Komatsu HD1500-7 User Manual

Page 1
HD1500-7
GROSS HORSEPOWER
1109 kW 1,487 HP
NET HORSEPOWER
1048 kW 1,406 HP
MAXIMUM GVW
249478 kg 550,000 lb
HD
1500
O
-H
IGHWAY
T
RUCK
Photo may include optional equipment
Page 2
HD1500-7
O FF-HIGHWAY T RUCK
WALK-AROUND
Productivity and Economy Features
High performance Komatsu SDA12V160 engine
Net horsepower 1048kW 1,406HP
Komatsu 7 speed, electronically controlled automatic powershift transmission
4-wheel oil-cooled, multiple-disc retarder
Automatic Retard Speed Control (ARSC) standard
Reliability Features
Flat face-to-face O-ring seals
Sealed DT connectors
Fully hydraulic brakes -
no air system
2
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OFF-HIGHWAY TRUCK
HD1500-7
GROSS HORSEPOWER
1109 kW 1,487 HP @ 1900 rpm
Operator Environment and Control
Spacious cab with excellent visibility
Ergonomically-designed cab
Easy-to-see instrument panel
Advanced K-ATOMiCS with “Skip-shift”
function
Built-in ROPS/FOPS cab (Level 2)
Parking brake on input shaft
Supplementary steering
Push-button operated secondary brake
NET HORSEPOWER
1048 kW 1,406 HP @ 1900 rpm
MAXIMUM GVW
249478 kg 550,000 lb
Easy Maintenance
Oil-cooled multiple-disc brakes and fully hydraulic-controlled braking system
Electric circuit breakers
Vehicle Health Monitoring System
(VHMS)
Remote mounted transmission
Photos may include optional equipment
3
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HD1500-7
O FF-HIGHWAY T RUCK
RODUCTIVITY &
P
High Performance Komatsu SDA12V160 Engine
The Komatsu SDA12V160 engine provides the highest horsepower in it’s class. With 1487 gross horsepower, this engine delivers faster acceleration and higher travel speeds with a high horsepower-to-ton ratio. High torque at low speed, impressive acceleration, and low fuel consumption ensure maximum productivity. Standard features of this engine include the Quantum electronic control system, Cummins Cense monitoring and pre-lubrication.
CONOMY
E
Seven-Speed Electronically Controlled, Automatic Powershift Transmission
Komatsu’s seven-speed, electronically controlled, automatic powershift transmission uses a rubber damper to comfortably reduce harmful engine shock and vibration to the transmission. A lock-up system, consisting of a wet multiple-disc clutch, is actuated in F1-F7 gears for higher fuel savings. Electronic shift control with automatic clutch modulation in all gears and full diagnostics with memory. The transmission circuit uses a separate hydraulic circuit and cooler.
Komatsu torque converter is transmission-mounted and lock-up clutch is electronically controlled.
Maximum travel speed (empty, 2% rolling resistance)
Gear 1 11.0 km/h 6.8 mph Gear 5 32.7 km/h 20.3 mph
Gear 2 14.7 km/h 9.1 mph Gear 6 44.2 km/h 27.5 mph
Gear 3 19.7 km/h 12.2 mph Gear 7 58.4 km/h 36.3 mph
Gear 4 24.5 km/h 15.2 mph Reverse 9.4 km/h 5.8 mph
EATURES
F
4
Four-Wheel, Oil Cooled, Multiple Disc Brakes
The HD1500-7 is equipped with four wheel, oil cooled, multiple disc brakes which provide the greatest retarding capabilities in its class. Effective and smooth braking characteristics are controlled through the retarding lever by a system of pressure proportioning valves (PPC), which precisely meter the appropriate amount of hydraulic pressure to each brake assembly. The elimination of an air system, common with dry disc brakes, improves reliability and reduces maintenance costs.
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OFF-HIGHWAY TRUCK
HD1500-7
Auto Retard Speed Control (ARSC)
ARSC allows the operator to simply set the downhill travel
speed and go down slopes at a constant speed. This allows
the operator to concentrate on steering. The speed can be
set at increments of 1 km/h 0.6 MPH per click
(±5 km/h 3.1 MPH of setting speed adjustment) to match
the optimum speed for the slope. The retarder cooling oil
temperature is constantly monitored and the descent speed
is automatically reduced, if necessary.
