Komatsu HD255-5 Dump Truck Workshop Service Repair Manual PDF - MKMTSHA255.zip
This is a full workshop service and repair manual featuring complete Electrical Wiring Diagrams for the Komatsu HD255 Dump Truck. It contains everything you need to service, troubleshoot, fix, and overhaul the machine to the same standard as factory-trained technicians.
Inside the Komatsu HD255 Dump Truck workshop service repair manual, you'll find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEBM00911 - Komatsu Dump Truck HD255-5 Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 613 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
COVER...1
CONTENTS...2
LIST OF REVISED PAGES...3
SAFETY...7
SAFETY NOTICE...7
FOREWORD...9
GENERAL...9
HOW TO READ THE SHOP MANUAL...10
HOISTING INSTRUCTIONS...11
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER...12
COATING MATERIALS...14
STANDARD TIGHTENING TORQUE...16
ELECTRIC WIRE CODE...19
CONVERSION TABLE...20
UNITS...26
01 GENERAL...27
DIMENSIONS...28
SPECIFICATIONS...30
WEIGHT TABLE...36
LIST OF LUBRICANTS AND COOLANT...37
10 STRUCTURE AND FUNCTION...39
RADIATOR, TORQUE CONVERTER AND BRAKE OIL COOLER, AND AFTERCOOLER...40
POWER TRAIN SKELETON...42
HYDRAULIC CIRCUIT DIAGRAM FOR TORQUE CONVERTER, TRANSMISSION, AND BRAKE COOLING...44
TORQUE CONVERTER...46
MAIN RELIEF VALVE...48
TORQUE CONVERTER VALVE...50
TRANSMISSION...55
TRANSMISSION VALVE...60
ECMV (ELECTRONIC CONTROL MODULATION VALVE)...61
FRONT AXLE...66
REAR AXLE...67
DIFFERENTIAL...68
FINAL DRIVE...69
FRONT BRAKE...70
REAR BRAKE...71
PARKING BRAKE...72
STEERING COLUMN...74
STEERING LINKAGE...76
DEMAND VALVE...77
CROSSOVER RELIEF VALVE...80
STEERING VALVE...81
FRONT SUSPENSION CYLINDER...82
REAR SUSPENSION CYLINDER...83
AIR GOVERNOR...84
SAFETY VALVE...86
CHECK VALVE...86
DOUBLE CHECK VALVE...87
HAND BRAKE VALVE (RETARDER CONTROL VALVE)...88
BRAKE VALVE...90
PARKING BRAKE CONTROL VAVLE...93
BRAKE RELAY VALVE...95
BRAKE RELAY VALVE (ACTS ALSO AS EMERGENCY RELAY)...97
PARKING BRAKE RELAY VALVE...104
PARKING BRAKE QUICK RELEASE VALVE...106
SPRING CYLINDER...107
SLACK ADJUSTER...108
FRONT BRAKE CHAMBER...109
REAR BRAKE CHAMBER...110
AIR DRIER (DRYING AGENT TYPE)...111
AIR SYSTEM DIAGRAM...113
HOIST VALVE...114
HOIST CYLINDER...115
AUTOMATIC SHIFT CONTROL SYSTEM...116
AUTOMATIC RETARDER VALVE...126
HORN VALVE...128
WIPER SWITCH...128
SENSORS, SWITCHES...129
METER LAMPS...140
20 TESTING AND ADJUSTING...151
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...152
STANDARD VALUE TABLE FOR CHASSIS...155
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM...163
TESTING AND ADJUSTING...175
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING...176
SKETCHES OF SPECIAL TOOLS...178
ADJUSTING VALVE CLEARANCE...180
MEASURING COMPRESSION PRESSURE...182
MEASURING BLOW-BY...184
TESTING AND ADJUSTING ALTERNATOR BELT TENSION AND FAN BELT TENSION...186
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION...187
MEASURING ENGINE SPEED...188
MEASURING ENGINE OIL PRESSURE...190
MEASURING BOOST PRESSURE...191
MEASURING EXHAUST GAS TEMPERATURE...192
MEASURING EXHAUST GAS COLOR...193
TESTING AND ADJUSTING FUEL INJECTION TIMING...194
BLEEDING AIR FROM FUEL INJECTION PUMP...196
HANDLING EQUIPMENT IN FUEL CIRCUIT...197
