Komatsu DUMP TRUCK HD465-7R HD605-7R Shop Manual SEN02283-16 – PDF

Description

Komatsu DUMP TRUCK HD465-7R HD605-7R Shop Manual SEN02283-16 – PDF DOWNLOAD

FILE DETAILS:

Komatsu DUMP TRUCK HD465-7R HD605-7R Shop Manual SEN02283-16 – PDF DOWNLOAD

Language : English
Pages :1806
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu DUMP TRUCK HD465-7R HD605-7R Shop Manual SEN02283-16 – PDF DOWNLOAD

SERIAL NUMBERS HD465-15001
HD605-15001 and up

1. General precautions

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.

TABLE OF CONTENTS:

Komatsu DUMP TRUCK HD465-7R HD605-7R Shop Manual SEN02283-16 – PDF DOWNLOAD

SERIAL NUMBERS HD465-15001
HD605-15001 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 65
Weight table 71
Fuel, coolant and lubricants 72
10 Structure, function and maintenance standard 77
Engine and cooling system 77
Radiator, torque converter oil cooler, after cooler, work equipment oil cooler, fuel cooler 78
Fuel system 80
Brake oil cooler 81
Output shaft 82
Power train, Part 1 85
Power train skeleton 86
Drive shaft 88
Torque converter and transmission hydraulic piping 90
Brake cooling oil control valve (BCV) 92
Torque converter 94
Torque converter valve 101
Transmission 103
Transmission control valve 119
ECMV 120
Power train, Part 2 129
Axle 130
Differential 132
Final drive 133
Wheels 134
Steering system 137
Steering column 138
Steering linkage 139
Brake system 143
Brake piping 144
Brake valve 146
Secondary brake valve 149
Relay valve 150
Front brake off valve 151
Accumulator charge valve 152
Accumulator 156
Slack adjuster 157
Brake 159
Parking brake solenoid valve 163
Undercarriage and frame 165
Suspension 166
Suspension cylinder 168
Rear axle support 174
Hydraulic system 177
Steering and hoist hydraulic piping 178
Dump body control 180
Hydraulic tank 181
Steering valve 182
Crossover relief valve 186
Steering cylinder 187
Steering control valve 188
Hoist valve 194
EPC valve 200
Hoist cylinder 201
Hydraulic pump 202
Work equipment (Body) 207
Auto greasing system 208
Cab and its attachments 231
ROPS cab 232
Air conditioner 233
Rear view monitor 239
Electrical system, Part 1 249
Machine monitor system 250
Electrical system, Part 2 311
Automatic shift control system 312
Transmission controller 316
External power supply heater 330
Automatic suspension system 336
Automatic emergency steering system 332
Retarder control system 339
Battery disconnect switch 350
Dump control lever 356
Electrical system, Part 3 361
Payload meter II (Card type) 362
Electrical system, Part 4 393
VHMS controller related 394
ASR system (If equipped) 418
Sensors, switches 424
20 Standard value table 443
Standard service value table 443
Standard value table for engine 444
Standard value table for machine 446
30 Testing and adjusting 457
Testing and adjusting, Part 1 457
Tools for testing, adjusting, and troubleshooting 459
Sketch of special tool 462
Testing engine speed 463
Testing air supply pressure (boost pressure) 464
Testing exhaust temperature 465
Testing exhaust gas color 467
Adjustment of valve clearance 469
Testing of compression pressure 471
Testing blow-by pressure 474
Testing engine oil pressure 475
Handling of fuel system devices 476
Releasing residual pressure from fuel system 476
Testing of fuel pressure 477
Cylinder cut-out mode operation 478
No-injection cranking 478
Testing of fuel return rate and fuel leakage 479
Bleeding air from fuel circuit 481
Testing the fuel circuit for leakage 482
Replacing and adjusting of fan belt 483
Replacing and adjusting of alternator and air conditioner compressor belt 484
Testing and adjusting, Part 2 487
Testing torque converter stall speed 489
Testing power train oil pressure 490
Adjusting transmission speed sensor 497
Testing and adjusting brake oil pressure 498
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 501
Testing brake performance 509
Releasing remaining pressure in brake circuit 511
Bleeding air from brake circuit 512
Testing wear of front brake pad 513
Testing wear of rear brake disc 514
Method of releasing parking brake in an emergency 515
Testing and adjusting front suspension cylinder 516
Testing and adjusting rear suspension cylinder 520
