Komatsu HD255-5 Dump Truck Shop Manual SEBM009118 PDF

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Komatsu HD255-5 Dump Truck Shop Manual SEBM009118 – PDF DOWNLOAD

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Komatsu HD255-5 Dump Truck Shop Manual SEBM009118 – PDF DOWNLOAD 

Language : English
Pages : 1038
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu HD255-5 Dump Truck Shop Manual SEBM009118 – PDF DOWNLOAD 

MACHINE MODEL          SERIAL NUMBER
HD255-5                            1001 and up

COVER 1
CONTENTS 2
01 GENERAL 27
DIMENSIONS 28
SPECIFICATIONS 30
WEIGHT TABLE 36
LIST OF LUBRICANTS AND COOLANT 37
10 STRUCTURE AND FUNCTION 39
RADIATOR, TORQUE CONVERTER AND BRAKE OIL COOLER, AND AFTERCOOLER 40
POWER TRAIN SKELETON 42
HYDRAULIC CIRCUIT DIAGRAM FOR TORQUE CONVERTER, TRANSMISSION, AND BRAKE COOLING 44
TORQUE CONVERTER 46
MAIN RELIEF VALVE 48
TORQUE CONVERTER VALVE 50
TRANSMISSION 55
TRANSMISSION VALVE 60
ECMV (ELECTRONIC CONTROL MODULATION VALVE) 61
FRONT AXLE 66
REAR AXLE 67
DIFFERENTIAL 68
FINAL DRIVE 69
FRONT BRAKE 70
REAR BRAKE 71
PARKING BRAKE 72
STEERING COLUMN 74
STEERING LINKAGE 76
DEMAND VALVE 77
CROSSOVER RELIEF VALVE 80
STEERING VALVE 81
FRONT SUSPENSION CYLINDER 82
REAR SUSPENSION CYLINDER 83
AIR GOVERNOR 84
SAFETY VALVE 86
CHECK VALVE 86
DOUBLE CHECK VALVE 87
HAND BRAKE VALVE (RETARDER CONTROL VALVE) 88
BRAKE VALVE 90
PARKING BRAKE CONTROL VAVLE 93
BRAKE RELAY VALVE 95
BRAKE RELAY VALVE (ACTS ALSO AS EMERGENCY RELAY) 97
PARKING BRAKE RELAY VALVE 104
PARKING BRAKE QUICK RELEASE VALVE 106
SPRING CYLINDER 107
SLACK ADJUSTER 108
FRONT BRAKE CHAMBER 109
REAR BRAKE CHAMBER 110
AIR DRIER (DRYING AGENT TYPE) 111
AIR SYSTEM DIAGRAM 113
HOIST VALVE 114
HOIST CYLINDER 115
AUTOMATIC SHIFT CONTROL SYSTEM 116
AUTOMATIC RETARDER VALVE 126
HORN VALVE 128
WIPER SWITCH 128
SENSORS, SWITCHES 129
METER LAMPS 140
20 TESTING AND ADJUSTING 151
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 152
STANDARD VALUE TABLE FOR CHASSIS 155
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM 163
TESTING AND ADJUSTING 175
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING 176
SKETCHES OF SPECIAL TOOLS 178
ADJUSTING VALVE CLEARANCE 180
MEASURING COMPRESSION PRESSURE 182
MEASURING BLOW-BY 184
TESTING AND ADJUSTING ALTERNATOR BELT TENSION AND FAN BELT TENSION 186
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 187
MEASURING ENGINE SPEED 188
MEASURING ENGINE OIL PRESSURE 190
MEASURING BOOST PRESSURE 191
MEASURING EXHAUST GAS TEMPERATURE 192
MEASURING EXHAUST GAS COLOR 193
TESTING AND ADJUSTING FUEL INJECTION TIMING 194
BLEEDING AIR FROM FUEL INJECTION PUMP 196
HANDLING EQUIPMENT IN FUEL CIRCUIT 197
RELEASING REMAINING PRESSURE IN FUEL SYSTEM 197
MEASURING FUEL PRESSURE 198
BLEEDING AIR FROM FUEL CIRCUIT 199
REDUCED CYLINDER MODE OPERATION FOR ENGINE 201
CHECKING FOR LEAKAGE IN FUEL CIRCUIT 202
ADJUSTING ENGINE STOP MOTOR CABLE 203
ADJUSTING ACCELERATOR PEDAL 204
ADJUSTING ENGINE SPEED SENSOR 205
TESTING OIL PRESSURE OF TORQUE CONVERTER VALVE 206
TESTING TORQUE CONVERTER STALL SPEED 207
TESTING BRAKE PRESSURE 208
BLEEDING AIR FROM BRAKE CIRCUIT 209
TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE 210
TESTING WEAR OF FRONT BRAKE PAD 211
TESTING WEAR OF REAR BRAKE DISC 212
TESTING AND ADJUSTING SUSPENSION CYLINDER 213
TESTING AND ADJUSTING AIR GOVERNOR SET PRESSURE 218
INSPECTION OF AIR DRIER (DESICCANT TYPE) 219
ADJUSTING HOIST LEVER LINKAGE 221
ADJUSTING BODY POSITIONER 222
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT 223
BLEEDING AIR FROM HYDRAULIC CYLINDER (STEERING CYLINDER) 226
EMERGENCY TRAVEL WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM 227
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM 228
