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KOMATSU HD465-7 HD605-7 SHOP MANUAL SEBM027618 – PDF DOWNLOAD
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Description
KOMATSU HD465-7 HD605-7 SHOP MANUAL SEBM027618 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU HD465-7 HD605-7 SHOP MANUAL SEBM027618 – PDF DOWNLOAD
Language : English
Pages : 1448
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU HD465-7 HD605-7 SHOP MANUAL SEBM027618 – PDF DOWNLOAD
COVER
................................................................................................................................................................................................... 1
CONTENTS................................................................................................................................................................................................. 2
LIST OF REVISED PAGES.................................................................................................................................................................................... 3
SAFETY................................................................................................................................................................................................... 9
SAFETY NOTICE........................................................................................................................................................................................ 9
FOREWORD................................................................................................................................................................................................. 11
GENERAL.............................................................................................................................................................................................. 11
HOW TO READ THE SHOP MANUAL.......................................................................................................................................................................... 12
HOISTING INSTRUCTIONS................................................................................................................................................................................ 13
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER........................................................................................................................................... 14
COATING MATERIALS.................................................................................................................................................................................... 16
STANDARD TIGHTENING TORQUE........................................................................................................................................................................... 18
ELECTRIC WIRE CODE................................................................................................................................................................................... 21
CONVERSION TABLE..................................................................................................................................................................................... 22
UNITS................................................................................................................................................................................................ 28
01 GENERAL............................................................................................................................................................................................... 29
SPECIFICATION DRAWINGS............................................................................................................................................................................... 30
SPECIFICATIONS....................................................................................................................................................................................... 31
WEIGHT TABLE......................................................................................................................................................................................... 37
FUEL,COOLANT AND LUBRICANTS.......................................................................................................................................................................... 38
10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD........................................................................................................................................................... 41
RADIATOR,TORQUE CONVERTER OIL COOLER,AFTER COOLER,WORK EQUIPMENT OIL COOLER,FUEL COOLER.............................................................................................................. 43
BRAKE OIL COOLER..................................................................................................................................................................................... 44
POWER TRAIN SKELETON................................................................................................................................................................................. 45
OUTPUT SHAFT......................................................................................................................................................................................... 46
DRIVE SHAFT.......................................................................................................................................................................................... 48
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING................................................................................................................................................... 50
TORQUE CONVERTER..................................................................................................................................................................................... 52
TRANSMISSION......................................................................................................................................................................................... 60
TRANSMISSION VALVE................................................................................................................................................................................... 69
ECMV................................................................................................................................................................................................. 70
AXLE................................................................................................................................................................................................. 80
DIFFERENTIAL......................................................................................................................................................................................... 82
FINAL DRIVE.......................................................................................................................................................................................... 84
WHEELS............................................................................................................................................................................................... 86
SUSPENSION........................................................................................................................................................................................... 88
SUSPENSION CYLINDER.................................................................................................................................................................................. 90
REAR AXLE SUPPORT.................................................................................................................................................................................... 96
STEERING COLUMN...................................................................................................................................................................................... 98
STEERING LINKAGE..................................................................................................................................................................................... 99
BRAKE PIPING......................................................................................................................................................................................... 102
BRAKE VALVE.......................................................................................................................................................................................... 106
EMERGENCY BRAKE VALVE................................................................................................................................................................................ 109
RELAY VALVE.......................................................................................................................................................................................... 110
FRONT BRAKE OFF VALVE................................................................................................................................................................................ 111
ACCUMULATOR CHARGE VALVE............................................................................................................................................................................. 113
