Komatsu HD465-7 Rigid Dump Truck Shop Manual SEBM040101 PDF

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Komatsu HD465-7 Rigid Dump Truck Shop Manual SEBM040101 – PDF DOWNLOAD 

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Komatsu HD465-7 Rigid Dump Truck Shop Manual SEBM040101 – PDF DOWNLOAD 

Language : English
Pages : 1076
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu HD465-7 Rigid Dump Truck Shop Manual SEBM040101 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NUMBER
HD465-7                     7512 and up

COVER 1
CONTENTS 2
01 GENERAL 28
SPECIFICATION DRAWINGS 29
SPECIFICATIONS 30
WEIGHT TABLE 33
FUEL, COOLANT AND LUBRICANTS 34
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 36
RADIATOR, TORQUE CONVERTER OIL COOLER, AFTER COOLER, WORK EQUIPMENT OIL COOLER, FUEL COOLER 38
BRAKE OIL COOLER 39
POWER TRAIN SKELETON 40
OUTPUT SHAFT 41
DRIVE SHAFT 43
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING 45
TORQUE CONVERTER 47
TRANSMISSION 55
TRANSMISSION VALVE 64
ECMV 65
AXLE 75
DIFFERENTIAL 77
FINAL DRIVE 79
WHEELS 81
SUSPENSION 83
SUSPENSION CYLINDER 85
REAR AXLE SUPPORT 91
STEERING COLUMN 93
STEERING LINKAGE 94
BRAKE PIPING 97
BRAKE VALVE 99
EMERGENCY BRAKE VALVE 102
RELAY VALVE 103
FRONT BRAKE OFF VALVE 104
ACCUMULATOR CHARGE VALVE 105
ACCUMULATOR 109
SLACK ADJUSTER 110
BRAKE 113
PROPORTIONAL REDUCING VALVE 118
PARKING BRAKE SOLENOID VALVE 119
STEERING AND HOIST HYDRAULIC PIPING 121
DUMP BODY CONTROL 123
HYDRAULIC TANK 124
STEERING CONTROL VALVE 125
CROSSOVER RELIEF VALVE 129
STEERING CYLINDER 130
DEMAND VALVE 131
HOIST VALVE 135
EPC VALVE 141
HOIST CYLINDER 142
HYDRAULIC PUMP 143
AIR CONDITIONER 147
MACHINE MONITOR SYSTEM 155
ENGINE CONTROL SYSTEM 170
AUTOMATIC SHIFT CONTROL SYSTEM 172
PAYLOAD METER Ⅱ(CARD TYPE) 184
AUTOMATIC EMERGENCY STEERING SYSTEM 217
AUTOMATIC SUSPENSION SYSTEM 219
RETARDER CONTROL SYSTEM 223
SENSORS, SWITCHES 235
DUMP LEVER 243
EXTERNAL POWER SUPPLY HEATER 247
20 TESTING AND ADJUSTING 248
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 249
STANDARD VALUE TABLE FOR CHASSIS 250
TESTING AND ADJUSTING 256
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 257
MEASURING ENGINE SPEED 261
ADJUSTING ENGINE SPEED SENSOR 263
MEASURING ENGINE OIL PRESSURE 264
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 265
MEASURING EXHAUST TEMPERATURE 267
MEASURING BLOW-BY PRESSURE 269
TROUBLESHOOTING OF INJECTOR 270
MEASURING COMPRESSION PRESSURE 271
HANDLING EQUIPMENT IN FUEL SYSTEM 273
MEASURING FUEL PUMP OUTLET PORT PRESSURE 273
MEASURING FUEL PUMP INLET PORT PRESSURE 275
VISUAL INSPECTION OF RETURN FUEL 275
ADJUSTING INJECTOR SET LOAD 276
BLEEDING AIR FROM FUEL CIRCUIT 278
MEASURING EXHAUST COLOR 280
ADJUSTING VALVE CLEARANCE 281
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 282
TESTING AND ADJUSTING, AIR CONDITIONER COMPRESSOR BELT TENSION 283
MEASURING POWER TRAIN OIL PRESSURE 284
ADJUSTING TRANSMISSION SPEED SENSOR 291
INSPECTING BRAKE OIL PRESSURE 292
BLEEDING AIR FROM BRAKE CIRCUIT 294
TESTING WEAR OF FRONT BRAKE PAD 295
TESTING WEAR OF REAR BRAKE DISC 296
METHOD OF RELEASING PARKING BRAKE IN AN EMERGENCY 297
TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER 298
TESTING AND ADJUSTING INVERTED TYPE REAR SUSPENSION CYLINDER 302
TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER (MODE SELECTOR HYDRAULIC CYLINDER) 305
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT 306
TESTING AND ADJUSTING OIL PRESSURE IN DUMP EPC CIRCUIT 309
AIR BLEEDING FROM STEERING CYLINDER 310
PROCEDURE FOR RAISING DUMP BODY IN EMERGENCY 311
ADJUSTING BODY POSITIONER SENSOR 312
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM 315
ADJUSTING MACHINE MONITOR (EMMS) 319
ADJUSTING TRANSMISSION CONTROLLER 323
INITIAL SETTING OF PAYLOAD METER 324
SETTING OF CARD-TYPE PAYLOAD METER AFTER INSTALLATION OR REPLACEMENT 325
SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS) 333
PERFORMING PM-CLINIC USING MANUAL SNAPSHOT (= QUICK PM) 385
PM-CLINIC SERVICE 389
TROUBLESHOOTING 392