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS 234
PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT 236
ADJUSTMENT OF TRANSMISSION 237
CHECK AFTER ADJUSTMENT OF TRANSMISSION SPEED SENSOR 238
PM CLINIC CHECK SHEET 239
TROUBLESHOOTING 243
POINTS TO REMEMBER WHEN TROUBLESHOOTING 244
SEQUENCE OF EVENTS IN TROUBLESHOOTING 245
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 246
CHECKS BEFORE TROUBLESHOOTING 254
TYPE OF CONNECTOR AND POSITION OF INSTALLATION (SERIAL NO 1001-1200) 256
CONNECTOR PIN ARRANGEMENT DIAGRAM (SERIAL NO 1001-1200) 260
TYPE OF CONNECTOR AND POSITION OF INSTALLATION (SERIAL NO 1201-1599) 264
CONNECTOR PIN ARRANGEMENT DIAGRAM (SERIAL NO 1201-1599) 268
TYPE OF CONNECTOR AND POSITION OF INSTALLATION (SERIAL NO 1601 AND UP) 272
CONNECTOR PIN ARRANGEMENT DIAGRAM (SERIAL NO 1601 AND UP) 276
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 282
METHOD OF USING JUDGEMENT TABLE 305
METHOD OF USING TROUBLESHOOTING CHARTS 306
METHOD OF LED DISPLAY FOR TRANSMISSION CONTROLLER 308
HOW TO DELETE FAILURE CODES FOR TRANSMISSION CONTROLLER AND ENGINE CONTROLLER 312
ACTION TAKEN BY TRANSMISSION CONTROLLER AND PROBLEMS ON MACHINE 314
TROUBLESHOOTING OF ENGINE SYSTEM (D MODE) 363
METHOD OF USING TROUBLESHOOTING CHART 364
D-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 368
D-2 ENGINE DOES NOT START 369
(1) ENGINE DOES NOT TURN 369
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 370
(3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 371
D-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 372
D-4 ENGINE STOPS DURING OPERATIONS 373
D-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 374
D-6 ENGINE LACKS OUTPUT (NO POWER) 375
D-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 376
D-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 377
D-9 OIL BECOMES CONTAMINATED QUICKLY 378
D-10 FUEL CONSUMPTION IS EXCESSIVE 379
D-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 380
D-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 381
D-13 OIL LEVEL RISES (WATER, FUEL IN OIL) 382
D-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 383
D-15 ABNORMAL NOISE IS MADE 384
D-16 VIBRATION IS EXCESSIVE 385
TROUBLESHOOTING OF ENGINE SYSTEM (D MODE) 387
POINTS TO REMEMBER WHEN TROUBLESHOOTING 388
METHOD OF USING TROUBLESHOOTING CHARTS 389
D-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 392
D-2 ENGINE DOES NOT START 393
D-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 396
D-4 ENGINE STOPS DURING OPERATIONS 397
D-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 398
D-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 399
D-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 400
D-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 401
D-9 OIL BECOMES CONTAMINATED QUICKLY 402
D-10 FUEL CONSUMPTION IS EXCESSIVE 403
D-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN) 404
D-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 405
D-13 OIL LEVEL RISES (WATER, FUEL IN OIL) 406
D-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 407
D-15 ABNORMAL NOISE IS MADE 408
D-16 VIBRATION IS EXCESSIVE 409
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (G MODE) 411
ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING 413
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED 416
ENGINE CONTROLLER RELATED JUDGEMENT TABLE 424
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM 426
G-1 ERROR CODE [C01b] [ABNORMALITY IN NE REVOLUTION SENSOR SYSTEM] 428
G-2 ERROR CODE [C01C] [ABNORMALITY IN G REVOLUTION SENSOR SYSTEM] 429
G-3 ERROR CODE [C020] [ABNORMALITY IN MODEL SELECTION SYSTEM] 430
G-4 ERROR CODE [C022] [OVERRUN] 431
G-5 ERROR CODE [C023] [OVERHEAT] 431
