Komatsu Dump Truck HD255-5 service & repair manual

Description Komatsu Dump Truck HD255-5 service & repair manual

Komatsu Dump Truck HD255-5 pdf workshop service manual

Serial numbers:
1001 and up

Specifications, testing, troubleshooting, maintenance, technical documentation, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
GENERAL
DIMENSIONS
SPECIFICATIONS
WEIGHT TABLE
LIST OF LUBRICANTS AND COOLANT

STRUCTURE AND FUNCTION
RADIATOR, TORQUE CONVERTER AND BRAKE OIL COOLER, AND AFTERCOOLER
POWER TRAIN SKELETON
HYDRAULIC CIRCUIT DIAGRAM FOR TORQUE CONVERTER, TRANSMISSION, AND BRAKE COOLING
TORQUE CONVERTER
MAIN RELIEF VALVE
TORQUE CONVERTER VALVE
TRANSMISSION
TRANSMISSION VALVE
ECMV (ELECTRONIC CONTROL MODULATION VALVE)
FRONT AXLE
REAR AXLE
DIFFERENTIAL
FINAL DRIVE
FRONT BRAKE
REAR BRAKE
PARKING BRAKE
STEERING COLUMN
STEERING LINKAGE
DEMAND VALVE
CROSSOVER RELIEF VALVE
STEERING VALVE
FRONT SUSPENSION CYLINDER
REAR SUSPENSION CYLINDER
AIR GOVERNOR
SAFETY VALVE
CHECK VALVE
DOUBLE CHECK VALVE
HAND BRAKE VALVE (RETARDER CONTROL VALVE)
BRAKE VALVE
PARKING BRAKE CONTROL VAVLE
BRAKE RELAY VALVE
BRAKE RELAY VALVE (ACTS ALSO AS EMERGENCY RELAY)
PARKING BRAKE RELAY VALVE
PARKING BRAKE QUICK RELEASE VALVE
SPRING CYLINDER
SLACK ADJUSTER
FRONT BRAKE CHAMBER
REAR BRAKE CHAMBER
AIR DRIER (DRYING AGENT TYPE)
AIR SYSTEM DIAGRAM
HOIST VALVE
HOIST CYLINDER
AUTOMATIC SHIFT CONTROL SYSTEM
AUTOMATIC RETARDER VALVE
HORN VALVE
WIPER SWITCH
SENSORS, SWITCHES
METER LAMPS

TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
SKETCHES OF SPECIAL TOOLS
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY
TESTING AND ADJUSTING ALTERNATOR BELT TENSION AND FAN BELT TENSION
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION
MEASURING ENGINE SPEED
MEASURING ENGINE OIL PRESSURE
MEASURING BOOST PRESSURE
MEASURING EXHAUST GAS TEMPERATURE
MEASURING EXHAUST GAS COLOR
TESTING AND ADJUSTING FUEL INJECTION TIMING
BLEEDING AIR FROM FUEL INJECTION PUMP
HANDLING EQUIPMENT IN FUEL CIRCUIT
RELEASING REMAINING PRESSURE IN FUEL SYSTEM
MEASURING FUEL PRESSURE
BLEEDING AIR FROM FUEL CIRCUIT
REDUCED CYLINDER MODE OPERATION FOR ENGINE
CHECKING FOR LEAKAGE IN FUEL CIRCUIT
ADJUSTING ENGINE STOP MOTOR CABLE
ADJUSTING ACCELERATOR PEDAL
ADJUSTING ENGINE SPEED SENSOR
TESTING OIL PRESSURE OF TORQUE CONVERTER VALVE
TESTING TORQUE CONVERTER STALL SPEED
TESTING BRAKE PRESSURE
BLEEDING AIR FROM BRAKE CIRCUIT
TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE
TESTING WEAR OF FRONT BRAKE PAD
TESTING WEAR OF REAR BRAKE DISC
TESTING AND ADJUSTING SUSPENSION CYLINDER
TESTING AND ADJUSTING AIR GOVERNOR SET PRESSURE
INSPECTION OF AIR DRIER (DESICCANT TYPE)
ADJUSTING HOIST LEVER LINKAGE
ADJUSTING BODY POSITIONER
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT
BLEEDING AIR FROM HYDRAULIC CYLINDER (STEERING CYLINDER)
EMERGENCY TRAVEL WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS
PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT
ADJUSTMENT OF TRANSMISSION
CHECK AFTER ADJUSTMENT OF TRANSMISSION SPEED SENSOR
PM CLINIC CHECK SHEET

TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
TYPE OF CONNECTOR AND POSITION OF INSTALLATION (SERIAL NO. 1001-1200)
CONNECTOR PIN ARRANGEMENT DIAGRAM (SERIAL NO. 1001-1200)
TYPE OF CONNECTOR AND POSITION OF INSTALLATION (SERIAL NO. 1201-1599)
CONNECTOR PIN ARRANGEMENT DIAGRAM (SERIAL NO. 1201-1599)
TYPE OF CONNECTOR AND POSITION OF INSTALLATION (SERIAL NO. 1601 AND UP)
CONNECTOR PIN ARRANGEMENT DIAGRAM (SERIAL NO. 1601 AND UP)
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
METHOD OF USING JUDGEMENT TABLE
METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF LED DISPLAY FOR TRANSMISSION CONTROLLER
HOW TO DELETE FAILURE CODES FOR TRANSMISSION CONTROLLER AND ENGINE CONTROLLER
ACTION TAKEN BY TRANSMISSION CONTROLLER AND PROBLEMS ON MACHINE
TROUBLESHOOTING OF ENGINE SYSTEM (D MODE)
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (G MODE)
TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM FOR START/STOP SYSTEM (ENG MODE)
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE)
TROUBLESHOOTING FOR METER PANEL SYSTEM (E MODE)
TROUBLESHOOTING FOR PILOT LAMP SYSTEM(F MODE)
TROUBLESHOOTING OF AIR SYSTEM ON MACHINE AIR COMPRESSOR(C MODE)
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS(H MODE)
TROUBLESHOOTING OF ARSC [AUTOMATIC RETARDER SPEED CONTROLLER] SYSTEM (R MODE)

DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
STARTING MOTOR
ALTERNATOR
ENGINE OIL COOLER
FUEL INJECTION PUMP
FUEL SUPPLY PUMP
AIR COMPRESSOR
AIR CONDITIONER COMPRESSOR
AIR CONDITIONER CONDENSER
WATER PUMP
AFTERCOOLER CORE
EXHAUST BRAKE CYLINDER
TURBOCHARGER
NOZZLE HOLDER
FUEL INJECTOR
NOZZLE TIP
CYLINDER HEAD
ENGINE FRONT SEAL
ENGINE REAR SEAL
ENGINE
RADIATOR
OIL COOLER
OUTPUT SHAFT
TORQUE CONVERTER, TRANSMISSION
TORQUE CONVERTER
PTO
TRANSMISSION
TRANSMISSION CONTROL VALVE (ECMV)
TRANSMISSION, MAIN RELIEF VALVE
DIFFERENTIAL
FRONT WHEEL
REAR WHEEL
FRONT BRAKE CALIPER PAD
FRONT BRAKE CALIPER
FRONT WHEEL HUB
FINAL DRIVE CARRIER
REAR WHEEL BRAKE
REAR BRAKE
FRONT SUSPENSION CYLINDER
REAR SUSPENSION CYLINDER
AIR GOVERNOR
BRAKE VALVE
PARKING BRAKE SPRING CYLINDER
PARKING BRAKE CHAMBER
FRONT BRAKE CHAMBER
REAR BRAKE CHAMBER
SLACK ADJUSTER
AIR DRIER (DESICCANT TYPE)
TRANSMISSION CONTROL, RETARDER BRAKE COOLING PUMP AND HOIST, STEERING PUMP
EMERGENCY STEERING MOTOR PUMP
STEERING VALVE
DEMAND VALVE
RELIEF VALVE
HOIST VALVE
STEERING CYLINDER
HOIST CYLINDER
DUMP BODY
SHIM OF DUMP BODY
TRANSMISSION CONTROLLER
ENGINE CONTROLLER
SHIFT INDICATOR CONTROLLER
PARKING BRAKE SHOE

