHARACTER DISPLAY FLOW CHART...

  • Page 107: Rear Electrical Compartment

    OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-37 REAR ELECTRICAL COMPARTMENT The following components are located behind the operator and passenger seats across the back wall of the operator cab (Refer to Figure 32-19): 1. ATC - Automatic Transmission Controller The ATC controls and monitors the automatic transmission.
  • Page 108 Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-38 FIGURE 32-19. REAR ELECTRICAL COMPARTMENT 1. Automatic Transmission Controller (ATC) 6. Payload Meter Download Connector 2. Fuse Panel 7. CENSE Engine Download Connector - 3. Retard Control Module (RCM) (SDA12V160 Only) 4.
  • Page 109 OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-39 FIGURE 32-20. REAR ELECTRICAL COMPARTMENT (Enclosure Removed) 1. Automatic Lubrication System Timer 8. Turn Signal Flasher 2. Ground Bus Bars 9. Steering Bleeddown Timer 3. Power Bus # 1, 24V Battery Direct Power 10.

  • Page 110: Automatic Retard Speed Control (Arsc)

    Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-40 AUTOMATIC RETARD SPEED CONTROL (ARSC) If any failure in the system occurs during operation, the alarm sounds and the central warning lamp will Automatic Retard Speed Control (ARSC) automati- illuminate.
  • Page 111 OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-41 FIGURE 32-21. ARSC CONTROLS 1. Retard Lever a. Set 2. ARSC Lever b. Increase Speed 3. ARSC Switch c. Decrease Speed 4. ARSC Pilot Lamp d. Cancel 5. ARSC Set Speed Indicator 6.
  • Page 112 Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-42 Recommended Set Speeds Refer to the retarding capacity chart in the cab for the maximum safe speeds for descending a grade. Set the travel speed so that the engine speed is above 1800 rpm.

  • Page 113: Automatic Spin Regulator (Asr)

    OM3238 9/11 Operator Cab and Controls - Section 32 Page 32-43 AUTOMATIC SPIN REGULATOR (ASR) The ASR cut switch controls the status of the system. Automatic Spin Regulator (ASR) is a traction control system that helps prevent slipping of the drive A: ASR system OFF - amber lamp wheels caused by excessive torque.
  • Page 114 Operator Cab and Controls - Section 32 09/11 OM3238 Page 32-44 When the ASR switch is on, the system is active. ASR monitors the individual rear wheel speeds. If it determines one of the rear wheels is slipping during acceleration, the brake is applied to the rear wheel with the higher speed.

  • Page 115: Exterior Lighting And Switches

    OM3400 Exterior Lighting and Switches - Section 34 Page 34-1 EXTERIOR LIGHTING AND SWITCHES Refer to Section 32, Operator Cab and Controls, for more specific information on controls and switches that are located in the cab. DECK LIGHTING FIGURE 34-1. LH DECK LIGHTS 1.

  • Page 116: Clearance/Turn Signal Lights

    Exterior Lighting and Switches - Section 34 OM3400 Page 34-2 FIGURE 34-2. RH DECK LIGHTS 1. Payload Indicator Lights 4. High Beam Headlight (Outer) 2. Deck Mounted Backup Light 5. High Beam Headlight (Inner) 3. Clearance/Turn Signal Lights Clearance/Turn Signal Lights Payload Indicator Lights Clearance/turn signal lights (4, Figure 34-1) and (3, Payload indicator lights (6, Figure 34-1) and (1,...

  • Page 117: Uprights

    OM3400 Exterior Lighting and Switches - Section 34 Page 34-3 UPRIGHTS FIGURE 34-3. UPRIGHTS 1. Ladder Lights 5. Ladder Light Switch 2. Low Beam Headlight (Outer) 6. Ground Level Engine Shutdown 3. Low Beam Headlight (Inner) Switch 4. Ground Level Download Box 7.

  • Page 118: Engine Service Lights

    Exterior Lighting and Switches - Section 34 OM3400 Page 34-4 REAR AXLE LIGHT BAR FIGURE 34-6. REAR AXLE LIGHT BAR 1. Backup Light 4. Retard/Clearance FIGURE 34-4. LH ENGINE SERVICE LIGHT 2. Backup Alarm Light 3. Turn Signal Light 5. Brake Light 1.