Testing and adjusting front suspension cylinder (Automatic suspension specification) 524
Testing and adjusting hydraulic pressure in steering, hoist circuit 525
Testing and adjusting oil pressure in dump EPC circuit 528
Air bleeding from steering cylinder 529
Procedure for raising dump body in emergency 530
Procedure for lowering dump body in emergency 531
Adjusting body positioner sensor 532
Resetting method for dump body seating control 533
Adjustment of tilt lock lever of steering wheel 534
Handling of voltage circuit of engine controller 535
Adjusting transmission controller 535
Method for emergency escape at electrical system failure 536
Testing and adjusting, Part 3 541
Setting and adjusting of devices 542
Special functions of machine monitor (EMMS) 555
Testing and adjusting, Part 4 579
Special functions of machine monitor (EMMS) 580
Testing and adjusting, Part 5 621
Request for opening ORBCOMM terminal 622
VHMS controller initial setting procedure 624
Using method of KOMTRAX functions of ORBCOMM terminal 644
Precautions for replacing VHMS controller 647
Pm Clinic check sheet 653
Initial setting of payload meter 656
Setting of payload meter built in VHMS 657
Setting of card-type payload meter (PLM-) after installation or replacement 665
40 Troubleshooting 673
Failure code table and fuse locations 673
Failure codes table 674
Fuse locations 685
General information on troubleshooting 691
Points to remember when troubleshooting 692
Sequence of events in troubleshooting 693
Check before troubleshooting 694
Classification and procedures for troubleshooting 695
Contents of troubleshooting table 696
Troubleshooting method for disconnecting wiring harness of pressure sensor system 698
Connection table for connector pin numbers 701
T- branch box and T- branch adapter table 737
Troubleshooting by failure code, Part 1 741
Failure code [1500L0] (Dual engagement) 743
Failure code [15B0NX] (Transmission oil filter: Clogging) 744
Failure code [15F0KM] (R → F shifting abuse 1: Mistake in operation) 746
Failure code [15F0MB] (R → F shifting abuse 2: Mistake in operation) 746
Failure code [15F7KM] (Forward clutch disk abuse: Mistake in operation or setting) 747
Failure code [15G0MW] (R clutch: Slipping) 748
Failure code [15G7KM] (Reverse clutch disk abuse: Mistake in operation or setting) 750
Failure code [15H0MW] (Hi clutch: Slipping) 752
Failure code [15J0MW] (Lo clutch: Slipping) 754
Failure code [15K0MW] (1st clutch: Slipping) 756
Failure code [15L0MW] (2nd clutch: Slipping) 758
Failure code [15M0MW] (3rd clutch: Slipping) 760
Failure code [15N0MW] (4th clutch: Slipping) 762
Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF) 764
Failure code [15SBMA] (R clutch solenoid: Malfunction) 766
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF) 767
Failure code [15SCMA] (Hi clutch solenoid: Malfunction) 770
Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF) 771
Failure code [15SDMA] (Lo clutch solenoid: Malfunction) 774
Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF) 775
Failure code [15SEMA] (1st clutch solenoid: Malfunction) 778
Troubleshooting by failure code, Part 2 827
Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF 830
Failure code [15SFMA] 2nd clutch solenoid: Malfunction 833
Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF 834
Failure code [15SGMA] 3rd clutch solenoid: Malfunction 837
Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF 838
Failure code [15SHMA] 4th clutch solenoid: Malfunction 841
Failure code [15SJMA] Lockup clutch solenoid: Malfunction 842
Failure code [2C4MNX] Retarder cooling oil filter: Clogging 844
Failure code [2F00KM] Parking brake: Mistake in operation or setting 846
Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front) 849
Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear) 849
Failure code [6014NX] Hydraulic oil filter: Clogging 850
Failure code [989A00] Engine over run prevention command signal: Operating 852
Failure code [989D00] Rear section tipping over alarm: Alarm is activated 852
Failure code [A570NX] Engine oil filter: Clogging 853
Failure code [AA10NX] Air cleaner element: Clogging 854
Failure code [AB00MA] Alternator: Malfunction 856
Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure 858
Failure code [B@BAZK] Engine oil: Level too low 859
Failure code [B@BCNS] Engine: Overheat 860
Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level 862
Failure code [B@BFZK] Lowering of fuel level 864
Failure code [B@C7NS] Brake cooling oil: Overheating (Rear) 866
Failure code [B@CENS] Overheating of torque converter oil 868
Failure code [B@GAZK] Battery electrolyte level: Lowering of level 869
Failure code [B@JANS] Steering oil temperature: Overheat 870
Troubleshooting by failure code, Part 3 873
Failure code [CA111] Abnormality in engine controller 876
Failure code [CA115] Engine Ne or Bkup speed sensor error 878
Failure code [CA122] Charge (boost) pressure sensor high error 880
Failure code [CA123] Charge (boost) pressure sensor low error 882
Failure code [CA131] Throttle sensor high error 884
Failure code [CA132] Throttle sensor low error 887
Failure code [CA135] Engine oil pressure sensor high error 890
Failure code [CA141] Engine oil pressure sensor low error 892
Failure code [CA144] Coolant temperature sensor high error 894
Failure code [CA145] Coolant temperature sensor low error 896
Failure code [CA153] Charge (boost) temperature sensor high error 898
Failure code [CA154] Charge (boost) temperature sensor low error 900
Failure code [CA187] Sensor power supply 2 low error 902
Failure code [CA212] Engine oil temperature sensor high error 904
Failure code [CA213] Engine oil temperature sensor low error 906
Failure code [CA221] Atmospheric pressure sensor high error 908
Failure code [CA222] Atmospheric pressure sensor low error 910
Failure code [CA227] Sensor power supply 2 high error 912
Failure code [CA234] Engine overspeed 913
Failure code [CA238] Ne speed sensor power supply error 914
Failure code [CA263] Fuel Temp Sensor High Error 916
Failure code [CA265] Fuel Temp Sensor Low Error 918
Failure code [CA271] PCV1 Short circuit 920
Failure code [CA272] PCV1 Disconnection 921
Failure code [CA273] PCV2 Short circuit 922
Failure code [CA274] PCV2 Disconnection 923
Failure code [CA322] Injector #1 open/short error 924
Failure code [CA323] Injector #5 open/short error 926
Failure code [CA324] Injector #3 open/short error 928
Failure code [CA325] Injector #6 open/short error 930
Failure code [CA331] Injector #2 open/short error 932
Failure code [CA332] Injector #4 open/short error 934
Failure code [CA342] Calibration code inconsistency 936
Failure code [CA351] Injectors drive circuit error 937
Failure code [CA352] Sens Supply 1 Volt Low Error 938
Failure code [CA386] Sensor power supply 1 high error 940
Troubleshooting by failure code, Part 4 943
Failure code [CA431] Idle validation switch error 945
Failure code [CA432] Idle validation action error 949
Failure code [CA441] Battery voltage low error 952
Failure code [CA442] Battery voltage high error 953
Failure code [CA449] Common rail pressure high error 2 954
Failure code [CA451] Rail Press Sensor High Error 956
Failure code [CA452] Rail Press Sensor Low Error 958
Failure code [CA553] Common rail pressure high error 1 960
Failure code [CA554] Common rail pressure sensor in range error 961
Failure code [CA559] Supply pump pressure very low error 1 962
Failure code [CA689] Engine Ne speed sensor error 966
Failure code [CA731] Engine Bkup speed sensor phase error 968
Failure code [CA757] All continuous data lost error 969
Failure code [CA778] Engine Bkup speed sensor error 970
Failure code [CA1633] KOMNET datalink timeout error 972
Failure code [CA2185] Throttle sensor supply voltage high error 974
Failure code [CA2186] Throttle sensor power supply low error 976
Failure code [CA2249] Supply pump pressure very low error 2 978
Failure code [CA2555] Intake air heater relay open circuit error 980
Failure code [CA2556] Intake air heater relay short circuit error 982
Troubleshooting by failure code, Part 5 985
Failure code [D19HKB] Stop lamp relay output system: Short circuit 987
Failure code [D5ZKKZ] Front brake cut-off solenoid valve: Disconnection, short circuit or short circuit to power supply line 988
Failure code [DAF9KM] Wrong connection of connector 990
Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication 991
Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of power supply voltage 992
Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller 994
Failure code [DAQ2KK] Transmission controller solenoid power supply: Power supply voltage too low 996
Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection 998
Failure code [DAQRKR] Abnormality in CAN communication (Transmission) 999
Failure code [DAQRMA] Transmission controller option setting: Malfunction1004
Failure code [DAQV00] Neutral coast caution1005
Failure code [DAQW00] Neutral over speed caution1006
Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller1007
Failure code [DB12KK] Retarder controller solenoid power supply: Power supply system trouble1008
Failure code [DB13KK] Retarder controller battery direct power supply: Power supply voltage too low1010
Failure code [DB19KQ] Disagreement of model selection (Retarder controller)1012
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled1013
Failure code [DB1RMA] Disagreement of option setting (Retarder controller)1017
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled1018
Failure code [DBB0KK] or VHMS_LED display: “n9” o “01”1024
Failure code [DBB0KQ] or VHMS_LED display: “nF” o “11”1026
Failure code [DBB3KK] or VHMS_LED display: “n9” o “05”1028
Failure code [DBB5KP] or VHMS_LED display: “n9” o “04”1030
Failure code [DBB6KP] or VHMS_LED display: “n9” o “02”1032
Failure code [DBB7KP] or VHMS_LED display: “n9” o “03”1034
Failure code [DBBQKR] or VHMS_LED display: “n8” o “02”1035
Failure code [DBBRKR] Abnormality in CAN communication (VHMS)1035
Failure code [DBC2KK] ABS controller solenoid power supply: Power supply system trouble1036
Failure code [DBC3KK] ABS controller battery direct power supply: Power supply voltage too low1038
Failure code [DBC9KQ] Disagreement of model selection (ABS controller)1040
Failure code [DBCRKR] Abnormality in CAN communication (ABS)1041
Failure code [DBCRMA] Disagreement of option setting (ABS controller)1045
Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range1046
Failure code [DDD8KA] ARSC system switch system: Disconnection (If equipped)1048
Failure code [DDD8KB] ARSC system switch system: Short circuit (If equipped)1050
Failure code [DDD9KA] ABS system switch system: Disconnection1052
Failure code [DDD9KB] ABS system switch system: Short circuit1054
Failure code [DDDAKA] ASR system switch: Disconnection1056
Failure code [DDDAKB] ASR system switch: Short circuit1058
Failure code [DDP6L4] Service brake pressure switch trouble (Rear)1060
Failure code [DDTHKA] Hi clutch fill switch: Disconnection1062
Failure code [DDTJKA] Lo clutch fill switch: Disconnection1064
Failure code [DDTKKA] 1st clutch fill switch: Disconnection1066
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection1068
Failure code [DDTMKA] (3rd clutch fill switch: Disconnection)1070
Failure code [DDTNKA] R clutch fill switch: Disconnection1072
Failure code [DDTPKA] 4th clutch fill switch: Disconnection1074
Failure code [DF10KA] Gear shift lever: Disconnection1076
Failure code [DF10KB] Gear shift lever: Short circuit1079
Failure code [DGE5KX] or VHMS_LED display: “n4” o “01”1084
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range1086
Failure code [DGR2KZ] Retarder oil temperature sensor system trouble : Ground fault (Rear wheel)1088
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range1090
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range1092
Troubleshooting by failure code, Part 61095
Failure code [DGT4KA] or VHMS_LED display: “n3” o “12” Exhaust gas temperature sensor (F): Disconnection1097
Failure code [DGT4KB] or VHMS_LED display: “n3” o “11” Exhaust gas temperature sensor (F): Short circuit1100
Failure code [DGT5KA] or VHMS_LED display: “n3” o “22” Exhaust gas temperature sensor (R): Disconnection1103
Failure code [DGT5KB] or VHMS_LED display: “n3” o “21” Exhaust gas temperature sensor (R): Short circuit1106
Failure code [DHE5KB] or VHMS_LED display: “n3” o “32” Blow-by pressure sensor: Short circuit1109
Failure code [DHE5KY] or VHMS_LED display: “n3” o “31” Blow-by pressure sensor: Short circuit with power supply line1112
