Komatsu DUMP TRUCK HD465-7R HD605-7R Shop Manual SEN02283-21 PDF

Description

Komatsu DUMP TRUCK HD465-7R HD605-7R Shop Manual SEN02283-21 – PDF DOWNLOAD

FILE DETAILS:

Komatsu DUMP TRUCK HD465-7R HD605-7R Shop Manual SEN02283-21 – PDF DOWNLOAD

Language : English
Pages :1858
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu DUMP TRUCK HD465-7R HD605-7R Shop Manual SEN02283-21 – PDF DOWNLOAD

SERIAL NUMBERS HD465-15001
HD605-15001 and up

1. General precautions k 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 SEN02283-21 – 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
Electrical system, Part 5 443
Mobile communication terminal 444
20 Standard value table 449
Standard service value table 449
Standard value table for engine 450
Standard value table for machine 452
30 Testing and adjusting 463
Testing and adjusting, Part 1 463
Tools for testing, adjusting, and troubleshooting 465
Sketch of special tool 468
Testing engine speed 469
Testing air supply pressure (boost pressure) 470
Testing exhaust temperature 471
Testing exhaust gas color 473
Testing engine oil pressure 481
Handling of fuel system devices 482
Releasing residual pressure from fuel system 482
Testing of fuel pressure 483
Cylinder cut-out mode operation 484
No-injection cranking 484
Testing of fuel return rate and fuel leakage 485
Bleeding air from fuel circuit 487
Testing the fuel circuit for leakage 488
Adjustment of valve clearance 475
Testing of compression pressure 477
Testing blow-by pressure 480
Replacing and adjusting of fan belt 489
Replacing and adjusting of alternator and air conditioner compressor belt 490
Testing and adjusting, Part 2 493
Testing torque converter stall speed 495
Testing power train oil pressure 496
Adjusting transmission speed sensor 503
Testing and adjusting brake oil pressure 504
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 507
Testing brake performance 515
Releasing remaining pressure in brake circuit 517
Bleeding air from brake circuit 518
Testing wear of front brake pad 519
Testing wear of rear brake disc 520
Method of releasing parking brake in an emergency 521
Testing and adjusting front suspension cylinder 522
Testing and adjusting rear suspension cylinder 526
Testing and adjusting front suspension cylinder (Automatic suspension specification) 530
Testing and adjusting hydraulic pressure in steering, hoist circuit 531
Testing and adjusting oil pressure in dump EPC circuit 534
Air bleeding from steering cylinder 535
Procedure for raising dump body in emergency 536
Procedure for lowering dump body in emergency 537
Adjusting body positioner sensor 538
Resetting method for dump body seating control 539
Adjustment of tilt lock lever of steering wheel 540
Handling of voltage circuit of engine controller 541
Adjusting transmission controller 541
Method for emergency escape at electrical system failure 542
Testing and adjusting, Part 3 547
Setting and adjusting of devices 548
Special functions of machine monitor (EMMS) 561
Testing and adjusting, Part 4 585
Special functions of machine monitor (EMMS) 586
Testing and adjusting, Part 5 627
Request for opening ORBCOMM terminal 628
VHMS controller initial setting procedure 630
Using method of KOMTRAX functions of ORBCOMM terminal 650
Precautions for replacing VHMS controller 653
Pm Clinic check sheet 659
Initial setting of payload meter 662
Setting of payload meter built in VHMS 663
Setting of card-type payload meter (PLM-) after installation or replacement 671
Testing and adjusting, Part 6 679
Setting of mobile communication terminal 680
40 Troubleshooting 691
Failure code table and fuse locations 691
Failure codes table 692
Fuse locations 703
General information on troubleshooting 709
Points to remember when troubleshooting 710
Sequence of events in troubleshooting 711
Check before troubleshooting 712
Classification and procedures for troubleshooting 713
Contents of troubleshooting table 714
Troubleshooting method for disconnecting wiring harness of pressure sensor system 716
Connection table for connector pin numbers 719
T- branch box and T- branch adapter table 755
Troubleshooting by failure code, Part 1 759
Failure code [1500L0] (Dual engagement) 761
Failure code [15B0NX] (Transmission oil filter: Clogging) 762
Failure code [15F0KM] (R → F shifting abuse 1: Mistake in operation) 764
Failure code [15F0MB] (R → F shifting abuse 2: Mistake in operation) 764
Failure code [15F7KM] (Forward clutch disk abuse: Mistake in operation or setting) 765
Failure code [15G0MW] (R clutch: Slipping) 766
Failure code [15G7KM] (Reverse clutch disk abuse: Mistake in operation or setting) 768