  • Page 119: Retard/Clearance Lights

    OM3400 Exterior Lighting and Switches - Section 34 Page 34-5 Retard/Clearance Lights Retard/clearance lights (4) are dual function red lights. When the headlights are on, a low beam clear- ance light will illuminate. When the operator uses the retard function to slow the truck, a more brilliant light will illuminate to signal to traffic that the truck is slow- ing.
  • Page 120 Exterior Lighting and Switches - Section 34 OM3400 Page 34-6 NOTES...

  • Page 121: Lubrication And Service

    OM4054 09/11 Lubrication and Service - Section 40 Page 40-1 LUBRICATION AND SERVICE Preventive maintenance contributes to the long life Unacceptable Practices and dependability of the truck and its components. • Use of high-silicate anti-freeze. The use of proper lubricants and the performance of •...

  • Page 122: Hydraulic Tank Service

    Lubrication and Service - Section 40 09/11 OM4054 Page 40-2 HYDRAULIC TANK SERVICE 4. Install the fill cap. Filling Instructions 5. Start the engine. Raise and lower the dump 1. Lower the dump body and turn the key switch body three times to circulate oil and fill hoses OFF.

  • Page 123: Periodic Replacement Of Critical Parts

    OM4054 09/11 Lubrication and Service - Section 40 Page 40-3 QUICK FILL SERVICE CENTER PERIODIC REPLACEMENT OF CRITICAL PARTS The service center (Figure 40-2) is located on the left To ensure safe operation of the truck, it is necessary side of the truck below the hydraulic tank. The ser- to perform periodic maintenance for critical parts.
  • Page 124 Lubrication and Service - Section 40 09/11 OM4054 Page 40-4 FIGURE 40-3. LUBRICATION CHART...

  • Page 125: 10 Hour (Daily) Inspection

    OM4054 09/11 Lubrication and Service - Section 40 Page 40-5 10 HOUR (DAILY) INSPECTION Perform a “walk around" inspection prior to each work shift. Check the general condition of the truck. Look for evi- dence of hydraulic leaks. Check all lights and mirrors for dirt and damage. Check the operator's cab for dirty or damaged accessories or controls.
  • Page 126 Lubrication and Service - Section 40 09/11 OM4054 Page 40-6 10 HOUR (DAILY) INSPECTION (continued) Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 2. Air Cleaners Check air cleaner vacuum gauges. Clean or replace filter elements if restriction vacuum reaches 6 kPa (25 in.

  • Page 127: 250 Hour Inspection

    OM4054 09/11 Lubrication and Service - Section 40 Page 40-7 250 HOUR INSPECTION Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS INITIAL 250 HOUR SERVICE 1. Perform the following maintenance after operating the machine for the first 250 hours.
  • Page 128 Lubrication and Service - Section 40 09/11 OM4054 Page 40-8 250 HOUR INSPECTION (continued) Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 3 Alternator Belt - Check the alternator belt for cracks, cuts or glazing.
  • Page 129 OM4054 09/11 Lubrication and Service - Section 40 Page 40-9 250 HOUR INSPECTION (continued) Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 15 HVAC Air Filter - Clean the filter element with mild soap and water.

  • Page 130: 500 Hour Inspection

    Section G3 in the service manual for instructions. 6 Engine Damper - Check the grease level in the engine damper. Fill as necessary with Komatsu grease (427-12-11871). The grease level must be maintained level with the fill plug opening.

  • Page 131: 1000 Hour Inspection

    OM4054 09/11 Lubrication and Service - Section 40 Page 40-11 1000 HOUR INSPECTION Perform the maintenance items for the 250 and 500 hour intervals at this time, also. Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS...

  • Page 132: 2000 Hour Inspection

    Lubrication and Service - Section 40 09/11 OM4054 Page 40-12 2000 HOUR INSPECTION Perform the maintenance items for the 250, 500 and 1000 hour intervals at this time, also. Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS...

  • Page 133: 5000 Hour Inspection

    OM4054 09/11 Lubrication and Service - Section 40 Page 40-13 5000 HOUR INSPECTION Perform the maintenance items for the 250, 500, and 1000 hour intervals at this time, also. Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS...
  • Page 134 Lubrication and Service - Section 40 09/11 OM4054 Page 40-14 NOTES...