POINTS TO REMEMBER WHEN TROUBLESHOOTING 393
SEQUENCE OF EVENTS IN TROUBLESHOOTING 394
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 395
CHECKS BEFORE TROUBLESHOOTING 403
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS 405
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 411
T-ADAPTER TABLE 435
TYPES AND LOCATIONS OF CONNECTORS 438
CONNECTOR ARRANGEMENT LOCATION 453
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ENG MODE) 462
ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL 465
INFORMATION IN TROUBLESHOOTING TABLE 467
[C111KT] ABNORMALITY IN ENGINE CONTROLLER MEMORY 469
[C112LK] ABNORMALITY IN TIMING RAIL ACTUATOR 469
[C113KZ] ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM 470
[C115KZ] ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS 471
[C116KX] ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM 473
[C117KX] ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM 474
[C118KX] ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM 475
[C119KX] ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM 476
[C121LC] ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEMS 476
[C122KX] ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR SYSTEM 477
[C123KX] ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR SYSTEM 478
[C131KX] ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM 479
[C132KX] ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM 481
[C135KX] ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM 482
[C141KX] ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM 483
[C143ZG] LOWERING OF ENGINE OIL PRESSURE 483
[C144KX] ABNORMALLY HIGH LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM 484
[C145KX] ABNORMALLY LOW LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM 485
[C148KX] ABNORMALITY IN FM THROTTLE: OUT OF INPUT SIGNAL RANGE 486
[C151NS] RISE OF ENGINE COOLANT TEMPERATURE 487
[C153KX] ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM 488
[C154KX] ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM 489
[C221KX] ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM 490
[C222KX] ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM 491
[C234NI] OVER-SPEED 491
[C254KZ] ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE 492
[C259FS] ABNORMALITY IN FUEL SHUT-OFF VALVE 493
[C261NS] ABNORMAL RISE OF FUEL TEMPERATURE 493
[C263KX] ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM 494
[C265KX] ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM 495
[C316KZ] ABNORMAL CURRENT OF FUEL PUMP ACTUATOR 496
[C318LK] ABNORMALITY IN FUEL PUMP ACTUATOR 497
[C346KT] ABNORMALITY IN POWER-DOWN UNIT OF ENGINE CONTROLLER 498
[C423L6] ABNORMALITY IN IN-RANGE OF TIMING RAIL PRESSURE SENSOR SYSTEM 500
[C431L4] ABNORMALITY IN IDLE VALIDATION SWITCH SYSTEM: *SEE SEPARATE LIST (L4) (BOTH SIGNAL VOLTAGES OF 2 SYSTEMS ARE SENSED) 502
[C432L5] ERROR IN IDLE VALIDATION PROCESS (*SEE SEPARATE LIST (L5)) 504
[C441KX] ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM 506
[C442KG] ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGE SYSTEM 506
[C451KX] ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM 507
[C452KX] ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM 508
[C455KZ] ABNORMAL CURRENT OF FUEL RAIL ACTUATOR 509
[C467LK] ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL 510
[C468LK] ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL 510
[C514LK] ABNORMALITY IN FUEL RAIL ACTUATOR 511
[C551L4] ABNORMALITY IN IDLE VALIDATION SWITCH SYSTEM: *SEE SEPARATE LIST (L4) (EITHER SIGNAL VOLTAGE OF 2 SYSTEMS IS NOT SENSED) 512
[C554L6] ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE SENSOR SYSTEM 514
ENG-1 ENGINE DOES NOT START 516
ENG-2 FAILURE IN PREHEATING 520
a) ENGINE IS NOT PREHEATED 520
b) PREHEATING IS ACTUATED EVEN UNDER NON-ACTUATION CONDITIONS FOR PREHEATING 523
ENG-3 AISS FUNCTION DOES NOT WORK NORMALLY 525
a) WHEN AISS SWITCH IS SET IN AUTO, LOW SPEED CONTROL IS SELECTED 525
b) WHEN AISS SWITCH IS SET IN LOW SPEED, AUTO CONTROL IS SELECTED 526