G-6 ERROR CODE [C024] [DROP IN OIL PRESSURE] 432
G-7 ERROR CODE [C030] [ABNORMALITY IN IDLING VALIDATION SIGNAL SYSTEM] 433
G-8 ERROR CODE [C031] [ABNORMALITY IN ACCELERATOR SENSOR SYSTEM] 435
G-9 ERROR CODE [C034] [ABNORMALITY IN HIGH ENGINE COOLANT TEMPERATURE SENSOR SYSTEM] 437
G-10 ERROR CODE [C036] [ABNORMALITY IN OIL PRESSURE SWITCH SYSTEM] 438
G-11 ERROR CODE [C03C] [ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM] 440
G-12 ERROR CODE [C03d] [ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM] 441
G-13 ERROR CODE [C050] [ABNORMALITY IN PREHEATING RELAY CONNECTING POINT SYSTEM] 442
G-14 ERROR CODE [C051] [ABNORMALITY IN PREHEATING RELAY COIL SYSTEM] 443
G-15 ERROR CODE [C054] [SHORT CIRCUIT IN STARTING SWITCH C SYSTEM] 444
G-16 ERROR CODE [C056] [POWER SOURCE SYSTEM ABNORMALITY 1] 445
G-17 ERROR CODE [C057] [POWER SOURCE SYSTEM ABNORMALITY 2] 447
G-18 ERROR CODE [C05A] [ABNORMALITY IN FUEL INJECTION QUANTITY CONTROL SWITCH SIGNAL] 448
G-19 ERROR CODE [C06A] [ABNORMALITY IN LOW ENGINE COOLANT TEMPERATURE SENSOR SYSTEM] 448
G-20 ERROR CODE [C070] [EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM] 449
G-21 ERROR CODE [C071] [EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM] 450
G-22 ERROR CODE [C074] [DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM] 451
G-23 ERROR CODE [C075] [DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM] 452
G-24 ERROR CODE [C077] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM] 453
G-25 ERROR CODE [C079] [COMMON RAIL HIGH FUEL PRESSURE ABNORMALITY 1] ERROR CODE [C07A] [COMMON RAIL HIGH FUEL PRESSURE ABNORMALITY 2] 454
G-26 ERROR CODE [C07C] [FUEL SUPPLY PUMP NON-FORCE FEED 1] ERROR CODE [C07b] [FUEL SUPPLY PUMP NON-FORCE FEED 2] 455
G-27 ERROR CODE [C07d] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE] 457
G-28 ERROR CODE [C080] [DEFECTIVE CONTROLLER] 457
G-29 ERROR CODE [C081] [DISCONNECTION IN NO 1 FUEL INJECTOR <A> SYSTEM] 458
G-30 ERROR CODE [C082] [DISCONNECTION IN NO 2 FUEL INJECTOR <E> SYSTEM] 459
G-31 ERROR CODE [C083] [DISCONNECTION IN NO 3 FUEL INJECTOR <C> SYSTEM] 460
G-32 ERROR CODE [C084] [DISCONNECTION IN NO 4 FUEL INJECTOR <F> SYSTEM] 461
G-33 ERROR CODE [C085] [DISCONNECTION IN NO 5 FUEL INJECTOR <B> SYSTEM] 462
G-34 ERROR CODE [C086] [DISCONNECTION IN NO 6 FUEL INJECTOR <D> SYSTEM] 463
G-35 ERROR CODE [C08A] [SHORT CIRCUIT IN NO 1 <A>, NO 2 <E>, NO 3 <C> FUEL INJECTOR SYSTEM] 464
G-36 ERROR CODE [C08b] [SHORT CIRCUIT IN NO 4 <F>, NO 5 <B>, NO 6 <D> FUEL INJECTOR SYSTEM] 467
TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM FOR START/STOP SYSTEM (ENG MODE) 471
SERIAL NO :1001-1599 472
ENG-1 ENGINE DOES NOT START (FUEL INJECTION PUMP STOP LEVER STAYS AT STOP POSITION) 472
ENG-2 ENGINE DOES NOT STOP (FUEL INJECTION PUMP STOP LEVER STAYS AT RUN POSITION) 479
SERIAL NO :1601 AND UP 484
ENG-1 ENGINE DOES NOT START (STARTING MOTOR DOES NOT ROTATE) 484
ENG-2 ENGINE DOES NOT START OR IT HUNTS (RUNS ROUGH) 488
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE) 489
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 491
JUDGMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS 492
A-1 ABNORMALITY IN POWER SOURCE 494
a) [ ][DEFECTIVE CONTROLLER POWER SOURCE]IS DISPLAYED(ALL LEDS OFF) 494
b) [0 1](DROP IN VOLTAGE OF CONTROLLER)IS DISPLAYED 498
c) [0 2](DROP IN VOLTAGE OF SOLENOID)IS DISPLAYED 499
A-2 [0 3](NEUTRAL SAFETY)IS DISPLAYED 501
A-3 CONTROLLER SYSTEM 503
a) [ ][ONLY DOT LIGHTS UP] OR [0 4](DATA ERROR)IS DISPLAYED 503
b) [0 5](DOUBLE ENGAGEMENT FOR CLUTCH)IS DISPLAYED 503
A-4 [0 6](DISCONNECTION,SHORT CIRCUIT,SHORT CIRCUIT WITH GROUND IN TRANSMISSION CUT RELAY)IS DISPLAYED 504
