HD1500-7 Introduction & General Service PDF

HD1500-7 Dump Truck
KT4045
Class Handout
Komatsu Training and Demonstration

Center Cartersville, GA
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Tab 1
Introduction and General Service
Contents Page
Machine Overview 1 of 120 - 40 of 120
Machine Safety 43 of 120 - 55 of 120
Machine Maintenance 57 of 120 - 91 of 120
Machine Controls and Operation 93 of 120 - 120 of 120
Classroom & Shop Reference Material

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disclosed except in accordance with written authorization from KAC.
Additionally, this manual is intended for use during a Komatsu training course and should not to be used
as a reference for service or repair purposes.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right
to make changes or add improvements at any time without incurring any obligation to install such
changes on products sold previously.
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latest revision.
Komatsu Training and Demonstration

Center Cartersville, GA
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Introduction and General Service Class Handouts
Machine Overview
Slide 1 KT404507
06/07 Classroom Reference Material 1 of 118

Appearance Comparison
1500-7
1500-5
Slide 2 KT404507
Outward appearance has not changed that much from the 1500-5 to the 1500-7.
Paint colors and decals have changed.
The truck frame and components will remain yellow in color, and not use the gray
color of the smaller HD models.

HD1500-7 New Features

● New Cab Components
● New Engine and Damper
● New Electronic Control System
● New Face Seal Hoses
● New DT Electrical Connectors
● New Design Brake Cabinet
● Front Spindles and Suspension Cylinders
Slide 3 KT404507
New cab components will be the new monitor and controllers along with wiring
harnesses and controller locations.
New designed front dash. The machine will no longer have MOM, DAD or PMC
New transmission shift tower. The shift console will resemble the smaller HD and
HM models.
New tier 2 engine option. The truck will still be available with the tier1 engine.
Adoption of DT connectors. The DT connectors used in the machine to cab
connections will be used through out the entire machine.
New face seal o rings fittings will be used through put the entire machine also
excluding the double flange fittings already being used.

Commonality of Major Components (1 of 2)

No. ITEM K25 Tier 1 K25 Tier 2 Remarks
Major component
1 engine O X QSK50 for Tier 2
2 radiator O X Increased cooling capacity
3 output shaft damper X X coupling size, rubber size, overall length
4 T/C, T/M ass'y X X DT connector, coupling size
5 drive shaft, front X X size 11 to12
6 drive shaft, rear O O
7 rear axle/brake O O
8 front axle/brake O O As complete assy.
9 electronic panel X X New dash 7 EDP
10 electronic controllers X X New CR710
11 parking brake O O
12 rim O O
13 suspension, front X X New upper seals, upper flange
14 suspension, rear O O
15 operator seat O O
16 brake valve, foot O O
17 retarder valve X X K25 uses Hydraforce PPC valves, HD1500 uses FEMA
18 hoist valve O O
19 steering valve O O
20 flow amp O O
21 steering pump O O
22 hoist pump O O
23 T/M pump X X Increased output
24 brake cooling pump O O
25 steering cylinder O O
26 hoist cylinder O O
27 steering accumulator X X
28 brake accumulator X X Change to bladder type (Regulation)
29 dump body O O
30 sheet metal (Tier 1) O X Tier 2 Chg to grille str., deck strs. (wider radiator)
O : Replaceable to HD1500-5
X : Not replaceable
Slide 4 KT404507
The new Tier 2 engine available will be the QSK 50 16 cylinder engine. Komatsu will
model this engine the SSA16V159-2
Some machines will use the QSK45 being used in the machine now. Komatsu will
still model this engine the SAA12V160-1
The transmission will be the same with a change to some clutch packs and the
harness consisting of DT connectors.
The clutch change will be an addition of clutches to the mid and second cltch
packs.
The diameter of the lock up clutch will increase.
Cab components are basically the same with the new monitor panel no longer using
MOM or DAD.
The cooling system will be some larger with the tier2 engine

Commonality of Major Components (2 of 2)
No. ITEM K25 Tier 1 K25 Tier 2 Remarks

Periodially changed parts
1 fuel filter (Tier 1) O xX Tier 2 primary, secondary
2 hydraulic tank breather O O
3 air cleaner element O O
4 hyd. Hi press. Filter O O
Repair parts, wear parts
1 brake disc plate, front O O
2 brake disc plate, rear O O
3 P/B disc/pad O O
4 susp. Bearing, front X X Using "DD" bushing material, seals, upper flange
5 susp. Bearing, rear O O
6 body pad O O
7 tire O O
Lock-up clutch size increase, Mid clutch disk qty incr.,
8 T/M
X xX 2nd clutch disk qty incr., Deutsch connectors
O : Replaceable to HD1500-5
X : Not replaceable
Slide 5 KT404507
Work equipment has not changed .

Hydraulic system has not changed.
Braking system has several changes.
The suspension system has some changes in the front cylinders.

HD1500-7 Features Reliability improvement
Bladder brake LED lights for Engine output

Brake control durability
accumulators damper durability
change for reliability improvement improvement
In brake cabinet
Utilize Deutsch Front

connectors driveshaft size
increase 11C
12C
Front Fuel tank

suspension stress, fuel
seal & gauge / wiring
bushing improvement
Rear axle
Battery charge housing
alternator stress
Niehoff Prestolite reduction
Front axle
durability T/M clutch
improvement – T/M pump Frame rail improvement
bearing & spindle output welding
increase improvement
Slide 6 KT404507
These changes have been made to increase reliability of the machine.

Some changes have been very extensive and will be discussed later in detail.

HD1500-7 Features Reliability improvement
Eliminate MOM &

PMC, change
controllers from
LH to CR
Ground level
VHMS standard
VHMS
download
Ground level
Autolube fill
Use HD “-7” display
panel hardware
Front brake cooling

hoses -
serviceability
Slide 7 KT404507
The elimination of MOM and the PMC will greatly increase reliability and diagnostic
capability.
Using the dash 7 display panel will be a benefit by making this the last mechanical
truck to adopt this monitor.
Following Komatsu’s guide to commonality with models.

HD1500-7 Tier 2 version specification
Major Specifications
Unit HD1500-7 Tier 2
Engine Model -- Cummins QSK50
Power (gross) HP @ rpm 1,500 @ 1,900
Power (net flywheel) HP @ rpm 1,399 @ 1,900
Torque maximum kgm @ rpm 697 @ 1,300
Torque rise % 21.6
Governor speed max rpm 1,980
Control -- Quantum
Displacement liter (in3) 50.5 (3,082)
Fuel tank capacity liter (gal) 2,120 (560)
105,755
Weight EVW (w/ no body liners) kg (lb)
(233,150)
Balance (Empty) front % / rear % 48.9% / 51.1%
Spec. sheet payload tons (tonnes) 150 (136)
Max. GVW kg (lb) 249,480 (550,000)
Balance (loaded) front % / rear % 33.6% / 66.4%
Tire Tire size 33.00R51
Body Heaped / Struck yd3 102 / 71
m3 78 / 54
Slide 8 KT404507
The tier2 engine will increase horse power, will be slightly heavier and require a
different frame.


