HD1500-7 - Komatsu America Corp.

GROSS HORSEPOWER
1119 kW 1,500 HP
NOMINAL GVW
249478 kg 550,000 lb
HD1500-7
HD
1500
Mechanical Drive Truck
Photos may include optional equipment
HD1500-7 M e c h a n i c a l d r i v e T r u c k
Walk-around
Productivity Features
● High performance Komatsu SDA16V159E-2 engine meets EPA Tier 2 emissions regulations
Gross horsepower 1119 kW 1,500 HP
● Komatsu electronically controlled, automatic seven-speed powershift transmission
● Advanced K-ATOMiCS clutch modulation system with Skip-shift function
● Automatic Spin Regulator (ASR) for traction control
● Automatic Retard Speed Control (ARSC)
● Tight turning radius 12.2 m 40'
● MacPherson-type independent suspension
● Integrated Komatsu Payload Meter
● Standard rock body and customer specific
design available
Reliability Features
● Enhanced frame design rated for
144 metric ton 159 short ton payload
● Rugged and durable dump body design
● Steering and brake accumulators
● Proven and reliable hydraulic system
● Hydraulically actuated, multiple-disc
wet brakes
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HD1500-7
Mechanical drive Truck
gross horsePoWer
1119 kW 1,500 hP
noMinal gvW
249478 kg 550,000 lb
Operator Environment
● Ergonomically designed, spacious cab with excellent visibility
● Fully adjustable driving position settings
● Four post ROPS/FOPS Level 2
● Advanced dash panel with payload display
● Auxiliary brake and automatic application
● AM/FM/CD/MP3/USB radio
Easy Maintenance
● KOMTRAX Plus allows immediate diagnosis
of key engine, chassis, and drive system
components
● Oil-cooled wet disc braking system reduces
wear and extends component replacement
intervals
● Automatic lubrication system
● Remote mounted transmission
● In-tank fast fuel system
Photos may include optional equipment
3
HD1500-7 M e c h a n i c a l d r i v e T r u c k
ProducTiviTy FeaTures
komatsu sda16v159e-2 engine
advanced k-aToMics with skip-shift
The Komatsu SDA16V159E-2 engine with 1119 kW
1,500 hP gross horsepower delivers greater acceleration
and higher travel speeds with a high horsepower-to-ton
ratio. High torque at low speeds and impressive acceleration
ensure maximum productivity with low fuel consumption.
Standard features of this engine include:
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.
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Pre-lube system designed to eliminate start-up wear
and increase overhaul life
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CENSE® on board monitoring of engine performance
for each cylinder
skip-shift Function
When driving uphill, the skip-shift function automatically
selects the gear according to the slope of the grade. This
function reduces the number of down-shifts, making the
driving smoother, improving the operator’s comfort and
reducing potential material spillage.
Powershift Transmission
Komatsu's HD1500-7 features a fully electronically
controlled, automatic seven-speed powershift transmission.
Main transmission features include:
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Electronic shift control with automatic clutch modulation
in all gears
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Transmission-mounted torque converter
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Lock-up clutch system that is activated in every forward
shift change
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Separate hydraulic circuit and cooler
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Rubber damper that reduces harmful engine shocks and
torsional vibration to the transmission
Rubber damper minimizes
torsional vibration effects to
power train components.
Differential mounted parking
brake provides easy access
for service and repair.
Modular design offers
excellent serviceability
4
automatic spin regulator (asr)
During slippery conditions, the traction control provided by the
ASR detects and corrects wheel spin on rear tires by applying
braking force independently to the drive wheels. The ASR
operates independently of the service brake system, providing an
additional means of controlling the machine in slippery conditions.
automatic retard speed control (arsc)
ARSC allows the operator to set a desired machine speed
according to the grade of the road. This function manages the
speed of all four wheels, allowing adjustments of the desired
speed on grade by using the options available in the ARSC lever.