A-5 [0 8](DISCONNECTION,SHORT CIRCUIT,SHORT CIRCUIT WITH GROUND IN AUTOMATIC RETARDER SOLENOID)IS DISPLAYED 508
A-6 [0 9](DISCONNECTION,SHORT CIRCUIT,SHORT CIRCUIT WITH GROUND IN EXHAUST BRAKE SOLENOID)IS DISPLAYED 512
A-7 SPEED SENSOR SYSTEM 516
a) [1 0](DISCONNECTION IN ENGINE SPEED SENSOR) OR [6 0](DEFECTIVE OUTPUT OF ENGINE SPEED SENSOR) 516
b) [1 1](DISCONNECTION IN TRANSMISSION INPUT SHAFT SPEED SENSOR) OR [6 1](DEFECTIVE OUTPUT OF TRANSMISSION INPUT SHAFT SPEED SENSOR) 519
c) [1 2](DISCONNECTION IN TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR) OR [6 2](DEFECTIVE OUTPUT OF TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR) 520
d) [1 3](DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR) OR [6 3](DEFECTIVE OUTPUT OF TRANSMISSION OUTPUT SHAFT SPEED SENSOR) 521
A-8 SLIPPING CLUTCH OR SPEED SENSOR SYSTEM 522
a) [2 1][DEFECTIVE LOCK-UP CLUTCH SYSTEM] IS DISPLAYED 522
b) [2 2][FAILURE IN HI CLUTCH OR INPUT SHAFT SPEED SENSOR SYSTEM] OR [2 3][FAILURE IN LO CLUTCH OR INPUT SHAFT SPEED SENSOR SYSTEM] IS DISPLAYED 522
c) [2 4][FAILURE IN 1ST CLUTCH OR OUTPUT SHAFT SPEED SENSOR SYSTEM] OR [2 5][FAILURE IN 2ND CLUTCH OR OUTPUT SHAFT SPEED SENSOR SYSTEM] OR [2 6][FAILURE IN 3RD CLUTCH OR OUTPUT SHAFT SPEED SENSOR SYSTEM] OR [2 8][FAILURE IN R CLUTCH OR OUTPUT SHAFT SPEED SENSOR SYSTEM] IS DISPLAYED 522
A-9 [A 1]ABNORMALITY IN MODEL SELECTION SIGNAL IS DISPLAYED 523
A-10 ABNORMALITY IN SHIFT LEVER SYSTEM 524
a) [0 7][SHORT CIRCUIT WITH 12V OUTPUT CIRCUIT] IS DISPLAYED 524
b) [1 5][SHORT CIRCUIT,SHORT CIRCUIT WITH GROUND IN LEVER SIGNAL SYSTEM] IS DISPLAYED 525
c) [1 6][DISCONNECTION IN LEVER SIGNAL SYSTEM] IS DISPLAYED 529
A-11 [A 1][DISCONNECTION IN ACCELERATOR SIGNAL,DEFECTIVE ADJUSTMENT,DISCONNECTED LINK] IS DISPLAYED 531
A-12 [1 9][SHORT CIRCUIT WITH GROUND IN TRANSMISSION VALVE OIL TEMPERATURE SENSOR] IS DISPLAYED 535
A-13 PRESSURE CONTROL VALVE SYSTEM 536
a) [3 1][DEFECTIVE LOCK-UP CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ] OR [3 2][DEFECTIVE HI CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ] 536
a) [3 3][DEFECTIVE LO CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ] OR [3 4][DEFECTIVE 1ST CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ] 536
a) [3 5][DEFECTIVE 2ND CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ] OR [3 6][DEFECTIVE 3RD CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ] 536
a) [3 8][DEFECTIVE R CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ] IS DISPLAYED 536
b) [4 1][DEFECTIVE LOCK-UP CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ] OR [4 2][DEFECTIVE HI CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ] 537
b) [4 3][DEFECTIVE LO CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ] OR [4 4][DEFECTIVE 1ST CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ] 537
b) [4 5][DEFECTIVE 2ND CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ] OR [4 6][DEFECTIVE 3RD CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ] 537
b) [4 8][DEFECTIVE R CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ] IS DISPLAYED 537
b1) CHECKING FILL SIGNAL SYSTEM 537
b2) CHECKING WHEN [4 2] OR [4 3] IS DISPLAYED 538
b3) CHECKING WHEN [4 4] OR [4 6] OR [4 8] IS DISPLAYED 538
A-14 FLOW DETECTION VALVE SYSTEM 539
[5 1][DISCONNECTION IN LOCK-UP CLUTCH FLOW CONTROL VALVE SYSTEM] OR [5 2][DISCONNECTION IN HI CLUTCH FLOW CONTROL VALVE SYSTEM] 539
[5 3][DISCONNECTION IN LO CLUTCH FLOW CONTROL VALVE SYSTEM] OR [5 4][DISCONNECTION IN 1ST CLUTCH FLOW CONTROL VALVE SYSTEM] 539
[5 5][DISCONNECTION IN 2ND CLUTCH FLOW CONTROL VALVE SYSTEM] OR [5 6][DISCONNECTION IN 3RD CLUTCH FLOW CONTROL VALVE SYSTEM] 539
[5 8][DISCONNECTION IN R CLUTCH FLOW CONTROL VALVE SYSTEM] IS DISPLAYED 539