Unit HD1500-7 Tier 2
Service Engine oil change interval 500 h * * conditional, based
Engine oil filter Engine mounted
on duty cycle
Engine bypass filter Engine mounted
Vandalism prevention locks optional
Front tow bar eyes with hooks STD
Wiggins quick fuel system STD
Ground level autolube fill STD
Ground level VHMS download STD
Quick disconnect buddy dump optional
Engine oil renewal system optional
Transmission sight gauge Bar type gauge
Accessories Traction Control STD
Auto Retarder STD
Front wet brake STD
Prelube starter STD
Electric starters, no air system STD
Front hood bumper mirror optional
Heaters eng coolant & oil optional
Heater fuel recirc non-elect none
Large Fuel tank option OPT 830 gal
Radiator shutters inside mntd none
Air starters (TDI or IR) none
Variable pitch fan (Flexxaire) none
Variable fan speed (Rockford) STD
Body Liners optional
Large body (96 / 119 cy) optional
Body tail extension optional
Slide 9 KT404507
Maintenance and service procedures will be changed for the tier2 engine and will be
discussed in detail later.


Cab Interior PLM3, MOM elimination
Cooling Piping X Some hoses change to tubes, new cooler ppg.
Center Display panel O
Electrical X Brake wear sensor removal, Deutsch connectors, MOM removal, PLM3
Engine O
Engine Control O
Engine Damper O
Engine Mount O
Engine Oil Filter O
Ether Quick Start O
Exhaust Optional deck mounted exhaust from Donaldson to Leonetti
Frame Quality improvement
Front & Rear Suspension O
Front Axle O
Front Drive Shaft X 10C --> 11C
Fuel Lines O
Fuel Tank Quality improvement
Hoist Group O
Hood O
Hydraulic Piping O
Prelube Starter O
Radiator O
Rear Axle X
Rear Drive Shaft X Koyo --> ICUG
Rockford Fan Clutch O
Sheet Metal Center deck, ladders, fan guard were changed
Steering Group O
T/C Oil Cooler X Combined with brake cooler
Transmission Piping X Cooler piping change
Slide 10 KT404507

HD1500 Reliability Enhancement

● Power Train
Output Shaft Damper
• Increase diameter and thickness of rubber dampers
• Eliminate Pilot Bearing
• Two main bearings HD1500-5
HD1500-7
One main
bearing
Pilot
bearing
Slide 11 KT404507
The new dash 7 out put damper will eliminate the pilot bearing, add a main bearing
and increase the diameter of the rubber dampers.

● Front Driveshaft
Size increase from 11C to 12C
Size increase 11C → 12C
HD1500-7
HD1500-5
Slide 12 KT404507
The engine to transmission drive shaft has increased from 11C to 12C in diameter.


● Rear Axle Change shape to reduce stress
Final Drive concentration and increase section
• Wider gears and bearings modulus
Axle Housing
• Diameter increase at spindle/housing
interface
Differential
• Increase bolt size
HD1500-7
HD1500-5
Slide 13 KT404507
Shape changes have been made to decrease stress in stress prone areas of the
differential housing.


● Front Axle
Wheel Bearing / Spindle
• Increase wheel bearing size and spindle size
• Integral inner gear and wheel hub HD1500-7
HD1500-5
Slide 14 KT404507
Front wheel bearing and spindle have been increased in size to improve reliability.


● Frame Casting Reinforcement / Welding Improvement
Center flange / frame rail interface
Hoist pivot / frame rail interface
Lower horsecollar casting
Rear cross member casting
HD1500-5
Rear cross
member HD1500-7
casting
Center flange
Hoist pivot
Lower horse
collar casting
Slide 15 KT404507
Casting and welding have improved at high stress points of the frame.


Center flange casting Hoist pivot casting
Increased length
to distribute stress
Tapered edge of casting

Flange length blends into rail side 2 piece casting,
increased to sheet Casting material integral part of rail
distribute stress spec. changed to
increase yield
Location of weld strength
joint moved higher
Horse collar casting

width increased
Casting wall
thickness increased Rear cross member casting
in high stress areas Horse collar
Slide 16 KT404507

Engine
● Tier 1 SDA12V160-1
Mechanical Injection 1486 HP @1900 RPM
● Tier 2
CRI (Common Rail Injection)
Electronically Controlled
Injection
SSA16V159-2
1500 HP @ 1900 RPM
NEW
Slide 17 KT404507
The HD1500-7 will offer two different engines depending on customer requests.
1.Tier 1 will be SDA12V160-1(QSK45) 12 cylinder
2.Tier 2 will be SSA16V159-2 (QSKTA 50CE) 16 cylinder

Common Rail Injection (CRI)

A. Supply Pump [A]
B. Rail and Sensors
C. Electronic Injector
[B]
NEW
[C]
Slide 18 KT404507
Common Rail Injection or commonly known as CRI engine consists of a low

pressure supply system supplying fuel to the high pressure supply pump which in
turn pressurizes the rail system supplying constant pressure to all injectors
consistently with the injectors being fired electronically. This does away with the
mechanical linkage being actuated by the cam. The high pressure also causes more
efficient atomization of fuel creating cleaner emissions.

Controllers (engine)
● Tier 2 Engine ECM

Total of Three
NEW
Slide 19 KT404507
The new tier2 engine will have three engine mounted ECMs and the capability to
perform engine diagnostics and communicate through the machine monitor.

Transmission
● Electronic Controlled [A]

NEW
A. ECMV
B. Transmission Shifter
C. New DT Connectors
Already used between chassis
and cab [B] NEW
Transmission harness
and sensors
[C]
Slide 20 KT404507
The transmission is essentially the same externally with improvements mainly to

internal components.
The transmission shifter has been changed and the same style shifter is used in all
smaller HD and HM trucks.
The electrical connections have been changed to DT or connections.

HD1500-7 Improvement items

● Transmission life improvements
A. Increased number of mid clutch disks (6 Æ 8)
B. Increased number of 2nd clutch disks (4 Æ 5)
C. Increased lube pump capacity
D. Reverse planetary gear hard shot peening
[C]
• Needle bearing heat treatment change
E. Increased size of torque converter input shaft bolt
F. Increased diameter of lockup clutch
[F]
[D]
[E]
[A]
[B]
Slide 21 KT404507
Reliability improvements to the transmission will increase transmission life.

Electronics
● Implement HD “-7” electronics system

Remove PMC, MOM
New Electronic Display Panel (common KLtd. dump truck hardware)
VHMS standard (PLM built into VHMS controller)
New T/M controller, brake controller (CR710 hardware)
Deutsch connectors
Controllers
Transmission harness
Sensors
Already used between chassis and cab harnesses
HD1500-5 HD1500-7
Slide 22 KT404507
The new HD1500-7 will incorporate the -7 monitor along with VHMS standard with
Pay Load Meter built in to the system.
The machine controllers will be updated with CR710 hardware.

Electrical System
A. Monitor
B. Transmission Control [C]
C. Electrical Connections NEW
[A] NEW
[C]
[B]
NEW
Slide 23 KT404507
All new electronic components through out the entire truck.

Cab and Components

[B]
A. Seat (No Change) NEW
B. New front dash and Monitor
C. New Transmission Shift Console
D. No MOM or DAD
[A] [C] NEW
[D]
NEW
Slide 24 KT404507
The cab of the HD1500-7 now incorporates the new electronic monitor which is
used for machine and engine diagnostics.
There is no longer a need for MOM or DAD.
The new truck transmission shift lever has changed and uses the new style used on
the smaller trucks.

Controllers (transmission and brake)
● Transmission
A. ATC (automatic transmission controller)
● Brake [A]
B. RCM (retard control module)
NEW
[B]
Slide 25 KT404507
Transmission ,Retarder, VHMS, and ORBCOMM controllers are mounted behind

the operators' seat for easy access.