AUTO RETARD SPEED CONTROL
CANCEL
Go down slope at constant speed
UP
SET
DOWN
Automatic Idling Setting System (AISS)
This system facilitates quick engine warm-up and cab cooling/warming. When setting the system ON, engine idle speed is kept at 1000 rpm when coolant temperature is 30°C 86°F or lower. Speed automatically returns to 650 rpm when coolant temperature goes above 30°C 86°F.
Small Turning Radius
The MacPherson strut type front suspension has a special
A-frame between each wheel and
the main frame. The wider
space created between the
front wheels and the main
frame increases the
turning angle of the
wheels. The larger this
turning angle, the smaller
the turning radius of the truck.
Photos may include optional equipment
5
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HD1500-7
O FF-HIGHWAY T RUCK
Long Wheelbase and Wide Tread
With an extra-long wheelbase, a wide tread, and an exceptionally low center of gravity, the HD1500-7 hauls its
oad at higher speed for greater productivity, and delivers
l superior driving comfort over rough terrain.
Large Body
A wide target area makes for easy loading with minimal spillage and more efficient hauling.
Heaped capacity : 78.0 m Target area (inside length x width) :
3
102.0 yd
7670 mm 25'2" x 5705 mm 18'8"
3
Advanced K-ATOMiCS
The electronically controlled all clutch modulation system, “K-ATOMiCS”, optimizes the clutch engagement oil pressure at every gear.This system optimizes the clutch lock-up process for smoother shifting with minimal torque shock.
“Skip-shift” function
When driving uphill, the skip-shift function automatically selects the gear according to the slope of the grade. It reduces the number of down-shifts, makes the driving smoother, improves the operator’s comfort, and reduces spilling of material.
Rear LED Lighting Rack
Frame mounted LED lighting rack at the rear of the truck provides tail, brake, and flasher lights. In addition, this bracket, protected from falling objects by the body structure, includes the reverse horn and back-up lights.
Push Button Actuated Auxiliary Brake
All four wet disc brakes are activated when the auxiliary brake button, located on the dash board, is deployed. In addition, the brakes will automatically apply when the hydraulic pressure drops below the specified level.
Supplementary Steering
Automatic supplementary steering is provided as a standard feature.
6
The MacPherson Strut-Type Front Suspension
The MacPherson-type independent suspension is utilized on the front wheels. This linkage arrangement allows the front wheel to follow the undulation of the road surface smoothly, realizing excellent riding comfort.
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OFF-HIGHWAY TRUCK
HD1500-7
PERATOR
O
Spacious Cab with Excellent Visibility
The HD1500-7 cab inherits the superior design features of Komatsu's ultra-class haul trucks. Wide windows in the front, side and back, plus plenty of space in the richly upholstered interior, provide a quiet, comfortable environment for better visibility and control over every aspect of the operation.
Ergonomically Designed Cab
The comfortable and ergonomically-designed operator's compartment makes it very easy for the operator to reach all controls. The result is more confident operation and greater productivity.
Easy-to-See Instrument Panel
The instrument panel makes it easy to monitor critical machine functions. In addition, a caution light warns the operator of any problems that may occur. Problems are recorded in the monitor and indicated as service codes. This makes the machine more user friendly and easier to service.
NVIRONMENT
E
Vehicle Health Monitoring System (VHMS)
VHMS controller monitors the health conditions of major components and enables remote analysis of the machine and its operation. This process is supported by the Komatsu
istributors, factory, and design team.
d
Satellite communication (Option)
Customer
OMATSU
K
Internet
WebCARE Server
Komatsu distributors
Ideal Driving Position Settings
The 5-way adjustable operator seat and the tilt-telescopic steering column provide an optimum driving posture for increased driving comfort and more control over machine operation. The suspension seat dampens vibrations transmitted from the machine and reduces operator fatigue as well as holding the operator securely. A 78 mm 3" wide seat belt is provided as standard equipment.
job site
Personal computer terminal (for downloading data)
Photos may include optional equipment
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HD1500-7
O FF-HIGHWAY T RUCK
Automatic Spin Regulator (ASR)
ASR automatically maximizes traction by preventing the rear tires from slipping on either side.
Integral Four-Post ROPS/FOPS Cab Structure (Level 2)
Wet multi-disc brakes and fully hydraulic controlled braking systems realize lower maintenance
costs and higher reliability. Wet disc brakes are fully sealed to keep contaminants out, reducing wear and maintenance. Brakes require no adjustments for wear, meaning even lower maintenance.