A-15 PRESSURE CONTEOL SOLENOID SYSTEM 540
a) [7 1][SHORT CIRCUIT IN LOCK-UP CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] OR [7 2][SHORT CIRCUIT IN HI CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] 540
a) [7 3][SHORT CIRCUIT IN LO CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] OR [7 4][SHORT CIRCUIT IN 1ST CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] 540
a) [7 5][SHORT CIRCUIT IN 2ND CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] OR [7 6][SHORT CIRCUIT IN 3RD CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] 540
a) [7 8][SHORT CIRCUIT IN R CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] IS DISPLAYED 540
b) [9 1][SHORT CIRCUIT IN LOCK-UP CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] OR [9 2][SHORT CIRCUIT IN HI CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] 542
b) [9 3][SHORT CIRCUIT IN LO CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] OR [9 4][SHORT CIRCUIT IN 1ST CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] 542
b) [9 5][SHORT CIRCUIT IN 2ND CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] OR [9 6][SHORT CIRCUIT IN 3RD CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] 542
b) [9 8][SHORT CIRCUIT IN R CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] IS DISPLAYED 542
A-16 PRESSURE SENSOR SYSTEM 544
a) [8 1][DEFECTIVE OUTPUT OF TORQUE CONVERTER INLET PRESSURE SENSOR] OR [8 3][DEFECTIVE OUTPUT OF TORQUE CONVERTER INLET PRESSURE SENSOR] IS DISPLAYED 544
b) [8 2][DEFECTIVE OUTPUT OF TORQUE CONVERTER OUTLET PRESSURE SENSOR] OR [8 4][DEFECTIVE OUTPUT OF TORQUE CONVERTER OUTLET PRESSURE SENSOR] IS DISPLAYED 545
ELECTRICAL CIRCUIT DIAGRAM FOR A MODE SYSTEM 546
TROUBLESHOOTING FOR METER PANEL SYSTEM (E MODE) 559
E-1 WATER TEMPERATURE GAUGE GIVES NO DISPLAY OR GIVES ABNORMAL DISPLAY 560
a) GIVES NO DISPLAY 560
b) GIVES ABNORMAL DISPLAY 560
E-2 TORQUE CONVERTER OIL TEMPERATURE GAUGE GIVES NO DISPLAY OR GIVES ABNORMAL DISPLAY 562
a) GIVES NO DISPLAY 562
b) GIVES ABNORMAL DISPLAY 562
E-3 RETARDER OIL TEMPERATURE GAUGE GIVES NO DISPLAY OR GIVES ABNORMAL DISPLAY 564
a) GIVES NO DISPLAY 564
b) GIVES ABNORMAL DISPLAY 564
E-4 FUEL GAUGE GIVES NO DISPLAY OR GIVES ABNORMAL DISPLAY 566
a) GIVES NO DISPLAY 566
b) GIVES ABNORMAL DISPLAY 566
E-5 SERVICE METER DOES NOT MOVE (SERIAL NO :1001-1599) 568
E-6 SERVICE METER AND TACHOMETOR DOES NOT MOVE (SERIAL NO :1601 AND UP) 569
TROUBLESHOOTING FOR PILOT LAMP SYSTEM(F MODE) 571
F-1 ABNORMALITY IN LIGHTING UP OF RETARDER PILOT LAMP 572
F-2 ABNORMALITY IN LIGHTING UP OF PARKING BRAKE PILOT LAMP 578
F-3 ABNORMALITY IN LIGHTING UP OF FRONT BRAKE OIL LEVEL PILOT LAMP 584
F-4 ABNORMALITY IN LIGHTING UP OF REAR BRAKE CAUTION LAMP 590
F-5 ABNORMALITY IN LIGHTING UP OF ENGINE OIL PRESSURE PILOT LAMP 596
F-6 ABNORMALITY IN LIGHTING UP OF BATTERY CHARGE CAUTION LAMP 600
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE SYSTEM 606
TROUBLESHOOTING OF AIR SYSTEM ON MACHINE AIR COMPRESSOR(C MODE) 609
TROUBLESHOOTING OF AIR SYSTEM ON MACHINE AIR COMPRESSOR 610
BASIC AIR CIRCUIT OF AIR COMPRESSOR 610
C-1 AIR PRESSURE DOES NOT RISE AT ALL 611
C-2 AIR PRESSURE DOES NOT RISE TO SPECIFIED PRESSURE RANGE(GREEN RANGE OF AIR GAUGE) 612
C-3 AIR PRESSURE RISES BUT CHARGING TAKES A LONG TIME 613
C-4 AIR BLOWS OUT FROM SAFETY VALVE 614
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS(H MODE) 615
METHOD OF USING MATRIX TROUBLESHOOTING TABLES 616
H-1 MACHINE DOES NOT START 618
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS) 620
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS) 620
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING 621
H-5 TRANSMISSION DOES NOT SHIFT UP 621
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING 622