Controllers (VHMS/ORBCOMM)
A. VHMS
B. Orbcom [A]
NEW
NEW
[B]
Slide 26 KT404507

ARSC (Auto Retard Speed Control)

● ARSC
A. Control [B]
B. Switch
C. Speedometer
D. Pilot Lamp NEW
[A]
[C]
[D]
Slide 27 KT404507
ARSC (Auto Retard Speed Control) is new to the 1500-7 and will be standard
equipment.

ASR (Automatic Spin Regulator)
A. Switch [A]
B. Speed Sensor
C. Control
[B]
[B] [C]
Slide 28 KT404507
ASR-Automatic Spin Regulator

Depressing the bottom of the switch turns the ASR system on.
Depressing the top of the switch turns the ASR system off.
When ASR is active the system monitors individual wheel speeds.
If it determines one of the rear wheels is slipping during acceleration, the brake is
applied to the rear wheel with the higher speed.

AISS (Automatic Idle Selection Switch)
A. Switch [A] NEW

B. Monitor
C. Engine ECM
[B] [C]
NEW NEW
Slide 29 KT404507
AISS switch controls the speed of the engine with the accelerator released.
The monitor panel sends a signal to the ECM for a low idle rpm.
This signal may be for either
650 rpm – normal low idle
1000 rpm – high low idle

Cooling System
● Mesabi Radiator
A. Replaceable Cores
B. Hoist & Steering
Cooler
C. A/C Condenser
[A] [B] [C]
Slide 30 KT404507
The 1500-7 will keep the Mesabi radiator and increase the capacity.

Cooling System
● Mesabi Heat Exchangers

A. Transmission Cooler [A]
B. Brake Cooling Cooler
[B]
Slide 31 KT404507
The 1500-7 will keep the Mesabi radiator and increase the capacity.

Work Equipment
● Body
A. Body Guides
[A]
B. Body Pads
C. Hinge Pins
[B]
[C]
Slide 32 KT404507
No changes will be made to the body.

Hydraulic System
A. Pumps
B. Hoist
C. Steering
D. Transmission
[B] [E]
E. Brake Cooling
F. New seal face O ring
hoses NEW
[C] [F]
[A] [D]
Slide 33 KT404507
The two changes to the hydraulic system will be the increased capacity of the
transmission lube pump and the use of seal face oring fittings.

Hydraulic System
● Cylinders
A. Hoist
B. Steering
[A] [B]
Slide 34 KT404507

Hydraulic System
● Valves [D]
A. Hoist
B. Steering
C. Steering Amplifier Valve
D. Bleed Down [C]
E. BCV (brake cooling
control valve) [E]
[B]
[A]
Slide 35 KT404507

Suspension System (Front)
● Front Suspension [B] [D]

A. Cylinder
B. Spindle
C. Hub
D. Tie Rod
E. A Frame NEW
[A]
[C] [E]
NEW
NEW
Slide 36 KT404507
Changes to the front suspension include larger bearing and spindle along with seal
changes to the suspension cylinder.

Suspension System (Rear)

● Rear Suspension
A. Cylinders [A]
B. Final Drive
C. Links (Diagonal, Lower, and
Center)
[C]
NEW
[B]
Slide 37 KT404507
Rear suspension changes will be DT connectors, sealface oring fittings, and diff
housing improvements.

Brakes
[A] [D]
A. Oil Cooled
● Multiple Disc
B. Front
C. Rear
D. Parking
E. Brake Control [B] [E]
F. Brake Cabinet
[C] [F]
NEW
Slide 38 KT404507
The brake cabinet has been completely redesigned and will incorporate bladder
accumulators instead of piston.

Emergency Braking System

• 3 Systems: [A]
- Front brake and accumulator [A]
- Rear brake and accumulator [A]
- Spring-applied park brake (24” disc, 3 calipers) [B]
• Manual emergency brake switch [C]
- Will apply front & rear service brakes
and parking brake
• Automatic emergency brake [D]
- When either accumulator drops to 1750 psi,
the operator is warned by warning light & buzzer NEW
- At 1650 psi, the accumulators apply
service brakes
[D] [C] [B]

NEW
Slide 39 KT404507
The new brake system will consist of the new cabinet and monitor and auxiliary
brake.

End Of
Machine Overview
Slide 40 KT404507

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Introduction and General Safety
Machine Safety
Slide 1 KT404507
Introduction to the Safety Section
● This is a general safety presentation.

● The pictures may, or may not be of the machine covered in this course.
● However, the same safety precautions apply.
Slide 2 KT404507

Safety Matters
Stop and Take Five
1. Stop, Look, Walk Around

2. Think Through the Task
3. Identify The Hazards
4. Control and Communicate
5. Do the Job safely
Slide 3 KT404507
Safety Rules
● Only trained and authorized personnel can operate and maintain the machine.
● Follow all safety rules, precautions and instructions when operating or performing
maintenance on the machine.
● Do not operate the machine while taking medication that may cloud your thought.
Slide 4 KT404507

Safety Features
● Be sure all guards and covers are

in their proper position. Have
guards and covers repaired if
damaged.
● Use safety features such as safety
lock levers and the seat belt
properly.
● Never remove any safety
features. Always keep them
in good condition.
Safety Lock Lever
Seat Belt
● Improper use of safety
features could result in
serious bodily injury or
death.
Slide 5 KT404507
Clothing and Personal Protective Items
Avoid loose clothing, jewelry and loose long hair.

They can catch on controls or in moving parts and cause serious injury or
death.
Always wear the proper Personal Protective Items applicable to your job.
Slide 6 KT404507

Mounting and Dismounting

● Never jump on or off a machine. Never get on or off a moving
machine.
● When getting on or off the machine, always face the machine and use
the handrails and steps.
● Never hold any control levers or lock levers when getting on or off the
machine.
● Always use three points of contact when
mounting or dismounting any machine.
One hand, two feet.
Two hands one foot.
Slide 7 KT404507
Mounting and Dismounting

● If there is any oil, grease, or mud on the handrails or steps, wipe it
off immediately.
● Always keep these parts clean.
● Repair any damage and tighten any
loose bolts.
Slide 8 KT404507

Fire Prevention For Fuel and Oil
● Do not smoke or use flame near fuel

or oil.
● Stop the engine when refueling.
● Do not leave machine while adding
fuel or oil.
● Tighten all fuel and oil caps
securely.
● Do not spill fuel on overheated
surfaces or on parts of the electrical
systems.
● Use well ventilated areas for adding
or storing oil and fuel.
Slide 9 KT404507
Precautions When Dealing With Temperatures

● Immediately after operations are stopped, the engine oil and hydraulic oil are at high
temperature and are still under pressure.
● Attempting to remove the cap, drain the oil or water, or replace the filters may lead to
serious burns.
Slide 10 KT404507