Service brake and retarder are isolated from the other truck hydraulic functions to ensure reliable performance. The parking brake is a spring applied, oil released, 3 caliper dry disc mounted on the input yoke to the differential. Fully hydraulic braking systems eliminate the air system; air bleeding is not required, and water condensation that can lead to contamination, corrosion, and freezing is eliminated.
Automatic Lubrication System
The Lincoln Auto-lube system features a deck mounted canister, ground level refill point, and an adjustable timer to ensure all pivot points are properly greased.
Body Dump System
Two 3-stage cylinders with new concept design and sealing system. Internal cushion valve and over­center damping provide smooth, reliable dumping. The quill design modulates the body return speed after dumping to manage forces into the frame and suspensions.
Hoist times
Power Up: 15 sec Power Down: 15 sec
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OFF-HIGHWAY TRUCK
DASH-7 FEATURES
HD1500-7
Komatsu Components
Komatsu manufactures the torque converter, transmission, hydraulic cylinders, and electrical parts on this dump truck. Komatsu dump trucks are manufactured with an integrated production system under strict quality control system guidelines.
High-Rigidity Frame
Front support is integrated with the frame. The frame rigidity has been substantially increased. As a result, flexural rigidity and torsional rigidity, which are indicators of drivability and ride quality, are significantly improved.
Rugged and Durable Dump Body Design
The standard dump body is made of high-tensile-strength steel with a Brinell hardness of 400 for excellent rigidity and reduced maintenance cost. The side and bottom plates of the dump section are reinforced with ribs for added strength.
Reliable Hydraulic System
A large capacity oil cooler is installed in each hydraulic circuit, improving the reliability of the hydraulic units during sudden temperature rises. Further, in addition to the main filter, a β the transmission control valve. This system helps prevent secondary faults.
Flat Face-to-Face O-Ring Seals
Flat face-to-face O-ring seals are used to securely seal all hydraulic hose connections and to prevent oil leakage.
10 = 3 (min) line filter is located at the entrance to
Nipple
Hose
O-ring
Sealed DT Connectors
Main harnesses and controller connectors are equipped with sealed DT connectors providing high reliability, water resistance, and dust resistance.
Protection Function Supported by Electronic Control
Item Function
Downshift inhibitor
Over-run inhibitor
Reverse inhibitor
Forward/Reverse shift inhibitor
Anti-hunting system
Neutral safety
Even if the driver downshifts accidentally, a speed appropriate to the current gear is automatically set, limiting potential over-runs.
When descending grades, if the vehicle’s speed surpasses the maximum for the current gear, the front and rear brakes automatically operate, limiting potential over-runs.
The vehicle is prevented from moving backward when operating the body.
This device makes it impossible to shift from forward to reverse when the vehicle’s speed surpasses 4 km/hr 2.5mph.
When running near a shift point, smooth automatic shifting takes place.
The engine is prevented from starting when the shift lever is not in neutral.
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HD1500-7
O FF-HIGHWAY T RUCK
SPECIFICATIONS
ENGINE
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Komatsu SDA12V160
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water-cooled, 4-cycle
Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . Turbo-charged, after-cooled
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Bore x Stroke . . . . . . . . . . . . . . . . . 159 mm x 190 mm 6.26" x 7.48"
Piston displacement . . . . . . . . . . . . . . . . . . . . . . . . . . 45 ltr 2,746 in
Horsepower
SAE J1995 . . . . . . . . . . . . . . . . . . . . . . . Gross 1109 kW 1,487 HP
ISO 9249 / SAE J1349 . . . . . . . . . . . . . . . Net 1048 kW 1,406 HP
Rated rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,900 rpm
Fan drive type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical
Maximum torque . . . . . . . . . . . . . . . . . . . . . . . . 697 kg•m 5,041 lb ft
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injection
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic control
Lubrication system
Method . . . . . . . . . . . . . . . . . . . . . . . . Gear pump, force-lubrication
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full-flow type
Air cleaner . . . . . . . . . . . . . . . . . . Dry type with double elements and
TRANSMISSION
Torque converter . . . . . . . . . . . . . . . . . . 3-elements, 1-stage, 2-phase
Transmission . . . . . . . . . . . . . . . . Full-automatic, planetary-shaft type
Speed range . . . . . . . . . . . . . . . . . . . 7 speeds forward and 1 reverse
Lockup clutch. . . . . . . . . . . . . . . . . . . . . . . . . Wet, multiple-disc clutch
Forward . . . . . . . . . . . . . . . . Torque converter drive 1st and 2nd gear
with direct drive lock-up in 1st through 7th
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque converter drive
Shift control. . . . . . . . . . . . . . . . Electronic shift control with automatic
Maximum travel speed . . . . . . . . . . . . . . . . . . . . . . 58 km/h
pre-cleaned, with dust indicator
clutch modulation in all gears
36 mph
BRAKES
Brakes meet ISO 3450 standard. Service brakes:
Front . . . . . . . . . . Fully hydraulic control, oil-cooled multiple-disc type
Rear . . . . . . . . . . Fully hydraulic control, oil-cooled multiple-disc type
Parking brake . . . .Spring applied, oil-released, 3 caliper dry disc mounted
3
Retarder . . . Oil-cooled, multiple-disc front and rear brakes act as retarder.