Failure code [15H0MW] (Hi clutch: Slipping) 770
Failure code [15J0MW] (Lo clutch: Slipping) 772
Failure code [15K0MW] (1st clutch: Slipping) 774
Failure code [15L0MW] (2nd clutch: Slipping) 776
Failure code [15M0MW] (3rd clutch: Slipping) 778
Failure code [15N0MW] (4th clutch: Slipping) 780
Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF) 782
Failure code [15SBMA] (R clutch solenoid: Malfunction) 784
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF) 785
Failure code [15SCMA] (Hi clutch solenoid: Malfunction) 788
Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF) 789
Failure code [15SDMA] (Lo clutch solenoid: Malfunction) 792
Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF) 793
Failure code [15SEMA] (1st clutch solenoid: Malfunction) 796
Troubleshooting by failure code, Part 2 845
Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF 848
Failure code [15SFMA] 2nd clutch solenoid: Malfunction 851
Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF 852
Failure code [15SGMA] 3rd clutch solenoid: Malfunction 855
Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF 856
Failure code [15SHMA] 4th clutch solenoid: Malfunction 859
Failure code [15SJMA] Lockup clutch solenoid: Malfunction 860
Failure code [2C4MNX] Retarder cooling oil filter: Clogging 862
Failure code [2F00KM] Parking brake: Mistake in operation or setting 864
Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front) 867
Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear) 867
Failure code [6014NX] Hydraulic oil filter: Clogging 868
Failure code [989A00] Engine over run prevention command signal: Operating 870
Failure code [989D00] Rear section tipping over alarm: Alarm is activated 870
Failure code [A570NX] Engine oil filter: Clogging 871
Failure code [AA10NX] Air cleaner element: Clogging 872
Failure code [AB00MA] Alternator: Malfunction 874
Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure 876
Failure code [B@BAZK] Engine oil: Level too low 877
Failure code [B@BCNS] Engine: Overheat 878
Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level 880
Failure code [B@BFZK] Lowering of fuel level 882
Failure code [B@C7NS] Brake cooling oil: Overheating (Rear) 884
Failure code [B@CENS] Overheating of torque converter oil 886
Failure code [B@GAZK] Battery electrolyte level: Lowering of level 887
Failure code [B@JANS] Steering oil temperature: Overheat 888
Troubleshooting by failure code, Part 3 891
Failure code [CA111] Abnormality in engine controller 894
Failure code [CA115] Engine Ne or Bkup speed sensor error 896
Failure code [CA122] Charge (boost) pressure sensor high error 898
Failure code [CA123] Charge (boost) pressure sensor low error 900
Failure code [CA131] Throttle sensor high error 902
Failure code [CA132] Throttle sensor low error 905
Failure code [CA135] Engine oil pressure sensor high error 908
Failure code [CA141] Engine oil pressure sensor low error 910
Failure code [CA144] Coolant temperature sensor high error 912
Failure code [CA145] Coolant temperature sensor low error 914
Failure code [CA153] Charge (boost) temperature sensor high error 916
Failure code [CA154] Charge (boost) temperature sensor low error 918
Failure code [CA187] Sensor power supply 2 low error 920
Failure code [CA212] Engine oil temperature sensor high error 922
Failure code [CA213] Engine oil temperature sensor low error 924
Failure code [CA221] Atmospheric pressure sensor high error 926
Failure code [CA222] Atmospheric pressure sensor low error 928
Failure code [CA227] Sensor power supply 2 high error 930
Failure code [CA234] Engine overspeed 931
Failure code [CA238] Ne speed sensor power supply error 932
Failure code [CA263] Fuel Temp Sensor High Error 934
Failure code [CA265] Fuel Temp Sensor Low Error 936
Failure code [CA271] PCV1 Short circuit 938
Failure code [CA272] PCV1 Disconnection 939
Failure code [CA273] PCV2 Short circuit 940
Failure code [CA274] PCV2 Disconnection 941
Failure code [CA322] Injector #1 open/short error 942
Failure code [CA323] Injector #5 open/short error 944
Failure code [CA324] Injector #3 open/short error 946
Failure code [CA325] Injector #6 open/short error 948
Failure code [CA331] Injector #2 open/short error 950
Failure code [CA332] Injector #4 open/short error 952
Failure code [CA342] Calibration code inconsistency 954
Failure code [CA351] Injectors drive circuit error 955
Failure code [CA352] Sens Supply 1 Volt Low Error 956
Failure code [CA386] Sensor power supply 1 high error 958
Troubleshooting by failure code, Part 4 961
Failure code [CA431] Idle validation switch error 963
Failure code [CA432] Idle validation action error 967
