Komatsu Dump Truck HD465-8 HD605-8 service & repair manual

Description Komatsu Dump Truck HD465-8 HD605-8 service & repair manual

Komatsu Dump Truck HD465-8, HD605-8 pdf workshop service repair manual

Serial numbers:
30001 and up

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

MANUAL CONTENT:
Index and Foreword
Abbreviation List
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions to Prevent Fire
Procedures If Fire Occurs
Precautions When You Dispose of Waste Materials
Engine Technology to Conform Exhaust Gas Emission
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Precautions When You Handle Fuel System Equipment
Precautions When You Handle Intake System Equipment
Practical Use of KOMTRAX
Disconnect and Connect Push-Pull Type Coupler
Precautions for Disconnection and Connection of Connectors
How to Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
How to Disconnect and Connect Connector with Lock to Pull
How to Disconnect and Connect Connector with Lock to Push
How to Disconnect and Connect Connector with Housing to Rotate
How to Read the Codes for Electric Cable
Explanation of Terms for Maintenance Standard
Standard Tightening Torque Table
Conversion Table

Specifications
Specification Drawing
Weight Table
Fuel, Coolant, Lubricant

Structure and Function
Boot-up System
Layout Drawing of Boot-up System
Layout Drawing of Boot-up System (Machine with Emergency Engine Stop Switch)
System Operating Lamp System
Battery Disconnect Switch
Engine Shutdown Secondary Switch
Engine System
Layout Drawing of Engine System
Engine Control System
Engine Power Mode Selector System (Machine with Engine Power Mode Selector System)
Automatic Idle Stop System
Component Parts of Engine System
Cooling System
Layout Drawing of Cooling System
Radiator Fan Control System
Component Parts of Cooling System
Control System
Layout Drawing of Control System
Layout Drawing of Control System (Machine with Mobile Communication Terminal)
Retarder and Hoist Control System
Machine Monitor System
Rearview Monitor System
KOMTRAX Plus System
Payload Meter System
Machine Lock-out System
Drowsiness Detection System
Component Parts of Control System
Hydraulic System
Layout Drawing of Hydraulic System
Component Parts of Hydraulic System
Power Train System
Layout Drawing of Power Train System
Transmission Control System
Gear Shift Control System
Direction Control System
Komatsu Traction Control System (KTCS)
Travel Speed Limitation System
Component Parts of Power Train System
Work Equipment System
Work Equipment Control
Hoist Control
Component Parts of Work Equipment System
Steering System
Layout Drawing of Steering System
Function of Steering System
Steering Column
Steering Linkage
Component Parts of Steering System
Brake System
Layout Drawing of Brake System
Retarder Control
ARSC System
Component Parts of Brake System
ABS
Auto-Greasing System
Layout Drawing of Auto-Greasing System
Auto-Greasing System Diagram
Function of Auto-Greasing System
Auto-Greasing System
Undercarriage and Frame
Suspension
Front Suspension
Rear Suspension
Suspension Cylinder
Work Equipment
Structure of Work Equipment
Function of Work Equipment
CAB Related Parts
ROPS CAB
CAB Mount

Standard Value Table
Standard Value Table for Engine
Standard Value Table for Engine: HD465-8
Standard Value Table for Engine: HD605-8
Standard Value Table for Machine
Standard Value Table for Machine: HD465-8
Standard Value Table for Machine: HD605-8
Machine Posture and Procedures to Measure Performance

