PDF Shop Manual Komatsu HD1500 Dump Truck - 2 MB
This comprehensive shop manual covers the Komatsu HD1500 Dump Truck, specifically for serial numbers A30001 and up.
It contains detailed instructions for every aspect of repair and maintenance, from the engine to the hydraulic systems.
This manual is the same one used by professional Komatsu technicians, providing the information you need to perform expert-level service.
Keep your heavy-duty dump truck running reliably with this essential guide.
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--- Page 1 ---
CEBM016105
Shop
Manual
DUMP TRUCK
SERIAL NUMBERS A30001 & UP
With SSA16V159 Engine
®
--- Page 3 ---
SECTION A3
GENERAL SAFETY AND OPERATION
INDEX
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Clothing And Personal Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Unauthorized Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Leaving The Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Mounting And Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Fire Prevention For Fuel And Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Precautions With High Temperature Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Asbestos Dust Hazard Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Prevention Of Injury By Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Fire Extinguisher And First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Precautions For ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Precautions For Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
HAUL ROADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Preparing For Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Ventilation In Enclosed Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
In Operator’s Cab - Before Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Mirrors, Windows, And Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
When Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
Precautions For Starting Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
Truck Operation - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
Traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9
Traveling In Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9
Traveling On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9
Ensure Good Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9
Operate Carefully On Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Avoid Damage To Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Driving Near High Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
When Dumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Working On Loose Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Loading The Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Parking The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3-11
A03025 03/11 General Safety and Operating Instructions A3-1
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DURING MAINTENANCE Rules To Follow When Adding Fuel Or Oil
Personnel • Spilled fuel and oil may cause
slipping. Always clean up spills,
• Only authorized personnel may service and immediately. Failure to clean up
repair the machine. fuel or oil spills may lead to fires.
• Always tighten the cap of the fuel and oil fillers
securely.
Attachments
• Never use fuel to wash parts.
• Place attachments that have
been removed from the machine • Always add fuel and oil in a well-ventilated area.
in a safe place and manner to
prevent them from falling.
Working Under The Machine
• Always lower all movable work
equipment to the ground or to their Radiator Water Level
lowest position before performing
service or repairs under the • If it is necessary to add
machine. coolant to the radiator, stop
the engine, and allow the
• Always block the tires of the machine securely. engine and radiator to cool.
• Never work under the machine if the machine is • Depress the pressure release
poorly supported. button on the cap to vent cooling system
pressure.
Keep The Machine Clean • Slowly loosen the cap to relieve any remaining
pressure during removal.
• Spilled oil or grease,
scattered tools, etc.
can cause you to slip or
Use Of Lighting
trip. Always keep the
machine clean and tidy. • When checking fuel, oil, coolant, etc., always use
• If water gets into the electrical system, there is lighting with anti-explosion specifications. If such
danger that the machine may move lighting equipment is not used, there is danger of
unexpectedly and/or damage to components explosion.
may occur. DO NOT use water or steam to clean
any sensors, connectors, or the inside of the
operator's compartment.
A3-14 General Safety and Operating Instructions 03/11 A03025
--- Page 5 ---
7. Apply the brake lock switch at the shovel and LOADING
dump areas. 1. Approach the loading area with caution.
8. Proceed slowly on rough terrain to avoid deep Remain at a safe distance while the truck ahead
ruts or large obstacles. Do not travel along soft is being loaded.
edges or the edge of the fill area. 2. DO NOT drive over unprotected power cables.
9. Truck operation requires concentrated effort by 3. When near loading areas, watch for other vehi-
the driver. Avoid distractions of any kind while cles and for personnel working in the area.
operating the truck.
4. When approaching a loader or shovel, follow
10. When driving at night or when visibility is poor, the spotter or shovel operator signals. The load-
the headlights must be on. DO NOT travel in ing process may be shortened by following sim-
these conditions if the headlights are inopera- ilar patterns of the trucks that have already
tive. been loaded.
11. DO NOT travel in reverse if the back-up horn or 5. The operator must remain in the truck cab with
lights are inoperative. the engine on during loading. Place the trans-
12. When driving in reverse, signal with three honks mission shift lever in NEUTRAL and apply the
on the horn. When starting forward, signal with brake lock switch.
two honks on the horn. Signal each time the
truck is moved forward or backward.
