Komatsu HD465-8 HD605-8 Dump Truck Shop Manual – Full PDF Workshop Guide
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Complete Komatsu HD465-8 and HD605-8 dump truck shop manual covering engine, transmission, brakes, hydraulics, electrical systems, troubleshooting, and disassembly/assembly procedures for serial numbers 30001 and up.
Description
Komatsu HD465-8 HD605-8 Dump Truck Shop Manual
This Komatsu HD465-8 HD605-8 Shop Manual is the complete workshop guide for the HD465-8 and HD605-8 dump trucks, covering serial numbers 30001 and up. It provides detailed service, repair, and troubleshooting information for every major system on these machines, from the SAA6D170E-7 diesel engine through the power train, brakes, steering, hydraulics, electrical equipment, and aftertreatment devices.
File Details
- Manual Type: Shop Manual (Workshop Service Manual)
- Brand: Komatsu
- Models Covered: HD465-8, HD605-8
- Serial Numbers: HD465-8 30001 and up, HD605-8 30001 and up
- Engine: Komatsu SAA6D170E-7 diesel engine
- Language: English
- Page Count: 3100
- File Format: PDF
- Document Number: SEN06605-11
- Systems Covered: Engine, cooling, power train, transmission, steering, brakes, suspension, hydraulics, electrical, aftertreatment, cab and ROPS
Chapters Covered
- 00 Index and Foreword
- Abbreviations
- Foreword, Safety, Basic Information
- How to Read the Shop Manual
- Safety Notice for Operation
- Precautions to Prevent Fire
- Actions if Fire Occurs
- Precautions for Removal of Dangerous Materials
- Steps Necessary to Meet Exhaust Gas Regulations
- Precautions for DEF
- DEF Storage Precautions
- Precautions When You Handle Hydraulic Equipment
- Precautions When You Disconnect and Connect Pipes
- Precautions When You Handle Electrical Equipment
- Precautions When You Handle Fuel System Equipment
- Precautions When You Handle Intake System Equipment
- Practical Usage of KOMTRAX
- Disconnect and Connect Push Pull Type Quick Disconnect
- Precautions for Disconnect and Connect of Connectors
- Procedure to Disconnect and Connect Deutsch Connector
- Procedure to Disconnect and Connect Slide Lock Connector
- Procedure to Disconnect and Connect Pull to Lock Type Connector
- Procedure to Disconnect and Connect Push to Lock Type Connector
- Procedure to Disconnect and Connect Twist Type Connectors
- How to Read Electrical Wire Codes
- Explanation of Terms for Maintenance Standard
- Standard Value Tighten Table
- Conversion Table
- 01 Specifications
- Abbreviations
- Specifications: HD465-8 and HD605-8
- Diagram Specification
- Weight Table
- Fuel, Coolant, and Lubricating Oil
- 10 Structure and Function
- Abbreviations
- Boot Up System
- System in Operation Lamp
- Battery Disconnect Switch
- Engine System
- Engine Control System
- Automatic Idle Stop System
- Engine Components
- Cooling System
- Cooling System Components
- Power Train System
- Transmission Control System
- Gear Shift Control System
- Direction Control System
- KTCS (Komatsu Traction Control System)
- Travel Speed Limitation System
- Power Train Components
- Torque Converter and PTO
- Transmission
- Transmission Control Valve
- ECMV (Electronic Control Modulation Valve)
- Main Relief Valve
- Main Flow Selector Valve
- Axle
- Differential
- Final Drive
- Work Equipment Control
- Hoist Control
- Work Equipment System Components
- Dump Lever
- Hoist EPC Valve
- Steering System
- Steering System Function
- Steering Column
- Steering Linkage
- Steering System Components
- Demand Valve
- Steering Relief Valve
- Orbitrol Valve
- Steering Pump Selector Solenoid Valve
- Cross-Over Relief Valve
- Secondary Steering Pump
- Secondary Steering Motor
- Brake System
- Retarder Control
- ARSC System
- Brake System Components
- Brake Charge Pump
- Parking Brake Solenoid Valve
- Accumulator Charge Valve
- Brake Circuit Accumulator
- Brake Valve
- Secondary Brake Valve
- Secondary Brake Relay Valve
- Proportion Pressure Reducing Valve
- Slack Adjuster
- Brake
- Parking Brake
- Brake Sub-Tank
- ABS
- Auto-Greasing System
- Undercarriage and Frame
- Suspension
- Front Suspension
- Rear Suspension
- Suspension Cylinder
- Work Equipment
- Cab and Attachments
- ROPS Cab
