Komatsu Dump Truck HD465-5 HD605-5 service & repair manual

Description Komatsu Dump Truck HD465-5 HD605-5 service & repair manual

Komatsu Dump Truck HD465-5, HD605-5 pdf workshop service manual + operation & maintenance manual

Serial numbers:
HD465-5 4001 and up, 4626 and up
HD605-5 1013 and up

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

MANUAL CONTENT:
GENERAL
GENERAL ASSEMBLY DRAWING
SPECIFICATIONS
WEIGHT TABLE
LIST OF LUBRICANT AND WATER

STRUCTURE AND FUNCTION
RADIATOR, TORQUE CONVERTER, OIL COOLER, AFTER COOLER, WORK EQUIPMENT OIL COOLER
BRAKE OIL COOLER
POWER TRAIN SKELETON
OUTPUT SHFT
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT SCHEMATICS
TORQUE CONVERTER
LOCKUP SOLENOID VALVE
TRANSMISSION
TRANSMISSION VALVE
ECMV(ELECTRONIC CONTROL MODULATION VALVE
LUBRICATION RELIEF VALVE
FRONT AXLE
REAR AXLE
DIFFERENTIAL
FINAL DRIVE
FRONT BRAKE
REAR BRAKE
PARKING BRAKE
WHEELS
AXLE SUPPORT
STEERING SYSTEM
STEERING WHEEL
STEERING LINKAGE
SUSPENSION SYSTEM
SUSPENSION CYLINDER
AIR PIPING
AIR CIRCUIT DIAGRAM
DESICCANT TYPE AIR DRIER
AIR GOVERNOR
SAFETY VALVE
CHECK VALVE
DOUBLE CHECK VALVE
AUTO DRAIN VALVE
HAND BRAKE VALVE
BRAKE VALVE
REDUCING VALVE
EMERGENCY BRAKE CONTROL VALVE
PARKING BRAKE CONTROL VALVE
RELAY VALVE
PARKING BRAKE RELAY VALVE
QUICK-RELEASE VALVE
PARKING BRAKE CHAMBER
FRONT BRAKE CHAMBER
REAR BRAKE CHAMBER
SLACK ADJUSTER
AIR DRIER (DESICCANT TYPE)
HYDRAULIIC PIPING
HYDRAULIC CIRCUIT DIAGRAM
DUMP BODY CONTROL
HYDRAULIC TANK AND BRAKE COOLING OIL TANK
BRAKE COOLING OIL CONTROL VALVE(BCV)
STEERING CONTROL VALVE
DEMAND VALVE
CROSS-OVER RELIEF VALVE
HOIST VALVE
STEERING CYLINDER
HOIST CYLINDER
ELECTRICAL CIRCUIT DIAGAM
STOP LAMP SWITCH
EXHAUST BRAKE SWITCH
FRONT BRAKE CUT-OFF VALVE
OVERRUN PREVENTION VALVE
EXHAUST BRAKE VALVE
HORN VALVE
PARKING BRAKE SWITCH
AIR CONDIYIONER
ENGINE CONTROL SYSTEM
APS
EXHAUST BRAKE
AUTOMATIC RETARD SPEED CONTROL SYSTEM
AUTOMATIC SHIFT CONTROL SYSYTEM
AUTOMATIC EMERGENCY STEERING SYSTEM
AUTOMATIC SUSPENSION SYSTEM
PAYLOAD METER (PRINTER TYPE)
PAYLOAD METER Ⅱ (CARD TYPE)
MACHINE MONITOR SYSTEM
TILT SWITCH

TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY
ADJUSTING FUEL INJECTION TIMING
BLEEDING AIR FROM FUEL-INJECTION PUMP
ADJUSTING ENGINE STOP MOTOR CABLE
ADJUSTING ACCELERATOR PEDAL
ADJUSTING ENGINE,TRANSIMSSION SPEED SENSORS
TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE
TESTING ECMV HYDRAULIC PRESSURE
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 PRESSURE IN AIR CIRCUIT
INSPECTION OF AIR DRIER (DESICCANT TYPE)
ADJUSTING HOIST LEVER LINKAGE
ADJUSTING BODY POSITIONER
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT
AIR BLEEDING FROM STEERING CYLINDER
ADJUSTING ELECTRONIC MONITOR
ADUSTING Q [FUEL INJECTION AMOUNT] WHEN REPLACING ENGINE CONTROLLER
SETTING ROTARY SWITCH WHEN REPLACING TRANSMISSION CONTROLLER
METHOD OF DELETING DATA FROM ENGINE CONTROLLER, TRANSMISSION CONTROLLER MEMORY(CONTROL FROM MONITOR PANEL)
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM
PROCEDURE FOR OPERATING MODULATION CHECKER
PERFORMONG PM CLINIC USING MANUAL SNAPSHOT(=QUICK PM)
PM-CLINIC SERVICE

TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTNG
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
CONNECTOR PIN ALLOCATION CHART
CONNECTION TABLE FOR CONNECTOR PIN NUKBERS
EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF ELECTRICAL SYSTEM
MONITOR PANEL USER COSDES AND SERVICE MODE FUNCTION
SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS
TABLE OF SERVICE CODES AND USER CODES
METHOD OF USING JUDGMENT TABLE
METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ELECTRONIC GOVERNOR SPECIFICATION G MODE)
TROUBLESHOOTING OF ENGINE SYSTEM (S MODDE)
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE)
TROUBLESHOOTING OF SUSPENSION CONTROLLER SYSTEM (SP MODE)
TROUBLESHOOTING OF PAYLOAD METER (PRINTER TYPE) SYSTEM (LP MODE)
TROUBLESHOOTING OF PAYLOAD METER (CARD TYPE) SYSTEM (LC NODE)
TROUBLESHOOTING OF ABS/ASR SYSTEM
TROUBLESHOOTING OF ARSC [AUTOMATIC RETARDER SPEED CONTROLLER] SYSTEM (R NODE)
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (P MODE)
VHMS MACHINE HEALTH DIAGNOSIS SYSTEM (OPT)

DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
STARTING MOTOR
ALTERNATOR
ENGINE OIL COOLER
AIR CONDITIONER COMPERSSOR
FUEL INJECTION PUMP
AIR COMPRESSOR
AIR CONDITIONER COMPERSSOR
WATER PUMP
AFTERCOOLER CORE
EXHAUST BRAKE CYLINDER
TURBOCHARGER
NOZZLE HOLDER
CYLINDER HEAD
ENGINE
ENGINE FRONT SEAL
ENGINE REAR SEAL
RADIATOR, TORQUE CONVERTER COOLER
BRAKE OIL COOLER
OUTPUT SHAFT
TORQUE CONVERTER, TRANSMISSION
PROCEDURE FOR CENTERING THE ENGINE ASSEMBLY AND TROQUE CONVERTER, TRANSMISSION ASSEMBLY
TORQUE CONVERTER, CONTROL VALVE
TORQUE CONVERTER AND TRANSMISSION
TORQUE CONVERTER, PTO
TRANSMISSION
TRANSMISSION CONTROL VALVE (ECMV ASSEMBLY)
ECMV
DIFFERENTIAL
FRONT WHEEL
REAR WHEEL
FRONT BRAKE CALIPER PAD
FRONT BRAKE CALIPER
FRONT WHEEL HUB
FINAL DRIVE CARRIER
FIANL DRIVE
REAR BRAKE
PARKING BRAKE PAD
PARKING BRAKE CALIPER
FRONT SUSPENSION CYLINDER
VARIABLE DAMPING SELECTOR VALVE
REAR SUSPENSION CYLINDER
AIR GOVERNOR
BRAKE VALVE
PARKING BRAKE CHAMBER
FRONT BRAKE CHAMBER
REAR BRAKE CHAMBER
SLACK ADJUSTER
AIR DRIER (DESICCANT TYPE)
TRANSMISSION LUBRICATION, RETARDER BRAKE PUMP
BRAKE COOLING PUMP
HOIST, STEERING PUMP
EMERGENCY STEERING MOTOR PUMP
BRAKE CONTROL VALVE
STEERING VALVE
DEMAND VALVE
RELIEF VALVE
HOIST VALVE
STEERING CYLINDER
HOIST CYLINDER
BODY
TRANSMISSION CONTROLLER
SUSPENSION CONTROLLER

MAINTENANCE STANDARD
OUTPUT SHAFT
TURQUE CONVERTER VALVE
TORQUE CONVERTER
TRANSMISSION
ECMV
FRONT AXLE
REAR AXLE SUPPORT
DIFFERENTIAL
FINAL DRIVE
FRONT BRAKE
REAR BRAKE
PARKING BRAKE
STEERING LINKAGE
FRONT SUSPENSION CYLINDER
REAR SUSPENSION CYLINDER
PARKING BRAKE CHAMBER
SLACK ADJUSTER
HYDRAULIC PUMP
DEMAND VALVE
CROSS-OVER RELIEF VALVE
HOIST VALVE
STEERING CYLINDER
HOIST CYLINDER

OTHERS
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CONTROL SYSTEM
AUTOMATIC RETARD SPEED CONTROL SYSTEM
AUTOMATIC SHIFT CONTROL SYSTEM
AUTOMATIC SUSPENSION SYSTEM
PAYLOAD METER (PRINTER TYPE)
PAYLOAD METER Ⅱ (CARD TYPE)
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM
VHMS MACHINE HEALTH DIAGNOSIS SYSTEM (OPT)

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