Testing and Adjusting
Precautions Before Work
Related Information on Testing and Adjusting
Tools for Testing and Adjusting
Sketch of Tools for Testing and Adjusting
Engine and Cooling System
Examine Engine Speed
Examine Boost Pressure
Examine Exhaust Gas Temperature
Examine Exhaust Gas Color
Examine Mass Air Flow and Temperature Sensor
Examine and Adjust Valve Clearance
Examine Compression Pressure
Examine Blowby Pressure
Examine Engine Oil Pressure
Examine EGR Valve and VGT Oil Pressure
Examine Fuel Pressure
Examine Fuel Return Rate and Leakage
Bleed Air from Fuel System
Examine Fuel Circuit for Leakage
Examine Supply Pump
Handle Cylinder Cut-out Mode Operation
Handle No-Injection Cranking Operation
Clean Fuel Doser
Write Injector Compensation Value to Engine Controller
Write Correction for Ash in Soot Accumulation to Engine Controller
Examine Torque Converter Stall Speed
Examine Radiator Fan Speed
Power Train
Examine Power Train Oil Pressure
Adjust Transmission Input Shaft Speed Sensor
Adjust Transmission Intermediate Shaft Speed Sensor
Adjust Transmission Output Shaft Speed Sensor
Examine After You Adjust Transmission Speed Sensor
Move Machine Which Has a Trouble in Electrical System
Steering System
Examine and Adjust Steering Circuit Oil Pressure
Examine Supply Pressure of Orbitrol Valve
Examine Steering Cylinder Pressure
Bleed Air from Steering Cylinder Circuit
Brake System
Release Remained Pressure in Brake Accumulator Circuit
Examine Wheel Brake Oil Pressure
Examine and Adjust Brake Accumulator Charge Pressure
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Nitrogen Gas
Examine Brake Performance
Bleed Air from Brake Circuit
Examine Parking Brake Oil Pressure
Release Parking Brake Manually
Examine Front Brake Pad Wear Volume
Examine Rear Brake Disc Wear Volume
Hydraulic System
Examine and Adjust Hoist Circuit Oil Pressure
Examine Hoist Cylinder Source Pressure
Examine Oil Pressure of Hoist EPC Valve Circuit
Examine Radiator Fan Circuit Oil Pressure
Examine and Adjust Front Suspension Cylinder
Examine and Adjust Front Suspension Cylinder (Automatic Suspension Specification)
Examine and Adjust Rear Suspension Cylinder
Examine KTCS Circuit Oil Pressure (For Machine with KTCS)
Work Equipment
Examine and Adjust Dump Body Positioner Sensor
Lower Dump Body Manually
Lift Dump Body Manually
CAB Related Parts
Adjust Tilt Lock Lever of Steering Wheel
Adjust Play of Operator Seat
Electrical System
Set and Adjust Each Equipment
Set and Operate Machine Monitor
How to Start Up KOMTRAX Terminal
How to Stop Use of KOMTRAX Terminal
How to Stop Use of KOMTRAX Terminal (Machine with Mobile Communication Terminal)
Default Setting of KOMTRAX Plus Controller
Default Setting of Wireless LAN Modem
Download KOMTRAX Plus Controller Data
Adjust When KOMTRAX Plus Controller Is Replaced
Adjust After Replacement of Wireless LAN Modem
Setting of Mobile Communication Terminal
Set Driver Status Monitor
Adjust Rearview Camera Angle
Adjust Optical Axis of Head Lamp
Handle Voltage Circuit of Engine Controller
Handle Battery Disconnect Switch
Battery Disconnect Switch (Machine with Mobile Communication Terminal)
Examine Diodes
Pm Clinic
Pm Clinic Service
Perform Quick Pm

Troubleshooting
Precautions Before Work
Related Information to Troubleshooting
General Troubleshooting Points
Troubleshooting Points for Aftertreatment System
Sequence of Events in Troubleshooting
Checks Before Troubleshooting
Inspection Procedure Before Troubleshooting
Test in Accordance with Testing Procedure
Preparation for Troubleshooting of Electrical System
Procedure for Troubleshooting
Symptom and Troubleshooting Numbers
Information Shown in Troubleshooting Table
Connector List and Layout
Connector Contact Connection Table
T-Branch Box and T-Branch Adapter Table
Fuse Location Table
Precautions When You Clean and Replace KDPF (KCSF and KDOC)
Prepare Troubleshoot Machine Monitor
Procedure to Make Harness Checker on Machine Monitor LCD Unit
Prepare of Short Socket Adapter (For Failure Codes [CA1883], [CB1883], [CA3135] and [CB3135])
Failure Code Table
Troubleshooting by Failure Code (Display of Code)
Troubleshooting of Electrical System (E-Mode)
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
Troubleshooting of Engine (S-Mode)