Secondary brake . . . . . . . . . . . . . . . . . . Manual - push button operated.
Automatically applied prior to hydraulic system
pressure dropping below established level.
Braking surface. . . . . . . . . . . . . . . . . . . . . . . . . . 159148 cm
BODY
Capacity:
Struck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 m371 yd
Heaped (2:1, SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . 78 m3102 yd
Nominal payload. . . . . . . . . . . . . . 144.1 metric tons 158.9 U.S. tons
Material . . . . . . . . . . . 400 Brinell hardness high tensile strength steel
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flat floor configuration
Material thickness:
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 mm 0.75"
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm 0.47"
Sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 mm 0.35"
Target area
(inside length x width) . . . . . . . 7670 mm x 5705 mm 25'2"x 18'9"
Dumping angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Height at full dump . . . . . . . . . . . . . . . . . . . . . . . . . . 11440 mm 37'6"
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust heating
on input yoke to differential
2
(front, sides, and bottom)
24,668 in
2
3
3
AXLES
Rear axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full-floating
Final drive type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planetary gear
Ratios:
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.647
Planetary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.235
SUSPENSION SYSTEM
Variable rate, hydropneumatic with integral rebound control.
Maximum front stroke. . . . . . . . . . . . . . . . . . . . . . . . . 375 mm 14.76"
Maximum rear stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 mm 4.17"
Rear axle oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +/- 9.2°
STEERING SYSTEM
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fully hydraulic power steering
Supplementary steering . . . . . . . . . . . . . . . . . . . . . . Accumulator assist
Minimum turning radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2 m 40'
Steering angle (left or right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41°
CAB
Integral 4-post ROPS/FOPS cab structure (meets SAEJ 1040 Apr 88)
MAIN FRAME
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Box-sectioned structure
with two double-acting cylinders,
ral front bumper
Integ
HYDRAULIC SYSTEM
Hoist cylinder. . . . . . . . . . . . . . . . . . . . . . Two, 3-stage telescopic type
Relief pressure . . . . . . . . . . . . . . . . 19.0 MPa 193.4 kg/cm
Hoist time
Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 sec
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 sec
WEIGHT (APPROXIMATE)
Empty weight . . . . . . . . . . . . . . . . . . . . . . . . . 105300 kg 232,144 lb
Max. gross vehicle weight. . . . . . . . . . . . . . . . 249478 kg 550,000 lb
Not to exceed max. gross vehicle weight, including options, fuel and payload. Empty weight is with 100% fuel and operator.
Weight distribution:
Empty: Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.6%
Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.4%
Loaded: Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.8%
Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.2%
TIRES
Standard tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.00 R51
SERVICE REFILL CAPACITIES
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2120 ltr. 560 U.S. Gal
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 ltr. 51 U.S. Gal
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . 900 ltr. 238 U.S. Gal
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297 ltr. 78 U.S. Gal
Final drives (total) . . . . . . . . . . . . . . . . . . . . . . 240 ltr. 63.5 U.S. Gal
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 153 ltr. 40.5 U.S. Gal
2
2,750 psi
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OFF-HIGHWAY TRUCK
HD1500-7
DIMENSIONS AND PERFORMANCE
TRAVEL PERFORMANCE
To determine travel performance: Read from gross weight down to the percent of total resistance. From this weight-resistance point, read horizontally to the curve with the highest obtainable speed range, then down to maximum speed. Usable rimpull depends upon traction available and weight on drive wheels.