Crushing or Cutting Prevention

● Do not enter, or put your hand
or arm or any other part of your
body between moveable parts
such as the work equipment
and cylinders, or between the
machine and the work
equipment.
● If the work equipment is
operated, the clearance will
change and this may lead to
serious personal damage.
● If it is necessary to go between
moveable parts, always lock the
levers and be sure the work
equipment cannot move.
Slide 11 KT404507
Fire Extinguisher and First Aid Kit
Always follow the precautions below

to prepare for action if any injury or
fire should occur.
● Be sure that fire extinguishers have

been provided and read the labels
to ensure you know how to use
them.
● Provide a first aid kit at the storage
point. Check periodically; add to
the contents when necessary.
● Know what to do in the event of a

fire or injury.
Slide 12 KT404507

Precautions for ROPS

● When carrying out modification or repairs, always
consult your Komatsu Distributor first.
● Even when the ROPS is installed, if you do not
fasten your seat belt, it cannot protect you
properly. Always fasten your seat belt when
operating the machine. The ROPS is installed to
protect the operator if the machine should turn
over. It is designed not only to take the load when
turns over, but also to absorb the impact energy.
● Do not operate machine with ROPS (Roll Over
Protection) removed if equipped
Slide 13 KT404507
Machines with Accumulators

● After the engine is stopped, the pilot and brake systems maintain stored pressure.
● Therefore when the hoist control lever is operated, the work equipment can move
down under its own weight as the main spool will function,
● In the brake system, the brakes can function normally for several brake
applications.
Slide 14 KT404507

Safety at Work Site
● Before starting operations,

thoroughly check the area for
any unusual conditions that
could be dangerous.
● Check the terrain and condition

of ground at the work site, and
determine the best and safest
method of operation.
Slide 15 KT404507
Safety at Work Site

● Check the ground condition and the depth and flow of water before
operating in water or crossing a river. Never be in water which is excess of
the permissible water depth as shown in Operation and Maintenance
Manual.
Slide 16 KT404507

Checks Before Starting Engine

A. Check the coolant level. [D]
B. Check oil level in the hydraulic tank.
C. Check for clogging of the air cleaner.
D. Check the electric wiring
E. Check engine oil [C]
[B]
[A] [E]
Slide 17 KT404507
Checks Before Starting Engine

A. Adjust the operators seat to a position where it is easy to carryout operations,
and check for wear or damage to the seat belt and seat belt mounting
equipment.
B. Check the gauges work properly, and check that the control levers are all at
the NEUTRAL position.
C. Check that the mirrors and window glass provide a clear view.
If the above inspections show an abnormality, carry out repairs immediately.
[A] [B] [C]
Slide 18 KT404507

When Starting Engine
● Just prior to mounting your machine, walk around it again to check for people and
objects that might be in the way.
● Never start the engine if a warning tag has been attached.
● When starting the engine, sound the horn as an alert.
● Do not allow anyone to ride on the
machine body. Passengers may only be
carried where additional seating is provided.
Slide 19 KT404507
Precautions When Starting to Move
● Before moving the machine, check again that there are no persons or
obstacles in the surrounding area.
● When moving the machine, sound the horn to warn people in the surrounding
area.
● One to start
● Two for forward
● Three for reverse
● Always sit in the operator’s seat when driving the machine.
Slide 20 KT404507

Precautions When Starting to Move

● Fasten your seat belt securely.
● Always close the door of the operator’s cab and check that the door is locked
in position securely.
Slide 21 KT404507
Precautions When Moving Forward or Backward

● Check that there is no one near the machine. Be particularly careful to
check behind the machine.
● When operating in areas that may be hazardous or have poor visibility,
designate a person to direct work site traffic.
● Ensure that no unauthorized person can come within the direction of
turning or travel.
Slide 22 KT404507

Precautions When Traveling
● It is dangerous to look around you when operating. Always concentrate on your

work.
● It is dangerous to drive too fast, or to start suddenly, stop suddenly, turn

sharply, or zigzag.
● If you find any abnormality in the machine during operation (noise, vibration,
smell, incorrect gauge readings, air leakage, oil leakage etc) Move the machine
to a safe place immediately and look for the cause.
Slide 23 KT404507
Machines Are Not Acrobats!
Slide 24 KT404507

End of Machine Safety
Section 1_2
Slide 25 KT404507

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Maintenance
Slide 1 KT404507

HD1500-7 Main Differences with HD1500-5

● Oil and Filter maintenance monitor
● Ground level auto lube refill
● VHMS (Vehicle Health Monitoring System)
● Ground Level VHMS and PLM download
● Available Tier 2 Engine
● Added Fuel Filtration for Tier 2 Engine
● Different Refill capacities with Tier 2 Engine
● 240 Amp Alternator
● Larger cooling Capacity 140/145 Gals.
● Bladder Accumulators
Slide 2 KT404507
Some new maintenance items include ground level aotu lube refill.
Ground level VHMS/PLM down load capability.
Addea fuel filtration for tier2 application.
Oil and filter maintenance monitor built in new monitoring system.

Out Line Of Service
● 10 Hour Daily Inspection

● 250 Hour Initial Inspection Service
● 250 Hour Inspection Service
● 2 Years or 4000 Hour Safety Critical Inspection
Slide 3 KT404507
Service intervals have not changed.

Oil Chart
● Lubrication Chart
● Refer to Operators Manual
● Use correct oils
● Use of proper grease and
intervals
● Perform proper oil and filter
change intervals
Slide 4 KT404507
The lubrication chart is placed on the left side of the radiator. The chart specifies
some of the critical maintenance items to be checked.
Component location and service intervals are specified on the chart. The lube key
lists the proper lubricants to be used. Refer to section 40 for more Information on
maintenance items.

Filter and Component Location
A. Engine [B] [E] [F]

B. Radiator
C. Front Suspension and
Front Wet Disc Brakes
D. Steering and
Brake Filter
E. Steering
Accumulators [C] [G]
F. Hydraulic Tank
G. Transmission
H. Hoist Cylinder
[A] [D] [H]
Slide 5 KT404507
General component and filter locations have not changed but a few have been
added.
Added fuel filtration has been added for the tier2 engine.


A. Final Drive
B. Rear Suspension [C] [F]
C. Differential
D. Rear Wet Brakes
● Brake Cooling Filters
E. Front
F. Rear
[D] [G]
G. Fuel tank
H. Pump Drive
[A]
[B] [E] [H]
Slide 6 KT404507

A. Transmission Filters [A] [D]

● Fuel Filters
B. Pre Filter
C. Main
D. Hydraulic Brake Cabinet
E. Engine Oil Filters
F. Corrosion Resistors [B] [E]
[C] [F]
Slide 7 KT404507
The tier2 engine will require different filters and added locations.

Capacities
● Engine Crankcase
151 Liters/40 gallons (1500-5 193/51)
● Cooling System
550 Liters/145 Gallons ( 1500-5 532/140.6)
● Hydraulic System
900 Liters/238 Gallons (Same)
● Differential Case
297 Liters/78 Gallons (1500-5 300/79)
● Final Drive Case (each planetary)
120 Liters/32 Gallons (Same)
● Fuel Tank
2120 Liters/560 gallons (Same)
● Transmission Case
153 Liters/41 gallons (Same)
Slide 8 KT404507
The engine, engine cooling, and the differential capacities will be different.

Safety Critical Parts

● Replace at 2 years or 4000 hours
Fuel System Hoses
Rubber Hoses for Brake Piping
High Pressure Hoses in Steering Circuit
High Pressure Hoses in Hoist Circuit
Hoses at Brake Cooling Inlet and Outlet (wheel)
Hose at Discharge side of Brake Cooling Pump
Hose at discharge side of Transmission Pump
Accumulators
After 3 years replace the seat belt
Slide 9 KT404507
Safety critical parts are mainly hoses with the addition of the bladder accumulators
and seat belt.
All these items should be inspected periodicly.