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR 628
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 630
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW 631
H-10 FRONT BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE 632
H-11 REAR BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE 633
H-12 STEERING WHEEL IS HEAVY 634
H-13 STEERING WHEEL DOES NOT WORK 635
H-14 STEERING WHEEL VIBRATES 635
H-15 HOIST CYLINDER LACKS LIFTING FORCE(LIFTING SPEED) 636
H-16 HOIST CYLINDER DOES NOT WORK 637
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY 638
TROUBLESHOOTING OF ARSC [AUTOMATIC RETARDER SPEED CONTROLLER] SYSTEM (R MODE) 639
OUTLINE 640
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM 644
R-1 0 1 (ABNORMALITY IN POWER SOURCE VOLTAGE) IS DISPLAYED 646
R-2 1 0 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 647
R-3 1 3 (DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM) IS DISPLAYED 648
R-4 1 5 (FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED 649
R-5 1 7 (FAILURE IN ACCELERATOR SIGNAL SYSTEM) IS DISPLAYED 650
R-6 1 8 (FAILURE IN SUSPENSION PRESSURE SENSOR “LEFT” SYSTEM) IS DISPLAYED 651
R-7 1 9 (FAILURE IN SUSPENSION PRESSURE SENSOR “RIGHT” SYSTEM) IS DISPLAYED 652
R-8 4 2 (DISCONNECTION IN EXHAUST BRAKE SELECTOR SIGNAL SYSTEM) IS DISPLAYED 653
R-9 4 3 (DISCONNECTION IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED 654
R-10 4 4 (DISCONNECTION IN READY LAMP SYSTEM) IS DISPLAYED 655
R-11 4 5 (DISCONNECTION IN PANEL CAUTION AND BUZZER SYSTEM) IS DISPLAYED 656
R-12 5 2 (SHORT CIRCUIT WITH GROUND IN EXHAUST BRAKE SELECTOR SIGNAL OUTPUT SYSTEM) IS DISPLAYED 657
R-13 5 3 (SHORT CIRCUIT WITH GROUND IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED 658
R-14 5 4 (SHORT CIRCUIT WITH GROUND IN READY OUTPUT CIRCUIT SYSTEM) IS DISPLAYED 659
R-15 5 5 (SHORT CIRCUIT WITH GROUND IN PANEL CAUTION LAMP AND BUZZER OUTPUT SYSTEM) IS DISPLAYED 660
R-16 6 0 (FAILURE IN ENGINE SPEED SYSTEM) IS DISPLAYED 661
R-17 7 0 (DISCONNECTION IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED 662
R-18 7 1 (DISCONNECTION IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED 663
R-19 7 2 (DISCONNECTION IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED 664
R-20 7 3 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED 665
R-21 7 4 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED 666
R-22 7 5 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED 667
R-23 8 1 (SHORT CIRCUIT WITH GROUND IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED 668
R-24 8 3 (DISCONNECTION IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED 669
R-25 8 5 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE REMAINS OPEN) IS DISPLAYED 670
R-26 8 7 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE DOES NOT OPEN) IS DISPLAYED 671
R-27 8 9 (SHORT CIRCUIT WITH GROUND IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED 672
R-28 9 0 (DISCONNECTION IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED 673
R-29 9 1 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (REMAINS OPEN)) IS DISPLAYED 674
R-30 9 2 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (DOES NOT OPEN)) IS DISPLAYED 675
R-31 9 3 (DISCONNECTION IN SYSTEM SWITCH SYSTEM) IS DISPLAYED 676
R-32 9 4 (SHORT CIRCUIT WITH GROUND IN SYSTEM SWITCH SYSTEM) IS DISPLAYED 677
R-33 9 5 (DISCONNECTION, SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED SETTING SWITCH SYSTEM) IS DISPLAYED 678
R-101 SET SPEED CANNOT BE SET 679
R-102 FAILURE CODE IS ALWAYS CLEARED (CONTROLLER DISPLAY WINDOW ALWAYS SHOWS “–“) OR FAILURE CODE CANNOT BE CLEARED 682