Mechanical drive Truck
HD1500-7
steering system
suspension
The MacPherson front suspension system has a special Aframe 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
turning radius of the HD1500-7 is 12.2 m 40', which
provides excellent maneuverability in tight loading and
dumping conditions. In addition, a secondary steering
system provides emergency hydraulic power in the case of
sudden loss of engine power or steering hydraulic
pressure. The steering accumulators comply with ISO-5010
standards.
The linkage arrangement utilized in the MacPherson
independent front suspension system allows the front
wheels to smoothly follow the undulation of the road
surface, providing excellent riding comfort.
customer specific Body
integrated komatsu Payload Meter
Integrated Komatsu Payload Meter is an electronic system
that monitors and records payload information for
Komatsu’s off-highway mining trucks. The accurate and
reliable payload measurement system is designed to help
Komatsu works with each customer to understand and
meet all of the criteria for body capacity and distribution.
The Komatsu Body Worksheet (BW) process obtains the
appropriate information from the customer about key
factors that will help to determine the correct body for their
site.
Komatsu offers a standard all-welded steel, flat floor body
with an over the cab canopy and horizontal bolsters.
• Standard Body Struck Capacity: 54 m3 71 yd3
optimize payload, maximize productivity and reduce the life
• Standard Body SAE Heaped 2:1: 78 m3 102 yd3
cycle cost of the machine. Integrated Komatsu Payload
• Standard Komatsu Body Weight: 19100 kg 42,108 lbs
Meter tracks and records the following key production
parameters:
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Payload
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Operator Identification
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Haul Cycle, Loading, Dumping Time and Date
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Distance Traveled (Loaded and Empty)
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Maximum Speed
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HD1500-7 M e c h a n i c a l d r i v e T r u c k
oPeraTor environMenT
ergonomically designed cab
Built-in roPs and FoPs structure
The Komatsu HD1500-7 cab provides a comfortable and
productive environment to meet today's mining market
demand. The cab includes tinted glass windows, heating
and air conditioning, acoustical insulation, double sealed
doors, and pressurized air filtration system. The instrument
panel makes it easy to monitor critical machine functions.
Komatsu offers an integral ROPS/FOPS Level 2 cab that
conforms to ISO standards 3471 and 3449.
Machine events are recorded and indicated as service
codes. A caution light warns the operator of any problems
that may occur. This makes the machine more user friendly
and easier to service.
operator seat
Komatsu recognizes that operator comfort is a key to
productivity in today's mining environment. The five-way
adjustable operator seat and the tilt-telescopic steering
column provide an optimum driving posture for increased
comfort and control over the machine. The suspension seat
absorbs vibrations transmitted from the machine while
reducing operator fatigue.
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auxiliary Brake and automatic application
All four wet disc brakes are activated when the auxiliary
brake button, located on the dashboard, is pressed. In
addition, the brakes will be automatically applied when the
hydraulic pressure drops below the specified level.
Mechanical drive Truck
HD1500-7
reliaBiliTy FeaTures
enhanced Frame design
The HD1500-7 frame has been enhanced to meet more
stringent Komatsu Engineering Standards (KES). This
enhanced frame design focuses on improving stress
distribution in order to offer superior strength. Furthermore,
increased casting thickness in high stress areas provides
the structural flexibility needed to carry loads and absorb
impacts in the toughest haul road conditions.
service Brakes
The HD1500-7 comes standard with four-wheel,
hydraulically actuated, oil-cooled service brakes. By using
a fully hydraulic braking system, the formation of water and
sediments - typical in air actuated braking systems - is no
longer present. This helps prevent contamination, freezing
and corrosion from affecting service brake component life.
The HD1500-7 stopping distance is well within ISO 3450
braking standard.
rugged and durable dump Body design
hoist cylinders
The newly designed
three-stage cylinders
deliver smooth and
reliable dumping by
using an internal
cushion valve and over-center damping. Internally, the
cylinders have a quill assembly that modulates the body
return speed after dumping. This reduces forces transferred
to the frame, body and suspension cylinders.
