Komatsu HD465-7E0 HD605-7E0 DUMP TRUCK Shop Manual SEN01081-28 PDF

Description

Komatsu HD465-7E0 HD605-7E0 DUMP TRUCK Shop Manual SEN01081-28 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HD465-7E0 HD605-7E0 DUMP TRUCK Shop Manual SEN01081-28 – PDF DOWNLOAD 

Language : English
Pages : 1872
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HD465-7E0 HD605-7E0 DUMP TRUCK Shop Manual SEN01081-28 – PDF DOWNLOAD 

SERIAL NUMBERS
HD465- 10001-10037
HD465-10101 and up
HD605- 8001-8032
HD605-10101 and up

How to read the shop manual 
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

Komatsu HD465-7E0 HD605-7E0 DUMP TRUCK Shop Manual SEN01081-28 – PDF DOWNLOAD

SERIAL NUMBERS
HD465- 10001-10037
HD465-10101 and up
HD605- 8001-8032
HD605-10101 and up 

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 21
Safety notice 22
How to read the shop manual 27
Explanation of terms for maintenance standard 29
Handling of electric equipment and hydraulic component 31
Handling of connectors newly used for engines 40
How to read electric wire code 43
Precautions when carrying out operation 46
Method of disassembling and connecting push-pull type coupler 49
Standard tightening torque table 52
Conversion table 56
01 Specification 63
Specification and technical data 63
Specification drawing 64
Specifications 66
Weight table 74
Fuel, coolant and lubricants 75
10 Structure, function and maintenance standard 79
Engine and cooling system 79
Radiator, torque converter oil cooler, after cooler, work equipment oil cooler, fuel cooler 80
Fuel system 82
Brake oil cooler 83
Output shaft 84
Power train, Part 1 87
Power train skeleton 88
Drive shaft 90
Torque converter and transmission hydraulic piping 92
Brake cooling oil control valve (BCV) 94
Torque converter 96
Torque converter valve 103
Transmission 105
Transmission control valve 121
ECMV 122
Power train, Part 2 131
Axle 132
Differential 134
Final drive 135
Wheels 136
Steering system 139
Steering column 140
Steering linkage 141
Brake system 145
Brake piping 146
Brake valve 148
Secondary brake valve 151
Relay valve 152
Front brake off valve 153
Accumulator charge valve 154
Accumulator 158
Slack adjuster 159
Brake 161
Parking brake solenoid valve 165
Undercarriage and frame 167
Suspension 168
Suspension cylinder 170
Rear axle support 178
Hydraulic system 181
Steering and hoist hydraulic piping 182
Dump body control 184
Hydraulic tank 185
Steering valve 186
Crossover relief valve 190
Steering cylinder 191
Steering control valve 192
Hoist valve 198
Dump control valve (EPC valve) 204
Hoist cylinder 208
Hydraulic pump 209
Work equipment (Body) 215
Auto greasing system 216
Cab and its attachments 239
ROPS cab 240
Air conditioner 241
Rear view monitor 247
Electrical system, Part 1 257
Machine monitor system 258
Electrical system, Part 2 291
Automatic shift control system 292
Transmission controller 296
External power supply heater 310
Automatic emergency steering system 312
Automatic suspension system 316
Retarder control system 319
Battery disconnector switch 330
Dump control lever 336
Electrical system, Part 3 341
Payload meter II (Card type) 342
Electrical system, Part 4 373
VHMS controller related 374
ASR system (If equipped) 398
Sensors, switches 404
Electrical system, Part 5 425
Mobile communication terminal 426
20 Standard value table 431
Standard service value table 431
Standard value table for engine 432
Standard value table for machine 434
30 Testing and adjusting 445
Testing and adjusting, Part 1 445
Tools for testing, adjusting, and troubleshooting 447
Sketch of special tool 453
Testing engine speed 454
Testing air supply pressure (boost pressure) 455
Testing exhaust temperature 456
Testing exhaust gas color 458
Adjustment of valve clearance 460
Testing of compression pressure 462
Testing blow-by pressure 465
Testing engine oil pressure 466
Testing EGR valve and bypass valve drive oil pressure 467
Handling of fuel system devices 469
Releasing residual pressure from fuel system 469
Testing of fuel pressure 470
Reduced cylinder mode operation 471
No-injection cranking 471
Testing of fuel return rate and fuel leakage 472
Bleeding air from fuel circuit 474
Testing the fuel circuit for leakage 475
Replacement and adjustment of fan belt 476
Replacement and adjustment of alternator and air conditioner compressor belt 477
Testing and adjusting, Part 2 479
Testing torque converter stall speed 481
Testing power train oil pressure 482
Adjusting transmission speed sensor 489
Testing and adjusting brake oil pressure 490
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 493