Failure code [DHP4KY] or VHMS_LED display: “n5” o “44” Short circuit in suspension pressure sensor system (Front right)1114
Failure code [DHP4KZ] or VHMS_LED display: “n5” o “43” Disconnection or ground fault in suspension pressure sensor system(Front right)1116
Failure code [DHP5KY] or VHMS_LED display: “n5” o “54” Short circuit in suspension pressure sensor system (Front left)1118
Failure code [DHP5KZ] or VHMS_LED display: “n5” o “53” Disconnection or ground fault in suspension pressure sensor system(Front left)1120
Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear)1122
Failure code [DHP6KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Right rear)1123
Failure code [DHP6KY] or VHMS_LED display: “n5” o “64” Suspension pressure sensor system: Short circuit (Right rear)1126
Failure code [DHP6KZ] or VHMS_LED display: “n5” o “63” Suspension pressure sensor system: Disconnection or ground fault (Right rear)1128
Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear)1130
Failure code [DHP7KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Left rear)1132
Failure code [DHP7KY] or VHMS_LED display: “n5” o “74” Suspension pressure sensor system: Short circuit (Left rear)1134
Failure code [DHP7KZ] or VHMS_LED display: “n5” o “73” Suspension pressure sensor system: Disconnection or ground fault (Left rear)1136
Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range1138
Failure code [DHT5L6] Torque converter oil pressure sensor: Disagreement of run and stop condition with signal1140
Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range1142
Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range1144
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right)1146
Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left)1148
Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Front right)1150
Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Front right)1152
Failure code [DHUTKX] Trouble in ABS cut valve pressure sensor1154
Failure code [DJF1KA] Fuel level sensor: Disconnection1156
Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection)1158
Failure code [DK51L5] Retarder lever potentiometer: Potentiometer signal is inconsistent with swich signal1159
Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range1162
Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal1164
Failure code [DK54KX] Body positioner sensor: Out of input signal range1166
Failure code [DKD0L6] Failure in steering speed sensor1168
Failure code [DKH0KX] Clinometer sensor signal out of range1170
Failure code [DKH1KX] or VHMS_LED display: “n4″o”33” Abnormality in clinometer sensor1172
Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection1174
Failure code [DLF1LC] Transmission input shaft speed sensor: Disagreement of revolution speed signal1176
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection1178
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal1180
Troubleshooting by failure code, Part 71183
Failure code [DLF8KA] (Wheel speed sensor: Disconnection (Right rear))1186
Failure code [DLF8L3] (Wheel speed sensor: Disconnection (Right rear))1188
Failure code [DLF8LC] (Wheel speed sensor: Trouble (Right rear))1190
Failure code [DLF8MA] (Wheel speed sensor: Disconnection (Right rear))1191
Failure code [DLF9KA] (Wheel speed sensor: Disconnection (Left rear))1192
Failure code [DLF9L3] (Wheel speed sensor: Trouble (Left rear))1194
Failure code [DLF9LC] (Wheel speed sensor: Trouble (Left rear))1196
Failure code [DLF9MA] (Wheel speed sensor: Disconnection (Left rear))1197
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)1198
Failure code [DLT3LC] (Transmission output shaft speed sensor: Disagreement of revolution speed signal)1200
Failure code [DLT4KA] (Transmission output shaft speed sensor: Disconnection)1202
Failure code [DLT4MA] (Transmission output shaft speed sensor: Malfunction)1204
Failure code [DV00KB] (Buzzer output: Short circuit)1206
Failure code [DW2AKA] (Main pressure variable valve output: Disconnection)1208
Failure code [DW2AKB] (Main pressure variable valve output circuit: Ground fault)1210
Failure code [DW2AKY] (Main pressure variable valve output circuit: Hot short)1212
Failure code [DW2AL1] (Main pressure variable valve: Defective reset)1214