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 additional strength.
simple and reliable hydraulic system
The hydraulic system is a proven and reliable design with
fewer parts than other OEMs. The system utilizes a single
tank, providing one common source of fluid for steering,
braking, and hoisting. In-line, replaceable filtration elements
provide protection from hydraulic system contamination.
This makes the system easier to service.
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HD1500-7 M e c h a n i c a l d r i v e T r u c k
easy MainTenance
automatic lubrication system
koMTraX Plus
The automatic lubrication system is designed to reduce
service downtime and improve durability of all pin joints by
having a centralized module that automatically distributes
grease at adjustable intervals. In addition, this hydraulically
activated system can be adjusted to deliver the precise
amount of grease required by each joint.
As part of a complete service and support program,
Komatsu equips every truck with KOMTRAX Plus. By using
a satellite-based communication system, KOMTRAX Plus
provides access to machine health parameters and trends,
payloads, and critical faults in a user friendly web interface.
The information available through KOMTRAX Plus allows
service personnel to review faults and trends, improve the
quality of the troubleshooting process and reduce
unscheduled machine downtime.
rear led lighting rack
An LED lighting rack at the rear of the truck provides rear,
brake and flasher lights. In addition, this bracket, protected
from falling objects by the body structure, includes the
back-up warning horn and warning lights.
o-ring Face seals & sealed dT connectors
O-ring face seals provide superior leak protection. All
hydraulic hose male connections have a straight thread and
o-ring in the face. The female connections have a straight
thread and machined flat face.
Komatsu trucks use Deutsch connectors in main harnesses
and controller connectors of its electrical wiring. Compact,
hermetically sealed, resistant to temperature and vibration
and easy to use, Deutsch connectors are designed to
withstand the harshest and most challenging environments.
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Mechanical drive Truck
HD1500-7
Payload ManageMenT
Payload Policy
10-10-20 load Policy criteria
Recognizing that variation occurs naturally in material
density, fill factors, and loading equipment, Komatsu
America Corp. deems it necessary to establish a consistent
payload policy. This payload policy is intended to identify
the guidelines and limitations for the loading of Komatsu
mining trucks, and is valid for approved applications and
haul profiles only.
1) The average monthly payload must not exceed the rated
payload of the truck.
2) 90% of all loads must be below 110% of the rated
payload of the truck.
3) 10% of all loads may be between 110% and 120% of
the rated payload of the truck.
4) No single payload may exceed 120% of the rated
payload of the truck.
Percent of rated Payload
KOMATSU LOADING MATCH CHART
Typical number of Passes to load
Nominal truck payload rating (short tons)
Bucket ratings are based on 1780 kg/lcm 3,000 lbs/lcy material density.