Disassembly and Assembly
Precautions Before Work
Related Information on Disassembly and Assembly
How to Read This Manual
Coating Materials List
Special Tool List
Sketches of Special Tools
Engine and Cooling System
Remove and Install Supply Pump Assembly
Remove and Install Injector Assembly
Remove and Install Fuel Doser Assembly
Remove and Install Cylinder Head Assembly
Remove and Install EGR Valve Assembly
Remove and Install EGR Cooler Assembly
Remove and Install Starter Assembly
Remove and Install Alternator Belt
Remove and Install Cooler Assembly
Remove and Install Radiator Core
Remove and Install Cooling Fan and Fan Motor Assembly
Remove and Install Aftercooler Assembly
Remove and Install Engine Assembly
Remove and Install Engine Front Oil Seal
Remove and Install Engine Rear Oil Seal
Remove and Install Damper Assembly
Disassemble and Assemble Damper Assembly
Remove and Install KDPF Assembly (with Bracket)
Remove and Install KDPF Assembly (Without Bracket)
Disassemble and Assemble KDPF Assembly
Remove and Install KCCV Assembly
Remove and Install Air Cleaner Assembly
Remove and Install Air Conditioner Compressor Assembly
Power Train
Remove and Install Torque Converter and Transmission Assembly
Disconnect and Connect Torque Converter and Transmission Assembly
Disassemble and Assemble Torque Converter Assembly
Disassemble and Assemble Transmission Assembly
Remove and Install Differential Assembly
Disassemble and Assemble Differential Assembly
Remove and Install Front Brake Caliper Pad
Remove and Install Front Brake Caliper Assembly
Disassemble and Assemble of Front Brake Caliper Assembly
Remove and Install Final Drive and Rear Brake Assembly
Remove and Install Final Drive, Rear Brake and Parking Brake Assembly
Disassemble and Assemble of Final Drive, Rear Brake and Parking Brake Assembly
Remove and Install Final Drive Carrier Assembly
Disassemble and Assemble Final Drive Carrier Assembly
Steering System
Disassemble and Assemble Steering Cylinder Assembly
Undercarriage and Frame
Remove and Install Front Wheel Assembly
Remove and Install Rear Wheel Assembly
Remove and Install Front Suspension Cylinder Assembly
Disassemble and Assemble Front Suspension Cylinder Assembly (Cylinder with Buffer Ring)
Remove and Install Rear Suspension Cylinder Assembly
Disassemble and Assemble Rear Suspension Cylinder Assembly (Cylinder with Buffer Ring)
Disassemble and Assemble of Front Wheel Hub Assembly
Hydraulic System
Disassemble and Assemble Hoist Cylinder Assembly
Work Equipment
Remove and Install Dump Body Assembly
CAB Related Parts
Remove and Install Air Conditioner Unit Assembly
Remove and Install Operator Seat Assembly
How to Remove and Install Seat Belt
Electrical System
Remove and Install Engine Controller Assembly
Remove and Install Retarder and Hoist Controller Assembly
Remove and Install ABS Controller Assembly
Remove and Install Transmission Controller Assembly
Remove and Install Machine Monitor Assembly
Remove and Install Monitor Controller Assembly
Remove and Install Mass Air Flow and Temperature Sensor
Remove and Install KCCV Crankcase Pressure Sensor
Remove And Install KOMTRAX Plus Controller Assembly
Remove and Install Mobile Communication Terminal
Remove and Install DC-DC Converter
Remove and Install Mobile Communication Terminal Wiring Harness
Remove and Install KOMTRAX Terminal Assembly
Remove and Install Wireless LAN Unit Assembly
Remove and Install Driver Status Monitor
Remove and Install Translator Controller
Remove and Install Drowsiness Detection Camera
Remove and Install Drowsiness Alarm Buzzer
Remove and Install Drowsiness Detection Wiring Harness

