Komatsu HD465-5 Dump Truck Shop Manual SEBM05690507 PDF

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Komatsu HD465-5 Dump Truck Shop Manual SEBM05690507 – PDF DOWNLOAD

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Komatsu HD465-5 Dump Truck Shop Manual SEBM05690507 – PDF DOWNLOAD 

Language : English
Pages : 828
Downloadable : Yes
File Type : PDF

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Komatsu HD465-5 Dump Truck Shop Manual SEBM05690507 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NO.
HD465-5                     4001 and up

COVER 1
CONTENTS 2
01 GENERAL 23
GENERAL ASSEMBLY DRAWING 24
SPECIFICATIONS 25
WEIGHT TABLE 31
LIST OF LUBRICANT AND WATER 32
10 STRUCTURE AND FUNCTION 33
RADIATOR, TORQUE CONVERTER OIL COOLER 35
RADIATOR, TORQUE CONVERTER OIL COOLER, AFTER COOLER, WORK EQUIPMENT OIL COOLER 36
BRAKE OIL COOLER 37
POWER TRAIN SKELETON 38
OUTPUT SHAFT 39
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING 40
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 41
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT SCHEMATICS 42
TORQUE CONVERTER 43
TORQUE CONVERTER VALVE 45
LOCKUP SOLENOID VALVE 50
TRANSMISSION 51
TRANSMISSION VALVE 53
ECMV (ELECTRONIC CONTROL MODULATION VALVE) 54
LUBRICATION RELIEF VALVE 59
FRONT AXLE 60
REAR AXLE 61
DIFFERENTIAL 62
FINAL DRIVE 63
FRONT BRAKE 65
REAR BRAKE 66
PARKING BRAKE 67
WHEELS 68
AXLE SUPPORT 69
STEERING SYSTEM 70
STEERING WHEEL 71
STEERING LINKAGE 72
SUSPENSION SYSTEM 74
SUSPENSION CYLINDER 76
AIR PIPING 82
AIR CIRCUIT DIAGRAM 84
AIR GOVERNOR 88
SAFETY VALVE 90
CHECK VALVE 90
DOUBLE-CHECK VALVE 91
AUTO DRAIN VALVE 92
HAND BRAKE VALVE (RETARDER CONTROL VALVE) 93
BRAKE VALVE 95
REDUCING VALVE (FOR RETARDER) 98
2-WAY CONTROL VALVE (PARKING BRAKE VALVE, EMERGENCY BRAKE VALVE) 100
EMERGENCY BRAKE CONTROL VALVE (VARIABLE CONTROL TYPE) 102
RELAY VALVE (ACTS ALSO AS EMERGENCY RELAY) 105
PARKING BRAKE RELAY VALVE 108
QUICK-RELEASE VALVE 110
BRAKE CHAMBER 111
PARKING BRAKE CHAMBER 114
SLACK ADJUSTER 115
HYDRAULIC PIPING (STEERING AND HOIST, AND BRAKE COOLING) 117
HYDRAULIC CIRCUIT DIAGRAM (STEERING AND HOIST, AND BRAKE COOLING) 119
DUMP BODY CONTROL 120
HYDRAULIC TANK AND BRAKE COOLING OIL TANK 121
HYDRAULIC PUMP 123
BRAKE COOLING OIL CONTROL VALVE (BCV) 126
STEERING CONTROL VALVE 127
DEMAND VALVE 131
CROSSOVER RELIEF VALVE 135
HOIST VALVE 136
STEERING CYLINDER 138
ELECTRICAL CIRCUIT DIAGRAM 139
STOP LAMP SWITCH 157
EXHAUST BRAKE SWITCH 157
TILT SWITCH 157
HORN VALVE 158
PARKING BRAKE SWITCH 158
FRONT BRAKE CUT-OFF VALVE 159
AUTOMATIC RETARDER VALVE 160
EXHAUST BRAKE VALVE 160
AIR CONDITIONER 161
ELECTRICAL CIRCUIT DIAGRAM 163
REFRIGERANT CIRCUIT DIAGRAM 164
UNIT 165
RECEIVER DRYER 166
CONDENSER 167
COMPRESSOR 168
ENGINE CONTROL SYSTEM (ELECTRONIC GOVERNOR TYPE) 169
SYSTEM DIAGRAM 169
AISS (AUTOMATIC IDLE SETTING SYSTEM) 171
FUEL INJECTION PUMP WITH ELECTRONIC GOVERNOR 172
ENGINE CONTROLLER 174
SENSORS, SWITCHES 175
ENGINE CONTROL SYSTEM (MECHANICAL GOVERNOR TYPE) 178
AUTOMATIC SHIFT CONTROL SYSTEM 179
TRANSMISSION CONTROLLER 182
SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES 183