TROUBLESHOOTING FOR TRANSMISSION CONTROLLER SYSTEM (TM MODE) 528
ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL 530
INFORMATION IN TROUBLESHOOTING TABLE 531
PHENOMENON CODE TABLE 532
[1380MW] LOCKUP CLUTCH: SLIP (MW) 533
[1500L0] DETECTION OF DOUBLE ENGAGEMENT: *SEE SEPARATE LIST (L0) 534
[15B0NX] CLOGGING OF TRANSMISSION OIL FILTER: CLOGGING (NX) 535
[15E0KM] R TO F GEAR SHIFT ABUSE 1: MISTAKE IN OPERATION OR SETTING (KM) 536
[15E7KM] R TO F GEAR SHIFT ABUSE 2: MISTAKE IN OPERATION OR SETTING (KM) 536
[15G0MW] R CLUTCH: SLIP (MW) 537
[15H0MW] HI CLUTCH: SLIP (MW) 538
[15J0MW] LO CLUTCH: SLIP (MW) 540
[15K0MW] 1ST CLUTCH: SLIP (MW) 542
[15L0MW] 2ND CLUTCH: SLIP (MW) 543
[15M0MW] 3RD CLUTCH: SLIP (MW) 544
[15N0MW] 4TH CLUTCH: SLIP (MW) 545
[15SBL1] R CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) 546
[15SBMA] R CLUTCH SOLENOID: MALFUNCTION (MA) 547
[15SCL1] HI CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) 548
[15SCMA] HI CLUTCH SOLENOID: MALFUNCTION (MA) 549
[15SDL1] LO CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) 550
[15SDMA] LO CLUTCH SOLENOID: MALFUNCTION (MA) 551
[15SEL1] 1ST CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) 552
[15SEMA] 1ST CLUTCH SOLENOID: MALFUNCTION (MA) 553
[15SFL1] 2ND CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) 554
[15SFMA] 2ND CLUTCH SOLENOID: MALFUNCTION (MA) 555
[15SGL1] 3RD CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) 556
[15SGMA] 3RD CLUTCH SOLENOID: MALFUNCTION (MA) 557
[15SHL1] 4TH CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) 558
[15SHMA] 4TH CLUTCH SOLENOID: MALFUNCTION (MA) 559
[15SJL1] LOCKUP CLUTCH SOLENOID: 15SJ (L1) 560
[15SJMA] LOCKUP CLUTCH SOLENOID: 15SJ (MA) 561
[2F00KM] PARKING BRAKE: MISTAKE IN OPERATION OR SETTING (KM) 562
[989A00] ENGINE OVERRUN PREVENTION COMMAND SIGNAL: OPERATION (00) 564
[989AKZ] ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ) 565
[AA10NX] AIR CLEANER ELEMENT: CLOGGING (NX) 566
[AB00MA] ALTERNATOR: MALFUNCTION (MA) 568
[B@BCZK] LOWERING OF RADIATOR WATER: LOWERING OF LEVEL (ZK) 570
[D1B0KZ] TRANSMISSION CONTROLLER CUTOUT: DISCONNECTION OR SHORT CIRCUIT (KZ) 571
[D5ZMKZ] DISCONNECTION, GROUNDING FAULT, OR SHORT CIRCUIT IN ENGINE OUTPUT MODE COMMAND LINE: DISCONNECTION OR SHORT CIRCUIT (KZ) 573
[DAQ0KK] TRANSMISSION CONTROLLER: LOWERING OF SOURCE/INPUT VOLTAGE (KK) 574
[DAQ1KK] MAIN POWER LINE OF TRANSMISSION CONTROLLER: LOWERING OF SOURCE/INPUT VOLTAGE (KK) 576
[DAQ2KK] TRANSMISSION CONTROLLER LOAD POWER LINE: LOWERING OF SOURCE/INPUT VOLTAGE (KK) 578
[DAQ3KK] DIRECT LINE OF TRANSMISSION CONTROLLER BATTERY: LOWERING OF SOURCE/INPUT VOLTAGE (KK) 580
[DAQ9KM] TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKE IN OPERATION OR SETTING (KM) 581
[DAQ9KQ] TRANSMISSION CONTROLLER WIRING HARNESS: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ) 582
[DAQAKQ] TRANSMISSION CONTROLLER ROTARY SWITCH: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ) 583
[DAQSMA] TRANSMISSION CONTROLLER: MALFUNCTION (MA) 583
[DDTGKA] LOCKUP CLUTCH FILL SWITCH: DISCONNECTION (KA) 584
[DDTHKA] HI CLUTCH FILL SWITCH: DISCONNECTION (KA) 585
[DDTJKA] LO CLUTCH FILL SWITCH: DISCONNECTION (KA) 586
[DDTKKA] 1ST CLUTCH FILL SWITCH: DISCONNECTION (KA) 587
[DDTLKA] 2ND CLUTCH FILL SWITCH: DISCONNECTION (KA) 588
[DDTMKA] 3RD CLUTCH FILL SWITCH: DISCONNECTION (KA) 589
[DDTNKA] R CLUTCH FILL SWITCH: DISCONNECTION (KA) 590
[DDTPKA] 4TH CLUTCH FILL SWITCH : DISCONNECTION (KA) 591
[DF10KA] SHIFT LEVER: DISCONNECTION (KA) 592
[DF10KB] SHIFT LEVER: SHORT CIRCUIT (KB) 596
[DGF1KX] TRANSMISSION VALVE OIL TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE (KX) 599
[DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR: OUT OF INPUTSIGNAL RANGE (KX) 601
[DHT5KX] TORQUE CONVERTER OIL PRESSURE SENSOR: OUT OF INPUT SIGNAL RANGE (KX) 602
[DHT5L6] TORQUE CONVERTER OIL PRESSURE SENSOR: *SEE SEPARATE LIST (L6) 604
[DJF1KA] FUEL LEVEL SENSOR: DISCONNECTION (KA) 605
[DK11KX] THROTTLE ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX) 606