Maintenance Standard
Engine and Cooling System
Maintenance Standard for Engine Mount
Maintenance Standard for Damper
Maintenance Standard for Cooling Fan Pump
Maintenance Standard for Servo Valve for Cooling Fan Pump
Maintenance Standard for Cooling Fan Motor
Power Train
Maintenance Standard for Drive Shaft
Maintenance Standard for Torque Converter and Transmission Mount
Maintenance Standard for Torque Converter and PTO
Maintenance Standard for Torque Converter Valve
Maintenance Standard for Transmission
Maintenance Standard for Transmission Control Valve
Maintenance Standard for H, L, 4th, 3rd, R, 2nd, and 1st ECMV
Maintenance Standard for Lockup Clutch ECMV
Maintenance Standard for Front Axle
Maintenance Standard for Rear Axle
Maintenance Standard for Differential
Maintenance Standard for Final Drive
Steering System
Maintenance Standard for Steering Column
Maintenance Standard for Steering Linkage
Maintenance Standard for Demand Valve
Maintenance Standard for Steering Cylinder
Brake System
Maintenance Standard for Slack Adjuster
Maintenance Standard for Front Brake
Maintenance Standard for Rear Brake
Undercarriage and Frame
Maintenance Standard for Front Suspension Cylinder
Maintenance Standard for Rear Suspension Cylinder
Hydraulic System
Maintenance Standard for Steering and Hoist Pump
Maintenance Standard for Servo Valve for Steering and Hoist Pump
Maintenance Standard for Power Train and Brake Cooling Duplex Pump
Maintenance Standard for Brake Cooling, Control Triple Pump
Maintenance Standard for Hoist Valve
Work Equipment
Maintenance Standard for Hoist Cylinder
CAB Related Parts
Maintenance Standard for CAB Mount

Others
Precautions Before Work
Air Conditioner System 
Precautions for Refrigerant
Air Conditioner Component
Specifications of Air Conditioner
Structure and Function of Refrigeration Cycle
Outline of Refrigeration Cycle
Component Parts of Air Conditioner System
Air Conditioner Unit
Component Parts of Air Conditioner Unit
Air Conditioner Controller
Compressor
Condenser
Air Conditioner Related Sensors
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner
Circuit Diagram and Configuration of Connector Pins of Air Conditioner
System Diagram of Air Conditioner
Input and Output Signals of Air Conditioner Controller
Locations of Air Conditioner Parts and Layout of Connectors
Examine Air Leakage (Duct)
How to Examine Air Leakage (Duct)
Examine Air Conditioner with Self-Diagnosis Function
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor
Examine Vent (Mode) Changeover
How to Examine Vent (Mode) Changeover
Examine Fresh/Recirc Air Changeover
How to Examine Fresh/Recirc Air Changeover
Examine Refrigerant (Dual) Pressure Switch
How to Examine Refrigerant (Dual) Pressure Switch
Examine Relay
How to Examine Relay
Air Conditioner Troubleshooting Chart
Information Shown in Troubleshooting Table
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)
A-4 Troubleshooting for Fresh/Recirc Air Changeover
Troubleshooting by Gauge Pressure
Connect Service Tool
How to Connect Service Tool
Precautions for Disconnection and Connection of Air Conditioner Piping
Handle Compressor Oil
How to Replace Desiccant

Circuit Diagrams
Abbreviation List
Hydraulic Circuit Diagram
Symbols Used in Hydraulic Circuit Diagram
Power Train Hydraulic Circuit Diagram
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram

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