ACCUMULATOR.......................................................................................................................................................................................... 117
SLACK ADJUSTER....................................................................................................................................................................................... 118
BRAKE................................................................................................................................................................................................ 120
PROPORTIONAL REDUCING VALVE.......................................................................................................................................................................... 125
PARKING BRAKE SOLENOID VALVE......................................................................................................................................................................... 126
STEERING AND HOIST HYDRAULIC PIPING.................................................................................................................................................................. 128
STEERING AND HOIST HYDRAULIC SYSTEM DIAGRAM.......................................................................................................................................................... 130
DUMP BODY CONTROL.................................................................................................................................................................................... 132
HYDRAULIC TANK....................................................................................................................................................................................... 133
STEERING CONTROL VALVE............................................................................................................................................................................... 134
CROSSOVER RELIEF VALVE............................................................................................................................................................................... 138
STEERING CYLINDER.................................................................................................................................................................................... 139
DEMAND VALVE......................................................................................................................................................................................... 140
HOIST VALVE.......................................................................................................................................................................................... 144
EPC VALVE............................................................................................................................................................................................ 150
HOIST CYLINDER....................................................................................................................................................................................... 151
HYDRAULIC PUMP....................................................................................................................................................................................... 152
AIR CONDITIONER...................................................................................................................................................................................... 156
MACHINE MONITOR SYSTEM............................................................................................................................................................................... 161
ENGINE CONTROL SYSTEM................................................................................................................................................................................ 176
AUTOMATIC SHIFT CONTROL SYSTEM....................................................................................................................................................................... 178
PAYLOAD METER Ⅱ(CARD TYPE)........................................................................................................................................................................... 193
AUTOMATIC EMERGENCY STEERING SYSTEM.................................................................................................................................................................. 226
AUTOMATIC SUSPENSION SYSTEM.......................................................................................................................................................................... 234
RETARDER CONTROL SYSTEM.............................................................................................................................................................................. 238
SENSORS,SWITCHES..................................................................................................................................................................................... 250
DUMP CONTROL LEVER................................................................................................................................................................................... 258
VHMS CONTROLLER...................................................................................................................................................................................... 262
BLOW-BY PRESSURE SENSOR.............................................................................................................................................................................. 262
ENGINE OIL PRESSURE SENSOR........................................................................................................................................................................... 263
EXHAUST TEMPERATURE SENSOR/AMP....................................................................................................................................................................... 264
AMBIENT TEMPERATURE SENSOR........................................................................................................................................................................... 264
COMMUNICATIONS (ORB・・・ORBCOMM) CONTROLLER/ANTENNA.................................................................................................................................................... 265
PAYLOAD METER (HAVING VHMS).......................................................................................................................................................................... 266
Auto greasing system................................................................................................................................................................................. 290
20 TESTING AND ADJUSTING................................................................................................................................................................................. 313
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS........................................................................................................................................................ 314
STANDARD VALUE TABLE FOR CHASSIS..................................................................................................................................................................... 315
TESTING AND ADJUSTING................................................................................................................................................................................ 327
TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING.................................................................................................................................................. 328
MEASURING ENGINE SPEED........................................................................................................................................................................... 334
ADJUSTING ENGINE SPEED SENSOR.................................................................................................................................................................... 336
MEASURING ENGINE OIL PRESSURE.................................................................................................................................................................... 337
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)................................................................................................................................................... 338
MEASURING EXHAUST TEMPERATURE.................................................................................................................................................................... 340
MEASURING BLOW-BY PRESSURE....................................................................................................................................................................... 342
TROUBLESHOOTING OF INJECTOR...................................................................................................................................................................... 343