SHIFT LEVER SWITCH 186
SENSORS, SWITCHES 187
TRANSMISSION SPEED SENSOR 187
TRANSMISSION OIL TEMPERATURE SENSOR 187
FILL SWITCH 188
ACCELERATOR SENSOR 188
SHIFT LIMIT SWITCH 189
MODE SELECTOR SWITCH 189
AUTOMATIC EMERGENCY STEERING SYSTEM 190
ELECTRICAL CIRCUIT DIAGRAM 191
FLOW SWITCH 193
RELAY TIMER 195
AUTOMATIC SUSPENSION SYSTEM 196
STRUCTURE OF SYSTEM 196
AUTOMATIC SUSPENSION MODE SELECTION CONTROL 198
SUSPENSION CONTROLLER 199
SENSORS, SWITCHES 200
STEERING ANGLE SENSOR 200
PRESSURE SENSOR 200
PAYLOAD METER 201
STRUCTURE OF SYSTEM 201
ELECTRICAL CIRCUIT DIAGRAM 202
PAYLOAD METER BLOCK DIAGRAM 202
PRINCIPLE OF CALCULATION 203
FEATURES OF EQUIPMENT 205
ELECTRONIC MONITOR SYSTEM 210
ELECTRONIC MONITOR SYSTEM 210
ELECTRONIC MONITOR DISPLAYS, FUNCTIONS 212
SENSORS, SWITCHES 218
ENGINE SPEED SENSOR 218
ENGINE OIL PRESSURE SENSOR 218
ENGINE WATER TEMPERATURE SENSOR 219
RETARDER OIL TEMPERATURE SENSOR 219
TORQUE CONVERTER OIL TEMPERATURE SENSOR 219
AIR PRESSURE SENSOR 219
FUEL LEVEL SENSOR 220
RADIATOR WATER LEVEL SENSOR 221
MAINTENANCE MONITOR SYSTEM 222
SYSTEM DIAGRAM 222
MONITOR PANEL 223
MONITOR DISPLAY, FUNCTIONS 224
FUNCTIONS OF SWITCHES 226
SENSORS, SWITCHES 228
ENGINE OIL LEVEL SENSOR 228
TRANSMISSION OIL LEVEL SENSOR 228
HYDRAULIC OIL LEVEL SENSOR 229
RETARDER OIL LEVEL SENSOR 229
AIR FILTER CLOGGING SENSOR 229
RETARDER BRAKE WATER SENSOR 230
HYDRAULIC FILTER SENSOR 230
RETARDER OIL FILTER SENSOR 230
TRANSMISSION OIL FILTER SENSOR 230
BATTERY ELECTROLYTE LEVEL SENSOR 231
FULL-FLOW FILTER SENSOR 231
20 TESTING AND ADJUSTING 232
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 233
STANDARD VALUE TABLE FOR CHASSIS 235
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM 243
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING 249
ADJUSTING VALVE CLEARANCE 251
MEASURING COMPRESSION PRESSURE 252
MEASURING BLOW-BY 253
ADJUSTING FUEL INJECTION TIMING 254
BLEEDING AIR FROM FUEL INJECTION PUMP 257
ADJUSTING ENGINE STOP MOTOR CABLE 259
ADJUSTING ACCELERATOR PEDAL 260
TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE 261
TESTING ECMV OIL PRESSURE (USING SHIFT CHECKER + MODULATION CHECKER) 262
TESTING ECMV OIL PRESSURE (USING FIXED VALVE) 263
TESTING TORQUE CONVERTER STALL SPEED 265
TESTING BRAKE PRESSURE 267
BLEEDING AIR FROM BRAKE CIRCUIT 268
TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE 269
TESTING WEAR OF FRONT BRAKE PAD 270
TESTING WEAR OF REAR BRAKE DISC 270
TESTING AND ADJUSTING SUSPENSION CYLINDER 271
TESTING AND ADJUSTING AIR PRESSURE IN AIR CIRCUIT 283
ADJUSTING HOIST LEVER LINKAGE 284
ADJUSTING BODY POSITIONER 285
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT 286
AIR BLEEDING FROM STEERING CYLINDER 288
ADJUSTING ENGINE SPEED SENSOR 289
ADJUSTING ELECTRONIC MONITOR (SPEEDOMETER, TACHOMETER MODULE) 290
METHOD FOR EMERGENCY OPERATION OF TRUCK WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM OF TRANSMISSION CONTROL SYSTEM 291
PROCEDURE FOR OPERATING SHIFT CHECKER AND MODULATION CHECKER 293
TROUBLESHOOTING 315
POINTS TO REMEMBER WHEN TROUBLESHOOTING 316
SEQUENCE OF EVENTS IN TROUBLESHOOTING 317