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HD1500-7 M e c h a n i c a l d r i v e T r u c k
sPeciFicaTions
ENGINE
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Komatsu SDA16V159E-2
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water-cooled, 4-cycle
Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . Turbo-charged, after-cooled
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Bore x Stroke . . . . . . . . . . . . . . . . . 159 mm x 159 mm 6.26" x 6.26"
Piston displacement . . . . . . . . . . . . . . . . . . . . . . . . . . 50 ltr 3,066 in3
Horsepower
SAE J1995 . . . . . . . . . . . . . . . . . . . . . . . Gross 1119 kW 1,500 hP
ISO 9249 / SAE J1349 . . . . . . . . . . . . . . . Net 1043 kW 1,399 hP
Rated rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,900 rpm
Fan drive type. . . . . . . . . . . . . . . . . . . . Electronic controlled hydraulic
Maximum torque . . . . . . . . . . . . . . . . . . . . . . . . 697 kg•m 5,042 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
pre-cleaned, with dust indicator
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
clutch modulation in all gears
Maximum travel speed . . . . . . . . . . . . . . . . . . . . . . 58 km/h 36 mph
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
with two double-acting cylinders,
Supplementary steering. . . . . . . . . . . . . . . . . . . . . . . Accumulator assist
Minimum turning radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2 m 40'
Steering angle (left or right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41°
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
on input yoke to differential
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 cm2 24,668 in2
BODY
Capacity:
Struck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 m3 71 yd3
Heaped (2:1, SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . 78 m3 102 yd3
Nominal payload. . . . . . . . . . . . . . 144.1 metric tons 158.9 u.s. tons
Material . . . . . . . . . . . 400 Brinell hardness high tensile strength steel
(front, sides, and bottom)
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"
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19100 kg 42,108 lb
HYDRAULIC SYSTEM
Hoist cylinder . . . . . . . . . . . . . . . . . . . . . Two, 3-stage telescopic type
Relief pressure . . . . . . . . . . . . . . . . 19.0 MPa 193.4 kg/cm2 2,750 psi
Hoist time
Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 sec
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 sec
WEIGHT (APPROXIMATE)
Empty weight . . . . . . . . . . . . . . . . . . . . . . . . . 105300 kg 232,144 lb
Nominal vehicle weight . . . . . . . . . . . . . . . . . . 249478 kg 550,000 lb
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
CAB
Integral 4-post ROPS/FOPS Level 2 cab structure
MAIN FRAME
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Box-sectioned structure
Integral front bumper
10
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2120 L 560 u.s. gal
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 L
51 u.s. gal
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . 900 L 238 u.s. gal
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297 L
78 u.s. gal
Final drives (total) . . . . . . . . . . . . . . . . . . . . . . . 240 L 63.5 u.s. gal
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 L 40.5 u.s. gal
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . 532 L 141 u.s. gal
Mechanical drive Truck
HD1500-7
DIMENSIONS AND PERFORMANCE
ProPulsion PerForMance charT
To determine travel speed during propulsion using this travel performance chart: 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.
reTarding PerForMance charT
To determine travel speed during retarding using this retarding performance chart: 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)
● AM/FM/CD/USB/MP3
● Electric windows (both doors)
● Glass, tinted
● Heater/defroster
● Instrumentation (gauge and monitor):
–speedometer
–tachometer
–engine coolant temperature
–brake oil temperature
–fuel level
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–shift indicator
–hourmeter
–odometer
–torque converter temperature
–warning lights
Insulated and sound-suppressed
Operator 3-point 51 mm 2" retractable
seat belt
Seat, air suspension (driver)
Seat, passenger
Side windows, tempered glass
Steering wheel, tilt and telescopic
Sun visor
Windshield, laminated glass
Windshield washer and wiper
Exhaust pipe blanket
Handrails
Heat shield behind engine
Horn (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/FOPS Level 2 cab-integral 4-post
Secondary brake system,
automatic and manual
● Anti-slip walkway on deck
● Supplementary steering system,
automatic
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lighTing
● Back-up light, rear (1)
● Back-up lights, axle mounted (2),
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
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
● KOMTRAX Plus
● 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
general
● Back-up warning alarm
● Body up cable
● Drive line protector (front and rear)
● Engine fan and pulley guards
OPTIONAL EQUIPMENT
(Optional equipment may change operating
weight.)
● Body with cab and 236 mm 9.29"
spill guard
● Body sideboards 669 mm 26.34"
● Disabled truck quick connects
● Ether start
AESS727-04
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Fast fill fuel, Wiggins left-hand side
Fire extinguisher
Hub odometer, miles or kilometers
Kim Hot Start
Mufflers, deck mounted
©2014 Komatsu America Corp.
www.komatsuamerica.com
Printed in USA
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Service center, Wiggins left-hand side
Spare rim
Suspension cylinder charging tool
Tires, 33R51
Tool kit
AD10(750)OTP
08/17 (EV-2)
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
KOMTRAX Plus is a trademark of Komatsu America Corp.