  • Page 135: Automatic Lubrication System

    OM4207 04/10 Automatic Lubrication System - Section 42 42-1 AUTOMATIC LUBRICATION SYSTEM GENERAL DESCRIPTION The automatic lubrication system is a pressurized lubri- During the down stroke, the pump cylinder is extended cant delivery system which delivers a controlled into the grease. Through the combination of shovel amount of lubricant to designated lube points.
  • Page 136 Section 42 - Automatic Lubrication System 04/10 OM4207 42-2 FIGURE 42-2. AUTOMATIC LUBRICATION SYSTEM ARRANGEMENT Group Lube Location A 3 Injectors Group Lube Location G 3 Injectors Group Lube Location B 3 Injectors Group Lube Location H 3 Injectors Group Lube Location C 3 Injectors Group Lube Location J 4 Injectors...
  • Page 137 OM4207 04/10 Automatic Lubrication System - Section 42 42-3 Figure 42-2. LUBE INJECTOR GROUPS Lube Group Number of Injectors Injector Point of Lubrication RH front suspension, top RH front suspension, rear A-arm RH front suspension, front A-arm LH front suspension, top LH front suspension, rear A-arm LH front suspension, front A-arm RH steering cylinder, spindle...

  • Page 138: System Components

    Section 42 - Automatic Lubrication System 04/10 OM4207 42-4 SYSTEM COMPONENTS Filter Solenoid Valve A filter assembly mounted on the grease reservoir fil- Solenoid valve (5), when energized, allows oil to flow to ters the grease from the shop supply. A bypass indica- the hydraulic motor.
  • Page 139 OM4207 04/10 Automatic Lubrication System - Section 42 42-5 Pump Cutoff Pressure Switch (Optional) Pump cutoff pressure switch (11, Figure 42-1) de-ener- gizes the pump solenoid relay when the grease pres- sure reaches the set pressure. This switch is used when the lubrication controller dip switch is set to “con- troller”.

  • Page 140: System Operation

    Section 42 - Automatic Lubrication System 04/10 OM4207 42-6 SYSTEM OPERATION 5. During this period, the injectors will meter the 1. During truck operation, the lubrication controller appropriate amount of grease to each lubrication will energize the system at a preset time interval. point.

  • Page 141: Injector Operation

    OM4207 04/10 Automatic Lubrication System - Section 42 42-7 INJECTOR OPERATION STAGE 1. Injector piston (2) is in its normal or “rest” position. Discharge chamber (3) is filled with lubricant from the previous cycle. With pres- sure applied from incoming lubricant (6), slide valve (5) is about to open passage (4) leading to measuring chamber (1).

  • Page 142: Lubricant Pump

    Section 42 - Automatic Lubrication System 04/10 OM4207 42-8 LUBRICANT PUMP Pump Housing Oil Level The pump housing must be filled to the proper level with SAE 10W-30 motor oil. Check the oil level at 1000 hour intervals. To add oil, remove plug (4, Figure 42-6) and fill the housing to the bottom of the plug hole.

  • Page 143: Injectors (Sl-1 Series "H"))

    OM4207 04/10 Automatic Lubrication System - Section 42 42-9 INJECTORS (SL-1 Series “H”)) Injector Specifications • Each lube injector services only one grease point. In case of pump malfunction, each injector is equipped with a covered grease fitting to allow the use of manual lubrication equipment.

  • Page 144: System Priming

    Section 42 - Automatic Lubrication System 04/10 OM4207 42-10 SYSTEM PRIMING The system must be full of grease and free of air pock- ets to function properly. After maintenance, if the pri- mary or secondary lubrication lines were replaced, it will be necessary to prime the system to purge entrapped air.

  • Page 145: System Check

    OM4207 04/10 Automatic Lubrication System - Section 42 42-11 SYSTEM CHECK To check system operation (not including timer), pro- The fourth dip switch is used to select “memory off” or ceed as follows: “memory on”. When the switch is set to “memory off”, a lube cycle will occur each time power is turned on.
  • Page 146 Section 42 - Automatic Lubrication System 04/10 OM4207 42-12 FIGURE 42-9. LUBRICATION TIMER 1. Off Time Switch 3. Cover 2. Mode Switch...