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 318
HANDLING CONNECTORS 325
CHECKS BEFORE TROUBLESHOOTING 326
METHOD OF USING TROUBLESHOOTING CHARTS AND TABLES 328
METHOD OF USING JUDGEMENT TABLE 332
EXPLANATION OF FUNCTION OF ELECTRICAL SYSTEM (CONTROL MECHANISM) 335
METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MONITOR PANEL AND EACH CONTROLLER 337
ACTION BY SELF-TESTER AND MACHINE SYMPTOMS 342
ACTION BY SELF-TESTING AND MACHINE SYMPTOMS (TRANSMISSION CONTROLLER SYSTEM) 344
ACTION BY SELF-TESTING AND MACHINE SYMPTOMS (SUSPENSION CONTROLLER SYSTEM) 350
TYPE AND LOCATION OF CONNECTOR, SENSOR 351
CONNECTION TABLE FOR CONNECTOR 357
TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM (FOR ENGINES WITH MECHANICAL GOVERNOR) 368
G-1 ENGINE DOES NOT START (FUEL INJECTION PUMP STOP LEVER STAYS AT STOP POSITION) 369
G-2 ENGINE DOES NOT STOP (FUEL INJECTION PUMP STOP LEVER STAYS AT FULL POSITION) 370
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE START AND STOP 371
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (FOR ELECTRONIC GOVERNOR) (SERIAL NO 4004-4406) 372
JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS 374
R-1 ABNORMALITY IN POWER SOURCE SYSTEM 375
R-2 ABNORMALITY IN CONTROLLER SYSTEM 376
R-3 ABNORMALITY IN RACK SENSOR SYSTEM 377
R-4 ABNORMALITY IN GOVERNOR SOLENOID SYSTEM 378
R-5 ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM 379
R-6 ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM 380
R-7 ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM 381
R-8 a) ABNORMALITY IN ENGINE SPEED SENSOR A SYSTEM 382
R-8 b) ABNORMALITY IN ENGINE SPEED SENSOR B SYSTEM 383
R-9 ABNORMALITY IN ACCELERATION SENSOR SYSTEM 384
R-10 ABNORMALITY IN GOVERNOR SERVO SYSTEM 386
R-11 ABNORMALITY IN MODEL SELECTOR SYSTEM 387
R-12 ENGINE DOES NOT START 388
CIRCUIT DIAGRAM OF ENGINE CONTROLLER SYSTEM 391
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (FOR ENGINES WITH ELECTRONIC GOVERNOR) SERIAL NO :4407 AND UP 392
JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS 393
R-1 [DOES NOT LIGHT OR 10] ABNORMALITY IN POWER SOURCE SYSTEM 394
R-2 [11] ABNORMALITY IN CONTROLLER SYSTEM 395
R-3 [12] ABNORMALITY IN RACK SENSOR SYSTEM 396
R-4 [14] ABNORMALITY IN GOVERNOR SYSTEM 397
R-5 [16] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM 398
R-6 [1d] ABNORMALITY IN PRE-SOLENOID SYSTEM 399
R-7 [18] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM 400
R-8 [16] a) ABNORMALITY IN ENGINE SPEED SENSOR A SYSTEM 401
R-8 [1c] b) ABNORMALITY IN ENGINE SPEED SENSOR B SYSTEM 402
R-9 [31] ABNORMALITY IN ACCELERATION SENSOR SYSTEM 403
R-10 [19] ABNORMALITY IN GOVERNOR SERVO SYSTEM 405
R-11 [21] ABNORMALITY IN MODEL SELECTOR WIRING 406
R-12 ENGINE DOES NOT START 407
CIRCUIT DIAGRAM OF ENGINE CONTROLLER SYSTEM 410
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 411
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 413
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS 414
A-1 ABNORMALITY IN POWER SOURCE 415
a) (OFF) SELF TESTING DISPLAY OF CONTROLLER DOES NOT LIGHT UP 415
b) DROP IN VOLTAGE OF CONTROLLER POWER SOURCE DISPLAYED 416