R-103 EFFECT OF RETARDER IS TOO STRONG WHEN MACHINE IS EMPTY, OR TOO WEAK WHEN MACHINE IS LOADED (DOES NOT JUDGE LOADED/UNLOADED CONDITION PROPERLY) 683
R-104 ABNORMALITY APPEARS IN OTHER CONTROLLER 683
R-105 WHEN TRAVELING DOWNHILL, EVEN WHEN SET SPEED IS EXCEEDED, NO CONTROL IS CARRIED OUT 684
R-106 MONITOR LAMP (BUZZER) STAYS ON (OR OFF) 685
R-107 READY LAMP DOES NOT LIGHT UP (OR STAYS LIGHTED UP) 686
R-108 EXHAUST BRAKE DOES NOT WORK PROPERLY [EXHAUST BRAKE IS ACTUATED WHEN EXHAUST BRAKE SWITCH IS OFF; OR EXHAUST BRAKE IS NOT ACTUATED WHEN EXHAUST BRAKE SWITCH IS ON] 688
R-109 RETARDER LAMP DOES NOT LIGHT UP, OR STAYS LIGHTED UP 690
R-110 TRAVEL SPEED DISPLAY ALWAYS GIVES DISPLAY (OR DOES NOT GIVE ANY DISPLAY) 691
30 DISASSEMBLY AND ASSEMBLY 693
SPECIAL TOOL LIST 696
SKETCHES OF SPECIAL TOOLS 700
STARTING MOTOR 702
REMOVAL AND INSTALLATION 702
ALTERNATOR 703
REMOVAL AND INSTALLATION 703
ENGINE OIL COOLER 704
REMOVAL AND INSTALLATION 704
FUEL INJECTION PUMP 705
REMOVAL AND INSTALLATION 705
FUEL SUPPLY PUMP 706
REMOVAL 706
INSTALLATION 708
AIR COMPRESSOR 710
REMOVAL AND INSTALLATION 710
AIR CONDITIONER COMPRESSOR 712
REMOVAL AND INSTALLATION 712
AIR CONDITIONER CONDENSER 714
REMOVAL AND INSTALLATION 714
WATER PUMP 715
REMOVAL AND INSTALLATION 715
AFTERCOOLER CORE 716
REMOVAL AND INSTALLATION 716
EXHAUST BRAKE CYLINDER 717
REMOVAL AND INSTALLATION 717
TURBOCHARGER 718
REMOVAL AND INSTALLATION 718
NOZZLE HOLDER 719
REMOVAL AND INSTALLATION 719
FUEL INJECTOR 720
REMOVAL 720
INSTALLATION 722
NOZZLE TIP 724
REMOVAL 724
INSTALLATION 726
CYLINDER HEAD 728
REMOVAL 728
INSTALLATION 730
ENGINE FRONT SEAL 741
REMOVAL 741
INSTALLATION 742
ENGINE REAR SEAL 744
REMOVAL 744
INSTALLATION 745
ENGINE 748
REMOVAL 748
INSTALLATION 751
RADIATOR 756
REMOVAL 756
INSTALLATION 758
OIL COOLER 763
REMOVAL AND INSTALLATION 763
OUTPUT SHAFT 764
REMOVAL AND INSTALLATION 764
DISASSEMBLY 765
ASSEMBLY 767
TORQUE CONVERTER, TRANSMISSION 771
REMOVAL 771
INSTALLATION 773
DISCONNECTION 775
CONNECTION 776
TORQUE CONVERTER 777
DISASSEMBLY 777
ASSEMBLY 783
PTO 789
DISASSEMBLY 789
ASSEMBLY 790
TRANSMISSION 792
DISASSEMBLY 792
ASSEMBLY 810
TRANSMISSION CONTROL VALVE (ECMV) 829
REMOVAL AND INSTALLATION 829
TRANSMISSION, MAIN RELIEF VALVE 830
REMOVAL AND INSTALLATION 830
DIFFERENTIAL 831
REMOVAL 831
INSTALLATION 832
DISASSEMBLY 833
ASSEMBLY 836
FRONT WHEEL 844
REMOVAL AND INSTALLATION 844
REAR WHEEL 845
REMOVAL AND INSTALLATION 845
FRONT BRAKE CALIPER PAD 846
REMOVAL AND INSTALLATION 846
FRONT BRAKE CALIPER 847
REMOVAL AND INSTALLATION 847
DISASSEMBLY 848
ASSEMBLY 849
FRONT WHEEL HUB 851
DISASSEMBLY 851
ASSEMBLY 852
FINAL DRIVE CARRIER 855
REMOVAL AND INSTALLATION 855
DISASSEMBLY AND ASSEMBLY 856
REAR WHEEL BRAKE 857
REMOVAL 857
INSTALLATION 859
REAR BRAKE 861
DISASSEMBLY 861
ASSEMBLY 863
FRONT SUSPENSION CYLINDER 866
REMOVAL 866
INSTALLATION 867
DISASSEMBLY 868
ASSEMBLY 869
REAR SUSPENSION CYLINDER 870
REMOVAL AND INSTALLATION 870
DISASSEMBLY 871
ASSEMBLY 872
AIR GOVERNOR 873
REMOVAL AND INSTALLATION 873
DISASSEMBLY AND ASSEMBLY 874
BRAKE VALVE 875
REMOVAL AND INSTALLATION 875
DISASSEMBLY 876
ASSEMBLY 878
PARKING BRAKE SPRING CYLINDER 880
REMOVAL AND INSTALLATION 880
PARKING BRAKE CHAMBER 881
DISASSEMBLY 881
ASSEMBLY 882
FRONT BRAKE CHAMBER 883
REMOVAL AND INSTALLATION 883
DISASSEMBLY 884
ASSEMBLY 886
REAR BRAKE CHAMBER 888
REMOVAL AND INSTALLATION 888
DISASSEMBLY 889
ASSEMBLY 893
SLACK ADJUSTER 896
REMOVAL AND INSTALLATION 896
DISASSEMBLY AND ASSEMBLY 897
AIR DRIER (DESICCANT TYPE) 898
REMOVAL AND INSTALLATION 898
DISASSEMBLY AND ASSEMBLY 899
TRANSMISSION CONTROL, RETARDER BRAKE COOLING PUMP AND HOIST, STEERING PUMP 916
REMOVAL AND INSTALLATION 916
EMERGENCY STEERING MOTOR PUMP 917
REMOVAL AND INSTALLATION 917
STEERING VALVE 918