  • Page 147: System Troubleshooting Chart

    OM4207 04/10 Automatic Lubrication System - Section 42 42-13 SYSTEM TROUBLESHOOTING CHART NOTE: If the following procedures do not correct the problem, contact a factory authorized service center. Symptom Possible Causes Corrective Action Lube system not grounded. Correct grounding connections to pump assem- bly and truck chassis.
  • Page 148 Section 42 - Automatic Lubrication System 04/10 OM4207 42-14 Symptom Possible Causes Corrective Action Pump Pressure Builds Very No signal at solenoid. Check timer. Slowly Or Not At All Controller Does Not No electric power to controller. Turn on electric power to pump. “POWER” Operate LED should light, “PUMP ON”...

  • Page 149: Preventative Maintenance

    OM4207 04/10 Automatic Lubrication System - Section 42 42-15 PREVENTATIVE MAINTENANCE Use the following maintenance procedures to ensure proper system operation. 3. Check the grease reservoir level. a. Fill the reservoir as needed. Check the filter Daily Lubrication System Inspection bypass indicator when filling the reservoir.
  • Page 150 Section 42 - Automatic Lubrication System 04/10 OM4207 42-16 i. If the system is working properly, the machine is ready for operation. j. If the system is malfunctioning, refer to the troubleshooting chart. 1000 Hour Inspection 1. Check the pump housing oil level. Fill to the bot- tom of the plug hole with SAE 10W-30 motor oil.
  • Page 151 Page 50-1 MAJOR COMPONENTS AND SPECIFICATIONS Engine Power Steering The Komatsu HD1500-7 dump truck is powered by a The HD1500-7 truck is equipped with a full time Komatsu SDA12V160 diesel engine. This engine is power steering system. The system provides positive Tier 1 compliant.

  • Page 152: 12. Differential

    Major Components & Specifications - Section 50 03/13 OM5045 Page 50-2 FIGURE 50-1. MAJOR COMPONENT LOCATION 1. Radiator 7. Pump Drive 13. Rear Suspension 2. Front Suspension 8. Transmission 14. Brake Cooling Filters 3. Front Wet Disc Brakes 9. Hoist Cylinders 15.
  • Page 153 Service Capacities Komatsu ..... . . SDA12V160* ......Liters . . U.S Gallons Number of Cylinders .
  • Page 154 Major Components & Specifications - Section 50 03/13 OM5045 Page 50-4 Steering Overall Truck Dimensions Loading Height ....4.965 m (16' 3") Turning Circle Diameter (SAE) ..24.4 m (80 ft) Minimum Clearance Height .

  • Page 155: Vehicle Health Monitoring System (Vhms)

    The VHMS system uses wireless components through a communications satellite (optional) to that transmit via radio waves. It is necessary to Komatsu. The data is compiled in the Komatsu com- conform to local laws when using this system. puter server and analyzed.

  • Page 156: Vhms Downloading

    VHMS - Section 60 10/11 OM6011 Page 60-2 NOTE: The Orbcomm modem installed from the factory on all new trucks may not be approved for use in certain countries of the world. Local regulation may prohibit the use of the Orbcomm modem/ satellite communicator.

  • Page 157: Payload Meter

    OM6011 10/11 VHMS - Section 60 Page 60-3 PAYLOAD METER Download connector inside cab The payload meter interprets machine data to calcu- late payload. The system uses the following inputs: suspension pressure sensors, inclinometer, body up switch, transmission shift lever, and speed sensors. The microcomputer built into the controller uses the inputs to calculate the payload.

  • Page 158: Normal Operation Display

    VHMS - Section 60 10/11 OM6011 Page 60-4 NORMAL OPERATION DISPLAY Machine condition Machine monitor display External display lamps When starting switch is ON Illuminates for 30 seconds When empty Stopped (*1) Standard display (*2) Traveling Standard display During loading Stopped Payload display (*3) Payload display...

  • Page 159: External Display Lamps

    OM6011 10/11 VHMS - Section 60 Page 60-5 EXTERNAL DISPLAY LAMPS The external lamps display the payload as follows. When the machine is loaded in this manner, the external display lamps illuminate as shown in the table below. Number Indicator Lights Explanation Of Loads The actual load...

  • Page 160: Calibrating Plm

    VHMS - Section 60 10/11 OM6011 Page 60-6 CALIBRATING PLM 3. With the service meter/odometer value dis- Perform calibrations when: played on character display (3), press the () • the machine is received portion of mode select switch (1) to switch to the operation information display.