- Cab Mount
- 20 Standard Value Table
- Abbreviations
- Standard Value Table for Engine: HD465-8
- Standard Value Table for Engine: HD605-8
- Standard Value Table for Machine: HD465-8
- Standard Value Table for Machine: HD605-8
- Machine Setting and Procedure to Measure Performance
- 30 Test and Adjust
- Abbreviations
- Related Information to Test and Adjust
- Tools to Test and Adjust
- Engine and Cooling System: Test Engine Speed, Boost Pressure, Exhaust Gas Temperature, Exhaust Gas Color, Valve Clearance, Compression, Blowby Pressure, Engine Oil Pressure, EGR/VGT Oil Pressure, Fuel Pressure, Fuel Return Rate and Leakage, Bleeding Air, Fuel Circuit Leak, Supply Pump, Cylinder Cut-Out Mode, No-Injection Cranking, Clean Fuel Doser, Program Injector Trim Code, Program Ash in Soot Accumulation Correction, Torque Converter Stall Speed, Radiator Fan Speed
- Power Train: Test Power Train Oil Pressure, Adjust Transmission Speed Sensors
- Move a Machine with Electrical System Problems
- Steering System: Test and Adjust Steering Circuit Oil Pressure, Test Supply Pressure of Orbitrol Valve, Test Steering Cylinder Pressure, Bleed Air from Steering Cylinder Circuit
- Brake System: Release Pressure, Test Wheel Brake Oil Pressure, Test and Adjust Brake Accumulator Pressure, Test Nitrogen Gas Pressure and Charge, Test Brake Performance, Bleed Air from Brake Circuit, Test Parking Brake Oil Pressure, Release Parking Brake Manually, Test Brake Pad and Disc Wear
- Hydraulic System: Test and Adjust Hoist Circuit Oil Pressure, Hoist Cylinder Supply Pressure, Hoist EPC Valve, Radiator Fan Circuit, Front and Rear Suspension Cylinders, KTCS Circuit Oil Pressure
- Work Equipment: Test and Adjust Dump Body Positioner Sensor, Lower and Lift Body Manually
- Cab and Attachments
- Electrical System: Set and Adjust Each Equipment, Set and Operate Machine Monitor, Procedure for Starting Up KOMTRAX Terminal, Default Setting of KOMTRAX Plus Controller, Setting Default of Wireless LAN Modem, Download KOMTRAX Plus Controller Data, Adjust Rearview Camera Angle, Adjust Optical Axis of Head Lamp, Engine Controller Voltage Circuit Work, Battery Disconnect Switch Work, Test Diodes
- Pm Clinic Service and Quick Pm
- 40 Troubleshooting
- Abbreviations
- Related Information on Troubleshooting
- General Troubleshooting Points
- Troubleshooting Points for Aftertreatment Systems
- Sequence of Events in Troubleshooting
- Checks Before Troubleshooting
- Inspection Procedure Before Troubleshooting
- Testing in Accordance with Testing Procedure
- Electrical System Troubleshooting – Preparation
- Procedure for Testing and Troubleshooting
- Symptom and Troubleshooting Numbers
- Information Described in Troubleshooting Table
- Connectors List and Layout
- Connector Contact Identification
- T-Branch Box and T-Branch Adapter Table
- Fuse Location Table
- Precautions for Cleaning and Replacing KDPF (KCSF and KDOC)
- Preparation for Troubleshooting of Machine Monitor
- Procedures for Creating Harness Checker on Machine Monitor LCD Unit
- Preparation of Short Socket Adapter
- Failure Codes Table
- Troubleshooting by Failure Code (Display of Code)
- Troubleshooting of Electrical System (E-Mode)
- Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
- Troubleshooting of Engine (S-Mode)
- 50 Disassembly and Assembly
- Abbreviations
- Disassemble and Assemble-Related Information
- How to Read This Manual
- Coating Materials List
- Special Tool List
- Diagrams of Special Tools
- Engine and Cooling System: Remove and Install Supply Pump Assembly, Injector Assembly, Fuel Doser Assembly, Cylinder Head Assembly, EGR Valve Assembly, EGR Cooler Assembly, Starting Motor Assembly, Alternator Belt, Cooler Assembly, Radiator, Cooling Fan and Fan Motor Assembly, Aftercooler Assembly, Engine Assembly, Engine Front Oil Seal, Engine Rear Oil Seal, Output Shaft Assembly
- Power Train, Steering, Brake, Hydraulic, Work Equipment, Cab and Attachments
- 60 Maintenance Standard
- Abbreviations
- Maintenance Standard for Engine, Power Train, Steering, Brake, Hydraulic, Work Equipment, Cab and Attachments
- 80 The Other Information