13. DO NOT stop or park on a haul road unless
unavoidable. If you must stop, move the truck to If the operator must leave the truck cab during
a safe place. Apply the parking brake and turn loading, the engine must be shut off and the
off the engine. Block the wheels securely and parking brake applied. DO NOT use the emer-
notify maintenance personnel for assistance. gency brake for parking. Remain far enough
14. If the low steering pressure warning illuminates away from the truck to avoid being struck by fly-
during operation, immediately steer the truck to ing material.
a safe stopping area away from other traffic.
Refer to the previous item above.
6. When the truck is loaded, drive away from the
15. Report adverse haul road conditions, immedi- shovel as quickly as possible, but with extreme
ately. Muddy or icy roads, pot holes or other caution.
obstructions can present hazards.
16. Keep cab doors closed at all times while the
truck is in motion or unattended.
17. Check for flat tires periodically during the shift. If
the truck has been operating on a flat tire, allow
the tire to cool before parking indoors.
A03025 03/11 General Safety and Operating Instructions A3-27
--- Page 6 ---
A warning decal is located below the key switch on
the instrument panel. The warning stresses the
importance of reading the operator's manual before
operation.
A grade/speed plate is located on the left front post of
the operator's cab. The decal provides the recom-
mended maximum speeds to be used when
descending various grades with a loaded truck.
Always refer to the decal in the operator's cab. This
decal may change with optional truck equipment. A plate attached to the right rear corner of the cab
states the Roll-Over Protective Structure (ROPS)
and Falling Object Protective Structure (FOPS) meet
various SAE performance requirements.
DO NOT modify these components. DO NOT
attempt to repair damage without written
approval from the manufacturer. Unauthorized
repairs will void certification.
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.
A plate is located next to the fill cap on the fuel tank
specifying diesel fuel only. Refer to the engine opera-
tion and maintenance manual for more information
on fuel requirements.
A4-2 Warnings and Cautions 10/11 A04055
--- Page 7 ---
TABLE 12.
Common Conversion Multipliers
English to Metric
To Convert Multiply
To
From By
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) kilometer (km) 1.61
square inch (in.2 ) square centimeters (cm )2 6.45
square feet (ft2) square centimeters (cm2) 929
cubic inches (in.3) cubic centimeters (cm3) 16.39
cubic inches (in.3) liters (l) 0.016
cubic feet (ft3) cubic meters (m3) 0.028
cubic feet (ft3) liters (l) 28.3
ounce (oz) kilogram (kg) 0.028
fluid ounce (fl oz) milliliter (ml) 29.573
pound (lb) kilogram (kg) 0.454
pound (lb) Newton (N) 4.448
inch pounds (in. lb) Newton meters (N·m) 0.113
foot pounds (ft lb) Newton meters (N·m) 1.356
foot pounds (ft lb) kilogram meters (kg·m) 0.138
kilogram meters (kg·m) Newton meters (N·m) 9.807
pounds/square inch (psi) kilopascals (kPa) 6.895
pounds/square inch (psi) megapascals (MPa) 0.007
pounds/square inch (psi) kilograms/square centimeter 0.0704
(kg/cm2)
short ton (tn) kilogram (kg) 907.2
short ton (tn) metric ton (t) 0.0907
quart (qt) liters (l) 0.946
gallon (gal) liters (l) 3.785
horsepower (hp) Watts (w) 745.7
horsepower (hp) kilowatts (kw) 0.745
A05005 09/11 Torque Tables And Conversion Charts A5-9
--- Page 8 ---
5. After all discrepancies have been corrected, the SHORT TERM ENGINE STORAGE
vehicle is ready for a road test. This test must
This procedure describes the proper method for the
be performed by a capable and experienced
short term storage of an engine - one to six months.
operator. Road test in a large, open area where
plenty of maneuvering room is available. Road
test checks include:
Preparing the Engine
Repeated braking efficiency tests at
progressively higher speeds. Start at slow 1. Operate the engine at high idle until the coolant
speeds. Don't take chances with higher temperature reaches 70° C (160° F).
speeds until the machine has been 2. Turn the engine off.
determined to be completely safe.
3. Disconnect the fuel lines to the engine fuel filter.
Progressive upshifting and downshifting Disconnect the injector return line.
through all speed ranges to ensure proper
4. Use a preservative oil. Use Dauber T Chemical
transmission shifting and synchronization.
NoxRust No. 518, or equivalent. The oil must
meet Military Specification MIL-L-644, Type P-
6. After all tests have been performed and the 9.
vehicle is ready for use, perform a final visual 5. Fill two containers, one with diesel fuel, and the
check. second with preservative oil. Put both fuel lines
7. Check lubricant service items as outlined in in the container of diesel fuel.
Section P, Lubrication and Service. 6. Start the engine.
