Description
Komatsu HD1500-8 Dump Truck Operation & Maintenance Manual
This Komatsu HD1500-8 Dump Truck Operation & Maintenance Manual is the complete PDF guide for operating and servicing the HD1500-8 mining dump truck, covering serial numbers 81001 and up. Whether you are an operator, fleet mechanic, or maintenance planner, this manual provides the factory procedures, specifications, and safety information needed to keep the HD1500-8 running safely and efficiently. The document number is PEN00889-00 and it was published in April 2017.
File Details
- Manual Type: Operation & Maintenance Manual
- Brand: Komatsu
- Model: HD1500-8 Dump Truck
- Serial Numbers: 81001 and up
- Document Number: PEN00889-00
- Publication Date: April 2017
- Language: English
- File Format: PDF
- Page Count: 489 pages
Chapters Covered
This Komatsu HD1500-8 manual is organised into the following major sections:
- Foreword, Safety Information, and Introduction
- Safety — Safety Labels, General Precautions, Operator Protection
- Operation — General View, Controls and Gauges, Machine Monitor, Switches, Control Levers and Pedals, Other Equipment
- Machine Operations and Controls — Checks Before Starting, Starting Engine, Warm-Up, Travel, Shifting Gears, Downhill Travel, Loading, Dumping, Parking
- KTCS (Komatsu Traction Control System)
- ARSC (Automatic Retarder Speed Control)
- Payload Meter Operation
- KomVision Camera and Radar System
- Rear View Monitor
- Cold Weather Operation
- Long-Term Storage
- Troubles and Actions — Running Out of Fuel, Transmission Troubles, Dump Body Lowering, Towing, Battery
- Maintenance — Precautions, Schedule, Procedures
- Every 250 / 500 / 1000 / 2000 / 4000 / 5000 / 15000 Hour Maintenance
- Specifications — HD1500-8
- Attachments and Options — Speed Limit Function, Overload Speed Limit Function
- Replacement Parts — Periodic Replacement of Defined Life Parts, Consumable Parts
- Recommended Fuel, Coolant, and Lubricant
- Index
Inside this HD1500-8 Operation & Maintenance Manual, you will find the complete walk-around check procedure, daily and periodic maintenance schedules, detailed component explanations for the machine monitor and switch panel, and step-by-step service instructions for systems including the engine, transmission, brakes, steering, hoist circuit, suspension, and final drives. The manual also documents the KomVision camera and radar system, the ARSC downhill speed control, and the KTCS traction control system, with dedicated troubleshooting tables and failure code references for when the machine monitor displays a warning.
Specifications and Service Data
The manual includes full machine specifications for the HD1500-8 — overall dimensions, travel speeds, engine rated horsepower, maximum torque, and operating temperature range. You will also find the refill capacities for engine oil, transmission, steering and hoist oil tank, brake oil tank, differential, final drive, fuel tank, and cooling system, along with the recommended fuel, coolant, and lubricants for the SDA16V159-3 engine and the ambient temperature ranges for each fluid type.