RELEASING REMAINING PRESSURE IN FUEL SYSTEM...197
MEASURING FUEL PRESSURE...198
BLEEDING AIR FROM FUEL CIRCUIT...199
REDUCED CYLINDER MODE OPERATION FOR ENGINE...201
CHECKING FOR LEAKAGE IN FUEL CIRCUIT...202
ADJUSTING ENGINE STOP MOTOR CABLE...203
ADJUSTING ACCELERATOR PEDAL...204
ADJUSTING ENGINE SPEED SENSOR...205
TESTING OIL PRESSURE OF TORQUE CONVERTER VALVE...206
TESTING TORQUE CONVERTER STALL SPEED...207
TESTING BRAKE PRESSURE...208
BLEEDING AIR FROM BRAKE CIRCUIT...209
TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE...210
TESTING WEAR OF FRONT BRAKE PAD...211
TESTING WEAR OF REAR BRAKE DISC...212
TESTING AND ADJUSTING SUSPENSION CYLINDER...213
TESTING AND ADJUSTING AIR GOVERNOR SET PRESSURE...218
INSPECTION OF AIR DRIER (DESICCANT TYPE)...219
ADJUSTING HOIST LEVER LINKAGE...221
ADJUSTING BODY POSITIONER...222
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT...223
BLEEDING AIR FROM HYDRAULIC CYLINDER (STEERING CYLINDER)...226
EMERGENCY TRAVEL WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM...227
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM...228
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS...234
PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT...236
PM CLINIC CHECK SHEET...237
TROUBLESHOOTING...241
POINTS TO REMEMBER WHEN TROUBLESHOOTING...242
SEQUENCE OF EVENTS IN TROUBLESHOOTING...243
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...244
CHECKS BEFORE TROUBLESHOOTING...252
TYPE OF CONNECTOR AND POSITION OF INSTALLATION (SERIAL NO. 1001-1200)...254
CONNECTOR PIN ARRANGEMENT DIAGRAM (SERIAL NO. 1001-1200)...258
TYPE OF CONNECTOR AND POSITION OF INSTALLATION (SERIAL NO. 1201-1599)...262
CONNECTOR PIN ARRANGEMENT DIAGRAM (SERIAL NO. 1201-1599)...266
TYPE OF CONNECTOR AND POSITION OF INSTALLATION (SERIAL NO. 1601 AND UP)...270
CONNECTOR PIN ARRANGEMENT DIAGRAM (SERIAL NO. 1601 AND UP)...274
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ...280
METHOD OF USING JUDGEMENT TABLE...303
METHOD OF USING TROUBLESHOOTING CHARTS...304
METHOD OF LED DISPLAY FOR TRANSMISSION CONTROLLER...306
HOW TO DELETE FAILURE CODES FOR TRANSMISSION CONTROLLER AND ENGINE CONTROLLER...310
ACTION TAKEN BY TRANSMISSION CONTROLLER AND PROBLEMS ON MACHINE...312
TROUBLESHOOTING OF ENGINE SYSTEM (D MODE)...361
METHOD OF USING TROUBLESHOOTING CHART...362
D-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...366
D-2 ENGINE DOES NOT START...367
(1) ENGINE DOES NOT TURN...367
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...368
(3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...369
D-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...370
D-4 ENGINE STOPS DURING OPERATIONS...371
D-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...372
D-6 ENGINE LACKS OUTPUT (NO POWER)...373
D-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...374
D-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...375
D-9 OIL BECOMES CONTAMINATED QUICKLY...376
D-10 FUEL CONSUMPTION IS EXCESSIVE...377
D-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN...378
D-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...379
D-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...380
D-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...381
D-15 ABNORMAL NOISE IS MADE...382