7. After the engine is operating smoothly, transfer
the fuel supply line to the container of preserva-
tive oil. Operate the engine until the preserva-
tive oil flows out of the injector return line.
8. Turn the engine off. Connect the fuel lines to
the fuel filter and the injector return line.
9. Drain the oil pan sump, oil filters, and fuel filters.
10. Install the drain plugs in the oil sump. The sump
can remain empty until the engine is ready to be
returned to service.
Put a warning tag on the engine. The tag must
indicate the following:
• The engine does not contain oil.
• DO NOT operate the engine.
11. Disconnect the electrical wiring from the fuel
pump solenoid.
A7-10 Storage Procedures A07005
--- Page 9 ---
SECTION B3
DUMP BODY
INDEX
DUMP BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4
BODY PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5
Body Pad Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6
BODY GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6
BODY-UP RETENTION CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7
ROCK EJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7
B03019 10/11 Dump Body B3-1
--- Page 10 ---
Cleaning Repair
The fuel tank is equipped with a drain and a cleaning Clean the fuel tank before and after repairs are per-
port. These items enable steam or solvent to be used formed.
to clean tanks that have accumulated foreign mate-
rial.
It is not necessary to remove the tank from the truck
for cleaning of sediment. However, rust and scale on
the walls and baffles requires complete tank removal. If a tank is to be welded, special precautions are
Rotating the tank in various positions enables clean- necessary to prevent fire or explosion. Consult
ing solutions to contact all interior surfaces. local authorities for safety regulations before
proceeding.
Prior to a cleaning procedure of this type, remove the
fuel gauge, vents, and hose connections. The tank
must be completely sealed. After all scale, rust, and
Installation
foreign material has been removed, the temporary
plugs can be removed. 1. Thoroughly clean the fuel tank mounting
brackets and cap screw hole threads. Repair
When a tank is to remain idle for a long period of the threads if damaged. Install rubber damp-
time, spray a small amount of rust preventive oil into ener (7, Figure 4-1) in each mount.
the tank to prevent rust formation. Seal all openings
for rust prevention. 2. Attach an appropriate lifting device to the fuel
tank lift brackets. The weight of the empty fuel
tank is approximately 932 kg (2055 lb).
3. Lift the fuel tank into position over the trunnion
mounts and lower into position. Place the trun-
nion caps into position. Install cap screws and
washers (4, Figure 4-2), but do not torque at
this time.
4. Place lower mounting brackets into position.
Install cap screw (5, Figure 4-1), flat washer
(8), flat washer (9), flat washer (6), and nut (4).
Refer to Figure 4-1 for positioning. Tighten the
cap screws to standard torque.
5. Place the trunnion caps on the upper mounts.
There is a chamfer on one edge of each cap.
The chamfered edge must face the fuel tank.
Install the cap screws and washers (4,
Figure 4-2). Tighten the cap screws to stan-
dard torque.
FIGURE 4-2. FUEL TANK 6. Connect fuel supply hose (2) and return hose
(3).
1. Lift Brackets 5. Fuel Gauge and 7. Reconnect all electrical connections to the
2. Fuel Supply Hose Sending Unit tank.
3. Fuel Return Hose 6. RH Fuel Receiver
4. Trunnion Cap 7. Fuel Tank
Breather
B4-4 Fuel Tank 10/11 B04027
--- Page 11 ---
18. Loosen the clamps that secure hump hose (8). To perform this inspection, remove about four ran-
Pry the hump hose off of the radiator tube. dom tubes from the air inlet side of the radiator.
19. Loosen the clamps that secure hump hose (10). Remove tubes from both the top and bottom cores,
Pry the hump hose off of the radiator tube. and near each end of the radiator. Refer to Disas-
sembly and Assembly in this section for proper
20. Attach a lifting sling and hoist to the top right fan instructions for tube removal and installation. Ana-
guard. Remove the hardware that secures the lyze any contaminant residue inside the tube to
section to the radiator and fan guard assembly. determine the cause. Flush the system before return-
Lift the guard from the truck and repeat for the ing the radiator to service. Contact your nearest L&M
remaining fan guard sections. Radiator facility for further instruction or visit the L&M
21. Attach an appropriate lifting device to the radia- website for further information at www.mesabi.com.
tor assembly. The weight of the radiator is 1191
kg (2626 lb).