- Air Conditioner Component, Specifications, Refrigeration Cycle, Air Conditioner Unit, Controller, Compressor, Condenser, Sensors
- Testing and Troubleshooting of Air Conditioner
- Circuit Diagram and Arrangement of Connector Pins
- Air Conditioner System Diagram
- Testing Air Leakage, Self-Diagnosis Function
- Testing Vent Changeover, Fresh/Recirc Air Changeover, Pressure Switch, Relays
- Air Conditioner Troubleshooting Charts
- 90 Circuit Diagrams
- Abbreviations
- Hydraulic Circuit Diagram
- Power Train Hydraulic Diagram
- Electrical Circuit Diagram: Internal Cab, External Cab
This manual provides the full scope of technical information needed to service and repair the HD465-8 and HD605-8 dump trucks. It covers the SAA6D170E-7 engine in complete detail including the common rail fuel system, EGR, VGT, KDPF aftertreatment, and KCCV system. The power train section documents the torque converter, 7-speed transmission with ECMV clutch control, differential, and final drives. Brake system coverage includes the oil-cooled multiple disc brakes, retarder, parking brake, ABS, and accumulator charging circuits. The steering section details the demand valve, orbitrol valve, secondary steering, and cross-over relief. Hydraulic content covers the hoist circuit, EPC valve, suspension cylinders, and radiator fan drive. Electrical troubleshooting spans failure codes for the engine controller, transmission controller, retarder/hoist controller, monitor controller, ABS controller, and KOMTRAX Plus, with connector layouts and T-adapter tables. Disassembly and assembly procedures are given for major components including the supply pump, injector, fuel doser, cylinder head, EGR valve and cooler, radiator, cooling fan, aftercooler, engine assembly, and output shaft. Maintenance standards, standard value tables, and test and adjust procedures are included for engine, power train, steering, brakes, hydraulics, and work equipment.
Why This Manual Matters
Correct service procedures and specifications are critical on machines of this size and complexity. The HD465-8 and HD605-8 use electronically controlled common rail injection, VGT turbochargers, EGR coolers, KDPF aftertreatment, ABS brakes, KTCS traction control, and multiple networked controllers. Working without the correct torque values, pressure specifications, failure code diagnostics, or disassembly sequences risks damaging expensive components, creating safety hazards, or causing repeat failures. This shop manual gives the technician the exact procedures, wear limits, and diagnostic paths needed to do the job correctly the first time.
What You Can Do With This Manual
- Diagnose and repair engine performance problems using the S-mode troubleshooting and failure code tables
- Test and adjust engine speed, boost pressure, exhaust gas temperature, fuel pressure, compression, valve clearance, and torque converter stall speed
- Service the common rail fuel system including supply pump, injector, fuel doser, and pressure limiter
- Overhaul the transmission, torque converter, differential, and final drives
- Test and adjust brake, retarder, parking brake, and ABS system pressures
- Bleed air from brake, steering, and fuel circuits
- Test and adjust hoist circuit, suspension cylinders, and radiator fan circuit
- Troubleshoot electrical faults using failure codes for all controllers and the connector layout tables
- Remove and install major components using the disassembly and assembly procedures
- Set up and adjust the machine monitor, KOMTRAX Plus controller, rearview camera, and head lamp optical axis
- Perform Pm Clinic service and Quick Pm procedures
- Reference hydraulic and electrical circuit diagrams for the complete machine
IMAGES PREVIEW
This Komatsu HD465-8 HD605-8 shop manual PDF is delivered as an instant download. No shipping, no waiting. The file works on any device that reads PDFs, and pages can be printed for use in the workshop. Whether you are servicing the engine, overhauling the transmission, diagnosing an electrical fault, or rebuilding a brake circuit, this manual gives you the correct procedures and specifications to complete the work.
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