[DLE2KA] ENGINE SPEED SENSOR: DISCONNECTION (KA) 608
[DLE2LC] ENGINE SPEED SENSOR: *SEE SEPARATE LIST (LC) 609
[DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION (KA) 610
[DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR: *SEE SEPARATE LIST (LC) 611
[DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISCONNECTION (KA) 612
[DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: *SEE SEPARATE LIST (LC) 613
[DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA) 614
[DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: *SEE SEPARATE LIST (LC) 615
[DXH1KA] DISCONNECTION IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID: DISCONNECTION (KA) 617
[DXH1KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID: SHORT CIRCUIT (KB) 618
[DXH2KA] DISCONNECTION IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID: DISCONNECTION (KA) 619
[DXH2KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID: SHORT CIRCUIT (KB) 620
[DXH3KA] DISCONNECTION IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID: DISCONNECTION (KA) 622
[DXH3KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID: SHORT CIRCUIT (KB) 623
[DXH4KA] DISCONNECTION IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID: DISCONNECTION (KA) 625
[DXH4KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID: SHORT CIRCUIT (KB) 626
[DXH5KA] DISCONNECTION IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID: DISCONNECTION (KA) 627
[DXH5KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID: SHORT CIRCUIT (KB) 628
[DXH6KA] DISCONNECTION IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID: DISCONNECTION (KA) 629
[DXH6KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID: SHORT CIRCUIT (KB) 630
[DXH7KA] DISCONNECTION IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID: DISCONNECTION (KA) 631
[DXH7KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID: SHORT CIRCUIT (KB) 632
[DXHHKA] DISCONNECTION IN OUTPUT CIRCUIT OF 4TH CLUTCH SOLENOID: DISCONNECTION (KA) 633
[DXHHKB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 4TH CLUTCH SOLENOID: SHORT CIRCUIT (KB) 634
TM-1 FUEL LEVEL GAUGE DOES NOT OPERATE NORMALLY (IT ALWAYS INDICATES “FULL”) 635
TM-2 ABNORMALITY IN BACKUP LAMP AND BACKUP BUZZER 636
a) WHEN THE SHIFT LEVER IS SET IN THE “R” POSITION, THE BACKUP LAMP AND BACKUP BUZZER ARE NOT TURNED ON 636
b) BACKUP LAMP IS NOT TURNED ON (BACKUP BUZZER IS NORMAL) 637
c) BACKUP BUZZER IS NOT TURNED ON (BACKUP LAMP IS NORMAL) 637
d) WHILE SHIFT LEVER IS NOT OPERATED, BACKUP LAMP AND BACKUP BUZZER ARE TURNED ON 638
TROUBLESHOOTING FOR RETARDER CONTROLLER SYSTEM (BK MODE) 640
ELECTRICAL SYSTEM DIAGRAM RELATED TO RETARDER CONTROL 643
INFORMATION IN TROUBLESHOOTING TABLE 645
PHENOMENON CODE TABLE 646
[2G42ZG] ACCUMULATOR (FRONT): LOWERING OF OIL PRESSURE (ZG) 647
[2G43ZG] ACCUMULATOR (REAR): LOWERING OF OIL PRESSURE (ZG) 647
[D1C0KZ] BRAKE CUTOUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ) 648
[D5ZNKZ] FAILURE OF FRONT BRAKE CUTOUT OUTPUT SYSTEM (DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT) (IF EQUIPPED): DISCONNECTION OR SHORT CIRCUIT (KZ) 650
[DB10KK] RETARDER CONTROLLER: LOWERING OF SOURCE/INPUT VOLTAGE (KK) 652
[DB11KK] MAIN POWER LINE OF RETARDER CONTROLLER: LOWERING OF SOURCE/INPUT VOLTAGE (KK) 654
[DB12KK] RETARDER CONTROLLER LOAD POWER LINE: LOWERING OF SOURCE/INPUT VOLTAGE (KK) 656
[DB13KK] DIRECT POWER SOURCE LINE OF RETARDER CONTROLLER BATTERY: LOWERING OF SOURCE/INPUT VOLTAGE (KK) 658
[DB19KM] RETARDER CONTROLLER WIRING HARNESS: MISTAKE IN OPERATION OR SETTING (KM) 659
[DB1SKQ] WRONG INFORMATION ON MODEL SELECTION: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ) 660
[DDD7KX] FAILURE IN TRAVEL SPEED SET SWITCH SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX) 661
[DDD8KA] ARSC SYSTEM SWITCH SYSTEM: DISCONNECTION (KA) 663
[DDD8KB] ARSC SYSTEM SWITCH SYSTEM: SHORT CIRCUIT (KB) 664
[dGR2L8] FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM: *SEE SEPARATE LIST (L8) 665
[DGR2L8] BRAKE OIL TEMPERATURE SENSOR (REAR): *SEE SEPARATE LIST (L8) 666
[dHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FR) SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX) 667
[DHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FR) SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX) 669
[dHP5KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FL) SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX) 671
[DHP5KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FL) SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX) 673
[DHU2KX] ACCUMULATOR OIL PRESSURE SENSOR (FRONT): OUT OF INPUT SIGNAL RANGE (KX) 675
[DHU3KX] ACCUMULATOR OIL PRESSURE SENSOR (REAR): OUT OF INPUT SIGNAL RANGE (KX) 677
[dK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX) 679
[DK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX) 680
[DK51L5] RETARDER LEVER POTENTIOMETER: *SEE SEPARATE LIST (L5) 681
[DK52KX] DUMP LEVER POTENTIOMETER 1: OUT OF INPUT SIGNAL RANGE (KX) 684
[DK53L8] DUMP LEVER POTENTIOMETER 2: *SEE SEPARATE LIST (L8) 686
[DK54KX] BODY POSITIONER SENSOR: OUT OF INPUT SIGNAL RANGE (KX) 687
[DKD0L6] FAILURE IN STEERING SPEED SENSOR (IF EQUIPPED): *SEE SEPARATE LIST (L6) 689
[dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA) 691
[dLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA) 692
[DW35KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 1 (IF EQUIPPED) (DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT): DISCONNECTION OR SHORT CIRCUIT (KZ) 693
[DW36KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 2 (IF EQUIPPED) (DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT): DISCONNECTION OR SHORT CIRCUIT (KZ) 694
[DW72KZ] FAILURE IN KICK-OUT SOLENOID OUTPUT SYSTEM (D_OUT3)(DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT): DISCONNECTION OR SHORT CIRCUIT (KZ) 695
[DW73KZ] FAILURE IN HOIST SELECT VALVE OUTPUT SYSTEM (D_OUT5) (DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT): DISCONNECTION OR SHORT CIRCUIT (KZ) 697
[DK11K4] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL: UNCONTROLLABLE (K4) 699
[DX11KA] DISCONNECTION IN OUTPUT CIRCUIT OF PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2): DISCONNECTION (KA) 701
[DX11KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2): SHORT CIRCUIT (KB) 702
[DX11KY] GROUNDING FAULT IN OUTPUT CIRCUIT OF PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2): SHORT CIRCUIT WITH POWER SOURCE LINE (KY) 703
[DX11MA] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL: MALFUNCTION (MA) 704
[DX13KA] DISCONNECTION IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3): DISCONNECTION (KA) 705
[DX13KB] GROUNDING FAULT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3): SHORT CIRCUIT (KB) 706
[DX13KY] SHORT CIRCUIT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3): SHORT CIRCUIT WITH POWER SOURCE LINE (KY) 707
BK-1 PARKING BRAKE DOES NOT OPERATE NORMALLY 709
a) WHEN THE PARKING BRAKE SWITCH IS SET IN THE OFF POSITION, THE PARKING BRAKE IS NOT RELEASED 709
b) WHEN THE PARKING BRAKE SWITCH IS SET IN THE PARK POSITION, THE PARKING BRAKE DOES NOT WORK 711
BK-2 RETARDER BRAKE OIL TEMPERATURE GAUGE DOES NOT OPERATE NORMALLY 713
BK-3 INCLINATION ALARM IS TURNED ON WHEN DUMP BODY IS RAISED (WHEN MACHINE IS NOT INCLINED MORE THAN 15°) 714
BK-4 TOUCH UP/DOWN AND CANCELLATION CANNOT BE PERFORMED 715
TROUBLESHOOTING FOR PAYLOAD METER SYSTEM (CARD TYPE)(LC MODE) 718
ELECTRICAL SYSTEM DIAGRAM RELATED TO PAYLOAD METER 719
SERVICE CODES OF PAYLOAD METER Ⅱ(CARD TYPE) AND CONTENTS OF SELF-DIAGNOSIS 721
INFORMATION IN TROUBLESHOOTING TABLE 724
PHENOMENON CODE TABLE 725
LC-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM IS NOT DISPLAYED 726
LC-2 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL PILOT LAMPS DO NOT LIGHT UP 728
LC-3 EXTERNAL LAMPS LIGHT UP WHILE CONDITION FOR LIGHTING IS NOT SET 731
LC-4 LIGHTING LEVEL OF EXTERNAL PILOT LAMPS IS ABNORMAL 733
LC-5 CYCLE DATA AND ENGINE ON/OFF DATA NOT RECORDED (CHARGE LEVEL SIGNAL SYSTEM: JUDGES THAT ENGINE IS STOPPED) 735