Testing brake performance 501
Releasing remaining pressure in brake circuit 502
Bleeding air from brake circuit 503
Testing wear of front brake pad 504
Testing wear of rear brake disc 505
Method of releasing parking brake in an emergency 506
Testing and adjusting front suspension cylinder 507
Testing and adjusting rear suspension cylinder 511
Testing and adjusting front suspension cylinder (Automatic suspension specification) 515
Testing and adjusting hydraulic pressure in steering, hoist circuit 516
Testing and adjusting oil pressure in dump EPC circuit 519
Air bleeding from steering cylinder 520
Procedure for raising dump body in emergency 521
Procedure for lowering dump body in emergency 522
Adjusting body positioner sensor 524
Resetting method for dump body seating control 525
Adjustment of tilt lock lever of steering wheel 526
Handling of voltage circuit of engine controller 527
Adjusting transmission controller 527
Method for emergency escape at electrical system failure 528
Testing and adjusting, Part 3 533
Setting and adjusting of devices 534
Special functions of machine monitor (EMMS) 547
Testing and adjusting, Part 4 571
Special functions of machine monitor (EMMS) 572
Testing and adjusting, Part 5 613
Request for opening ORBCOMM terminal 614
VHMS controller initial setting procedure 616
Using method of KOMTRAX functions of ORBCOMM terminal 636
Precautions for replacing VHMS controller 639
Pm Clinic check sheet 645
Initial setting of payload meter 649
Setting of payload meter built in VHMS 650
Setting of card-type payload meter (PLM-II) after installation or replacement 658
Testing and adjusting, Part 6 665
Setting of mobile communication terminal 666
40 Troubleshooting 677
General information on troubleshooting 677
Points to remember when troubleshooting 678
Sequence of events in troubleshooting 679
Check before troubleshooting 680
Classification and procedures for troubleshooting 681
Contents of troubleshooting table 682
Connection table for connector pin numbers 684
T-branch box and T-branch adapter table 720
Failure code table and fuse locations 725
Failure codes table 726
Fuse locations 737
Troubleshooting by failure code, Part 1 743
Failure code [1500L0] (Dual engagement) 745
Failure code [15B0NX] (Transmission oil filter: Clogging) 746
Failure code [15F0KM] (R → F shifting abuse 1: Mistake in operation) 748
Failure code [15F0MB] (R → F shifting abuse 2: Mistake in operation) 748
Failure code [15F7KM] (Forward clutch disk abuse: Mistake in operation or setting) 749
Failure code [15G0MW] (R clutch: Slipping) 750
Failure code [15G7KM] (Reverse clutch disk abuse: Mistake in operation or setting) 752
Failure code [15H0MW] (Hi clutch: Slipping) 754
Failure code [15J0MW] ( Lo clutch: Slipping) 756
Failure code [15K0MW] (1st clutch: Slipping) 758
Failure code [15L0MW] (2nd clutch: Slipping) 760
Failure code [15M0MW] (3rd clutch: Slipping) 762
Failure code [15N0MW] (4th clutch: Slipping) 764
Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF) 766
Failure code [15SBMA] (R clutch solenoid: Malfunction) 768
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF) 769
Failure code [15SCMA] (Hi clutch solenoid: Malfunction) 772
Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF) 773
Failure code [15SDMA] (Lo clutch solenoid: Malfunction) 776
Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF) 777
Failure code [15SEMA] (1st clutch solenoid: Malfunction) 780
Troubleshooting by failure code, Part 2 783
Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF 786
Failure code [15SFMA] 2nd clutch solenoid: Malfunction 789
Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF 790
Failure code [15SGMA] 3rd clutch solenoid: Malfunction 793
Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF 794
Failure code [15SHMA] 4th clutch solenoid: Malfunction 797
Failure code [15SJMA] Lockup clutch solenoid: Malfunction 798
Failure code [2C4MNX] Retarder cooling oil filter: Clogging 800
Failure code [2F00KM] Parking brake: Mistake in operation or setting 802
Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front) 805
Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear) 805
Failure code [6014NX] Hydraulic oil filter: Clogging 806
Failure code [989A00] Engine over run prevention command signal: Operating 808
Failure code [989D00] Rear section tipping over alarm: Alarm is activated 808
Failure code [A570NX] Engine oil filter: Clogging 809
Failure code [AA10NX] Air cleaner element: Clogging 810
Failure code [AB00MA] Alternator: Malfunction 812
Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure 814
