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Komatsu HD1500-7 Dump Truck Operation and Maintenance Manual (CEAM027201)

Format: PDF (Printable Document)

File Language: English

File Pages: 119

File Size: 4.16 MB (Speed Download Link)

Brand: Komatsu

Model: D95S-2 Dozer Shovel

Book No: SEAM155B01

Type of Document: Operation and Maintenance Manual

Categories: ,

$ 40

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Komatsu HD1500-7 Dump Truck Operation and Maintenance Manual (CEAM027201)

Komatsu HD1500-7 Dump Truck Operation and Maintenance Manual (CEAM027201)

Running a Komatsu HD1500-7, you’re usually in a hard rock pit or big overburden job where this truck hauls nonstop and downtime gets expensive fast. This Operation and Maintenance Manual is what I keep handy to set a solid service rhythm and make sure the truck survives that abuse day after day. When a driver reports the truck feels “sluggish” on a grade or the body isn’t dumping clean, I use this book to walk through basic checks, verify what the operator should be doing, and decide if it’s a quick adjustment or needs shop time.

Applications & Use Cases

  • Plan preventive maintenance so inspections, filter changes, and adjustments get done before failures park the truck.
  • Walk operators through correct start‑up and shutdown to avoid hard wear on the engine, brakes, and drivetrain.
  • Trace early warning signs from gauges, warning lights, and unusual noises to catch issues before they snowball.
  • Standardize daily walk‑around inspections so every shift checks the same critical points.
  • Coordinate parts and shop work by knowing what’s coming due and when you can safely extend or must stop.

FAQ

Q: Can I keep this manual on a tablet in the cab?

A: Yes, that’s common; just make sure it’s downloaded so you can search it offline and protect the device from dust and vibration.

Q: Is it worth printing sections of this manual?

A: I usually print the routine inspection and service pages, laminate them, and keep them in the service truck for quick reference on the bench or in the pit.

Safety Note

Always follow the manual’s safety procedures before inspecting or servicing the truck, especially when working under the body or around high-pressure systems.

📘 Show Index

Komatsu HD1500-7 Dump Truck Index:

  • FOREWORD
    • ALERTS PAGE
    • TABLE OF CONTENTS
    • TRUCK MODEL ILLUSTRATION
    • ABOUT THIS MANUAL
  • TORQUE TABLES AND CONVERSION CHARTS
    • EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values
    • STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts
    • STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws
    • SAE Grade 9 Capscrews
      • Hardware Tightening Method
  • SAFETY
    • Safety Rules
    • Safety Features
    • Clothing And Personal Items
    • Unauthorized Modification
    • Leaving The Operator’s Seat
    • Mounting And Dismounting
    • Fire Prevention For Fuel And Oil
    • Precautions With High Temperature Fluids
    • Asbestos Dust Hazard Prevention
    • Prevention Of Injury By Work Equipment
    • Fire Extinguisher And First Aid Kit
    • Precautions For ROPS
    • Precautions For Attachments
    • HAUL ROADS
    • PRECAUTIONS DURING OPERATION
      • BEFORE STARTING THE ENGINE
      • OPERATING THE MACHINE
      • TOWING
      • WORKING NEAR BATTERIES
    • PRECAUTIONS FOR MAINTENANCE
      • BEFORE PERFORMING MAINTENANCE
      • DURING MAINTENANCE
      • TIRES
      • WHEN REPAIRS ARE NECESSARY
    • ADDITIONAL JOB SITE RULES
  • WARNINGS AND CAUTIONS
  • OPERATING INSTRUCTIONS
    • PREPARING FOR OPERATION
      • Safety Is Thinking Ahead
      • Walk Around Inspection
      • Cold Weather Heating System
    • ENGINE START-UP
      • Cold Weather Starting
      • Jump Starting
    • EMERGENCY STEERING SYSTEM
      • Operation
      • Pre-Operation Testing
    • AFTER THE ENGINE HAS STARTED
    • MACHINE OPERATION SAFETY PRECAUTIONS
    • LOADING
    • HAULING
    • RETARDER OPERATION
    • ENGINE OVERSPEED
    • PASSING
    • DUMPING
      • Raising the Dump Body
      • Lowering The Dump Body
    • SAFE PARKING PROCEDURES
    • TURNING OFF THE ENGINE
    • SUDDEN LOSS OF ENGINE POWER
      • Emergency Steering and Secondary Braking
    • DISABLED TRUCK DUMPING PROCEDURE
      • Hookup
      • Raising the Body
      • Lowering the Body
    • DISABLED TRUCK STEERING AND BRAKING
    • TOWING
  • OPERATOR CAB AND CONTROLS
    • STEERING WHEEL AND CONTROLS
      • Horn Button
      • ARSC Set Lever
      • Telescoping/Tilt Wheel Lever
      • Multi-Function Turn Signal Lever
    • RETARDER CONTROL LEVER
    • SERVICE BRAKE PEDAL
    • ACCELERATOR PEDAL
    • INSTRUMENT PANEL
    • HEATER / AIR CONDITIONER CONTROLS
      • Fan Control Knob
      • Temperature Control Knob
      • Air Conditioning & Heater
      • Air Flow Directional Knob
      • Heater/Air Conditioner Vents
    • RETARDING CAPACITY CHART
    • OVERHEAD PANEL
      • Radio Speakers
      • Air Cleaner Vacuum Gauges
      • Warning Alarm Buzzer
      • AM/FM RADIO / CD Player
    • CENTER CONSOLE
      • Hoist Control Lever
      • Transmission Shift Lever
      • Parking Brake Switch
      • LH Window Control Switch
      • RH Window Control Switch
      • Auxiliary Power Outlets
    • OPERATOR SEAT
      • Seat Belts And Tethers
    • Adjustment
    • INSTRUMENT PANEL AND INDICATORS
      • UPPER RH SWITCH PANEL
      • LOWER RH SWITCH PANEL
      • UPPER LH SWITCH PANEL
      • LOWER LH SWITCH PANEL
    • ELECTRONIC DISPLAY PANEL
      • PILOT DISPLAY ITEMS
      • METER DISPLAYS
      • CAUTION ITEMS
      • EMERGENCY STOP ITEMS
      • CHARACTER DISPLAY
      • ACTION CODE DISPLAYS
      • CHECKING FAILURE CODES
      • CHARACTER DISPLAY FLOW CHART
    • REAR ELECTRICAL COMPARTMENT
    • AUTOMATIC RETARD SPEED CONTROL (ARSC)
    • AUTOMATIC SPIN REGULATOR (ASR)
  • EXTERIOR LIGHTING AND SWITCHES
    • DECK LIGHTING
      • High Beam Headlights
      • Forward Warning Horns
      • Clearance/Turn Signal Lights
      • Deck Mounted Backup Lights
      • Payload Indicator Lights
    • UPRIGHTS
      • Ladder Lights
      • Low Beam Headlights
      • Ground Level Download Box
      • Ground Level Engine Shutdown Switch
      • Remote Grease Fill Port
      • Engine Service Lights
    • REAR AXLE LIGHT BAR
      • Backup Lights
      • Backup Alarm
      • Turn Signal Lights
      • Retard/Clearance Lights
      • Brake Light
  • LUBRICATION AND SERVICE
    • COOLANT SPECIFICATIONS
      • Unacceptable Practices
    • RADIATOR FILL PROCEDURE
    • HYDRAULIC TANK SERVICE
      • Filling Instructions
    • TRANSMISSION OIL LEVEL CHECK
    • FUEL SYSTEM SERVICE
      • Fuel Tank Cleaning
      • Fuel Filter Service
    • CAB AIR FILTER SERVICE
    • HVAC RECIRCULATION FILTER
    • CAB AIR FILTER
    • AIR INTAKE CLEANER SERVICE
    • QUICK FILL SERVICE CENTER
    • PERIODIC REPLACEMENT OF CRITICAL PARTS
    • 10 HOUR (DAILY) INSPECTION
    • 10 HOUR (DAILY) INSPECTION (continued)
    • 250 HOUR INSPECTION
    • 250 HOUR INSPECTION (continued)
    • 250 HOUR INSPECTION (continued)
    • 500 HOUR INSPECTION
    • 1000 HOUR INSPECTION
    • 2000 HOUR INSPECTION
    • 5000 HOUR INSPECTION
    • 18,000 HOUR INSPECTION
  • AUTOMATIC LUBRICATION SYSTEM
    • GENERAL DESCRIPTION
    • SYSTEM COMPONENTS
    • SYSTEM OPERATION
    • INJECTOR OPERATION
    • LUBRICANT PUMP
      • Pump Housing Oil Level
      • Pump Pressure Control
    • INJECTORS (SL-1 Series “H”))
      • Injector Specifications
      • Injector Adjustment
    • SYSTEM PRIMING
      • Filter Assembly
    • SYSTEM CHECK
      • Lubrication Controller Check
      • Lubrication Controller Operation
      • Lubrication Controller Components
      • Lubrication Controller Adjustment
    • SYSTEM TROUBLESHOOTING CHART
    • PREVENTATIVE MAINTENANCE
      • Daily Lubrication System Inspection
      • 250 Hour Inspection
      • 1000 Hour Inspection
  • MAJOR COMPONENTS AND SPECIFICATIONS
    • ENGINE
    • TRANSMISSION
    • SPECIFICATIONS
  • KOMTRAX Plus
    • KOMTRAX Plus DOWNLOADING
    • PAYLOAD METER
      • NORMAL OPERATION DISPLAY
      • EXTERNAL DISPLAY LAMPS
      • PREDICTED LOAD DISPLAY
      • CALIBRATING PLM
      • DATA STORED IN PAYLOAD METER
      • PLM DOWNLOADING
      • SETTING THE MACHINE ID AND OPEN ID
      • PAYLOAD – CYCLE DATA ITEM
      • ADDITIONAL FUNCTIONS
  • AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER
    • OPERATING INSTRUCTIONS
      • GENERAL RADIO RECEIVER FUNCTIONS
      • USING THE RADIO
      • USING THE CLOCK
      • USING THE ALARM
      • USING THE WEATHERBAND (USA Only)
      • USING THE COMPACT DISC PLAYER/USB
      • PLAYING AN MP3 DISC/USB
      • PLAYING MP3 FILES
      • USING AN iPOD®
      • OPERATING TIPS
      • TROUBLESHOOTING

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