Why This Manual Matters
Operating and maintaining a Komatsu HD1500-8 dump truck without the correct procedures and specifications is a risk to both the machine and the people around it. This manual gives you the correct torque values, wear limits, maintenance intervals, and safety warnings so that every repair and service task is done to Komatsu’s specification. The troubleshooting and failure code sections help you diagnose issues quickly, reducing downtime and preventing small problems from becoming major failures.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Komatsu HD1500-8 Dump Truck Operation & Maintenance Manual – PDF Download” are as follows:
COVERp. 1
+FOREWORDp. 2
READ THIS MANUALp. 3
SAFETY INFORMATIONp. 4
+INTRODUCTIONp. 5
MAIN USE OF MACHINEp. 5
DIRECTIONS OF MACHINEp. 5
VISIBILITY FROM OPERATOR'S SEATp. 6
+PRODUCT INFORMATIONp. 7
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATEp. 7
LOCATION OF ENGINE NUMBER PLATEp. 7
SERVICE METER LOCATIONp. 8
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTORp. 8
TABLE OF CONTENTSp. 9
+SAFETYp. 12
+SAFETY LABELSp. 13
LOCATION OF SAFETY LABELSp. 14
CONTENTS OF SAFETY LABELSp. 17
+GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCEp. 23
+PRECAUTIONS BEFORE STARTING OPERATIONp. 23
ENSURE SAFE OPERATIONp. 23
UNDERSTAND THE MACHINEp. 23
+PREPARATIONS FOR SAFE OPERATIONp. 23
PRECAUTIONS FOR SAFETY-RELATED EQUIPMENTp. 23
INSPECT MACHINEp. 23
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENTp. 23
KEEP MACHINE CLEANp. 24
PRECAUTIONS FOR INSIDE OPERATOR'S COMPARTMENTp. 24
PROVIDE FIRE EXTINGUISHER AND FIRST AID KITp. 24
IF ANY PROBLEM IS FOUNDp. 24
+PRECAUTIONS TO PREVENT FIREp. 25
ACTIONS IF FIRE OCCURSp. 25
PREVENT FIREp. 25
+PRECAUTIONS WHEN GETTING ON OR OFF MACHINEp. 27
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINEp. 27
NO JUMPING ON OR OFF MACHINEp. 27
PEOPLE ON DUMP BODYp. 27
WHEN STANDING UP FROM OPERATOR'S SEATp. 28
PRECAUTIONS WHEN LEAVING MACHINEp. 28
EMERGENCY EXIT FROM OPERATOR'S CABp. 28
DO NOT GET CAUGHT IN WORK EQUIPMENTp. 29
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURESp. 29
UNAUTHORIZED MODIFICATIONp. 29
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONSp. 29
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDINGp. 30
+PRECAUTIONS FOR OPERATIONp. 31
+PRECAUTIONS FOR JOBSITEp. 31
INVESTIGATE AND CONFIRM JOBSITE CONDITIONSp. 31
PRECAUTIONS WHEN WORKING ON LOOSE GROUNDp. 31
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLESp. 32
ENSURE GOOD VISIBILITYp. 32
CHECK SIGNS AND SIGNALMAN'S SIGNALSp. 33
BEWARE OF ASBESTOS DUSTp. 33
+START ENGINEp. 34
USE WARNING TAGSp. 34
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINEp. 35
PRECAUTIONS WHEN STARTING ENGINEp. 35
IN COLD AREASp. 35
START ENGINE WITH JUMPER CABLESp. 36
START ENGINE WITH AUXILIARY ENGINE STARTING CONNECTORp. 36