MEASURING COMPRESSION PRESSURE................................................................................................................................................................... 344
HANDLING EQUIPMENT IN FUEL SYSTEM................................................................................................................................................................ 346
MEASURING FUEL PUMP OUTLET PORT PRESSURE......................................................................................................................................................... 346
MEASURING FUEL PUMP INLET PORT PRESSURE.......................................................................................................................................................... 348
VISUAL INSPECTION OF RETURN FUEL................................................................................................................................................................. 348
ADJUSTING INJECTOR SET LOAD...................................................................................................................................................................... 349
BLEEDING AIR FROM FUEL CIRCUIT................................................................................................................................................................... 351
MEASURING EXHAUST COLOR.......................................................................................................................................................................... 353
ADJUSTING VALVE CLEARANCE........................................................................................................................................................................ 354
TESTING AND ADJUSTING ALTERNATOR BELT TENSION.................................................................................................................................................... 355
TESTING AND ADJUSTING,AIR CONDITIONER COMPRESSOR BELT TENSION.................................................................................................................................... 356
MEASURING POWER TRAIN OIL PRESSURE............................................................................................................................................................... 357
ADJUSTING TRANSMISSION SPEED SENSOR.............................................................................................................................................................. 364
INSPECTING BRAKE OIL PRESSURE.................................................................................................................................................................... 365
TESTING OF ACCUMULATORNITROGEN GAS PRESSUREAND PROCEDURE FORCHARGING ACCUMULATORWITH NITROGEN GAS................................................................................................ 367
BLEEDING AIR FROM BRAKE CIRCUIT.................................................................................................................................................................. 375
TESTING WEAR OF FRONT BRAKE PAD.................................................................................................................................................................. 376
TESTING WEAR OF REAR BRAKE DISC.................................................................................................................................................................. 377
METHOD OF RELEASING PARKING BRAKE IN AN EMERGENCY................................................................................................................................................ 378
TESTING AND ADUSTING FRONT SUSPENSION CYLINDER................................................................................................................................................... 379
TESTING AND ADJUSTING INVERTED TYPE REAR SUSPENSION CYLINDER..................................................................................................................................... 383
TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER(MODE SELECTOR HYDRAULIC CYLNDER)................................................................................................................. 386
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING,HOIST CIRCUIT............................................................................................................................... 387
TESTING AND ADJUSTING OIL PRESSURE IN DUMP EPC CIRCUIT........................................................................................................................................... 390
AIR BLEEDING FROM STEERING CYLINDER.............................................................................................................................................................. 391
PROCEDURE FOR RAISING DUMP BODY IN EMERGENCY..................................................................................................................................................... 392
ADJUSTING BODY POSITIONER SENSOR................................................................................................................................................................. 393
ADJUSTMENT OF TILT LOCKLEVER OF STEERING WHEEL................................................................................................................................................... 395
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM........................................................................................................................... 396
ADJUSTING MACHINE MONITOR(EMMS).................................................................................................................................................................. 400
ADJUSTING TRANSMISSION CONTROLLER................................................................................................................................................................ 404
INITIAL SETTING OF PAYLOAD METER................................................................................................................................................................. 405
SETTING OF CARD-TYPE PAYLOAD METER AFTER INSTALLATION OR REPLACEMENT............................................................................................................................. 406
SPECIAL FUNCTIONS OF MACHINE MONITOR(EMMS)....................................................................................................................................................... 415
BASIC PRECAUTIONS................................................................................................................................................................................ 470
OUTLINE.......................................................................................................................................................................................... 473
SETTING UP VHMS CONTROLLER ...................................................................................................................................................................... 478
COLLECTION,TRANSMISSION OF DATA.................................................................................................................................................................. 480
INSPECTION AND MAINTENANCE....................................................................................................................................................................... 485
REPLACING PARTS.................................................................................................................................................................................. 485
PROCEDURE FOR INITIAL SETUP OF VHMS.............................................................................................................................................................. 486
PROCEDURE FOR OPENING ORBCOMM SERVICE............................................................................................................................................................ 489
PERFORMING PM-CLINIC USING MANUAL SNAPSHOT(=QUICK PM)............................................................................................................................................ 492
PM CLINIC SERVICE................................................................................................................................................................................ 497
TROUBLESHOOTING...................................................................................................................................................................................... 501
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................................................................................................... 502
SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................................................................................................ 503
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE................................................................................................................................................. 504
CHECKS BEFORE TROUBLESHOOTING.................................................................................................................................................................... 512
CATEGORIES, PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS................................................................................................................................. 515