Failure code [B@BAZK] Engine oil: Level too low 815
Failure code [B@BCNS] Engine: Overheat 816
Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level 818
Failure code [B@BFZK] Lowering of fuel level 820
Failure code [B@C7NS] Brake cooling oil: Overheating (Rear) 822
Failure code [B@CENS] Overheating of torque converter oil 824
Failure code [B@GAZK] Battery electrolyte level: Lowering of level 825
Failure code [B@JANS] Steering oil temperature: Overheat 826
Troubleshooting by failure code, Part 3 829
Failure code [CA111] Abnormality in engine controller 832
Failure code [CA115] Engine Ne or Bkup speed sensor error 834
Failure code [CA122] Charge (boost) pressure sensor high error 836
Failure code [CA123] Charge (boost) pressure sensor low error 838
Failure code [CA131] Throttle sensor high error 840
Failure code [CA132] Throttle sensor low error 843
Failure code [CA135] Engine oil pressure sensor high error 846
Failure code [CA141] Engine oil pressure sensor low error 848
Failure code [CA144] Coolant temperature sensor high error 850
Failure code [CA145] Coolant temperature sensor low error 852
Failure code [CA153] Charge (boost) temperature sensor high error 854
Failure code [CA154] Charge (boost) temperature sensor low error 856
Failure code [CA187] Sensor power supply 2 low error 858
Failure code [CA212] Engine oil temperature sensor high error 860
Failure code [CA213] Engine oil temperature sensor low error 862
Failure code [CA221] Atmospheric pressure sensor high error 864
Failure code [CA222] Atmospheric pressure sensor low error 866
Failure code [CA227] Sensor power supply 2 high error 868
Failure code [CA234] Engine overspeed 869
Failure code [CA238] Ne speed sensor power supply error 870
Failure code [CA263] Fuel Temp Sensor High Error 872
Failure code [CA265] Fuel Temp Sensor Low Error 874
Failure code [CA271] PCV1 Short circuit 876
Failure code [CA272] PCV1 Disconnection 877
Failure code [CA273] PCV2 Short circuit 878
Failure code [CA274] PCV2 Disconnection 879
Failure code [CA322] Injector #1 open/short error 880
Failure code [CA323] Injector #5 open/short error 882
Failure code [CA324] Injector #3 open/short error 884
Failure code [CA325] Injector #6 open/short error 886
Failure code [CA331] Injector #2 open/short error 888
Failure code [CA332] Injector #4 open/short error 890
Failure code [CA342] Calibration code inconsistency 892
Failure code [CA351] Injectors drive circuit error 893
Failure code [CA352] Sens Supply 1 Volt Low Error 894
Failure code [CA386] Sensor power supply 1 high error 896
Troubleshooting by failure code, Part 4 899
Failure code [CA431] Idle validation switch error 901
Failure code [CA432] Idle validation action error 905
Failure code [CA441] Battery voltage low error 908
Failure code [CA442] Battery voltage high error 909
Failure code [CA449] Common rail pressure high error 2 910
Failure code [CA451] Rail Press Sensor High Error 912
Failure code [CA452] Rail Press Sensor Low Error 914
Failure code [CA553] Common rail pressure high error 1 916
Failure code [CA554] Common rail pressure sensor in range error 917
Failure code [CA559] Supply pump pressure very low error 1 918
Failure code [CA689] Engine Ne speed sensor error 922
Failure code [CA731] Engine Bkup speed sensor phase error 924
Failure code [CA757] All continuous data lost error 925
Failure code [CA778] Engine Bkup speed sensor error 926
Failure code [CA1228] EGR valve servo error 1 928
Failure code [CA1625] EGR valve servo error 2 929
Failure code [CA1626] (Bypass valve solenoid current high error) 930
Failure code [CA1627] (Bypass valve solenoid current low error) 932
Failure code [CA1628] Bypass Valve Servo Error 1 934
Failure code [CA1629] Bypass Valve Servo Error 2 935
Failure code [CA1631] (Bypass valve lift sensor high error) 936
Failure code [CA1632] (Bypass valve lift sensor low error) 938
Failure code [CA1633] KOMNET datalink timeout error 940
Failure code [CA2185] Throttle sensor supply voltage high error 942
Failure code [CA2186] Throttle sensor power supply low error 944
Failure code [CA2249] Supply pump pressure very low error 2 946
Failure code [CA2271] EGR valve lift sensor high error 948
Failure code [CA2272] EGR valve lift sensor low error 950
Failure code [CA2351] EGR valve solenoid operation short circuit 952
Failure code [CA2352] EGR valve solenoid operation disconnect 954
Failure code [CA2555] Intake air heater relay open circuit error 956
Failure code [CA2556] Intake air heater relay short circuit error 958
Troubleshooting by failure code, Part 5 961
