Komatsu Dump Truck HD465-8E0 HD605-8E0 service & repair manual

Description Komatsu Dump Truck HD465-8E0 HD605-8E0 service & repair manual

Komatsu Dump Truck HD465-8E0, HD605-8E0 pdf workshop service repair manual

Serial number 35001 and up

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

MANUAL CONTENT:
INDEX AND FOREWORD
FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
SAFETY NOTICE FOR OPERATION
PRECAUTIONS TO PREVENT FIRE
ACTIONS IF FIRE OCCURS
PRECAUTIONS FOR REMOVAL OF DANGEROUS MATERIALS
STEPS NECESSARY TO MEET EXHAUST GAS REGULATIONS
PRECAUTIONS WHEN YOU HANDLE HYDRAULIC EQUIPMENT
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPES
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT
PRECAUTIONS WHEN YOU HANDLE FUEL SYSTEM EQUIPMENT
PRECAUTIONS WHEN YOU HANDLE INTAKE SYSTEM EQUIPMENT
PRACTICAL USEAGE OF KOMTRAX
DISCONNECT AND CONNECT PUSH PULL TYPE QUICK DISCONNECT
PRECAUTIONS FOR DISCONNECT AND CONNECT OF CONNECTORS
PROCEDURE TO DISCONNECT AND CONNECT DEUTSCH CONNECTOR
PROCEDURE TO DISCONNECT AND CONNECT SLIDE LOCK CONNECTOR
PROCEDURE TO DISCONNECT AND CONNECT PULL TO LOCK TYPE CONNECTOR
PROCEDURE TO DISCONNECT AND CONNECT PUSH TO LOCK TYPE CONNECTOR
PROCEDURE TO DISCONNECT AND CONNECT TWIST TYPE CONNECTORS
HOW TO READ ELECTRICAL WIRE CODES
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
STANDARD VAULE TIGHTEN TABLE
CONVERSION TABLE

SPECIFICATIONS
DIAGRAM SPECIFICATION
WEIGHT TABLE
FUEL, COOLANT, AND LUBRICATING OIL

STRUCTURE AND FUNCTION
NOx CONTROL SYSTEM
FUNCTION OF NOx CONTROL SYSTEM
BOOT UP SYSTEM
BOOT UP SYSTEM DIAGRAM
BOOT UP SYSTEM DIAGRAM (For machines equipped with emergency engine stop switch)
SYSTEM IN OPERATION LAMP
BATTERY DISCONNECT SWITCH
ENGINE SYSTEM
ENGINE SYSTEM DIAGRAM
ENGINE CONTROL SYSTEM
AUTOMATIC IDLE STOP SYSTEM
ENGINE COMPONENTS
COOLING SYSTEM
COOLING SYSTEM DIAGRAM
RADIATOR FAN CONTROL SYSTEM
COOLING SYSTEM COMPONENTS
CONTROL SYSTEM
CONTROL SYSTEM DIAGRAM
RETARDER AND HOIST CONTROL SYSTEM
MACHINE MONITOR SYSTEM
REARVIEW MONITOR SYSTEM
KOMTRAX PLUS SYSTEM
PAYLOAD METER SYSTEM
MACHINE LOCK-OUT SYSTEM
CONTROL SYSTEM COMPONENTS
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM DIAGRAM
HYDRAULIC SYSTEM COMPONENTS
POWER TRAIN SYSTEM
POWER TRAIN DIAGRAM
TRANSMISSION CONTROL SYSTEM
GEAR SHIFT CONTROL SYSTEM
DIRECTION CONTROL SYSTEM
KOMATSU TRACTION CONTROL SYSTEM (KTCS)
TRAVEL SPEED LIMITATION SYSTEM
POWER TRAIN COMPONENTS
WORK EQUIPMENT SYSTEM
WORK EQUIPMENT CONTROL
HOIST CONTROL
WORK EQUIPMENT SYSTEM COMPONENTS
STEERING SYSTEM
STEERING SYSTEM DIAGRAM
STEERING SYSTEM FUNCTION
STEERING COLUMN
STEERING LINKAGE
STEERING SYSTEM COMPONENTS
BRAKE SYSTEM
BRAKE SYSTEM DIAGRAM
RETARDER CONTROL
ARSC SYSTEM
BRAKE SYSTEM COMPONENTS
ABS
AUTO-GREASING SYSTEM
AUTO-GREASING SYSTEM DIAGRAM
AUTO-GREASING SYSTEM DIAGRAM
FUNCTION OF AUTO-GREASING SYSTEM
COMPONENT PARTS OF AUTO-GREASING SYSTEM
UNDERCARRIAGE AND FRAME
SUSPENSION
FRONT SUSPENSION
REAR SUSPENSION
SUSPENSION CYLINDER
WORK EQUIPMENT
STRUCTURE OF WORK EQUIPMENT
FUNCTION OF WORK EQUIPMENT
CAB AND ATTACHMENTS
ROPS CAB
CAB MOUNT

STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE: HD465-8E0
STANDARD VALUE TABLE FOR ENGINE: HD605-8E0
STANDARD VALUE TABLE FOR MACHINE
STANDARD VALUE TABLE FOR MACHINE: HD465-8E0
STANDARD VALUE TABLE FOR MACHINE: HD605-8E0
MACHINE SETTING AND PROCEDURE TO MEASURE PERFORMANCE

TEST AND ADJUST
RELATED INFORMATION TO TEST AND ADJUST
TOOLS TO TEST AND ADJUST
DIAGRAM FOR TEST AND ADJUST TOOLS
ENGINE AND COOLING SYSTEM
TEST ENGINE SPEED
TEST BOOST PRESSURE
TESTING EXHAUST GAS TEMPERATURE
TEST EXHAUST GAS COLOR
TEST AND ADJUST VALVE CLEARANCE
COMPRESSION TEST
BLOWBY PRESSURE TEST
TEST ENGINE OIL PRESSURE
EGR VALVE AND VGT OIL PRESSURE TEST
FUEL PRESSURE TEST
FUEL RETURN RATE AND LEAKAGE TEST
BLEEDING AIR FROM FUEL SYSTEM
FUEL CIRCUIT LEAK TEST
SUPPLY PUMP TEST
CYLINDER CUT-OUT MODE
NO-INJECTION CRANKING
CLEAN FUEL DOSER
PROGRAM INJECTOR TRIM CODE VALUE TO ENGINE CONTROLLER
PROGRAM ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER
TEST TORQUE CONVERTER STALL SPEED
RADIATOR FAN SPEED TEST
POWER TRAIN
TEST POWER TRAIN OIL PRESSURE
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR
ADJUST TRANSMISSION INTERMEDIATE SPEED SENSOR
ADJUST TRANSMISSION OUTPUT SPEED SENSOR
CHECK AFTER ADJUSTMENT OF TRANSMISSION SPEED SENSORS
MOVE A MACHINE WITH ELECTRICAL SYSTEM PROBLEMS
STEERING SYSTEM
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE
TEST SUPPLY PRESSURE OF ORBITROL VALVE
TEST STEERING CYLINDER PRESSURE
BLEED AIR FROM STEERING CYLINDER CIRCUIT
BRAKE SYSTEM
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT
TEST WHEEL BRAKE OIL PRESSURE
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR AND CHARGE NITROGEN GAS
TEST BRAKE PERFORMANCE
BLEED AIR FROM BRAKE CIRCUIT
TEST PARKING BRAKE OIL PRESSURE
RELEASE PARKING BRAKE MANUALLY
TEST THE AMOUNT OF FRONT BRAKE PAD WEAR
TEST THE QUANTITY OF REAR BRAKE DISC WEAR
HYDRAULIC SYSTEM
TEST AND ADJUST HOIST CIRCUIT OIL PRESSURE
TEST HOIST CYLINDER SUPPLY PRESSURE
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT
TEST RADIATOR FAN CIRCUIT OIL PRESSURE
TEST AND ADJUST FRONT SUSPENSION CYLINDER
TEST AND ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION)
TEST AND ADJUST REAR SUSPENSION CYLINDER
TEST KTCS CIRCUIT OIL PRESSURE (FOR MACHINE WITH KTCS)
WORK EQUIPMENT
TEST AND ADJUST DUMP BODY POSITIONER SENSOR
LOWER THE BODY MANUALLY
LIFT THE BODY MANUALLY
CAB AND ITS ATTACHMENTS
ADJUST STEERING WHEEL TILT LOCK LEVER
ADJUST RATTLING OPERATORS SEAT
ELECTRICAL SYSTEM
SET AND ADJUST EACH EQUIPMENT
SET AND OPERATE OF MACHINE MONITOR
PROCEDURE FOR STARTING UP KOMTRAX TERMINAL
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER
SETTING DEFAULT OF WIRELESS LAN MODEM
DOWNLOAD KOMTRAX Plus CONTROLLER DATA
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED
ADJUST REARVIEW CAMERA ANGLE
ADJUST OPTICAL AXIS OF HEAD LAMP
ENGINE CONTROLLER VOLTAGE CIRCUIT WORK
BATTERY DISCONNECT SWITCH WORK
TEST DIODES
Pm CLINIC
Pm CLINIC SERVICE
PERFORMING QUICK Pm