22. Loosen mounting hardware (9) at the lower External Cleaning
mounts and then disconnect upper support rods Many radiator shops use a hot alkaline soap, caustic
(7, Figure 3-3). soda, or chemical additives in their boil-out tanks
23. Remove the cap screws from the lower mounts. which can attack solders. These tanks are generally
Before removing the radiator, verify that all not recommended.
hoses and wiring harnesses are disconnected
from the radiator.
24. Carefully slide the radiator forward until the
shroud is clear of the fan blades. Verify the con-
denser will not interfere in the path of the radia- Before such tanks are used for cleaning, ensure
tor. that the cleaning solutions are not harmful to sol-
der. Otherwise, damage to the radiator will result.
25. Lift the radiator off the frame. Move the radiator
to a storage or repair area. Remove the shims
Completely rinse the cleaned tube/core in clean
from the lower radiator mount location and save
for use during installation. water after removing from the boil-out tank.
26. Remove the remaining hoses and clamping As an alternative to boil-out tanks, radiators can be
from the radiator as necessary. cleaned externally with a high pressure washer and
soap. In most cases, it may be best to blow out any
27. Inspect all hoses, clamps, tube connectors, etc. dry dirt with a high pressure air gun prior to washing
Replace damaged or worn parts. the core with the high pressure washer.
Pressure washers must not exceed 8274 kPa (1200
psi). Unlike conventional cores, it is recommended to
RADIATOR REPAIR hold the spray nozzle directly next to the core. Start-
ing from the air exit side, place the high pressure
Internal Inspection washer nozzle next to the fins. Concentrate on a
If desired, an internal inspection can be performed on small area, slowly working from the top to the bottom.
the radiator before complete disassembly. The Spray straight into the core, not at an angle. Continue
inspection entails removing tubes in the radiator core washing until the exit water is free of dirt. Repeat
and cutting them open. This type of inspection can from the opposite side.
indicate overall radiator condition, as well as coolant
and additive breakdown.
C03031 10/11 Cooling System C3-7
--- Page 12 ---
FIGURE 4-3. AIR CONDITIONER COMPRESSOR
1. Belt Guard 4. Suction Hose
2. A/C Compressor 5. Clutch Connector
FIGURE 4-2. COOLER ASSEMBLY PIPING 3. Mounting Bracket 6. Harness Clamps
1. Alternator 5. Fan Clutch
2. Cooler Assembly 6. Heater Shutoff Valves
3. Water Pump Inlet Pipe
4. Coolant Temperature
Sensor
10. Remove water pump inlet pipe (3, Figure 4-2)
between the engine and cooler assembly (2).
11. Close heater shut-off valves (6) and disconnect
the hoses.
12. Disconnect the heater hoses and remove the
clamps to allow the hoses to be positioned
away from the engine.
13. Disconnect the suction and discharge hoses
from air conditioning compressor (2, Figure 4-
3).
14. Disconnect compressor clutch connector (5).
Remove harness clamps (6). Disconnect the tri-
nary switch from the receiver/drier.
15. Disconnect coolant temperature sensor (2, Fig-
ure 4-4) from the front right side of the engine. FIGURE 4-4. COOLANT TEMPERATURE
SENSOR
1. Right Front Cylinder 2. Coolant Temperature
Head Sensor
C4-4 Engine 03/09 C04031
--- Page 13 ---
FIGURE 4-28. GREASE MAP
C04031 03/09 Engine C4-17
--- Page 14 ---
NOTES
C5-10 Air Filtration System 07/10 C05014
--- Page 15 ---
40. Ensure the pitot tube holes in the shaft are
clean and free of burrs and staking material, to
allow the pitot tubes to fit into the holes and seat 42. Install front bearing (5) in front bearing retainer
completely to the bottom. Apply a thin coating of (12). Press only on the outer race of the bear-
Loctite® #609, or equivalent, on the straight ing, and press it to the bottom of the bore.
end of one pitot tube (33). Coat the tube to
approximately 20 mm (0.75 in.) from the end.
Push the pitot tubes to the bottom of the hole.
The outer end of the tube must be located well
within the pulley-locating shoulder of the bear-
ing retainer. Rotate the tube so the open, bent
end faces in a counter-clockwise direction, and
is exactly parallel to the surface of the bearing
retainer. A large Phillips-head screwdriver
inserted in the end of the tube can be conve-
niently used as an alignment gage.
Install the second pitot tube in the same manner