LC-6 CALIBRATION CANNOT BE PERFORMED AND DISPLAYED CLOCK DOES NOT CONFORM TO CONDITION (SHIFT LEVER “N” POSITION SIGNAL SYSTEM) 736
LC-7 DISPLAYED LOGIC IS ABNORMAL 738
a) WHEN LOADED DUMP TRUCK STARTS TRAVELING, “0” IS KEPT DISPLAYED 738
b) AFTER LOADED DUMP TRUCK START TRAVELING, DISPLAY OF ODOMETER DOES NOT INCREASE 738
c) WHEN TRAVEL SPEED EXCEEDS LIMIT SPEED, “SP:SP” DOES NOT GO OFF 738
d) INTEGRATED PAY LOAD IS NOT DISPLAYED 739
e) DISPLAYED AND SAVED PAY LOAD IS NOT CORRECT 740
LC-8 PAYLOAD METER KEEPS DISPLAYING “b:FL” (BODY “FLOAT” SIGNAL SYSTEM: DUMP LEVER IS NOT IN “FLOAT” POSITION WHILE TRUCK IS NOT DUMPING) 741
LC-9 PAYLOAD METER DISPLAYS “F:09” (LOWERING OF INTERNAL BACKUP BATTERY VOLTAGE) 743
LC-10 PAYLOAD METER DISPLAYS “□:FULL” (DATA SAVING MEMORY IS FULL) 743
LC-11 PAYLOAD METER DISPLAYS “F-20”: FAILURE IN POWER SOURCE OF SUSPENSION PRESSURE SENSOR AND CLINOMETER SYSTEM 744
LC-12 PAYLOAD METER DISPLAYS “F-21″－”F-24”: DISCONNECTION OR GROUNDING FAULT IN SUSPENSION SENSOR SIGNAL SYSTEM 746
LC-13 PAYLOAD METER DISPLAYS “F-25″－”F-28”: SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN SUSPENSION SENSOR SIGNAL SYSTEM 749
LC-14 PAYLOAD METER DISPLAYS “F-CAL” (NEGLIGENCE OF CALIBRATION OR INTERNAL DAMAGE OF PAYLOAD METER) 751
LC-15 PAYLOAD METER DISPLAYS “F:43″－”F:45” (SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN EXTERNAL PILOT LAMP RELAY SYSTEM) 752
LC-16 PAYLOAD METER DISPLAYS “L-bad” (CYCLE DATA WERE SAVED WHILE TRUCK BODY WAS PITCHING) 754
LC-17 EXTERNAL PILOT LAMP INDICATES FORECAST WHILE TRUCK IS NOT BEING LOADED OR CLOCK IS DISPLAYED WHILE TRUCK TRAVELS FOR 160 M AFTER IT IS LOADED 756
LC-18 PAYLOAD METER DISPLAYS “F-31”: GROUNDING FAULT OR DISCONNECTION IN CLINOMETER SENSOR SIGNAL SYSTEM 757
LC-19 PAYLOAD METER DISPLAYS “F-32”: SHORT CIRCUIT WITH POWER SOURCE IN CLINOMETER SENSOR SIGNAL SYSTEM 759
LC-20 PAYLOAD METER DISPLAYS “F:18” (DISCONNECTION IN CHARGE LEVEL SIGNAL SYSTEM) 761
TROUBLESHOOTING FOR MONITOR SYSTEM (MON MODE) 762
ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR 765
INFORMATION IN TROUBLESHOOTING TABLE 766
PHENOMENON CODE TABLE 767
[B@C7NS] REAR BRAKE OIL: OVERHEATING (NS) 768
[B@CENS] TORQUE CONVERTER: OVERHEATING (NS) 768
[DAF0KM] MONITOR PANEL: MISTAKE IN OPERATION OR SETTING (KM) 769
[DAF9KM] MONITOR PANEL: MISTAKE IN OPERATION OR SETTING (KM) 772
[DAFSKQ] MONITOR PANEL: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ) 773
[DAQSKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN TRANSMISSION CON-TROLLER AND MACHINE MONITOR) (KR) 774
[DASRKR] CAN COMMUNICATION/COMMUNICATION DEFECTIVE: ABNORMALITY IN OBJECTIVE COMPONENT (KR) 777
[DB1SKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN RETARDER CONTROLLER AND MACHINE MONITOR) (KR) 779
[DV00KB] SHORT CIRCUIT IN ALARM BUZZER OUTPUT: SHORT CIRCUIT (KB) 782
MON-1 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR DOES NOT DISPLAY ANY ITEM 783
MON-2 WHEN STARTING SWITCH IS TURNED OFF AND MACHINE MONITOR DOES NOT OPERATE NORMALLY 784
MON-3 ALARM BUZZER DEFECTIVE 786
a) ALARM BUZZER DOES NOT SOUND 786
b) ALARM BUZZER DOES NOT STOP DOUNDING 787
MON-4 ITEMS DISPLAYED BY GAUGES, WARNING LAMPS, AND CHARACTER DISPLAY OF MACHINE MONITOR ARE ABNORMAL 788
a) ITEMS DISPLAYED BY GAUGES ARE DIFFERENT FROM MACHINE CONDITION 788
b) ITEMS DISPLAYED BY WARMING LAMPS ARE DIFFERENT FROM MACHINE CONDITION 789
c) CHARACTER DISPLAYED DOES NOT DISPLAY ANY ITEM OR IT DISPLAYS ABNORMALLY 789
MON-5 OPERATION OF MACHINE MONITOR CANNOT BE CHECKED NORMALLY 790
MON-6 DISPLAY OF CHARACTER DISPLAY CANNOT BE SELECTED NORMALLY 791
a) MACHINE MONITOR MODE SELECT SWITCH 1 SYSTEM IS ABNORMAL 791
b) MACHINE MONITOR MODE SELECT SWITCH 2 SYSTEM IS ABNORMAL 793
MON-7 POWER MODE SELECT FUNCTION DOES NOT WORK NORMALLY 795
MON-8 SEAT BELT WARNING LAMP DOES NOT OPERATE NORMALLY 796
a) LAMP LIGHTS UP WHILE SEAT BELT IS FASTENED 796
b) LAMP DOES NOT LIGHT UP WHILE SEAT BELT IS UNFASTENED 797
MON-9 TURN SIGNALS AND HAZARD LAMP DO NOT OPERATE NORMALLY 798
a) WHEN TURN SIGNAL LEVER AND HAZARD LAMP SWITCH ARE OPERATED, ANY TURN SIGNAL LAMP DOES NOT FLASH 798