+PRECAUTIONS FOR OPERATIONp. 37
CHECKS BEFORE OPERATIONp. 37
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSEp. 37
WHEN TRAVELINGp. 38
PRECAUTIONS WHEN TRAVELING ON SLOPESp. 38
PRECAUTIONS WHEN OPERATING MACHINEp. 38
WHEN LOADING ON DUMP BODYp. 39
WHEN DUMPINGp. 39
WHEN OPERATING ON SNOW OR FROZEN SURFACESp. 39
WHEN PARKING MACHINEp. 40
TRANSPORTATIONp. 40
+TOWING AND BEING TOWEDp. 41
PRECAUTIONS FOR TOWING AND BEING TOWEDp. 41
+PRECAUTIONS FOR MAINTENANCEp. 42
+PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCEp. 42
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCEp. 42
KEEP WORK PLACE CLEAN AND TIDYp. 42
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCEp. 42
ONLY AUTHORIZED PERSONNELp. 42
APPOINT LEADER WHEN WORKING WITH OTHERSp. 42
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCEp. 42
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNINGp. 44
PRECAUTIONS WHEN INSTALLING, REMOVING, OR STORING ATTACHMENTSp. 45
PRECAUTIONS FOR WORKING AT HIGH PLACESp. 45
PRECAUTIONS WHEN WORKING ON MACHINEp. 45
PRECAUTIONS WHEN WORKING UNDER MACHINEp. 45
USE PROPER TOOLSp. 46
+PRECAUTIONS FOR CHECK AND MAINTENANCEp. 47
TURN BATTERY DISCONNECT SWITCH TO OFF POSITIONp. 47
PRECAUTIONS FOR WELDINGp. 47
HANDLE BATTERYp. 47
WHEN USING HAMMERp. 48
PRECAUTIONS FOR HIGH-TEMPERATURE COOLANTp. 48
PRECAUTIONS FOR HIGH-TEMPERATURE OILp. 48
PRECAUTIONS FOR HIGH-TEMPERATURE PARTSp. 49
PRECAUTIONS FOR HIGH-PRESSURE OILp. 49
PRECAUTIONS FOR HIGH-PRESSURE FUELp. 49
HANDLE HIGH-PRESSURE HOSES AND PIPINGp. 49
PRECAUTIONS FOR HIGH VOLTAGEp. 50
PRECAUTIONS FOR NOISEp. 50
HANDLE SUSPENSION CYLINDERS, ACCUMULATOR AND GAS SPRINGSp. 50
PRECAUTIONS FOR COMPRESSED AIRp. 50
MAINTENANCE OF AIR CONDITIONERp. 50
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALSp. 51
METHOD FOR SELECTING WINDOW WASHER FLUIDp. 51
PERIODIC REPLACEMENT OF DEFINED LIFE PARTSp. 51
+TIRESp. 52
HANDLE TIRESp. 52
PRECAUTIONS FOR STORING TIRESp. 52
+OPERATIONp. 54
+GENERAL VIEWp. 55
MACHINE EQUIPMENT NAMEp. 55
+CONTROLS AND GAUGES NAMESp. 57
MACHINE MONITOR EQUIPMENT NAMEp. 59
OTHER EQUIPMENT NAMEp. 61
+EXPLANATION OF COMPONENTSp. 63
+EXPLANATION OF MACHINE MONITOR EQUIPMENTp. 63
BASIC OPERATION OF MACHINE MONITORp. 64
WARNING DISPLAYp. 71
ACTION LEVEL DISPLAYp. 72
ENGINE COOLANT TEMPERATURE CAUTION LAMPp. 76
TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMPp. 76
RETARDER OIL TEMPERATURE CAUTION LAMPp. 76
FUEL LEVEL CAUTION LAMPp. 76
BRAKE OIL PRESSURE CAUTION LAMPp. 77
SEATBELT CAUTION LAMPp. 77
STEERING SYSTEM CAUTION LAMPp. 77
STEERING OIL PRESSURE CAUTION LAMPp. 78
STEERING OIL TEMPERATURE CAUTION LAMPp. 78
SECONDARY STEERING SYSTEM CAUTION LAMPp. 78
SECONDARY STEERING MOTOR CAUTION LAMPp. 79
HOIST CONTROL SYSTEM CAUTION LAMPp. 79
BODY FLOAT CAUTION LAMPp. 79
INCLINATION CAUTION LAMPp. 80
SYSTEM CAUTION LAMPp. 80