Walk Around Inspection

A. Front [A] [B]
B. Left Side
C. Left Front [D]

[C]
D. Rear
E. Right Side
[E] [F]
F. Right Front
Slide 10 KT404507
Always perform a walk around inspection before moving a machine or performing

maintenance.

Maintenance When Required (10 hour daily inspection)

● Air Cleaners
Clean or check vacuum gages [A]
• Dual Indicators [B] [E]
Clean or replace filter elements
• Engine [C]
– Dual Filters [D]
• A/C
– Fresh [E]
– Re Circulation [F] [C]
[D]
[A]
[F]
[B]
Slide 11 KT404507
All air cleaners should be inspected on a regular schedule dependant upon working
conditions.

● Drive Belts
A. Check condition of Alternator and Fan Belts
B. Check for proper tension
C. Inspect belt alignment
[A] [B] [C]
Slide 12 KT404507
Drive belts should be inspected during the daily inspection.

A. Engine and Turbochargers

B. Check for leaks
C. Vibrations
D. Odd noises
[A] [B]
[C] [D]
Slide 13 KT404507
Visually inspect these components during your walk around.

● Tires
Check for proper inflation and wear
Check for embedded debris, cuts, or damage
Slide 14 KT404507
Do a visual inspection of your tires during your walk around.

Engine Oil Level
A. Engine Oil Dip Stick and Fill Tube

B. Follow Refill Recommendations
[A] [B]
Slide 15 KT404507
Engine oil should be checked at every preshift inspection.

Transmission
A. Transmission Oil Level Check
B. Site Gauge
C. Upper and Lower marks
[B]
[C]
[A]
Slide 16 KT404507
When checking transmission oil levels if the engine is running the transmission
should be warm to operating temperature and the engine should be at an idle.
If checking the transmission cold with the engine off the machine should set for at
least 8 hours.

Steering/Hoist and Brake Cooling Oil Level
● Steering and Hoist Tank
● Steering and Hoist Oil Level
● Proper checking Procedure
Slide 17 KT404507
Always check the hydraulic tank oil level with the engine off and the bed in the
seated position.

Fuel Level
A. Fuel Tank [B] [C]

B. External Fuel Gauge
C. Quick Fuel
D. In Cab Fuel Gauge
[A] [B]
[D]
Slide 18 KT404507
The fuel level can be checked at ground level or in the cab through the monitor.

Fuel Tank Sediment

A. Fuel Drain Valve
[B]
B. Fuel Shut Off Valve
C. Water Separator Drain
[A]
[C]
Slide 19 KT404507
Fuel tank sediment should be drained daily at the tank.

The tier2 engine will have water separator filters that should be checked and
drained on a regular schedule.

Monitor
A. New Monitor [A] [A]
B. Old Monitor
C. Mom
D. Dad [B]
[B]
[C] [D]
Slide 20 KT404507
The new monitor will be equipped with self diagnostic features and will have oil and
filter change reminder capability.

Emergency Steering
A. Accumulators
[A]
B. Sensors
C. Switches
D. Cylinders
[B] [C] [D]
Slide 21 KT404507
Emergency steering will still activate at a low pressure using the bladder
accumulators for this function.

Body Positioner
● Body Seated Switch
● Body Up Switch
Slide 22 KT404507
The body up switch will send a signal to the controller sensing a bed raised
situation.
The body seated switch will send a signal to the controller sensing a bed down
situation.

VHMS/PLM
● VHMS Controller [A]
In Cab Down Load Port [B] [C] [F]
Ground Level Down Load Port [C] [H]
● PLM (Payload Meter)
PLM Display [D]
External Display Lamps
• Right Side [E]
• Left Side [F]
In Cab Down Load Port [G] [D] [I]
Ground Level Down Load Port [H]
● ORBCOM Controller (optional) [ I ]
● GPS Antenna (optional) [J]
[A]
[G] [B] [E] [J]
Slide 23 KT404507
VHMS will be standard for the 1500-7 and incorporate PLM and Orbcom.

Initial 250 Hour Service

● Transmission Oil [A]
Filters[B] [B] [E]
● Hydraulic Oil [C]

Filters [D]
• Steering/Brake [D]
• Hoist/Brake Cooling [E]
[E]
● Differential case
Drain [F] [C]
Fill [G] [G]
● Final Drive Case [H]

[F]
[A]
[D] [H]
Slide 24 KT404507
Refer to the operators manual for the correct oil change intervals.

250 Hour Service

● Lubrication [B]
Dump Body Hinge Pins - 2 Points [A]
Rear Suspension - 4 Points [B]
Axle Support Pins – 8 Points [C]
Hoist Cylinder Pins – 4 Points
Front Suspension Assembly – 8 Points [D] [C]
Steering Cylinder Pins – 4 Points [E]
Steering Linkage – 5 Points
Front Transmission Mount 1 Point
● Refill Grease Reservoir [F]
[D] [E]
[A]
[A] [F]
Slide 25 KT404507
The auto lube system is standard for the HD1500-7 and now has ground level refill
capability.

250 Hour Service (cont.)

● Engine [B] [E]
A. Engine Oil (change)
B. Engine Oil Lube Filters
(change)
C. Alternator Belt (check)
D. A/C Compressor Belt (check) [C] [F]
E. Fan Belt (check)
F. Transmission Case Breathers
(check and clean)
[A]
[F]
[D]
Slide 26 KT404507
After initial 250 hour service.

A. Hydraulic Tank Breather (check and clean)

B. Differential Case (check oil level)
C. Differential Case Breather ( check and clean)
D. Final Drive cases (check and fill) [C]
[A] [B]
[D]
Slide 27 KT404507
Check and clean breathers on a regular schedule more often in extreme conditions.

A. Parking Brake (wear and clearance)

B. Fuel Filter (change)
C. Corrosion Resistor (change)
[A] [B]
[C]
[B]
Slide 28 KT404507
Remove and replacefilters and inspect and adjust park brake.

500 Hour Service

A. Radiator (check and clean) [C]
● Transmission Filters
B. Remove and replace two filters (change)
C. Remove and replace transmission control filter
(change)
D. Check Toe In Adjustment on Front Suspension
E. Bladder Accumulators
Pressure must be checked every 500 hours.
[D]
[A] [B]
[E]
Slide 29 KT404507
Check and clean radiator.

Check pre charge pressure for bladder accumulators. ( refer to service manual for
correct pressure.)

1000 Hour Service

● Manually Lubricate the parking Brake linkage
A. 6 Points 2 on each caliper
● Transmission [C]
B. Drain Oil
C. Replace Element
D. Remove and clean 3 magnetic strainers
[A]
[D]
[B]
[B]
Slide 30 KT404507
Lubricate 2 fittings on each caliper for the park brake.

Drain and change transmission filters and remove magnetic strainers and inspect.


A. Replace Steering & Brake Filters [D]
B. Replace Hoist & Rear Brake Cooling
Filters
C. Replace Front Brake Cooling Filters
D. Check Front & Rear brake Wear
E. Engine Breather [D]
[A]
[B]
[E]
[C]
Slide 31 KT404507
Replace all hydraulic filters.

Check brake wear on front and rear.
Check and clean engine breather.

2000 Hour Service

A. Hydraulic Tank Oil [D]
B. Drain Tank & Refill
C. Remove and Clean Hydraulic Tank Strainers
● Front Wheel Hubs
D. Drain Oil From Each Hub
• Drain The Hydraulic Tank Before Draining
Hubs
E. Final Drives Both Sides
F. Differential Case [C] [E]
[A]
[F]
[B]
Slide 32 KT404507
Drain the hydraulic tank before draining hubs. Gravity will allow the hydraulic tank to
drain through the hubs.