  • Page 161: Data Stored In Payload Meter

    OM6011 10/11 VHMS - Section 60 Page 60-7 7. Continue traveling at a speed of 10 km/h (6 mph). After approximately 30 seconds, the cali- bration should be completed and the display will change back to “PLM”. DATA STORED IN PAYLOAD METER The payload meter interprets the period from one dump to the next dump as one cycle and records that data.

  • Page 162: Plm Downloading

    VHMS - Section 60 10/11 OM6011 Page 60-8 PLM DOWNLOADING Downloading From Ground Level Box Download the recorded data to a laptop computer that has the download software installed. Downloading From Inside Of The Cab Before downloading from the ground level box, turn the key switch to the OFF position.

  • Page 163: Setting The Machine Id And Open Id

    OM6011 10/11 VHMS - Section 60 Page 60-9 SETTING THE MACHINE ID AND OPEN ID 5. Press the () portion of mode select switch 1. It is possible to change the machine ID (identifica- tion) and open ID. These pieces of data are cycle data items.

  • Page 164: Payload - Cycle Data Item

    Please consult your Komatsu distributor. If it is necessary to change the method for confirming the haul payload, consult your Komatsu distributor for • For computers that don’t have a RS232C port, it instructions.

  • Page 165: Am/Fm Radio/Cd Player

    OM7006 03/10 Radio / CD Player - Section 70 Page 70-1 AM/FM RADIO / CD PLAYER FIGURE 70-1. AM/FM RADIO / CD PLAYER 1. Ejects CD 7. Push Buttons 1-6 Pre-set stations/CD/MP3 func- tions 2. BAND Switches between AM, FM1, FM2, FM3, WX (Weatherband) and Auxiliary Mode 8.
  • Page 166 Radio / CD Player - Section 70 03/10 OM7006 Page 70-2 Display Auxiliary Mode The receiver will display the time of day when it is off. When in Auxiliary mode, the radio can play an audio Momentarily pressing the TMSET/DSPL (3) button source from an iPOD or an MP3 player that is con- when the receiver is on allows to toggle between dis- nected via the auxiliary radio lines.

  • Page 167: Using The Clock

    OM7006 03/10 Radio / CD Player - Section 70 Page 70-3 USING THE ALARM SEEK SENSITIVITY: To adjust seek sensitivity, press the AUDIO knob until SEEK and the sensitivity Momentarily pressing the ALARM (10) button will dis- level appear. Rotate the AUDIO knob to the desired play the alarm set time.

  • Page 168: Using The Radio

    Radio / CD Player - Section 70 03/10 OM7006 Page 70-4 After 5 seconds of inactivity, the receiver will return to the default display and the volume level at which the SCAN: Press SCAN/DIM (9) to scan all stations on receiver was previously playing.

  • Page 169: Using The Weatherband

    OM7006 03/10 Radio / CD Player - Section 70 Page 70-5 USING THE WEATHERBAND USING THE COMPACT DISC PLAYER NOAA Weather Radio is a service of the National The integral CD player plays full size CDs and MP3 Weather Service. It provides continuous broadcasts discs.

  • Page 170: Playing An Mp3 Disc

    Radio / CD Player - Section 70 03/10 OM7006 Page 70-6 5/FF: Press and hold FF to fast-forward. Upon Root Directory release, the CD will play at normal speed. The dis- The root directory is treated as a folder. If the root play will show the track number and elapsed time.
  • Page 171 OM7006 03/10 Radio / CD Player - Section 70 Page 70-7 Pre-Programmed Playlists Button Functions Pre-programmed playlist function like folders contain- 1/FLD (NEXT FOLDER): Press this button to go to ing compressed audio song files. This radio plays the first track in the next folder or playlist. Pressing pls, m3u, and rmp playlist formats.

  • Page 172: Troubleshooting

    Radio / CD Player - Section 70 03/10 OM7006 Page 70-8 TROUBLESHOOTING DSPL/TM SET: Pressing this button toggles between the ID3 tag (song title, artist and album title) and time The following error messages may appear while of day. There are 3 display types that can be set as playing a CD or MP3 disc: default: track, folder/playlist, and time of day.

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