D-16 VIBRATION IS EXCESSIVE...383
TROUBLESHOOTING OF ENGINE SYSTEM (D MODE)...385
POINTS TO REMEMBER WHEN TROUBLESHOOTING...386
METHOD OF USING TROUBLESHOOTING CHARTS...387
D-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...390
D-2 ENGINE DOES NOT START...391
D-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...394
D-4 ENGINE STOPS DURING OPERATIONS...395
D-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...396
D-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...397
D-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...398
D-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...399
D-9 OIL BECOMES CONTAMINATED QUICKLY...400
D-10 FUEL CONSUMPTION IS EXCESSIVE...401
D-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)...402
D-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...403
D-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...404
D-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...405
D-15 ABNORMAL NOISE IS MADE...406
D-16 VIBRATION IS EXCESSIVE...407
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (G MODE)...409
ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING...411
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED...414
ENGINE CONTROLLER RELATED JUDGEMENT TABLE...422
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM...424
G-1 ERROR CODE [C01b] [ABNORMALITY IN NE REVOLUTION SENSOR SYSTEM]...426
G-2 ERROR CODE [C01C] [ABNORMALITY IN G REVOLUTION SENSOR SYSTEM]...427
G-3 ERROR CODE [C020] [ABNORMALITY IN MODEL SELECTION SYSTEM]...428
G-4 ERROR CODE [C022] [OVERRUN]...429
G-5 ERROR CODE [C023] [OVERHEAT]...429
G-6 ERROR CODE [C024] [DROP IN OIL PRESSURE]...430
G-7 ERROR CODE [C030] [ABNORMALITY IN IDLING VALIDATION SIGNAL SYSTEM]...431
G-8 ERROR CODE [C031] [ABNORMALITY IN ACCELERATOR SENSOR SYSTEM]...433
G-9 ERROR CODE [C034] [ABNORMALITY IN HIGH ENGINE COOLANT TEMPERATURE SENSOR SYSTEM]...435
G-10 ERROR CODE [C036] [ABNORMALITY IN OIL PRESSURE SWITCH SYSTEM]...436
G-11 ERROR CODE [C03C] [ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM]...438
G-12 ERROR CODE [C03d] [ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM]...439
G-13 ERROR CODE [C050] [ABNORMALITY IN PREHEATING RELAY CONNECTING POINT SYSTEM]...440
G-14 ERROR CODE [C051] [ABNORMALITY IN PREHEATING RELAY COIL SYSTEM]...441
G-15 ERROR CODE [C054] [SHORT CIRCUIT IN STARTING SWITCH C SYSTEM]...442
G-16 ERROR CODE [C056] [POWER SOURCE SYSTEM ABNORMALITY 1]...443
G-17 ERROR CODE [C057] [POWER SOURCE SYSTEM ABNORMALITY 2]...445
G-18 ERROR CODE [C05A] [ABNORMALITY IN FUEL INJECTION QUANTITY CONTROL SWITCH SIGNAL]...446
G-19 ERROR CODE [C06A] [ABNORMALITY IN LOW ENGINE COOLANT TEMPERATURE SENSOR SYSTEM]...446
G-20 ERROR CODE [C070] [EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM]...447
G-21 ERROR CODE [C071] [EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM]...448
G-22 ERROR CODE [C074] [DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM]...449
G-23 ERROR CODE [C075] [DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM]...450
G-24 ERROR CODE [C077] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM]...451
G-25 ERROR CODE [C079] [COMMON RAIL HIGH FUEL PRESSURE ABNORMALITY 1] ERROR CODE [C07A] [COMMON RAIL HIGH FUEL PRESSURE ABNORMALITY 2]...452