5000 Hour Service

A. Engine Drive Line Adapter
B. Remove & Inspect Rubber Dampers
C. Front & Rear Drive Shafts
D. Grease U joints on Both Drive Shafts
Check front & rear for binding, wear, & vibration
[B] [D]
[A]
[C] [D]
Slide 33 KT404507
The drive line adapter damper should be removed and inspected every 5000 hours
and refilled with correct Komatsu specified grease.


A. Front Wheel Bearings
B. Adjustment
[C]
C. Front Suspension
Drain Front Suspension & replace oil and gas
Disassemble and Inspect Upper Flange Internal
Bearing for wear
D. Engine Pre lube System
Wear & Leakage
[A]
[D]
[B]
Slide 34 KT404507
Check pre load adjustment on front wheel bearings.

Drain and inspect upper flange bearing and refill front suspension cylinders with
correct oil and nitrogen.

End of Machine Maintenance
Section 1_3
Slide 35 KT404507

Blank Page

Machine Controls And Operation
Slide 1 KT404507

General View Of Controls And Gauges (Center Console)
A. Steering Wheel
B. Retarder Control Lever
C. Service Brake Pedal
D. Accelerator Pedal [C]
E. Instrument Panel [D]
F. Heater/Air Conditioner Controls
G. ARSC set lever
[E] [B]
[A] [G] [F]
Slide 2 KT404507
The steering wheel will telescope in and out and adjust at a tilt angle to provide a
comfortable wheel position for most operators.

A. Heater/Air Conditioner Vents

B. Retarding Capacity Chart [C]
C. Radio and Speakers
D. Air Cleaner Vacuum Gauges
E. Warning Alarm Buzzer
[A]
[E]
[B] [D]
Slide 3 KT404507
Al gauges and controls are visible and accessible from the operators seat.

Center Console
A. Left Hand Window Control Switch
B. Hoist Control Lever [D]
C. Transmission Shift Lever
[A] [E]
D. Auxiliary Power Outlets [B]
E. Parking Brake Switch
F. Right Hand Window Control Switch
[C]
[D]
Slide 4 KT404507
The center console has changed but all the controls remain in the same position as
the HD1500-5.

Operators Seat
A. Head Rest [A]

B. Arm Rest Adjustment
C. Back Rest Adjustment
D. Seat Belt [B]
E. Seat Slope Adjustment
F. Upper Lumbar Support
G. Lower Lumbar Support
H. Height Adjustment
I. Fore & Aft Adjustment
J. Seat Tether Bolt
K. Seat Height Adjustment [C]
[D]
[I] [K]
[E]
[F] [J]
[H] [G]
Slide 5 KT404507
The seat has not changed.

Instrument Panel
A. Upper LH Switch Panel

B. Center Electronic Display Panel
C. Upper RH Switch Panel
D. Lower L H Switch Panel
E. Key Switch
F. Lower RH Switch Panel
[B]
[C]
[A]
[F]
[D] [E]
Slide 6 KT404507
The front console has change with the use of the new monitor and added controls
and switches.

Upper Right Hand Switch Panel
A. Brake Lock Switch

Used for dumping and loading
B. F1 Start Switch
Insure the transmission starts in
first
C. Hazard Flasher Switch
[B]
[C]
[A]
Slide 7 KT404507
Brake Lock Switch.

The on position (up) applies the brake lock
The off position (down) releases the brake lock
The brake lock can only be used with the engine running.
It is used for dumping and loading only.
F1 start switch.
This switch is used to ensure the transmission starts in F1 when the transmission
shift lever is in D.
When this switch is off and the transmission lever is in d the transmission will start
out in 2nd.
Hazard warning lamp.
When this switch is used it causes all turn signal lamps to light simultaneously.

Lower Right Hand Switch Panel
A. Key Switch
B. Either Starting Aid (optional)
C. ASR Cut Switch
D. ARSC Switch
E. AISS Switch
F. Auxiliary Brake Switch
[C] [D] [E]
[B]
[A]
[F]
Slide 8 KT404507
Ether Start Switch

This switch is an on/off type rocker switch that is spring loaded to the off position and is optional.
ASR ( automatic spin regulator) cut switch is used to activate or de-activate the traction control
system.
ARSC (automatic retard speed control) activates the speed control system. Press the top to activate
system and press the bottom to de-activate the system.
AISS ( automatic idle select switch) controls the idle speed of the engine with the accelerator pedal
released.
650 normal low idle
100rpm high low idle
Depending on following conditions.
Pressing the top will turn system off causing machine to idle up to 1000 rpm’s for cold starts and
brake released.
Pressing the bottom will turn the system on and the machine will idle at 650 rpm’s
Auxiliary Brake Switch
Depress the button to apply auxiliary brake.
Pull the button out to release the auxiliary brake.
When the auxiliary brake is activated full un modulated brake pressure is applied ( or what ever
pressure is left if the brake system is failing.)
In addition the parking brake is applied.

Upper Left Hand Switch Panel
● Automatic Lubrication Indicator
Slide 9 KT404507
The upper left hand switch panel does not contain any switches but this is where the
auto lube indicator is located.
This indicator illuminates if after one minute the system pressure does not reach
2000 psi after the timer initiates a cycle.

Lower Left Hand Switch Panel

A. Head Light Switch
B. Ladder Light Switch
C. Back Up Light Switch
D. Fog Lamp Switch (optional)
E. Mode Selection Switch #1
F. Mode Selection Switch #2
G. Panel Dimmer Switch
[A] [C] [E] [G]
[B] [D] [F]
Slide 10 KT404507
The lower left switch panel holds all the working lamp switches along with the mode
selection switches for diagnostics.

Monitor Panel (pilot display items)
Turn signal High beam pilot

direction lamps lamp
Retarder Pilot
Lamp
Lock up pilot ARSC Set Speed

lamp Indicator
ASR Actuation
Lamp
Shift Lever
Shift Indicator Position
ARSC pilot
lamp
Slide 11 KT404507
EDP (Electronic Display Panel)

Pilot Display Items.
When the key switch is in the on position,
controls that have been activated will illuminate the corresponding pilot display lamps.
Lock up pilot lamp will illuminate when the torque converter lock up is engaged and the
transmission is in direct drive.
The turn signal pilot lamps will flash simultaneously as the exterior signal lamps flash.
The high beam pilot lamp will illuminate when the head lamps are set to high beam.
The retarder pilot lamp will illuminate when the retarder control lever is actuated and the retarding
system is activated.
The ARSC set speed indicator displays the set travel speed for the auto retarder speed control
When the ASR system is active, this lamp will illuminate when slipping from the rear wheels is
detected.
The lamp indicates that the ASR system has actuated the brakes to prevent the slippage.
The ARSC pilot lamp indicates that the automatic retard system is active. The system will maintain
the set speed.
The shift lever pilot lamp displays the position of the shift lever.
The shift indicator displays the transmission shift range (speed range)

Monitor Panel (meter displays )
Engine Speedometer
Tachometer
Retarder Oil
Engine Coolant Temperature
Temperature
Gauge
Torque
Converter Oil
Temperature Fuel Gauge
Slide 12 KT404507
The Torque Converter Oil Temperature Gauge displays the torque converter oil
temperature.
The white range indicates normal operating temperature.
If the temperature rises to the red range during operation, the alarm buzzer will
sound and the central warning lamp will illuminate.
The coolant temperature gauge displays the engine coolant temperature.
The engine tachometer displays the engine speed.
When the engine speed exceeds 2500 rpm’s and moves into the red range on the
meter, the alarm buzzer sounds and the central warning lamp will illuminate.
The retarder oil temperature gauge displays the retarder oil temperature.
The white range indicates normal operating temperature. If the temperature rises to
the red range during operation, the alarm buzzer sounds and the central warning
lamp will illuminate.
The Fuel gauge displays the amount of fuel remaining in the tank. The fuel
warning lamp will illuminate when the fuel level drops below 140 liters (37 gals.)