c) ABNORMALITY IN TRANSMISSION CUT RELAY POWER SOURCE DISPLAYED 417
A-2 ABNORMALITY IN NEUTRAL SAFETY SYSTEM DISPLAYED 418
A-3 ABNORMALITY IN CONTROLLER SYSTEM 419
a) ONLY DOT LIGHTS UP OR ABNORMALITY IN CONTROLLER DISPLAYED (ONLY DOT LIGHTS UP) 419
b) DOUBLE SYSTEM FOR CLUTCH DISPLAYED 420
A-4 ABNORMALITY IN TRANSMISSION [CUT RELAY] SYSTEM DISPLAYED 421
A-5 ABNORMALITY IN AUTO-RETARDER BRAKE SOLENOID SYSTEM DISPLAYED 422
A-6 DISPLAYES ABNORMALITY IN EXHAUST BRAKE SOLENOID SYSTEM 423
A-7 ABNORMALITY IN SPEED SENSOR SYSTEM 424
a) ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM DISPLAYED 424
b) ABNORMALITY IN INTERMEDIATE SHAFT SPEED SENSOR SYSTEM DISPLAYED 425
c) DISCONNECTION IN TRAVEL SPEED SENSOR (TRANSMISSION OUTPUT SHAFT SPEED SENSOR) DISPLAYED 426
A-8 SPEED SENSOR SYSTEM, CLUTCH SLIPPING 427
a) LNPUT SHAFT SENSOR OR H L CLUTCH SYSTEM DISPLAYED 427
b) TRAVEL SPEED SENSOR OR SPEED CLUTCH (1,2,3,4,R) SYSTEM DISPLAYED 428
A-9 ABNORMALITY IN MODEL SELECTION DISPLAYED 429
A-10 ABNORMALITY IN TRANSMISSION SHIFT LEVER SYSTEM 430
a) SHORT CIRCUIT IN TRANSMISSION SHIFT LEVER ASSEMBLY POWER SOURCE DISPLAYED 430
b) SHIFT LEVER POSITION SIGNAL DISPLAYS TWO OR MORE SYSTEM 431
c) TRANSMISSION SHIFT LEVER POSITION SIGNAL IS NOT INPUT 434
A-11 ABNORMALITY IN ACCELERATOR SIGNAL DISPLAYED 435
A-12 ABNORMALITY IN TRANSMISSION OIL TEMPERATURE SENSOR DISPLAYED 437
A-13 ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM 438
a) FILL SIGNAL DISPLAYES ON REGARDLESS OF COMMAND 438
b) FILL SIGNAL IS NOT INPUT AND CLUTCH SLIPPING IS DISPLAYED 439
A-14 WHEN FILL SIGNAL IS NOT INPUT (FLOW DETECTOR VALVE SYSTEM) 442
A-15 SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID SYSTEM DISPLAYED OR DISCONNECTION IN PRESSURE CONTROL VALVE SOLENOID SYSTEM DISPLAYED 443
ELECTRICAL CIRCUIT DIAGRAM 445
TROUBLESHOOTING OF SUSPENSION CONTROLLER SYSTEM 446
JUDGEMENT TABLE FOR SUSPENSION CONTROLLER, SUSPENSION RELATED PARTS 447
S-1 ABNORMALITY IN POWER SOURCE SYSTEM 448
S-2 ABNORMALITY IN PRESSURE SENSOR [RIGHT] SYSTEM 449
S-3 ABNORMALITY IN PRESSURE SENSOR [LEFT] SYSTEM 450
S-4 ABNORMALITY IN TRAVEL SPEED SENSOR SYSTEM 451
S-5 ABNORMALITY IN STEERING SENSOR SYSTEM 452
S-6 ABNORMALITY IN MODEL SELECTOR SYSTEM 453
S-7 ABNORMALITY IN SOLENOID [I] SYSTEM 454
S-8 ABNORMALITY IN SOLENOID [II] SYSTEM 455
S-9 ABNORMALITY IN SOLENOID [III] SYSTEM 456
S-10 ABNORMALITY IN CONTROLLER SYSTEM 457
ELECTRICAL CIRCUIT DIAGRAM FOR SUSPENSION CONTROL SYSTEM 458
TROUBLESHOOTING OF PAYLOAD METER SYSTEM 459
L-1 WHEN THE STARTING SWITCH IS TURNED ON, NO DISPLAY APPEARS 460
L-2 AFTER THE STARTING SWITCH IS TURNED ON, THE DEMAND FOR CALIBRATION (CAL FLASHES) CONTINUES TO BE GIVEN 460
L-3 CALIBRATION CANNOT BE CARRIED OUT 461
L-4 AFTER THE STARTING SWITCH IS TURNED ON, THE EXTERNAL DISPLAY LAMPS DO NOT ALL LIGHT UP 463
L-5 EXTERNAL DISPLAY LAMPS LIGHT UP EVEN WHEN IT IS NOT THE CONDITION FOR LIGHTING UP 463
L-6 THE LEVEL OF LIGHTING UP OF THE EXTERNAL DISPLAY LAMPS IS NOT CORRECT 464
L-7 THERE IS ABNORMALITY IN THE DISPLAY LOGIC 465
a) EVEN WHEN THE DUMP BODY IS OPERATED, THE DISPLAY DOES NOT BECOME 0 TON 465