Failure code [CA441] Battery voltage low error 970
Failure code [CA442] Battery voltage high error 971
Failure code [CA449] Common rail pressure high error 2 972
Failure code [CA451] Rail Press Sensor High Error 974
Failure code [CA452] Rail Press Sensor Low Error 976
Failure code [CA553] Common rail pressure high error 1 978
Failure code [CA554] Common rail pressure sensor in range error 979
Failure code [CA559] Supply pump pressure very low error 1 980
Failure code [CA689] Engine Ne speed sensor error 984
Failure code [CA731] Engine Bkup speed sensor phase error 986
Failure code [CA757] All continuous data lost error 987
Failure code [CA778] Engine Bkup speed sensor error 988
Failure code [CA1633] KOMNET datalink timeout error 990
Failure code [CA2185] Throttle sensor supply voltage high error 992
Failure code [CA2186] Throttle sensor power supply low error 994
Failure code [CA2249] Supply pump pressure very low error 2 996
Failure code [CA2555] Intake air heater relay open circuit error 998
Failure code [CA2556] Intake air heater relay short circuit error1000
Troubleshooting by failure code, Part 51003
Failure code [D19HKB] Stop lamp relay output system: Short circuit1005
Failure code [D5ZKKZ] Front brake cut-off solenoid valve: Disconnection, short circuit or short circuit to power supply line1006
Failure code [DAF9KM] Wrong connection of connector1008
Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication1009
Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of power supply voltage1010
Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller1012
Failure code [DAQ2KK] Transmission controller solenoid power supply: Power supply voltage too low1014
Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection1016
Failure code [DAQRKR] Abnormality in CAN communication (Transmission)1017
Failure code [DAQRMA] Transmission controller option setting: Malfunction1022
Failure code [DAQV00] Neutral coast caution1023
Failure code [DAQW00] Neutral over speed caution1024
Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller1025
Failure code [DB12KK] Retarder controller solenoid power supply: Power supply system trouble1026
Failure code [DB13KK] Retarder controller battery direct power supply: Power supply voltage too low1028
Failure code [DB19KQ] Disagreement of model selection (Retarder controller)1030
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled1031
Failure code [DB1RMA] Disagreement of option setting (Retarder controller)1035
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled1036
Failure code [DBB0KK] or VHMS_LED display: “n9” o “01”1042
Failure code [DBB0KQ] or VHMS_LED display: “nF” o “11”1044
Failure code [DBB3KK] or VHMS_LED display: “n9” o “05”1046
Failure code [DBB5KP] or VHMS_LED display: “n9” o “04”1048
Failure code [DBB6KP] or VHMS_LED display: “n9” o “02”1050
Failure code [DBB7KP] or VHMS_LED display: “n9” o “03”1052
Failure code [DBBQKR] or VHMS_LED display: “n8” o “02”1053
Failure code [DBBRKR] Abnormality in CAN communication (VHMS)1053
Failure code [DBC2KK] ABS controller solenoid power supply: Power supply system trouble1054
Failure code [DBC3KK] ABS controller battery direct power supply: Power supply voltage too low1056
Failure code [DBC9KQ] Disagreement of model selection (ABS controller)1058
Failure code [DBCRKR] Abnormality in CAN communication (ABS)1059
Failure code [DBCRMA] Disagreement of option setting (ABS controller)1063
Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range1064
Failure code [DDD8KA] ARSC system switch system: Disconnection (If equipped)1066
Failure code [DDD8KB] ARSC system switch system: Short circuit (If equipped)1068
Failure code [DDD9KA] ABS system switch system: Disconnection1070
Failure code [DDD9KB] ABS system switch system: Short circuit1072
Failure code [DDDAKA] ASR system switch: Disconnection1074
Failure code [DDDAKB] ASR system switch: Short circuit1076
Failure code [DDP6L4] Service brake pressure switch trouble (Rear)1078
Failure code [DDTHKA] Hi clutch fill switch: Disconnection1080
Failure code [DDTJKA] Lo clutch fill switch: Disconnection1082
Failure code [DDTKKA] 1st clutch fill switch: Disconnection1084
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection1086
Failure code [DDTMKA] (3rd clutch fill switch: Disconnection)1088
Failure code [DDTNKA] R clutch fill switch: Disconnection1090
Failure code [DDTPKA] 4th clutch fill switch: Disconnection1092
Failure code [DF10KA] Gear shift lever: Disconnection1094
Failure code [DF10KB] Gear shift lever: Short circuit1097
Failure code [DGE5KX] or VHMS_LED display: “n4” o “01”1102