Failure code [D19HKB] Stop lamp relay output system: Short circuit 963
Failure code [D5ZKKZ] Front brake cut-off solenoid valve: Disconnection, short circuit or short circuit to power supply line 964
Failure code [DAF9KM] Wrong connection of connector 966
Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication 967
Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of power supply voltage 968
Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller 970
Failure code [DAQ2KK] Transmission controller solenoid power supply: Power supply voltage too low 972
Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection 974
Failure code [DAQRKR] Abnormality in CAN communication (Transmission) 975
Failure code [DAQRMA] Transmission controller option setting: Malfunction 980
Failure code [DAQV00] Neutral coast caution 981
Failure code [DAQW00] Neutral over speed caution 982
Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller 983
Failure code [DB12KK] Retarder controller solenoid power supply: Power supply system trouble 984
Failure code [DB13KK] Retarder controller battery direct power supply: Power supply voltage too low 986
Failure code [DB19KQ] Disagreement of model selection (Retarder controller) 988
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled 989
Failure code [DB1RMA] Disagreement of option setting (Retarder controller) 993
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled 994
Failure code [DBB0KK] or VHMS_LED display: “n9” o “01” 1000
Failure code [DBB0KQ] or VHMS_LED display: “nF” o “11” 1002
Failure code [DBB3KK] or VHMS_LED display: “n9” o “05” 1004
Failure code [DBB5KP] or VHMS_LED display: “n9” o “04” 1006
Failure code [DBB6KP] or VHMS_LED display: “n9” o “02” 1008
Failure code [DBB7KP] or VHMS_LED display: “n9” o “03” 1010
Failure code [DBBQKR] or VHMS_LED display: “n8” o “02” 1011
Failure code [DBBRKR] Abnormality in CAN communication (VHMS) 1011
Failure code [DBC2KK] ABS controller solenoid power supply: Power supply system trouble 1012
Failure code [DBC3KK] ABS controller battery direct power supply: Power supply voltage too low 1014
Failure code [DBC9KQ] Disagreement of model selection (ABS controller) 1016
Failure code [DBCRKR] Abnormality in CAN communication (ABS) 1017
Failure code [DBCRMA] Disagreement of option setting (ABS controller) 1021
Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range 1022
Failure code [DDD8KA] ARSC system switch system: Disconnection (If equipped) 1024
Failure code [DDD8KB] ARSC system switch system: Short circuit (If equipped) 1026
Failure code [DDD9KA] ABS system switch system: Disconnection 1028
Failure code [DDD9KB] ABS system switch system: Short circuit 1030
Failure code [DDDAKA] ASR system switch: Disconnection 1032
Failure code [DDDAKB] ASR system switch: Short circuit 1034
Failure code [DDP6L4] Service brake pressure switch trouble (Rear) 1036
Failure code [DDTHKA] Hi clutch fill switch: Disconnection 1038
Failure code [DDTJKA] Lo clutch fill switch: Disconnection 1040
Failure code [DDTKKA] 1st clutch fill switch: Disconnection 1042
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection 1044
Failure code [DDTMKA] (3rd clutch fill switch: Disconnection) 1046
Failure code [DDTNKA] R clutch fill switch: Disconnection 1048
Failure code [DDTPKA] 4th clutch fill switch: Disconnection 1050
Failure code [DF10KA] Gear shift lever: Disconnection 1052
Failure code [DF10KB] Gear shift lever: Short circuit 1055
Failure code [DGE5KX] or VHMS_LED display: “n4” o “01” 1060
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range 1062
Failure code [DGR2KZ] Retarder oil temperature sensor system trouble : Ground fault (Rear wheel) 1064
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range 1066
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range 1068
Troubleshooting by failure code, Part 6 1071
Failure code [DGT4KA] or VHMS_LED display: “n3” o “12” Exhaust gas temperature sensor (F): Disconnection 1073
Failure code [DGT4KB] or VHMS_LED display: “n3” o “11” Exhaust gas temperature sensor (F): Short circuit 1076
Failure code [DGT5KA] or VHMS_LED display: “n3” o “22” Exhaust gas temperature sensor (R): Disconnection 1079
Failure code [DGT5KB] or VHMS_LED display: “n3” o “21” Exhaust gas temperature sensor (R): Short circuit 1082
Failure code [DHE5KB] or VHMS_LED display: “n3” o “32” Blow-by pressure sensor: Short circuit 1085
Failure code [DHE5KY] or VHMS_LED display: “n3” o “31” Blow-by pressure sensor: Short circuit with power supply line 1088
Failure code [DHP4KY] or VHMS_LED display: “n5” o “44” Short circuit in suspension pressure sensor system (Front right) 1090