TRANSMISSION SYSTEM CAUTION LAMPp. 80
TRANSMISSION OIL FILTER CLOGGING CAUTION LAMPp. 81
RETARDER SYSTEM CAUTION LAMPp. 81
ENGINE SYSTEM CAUTION LAMPp. 81
PARKING BRAKE SYSTEM CAUTION LAMPp. 82
KTCS SYSTEM CAUTION LAMPp. 82
ENGINE OIL PRESSURE CAUTION LAMPp. 82
ENGINE OVERRUN CAUTION LAMPp. 82
CHARGE LEVEL CAUTION LAMPp. 83
AIR CLEANER CLOGGING CAUTION LAMPp. 83
FAN CONTROL SYSTEM CAUTION LAMPp. 83
AIR CONDITIONER SYSTEM CAUTION LAMPp. 83
ARSC SYSTEM CAUTION LAMPp. 84
ARSC OVERHEAT NOTICE CAUTION LAMPp. 84
PAYLOAD METER SYSTEM CAUTION LAMPp. 84
CAMERA SYSTEM CAUTION LAMPp. 85
RADAR SYSTEM CAUTION LAMPp. 85
MAINTENANCE TIME CAUTION LAMPp. 85
CENTRALIZED WARNING LAMPp. 86
PILOT DISPLAY AND METER DISPLAYp. 88
USER MENUp. 104
+SWITCHESp. 157
STARTING SWITCHp. 159
CIGARETTE LIGHTERp. 159
LAMP SWITCHp. 160
DIMMER SWITCHp. 160
TURN SIGNAL LEVERp. 160
WIPER, WINDOW WASHER SWITCHp. 161
HORN BUTTONp. 161
MONITOR BRIGHTNESS SELECTOR SWITCHp. 162
SWITCH FOR MIRROR WITH HEATED WIREp. 162
HAZARD LAMP SWITCHp. 162
SECONDARY STEERING SWITCHp. 163
REARVIEW MONITOR BRIGHTNESS ADJUSTMENT SWITCHp. 163
KomVision MONITOR BRIGHTNESS ADJUSTMENT SWITCHp. 163
AISS LOW SWITCHp. 164
ENGINE POWER MODE SELECTOR SWITCHp. 164
MANUAL GREASING SWITCHp. 164
PARKING BRAKE SWITCHp. 165
FOG LAMP SWITCHp. 165
POWER WINDOW SWITCHp. 166
SIDE LAMP SWITCHp. 166
ROOM LAMP1 SWITCHp. 167
ROOM LAMP2 SWITCHp. 167
HEATED WIRE GLASS SWITCHp. 168
REVOLVING LAMP SWITCHp. 168
SCREEN MODE SELECTOR SWITCHp. 168
OBSTACLE WARNING CANCEL SWITCHp. 168
LEFT FRONT CAMERA SELECTOR SWITCHp. 169
LEFT REAR CAMERA SELECTOR SWITCHp. 169
FRONT CAMERA SELECTOR SWITCHp. 169
REAR CAMERA SELECTOR SWITCHp. 169
RIGHT FRONT CAMERA SELECTOR SWITCHp. 170
RIGHT REAR CAMERA SELECTOR SWITCHp. 170
RADAR CHECK SWITCHp. 170
ENGINE SHUTDOWN SECONDARY SWITCHp. 171
STAIRCASE LIGHTING SWITCHp. 172
+CONTROL LEVERS AND PEDALSp. 173
BRAKE PEDALp. 173
SECONDARY BRAKE PEDALp. 173
ACCELERATOR PEDALp. 174
GEAR SHIFT LEVERp. 174
RETARDER CONTROL LEVERp. 176
ARSC TRAVEL SPEED SET LEVERp. 176
DUMP LEVERp. 177
DUMP LEVER LOCK KNOBp. 177
+OTHER EQUIPMENTp. 178
CAB DOORp. 178
DRINK BOXp. 179
LUNCH BOX TRAYp. 179
MAGAZINE BOXp. 179
CUP HOLDERp. 180
ASHTRAYp. 180
POWER SUPPLY OUTLETp. 180
KomVision SYSTEM INDICATORp. 180
FUSEp. 181
FIRE EXTINGUISHERp. 184
ENGINE ROOM LAMP SWITCHp. 185
BATTERY DISCONNECT SWITCHp. 186
SYSTEM OPERATING LAMPp. 187
HANDLE AUXILIARY ENGINE STARTING CONNECTORp. 187
STARTING MOTOR DISCONNECT SWITCHp. 188
EXTERNAL ENGINE SHUTDOWN SECONDARY SWITCHp. 189
CIRCUIT BREAKERp. 190
DUST INDICATORp. 191
DUMP BODY LOCK WIREp. 192
ESCAPE DOORp. 193
SERVICE CENTERp. 195
HANDLE AUTO-GREASING SYSTEMp. 197
KOMTRAX Plusp. 202
+MACHINE OPERATIONS AND CONTROLSp. 203
+CHECKS AND ADJUSTMENT BEFORE STARTING ENGINEp. 203
METHOD FOR WALK-AROUND CHECKp. 203
METHOD FOR CHECKING BEFORE STARTINGp. 206