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range1104
Failure code [DGR2KZ] Retarder oil temperature sensor system trouble : Ground fault (Rear wheel)1106
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range1108
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range1110
Troubleshooting by failure code, Part 61113
Failure code [DGT4KA] or VHMS_LED display: “n3” o “12” Exhaust gas temperature sensor (F): Disconnection1115
Failure code [DGT4KB] or VHMS_LED display: “n3” o “11” Exhaust gas temperature sensor (F): Short circuit1118
Failure code [DGT5KA] or VHMS_LED display: “n3” o “22” Exhaust gas temperature sensor (R): Disconnection1121
Failure code [DGT5KB] or VHMS_LED display: “n3” o “21” Exhaust gas temperature sensor (R): Short circuit1124
Failure code [DHE5KB] or VHMS_LED display: “n3” o “32” Blow-by pressure sensor: Short circuit1127
Failure code [DHE5KY] or VHMS_LED display: “n3” o “31” Blow-by pressure sensor: Short circuit with power supply line1130
Failure code [DHP4KY] or VHMS_LED display: “n5” o “44” Short circuit in suspension pressure sensor system (Front right)1132
Failure code [DHP4KZ] or VHMS_LED display: “n5” o “43” Disconnection or ground fault in suspension pressure sensor system(Front right)1134
Failure code [DHP5KY] or VHMS_LED display: “n5” o “54” Short circuit in suspension pressure sensor system (Front left)1136
Failure code [DHP5KZ] or VHMS_LED display: “n5” o “53” Disconnection or ground fault in suspension pressure sensor system(Front left)1138
Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear)1140
Failure code [DHP6KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Right rear)1141
Failure code [DHP6KY] or VHMS_LED display: “n5” o “64” Suspension pressure sensor system: Short circuit (Right rear)1144
Failure code [DHP6KZ] or VHMS_LED display: “n5” o “63” Suspension pressure sensor system: Disconnection or ground fault (Right rear)1146
Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear)1148
Failure code [DHP7KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Left rear)1150
Failure code [DHP7KY] or VHMS_LED display: “n5” o “74” Suspension pressure sensor system: Short circuit (Left rear)1152
Failure code [DHP7KZ] or VHMS_LED display: “n5” o “73” Suspension pressure sensor system: Disconnection or ground fault (Left rear)1154
Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range1156
Failure code [DHT5L6] Torque converter oil pressure sensor: Disagreement of run and stop condition with signal1158
Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range1160
Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range1162
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right)1164
Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left)1166
Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Front right)1168
Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Front right)1170
Failure code [DHUTKX] Trouble in ABS cut valve pressure sensor1172
Failure code [DJF1KA] Fuel level sensor: Disconnection1174
Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection)1176
Failure code [DK51L5] Retarder lever potentiometer: Potentiometer signal is inconsistent with swich signal1177
Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range1180
Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal1182
Failure code [DK54KX] Body positioner sensor: Out of input signal range1184
Failure code [DKD0L6] Failure in steering speed sensor1186
Failure code [DKH0KX] Clinometer sensor signal out of range1188
Failure code [DKH1KX] or VHMS_LED display: “n4″o”33” Abnormality in clinometer sensor1190
Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection1192
Failure code [DLF1LC] Transmission input shaft speed sensor: Disagreement of revolution speed signal1194
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection1196
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal1198
Troubleshooting by failure code, Part 71201
Failure code [DLF8KA] (Wheel speed sensor: Disconnection (Right rear))1204
Failure code [DLF8L3] (Wheel speed sensor: Disconnection (Right rear))1206
Failure code [DLF8LC] (Wheel speed sensor: Trouble (Right rear))1208
Failure code [DLF8MA] (Wheel speed sensor: Disconnection (Right rear))1209
Failure code [DLF9KA] (Wheel speed sensor: Disconnection (Left rear))1210
Failure code [DLF9L3] (Wheel speed sensor: Trouble (Left rear))1212
Failure code [DLF9LC] (Wheel speed sensor: Trouble (Left rear))1214
Failure code [DLF9MA] (Wheel speed sensor: Disconnection (Left rear))1215
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)1216
Failure code [DLT3LC] (Transmission output shaft speed sensor: Disagreement of revolution speed signal)1218