Failure code [DHP4KZ] or VHMS_LED display: “n5” o “43” Disconnection or ground fault in suspension pressure sensor system(Front right) 1092
Failure code [DHP5KY] or VHMS_LED display: “n5” o “54” Short circuit in suspension pressure sensor system (Front left) 1094
Failure code [DHP5KZ] or VHMS_LED display: “n5” o “53” Disconnection or ground fault in suspension pressure sensor system(Front left) 1096
Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear) 1098
Failure code [DHP6KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Right rear) 1099
Failure code [DHP6KY] or VHMS_LED display: “n5” o “64” Suspension pressure sensor system: Short circuit (Right rear) 1102
Failure code [DHP6KZ] or VHMS_LED display: “n5” o “63” Suspension pressure sensor system: Disconnection or ground fault (Right rear) 1104
Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear) 1106
Failure code [DHP7KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Left rear) 1108
Failure code [DHP7KY] or VHMS_LED display: “n5” o “74” Suspension pressure sensor system: Short circuit (Left rear) 1110
Failure code [DHP7KZ] or VHMS_LED display: “n5” o “73” Suspension pressure sensor system: Disconnection or ground fault (Left rear) 1112
Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range 1114
Failure code [DHT5L6] Torque converter oil pressure sensor: Disagreement of run and stop condition with signal 1116
Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range 1118
Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range 1120
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right) 1122
Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left) 1124
Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Front right) 1126
Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Front right) 1128
Failure code [DHUTKK] Trouble in ABS cut valve pressure sensor 1130
Failure code [DJF1KA] Fuel level sensor: Disconnection 1132
Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection) 1134
Failure code [DK51L5] Retarder lever potentiometer: Potentiometer signal is inconsistent with swich signal 1135
Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range 1138
Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal 1140
Failure code [DK54KX] Body positioner sensor: Out of input signal range 1142
Failure code [DKD0L6] Failure in steering speed sensor 1144
Failure code [DKH0KX] Clinometer sensor signal out of range 1146
Failure code [DKH1KX] or VHMS_LED display: “n4″o”33” Abnormality in clinometer sensor 1148
Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection 1150
Failure code [DLF1LC] Transmission input shaft speed sensor: Disagreement of revolution speed signal 1152
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection 1154
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal 1156
Troubleshooting by failure code, Part 7 1159
Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right) 1161
Failure code [DLF6L3] Trouble in wheel speed sensor (Front right) 1162
Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left) 1163
Failure code [DLF7L3] Trouble in wheel speed sensor (Front left) 1164
Failure code [DLF8KA] Disconnection in wheel speed sensor (Right rear) 1166
Failure code [DLF8L3] Trouble in wheel speed sensor (Right rear) 1168
Failure code [DLF8LC] Trouble in wheel speed sensor system (Right rear) 1170
Failure code [DLF8MA] Disconnection in wheel speed sensor (Right rear) 1171
Failure code [DLF9KA] Disconnection in wheel speed sensor (Left rear) 1172
Failure code [DLF9L3] Trouble in wheel speed sensor (Left rear) 1174
Failure code [DLF9LC] Trouble in wheel speed sensor system (Left rear) 1176
Failure code [DLF9MA] Disconnection in wheel speed sensor (Left rear) 1177
Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system 1178
Failure code [DLT3LC] Trouble in transmission output shaft speed sensor 1180
Failure code [DLT4KA] Disconnection in transmission output shaft speed sensor 1182
Failure code [DLT4MA] Disconnection in transmission output shaft speed sensor 1184
Failure code [DV00KB] Short circuit in buzzer output 1186
Failure code [DW2AKA] Disconnection in main pressure variable valve output 1188
Failure code [DW2AKB] Ground fault in main pressure variable valve output circuit 1190
Failure code [DW2AKY] Hot short in main pressure variable valve output circuit 1192
Failure code [DW2AL1] Defective reset of main pressure variable valve 1194
Failure code [DW2ALH] Malfunction of main pressure variable valve 1196
Failure code [DW35KZ] Trouble in output system of auto suspension solenoid 1 (Disconnection or short circuit) 1198