REMOVAL AND INSTALLATION 918
DISASSEMBLY 919
ASSEMBLY 924
DEMAND VALVE 932
REMOVAL AND INSTALLATION 932
DISASSEMBLY AND ASSEMBLY 933
RELIEF VALVE 934
DISASSEMBLY AND ASSEMBLY 934
HOIST VALVE 935
REMOVAL AND INSTALLATION 935
DISASSEMBLY 936
ASSEMBLY 937
STEERING CYLINDER 938
REMOVAL AND INSTALLATION 938
DISASSEMBLY 939
ASSEMBLY 941
HOIST CYLINDER 943
REMOVAL AND INSTALLATION 943
DISASSEMBLY 944
ASSEMBLY 947
DUMP BODY 950
REMOVAL AND INSTALLATION 950
SHIM OF DUMP BODY 951
PROCEDURE FOR ADJUSTING 951
TRANSMISSION CONTROLLER 952
REMOVAL AND INSTALLATION 952
ENGINE CONTROLLER 953
REMOVAL AND INSTALLATION 953
SHIFT INDICATOR CONTROLLER 954
REMOVAL AND INSTALLATION 954
PARKING BRAKE SHOE 955
REMOVAL 955
INSTALLATION 956
40 MAINTENANCE STANDARD 957
DAMPER 959
TORQUE CONVERTER 960
TRANSMISSION 962
MAIN RELIEF VALVE 965
TRANSMISSION VALVE, ECMV 966
FRONT AXLE 967
DIFFERENTIAL 969
FINAL DRIVE 972
FRONT BRAKE 973
REAR BRAKE 974
PARKING BRAKE 976
REAR BRAKE CHAMBER 977
FRONT BRAKE CHAMBER 978
SLACK ADJUSTER 979
HYDRAULIC PUMP 980
STEERING, HOIST PUMP 981
STEERING CYLINDER 982
DEMAND VAVLE 983
CROSSOVER RELIEF VALVE 983
HOIST VALVE 984
HOIST CYLINDER 985
STEERING LINKAGE 986
REAR AXLE SUPPORT 987
FRONT SUSPENSION CYLINDER 988
REAR SUSPENSION CYLINDER 989
90 OTHERS 991
AIR CIRCUIT DIAGRAM (STANDARD SPECIFICATION SERIAL NO :1001-1200) 993
AIR CIRCUIT DIAGRAM (STANDARD SPECIFICATION SERIAL NO :1201-1600) 995
AIR CIRCUIT DIAGRAM (EMERGENCY BRAKE SPECIFICATION SERIAL NO :1001-1200) 997
AIR CIRCUIT DIAGRAM (EMERGENCY BRAKE SPECIFICATION SERIAL NO :1201-1600) 999
AIR CIRCUIT DIAGRAM (EMERGENCY BRAKE SPECIFICATION SERIAL NO :1601 AND UP) 1001
HYDRAULIC CIRCUIT DIAGRAM FOR TORQUE CONVERTER, TRANSMISSION, AND BRAKE COOLING 1003
STEERING, HOIST HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO :1001-1200) 1005
STEERING, HOIST HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO :1201 AND UP) 1007
ELECTRIC CIRCUIT DIAGRAM (1/2) (SERIAL NO :1001-1200) 1009
ELECTRIC CIRCUIT DIAGRAM (2/2) (SERIAL NO :1001-1200) 1011
ELECTRIC CIRCUIT DIAGRAM (1/2) (SERIAL NO :1201-1600) 1013
ELECTRIC CIRCUIT DIAGRAM (2/2) (SERIAL NO :1201-1600) 1015
ELECTRIC CIRCUIT DIAGRAM (1/4) (SERIAL NO :1601-1685) 1017
ELECTRIC CIRCUIT DIAGRAM (2/4) (SERIAL NO :1601-1685) 1019
ELECTRIC CIRCUIT DIAGRAM (3/4) (SERIAL NO :1601-1685) 1021
ELECTRIC CIRCUIT DIAGRAM (4/4) (SERIAL NO :1601-1685) 1023
ELECTRIC CIRCUIT DIAGRAM (1/4) (SERIAL NO :1686 AND UP) 1025
ELECTRIC CIRCUIT DIAGRAM (2/4) (SERIAL NO :1686 AND UP) 1027
ELECTRIC CIRCUIT DIAGRAM (3/4) (SERIAL NO :1686 AND UP) 1029
ELECTRIC CIRCUIT DIAGRAM (4/4) (SERIAL NO :1686 AND UP) 1031
ELECTRIC CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM 1033
ELECTRIC CIRCUIT DIAGRAM OF AIR CONDITIONER (SERIAL NO :1001-1200) 1035
ELECTRIC CIRCUIT DIAGRAM OF AIR CONDITIONER (SERIAL NO : 1201 – 1600) 1036
ELECTRIC CIRCUIT DIAGRAM OF AIR CONDITIONER (SERIAL NO : 1601 AND UP) 1037

DESCRIPTION:

Komatsu HD255-5 Dump Truck Shop Manual SEBM009118 – PDF DOWNLOAD 

MACHINE MODEL          SERIAL NUMBER
HD255-5                            1001 and up

FOREWORD:
GENERAL:

• This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
  accurate understanding of the product and by showing him the correct way to perform repairs and make judgements.
  Make sure you understand the contents of this manual and use it to full effect at every opportunity.
• This shop manual mainly contains the necessary technical information for operations performed in a service
  workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further
  divided into the each main group of components.

STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

IMAGES PREVIEW OF THE MANUAL:

S.V  25/12/24