ADJUST BEFORE OPERATIONp. 226
METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINEp. 240
METHOD FOR STARTING ENGINEp. 245
+METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINEp. 247
METHOD FOR CANCELING TO HOLD DUMP BODYp. 247
METHOD FOR CHECKING STARTING CONDITION AND UNUSUAL NOISE OF ENGINEp. 247
METHOD FOR CHECKING LOW-SPEED RUN AND ACCELERATION OF ENGINEp. 247
METHOD FOR RUNNING-IN THE NEW MACHINEp. 248
METHOD FOR WARM-UP OPERATIONp. 248
FUNCTION OF FILLING ACCUMULATORp. 249
METHOD FOR STOPPING ENGINEp. 250
METHOD FOR CHECKING AFTER STOPPING ENGINEp. 251
+METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MACHINEp. 252
METHOD FOR MOVING MACHINEp. 252
METHOD FOR TRAVELING REVERSEp. 254
METHOD FOR STOPPING MACHINEp. 255
METHOD FOR SHIFTING GEARSp. 258
+METHOD FOR TRAVELING DOWNHILLp. 260
HANDLE Automatic Retarder Speed Control (ARSC)p. 262
BRAKE PERFORMANCE CURVEp. 267
METHOD FOR TURNING MACHINEp. 271
HANDLE KOMATSU TRACTION CONTROL SYSTEM (KTCS)p. 272
OPERATION OF KTCSp. 272
METHOD FOR OPERATING MACHINE WHEN TIRES ARE STUCK IN GROUNDp. 272
METHOD FOR LOADINGp. 273
+HANDLING PAYLOAD METERp. 274
OUTLINE OF SYSTEMp. 274
PAYLOAD DISPLAYp. 276
EXTERNAL DISPLAY LAMPp. 278
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METERp. 279
METHOD FOR DOWNLOADING DATA FROM CONNECTOR FOR DOWNLOADp. 280
DISPLAY TOTAL PAYLOAD AND NUMBER OF CYCLESp. 285
DISPLAY FUEL CONSUMPTION RECORDp. 287
SETTING MACHINE ID AND OPEN IDp. 289
METHOD FOR PERFORMING CALIBRATIONp. 291
METHOD FOR DUMPINGp. 293
+PRECAUTIONS FOR OPERATIONp. 295
PERMISSIBLE WATER DEPTHp. 295
METHOD FOR PARKING MACHINEp. 296
METHOD FOR CHECKING AFTER FINISHING WORKp. 297
+LOCKp. 298
METHOD FOR OPENING AND CLOSING FUEL FILLER PORT CAPp. 299
METHOD FOR OPENING AND CLOSING TRANSMISSION CASE FILLER CAPp. 300
METHOD FOR OPENING AND CLOSING OIL FILLER CAP OF STEERING AND HOIST OIL TANKp. 301
METHOD FOR OPENING AND CLOSING BRAKE OIL TANK FILLER CAPSp. 302
METHOD FOR OPENING AND CLOSING OPERATOR CAB DOORp. 303
+HANDLE TIREp. 304
PRECAUTIONS WHEN HANDLING TIRESp. 304
T.Km.P.H (Ton-Km-Hour-Rating)p. 304
TIRE T.Km.P.H VALUE AND CONTINUOUS MAX TRAVEL SPEEDp. 305
PRECAUTIONS FOR LONG DISTANCE TRAVELp. 306
+HANDLE AIR CONDITIONERp. 307
+EXPLANATION OF AIR CONDITIONER EQUIPMENTp. 308
OFF SWITCHp. 308
FAN SWITCHp. 309
TEMPERATURE CONTROL SWITCHp. 310
VENT SELECTOR SWITCHp. 311
AUTO SWITCHp. 312
FRESH/RECIRC AIR SELECTOR SWITCHp. 312
AIR CONDITIONER DISPLAYp. 313
AIR CONDITIONER SWITCHp. 313
DEFROSTER SWITCHp. 314
+METHOD FOR OPERATING AIR CONDITIONERp. 315
METHOD FOR AUTOMATIC OPERATIONp. 315
METHOD FOR STOPPING AUTOMATIC OPERATIONp. 316
METHOD FOR MANUAL OPERATIONp. 316
METHOD FOR STOPPING MANUAL OPERATIONp. 317
METHOD FOR OPERATING WITH COLD AIR TO FACE AND WARM AIR TO FEETp. 318
METHOD FOR OPERATING DEFROSTERp. 320
+HANDLE RADIOp. 322
+EXPLANATION OF RADIO EQUIPMENTp. 322