Monitor Panel (caution items)
Parking Brake
Maintenance Pilot Lamp Check Engine
Caution Lamp Lamp Fuel Level
Caution Lamp
Accumulator
Charge
Pressure Lamp
Dump Body Emergency
Pilot Lamp Steering Lamp
Slide 13 KT404507
The maintenance caution lamp illuminates if any of the following occur:

•Low engine oil level
•Clogged engine oil filter
•Low hydraulic oil level
•Clogged air cleaner
•Clogged steering/hoist oil filter
•Clogged transmission oil filter
•Low coolant level
•Clogged brake cooling oil filter
•Worn rear brake discs
•Low battery electrolyte level
•Low transmission oil level
The parking brake lamp illuminates when the parking brake is applied.
The dump body pilot lamp illuminates when the dump body is raised or the dump body lever is in
any position other than float.
The check engine lamp will illuminate if a problem occurs in the engine control system.
The engine must be serviced within 24 hours of the illumination of the lamp.
The emergency steering lamp illuminates when the steering pressure drops below 12,800 kPa
(1850 psi)
The accumulator charge pressure lamp will illuminate if the if the steering accumulator nitrogen
pressure is below 5861 kPa (850 psi)
The fuel level caution lamp illuminates when the level in the fuel tank falls below 140 liters(37 gals.)
If the lamp is on , it will be necessary to add fuel shortly.

Monitor Panel (emergency stop items)
Coolant Retarder Oil

Temperature Temperature
Torque Caution Lamp Caution Lamp
Charging
Converter Oil
System
Temperature
Caution Lamp
Caution Lamp
Engine Oil
Pressure
Caution Lamp
Brake Oil
Pressure
Caution Lamp
Central Warning
Caution Lamp
Machine
Monitor
Caution Lamp
Retarder
Engine Transmission System
Caution Lamp Caution Lamp Caution Lamp
Slide 14 KT404507
The coolant temperature caution lamp will illuminate when the coolant
temperature has risen to a critical level. When the lamp is lit, E02 ENGINE OVER
HEAT will be displayed on the character display
The charging system caution lamp illuminates when an abnormality in the
charging system has occurred with the engine on. When the lamp is lit, E03 CHECH
RIGHT NOW will appear on the character display
The engine oil pressure caution lamp will illuminate when the engine oil pressure
has dropped to a critical level. Oil pressure is monitored only when the engine is
running.
When the lamp is lit, E03 CHECH RIGHT NOW will appear on the character
display.
The brake oil pressure lamp will illuminate if accumulator oil pressure fails to
reach the specified value 30 seconds after engine start up.
If the brake accumulator oil pressure has dropped below the specified value during
truck operation the lamp will also illuminate.
When the lamp is lit, E03 CHECH RIGHT NOW will appear on the character
display.
The retarder oil temperature caution lamp will illuminate when the brake oil
temperature has risen to a critical level. When the lamp is lit, E02 BRAKE OVER
HEAT will be displayed on the character display.
The central warning lamp and the alarm buzzer will sound intermittently to indicate
that a failure is present.
Any of the following will cause the
06/07
central warning lamp to light.
Classroom Reference Material 106 of 118
•When an abnormality has occurred in any of the emergency stop items.
Monitor Panel (character display)
EDP
(Electronic
Display Panel)
Character
Display
Slide 15 KT404507
Normally the service meter/odometer is displayed on the character display.

If the machine experiences a failure or if it is necessary to perform maintenance, an
action code is displayed to recommend a suitable response.
Check the display to verify there are no faults before driving the truck.
The following table lists the various displays of the character display while in the
Operator Mode.
1. Service meter/odometer (default)
2. Operation information
3. Reverse travel distance display function.
4. Filter replacement, oil change interval display function.
5. Telephone number input function.
6. Language selection function.
7. PLM setup function.
8. Action code display function.
9. Failure code display function.

Character Display (operator)
1. Service meter/odometer (default)
2. Operation information
3. Reverse travel distance display

function.
4. Filter replacement, oil change

interval display function.
5. Telephone number input function.
Slide 16 KT404507
Normally the service meter/odometer is displayed on the character display.

Character Display (Operator)
1. Language selection function.
2. PLM setup function.
3. Action code display function.
4. Failure code display function
Slide 17 KT404507
If the machine experiences a failure or if it is necessary to perform maintenance, an

action is displayed to recommend a suitable response.
Check the display to verify there are no faults before driving the truck.

Action Code Displays
● E03
Stop the machine immediately.
Check the failure code
● E02
Over speed
Overheat
● E01
Maintenance required
Slide 18 KT404507
If there is a machine failure or if maintenance is necessary, an action code is

displayed to recommend a suitable response.
If more than one failure is present, the most important action code is displayed. The
order of importance, starting from the highest is E03, E02, and E01.
If failures of equal importance occur at the same time the latest one is displayed.
When action codes E02 or E03 occur, the alarm buzzer sounds intermittently and
the central warning lamp illuminates.

Checking Failure Codes

● With action code present
Press arrow right of selection switch 2
Press arrow right switch again for
additional codes
● The six digit code will display on the top line
● The controller that detects the fault will
display at the right
MON. Machine monitor
TM automatic transmission
controller
BK retard control module
● The system that generated the failure
will display on the bottom line.
Slide 19 KT404507

ARSC ( Auto Retard Speed control )

Fixed Down Slope Speed
Similar with Auto cruise feeling
•Concentrating Steering
Operation for operator
•Improve Hauling efficiency
•Reduce Operator Fatigue
ARSC
• Realizing Fixed Slope Descending Speed by ARSC
• Possible to adjust 10～55km/h at Descending Speed
• Tap Operation can adjust ±5km/h, can adjust in Fine
• Retarder Oil Overheating Caution Lamp
• 4 –Wheels Auto Retarder
Speed Up
Speed Down
Slide 20 KT404507 17
Automatic Retard Speed Control (ARSC) automatically actuates the retard

system to maintain the travel speed at a set speed controlled by the
operator.
This system is designed to make retarding easier and more consistent.
For instance, if the ARSC is on, and the set speed is set to 20km/h (12mph),
the ARSC system will automatically apply the retarding effort to slow the
truck.
As the truck descends a grade and attempts to exceed 20km/h (12mph), the
ARSC maintains the set speed without the operator having to use the brake
pedal or manual retarder lever.
Set the travel speed so that the engine speed is above 1800rpm.
If the retarder oil is close to over heating the set speed is automatically
reduced 1 km/h every three seconds.
The set speed will not drop below 10km/h (6 mph).

