Komatsu Dump Truck HD465-7R HD605-7R service & repair manual

Description Komatsu Dump Truck HD465-7R HD605-7R service & repair manual

Komatsu Dump Truck HD465-7R, HD605-7R pdf workshop service repair manual

Serial numbers:
HD465-7R 15001 and up, 16132 and up
HD605-7R 15001 and up

Technical data, specifications, maintenance, testing, troubleshooting, electrical wiring diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and foreword
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

Specification
Specification and technical data
Specification drawing
Weight table
Fuel, coolant and lubricants

Structure, function and maintenance standard
Engine and cooling system
Radiator, torque converter oil cooler, after cooler, work equipment oil cooler, fuel cooler
Fuel system
Brake oil cooler
Output shaft
Power train, Part 1
Power train skeleton
Drive shaft
Torque converter and transmission hydraulic piping
Brake cooling oil control valve (BCV)
Torque converter
Torque converter valve
Transmission
Transmission control valve
ECMV
Power train, Part 2
Axle
Differential
Final drive
Wheels
Steering system
Steering column
Steering linkage
Brake system
Brake piping
Brake valve
Secondary brake valve
Relay valve
Front brake off valve
Accumulator charge valve
Accumulator
Slack adjuster
Brake
Parking brake solenoid valve
Undercarriage and frame
Suspension
Suspension cylinder
Rear axle support
Hydraulic system
Steering and hoist hydraulic piping
Dump body control
Hydraulic tank
Steering valve
Crossover relief valve
Steering cylinder
Steering control valve
Hoist valve
EPC valve
Hoist cylinder
Hydraulic pump
Work equipment (Body)
Auto greasing system
Cab and its attachments
ROPS cab
Air conditioner
Rear view monitor
Electrical system, Part 1
Machine monitor system
Electrical system, Part 2
Automatic shift control system
Transmission controller
External power supply heater
Automatic emergency steering system
Automatic suspension system
Retarder control system
Battery disconnect switch
Dump control lever
Electrical system, Part 3
Payload meter (Card type)
Electrical system, Part 4
VHMS controller related
ASR system (If equipped)
Sensors, switches
Electrical system, Part 5
Mobile communication terminal

Standard value table
Standard service value table
Standard value table for engine
Standard value table for machine

Testing and adjusting
Tools for testing, adjusting, and troubleshooting
Sketch of special tool
Testing engine speed
Testing air supply pressure (boost pressure)
Testing exhaust temperature
Testing exhaust gas color
Adjustment of valve clearance
Testing of compression pressure
Testing blow-by pressure
Testing engine oil pressure
Handling of fuel system devices
Releasing residual pressure from fuel system
Testing of fuel pressure
Cylinder cut-out mode operation
No-injection cranking
Testing of fuel return rate and fuel leakage
Bleeding air from fuel circuit
Testing the fuel circuit for leakage
Replacing and adjusting of fan belt
Replacing and adjusting of alternator and air conditioner compressor belt
Testing torque converter stall speed
Testing power train oil pressure
Adjusting transmission speed sensor
Testing and adjusting brake oil pressure
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas
Testing brake performance
Releasing remaining pressure in brake circuit
Bleeding air from brake circuit
Testing wear of front brake pad
Testing wear of rear brake disc
Method of releasing parking brake in an emergency
Testing and adjusting front suspension cylinder
Testing and adjusting rear suspension cylinder
Testing and adjusting front suspension cylinder (Automatic suspension specification)
Testing and adjusting hydraulic pressure in steering, hoist circuit
Testing and adjusting oil pressure in dump EPC circuit
Air bleeding from steering cylinder
Procedure for raising dump body in emergency
Procedure for lowering dump body in emergency
Adjusting body positioner sensor
Resetting method for dump body seating control
Adjustment of tilt lock lever of steering wheel
Handling of voltage circuit of engine controller
Adjusting transmission controller
Method for emergency escape at electrical system failure
Setting and adjusting of devices
Special functions of machine monitor (EMMS)
Request for opening ORBCOMM terminal
VHMS controller initial setting procedure
Using method of KOMTRAX functions of ORBCOMM terminal
Precautions for replacing VHMS controller
Pm Clinic check sheet
Initial setting of payload meter
Setting of payload meter built in VHMS
Setting of card-type payload meter (PLM- ) after installation or replacement
Setting of mobile communication terminal

Troubleshooting
Failure code table and fuse locations
Failure codes table
Fuse locations
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Check before troubleshooting
Classification and procedures for troubleshooting
Contents of troubleshooting table
Troubleshooting method for disconnecting wiring harness of pressure sensor system
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure code
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
General information on disassembly and assembly
How to read this manual
List of adhesives
Special tool list
Sketches of special tools
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of engine assembly
Removal and installation of radiator assembly
Removal and installation of damper assembly
Disassembly and assembly of damper assembly
Removal and installation of brake and power train oil cooler assembly
Power train, Part 1
Removal and installation of torque converter and transmission assembly
Separation and coupling of transmission assembly and torque converter assembly
Disassembly and assembly of torque converter and control valve assembly
Disassembly and assembly of torque converter assembly
Disassembly and assembly of transmission assembly
Removal and installation of transmission control valve assembly (ECMV assembly)
Disassembly and assembly of transmission control valve assembly (ECMV assembly)
Power train, Part 2
Removal and installation of differential assembly
Disassembly and assembly of differential assembly
Removal and installation of final drive carrier assembly
Disassembly and assembly of final drive carrier assembly
Disassembly and assembly of front wheel hub assembly
Steering system
Disassembly and assembly of steering cylinder assembly
Brake system
Removal and installation of front brake caliper pads
Removal and installation of front brake calipers assembly
Disassembly and assembly of front brake calipers assembly
Removal and installation of final drive and rear brake assembly
Removal and installation of final drive, rear brake, and parking brake assembly
Disassembly and assembly of final drive, rear brake, and parking brake assembly
Undercarriage and frame
Removal and installation of front wheel assembly
Removal and installation of rear wheel assembly
Removal and installation of front suspension cylinder assembly
Disassembly and assembly of front suspension cylinder assembly (cylinder with buffer ring)
Removal and installation of rear suspension cylinder assembly
Disassembly and assembly of rear suspension cylinder assembly (cylinder with buffer ring)
Hydraulic system
Disassembly and assembly of hoist cylinder assembly
Body
Removal and installation of body assembly
Cab and its attachments
Disassembly and assembly of operator's seat assembly
Removal and installation of air conditioner unit assembly
Electrical system, Part 1
Removal and installation of engine controller assembly
Removal and installation of transmission controller assembly
Removal and installation of retarder controller assembly
Electrical system, Part 2
Removal and installation of mobile communication terminal
Removal and installation of DC/DC converter
Removal and installation of mobile communication terminal harness

Diagrams and drawings
Hydraulic diagrams and drawings
Power train hydraulic circuit diagram
Steering and hoist hydraulic circuit diagram
Brake hydraulic circuit diagram
Electrical diagrams and drawings
Electrical circuit diagram inside cab
Electrical circuit diagram outside cab
Electrical circuit diagram for VHMS
Electrical circuit diagram for ASR (If equipped)
Electrical circuit diagram for ABS (If equipped)
Air conditioner electrical circuit diagram
Electrical circuit diagram for auto greasing (If equipped)
Electrical circuit diagram of mobile communication terminal (if equipped)
Connectors table and arrangement drawing

Engine SAA6D170E-5 workshop service manual