b) WHEN TURN SIGNAL LEVER AND HAZARD LAMP SWITCH ARE OPERATED, THE TURN SIGNAL LAMPS DO NOT FLASH BUT LIGHT UP 799
c) WHEN TURN SIGNAL LEVER IS OPERATED, TURN SIGNAL LAMPS ON EITHER OR BOTH SIDES DO NOT FLASH (WHEN HAZARD LAMP SWITCH IS OPERATED, HOWEVER, TURN SIGNAL LAMPS FLASH NORMALLY) 800
d) WHEN HAZARD LAMP SWITCH IS TURNED ON, ANY TURN SIGNAL LAMP DOES NOT FLASH (WHEN TURN SIGNAL LEVER IS OPERATED, HOWEVER, TURN SIGNAL LAMPS FLASH NORMALLY) 801
e) WHEN HAZARD LAMP SWITCH IS TURNED OFF, TURN SIGNAL LAMPS CONTINUE FLASHING (WHEN TURN SIGNAL LEVER IS OPERATED, HOWEVER, TURN SIGNAL LAMPS FLASH NORMALLY) 803
f) TURN SIGNAL PILOT LAMPS DO NOT FLASH NORMALLY (TURN SIGNAL LAMPS FLASH NORMALLY, HOWEVER) 804
MON-10 NIGHT LIGHTING IS ABNORMAL 806
a) WHEN LAMP SWITCH IS SET IN 1ST OR 2ND POSITION, ANY OF SMALL LAMP, NIGHT LAMP, AND HEAD LAMP DOES NOT LIGHT UP 806
b) WHEN LAMP SWITCH IS SET IN 1ST POSITION, SMALL LAMP AND NIGHT LAMP DO NOT LIGHT UP 807
c) WHEN LAMP SWITCH IS OFF, SMALL LAMP AND NIGHT LAMP LIGHT UP 808
d) WHEN DIMMER SWITCH IS OPERATED, BRIGHTNESS OF NIGHT LIGHTING DOES NOT CHANGE 809
e) HEAD LAMP “HI” BEAM DOES NOT LIGHT UP 810
f) HEAD LAMP “LO” BEAM DOES NOT LIGHT UP 811
g) HEAD LAMP CANNOT BE SET TO “HI” OR “LO” 812
h) WHEN HEAD LAMP IS SET TO “HI” BEAM, PILOT LAMP OF MACHINE MONITOR DOES NOT LIGHT UP 813
MON-11 POWER WINDOW DOES NOT OPERATE NORMALLY 815
a) OPERATING LEFT SIDE DOES NOT 815
b) OPERATING RIGHT SIDE DOES NOT 816
MON-12 DEFECTIVE AIR CONDITIONER 818
a) AIR CONDITIONER DOES NOT OPERATE 818
b) AIR DOES NOT COME OUT OR AIR FLOW CANNOT BE ADJUSTED 819
c) AIR IS NOT COOLED OR TEMPERATURE CANNOT BE ADJUSTED (ELECTRIC SYSTEM) 821
d) RECIRCULATED AIR AND FRESH AIR CANNOT BE SELECTED 823
e) AIR OUTLETS CANNOT BE SELECTED 824
f) AIR IS NOT COOLED (MECHANICAL SYSTEM) 826
g) AIR IS NOT HEATED (DEFECTIVE HOT WATER CIRCUIT) 827
h) ABNORMAL SOUND COMES OUT 827
i) WATER LEAKS 828
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 830
H-1 MACHINE DOES NOT START 831
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS) 833
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS) 833
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING 834
H-5 TRANSMISSION DOES NOT SHIFT UP 834
a DOES NOT SHIFT UP 834
b DOES NOT SHIFT UP 834
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING 835
a ABNORMALITY AT ALL SPEED RANGES 835
b TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE 836
c ABNORMALITY AT SPECIFIC SPEED RANGES 837
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR 839
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 841
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW 842
H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE 843
H-11 REAR BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE 844
H-12 STEERING WHEEL IS HEAVY 845
H-13 STEERING WHEEL DOES NOT WORK 846
H-14 STEERING WHEEL VIBRATES 846
H-15 HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED) 847
H-16 HOIST CYLINDER DOES NOT WORK 848
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY 849
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 850
POINTS TO REMEMBER WHEN TROUBLESHOOTING 851
METHOD OF USING TROUBLESHOOTING CHARTS 852
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 855
S-2 ENGINE DOES NOT START 858
a) ENGINE DOES NOT TURN 858
b) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 859
c) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 861
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 863
S-4 ENGINE STOPS DURING OPERATIONS 865
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 867
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 869
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 871
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 874
S-9 OIL BECOMES CONTAMINATED QUICKLY 875
S-10 FUEL CONSUMPTION IS EXCESSIVE 876
S-11 OIL IS IN COOLANT, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 877
S-12 OIL PRESSURE WARNING LAMP LIGHTS UP (DROP IN OIL PRESSURE) 878
