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KOMATSU HD465-5 Rigid Dump Truck Service Repair Workshop Manual – PDF DOWNLOAD
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KOMATSU HD465-5 Rigid Dump Truck Service Repair Workshop Manual
Book Code: SEBM05690507
MACHINE MODEL SERIAL NUMBER
HD465-5 4001 and up
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Description
KOMATSU HD465-5 Rigid Dump Truck Service Repair Workshop Manual
FILE DETAILS:
KOMATSU HD465-5 Rigid Dump Truck Service Repair Workshop Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: HD465-5
Serial Number: 4001 and up
Book Code: SEBM05690507
Language: English
Pages: 828
File Format: Portable Document Format (PDF)
DESCRIPTION:
KOMATSU HD465-5 Rigid Dump Truck Service Repair Workshop Manual
FOREWORD:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen 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 centains the necessary technical information for operations performed in a service workshop.
- For ease of understanding. the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections.
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.
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” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing. installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU HD465-5 Rigid Dump Truck Service Repair Workshop Manual
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
KOMATSU HD465-5 RIGID DUMP TRUCK SERVICE REPAIR WORKSHOP MANUAL – PDF DOWNLOAD:
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