b) THE DISPLAY STAYS AT 0 TON AND DOES NOT CHANGE 465
c) WHEN THE TRANSMISSION LEVER IS AT NEUTRAL, THE WEIGHT DISPLAY IS NOT GIVEN (TIME DISPLAY IS GIVEN) 466
d) WHEN THE TRANSMISSION LEVER IS AT POSITION OTHER THAN NEUTRAL, THE TIME DISPLAY IS NOT GIVEN 468
L-8 E01-E04 IS DISPLAYED 469
L-9 E11-E14 IS DISPLAYED 470
L-10 E21-E28 IS DISPLAYED BY SENSOR CHECK 470
L-11 E31 IS DISPLAYED 471
L-12 E32 IS DISPLAYED 473
L-13 E41 IS DISPLAYED 473
L-14 E42 IS DISPLAYED 474
L-15 THE PRINTER DOES NOT PRINT ANYTHING (ONLY BLANK PAPER COMES OUT) 474
L-16 THE PRINTER ONLY PRINTS NO DATA 475
L-17 EVEN WHEN THE [PRT] SWITCH IS PRESSED, NOTING IS PRINTED OUT 475
L-18 PAPE FLASHES 476
L-19 THE TIME IS WRONG 476
L-20 E33 IS DISPLAYED 476
RELATED ELECTRICAL CIRCUIT DIAGRAMS 477
ELECTRICAL CIRCUIT DIAGRAMS FOR PAYLOAD METER SYSTEM 480
TROUBLESHOOTING OF MONITOR PANEL SYSTEM 481
P-1 MONITOR PANEL DOES NOT WORK AT ALL 483
P-2 PART OF MONITOR PANEL DOES NOT WORK 484
a) SPEEDOMETER DISPLAY DOES NOT WORK 484
b) SPEEDOMETER DISPLAY WORKS, BUT OTHER PARTS DO NOT WORK 484
c) SUSPENSION DISPLAY DOES NOT WORK 484
d) (MECHATRONICS) CAUTION, FUEL GAUGE DISPLAYS DO NOT WORK 485
P-3 ENGINE (MECHATRONICS) DISPLAY FLASHES 486
P-4 AUTOMATIC SHIFT DISPLAY (MECHATRONICS) FLASHES 487
P-5 SUSPENSION (MECHATRONICS) FLASHES 487
P-6 ABNORMALITY IN POWER MODE DISPLAY・HIGH POWER DISPLAY DOES NOT LIGHT UP 488
P-7 ABNORMALITY IN SUSPENSION DISPLAY 489
a) HIGH POWER DISPLAY DOES NOT LIGHT UP 489
b) MEDIUM DISPLAY DOES NOT LIGHT UP 489
c) SOFT DISPLAY DOES NOT LIGHT UP 490
d) SUSPENSION MODE DISPLAYS ALL LIGHT UP 490
P-8 ABNORMALITY IN SHIFT POSITION DISPLAY 491
a) R DISPLAY DOES NOT LIGHT UP 491
b) N DISPLAY DOES NOT LIGHT UP 491
c) D DISPLAY DOES NOT LIGHT UP 492
d) 5 DISPLAY DOES NOT LIGHT UP 492
e) 4 DISPLAY DOES NOT LIGHT UP 493
f) 3 DISPLAY DOES NOT LIGHT UP 493
g) L DISPLAY DOES NOT LIGHT UP 494
P-9 SHIFT LIMITER DISPLAY DOES NOT LIGHT UP 495
P-10 LOCK-UP DISPLAY DOES NOT LIGHT UP 495
P-11 HI BEAM DISPLAY DOES NOT LIGHT UP 496
P-12 ABNORMALITY IN TURN SIGNAL 497
a) RIGHT TURN SIGNAL LAMP DOES NOT LIGHT UP 497
b) LEFT TURN SIGNAL LAMP DOES NOT LIGHT UP 497
P-13 ABNORMALITY IN SHIFT INDICATOR DISPLAY 498
a) WHEN 1,2,4,6, R IS DISPLAYED, DISPLAY CHANGES TO E 498
b) WHEN 3,5,7 IS DISPLAYED, DISPLAY CHANGES TO E 498
c) WHEN 1 IS DISPLAYED, DISPLAY CHANGES TO E 499
d) WHEN 2,3 IS DISPLAYED, DISPLAY CHANGES TO E 499
e) WHEN 4,5 IS DISPLAYED, DISPLAY CHANGES TO E 500
f) WHEN 6,7 IS DISPLAYED, DISPLAY CHANGES TO E 500
g) WHEN R IS DISPLAYED, DISPLAY CHANGES TO E 501
P-14 SPEEDOMETER DOES NOT WORK NORMALLY 502
P-15 TACHOMETER DOES NOT WORK NORMALLY 502
P-16 SERVICE METER DOES NOT WORK 503
P-17 ODOMETER DOES NOT WORK 503
P-18 ABNORMALITY IN ALARM BUZZER 504
a) CAUTION DISPLAY IS FLASHING (LIGHTED UP), BUT ALARM BUZZER DOES NOT SOUND 504
b) ALARM BUZZER CONTINUES TO SOUND 504
P-19 ABNORMALITY IN WARNING LAMP 505
a) CAUTION DISPLAY IS FLASHING (LIGHTED UP), BUT ALARM BUZZER DOES NOT FLASH 505
b) WARNING LAMP STAYS ON 505
P-20 CAUTION DISPLAY DOES NOT FLASH (DOES NOT LIGHT UP), BUT WARNING LAMP FLASHES AND ALARM BUZZER SOUNDS 506