POWER BUTTONp. 322
BAND/AUX SELECTOR BUTTONp. 322
VOLUME CONTROL BUTTONp. 322
TUNING/TIME ADJUSTMENT BUTTONp. 322
PRESET BUTTONp. 323
DISPLAY SELECTOR BUTTONp. 323
SOUND CONTROL BUTTONp. 323
DISPLAYp. 323
AUXp. 323
+METHOD FOR CONTROLLING RADIOp. 324
METHOD FOR ADJUSTING FREQUENCYp. 324
METHOD FOR ADJUSTING FREQUENCY (AUTO PRESETTING)p. 324
METHOD FOR CALLING PRESETp. 324
METHOD FOR REGISTERING PRESETp. 325
METHOD FOR ADJUSTING SOUND BALANCEp. 325
METHOD FOR ADJUSTING HIGH REGISTER RANGE (TREBLE)p. 325
METHOD FOR ADJUSTING LOW REGISTER RANGE (BASS)p. 325
METHOD FOR ADJUSTING CLOCKp. 326
+HANDLE KomVisionp. 327
PRECAUTIONS WHEN USING KomVisionp. 327
KomVision CAMERA DISPLAY RANGEp. 328
+BASIC OPERATION OF KomVision MONITORp. 329
BASIC OPERATION OF KomVision MONITOR WHEN STARTING ENGINE IN NORMAL SITUATIONp. 329
BASIC OPERATION OF KomVision MONITOR WHEN TROUBLE OCCURSp. 330
+EXPLANATION OF KomVision MONITOR SCREENp. 332
DEFINITION OF TRAVEL SPEED IN KomVisionp. 332
SWITCH SCREEN MODEp. 333
BIRD'S EYE VIEW DISPLAYp. 334
MACHINE BODY DISPLAYp. 334
GUIDANCE DISPLAYp. 335
RADAR PILOT LAMPp. 335
CAMERA IMAGE SWITCH DISPLAYp. 336
CAMERA IMAGEp. 337
REFERENCE LINEp. 338
+HANDLE KomVision RADARp. 340
OPERATION AND OBSTACLE DETECTION RANGE OF KomVision RADARp. 340
+WARNING WHEN OBSTACLE IS DETECTEDp. 341
AUTOMATIC SWITCHING OF CAMERA IMAGE AND OBSTACLE ALARM BUZZER WHEN OBSTACLE IS DETECTEDp. 343
METHOD FOR CANCELING OBSTACLE WARNINGp. 344
+HANDLE REAR VIEW MONITORp. 345
SELF-CHECK FUNCTION FOR REAR VIEW MONITORp. 346
PRECAUTIONS FOR USING REAR VIEW MONITORp. 347
DETERMINE AND MAINTAIN TRAVEL ROADp. 348
+TRANSPORTATIONp. 349
PRECAUTIONS FOR TRANSPORTATIONp. 349
SELECT TRANSPORTATION METHODp. 349
METHOD FOR SECURING MACHINEp. 349
+PRECAUTIONS FOR LIFTING MACHINEp. 350
PROCEDURE FOR LIFTING MACHINEp. 352
+COLD WEATHER OPERATIONp. 353
+COLD WEATHER OPERATION INFORMATIONp. 353
FUEL AND LUBRICANTSp. 353
COOLANTp. 353
BATTERYp. 354
PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHERp. 354
AFTER COLD WEATHER SEASONp. 355
+PRECAUTIONS FOR LONG-TERM STORAGEp. 356
PREPARATION FOR LONG-TERM STORAGEp. 356
MAINTENANCE DURING LONG-TERM STORAGEp. 356
STARTING MACHINE AFTER LONG-TERM STORAGEp. 357
PREPARATION BEFORE TRAVELING AFTER LONG-TERM STORAGEp. 357
+TROUBLES AND ACTIONSp. 358
+ACTIONS WHEN RUNNING OUT OF FUELp. 358
PROCEDURES FOR BLEEDING AIR FROM FUEL CIRCUITp. 358
ACTIONS IF TRANSMISSION HAS TROUBLEp. 359
METHOD FOR LOWERING DUMP BODY IF TROUBLES OCCURp. 360
+PRECAUTIONS FOR TOWING MACHINEp. 361
METHOD FOR RELEASING PARKING BRAKEp. 364
+PRECAUTIONS FOR DISCHARGED BATTERYp. 366
PRECAUTIONS FOR REMOVING AND INSTALLING BATTERYp. 367
PRECAUTIONS FOR CHARGING BATTERYp. 368
START ENGINE WITH JUMPER CABLESp. 369
START ENGINE WITH AUXILIARY ENGINE STARTING CONNECTORp. 371
+OTHER TROUBLEp. 372