Failure code [DW36KZ] Trouble in output system of auto suspension solenoid 2 (Disconnection or short circuit) 1200
Failure code [DW72KZ] Trouble in kick-out solenoid output system (Disconnection or short circuit) 1202
Failure code [DW73KZ] Trouble in hoist select valve output system (Disconnection or short circuit) 1204
Failure code [DW78KZ] Trouble in brake cooling valve (BCV) (rear wheel) output system (Disconnection or short circuit) 1206
Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps operating) 1208
Failure code [DWNBKA] Disconnection in ASR shut-off valve output circuit 1210
Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit 1212
Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit 1214
Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate) 1215
Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system 1216
Failure code [DWNDMA] Defective ABS cut-off valve (Front) 1218
Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system 1220
Failure code [DWNEMA] Defective ABS cut-off valve (Rear) 1222
Troubleshooting by failure code, Part 8 1225
Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve: Out of control) 1228
Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection) 1230
Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit) 1232
Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line) 1233
Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction) 1234
Failure code [DX13KA] (Output circuit of hoist EPC valve: Disconnection) 1236
Failure code [DX13KB] (Output circuit of hoist EPC valve: Short circuit) 1238
Failure code [DX13KY] (Output circuit of hoist EPC valve: Short circuit with power source line) 1240
Failure code [DX17K4] (ASR proportional pressure reducing solenoid valve (right): Trouble (Valve keeps operating)) 1242
Failure code [DX17KA] (ASR proportional pressure reducing solenoid valve (right) output circuit: Disconnection) 1244
Failure code [DX17KB] (ASR proportional pressure reducing solenoid valve (right) output circuit: Ground fault) 1246
Failure code [DX17KY] (ASR proportional pressure reducing solenoid valve (right) output circuit: Short circuit) 1248
Failure code [DX17MA] (ASR proportional pressure reducing solenoid valve (right): Trouble (Valve does not operate)) 1249
Failure code [DX18K4] (ASR proportional pressure reducing solenoid valve (left): Trouble (Valve keeps operating)) 1250
Failure code [DX18KA] (ASR proportional pressure reducing solenoid valve (left) output circuit: Disconnection) 1252
Failure code [DX18KB] (ASR proportional pressure reducing solenoid valve (left) output circuit: Ground fault) 1254
Failure code [DX18KY] (ASR proportional pressure reducing solenoid valve (left) output circuit: Short circuit) 1256
Failure code [DX18MA] (ASR proportional pressure reducing solenoid valve (left): Trouble (Valve does not operate)) 1257
Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right) 1258
Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right) 1259
Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right) 1260
Failure code [DX21MA] Defective ABS control valve (Front right) 1262
Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left) 1264
Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left) 1265
Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left) 1266
Failure code [DX22MA] Defective ABS control valve (Front left) 1268
Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right) 1270
Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right) 1271
Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right) 1272
Failure code [DX23MA] Defective ABS control valve (Rear right) 1274
Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left) 1276
Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left) 1277
Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left) 1278
Failure code [DX24MA] Defective ABS control valve (Rear left) 1280
Failure code [DX25MA] Defective ABS front wheel system control valve 1282
Failure code [DX26MA] Defective ABS rear wheel system control valve 1282
Troubleshooting by failure code, Part 9 1285
Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection 1288
Failure code [DXH1KB] Lockup clutch solenoid output circuit: Short circuit 1290
Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuitto power supply line 1292
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection 1294
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit 1296
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit top ower supply line 1298
Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection 1302