a) WARNING LAMP FLASHES AND ALARM BUZZER SOUNDS 506
b) WARNING LAMP FLASHES WHEN ENGINE STOPS 506
c) WARNING LAMP FLASHES WHEN ENGINE IS RUNNING 506
P-21 ABNORMALITY IN PRESSURE GAUGE 507
a) NO DISPLAY GIVEN IN DISPLAY AREA 507
b) DISPLAY SHOWS HIGHEST LEVEL AND DOES NOT MOVE 507
P-22 ABNORMALITY IN COOLANT TEMPERATURE GAUGE 508
a) NO DISPLAY GIVEN IN DISPLAY AREA 508
b) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE 508
P-23 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE 509
a) NO DISPLAY GIVEN IN DISPLAY AREA 509
b) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE 509
P-24 ABNORMALITY IN RETARDER OIL TEMPERATURE GAUGE 510
a) NO DISPLAY GIVEN IN DISPLAY AREA 510
b) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE 510
P-25 ABNORMALITY IN FUEL GAUGE 511
a) NO DISPLAY GIVEN IN DISPLAY AREA 511
b) DISPLAY SHOWS FULL AND DOES NOT MOVE 511
P-26 ABNORMALITY IN NIGHT LIGHTING 512
a) NONE OF PANEL LAMPS LIGHT UP 512
b) SERVICE METER AND ODOMETER LIGHT UP, BUR OTHER PARTS DO NOT LIGHT UP 513
c) SERVICE METER AND ODOMETER OD NOT LIGHT UP 513
RELATED ELECTRICAL CIRCUIT DIAGRAMS 514
ELECTRICAL CIRCUIT FOR MONITOR PANEL SYSTEM 522
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM 523
M-1 MAINTENANCE MONITOR DOES NOT WORK 524
a) WHEN NOTHING WORKS 524
b) WHEN CHECK DISPLAY DOES NOT WORK 524
M-2 WHEN ENGINE IS STOPPED, ENGINE OIL LEVEL DISPLAY FLASHES 525
M-3 WHEN ENGINE IS STOPPED, TRANSMISSION OIL LEVEL DISPLAY FLASHES 526
M-4 WHEN ENGINE IS STOPPED, HYDRAULIC OIL LEVEL DISPLAY FLASHES 527
M-5 WHEN ENGINE IS STOPPED, RETARDER OIL LEVEL DISPLAY FLASHES 528
M-6 WHEN ENGINE IS STOPPED, BRAKE OIL LEVEL DISPLAY FLASHES 529
M-7 WHEN ENGINE IS STOPPED, BATTERY ELECTROLYTE LEVEL DISPLAY FLASHES 530
M-8 RETARDER WEAR DISPLAY FLASHES 531
M-9 WHEN ENGINE IS RUNNING, AIR CLEANER CLOGGING DISPLAY FLASHES 532
M-10 WHEN ENGINE IS RUNNING, FULL-FLOW FILTER CLOGGING DISPLAY FLASHES 533
M-11 WHEN ENGINE IS RUNNING, TRANSMISSION FILTER CLOGGING DISPLAY FLASHES 534
M-12 WHEN ENGINE IS RUNNING, HYDRAULIC FILTER CLOGGING DISPLAY FLASHES 535
M-13 WHEN ENGINE IS RUNNING, RETARDER FILTER CLOGGING DISPLAY FLASHES 536
M-14 MAINTENANCE TIMER DOES NOT WORK 537
M-15 ABNORMALITY IN SWITCH 538
a) CONFIRMATION SWITCH FOR OIL OR FILTER REPLACEMENT TIME DOES NOT WORK 538
b) REPLACEMENT SWITCH, MISOPERATION CANCEL SWITCH DO NOT WORK 538
M-16 NIGHT LIGHTING DOES NOT LIGHT UP 539
ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM 540
TROUBLESHOOTING OF PILOT LAMP SYSTEM 541
F-1 ABNORMALITY IN LIGHTING UP OF REAR BRAKE LAMP 542
a) BRAKE IS NOT BEING APPLIED, BUT PILOT LAMP LIGHTS UP 542
b) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN BRAKE IS APPLIED 543
F-2 ABNORMALITY IN LIGHTING UP OF BODY FLOAT PILOT LAMP 544
a) HOIST LEVER IS AT FLOAT POSITION, BUT PILOT LAMP LIGHTS UP 544
b) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN HOIST LEVER IS OPERATED 545
F-3 ABNORMAL LIGHTING UP OF EXHAUST BRAKE PILOT LAMP 546
a) PILOT LAMP LIGHTS UP EVEN WHEN EXHAUST BRAKE IS NOT BEING OPERATED 546
b) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN EXHAUST BRAKE IS BEING OPERATED 547
F-4 ABNORMALITY IN LIGHTING UP OF PARKING BRAKE PILOT LAMP 548
a) PARKING BRAKE IS NOT BEING APPLIED, BUT PILOT LAMP LIGHT UP 548
b) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN PARKING BRAKE IS APPLIED 549
ELECTRICAL CIRCUIT DIAGRAM FOR PILOT LAMP SYSTEM 550
TROUBLESHOOTING OF AIR SYSTEM ON MACHINE AIR COMPRESSOR 551
BASIC AIR CIRCUIT OF AIR COMPRESSOR 552
C-1 AIR PRESSURE DOES NOT RISE AT ALL 553
C-2 AIR PRESSURE DOES NOT RISE TO SPECIFIED RANGE 555
C-3 AIR PRESSURE RISE, BUT TAKES A LONG TIME TO CHANGE 556
C-4 WHEN AIR PRESSURE REACHES TOP OF GREEN RANGE ON AIR GAUGE, AIR PRESSURE SUDDENLY DROPS TO BOTTOM OF GREEN RANGE ON AIR GAUGE EVEN WHEN NO AIR IS USED 556
C-5 AIR BLOWS OUT FROM SAFETY VALVE 557
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM 558
H-1: MACHINE DOES NOT MOVE 559
H-2: MACHINE DOES NOT TRAVEL SMOOTHLY 561
H-3: LOCK-UP CLUTCH CANNOT BE DISENGAGED 561
H-4: LARGE SHOCK WHEN STARTING OR SHIFTING 562
H-5: TRANSMISSION DOES NOT SHIFT UP 562
H-6: MACHINE LACKS POWER OR SPEED WHEN TRAVELING 563
H-7: TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR 569
H-8: TORQUE CONVERTER OIL TEMPERATURE IS HIGH 571
H-9: TORQUE CONVERTER OIL PRESSURE IS LOW 572
H-10: FRONT BRAKE IS INEFFECTIVE OR EFFECTIVE ONE SIDE 573
H-11: REAR BRAKE IS INEFFECTIVE OR EFFECTIVE ONE SIDE 574
H-12: STEERING WHEEL IS HEAVY 575
H-13: STEERING WHEEL DOES NOT FUNCTION 576
H-14: STEERING WHEEL VIBRATES 576
H-15: HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED) 577
H-16: HOIST CYLINDER DOES NOT WORK 578
H-17: EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY 579
30 DISASSEMBLY AND ASSEMBLY 580
METHOD OF USING MANUAL 582
PRECAUTIONS WHEN CARRYING OUT OPERATION 583
SPECIAL TOOL LIST 585
STARTING MOTOR 587
REMOVAL 587
INSTALLATION 587
ALTERNATOR 588
REMOVAL 588
INSTALLATION 588
ENGINE OIL COOLER 589
REMOVAL 589
INSTALLATION 589
FUEL INJECTION PUMP 590
REMOVAL 590
INSTALLATION 591
AIR COMPRESSOR 592
REMOVAL 592
INSTALLATION 592
AIR CONDITIONER COMPRESSOR 593
REMOVAL 593
INSTALLATION 593
AIR CONDITIONER CONDENSER 594
REMOVAL 594
INSTALLATION 594
WATER PUMP 595
REMOVAL 595
INSTALLATION 595
AFTERCOOLER CORE 596
REMOVAL 596
INSTALLATION 596
AFTERCOOLER 598
REMOVAL 598
INSTALLATION 598
EXHAUST BRAKE CYLINDER 599
REMOVAL 599
INSTALLATION 599
TURBOCHARGER 601
REMOVAL 601
INSTALLATION 601
NOZZLE HOLDER 603
REMOVAL 603
INSTALLATION 603
CYLINDER HEAD 605
REMOVAL 605
INSTALLATION 611
ENGINE 613
REMOVAL 613
INSTALLATION 616
RADIATER, TORQUE CONVERTER OIL COOLER 617
REMOVAL 617
INSTALLATION 619
BRAKE OIL COOLER 620
REMOVAL 620
INSTALLATION 620
OUTPUT SHAFT 621
REMOVAL 621
INSTALLATION 621
DISASSEMBLY 623
ASSEMBLY 624
TORQUE CONVERTER, TRANSMISSION 626
REMOVAL 626
INSTALLATION 627
TORQUE CONVERTER VALVE 629
REMOVAL 629
INSTALLATION 629
DISASSEMBLY 630
ASSEMBLY 630
TORQUE CONVERTER VALVE AND TRANSMISSION 631
DISCONNECTION 631
CONNECTION 632
TORQUE CONVERTER, PTO 633
DISASSEMBLY 633
ASSEMBLY 639
TRANSMISSION 646
DISASSEMBLY 646
ASSEMBLY 662
TRANSMISSION CONTROL VALVE 679
REMOVAL 679
INSTALLATION 679
ECMV 680