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....................................................................................................................................................... 522
T-ADAPTER TABLE.................................................................................................................................................................................. 547
TYPES AND LOCATIONS OF CONNECTORS................................................................................................................................................................ 550
CONNECTOR ARRANGEMENT LOCATION................................................................................................................................................................... 566
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM(ENG MODE)............................................................................................................................................ 579
ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL............................................................................................................................................. 582
INFORMATION IN TROUBLESHOOTING TABLE......................................................................................................................................................... 588
[C111KT] ABNORMALITY IN ENGINE CONTROLLER MEMORY............................................................................................................................................. 590
[C112LK] ABNORMALITY IN TIMING RAIL ACTUATOR................................................................................................................................................. 590
[C113KZ] ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM..................................................................................................................................... 591
[C115KZ] ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS........................................................................................................................................ 592
[C116KX] ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM......................................................................................................................... 594
[C117KX] ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM.......................................................................................................................... 595
[C118KX] ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM........................................................................................................................... 596
[C119KX] ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM............................................................................................................................ 597
[C121LC] ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEMS........................................................................................................................................ 597
[C122KX] ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR SYSTEM............................................................................................................................... 598
[C123KX] ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR SYSTEM................................................................................................................................ 599
[C131KX] ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM..................................................................................................................................... 600
[C132KX] ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM...................................................................................................................................... 602
[C135KX] ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM.......................................................................................................................... 603
[C141KX] ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM........................................................................................................................... 604
[C143ZG] LOWERING OF ENGINE OIL PRESSURE..................................................................................................................................................... 604
[C144KX] ABNORMALLY HIGH LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM................................................................................................................... 605
[C145KX] ABNORMALLY LOW LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM.................................................................................................................... 606
[C148KX] ABNORMALITY IN FM THROTTLE:OUT OF INPUT SIGNAL RANGE................................................................................................................................ 607
[C151NS] RISE OF ENGINE COOLANT TEMPERATURE.................................................................................................................................................. 608
[C153KX] ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM....................................................................................................................... 609
[C154KX] ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM........................................................................................................................ 610
[C221KX] ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM......................................................................................................................... 611
[C222KX] ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM.......................................................................................................................... 612
[C234NI] OVER-SPEED.......................................................................................................................................................................... 612
[C254KZ] ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE............................................................................................................................................. 613
[C259FS] ABNORMALITY IN FUEL SHUT-OFF VALVE.................................................................................................................................................. 614
[C261NS] ABNORMAL RISE OF FUEL TEMPERATURE................................................................................................................................................... 614
[C263KX] ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM............................................................................................................................. 615
[C265KX] ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM.............................................................................................................................. 616
[C316KZ] ABNORMAL CURRENT OF FUEL PUMP ACTUATOR.............................................................................................................................................. 617
[C318LK] ABNORMALITY IN FUEL PUMP ACTUATOR................................................................................................................................................... 618
[C346KT] ABNORMALITY IN POWER-DOWN UNIT OF ENGINE CONTROLLER................................................................................................................................. 619
[C423L6] ABNORMALITY IN IN-RANGE OF TIMING RAIL PRESSURE SENSOR SYSTEM....................................................................................................................... 621
[C431L4] ABNORMALITY IN IDLING VALIDATION SWITCH SYSTEM:※ SEE SEPARATE LIST(L4)(BOTH SIGNAL VOLTAGES OF 2 SYSTEMS ARE SENSED)................................................................ 623
[C432L5] ERROR IN IDLING VALIDATION PROCESS(※ SEE SEPARATE LIST(L5))......................................................................................................................... 625
[C441KK] ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM...................................................................................................................................... 627
[C442KG] ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGE SYSTEM..................................................................................................................................... 627
[C451KX] ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM........................................................................................................................... 628
[C452KX] ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM............................................................................................................................ 629
[C455KZ] ABNORMAL CURRENT OF FUEL RAIL ACTUATOR.............................................................................................................................................. 630
[C467LK] ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL......................................................................................................................................... 631