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEMp. 372
PHENOMENA AND ACTIONS FOR CHASSISp. 373
PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTSp. 375
IF MACHINE MONITOR SHOWS WARNING DISPLAYp. 377
+MAINTENANCEp. 378
+PRECAUTIONS FOR MAINTENANCEp. 379
CHECK SERVICE METER READINGp. 379
KOMATSU GENUINE REPLACEMENT PARTSp. 379
KOMATSU GENUINE LUBRICANTSp. 379
ALWAYS USE CLEAN WASHER FLUIDp. 379
FRESH AND CLEAN LUBRICANTSp. 379
CHECK DRAINED OIL AND USED FILTERp. 379
PRECAUTIONS FOR REFILLING OIL OR FUELp. 379
PRECAUTIONS FOR WELDINGp. 379
DO NOT DROP THINGS INSIDE MACHINEp. 379
DUSTY JOBSITESp. 380
AVOID MIXING OILp. 380
LOCK INSPECTION COVERSp. 380
BLEED AIR FROM HYDRAULIC CIRCUITp. 380
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSESp. 380
CHECKS AFTER INSPECTION AND MAINTENANCEp. 380
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATUREp. 380
PRECAUTIONS FOR JACK-UPp. 381
+OUTLINE OF MAINTENANCEp. 382
+HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINICp. 382
OILp. 382
FUELp. 383
COOLANT AND WATER FOR DILUTIONp. 383
GREASEp. 384
PERFORM KOWA (Komatsu Oil Wear Analysis)p. 385
STORE OIL AND FUELp. 385
FILTERp. 386
HANDLE ELECTRICAL COMPONENTSp. 386
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTSp. 387
+MAINTENANCE SCHEDULEp. 390
MAINTENANCE SCHEDULE TABLEp. 390
+MAINTENANCE PROCEDUREp. 392
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)p. 392
+WHEN REQUIREDp. 393
METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANERp. 393
METHOD FOR CLEANING INSIDE OF COOLING SYSTEMp. 399
METHOD FOR CLEANING RADIATOR FINS AND OIL COOLER FINSp. 402
METHOD FOR CLEANING HYDRAULIC TANK STRAINERp. 402
METHOD FOR REPLACING ETHER CARTRIDGEp. 403
METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL, ADDING FLUIDp. 403
METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONERp. 404
METHOD FOR CHECKING DUMP BODYp. 405
METHOD FOR CHECKING LENGTH OF SUSPENSION CYLINDERp. 406
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUITp. 408
METHOD FOR BLEEDING AIR FROM STEERING AND HOIST CIRCUITp. 412
METHOD FOR BLEEDING AIR FROM PISTON PUMPp. 412
METHOD FOR BLEEDING AIR FROM STEERING CYLINDERp. 414
METHOD FOR BLEEDING AIR FROM HOIST CYLINDERp. 415
METHOD FOR BLEEDING AIR FROM BRAKE COOLING CIRCUITp. 417
METHOD FOR CHECKING PLAY OF OUTPUT COUPLING OF OUTPUT SHAFTp. 418
SELECT AND CHECK TIRESp. 419
METHOD FOR CLEANING LAMPS, CAMERAS AND RADAR DEVICEp. 421
CHECKS BEFORE STARTINGp. 423
+EVERY 250 HOURS MAINTENANCEp. 424
METHOD FOR CHANGING OIL IN ENGINE OIL PAN, REPLACING ENGINE OIL FILTER CARTRIDGEp. 424
METHOD FOR CHECKING AND ADDING OIL IN DIFFERENTIAL CASEp. 425
METHOD FOR CHECKING OIL LEVEL IN FINAL DRIVE CASE, ADDING OILp. 426
METHOD FOR CHECKING DRIVE SHAFTp. 426
METHOD FOR CHECKING BATTERY ELECTROLYTE LEVELp. 427
METHOD FOR CHECKING AND ADJUSTING CONCENTRATION OF COOLANT ADDITIVE AGENTp. 430