BRAKE PERFORMANCE
To determine brake performance: These curves are provided to establish the maximum speed and gearshift position for safer descents on roads with a given distance. Read from gross weight down to the percent of total resistance. From this weight resistance point, read horizontally to the curve with the highest obtainable speed range, then down to maximum descent speed the brakes can safely handle without exceeding cooling capacity.
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STANDARD EQUIPMENT
POWERTRAIN
Air cleaner (2); battery disconnect; engine electronic control; engine electronic monitor; engine overspeed protection; engine pre-lube system; ground level shutdown; variable speed engine fan (electronic-over-hydraulic)
Powertrain Management (these items located in the cab): –transmission controller –retard controller –monitor display –data download port
Seven-speed automatic transmission: –electronic control –body-up reverse interlock –body-up shift inhibitor –downshift/reverse shift inhibitor –neutral start switch –transmission belly guard
Torque converter (electronic lockup control)
CAB
Air conditioning (R134A)
Electric windows (both doors)
Glass, tinted
Heater/defroster
Instrumentation (gauge and monitor):
–speedometer –tachometer –engine coolant temperature –brake oil temperature –fuel lever –shift indicator
–hourmeter –odometer –torque converter temperature –warning lights
Insulated and sound-suppressed
Radio, AM/FM/Cassette
Seat, air suspension (driver)
Seat, passenger
Seat belts 78 mm 3" retractable
Steering wheel, tilt and telescopic
Sun visor
Windshield washer and wiper
LIGHTING
Back-up light, rear (1)
Back-up lights, deck-mounted (2)
Clearance lights, front
Engine service lights (2)
Headlights, halogen (8)
Hi-low beam selector
Instrument panel lights
Ladder lights, driver side
Retarder lights (2)
Stop and tail lights LED
Turn signals LED
GENERAL
Back-up warning alarm
Body up cable
Cab guard (on canopy)
Drive line protector (front and rear)
Engine fan and pulley guards
Exhaust pipe blanket
Ground level engine shutdown
Handrails
Heat shield behind engine
Horn, electric (2)
Ladder, deck-to-transmission
Ladders, right and left (front)
Mirrors, right and left
Mud flaps
Parking brake (3 caliper, spring-applied)
Reverse hoist interlock
Rock ejectors
ROPS cab (integral 4-post)
Secondary brake system,
automatic and manual
Skid-resistant walkway on deck
Supplementary steering system,
automatic
Windshield, laminated safety glass
OTHER
Auto-Retard Speed Control (ARSC)
Automatic Spin Regulator (ASR)
Automatic lubrication system
Body mounting group
Fast fill fuel system (Wiggins) right-hand
side of the machine
Integrated Komatsu Payload Meter
Operation, parts, and maintenance
manuals (1 set)
Rims (6), 24 x 51 (for 33 x 51 and 33R51 tires)
Tow hooks, front
Tow pin, rear
Vehicle health monitoring system
(VHMS)
OPTIONAL EQUIPMENT
(Optional equipment may change operating weight.) Weights listed are approximate change from operating weight.
Hub odometer, miles or kilometers . . . . . . . . . . . . . . . . 2 kg 5 lb
Disabled truck quick connects . . . . . . . . . . . . . . . . . 13.5 kg 29.8 lb
Kim Hot Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fast fill fuel, Wiggins left-hand side . . . . . . . . . . . . . . . 2 kg 5 lb
16 kg
35 lb
Fast oil change, Wiggins (engine) . . . . . . . . . . . . . . . . . 7 kg 15 lb
Service center, Wiggins left-hand side . . . . . . . . . . . . 36 kg 80 lb
Muffler, deck-mounted . . . . . . . . . . . . . . . . . . . . . . . . 50 kg 110 lb
Fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 kg 30 lb
Body liners
–19 mm 0.75" floor, 9 mm 0.35" side, front and
rear half of canopy (400 Brinell Steel) . . . . . . . 8320 kg 18,340 lb
AESS727-00 ©2007 Komatsu America Corp. Printed in USA D08(2.5M)C 8/07 (EV-1)
www.KomatsuAmerica.com Komatsu America Corp. is an authorized licensee of Komatsu Ltd.
Materials and specifications are subject to change without notice
is a registered trademark of Komatsu Ltd., Japan
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