[C468LK] ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL........................................................................................................................................... 631
[C514LK] ABNORMALITY IN FUEL RAIL ACTUATOR................................................................................................................................................... 632
[C551L4] ABNORMALITY IN IDLING VALIDATION SWITCH SYSTEM:※ SEE SEPARATE LIST(L4)(EITHER SIGNAL VOLTAGE OF 2 SYSTEMS IS NOT SENSED)............................................................ 633
[C554L6] ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE SENSOR SYSTEM......................................................................................................................... 635
ENG-1 ENGINE DOES NOT START.................................................................................................................................................................. 637
ENG-2 FAILURE IN PREHEATING.................................................................................................................................................................. 641
a) ENGINE IS NOT PREHEATED............................................................................................................................................................... 641
b) PREHEATING IS ACTUATED EVEN UNDER NON-ACTUATION CONDITIONS FOR PREHEATING............................................................................................................. 644
ENG-3 AISS FUNCTION DOES NOT WORK NORMALLY................................................................................................................................................... 646
a) WHEN AISS SWITCH IS SET IN AUTO,LOW SPEED CONTROL IS SELECTED......................................................................................................................... 646
b) WHEN AISS SWITCH IS SET IN LOW SPEED,AUTO CONTROL IS SELECTED......................................................................................................................... 647
TROUBLESHOOTING FOR TRANSMISSION CONTROLLER SYSTEM (TM MODE)..................................................................................................................................... 649
ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL.................................................................................................................................... 651
INFORMATION IN TROUBLESHOOTING TABLE......................................................................................................................................................... 652
TROUBLE CODE TABLE........................................................................................................................................................................... 653
[1380MW] LOCKUP CLUTCH・SLIP(MW) ............................................................................................................................................................. 654
[1500L0] DETECTION OF DOUBLE ENGAGEMENT・※ SEE SEPARATE LIST(L0).............................................................................................................................. 655
[15B0NX] CLOGGING OF TRANSMISSION OIL FILTER・CLOGGING(NX).................................................................................................................................... 656
[15E0KM] R→F GEAR SHIFT ABUSE 1・MISTAKE IN OPERATION OR SETTING (KM)......................................................................................................................... 657
[15E7KM] R→F GEAR SHIFT ABUSE 2・MISTAKE IN OPERATION OR SETTING (KM)......................................................................................................................... 657
[15G0MW] R CLUTCH・SLIP (MW).................................................................................................................................................................. 658
[15H0MW] HI CLUTCH・SLIP (MW)................................................................................................................................................................. 659
[15J0MW] LO CLUTCH・SLIP(MW).................................................................................................................................................................. 661
[15K0MW] 1ST CLUTCH・SLIP(MW)................................................................................................................................................................. 663
[15L0MW] 2ND CLUTCH・SLIP(MW)................................................................................................................................................................. 664
[15M0MW] 3RD CLUTCH・SLIP(MW)................................................................................................................................................................. 665
[15N0MW] 4TH CLUTCH・SLIP(MW)................................................................................................................................................................. 666
[15SBL1] R CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1)........................................................................................................................................... 667
[15SBMA] R CLUTCH SOLENOID・※ MALFUNCTION(MA)................................................................................................................................................. 668
[15SCL1] HI CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1).......................................................................................................................................... 669
[15SCMA] HI CLUTCH SOLENOID・MALFUNCTION(MA).................................................................................................................................................. 670
[15SDL1] LO CLUTCH SOLENOID・※ SEE SEPARATE LIST (L1)......................................................................................................................................... 671
[15SDMA] LO CLUTCH SOLENOID・MALFUNCTION(MA).................................................................................................................................................. 672
[15SEL1] 1ST CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1)......................................................................................................................................... 673
[15SEMA] 1ST CLUTCH SOLENOID・MALFUNCTION(MA)................................................................................................................................................. 674
[15SFL1] 2ND CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1)......................................................................................................................................... 675
[15SFMA] 2ND CLUTCH SOLENOID・MALFUNCTION(MA)................................................................................................................................................. 676
[15SGL1] 3RD CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1)......................................................................................................................................... 677
[15SGMA] 3RD CLUTCH SOLENOID・MALFUNCTION(MA)................................................................................................................................................. 678
[15SHL1] 4TH CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1)......................................................................................................................................... 679
[15SHMA] 4TH CLUTCH SOLENOID・MALFUNCTION(MA)................................................................................................................................................. 680
[15SJL1] LOCKUP CLUTCH SOLENOID・15SJ(L1)..................................................................................................................................................... 681
[15SJMA] LOCKUP CLUTCH SOLENOID・15SJ(MA)..................................................................................................................................................... 682
[2F00KM] PARKING BRAKE・MISTAKE IN OPERATION OR SETTING(KM)................................................................................................................................... 683
[989A00] ENGINE OVERRUN PREVENTION COMMAND SIGNAL・OPERATION(00).............................................................................................................................. 685
[989AKZ] ENGINE OVERRUN PREVENTION COMMAND SIGNAL・DISCONNECTION OR SHORT CIRCUIT(KZ)......................................................................................................... 686
[AA10NX] AIR CLEANER ELEMENT・CLOGGING(NX).................................................................................................................................................... 687
[AB00MA] ALTERNATOR・MALFUNCTION(MA).......................................................................................................................................................... 689
[B@CZK] LOWERING OF RADIATOR WATER:LOWERING OF LEVER (ZK).................................................................................................................................... 691