Failure code [DLT4KA] (Transmission output shaft speed sensor: Disconnection)1220
Failure code [DLT4MA] (Transmission output shaft speed sensor: Malfunction)1222
Failure code [DV00KB] (Buzzer output: Short circuit)1224
Failure code [DW2AKA] (Main pressure variable valve output: Disconnection)1226
Failure code [DW2AKB] (Main pressure variable valve output circuit: Ground fault)1228
Failure code [DW2AKY] (Main pressure variable valve output circuit: Hot short)1230
Failure code [DW2AL1] (Main pressure variable valve: Defective reset)1232
Failure code [DW2ALH] (Main pressure variable valve: Malfunction)1234
Failure code [DW35KZ] (Failure in output system of auto suspension solenoid 1: Disconnection or short circuit)1236
Failure code [DW36KZ] (Failure in output system of auto suspension solenoid 2: Disconnection or short circuit) (If equipped)1238
Failure code [DW72KZ] (Kick-out solenoid output system trouble: Disconnection or short circuit)1240
Failure code [DW73KZ] (Failure in hoist select valve output system: Disconnection or short circuit)1242
Failure code [DW78KZ] (Brake cooling valve (BCV) (rear wheel) output system trouble: Disconnection or short circuit)1244
Failure code [DWNBK4] (ASR shut-off valve: Trouble (Valve keeps operating))1246
Failure code [DWNBKA] (ASR shut-off valve output circuit: Disconnection)1248
Failure code [DWNBKB] (ASR shut-off valve output circuit: Ground fault)1250
Failure code [DWNBKY] (ASR shut-off valve output circuit: Short circuit)1252
Failure code [DWNBMA] (ASR shut-off valve: Trouble (Valve does not operate))1253
Troubleshooting by failure code, Part 81255
Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve: Out of control)1258
Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection)1260
Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit)1262
Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line)1263
Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction)1264
Failure code [DX13KA] (Output circuit of hoist EPC valve: Disconnection)1266
Failure code [DX13KB] (Output circuit of hoist EPC valve: Short circuit)1268
Failure code [DX13KY] (Output circuit of hoist EPC valve: Short circuit with power source line)1270
Failure code [DX17K4] (ASR proportional pressure reducing solenoid valve (right): Trouble (Valve keeps operating))1272
Failure code [DX17KA] (ASR proportional pressure reducing solenoid valve (right) output circuit: Disconnection)1274
Failure code [DX17KB] (ASR proportional pressure reducing solenoid valve (right) output circuit: Ground fault)1276
Failure code [DX17KY] (ASR proportional pressure reducing solenoid valve (right) output circuit: Short circuit)1278
Failure code [DX17MA] (ASR proportional pressure reducing solenoid valve (right): Trouble (Valve does not operate))1279
Failure code [DX18K4] (ASR proportional pressure reducing solenoid valve (left): Trouble (Valve keeps operating))1280
Failure code [DX18KA] (ASR proportional pressure reducing solenoid valve (left) output circuit: Disconnection)1282
Failure code [DX18KB] (ASR proportional pressure reducing solenoid valve (left) output circuit: Ground fault)1284
Failure code [DX18KY] (ASR proportional pressure reducing solenoid valve (left) output circuit: Short circuit)1286
Failure code [DX18MA] (ASR proportional pressure reducing solenoid valve (left): Trouble (Valve does not operate))1287
Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right)1288
Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right)1289
Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right)1290
Failure code [DX21MA] Defective ABS control valve (Front right)1292
Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left)1294
Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left)1295
Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left)1296
Failure code [DX22MA] Defective ABS control valve (Front left)1298
Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right)1300
Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right)1301
Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right)1302
Failure code [DX23MA] Defective ABS control valve (Rear right)1304
Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left)1306
Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left)1307
Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left)1308
Failure code [DX24MA] Defective ABS control valve (Rear left)1310
Failure code [DX25MA] Defective ABS front wheel system control valve1312
Failure code [DX26MA] Defective ABS rear wheel system control valve1312
Troubleshooting by failure code, Part 91315
Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection1318
Failure code [DXH1KB] Lockup clutch solenoid output circuit: Short circuit1320
Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power supply line1322
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection1324
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit1326
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power supply line1328
Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection1332
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit1334
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power supply line1336
Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection1340
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit1342
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power supply line1344
Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection1348
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit1350
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power supply line1352
Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection1356
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit1358
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power supply line1360
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection1364
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit1366
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power supply line1368
Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection1370
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit1372
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power supply line1374
Failure code [F@BBZL] or VHMS_LED display: “n3″→”38” Blow-by pressure: High error1377
Failure code [F@BYNR] or VHMS_LED display: “n3″→”62” Exhaust gas temperature (F): Abnormal heat1378
Failure code [F@BYNS] or VHMS_LED display: “n3″→”61” Exhaust gas temperature (F): Overheat1380
Failure code [F@BZNR] or VHMS_LED display: “n3″→”72” Exhaust gas temperature (R): Abnormal heat1382
Failure code [F@BZNS] or VHMS_LED display: “n3″→”71” Exhaust gas temperature (R): Overheat1384
Troubleshooting of electrical system (E-mode)1387
Before troubleshooting of electric system1389
Contents of troubleshooting table1390
E-1 Engine does not start1391
E-2 Automatic preheating does not operate1394
E-3 Machine monitor does not display all, when starting switch is turned ON1398
E-4 Machine monitor does not operate when starting switch is OFF1400
E-5 Alarm buzzer does not sound1402
E-6 Alarm buzzer does not stop sounding1404
E-7 Gauges of machine monitor, caution lamps or character display section do not display properly1406
E-8 A selection of the display in character display section cannot be changed1407
E-9 Power mode selecting function does not operate properly1410
E-10 AISS function does not operate properly1411
E-11 Seat belt caution lamp does not display properly1412
E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly1413
E-13 Night illumination (lighting) does not work properly1416
E-14 Emergency steering does not operate1428
E-15 Hoist lever does not operate normally1438
E-16 Electric priming pump does not operate or does not stop automatically1440
E-17 Cannot access to the setting screen of the mobile communication terminal1442
E-18 Cannot log in to the setting screen of the mobile communication terminal because the log in password is unknown1447
E-19 VHMS controller is not detected1449
E-20 VHMS controller does not become active1450
E-21 Communication between mobile communication terminal and KOMTRAX Plus server fails1451
E-22 Data is not sent to KOMTRAX Plus server1454
Troubleshooting of hydraulic and mechanical system (H-mode)1457
Contents of troubleshooting table1459
H-1 Machine does not start1460
H-2 Machine does not travel smoothly (hunting)1462
H-3 Lockup cannot be cancelled1462
H-4 Excessive shock when starting or shifting excessive1463
H-5 Transmission does not shift up1464
H-6 Machine lacks power or speed when traveling1466
H-7 Time lag is excessive when starting or shifting gear1470
H-8 Torque converter oil temperature is high1472
H-9 Torque converter oil pressure is low1473
H-10 Front brake is ineffective1474
H-11 Rear brake is ineffective1475
H-12 Steering wheel is heavy1476
H-13 Steering wheel does not work1477
H-14 Steering wheel vibrates1478
H-15 Dump body lifting speed is slow1479
H-16 Dump body does not work1480
H-17 Excessive hydraulic drift of dump body1481
Troubleshooting of engine (S-mode)1483
Method of using troubleshooting chart1486
S-1 Starting performance of engine is poor1490
S-2 Engine does not start1491
S-3 Engine does not pick up smoothly1494