TROUBLESHOOTING
RELATED INFORMATION ON TROUBLESHOOTING
GENERAL TROUBLESHOOTING POINTS
TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEMS
SEQUENCE OF EVENTS IN TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
TESTING IN ACCORDANCE WITH TESTING PROCEDURE
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION
PROCEDURE FOR TESTING AND TROUBLESHOOTING
SYMPTOM AND TROUBLESHOOTING NUMBERS
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
CONNECTORS LIST AND LAYOUT
CONNECTOR CONTACT IDENTIFICATION
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
FUSE LOCATION TABLE
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT
PREPARATION OF SHORT SOCKET ADAPTER (FOR FAILURE CODES [CA1883], [CB1883], [CA3135], AND [CB3135])
FAILURE CODES 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
DISASSEMBLE AND ASSEMBLE-RELATED INFORMATION
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOL LIST
DIAGRAMS 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 STARTING MOTOR ASSEMBLY
REMOVE AND INSTALL ALTERNATOR BELT
REMOVE AND INSTALL COOLER ASSEMBLY
REMOVE AND INSTALL RADIATOR
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 OUTPUT SHAFT ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF OUTPUT SHAFT ASSEMBLY
REMOVE AND INSTALL KDPF ASSEMBLY (WITH BRACKET)
REMOVE AND INSTALL KDPF ASSEMBLY (WITHOUT BRACKET)
DISASSEMBLE AND ASSEMBLE OF 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 OF TORQUE CONVERTER ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF TRANSMISSION ASSEMBLY
REMOVE AND INSTALL DIFFERENTIAL ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF 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 OF FINAL DRIVE CARRIER ASSEMBLY
STEERING SYSTEM
DISASSEMBLE AND ASSEMBLE OF 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 OF FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)
DISASSEMBLE AND ASSEMBLE OF FRONT WHEEL HUB ASSEMBLY
HYDRAULIC SYSTEM
DISASSEMBLE AND ASSEMBLE OF HOIST CYLINDER ASSEMBLY
WORK EQUIPMENT
REMOVE AND INSTALL DUMP BODY ASSEMBLY
CAB AND ITS ATTACHMENTS
REMOVE AND INSTALL AIR CONDITIONER ASSEMBLY
REMOVE AND INSTALL OPERATORS SEAT ASSEMBLY
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 KOMTRAX CONTROLLER ASSEMBLY
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY

MAINTENANCE STANDARD
ABBREVIATIONS
ENGINE AND COOLING SYSTEM
MAINTENANCE STANDARD FOR ENGINE MOUNT
MAINTENANCE STANDARD FOR OUTPUT SHAFT
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 AND ITS ATTACHMENTS
MAINTENANCE STANDARD FOR CAB MOUNT

THE OTHER INFORMATION
AIR CONDITIONER SYSTEM
PRECAUTIONS FOR REFRIGERANT
AIR CONDITIONER COMPONENT
SPECIFICATIONS OF AIR CONDITIONER
CONFIGURATION 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
SENSORS FOR AIR CONDITIONER SYSTEM
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER
AIR CONDITIONER SYSTEM DIAGRAM
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS
TESTING AIR LEAKAGE (DUCT)
METHOD FOR TESTING AIR LEAKAGE (DUCT)
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR
TEST VENT (MODE) CHANGEOVER
METHOD FOR TESTING VENT (MODE) CHANGEOVER
TESTING FRESH/RECIRC AIR CHANGEOVER
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT
TEST RELAYS
METHOD FOR TESTING RELAYS
AIR CONDITIONER TROUBLESHOOTING CHART
INFORMATION DESCRIBED 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 USING GAUGE PRESSURE
CONNECTION OF SERVICE TOOL
METHOD FOR CONNECTING SERVICE TOOL
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS
HANDLE COMPRESSOR OIL
METHOD FOR REPLACING DESICCANT

CIRCUIT DIAGRAMS
HYDRAULIC CIRCUIT DIAGRAM
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM
POWER TRAIN HYDRAULIC DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL DIAGRAMS SYMBOLS

Engine SAA6D170E–7 workshop service repair manual