[D1B0KZ] TRANSMISSION CONTROLLER CUTOUT: DISCONNECTION OR SHORT CIRCUIT (KZ)................................................................................................................. 692
[D5ZMKZ] DISCONNECTION,GROUNDING FAULT,OR SHORT CIRCUIT IN ENGINE OUTPUT MODE COMMAND LINE・DISCONNECTION OR SHORT CIRCUIT(KZ)................................................................ 694
[DAQ0KK] TRANSMISSION CONTROLLER・LOWERING OF SOURCE/INPUT VOLTAGE(KK)........................................................................................................................ 695
[DAQ1KK] MAIN POWER LINE OF TRANSMISSION CONTROLLER・LOWERING OF SOURCE/INPUT VOLTAGE (KK).................................................................................................... 697
[DAQ2KK] TRANSMISSION CONTROLLER LOAD POWER LINE・LOWERING OF SOURCE/INPUT VOLTAGE(KK)........................................................................................................ 699
[DAQ3KK] DIRECT LINE OF TRANSMISSION CONTROLLER BATTERY・LOWERING OF SOURCE/INPUT VOLTAGE (KK)................................................................................................ 701
[DAQ9KM] TRANSMISSION CONTROLLER WIRING HARNESS・MISTAKE IN OPERATION OR SETTING(KM).......................................................................................................... 702
[DAQ9KQ] TRANSMISSION CONTROLLER WIRING HARNESS・DISAGREEMENT OF MODEL SELECTION SIGNALS(KQ).................................................................................................. 703
[DAQAKQ] TRANSMISSION CONTROLLER ROTARY SWITCH・DISAGREEMENT OF MODEL SELECTION SIGNALS(KQ)................................................................................................... 704
[DAQSMA] TRANSMISSION CONTROLLER・MALFUNCTION(MA)............................................................................................................................................. 704
[DDTGKA] LOCKUP CLUTCH FILL SWITCH:DISCONNECTION(KA)......................................................................................................................................... 705
[DDTHKA] HI CLUTCH FILL SWITCH:DISCONNECTION(KA)............................................................................................................................................. 706
[DDTJKA] LO CLUTCH FILL SWITCH:DISCONNECTION(KA)............................................................................................................................................. 707
[DDTKKA] 1ST CLUTCH FILL SWITCH:DISCONNECTION (KA)........................................................................................................................................... 708
[DDTLKA] 2ND CLUTCH FILL SWITCH:DISCONNECTION(KA)............................................................................................................................................ 709
[DDTMKA] 3RD CLUTCH FILL SWITCH:DISCONNECTION(KA)............................................................................................................................................ 710
[DDTNKA] R CLUTCH FILL SWITCH:DISCONNECTION(KA).............................................................................................................................................. 711
[DDTRKA] 4TH CLUTCH FILL SWITCH:DISCONNECTION(KA)............................................................................................................................................ 712
[DF10KA] SHIFT LEVER:DISCONNECTION(KA)....................................................................................................................................................... 713
[DF10KB] SHIFT LEVER:SHORT CIRCUIT(KB)....................................................................................................................................................... 717
[DGF1KX] TRANSMISSION VALVE OIL TEMPERATURE SENSOR:OUT OF INPUT SIGNAL RANGE(KX)............................................................................................................. 720
[DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR:OUT OF INPUTSIGNAL RANGE(KX)................................................................................................................ 722
[DHT5KX] TORQUE CONVERTER OIL PRESSURE SENSOR:OUT OF INPUT SIGNAL RANGE(KX).................................................................................................................. 723
[DHT5L6] TORQUE CONVERTER OIL PRESSURE SENSOR:※ SEE SEPARATE LIST(L6)........................................................................................................................ 725
[DJF1KA] FUEL LEVEL SENSOR:DISCONNECTION(KA)................................................................................................................................................. 726
[DK11KX] THROTTLE ANGLE SENSOR:OUT OF INPUT SIGNAL RANGE(KX)................................................................................................................................. 727
[DLE2KA] ENGINE SPEED SENSOR:DISCONNECTION(KA)............................................................................................................................................... 729
[DLE2LC] ENGINE SPEED SENSOR:※ SEE SEPARATE LIST(LC)......................................................................................................................................... 730
[DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR:DISCONNECTION(KA)............................................................................................................................. 731
[DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR:※ SEE SEPARATE LIST(LC)....................................................................................................................... 732
[DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR:DISCONNECTION(KA)...................................................................................................................... 733
[DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR:※ SEE SEPARATE LIST(LC)................................................................................................................ 734
[DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:DISCONNECTION(KA)............................................................................................................................ 735
[DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:※ SEE SEPARATE LIST(LC)...................................................................................................................... 736
[DXH1KA] DISCONNECTION IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID:DISCONNECTION(KA)......................................................................................................... 738
[DXH1KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID:SHORT CIRCUIT (KB)........................................................................................................ 739
[DXH2KA] DISCONNECTION IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID:DISCONNECTION(KA)............................................................................................................. 740
[DXH2KB] SHORT CIRCUIT OF HI CLUTCH SOLENOID:SHORT CIRCUIT(KB)............................................................................................................................... 741
[DXH3KA] DISCONNECTION IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID:DISCONNECTION(KA)............................................................................................................. 743
[DXH3KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID:SHORT CIRCUIT(KB)............................................................................................................. 744
[DXH4KA] DISCONNECTION IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID:DISCONNECTION(KA)............................................................................................................ 746
[DXH4KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID:SHORT CIRCUIT(KB)............................................................................................................ 747
[DXH5KA] DISCONNECTION IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID:DISCONNECTION(KA)............................................................................................................ 748
[DXH5KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID:SHORT CIRCUIT(KB)............................................................................................................ 749
[DXH6KA] DISCONNECTION IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID:DISCONNECTION(KA)............................................................................................................ 750
[DXH6KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID:SHORT CIRCUIT(KB)............................................................................................................ 751
[DXH7KA] DISCONNECTION IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID:DISCONNECTION(KA).............................................................................................................. 752
[DXH7KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID:SHORT CIRCUIT(KB).............................................................................................................. 753
[DXHHKA] DISCONNECTION IN OUTPUT CIRCUIT OF 4TH CLUTCH SOLENOID:DISCONNECTION(KA)............................................................................................................ 754