Failure code [DW2ALH] (Main pressure variable valve: Malfunction)1216
Failure code [DW35KZ] (Failure in output system of auto suspension solenoid 1: Disconnection or short circuit)1218
Failure code [DW36KZ] (Failure in output system of auto suspension solenoid 2: Disconnection or short circuit) (If equipped)1220
Failure code [DW72KZ] (Kick-out solenoid output system trouble: Disconnection or short circuit)1222
Failure code [DW73KZ] (Failure in hoist select valve output system: Disconnection or short circuit)1224
Failure code [DW78KZ] (Brake cooling valve (BCV) (rear wheel) output system trouble: Disconnection or short circuit)1226
Failure code [DWNBK4] (ASR shut-off valve: Trouble (Valve keeps operating))1228
Failure code [DWNBKA] (ASR shut-off valve output circuit: Disconnection)1230
Failure code [DWNBKB] (ASR shut-off valve output circuit: Ground fault)1232
Failure code [DWNBKY] (ASR shut-off valve output circuit: Short circuit)1234
Failure code [DWNBMA] (ASR shut-off valve: Trouble (Valve does not operate))1235
Troubleshooting by failure code, Part 81237
Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve: Out of control)1240
Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection)1242
Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit)1244
Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line)1245
Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction)1246
Failure code [DX13KA] (Output circuit of hoist EPC valve: Disconnection)1248
Failure code [DX13KB] (Output circuit of hoist EPC valve: Short circuit)1250
Failure code [DX13KY] (Output circuit of hoist EPC valve: Short circuit with power source line)1252
Failure code [DX17K4] (ASR proportional pressure reducing solenoid valve (right): Trouble (Valve keeps operating))1254
Failure code [DX17KA] (ASR proportional pressure reducing solenoid valve (right) output circuit: Disconnection)1256
Failure code [DX17KB] (ASR proportional pressure reducing solenoid valve (right) output circuit: Ground fault)1258
Failure code [DX17KY] (ASR proportional pressure reducing solenoid valve (right) output circuit: Short circuit)1260
Failure code [DX17MA] (ASR proportional pressure reducing solenoid valve (right): Trouble (Valve does not operate))1261
Failure code [DX18K4] (ASR proportional pressure reducing solenoid valve (left): Trouble (Valve keeps operating))1262
Failure code [DX18KA] (ASR proportional pressure reducing solenoid valve (left) output circuit: Disconnection)1264
Failure code [DX18KB] (ASR proportional pressure reducing solenoid valve (left) output circuit: Ground fault)1266
Failure code [DX18KY] (ASR proportional pressure reducing solenoid valve (left) output circuit: Short circuit)1268
Failure code [DX18MA] (ASR proportional pressure reducing solenoid valve (left): Trouble (Valve does not operate))1269
Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right)1270
Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right)1271
Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right)1272
Failure code [DX21MA] Defective ABS control valve (Front right)1274
Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left)1276
Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left)1277
Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left)1278
Failure code [DX22MA] Defective ABS control valve (Front left)1280
Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right)1282
Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right)1283
Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right)1284
Failure code [DX23MA] Defective ABS control valve (Rear right)1286
Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left)1288
Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left)1289
Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left)1290
Failure code [DX24MA] Defective ABS control valve (Rear left)1292
Failure code [DX25MA] Defective ABS front wheel system control valve1294
Failure code [DX26MA] Defective ABS rear wheel system control valve1294
Troubleshooting by failure code, Part 91297
Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection1300
Failure code [DXH1KB] Lockup clutch solenoid output circuit: Short circuit1302
Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power supply line1304
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection1306
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit1308
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power supply line1310
Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection1314
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit1316
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power supply line1318
Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection1322
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit1324
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power supply line1326
Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection1330
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit1332
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power supply line1334
Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection1338
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit1340
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power supply line1342
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection1346
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit1348
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power supply line1350
Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection1352
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit1354
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power supply line1356
Failure code [F@BBZL] or VHMS_LED display: “n3″→”38” Blow-by pressure: High error1359
Failure code [F@BYNR] or VHMS_LED display: “n3″→”62” Exhaust gas temperature (F): Abnormal heat1360
Failure code [F@BYNS] or VHMS_LED display: “n3″→”61” Exhaust gas temperature (F): Overheat1362
Failure code [F@BZNR] or VHMS_LED display: “n3″→”72” Exhaust gas temperature (R): Abnormal heat1364
Failure code [F@BZNS] or VHMS_LED display: “n3″→”71” Exhaust gas temperature (R): Overheat1366
Troubleshooting of electrical system (E-mode)1369
Before troubleshooting of electric system1371
Contents of troubleshooting table1372
E-1 Engine does not start1373
E-2 Automatic preheating does not operate1376
E-3 Machine monitor does not display all, when starting switch is turned ON1380
E-4 Machine monitor does not operate when starting switch is OFF1382
E-5 Alarm buzzer does not sound1384
E-6 Alarm buzzer does not stop sounding1386
E-7 Gauges of machine monitor, caution lamps or character display section do not display properly1388
E-8 A selection of the display in character display section cannot be changed1389
E-9 Power mode selecting function does not operate properly1392
E-10 AISS function does not operate properly1393
E-11 Seat belt caution lamp does not display properly1394
E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly1395
E-13 Night illumination (lighting) does not work properly1398
E-14 Emergency steering does not operate1410
E-15 Hoist lever does not operate normally1420
E-16 Electric priming pump does not operate or does not stop automatically1422
Troubleshooting of hydraulic and mechanical system (H-mode)1425
Contents of troubleshooting table1427
H-1 Machine does not start1428
H-2 Machine does not travel smoothly (hunting)1430
H-3 Lockup cannot be cancelled1430
H-4 Excessive shock when starting or shifting excessive1431
H-5 Transmission does not shift up1432
H-6 Machine lacks power or speed when traveling1434
H-7 Time lag is excessive when starting or shifting gear1438
H-8 Torque converter oil temperature is high1440
H-9 Torque converter oil pressure is low1441
H-10 Front brake is ineffective1442
H-11 Rear brake is ineffective1443
H-12 Steering wheel is heavy1444
H-13 Steering wheel does not work1445
H-14 Steering wheel vibrates1446
H-15 Dump body lifting speed is slow1447
H-16 Dump body does not work1448
H-17 Excessive hydraulic drift of dump body1449
Troubleshooting of engine (S-mode)1451
Method of using troubleshooting chart1454
S-1 Starting performance of engine is poor1458
S-2 Engine does not start1459
S-3 Engine does not pick up smoothly1462
S-4 Engine stops during operation1463
S-5 Engine does not rotate smoothly1464
S-6 Engine lack output (or lacks power)1465
S-7 Exhaust gas is black (incomplete combustion)1466