G-26 ERROR CODE [C07C] [FUEL SUPPLY PUMP NON-FORCE FEED 1] ERROR CODE [C07b] [FUEL SUPPLY PUMP NON-FORCE FEED 2]...453
G-27 ERROR CODE [C07d] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE]...455
G-28 ERROR CODE [C080] [DEFECTIVE CONTROLLER]...455
G-29 ERROR CODE [C081] [DISCONNECTION IN NO.1 FUEL INJECTOR SYSTEM]...456
G-30 ERROR CODE [C082] [DISCONNECTION IN NO.2 FUEL INJECTOR SYSTEM]...457
G-31 ERROR CODE [C083] [DISCONNECTION IN NO.3 FUEL INJECTOR SYSTEM]...458
G-32 ERROR CODE [C084] [DISCONNECTION IN NO.4 FUEL INJECTOR SYSTEM]...459
G-33 ERROR CODE [C085] [DISCONNECTION IN NO.5 FUEL INJECTOR SYSTEM]...460
G-34 ERROR CODE [C086] [DISCONNECTION IN NO.6 FUEL INJECTOR SYSTEM]...461
G-35 ERROR CODE [C08A] [SHORT CIRCUIT IN NO.1 , NO.2 , NO.3 FUEL INJECTOR SYSTEM]...462
G-36 ERROR CODE [C08b] [SHORT CIRCUIT IN NO.4 , NO.5 , NO.6 FUEL INJECTOR SYSTEM]...465
TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM FOR START/STOP SYSTEM (ENG MODE)...469
ENG-1 ENGINE DOES NOT START (FUEL INJECTION PUMP STOP LEVER STAYS AT STOP POSITION)...470
ENG-2 ENGINE DOES NOT STOP (FUEL INJECTION PUMP STOP LEVER STAYS AT RUN POSITION)...477
ENG-1 ENGINE DOES NOT START (STARTING MOTOR DOES NOT ROTATE)...482
ENG-2 ENGINE DOES NOT START OR IT HUNTS (RUNS ROUGH)...486
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE)...487
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM...489
JUDGMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS...490
A-1 ABNORMALITY IN POWER SOURCE...492
a) [ ][DEFECTIVE CONTROLLER POWER SOURCE]IS DISPLAYED(ALL LEDS OFF)...492
b) [0.1](DROP IN VOLTAGE OF CONTROLLER)IS DISPLAYED...496
c) [0.2](DROP IN VOLTAGE OF SOLENOID)IS DISPLAYED...497
A-2 [0.3](NEUTRAL SAFETY)IS DISPLAYED...499
a) [ . ][ONLY DOT LIGHTS UP] OR [0.4](DATA ERROR)IS DISPLAYED...501
b) [0.5](DOUBLE ENGAGEMENT FOR CLUTCH)IS DISPLAYED...501
A-8 SLIPPING CLUTCH OR SPEED SENSOR SYSTEM...520
a) [2.1][DEFECTIVE LOCK-UP CLUTCH SYSTEM] IS DISPLAYED...520
A-9 [A.1]ABNORMALITY IN MODEL SELECTION SIGNAL IS DISPLAYED...521
A-10 ABNORMALITY IN SHIFT LEVER SYSTEM...522
a) [0.7][SHORT CIRCUIT WITH 12V OUTPUT CIRCUIT] IS DISPLAYED...522
b) [1.5][SHORT CIRCUIT,SHORT CIRCUIT WITH GROUND IN LEVER SIGNAL SYSTEM] IS DISPLAYED...523
c) [1.6][DISCONNECTION IN LEVER SIGNAL SYSTEM] IS DISPLAYED...527
A-13 PRESSURE CONTROL VALVE SYSTEM...534
a) [3.8][DEFECTIVE R CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ] IS DISPLAYED...534
b) [4.8][DEFECTIVE R CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ] IS DISPLAYED...535
b1) CHECKING FILL SIGNAL SYSTEM...535
b2) CHECKING WHEN [4.2] OR [4.3] IS DISPLAYED...536
b3) CHECKING WHEN [4.4] OR [4.6] OR [4.8] IS DISPLAYED...536
A-14 FLOW DETECTION VALVE SYSTEM...537
[5.8][DISCONNECTION IN R CLUTCH FLOW CONTROL VALVE SYSTEM] IS DISPLAYED...537
A-15 PRESSURE CONTEOL SOLENOID SYSTEM...538
a) [7.8][SHORT CIRCUIT IN R CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] IS DISPLAYED...538
b) [9.8][SHORT CIRCUIT IN R CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] IS DISPLAYED...540
A-16 PRESSURE SENSOR SYSTEM...542
ELECTRICAL CIRCUIT DIAGRAM FOR A MODE SYSTEM...544
TROUBLESHOOTING FOR METER PANEL SYSTEM (E MODE)...557
E-1 WATER TEMPERATURE GAUGE GIVES NO DISPLAY OR GIVES ABNORMAL DISPLAY...558