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit 1304
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power supply line 1306
Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection 1310
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit 1312
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power supply line 1314
Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection 1318
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit 1320
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power supply line 1322
Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection 1326
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit 1328
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power supply line 1330
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection 1334
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit 1336
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power supply line 1338
Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection 1340
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit 1342
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power supply line 1344
Failure code [F@BBZL] or VHMS_LED display: “n3″→”38” Blow-by pressure: High error 1347
Failure code [F@BYNR] or VHMS_LED display: “n3″→”62” Exhaust gas temperature (F): Abnormal heat 1348
Failure code [F@BYNS] or VHMS_LED display: “n3″→”61” Exhaust gas temperature (F): Overheat 1350
Failure code [F@BZNR] or VHMS_LED display: “n3″→”72” Exhaust gas temperature (R): Abnormal heat 1352
Failure code [F@BZNS] or VHMS_LED display: “n3″→”71” Exhaust gas temperature (R): Overheat 1354
Troubleshooting of electrical system (E-mode) 1357
Before troubleshooting of electric system 1359
Contents of troubleshooting table 1360
E-1 Engine does not start 1361
E-2 Automatic preheating does not operate 1364
E-3 Machine monitor does not display all, when starting switch is turned ON 1368
E-4 Machine monitor does not operate when starting switch is OFF 1370
E-5 Alarm buzzer does not sound 1372
E-6 Alarm buzzer does not stop sounding 1374
E-7 Gauges of machine monitor, caution lamps or character display section do not display properly 1376
E-8 A selection of the display in character display section cannot be changed 1377
E-9 Power mode selecting function does not operate properly 1380
E-10 AISS function does not operate properly 1381
E-11 Seat belt caution lamp does not display properly 1382
E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly 1383
E-13 Night illumination (lighting) does not work properly 1386
E-14 Emergency steering does not operate 1398
E-15 Hoist lever does not operate normally 1412
E-16 Electric priming pump does not operate or does not stop automatically 1414
E-17 Cannot access to the setting screen of the mobile communication terminal 1416
E-18 Cannot log in to the setting screen of the mobile communication terminal because the log in password is unknown 1421
E-19 VHMS controller is not detected 1423
E-20 VHMS controller does not become active 1424
E-21 Communication between mobile communication terminal and KOMTRAX Plus server fails 1425
E-22 Data is not sent to KOMTRAX Plus server 1428
Troubleshooting of hydraulic and mechanical system (H-mode) 1431
Contents of troubleshooting table 1433
H-1 Machine does not start 1434
H-2 Machine does not travel smoothly (hunting) 1436
H-3 Lockup cannot be cancelled 1436
H-4 Excessive shock when starting or shifting excessive 1437
H-5 Transmission does not shift up 1438
H-6 Machine lacks power or speed when traveling 1440
H-7 Time lag is excessive when starting or shifting gear 1444
H-8 Torque converter oil temperature is high 1446
H-9 Torque converter oil pressure is low 1447
H-10 Front brake is ineffective 1448
H-11 Rear brake is ineffective 1449
H-12 Steering wheel is heavy 1450
H-13 Steering wheel does not work 1451
H-14 Steering wheel vibrates 1452
H-15 Dump body lifting speed is slow 1453
H-16 Dump body does not work 1454
H-17 Excessive hydraulic drift of dump body 1455
Troubleshooting of engine (S-mode) 1457
Method of using troubleshooting chart 1460
S-1 Starting performance of engine is poor 1464
S-2 Engine does not start 1466
S-3 Engine does not pick up smoothly 1470
S-4 Engine stops during operation 1471
S-5 Engine does not rotate smoothly 1472
S-6 Engine lack output (or lacks power) 1473
S-7 Exhaust gas is black (incomplete combustion) 1474
S-8 Oil consumption is excessive (or exhaust gas is blue) 1476
S-9 Oil becomes dirty quickly 1477
S-10 Fuel consumption is excessive 1478