S-4 Engine stops during operation1495
S-5 Engine does not rotate smoothly1496
S-6 Engine lack output (or lacks power)1497
S-7 Exhaust gas is black (incomplete combustion)1498
S-8 Oil consumption is excessive (or exhaust gas is blue)1500
S-9 Oil becomes dirty quickly1501
S-10 Fuel consumption is excessive1502
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1503
S-12 Oil pressure drops1504
S-13 Oil level rises (Entry of coolant or fuel)1505
S-14 Coolant temperature becomes too high (Overheating)1506
S-15 Abnormal noise is made1507
S-16 Vibration is excessive1508
50 Disassembly and assembly1511
General information on disassembly and assembly1511
How to read this manual1512
Coating materials list1514
Special tool list1517
Sketches of special tools1521
Engine and cooling system1529
Removal and installation of fuel supply pump assembly1530
Removal and installation of fuel injector assembly1535
Removal and installation of engine assembly1541
Removal and installation of radiator assembly1552
Removal and installation of damper assembly1559
Disassembly and assembly of damper assembly1562
Removal and installation of brake and power train oil cooler assembly1566
Power train, Part 11571
Removal and installation of torque converter and transmission assembly1572
Separation and coupling of transmission assembly and torque converter assembly1577
Disassembly and assembly of torque converter and control valve assembly1590
Disassembly and assembly of torque converter assembly1592
Disassembly and assembly of transmission assembly1608
Removal and installation of transmission control valve assembly (ECMV assembly)1648
Disassembly and assembly of transmission control valve assembly (ECMV assembly)1650
Power train, Part 21655
Removal and installation of differential assembly1656
Disassembly and assembly of differential assembly1659
Removal and installation of final drive carrier assembly1673
Disassembly and assembly of final drive carrier assembly1676
Disassembly and assembly of front wheel hub assembly1678
Steering system1685
Disassembly and assembly of steering cylinder assembly1686
Brake system1693
Removal and installation of front brake caliper pads1694
Removal and installation of front brake calipers assembly1696
Disassembly and assembly of front brake calipers assembly1699
Removal and installation of final drive and rear brake assembly1701
Removal and installation of final drive, rear brake, and parking brake assembly1706
Disassembly and assembly of final drive, rear brake, and parking brake assembly1709
Undercarriage and frame1725
Removal and installation of front wheel assembly1726
Removal and installation of rear wheel assembly1729
Removal and installation of front suspension cylinder assembly1732
Disassembly and assembly of front suspension cylinder assembly (cylinder with buffer ring)1735
Removal and installation of rear suspension cylinder assembly1739
Disassembly and assembly of rear suspension cylinder assembly (cylinder with buffer ring)1742
Hydraulic system1747
Disassembly and assembly of hoist cylinder assembly1748
Body1757
Removal and installation of body assembly1758
Cab and its attachments1763
Disassembly and assembly of operator’s seat assembly1764
Removal and installation of air conditioner unit assembly1775
Electrical system, Part 11781
Removal and installation of engine controller assembly1782
Removal and installation of transmission controller assembly1785
Removal and installation of retarder controller assembly1787
Electrical system, Part 21791
Removal and installation of mobile communication terminal1792
Removal and installation of DC/DC converter1794
Removal and installation of mobile communication terminal harness1796
90 Diagrams and drawings1807
Hydraulic diagrams and drawings1807
Power train hydraulic circuit diagram1808
Steering and hoist hydraulic circuit diagram1809
Brake hydraulic circuit diagram1813
Electrical diagrams and drawings1819
Electrical circuit diagram inside cab (1/3)1821
Electrical circuit diagram inside cab (2/3)1825
Electrical circuit diagram inside cab (3/3)1829
Electrical circuit diagram outside cab (1/3)1833
Electrical circuit diagram outside cab (2/3)1835
Electrical circuit diagram outside cab (3/3)1837
Electrical circuit diagram for VHMS1839
Electrical circuit diagram for ASR (If equipped)1841
Electrical circuit diagram for ABS (If equipped)1843
Air conditioner electrical circuit diagram1847
Electrical circuit diagram for auto greasing (If equipped)1849
Electrical circuit diagram of mobile communication terminal (if equipped)1851
Connectors table and arrangement drawing1853

IMAGES PREVIEW OF THE MANUAL:

S.M 28/12/24