[DXHHKB] SHORT CIRCUIT OF 4TH CLUTCH SOLENOID:SHORT CIRCUIT(KB).............................................................................................................................. 755
TM-1 FUEL LEVEL GAUGE DOES NOT OPERATE NORMALLY(IT ALWAYS INDICATES"FULL")................................................................................................................... 756
TM-2 ABNORMALITY IN BACKUP LAMP AND BACKUP BUZZER............................................................................................................................................ 757
a) WHEN THE SHIFT LEVER IS SET IN THE "R" POSITION,THE BACKUP LAMP AND BACKUP BUZZER ARE NOT TURNER ON................................................................................... 757
b) BACKUP LAMP IS NOT TURNED ON(BACKUP BUZZER IS NORMAL)................................................................................................................................. 758
c) BACKUP BUZZER IS NOT TURNED ON(BACKUP LAMP IS NORMAL)................................................................................................................................. 758
d) WHILE SHIFT LEVER IS NOT OPERATED,BACKUP LAMP AND BACKUP BUZZER ARE TURNED ON......................................................................................................... 759
TROUBLESHOOTING FOR RETARDER CONTROLLER SYSTEM(BK MODE).......................................................................................................................................... 761
ELECTRICAL SYSTEM DIAGRAM RELATED TO RETARDER CONTROL........................................................................................................................................ 764
INFORMATION IN TROUBLESHOOTING TABLE......................................................................................................................................................... 766
TROUBLE CODE TABLE........................................................................................................................................................................... 767
[2G42ZG] ACCUMULATOR(FRONT):LOWERING OF OIL PRESSURE(ZG)..................................................................................................................................... 768
[2G43ZG] ACCUMULATOR(REAR):LOWERING OF OIL PRESSURE(ZG)...................................................................................................................................... 768
[D1C0KZ] BRAKE CUTOUT RELAY:DISCONNECTION OR SHORT CIRCUIT(KZ)............................................................................................................................... 769
[D5ZNKZ] FAILURE OF FRONT BRAKE CUTOUT OUTPUT SYSTEM(DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT)(OPT):DISCONNECTION OR SHORT CIRCUIT(KZ).................................................... 771
[DB10KK] RETARDER CONTROLLER:LOWERING OF SOURCE/INPUT VOLTAGE(KK)............................................................................................................................ 773
[DB11KK] MAIN POWER LINE OF RETARDER CONTROLLER:LOWERING OF SOURCE/INPUT VOLTAGE(KK)......................................................................................................... 775
[DB12KK] RETARDER CONTROLLER LOAD POWER LINE:LOWERING OF SOURCE/INPUT VOLTAGE(KK)............................................................................................................ 777
[DB13KK] DIRECT LINE OF RETARDER CONTROLLER BATTERY:LOWERING OF SOURCE/INPUT VOLTAGE(KK)..................................................................................................... 779
[DB19KM] RETARDER CONTROLLER WIRING HARNESS:MISTAKE IN OPERATION OR SETTING(KM).............................................................................................................. 780
[DB1SKQ] WRONG INFORMATION ON MODEL SELECTION:DISAGREEMENT OF MODEL SELECTION SIGNALS(KQ).................................................................................................... 781
[DDD7KX] FAILURE IN TRAVEL SPEED SET SWITCH SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX)........................................................................................................ 782
[DDD8KA] ARSC SYSTEM SWITCH SYSTEM:DISCONNECTION(KA)......................................................................................................................................... 784
[DDD8KB] ARSC SYSTEM SWITCH SYSTEM:SHORT CIRCUIT(KB)......................................................................................................................................... 785
[dGR2L8] FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM:※ SEE SEPARATE LIST(L8)........................................................................................................... 786
[DGR2L8] BRAKE OIL TEMPERATURE SENSOR(REAR):※ SEE SEPARATE LIST(L8).......................................................................................................................... 787
[dHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR(FR) SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX)................................................................................................. 788
[DHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR(FR) SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX)................................................................................................. 790
[dHP5KX] FAILURE IN SUSPENSION PRESSURE SENSOR(FL) SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX)................................................................................................. 792
[DHP5KX] FAIURE IN SUSPENSION PRESSURE SENSOR (FL) SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX)................................................................................................. 794
[DHU2KX] ACCUMULATOR OIL PRESSURE SENSOR (FRONT):OUT OF INPUT SIGNAL RANGE (KX).............................................................................................................. 796
[DHU3KX] ACCUMULATOR OIL PRESSURE SENSOR (REAR):OUT OF INPUT SIGNAL RANGE (KX)............................................................................................................... 798
[dK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (OPT):OUT OF INPUT SIGNAL RANGE (KX).......................................................................................................... 800
[DK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (OPT):OUT OF INPUT SIGNAL RANGE (KX).......................................................................................................... 801
[DK51L5] RETARDER LEVER POTENTIOMETER:※ SEE SEPARATE LIST (L5)............................................................................................................................... 802
[DK52KX] DUMP LEVER POTENTIOMETER 1:OUT OF INPUT SIGNAL RANGE (KX)........................................................................................................................... 805
[DK53L8] DUMP LEVER POTENTIOMETER 2:※ SEE SEPARATE LIST (L8)................................................................................................................................. 807
[DK54KX] BODY POSITIONER SENSOR:OUT OF INPUT SIGNAL RANGE (KX)............................................................................................................................... 808
[DKD0L6] FAILURE IN STEERING SPEED SENSOR (OPT):※ SEE SEPARATE LIST (L6)..................................................................................................................... 810
[dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:DISCONNECTION (KA)........................................................................................................................... 812
[DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:DISCONNECTION (KA)........................................................................................................................... 813
[DW35KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 1 (OPT)(DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT):DISCONNECTION OR SHORT CIRCUIT (KZ)....................................... 814
[DW36KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 2 (OPT) (DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT):DISCONNECTION OR SHORT CIRCUIT (KZ)...................................... 815
[DW72KZ] FAILURE IN KICK-OUT SOLENOID OUTPUT SYSTEM (D_OUT3)(DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT):DISCONNECTION OR SHORT CIRCUIT (KZ)................................................ 816
[DW73KZ] FAILURE IN HOIST SELECT VALVE OUTPUT SYSTEM (D_OUT5)(DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT):DISCONNECTION OR SHORT CIRCUIT (KZ)............................................... 818
[DK11K4] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL:UNCONTROLLABLE (K4)..................................................................................................... 820
[DX11KA] DISCONNECTION IN OUTPUT CIRCUIT OF ELECTROMAGNETIC PROPORTIONAL PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2):DISCONNECTION (KA)................................................... 822
[DX11KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF ELECTROMAGNETIC PROPORTIONAL PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2):SHORT CIRCUIT (KB)................................................... 823
[DX11KY] GROUNDING FAULT IN OUTPUT CIRCUIT OF ELECTROMAGNETIC PROPORTIONAL PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2):SHORT CIRCUIT WITH POWER LINE (KY)................................. 824