DISASSEMBLY 680
ASSEMBLY 680
DIFFERENTIAL 682
REMOVAL 682
INSTALLATION 682
DISASSEMBLY 683
ASSEMBLY 687
FRONT WHEEL 696
REMOVAL 696
INSTALLATION 696
REAR WHEEL 697
REMOVAL 697
INSTALLATION 698
FRONT BRAKE CALIPER PAD 699
REMOVAL 699
INSTALLATION 699
FRONT BRAKE CALIPER 700
REMOVAL 700
INSTALLATION 700
DISASSEMBLY 701
ASSEMBLY 701
FRONT WHEEL HUB 702
DISASSEMBLY 702
ASSEMBLY 704
FINAL DRIVE CARRIER 707
REMOVAL 707
INSTALLATION 707
DISASSEMBLY 708
ASSEMBLY 708
FINAL DRIVE 710
DISASSEMBLY 710
ASSEMBLY 712
REAR BRAKE 714
REMOVAL 714
INSTALLATION 714
DISASSEMBLY 715
ASSEMBLY 716
PARKING BRAKE PAD 718
REMOVAL 718
INSTALLATION 718
PARKING BRAKE CALIPER 719
REMOVAL 719
INSTALLATION 719
DISASSEMBLY 720
ASSEMBLY 720
FRONT SUSPENSION CYLINDER 721
REMOVAL 721
INSTALLATION 721
DISASSEMBLY 723
ASSEMBLY 724
VARIABLE DAMPING SELECTOR VALVE 725
DISASSEMBLY 725
ASSEMBLY 726
FIXED DAMPING VALVE 727
DISASSEMBLY 727
ASSEMBLY 728
REAR SUSPENSION CYLINDER 729
REMOVAL 729
INSTALLATION 729
DISASSEMBLY 731
ASSEMBLY 732
AIR GOVERNOR 735
REMOVAL 735
INSTALLATION 735
DISASSEMBLY 736
ASSEMBLY 736
BRAKE VALVE 737
REMOVAL 737
INSTALLATION 737
DISASSEMBLY 738
ASSEMBLY 740
PARKING BRAKE CHAMBER 742
REMOVAL 742
INSTALLATION 742
DISASSEMBLY 743
ASSEMBLY 744
FRONT BRAKE CHAMBER 746
REMOVAL 746
INSTALLATION 746
DISASSEMBLY 747
ASSEMBLY 749
REAR BRAKE CHAMBER 746
REMOVAL 746
INSTALLATION 746
DISASSEMBLY 751
ASSEMBLY 753
SLACK ADJUSTER 761
REMOVAL 761
INSTALLATION 761
DISASSEMBLY 762
ASSEMBLY 762
TRANSMISSION LUBRICATION, RETERDER BRAKE PUMP 763
REMOVAL 763
INSTALLATION 763
BRAKE COOLING PUMP 764
REMOVAL 764
INSTALLATION 764
HOIST, STEERING PUMP 764
REMOVAL 764
INSTALLATION 764
EMERGENCY STEERING MOTOR PUMP 765
REMOVAL 765
INSTALLATION 765
BRAKE CONTROL VALVE 766
REMOVAL 766
INSTALLATION 766
STEERING VALVE 767
REMOVAL 767
INSTALLATION 767
DISASSEMBLY 768
ASSEMBLY 772
DEMAND VALVE 778
REMOVAL 778
INSTALLATION 778
DISASSEMBLY 779
ASSEMBLY 779
RELIEF VALVE 780
DISASSEMBLY 780
ASSEMBLY 780
HOIST VALVE 781
REMOVAL 781
INSTALLATION 781
DISASSEMBLY 782
ASSEMBLY 783
STEERING CYLINDER 784
REMOVAL 784
INSTALLATION 784
DISASSEMBLY 785
ASSEMBLY 787
HOIST CYLINDER 789
REMOVAL 789
INSTALLATION 789
DISASSEMBLY 790
ASSEMBLY 791
BODY 792
REMOVAL 792
INSTALLATION 793
TRANSMISSION CONTROLLER 794
REMOVAL 794
INSTALLATION 794
SUSPENSION CONTROLLER 794
REMOVAL 794
INSTALLATION 794
40 MAINTENANCE STANDARD 795
OUTPUT SHAFT 796
TORQUE CONVERTER VALVE 797
TORQUE CONVERTER 798
TRANSMISSION 800
ECMV (ELECTRONIC CONTROL MODULATION VALVE) 804
FRONT AXLE 805
REAR AXLE SUPPORT 807
DIFFERENTIAL 808
FINAL DRIVE 809
FRONT BRAKE 811
REAR BRAKE 813
PARKING BRAKE 814
STEERING LINKAGE 816
FRONT SUSPENSION CYLINDER 818
REAR SUSPENSION CYLINDER 819
PARKING BRAKE CHAMBER 820
SLACK ADJUSTER 821
HYDRAULIC PUMP 822
DEMAND VALVE 825
CLOSS-OVER RELIEF VALVE 825
HOIST VALVE 826
STEERING CYLINDER 827
HOIST CYLINDER 828

DESCRIPTION:

Komatsu HD465-5 Dump Truck Shop Manual SEBM05690507 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NO.
HD465-5                     4001 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

S.V 26/12/24