MAINTENANCE STANDARD
DAMPER
TORQUE CONVERTER
TRANSMISSION
MAIN RELIEF VALVE
TRANSMISSION VALVE, ECMV
FRONT AXLE
DIFFERENTIAL
FINAL DRIVE
FRONT BRAKE
REAR BRAKE
PARKING BRAKE
REAR BRAKE CHAMBER
FRONT BRAKE CHAMBER
SLACK ADJUSTER
HYDRAULIC PUMP
STEERING, HOIST PUMP
STEERING CYLINDER
DEMAND VAVLE
CROSSOVER RELIEF VALVE
HOIST VALVE
HOIST CYLINDER
STEERING LINKAGE
REAR AXLE SUPPORT
FRONT SUSPENSION CYLINDER
REAR SUSPENSION CYLINDER

OTHERS
AIR CIRCUIT DIAGRAM (STANDARD SPECIFICATION SERIAL NO.:1001-1200)
AIR CIRCUIT DIAGRAM (STANDARD SPECIFICATION SERIAL NO.:1201-1600)
AIR CIRCUIT DIAGRAM (EMERGENCY BRAKE SPECIFICATION SERIAL NO.:1001-1200)
AIR CIRCUIT DIAGRAM (EMERGENCY BRAKE SPECIFICATION SERIAL NO.:1201-1600)
AIR CIRCUIT DIAGRAM (EMERGENCY BRAKE SPECIFICATION SERIAL NO.:1601 AND UP)
HYDRAULIC CIRCUIT DIAGRAM FOR TORQUE CONVERTER, TRANSMISSION, AND BRAKE COOLING
STEERING, HOIST HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO.:1001-1200)
STEERING, HOIST HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO.:1201 AND UP)
ELECTRIC CIRCUIT DIAGRAM (1/2) (SERIAL NO.:1001-1200)
ELECTRIC CIRCUIT DIAGRAM (2/2) (SERIAL NO.:1001-1200)
ELECTRIC CIRCUIT DIAGRAM (1/2) (SERIAL NO.:1201-1600)
ELECTRIC CIRCUIT DIAGRAM (2/2) (SERIAL NO.:1201-1600)
ELECTRIC CIRCUIT DIAGRAM (1/4) (SERIAL NO.:1601-1685)
ELECTRIC CIRCUIT DIAGRAM (2/4) (SERIAL NO.:1601-1685)
ELECTRIC CIRCUIT DIAGRAM (3/4) (SERIAL NO.:1601-1685)
ELECTRIC CIRCUIT DIAGRAM (4/4) (SERIAL NO.:1601-1685)
ELECTRIC CIRCUIT DIAGRAM (1/4) (SERIAL NO.:1686 AND UP)
ELECTRIC CIRCUIT DIAGRAM (2/4) (SERIAL NO.:1686 AND UP)
ELECTRIC CIRCUIT DIAGRAM (3/4) (SERIAL NO.:1686 AND UP)
ELECTRIC CIRCUIT DIAGRAM (4/4) (SERIAL NO.:1686 AND UP)
ELECTRIC CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM
ELECTRIC CIRCUIT DIAGRAM OF AIR CONDITIONER (SERIAL NO.:1001-1200)
ELECTRIC CIRCUIT DIAGRAM OF AIR CONDITIONER (SERIAL NO.: 1201 – 1600)
ELECTRIC CIRCUIT DIAGRAM OF AIR CONDITIONER (SERIAL NO.: 1601 AND UP)

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