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 1479
S-12 Oil pressure drops 1480
S-13 Oil level rises (Entry of coolant or fuel) 1482
S-14 Coolant temperature becomes too high (Overheating) 1484
S-15 Abnormal noise is made 1485
S-16 Vibration is excessive 1486
S-17 Air cannot be bled from fuel circuit 1488
50 Disassembly and assembly 1491
General information on disassembly and assembly 1491
How to read this manual 1492
Coating materials list 1494
Special tool list 1497
Sketches of special tools 1501
Engine and cooling system 1509
Removal and installation of fuel supply pump assembly 1510
Removal and installation of fuel injector assembly 1515
Removal and installation of cylinder head assembly 1521
Removal and installation of engine front seal 1539
Removal and installation of engine rear seal 1543
Removal and installation of engine assembly 1549
Removal and installation of radiator assembly 1560
Removal and installation of damper assembly 1567
Disassembly and assembly of damper assembly 1570
Removal and installation of brake and power train oil cooler assembly 1574
Power train, Part 1 1579
Removal and installation of torque converter and transmission assembly 1580
Separation and coupling of transmission assembly and torque converter assembly 1585
Disassembly and assembly of torque converter and control valve assembly 1598
Disassembly and assembly of torque converter assembly 1600
Disassembly and assembly of transmission assembly 1616
Removal and installation of transmission control valve assembly (ECMV assembly) 1656
Disassembly and assembly of transmission control valve assembly (ECMV assembly) 1658
Power train, Part 2 1663
Removal and installation of differential assembly 1664
Disassembly and assembly of differential assembly 1667
Removal and installation of final drive carrier assembly 1681
Disassembly and assembly of final drive carrier assembly 1684
Disassembly and assembly of front wheel hub assembly 1686
Steering system 1693
Disassembly and assembly of steering cylinder assembly 1694
Brake system 1701
Removal and installation of front brake caliper pads 1702
Removal and installation of front brake calipers assembly 1704
Disassembly and assembly of front brake calipers assembly 1707
Removal and installation of final drive and rear brake assembly 1709
Removal and installation of final drive, rear brake, and parking brake assembly 1714
Disassembly and assembly of final drive, rear brake, and parking brake assembly 1717
Undercarriage and frame 1733
Removal and installation of front wheel assembly 1734
Removal and installation of rear wheel assembly 1738
Removal and installation of front suspension cylinder assembly 1742
Disassembly and assembly of front suspension cylinder assembly (cylinder with buffer ring) 1745
Removal and installation of rear suspension cylinder assembly 1749
Disassembly and assembly of rear suspension cylinder assembly (cylinder with buffer ring) 1752
Hydraulic system 1757
Disassembly and assembly of hoist cylinder assembly 1758
Body 1767
Removal and installation of body assembly 1768
Cab and its attachments 1773
Disassembly and assembly of operator’s seat assembly 1774
Removal and installation of air conditioner unit assembly 1785
Electrical system, Part 1 1791
Removal and installation of engine controller assembly 1792
Removal and installation of transmission controller assembly 1795
Removal and installation of retarder controller assembly 1797
Electrical system, Part 2 1801
Removal and installation of mobile communication terminal 1802
Removal and installation of DC/DC converter 1804
Removal and installation of mobile communication terminal harness 1806
90 Diagrams and drawings 1817
Hydraulic diagrams and drawings 1817
Power train hydraulic circuit diagram 1818
Steering and hoist hydraulic circuit diagram 1819
Brake hydraulic circuit diagram 1825
Brake hydraulic circuit diagramfor ASR specification (If equipped) 1827
Brake hydraulic circuit diagramfor ABS specification (If equipped)for ABS + ASR specification (If equipped) 1829
Electrical diagrams and drawings 1833
Electrical circuit diagram inside cab 1835
Electrical circuit diagram outside cab 1847
Electrical circuit diagram for VHMS 1853
Electrical circuit diagram for ASR (If equipped) 1855
Electrical circuit diagram for ABS (If equipped) 1857
Air conditioner electrical circuit diagram 1861
Electrical circuit diagram for auto greasing (If equipped) 1863
Electrical circuit diagram of mobile communication terminal (if equipped) 1865
Connectors table and arrangement drawing 1867

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S.V  17/12/24