ASR (Automatic Spin Regulator)
A. The ASR switch is an on/off

rocker switch.
[D]
Depressing the bottom turns the
system on.
Depressing the top of the switch
turns the system off.
B. ASR activation lamp
C. Character display
D. Retarder lever
E. Brake pedal
F. Accelerator pedal
[C] [B]
[A]
[F]
[E]
Slide 21 KT404507
Automatic Spin Regulator (ASR) is a traction control system that helps prevent
slipping of the drive wheels caused by excessive torque.
ASR also provides traction on slippery road surfaces.
When ASR is active, the system monitors individual wheel speeds. If it determines
one of the rear wheels is slipping during acceleration, the brake is applied to the
rear wheel with the higher speed.
If the brake pedal or the retarder lever are actuated during ASR actuation, ASR
actuation will be canceled.
The ASR system is actuated only when the accelerator pedal is being depressed
and the travel speed is 0 to 30km/h.
If the pedal is released while ASR is being actuated, the actuation of the ASR
system is canceled.
If any abnormality occurs in the ASR system, an action code is shown on the
character display.

VHMS
● VHMS Downloading
Inside the Cab
A. Turn the key switch to the ON position.
B. Remove the download connector and
[B]
connect to a laptop computer.
• Download the data.
Ground Level.
C. Turn the key switch to the OFF
position.
D. Open the download box on the left
bumper.
E. Move switch in side the box to the ON
position. When the green light
illuminates the system is ready to
download.
F. After completion of downloading return
the switch to the OFF position.
[D]
[E]
[F]
[A] [C]
Slide 22 KT404507
The VHMS system is a machine management system.

The VHMS controller gathers machine data sent from the other controllers and
sensors installed on the machine.
The data stored in the VHMS controller is sent via personal computer or sent
automatically through a communications satellite to Komatsu.
The data is compiled in the Komatsu server and then analyzed.

Handling Payload Meter (VHMS Built-in Type)
A. Payload display
B. External display lamps [A]

Left side [B] [B]
Right side
C. Download connector
inside cab [C]
(Marked PLM)
[D]
D. Download connector
outside cab
(Marked PLM)
Slide 23 KT404507
The payload meter interprets machine data to calculate payload.

The system uses the following inputs: suspension pressure sensors, inclinometer,
body up switch, transmission shift lever, and speed sensors.
The microcomputer built into the controller uses the inputs to calculate the payload.
The calculated payload is displayed on the character display on the Electronic
Display Panel (EDP).
The external display lamps also display the payload condition.
Data stored in the payload meter can be downloaded to a laptop computer using
special software.
To insure payload accuracy, set the shift lever to N, apply the park brake, and
release the retarder lever before dumping.
Allow the machine to stabilize before dumping.
If the machine is abruptly stopped at the dumping point, it will take a few moments
for the payload display to stabilize.
Dump on flat ground.

External Display Lamps
• The external lamps display the payload as follows.

WARNING!
If the red lamp illuminates
the truck is overloaded
● The green light signifies that additional loading is acceptable.

● The yellow light warns the operators that the load limit is
approaching.
● The red light indicates an overload.
Slide 24 KT404507
Predicted Load Display

When the load changes as each bucket is loaded, the system estimates the total
payload and flashes the appropriate lamp to prevent over loading.
The predicted load display and actual payload display are shown at the same time.

Performing PLM Calibration

● Perform calibration when:
The machine is received
Once every month
When the suspension cylinder oil or nitrogen charge has been changed
When a suspension pressure sensor has been replaced
When the machine has been modified and the Empty Vehicle Weight (EVW) has changed more than
100kg (221lbs) With the engine on and the shift lever in N apply the park brake.
● With the service meter/odometer displayed press the (diamond) of mode select switch (1) and switch to
the operator information screen.
● Press the (right arrow) portion of mode switch (2) until PLM is displayed.
● Press the (diamond) portion of mode selector switch (1) to display the CALIBRATION, Then press the
(diamond) again. The CALIBRATION display will flash.
● Drive the machine at a speed of 10km/h (6mph). When the travel speed becomes stable press the
(diamond) portion of select switch (1) to display CALIBRATION. The CALIBRATION display will flash two
or three times and will change to the Calibration mode.
Slide 25 KT404507
Empty the body before calibration.

Lower the body completely onto the frame.
Place the hoist control in the FLOAT position.
Ensure no existing fault codes are present before calibration is carried out.
During calibration , operate the truck on flat road surfaces.
Travel in a straight line and maintain a speed of 10km/h (6mph).
With the engine on and the shift lever in N apply the park brake.
With the service meter/odometer displayed press the (diamond) of mode select switch (1) and switch to the operator information screen.
Press the (right arrow) portion of mode switch (2) until PLM is displayed.
Press the (diamond) portion of mode selector switch (1) to display the CALIBRATION, Then press the (diamond) again. The CALIBRATION display will flash.
Drive the machine at a speed of 10km/h (6mph). When the travel speed becomes stable press the (diamond) portion of select switch (1) to display
CALIBRATION. The CALIBRATION display will flash two or three times and will change to the Calibration mode.

End of Machine Controls and

Operation
Section 1_4
Slide 26 KT404507

HD1500-7 Introduction & General Service PDF

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HD1500-7 Dump Truck

Komatsu Training and Demonstration

Classroom & Shop Reference Material

Komatsu Training and Demonstration

Introduction and General Service

06/07 Classroom Reference Material 1 of 118

06/07 Classroom Reference Material 2 of 118

HD1500-7 New Features

● New Engine and Damper

● New Electronic Control System

● New Face Seal Hoses

● New DT Electrical Connectors

● New Design Brake Cabinet

● Front Spindles and Suspension Cylinders

06/07 Classroom Reference Material 3 of 118

Commonality of Major Components (1 of 2)

06/07 Classroom Reference Material 4 of 118

Commonality of Major Components (2 of 2)

No. ITEM K25 Tier 1 K25 Tier 2 Remarks

Work equipment has not changed .

06/07 Classroom Reference Material 5 of 118

HD1500-7 Features Reliability improvement

Bladder brake LED lights for Engine output

Utilize Deutsch Front

Front Fuel tank

These changes have been made to increase reliability of the machine.

06/07 Classroom Reference Material 6 of 118

HD1500-7 Features Reliability improvement

Eliminate MOM &

Front brake cooling

06/07 Classroom Reference Material 7 of 118

HD1500-7 Tier 2 version specification

06/07 Classroom Reference Material 8 of 118

HD1500-7 Tier 2 version specification

06/07 Classroom Reference Material 9 of 118

HD1500-7 Tier 2 version specification

06/07 Classroom Reference Material 10 of 118

HD1500 Reliability Enhancement

06/07 Classroom Reference Material 11 of 118

HD1500 Reliability Enhancement

06/07 Classroom Reference Material 12 of 118

HD1500 Reliability Enhancement

06/07 Classroom Reference Material 13 of 118

HD1500 Reliability Enhancement

06/07 Classroom Reference Material 14 of 118

HD1500 Reliability Enhancement

06/07 Classroom Reference Material 15 of 118

HD1500 Reliability Enhancement

Tapered edge of casting

Horse collar casting

06/07 Classroom Reference Material 16 of 118

06/07 Classroom Reference Material 17 of 118

Common Rail Injection (CRI)

Common Rail Injection or commonly known as CRI engine consists of a low

06/07 Classroom Reference Material 18 of 118

● Tier 2 Engine ECM

06/07 Classroom Reference Material 19 of 118

● Electronic Controlled [A]

The transmission is essentially the same externally with improvements mainly to

06/07 Classroom Reference Material 20 of 118

HD1500-7 Improvement items

Reliability improvements to the transmission will increase transmission life.