S-8 Oil consumption is excessive (or exhaust gas is blue)1468
S-9 Oil becomes dirty quickly1469
S-10 Fuel consumption is excessive1470
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1471
S-12 Oil pressure drops1472
S-13 Oil level rises (Entry of coolant or fuel)1473
S-14 Coolant temperature becomes too high (Overheating)1474
S-15 Abnormal noise is made1475
S-16 Vibration is excessive1476
50 Disassembly and assembly1479
General information on disassembly and assembly1479
How to read this manual1480
Coating materials list1482
Special tool list1485
Sketches of special tools1489
Engine and cooling system1497
Removal and installation of fuel supply pump assembly1498
Removal and installation of fuel injector assembly1503
Removal and installation of engine assembly1509
Removal and installation of radiator assembly1520
Removal and installation of output shaft assembly1527
Disassembly and assembly of output shaft assembly1530
Removal and installation of brake and power train oil cooler assembly1534
Power train, Part 11539
Removal and installation of torque converter and transmission assembly1540
Separation and coupling of transmission assembly and torque converter assembly1545
Disassembly and assembly of torque converter and control valve assembly1558
Disassembly and assembly of torque converter assembly1560
Disassembly and assembly of transmission assembly1576
Removal and installation of transmission control valve assembly (ECMV assembly)1616
Disassembly and assembly of transmission control valve assembly (ECMV assembly)1618
Power train, Part 21623
Removal and installation of differential assembly1624
Disassembly and assembly of differential assembly1627
Removal and installation of final drive carrier assembly1641
Disassembly and assembly of final drive carrier assembly1644
Disassembly and assembly of front wheel hub assembly1646
Steering system1653
Disassembly and assembly of steering cylinder assembly1654
Brake system1661
Removal and installation of front brake caliper pads1662
Removal and installation of front brake calipers assembly1664
Disassembly and assembly of front brake calipers assembly1667
Removal and installation of final drive and rear brake assembly1669
Removal and installation of final drive, rear brake, and parking brake assembly1674
Disassembly and assembly of final drive, rear brake, and parking brake assembly1677
Undercarriage and frame1693
Removal and installation of front wheel assembly1694
Removal and installation of rear wheel assembly1697
Removal and installation of front suspension cylinder assembly1700
Disassembly and assembly of front suspension cylinder assembly (cylinder with buffer ring)1703
Removal and installation of rear suspension cylinder assembly1707
Disassembly and assembly of rear suspension cylinder assembly (cylinder with buffer ring)1710
Hydraulic system1715
Disassembly and assembly of hoist cylinder assembly1716
Body1725
Removal and installation of body assembly1726
Cab and its attachments1731
Disassembly and assembly of operator’s seat assembly1732
Removal and installation of air conditioner unit assembly1743
Electrical system1749
Removal and installation of engine controller assembly1750
Removal and installation of transmission controller assembly1753
Removal and installation of retarder controller assembly1755
90 Diagrams and drawings1759
Hydraulic diagrams and drawings1759
Power train hydraulic circuit diagram1760
Steering and hoist hydraulic circuit diagram1761
Brake hydraulic circuit diagram1765
Electrical diagrams and drawings1771
Electrical circuit diagram inside cab (1/3)1773
Electrical circuit diagram inside cab (2/3)1777
Electrical circuit diagram inside cab (3/3)1781
Electrical circuit diagram outside cab (1/3)1785
Electrical circuit diagram outside cab (2/3)1787
Electrical circuit diagram outside cab (3/3)1789
Electrical circuit diagram for VHMS1791
Electrical circuit diagram for ASR (If equipped)1793
Electrical circuit diagram for ABS (If equipped)1795
Air conditioner electrical circuit diagram1799
Electrical circuit diagram for auto greasing (If equipped)1801
Connectors table and arrangement drawing1803

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24