METHOD FOR CHECKING FRAMEp. 431
METHOD FOR CHECKING FOOT BRAKE PERFORMANCEp. 431
METHOD FOR CHECKING RETARDER BRAKE PERFORMANCEp. 432
METHOD FOR CHECKING PARKING BRAKE PERFORMANCEp. 433
METHOD FOR CHECKING FUNCTION OF ACCUMULATORp. 434
+EVERY 500 HOURS MAINTENANCEp. 436
METHOD FOR REPLACING FUEL FILTER CARTRIDGEp. 436
METHOD FOR REPLACING TRANSMISSION OIL FILTER ELEMENTp. 438
METHOD FOR CHECKING AND REPLACING AIR CONDITIONER COMPRESSOR BELTp. 439
+EVERY 1000 HOURS MAINTENANCEp. 441
METHOD FOR CHANGING OIL IN TRANSMISSION CASE AND CLEANING STRAINERp. 441
METHOD FOR REPLACING BRAKE COOLING OIL FILTER ELEMENTp. 442
METHOD FOR REPLACING BRAKE CONTROL OIL FILTER ELEMENTp. 443
METHOD FOR REPLACING FUEL TANK BREATHER ELEMENTp. 444
METHOD FOR LUBRICATINGp. 444
METHOD FOR CHECKING FRONT BRAKE DISC WEAR AMOUNTp. 445
METHOD FOR CHECKING REAR BRAKE DISC WEAR AMOUNTp. 446
METHOD FOR COLLECTING LEAKED OIL FROM FLOATING SEALp. 447
METHOD FOR CHECKING FOR LOOSENESS OF ENGINE INTAKE PIPE CLAMPp. 448
+EVERY 2000 HOURS MAINTENANCEp. 449
METHOD FOR REPLACING STEERING AND HOIST OIL FILTER ELEMENTp. 449
METHOD FOR CHANGING OIL IN BRAKE OIL TANKp. 450
METHOD FOR CHANGING OIL IN FINAL DRIVE CASEp. 452
METHOD FOR CHANGING OIL IN DIFFERENTIAL CASEp. 452
METHOD FOR CLEANING DIFFERENTIAL CASE BREATHERp. 453
METHOD FOR CHECKING FRONT WHEEL BEARINGp. 453
METHOD FOR CHECKING REAR WHEEL BEARINGp. 453
METHOD FOR CLEANING TRANSMISSION CASE BREATHERp. 454
METHOD FOR REPLACING STEERING AND HOIST OIL TANK BREATHER ELEMENTp. 455
METHOD FOR CLEANING BRAKE OIL TANK BREATHERp. 455
METHOD FOR CHECKING ACCUMULATOR GAS PRESSUREp. 455
METHOD FOR CLEANING FINAL DRIVE MAGNETp. 455
+EVERY 4000 HOURS MAINTENANCEp. 456
REPLACE DEFINED LIFE PARTSp. 456
METHOD FOR CHANGING OIL IN STEERING AND HOIST OIL TANKp. 457
METHOD FOR CHECKING VIBRATION DAMPERp. 457
METHOD FOR CHECKING ACCUMULATORp. 458
+EVERY 5000 HOURS MAINTENANCEp. 459
METHOD FOR LUBRICATING DRIVE SHAFTp. 459
+EVERY 15000 HOURS MAINTENANCEp. 460
METHOD FOR CHECKING AND REPLACING STEERING-A ARM MOUNTING BOLTp. 460
+SPECIFICATIONSp. 462
+SPECIFICATIONSp. 463
SPECIFICATIONS: HD1500-8p. 463
+ATTACHMENTS AND OPTIONSp. 466
+HANDLE SPEED LIMIT FUNCTIONp. 467
OPERATION OF SPEED LIMIT FUNCTIONp. 468
OPERATION IF TROUBLES ON SYSTEM OCCURp. 469
+HANDLE OVERLOAD SPEED LIMIT FUNCTIONp. 470
OPERATION OF OVERLOAD SPEED LIMIT FUNCTIONp. 470
OPERATION IF TROUBLES ON SYSTEM OCCURp. 472
+REPLACEMENT PARTSp. 474
+PERIODIC REPLACEMENT OF DEFINED LIFE PARTSp. 475
DEFINED LIFE PARTS LISTp. 475
+CONSUMABLE PARTSp. 476
CONSUMABLE PARTS LISTp. 476
+RECOMMENDED FUEL, COOLANT, AND LUBRICANTp. 477
LUBRICATION CHARTp. 478
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATUREp. 480
RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILSp. 481
INDEXp. 482
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