S-13 OIL LEVEL RISES 879
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 880
S-15 ABNORMAL NOISE IS MADE 881
S-16 VIBRATION IS EXCESSIVE 882
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 884
ELECTRICAL SYSTEM DIAGRAM RELATED TO EMERGENCY STEERING CONTROL 885
INFORMATION IN TROUBLESHOOTING TABLE 886
E-1 EMERGENCY STEERING SYSTEM DOES NOT OPERATE 888
30 DISASSEMBLY AND ASSEMBLY 892
METHOD OF USING MANUAL 894
PRECAUTIONS WHEN CARRYING OUT OPERATION 895
SPECIAL TOOL LIST 897
SKETCH OF SPECIAL TOOL 900
FUEL INJECTION PUMP 901
REMOVAL AND INSTALLATION 901
RADIATOR 902
REMOVAL 902
INSTALLATION 903
ENGINE AND TORQUE CONVERTER AND TRANSMISSION OIL COOLER 904
REMOVAL AND INSTALLATION 904
ENGINE FRONT SEAL 905
REMOVAL AND INSTALLATION 905
OUTPUT SHAFT ASSEMBLY 906
REMOVAL AND INSTALLATION 906
DISASSEMBLY 907
ASSEMBLY 908
ENGINE REAR SEAL 910
REMOVAL AND INSTALLATION 910
CYLINDER HEAD 912
REMOVAL 912
INSTALLATION 914
ENGINE 917
REMOVAL 917
INSTALLATION 919
TORQUE CONVERTER AND TRANSMISSION 920
REMOVAL 920
INSTALLATION 922
TRANSMISSION AND TORQUE CONVERTER 923
SEPARATION AND COUPLING 923
TORQUE CONVERTER 924
DISASSEMBLY 924
ASSEMBLY 928
TRANSMISSION 934
DISASSEMBLY 934
ASSEMBLY 947
DIFFERENTIAL 962
REMOVAL 962
INSTALLATION 963
DISASSEMBLY 964
ASSEMBLY 968
FRONT WHEEL 976
REMOVAL AND INSTALLATION 976
REAR WHEEL 977
REMOVAL 977
INSTALLATION 978
FRONT BRAKE CALIPER PADS 979
REMOVAL AND INSTALLATION 979
FRONT BRAKE CALIPERS 980
REMOVAL AND INSTALLATION 980
DISASSEMBLY AND ASSEMBLY 981
FRONT WHEEL HUB 983
DISASSEMBLY 983
ASSEMBLY 984
FINAL DRIVE CARRIER 986
REMOVAL AND INSTALLATION 986
DISASSEMBLY AND ASSEMBLY 987
FINAL DRIVE AND REAR BRAKE 988
REMOVAL 988
INSTALLATION 990
FINAL DRIVE, REAR BRAKE AND PARKING BRAKE 992
REMOVAL AND INSTALLATION 992
DISASSEMBLY 993
ASSEMBLY 998
FRONT SUSPENSION CYLINDER 1004
REMOVAL 1004
INSTALLATION 1005
DISASSEMBLY (STANDARD CYLINDER) 1006
ASSEMBLY (STANDARD CYLINDER) 1007
DISASSEMBLY (CYLINDER WITH BUFFER RING) 1009
ASSEMBLY (CYLINDER WITH BUFFER RING) 1010
REAR SUSPENSION CYLINDER 1012
REMOVAL AND INSTALLATION 1012
DISASSEMBLY (STANDARD CYLINDER) 1013
ASSEMBLY (STANDARD CYLINDER) 1014
DISASSEMBLY (CYLINDER WITH BUFFER RING) 1016
ASSEMBLY (CYLINDER WITH BUFFER RING) 1017
RETARDER COOLING PUMP 1019
REMOVAL AND INSTALLATION 1019
STEERING, HOIST, AND HOIST CONTROL PUMP 1020
REMOVAL AND INSTALLATION 1020
TORQUE CONVERTER, TRANSMISSION AND RETARDER COOLING, AND BRAKE PUMP 1021
REMOVAL AND INSTALLATION 1021
STEERING VALVE 1022
REMOVAL AND INSTALLATION 1022
PREPARATION 1023
DISASSEMBLY 1023
ASSEMBLY 1026
DEMAND VALVE 1033
REMOVAL AND INSTALLATION 1033
HOIST VALVE 1034
REMOVAL AND INSTALLATION 1034
STEERING CYLINDER 1035
DISASSEMBLY 1035
ASSEMBLY 1036
HOIST CYLINDER 1038
DISASSEMBLY 1038
ASSEMBLY 1039
DUMP BODY 1042
REMOVAL 1042
INSTALLATION 1043
OPERATOR’S SEAT 1045
DISASSEMBLY 1045
ASSEMBLY 1050
90 OTHERS 1054
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 1055
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM 1056
BRAKE HYDRAULIC CIRCUIT DIAGRAM 1058
ELECTRICAL CIRCUIT DIAGRAM (1/6) 1060
ELECTRICAL CIRCUIT DIAGRAM (2/6) 1061
ELECTRICAL CIRCUIT DIAGRAM (3/6) 1062
ELECTRICAL CIRCUIT DIAGRAM (4/6) 1063
ELECTRICAL CIRCUIT DIAGRAM (5/6) 1064
ELECTRICAL CIRCUIT DIAGRAM (6/6) 1065
ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL 1066
ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR 1067
ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE) (1/2) 1068
ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE) (2/2) 1069
CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE) 1070
EXTERNAL POWER SUPPLY HEATER 1071
ELECTRICAL CIRCUIT DIAGRAM OF OPTION PARTS 1073

DESCRIPTION:

Komatsu HD465-7 Rigid Dump Truck Shop Manual SEBM040101 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NUMBER
HD465-7                     7512 and up

GENERAL PRECAUTIONS :

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

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

IMAGES PREVIEW OF THE MANUAL:

S.V  25/12/24