[DX11MA] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL:MALFUNCTION (MA)........................................................................................................ 825
[DX13KA] DISCONNECTION IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):DISCONNECTION (KA)...................................................................................................... 827
[DX13KB] GROUNDING FAULT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):SHORT CIRCUIT (KB).................................................................................................... 828
[DX13KY] SHORT CIRCUIT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):SHORT CIRCUIT WITH POWER LINE (KY)...................................................................................... 829
BK-1 PARKING BRAKE DOES NOT OPERATE NORMALLY................................................................................................................................................. 831
a) WHEN THE PARKING BRAKE SWITCH IS SET IN THE OFF POSITION, THE PARKING BRAKE IS NOT RELEASED........................................................................................... 831
b) WHEN THE PARKING BRAKE SWITCH IS SET IN THE PARK POSITION, THE PARKING BRAKE DOES NOT WORK............................................................................................ 833
BK-2 RETARDER BRAKE OIL TEMPERATURE GAUGE DOES NOT OPERATE NORMALLY.......................................................................................................................... 835
BK-3 INCLINATION ALARM IS TURNED ON WHEN DUMP BODY IS RAISED (WHEN MACHINE IS NOT INCLINED MORE THAN 15°).................................................................................... 836
BK-4 TOUCH UP/DOWN AND CANCELLATION CANNOT BE PERFORMED...................................................................................................................................... 837
TROUBLESHOOTING FOR PAYLOAD METER SYSTEM (CARD TYPE) (LC MODE)................................................................................................................................... 839
ELECTRICAL SYSTEM DIAGRAM RELATED TO PAYLOAD METER........................................................................................................................................... 840
SERVICE CODES OF PAYLOAD METER Ⅱ (CARD TYPE) AND CONTENTS OF SELF-DIAGNOSIS.................................................................................................................. 842
INFORMATION IN TROUBLESHOOTING TABLE......................................................................................................................................................... 845
TROUBLE CODE TABLE........................................................................................................................................................................... 846
LC-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM IS NOT DISPLAYED............................................................................................................................ 847
LC-2 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL PILOT LAMPS DO NOT LIGHT UP ........................................................................................................... 849
LC-3 EXTERNAL LAMPS LIGHT UP WHILE CONDITION FOR LIGHTING IS NOT SET......................................................................................................................... 852
LC-4 LIGHTING LEVEL OF EXTERNAL PILOT LAMPS IS ABNORMAL...................................................................................................................................... 854
LC-5 CYCLE DATA AND ENGINE ON/OFF DATA NOT RECORDED (CHARGE LEVEL SIGNAL SYSTEM: JUDGES THAT ENGINE IS STOPPED).............................................................................. 856
LC-6 CALIBRATION CANNOT BE PERFORMED AND DISPLAYED CLOCK DOES NOT CONFORM TO CONDITION (SHIFT LEVER "N" POSITION SIGNAL SYSTEM).............................................................. 857
LC-7 DISPLAYED LOGIC IS ABNORMAL............................................................................................................................................................. 859
a) WHEN LOADED DUMP TRUCK STARTS TRAVELING, "O" IS KEPT DISPLAYED........................................................................................................................ 859
b) AFTER LOADED DUMP TRUCK STARTS TRAVELING, DISPLAY OF ODOMETER DOES NOT INCREASE....................................................................................................... 859
c) WHEN TRAVEL SPEED EXCEEDS LIMIT SPEED, "SP:SP" DOES NOT GO OFF........................................................................................................................ 859
d) INTEGRATED PAY LOAD IS NOT DIAPLAYED.................................................................................................................................................. 860
e) DISPLAYED AND SAVED PAY LOAD IS NOT CORRECT........................................................................................................................................... 861
LC-8 PAYLOAD METER KEEPS DISPLAYING "b:FL" (BODY "FLOAT" SIGNAL SYSTEM: DUMP LEVER IS NOT IN "FLOAT" POSITION WHILE TRUCK IS NOT DUMPING).................................................... 862
LC-9 PAYLOAD METER DISPLAYS "F:09" (LOWERING OF INTERNAL BACKUP BATTERY VOLTAGE)............................................................................................................. 864
LC-10 PAYLOAD METER DISPLAYS "□:FULL" (DATA SAVING MEMORY IS FULL)........................................................................................................................... 864
LC-11 PAYLOAD METER DISPLAYS "F-20":FAILURE IN POWER SOURCE OF SUSPENSION PRESSURE SENSOR AND CLINOMETER SYSTEM.............................................................................. 865
LC-12 PAYLOAD METER DISPLAYS "F-21"-"F-24":DISCONNECTION OR GROUNDING FAULT IN SUSPENSION SENSOR SIGNAL SYSTEM............................................................................... 867
LC-13 PAYLOAD METER DISPLAYS "F-25"-"F-28":SHORT CIRCUIT WITH POWER SOURCE IN SUSPENSION SENSOR SIGNAL SYSTEM................................................................................ 870
LC-14 PAYLOAD METER DISPLAYS "F-CAL" (NEGLIGENCE OF CALIBRATION OR INTERNAL DAMAGE OF PAYLOAD METER)......................................................................................... 872
LC-15 PAYLOAD METER DISPLAYS "F:43"-"F:45" (SHORT CIRCUIT WITH POWER SOURCE IN EXTERNAL PILOT LAMP RELAY SYSTEM)............................................................................. 873
LC-16 PAYLOAD METER DISPLAYS "L-bad" (CYCLE DATA WERE SAVED WHILE TRUCK BODY WAS PITCHING)................................................................................................... 875
LC-17 EXTERNAL PILOT LAMP INDICATES FORECAST WHILE TRUCK IS NOT BEING LOADED OR CLOCK IS DISPLAYED WHILE TRUCK TRAVELS FOR 160 M AFTER IT IS LOADED.......................................... 877
LC-18 PAYLOAD METER DISPLAYS"F-31":GROUNDING FAULT OR DISCONNECTION IN CLINOMETER SENSOR SIGNAL SYSTEM....................................................................................... 878
LC-19 PAYLOAD METER DISPLAYS "F-32":SHORT CIRCUIT WITH POWER SOURCE IN CLINOMETER SENSOR SIGNAL SYSTEM....................................................................................... 880
LC-20 PAYLOAD METER DISPLAYS "F:18" (DISCONNECTION IN CHARGE LEVEL SIGNAL SYSTEM)............................................................................................................ 882
TROUBLESHOOTING FOR MONITOR SYSTE (MON MODE)..................................................................................................................................................... 883
ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR................................................................................................................................................. 886
INFORMATION IN TROUBLESHOOTING TABLE......................................................................................................................................................... 887
TROUBLE CODE TABLE........................................................................................................................................................................... 888
[B@C7NS] REAR BRAKE OIL:OVERHEATING (NS)..................................................................................................................................................... 889
[B@CENS] TORQUE CONVERTER:OVERHEATING (NS)................................................................................................................................................... 889
[DAF0KM] MONITOR PANEL:MISTAKE IN OPERATION OR SETTING (KM).................................................................................................................................. 890
[DAF9KM] MONITOR PANEL:MISTAKE IN OPERATION OR SETTING (KM).................................................................................................................................. 893
[DAFSKQ] MONITOR PANEL:DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ).......................................................................................................................... 894
[DAQSKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN TRANSMISSION CONTROLLER AND MACHINE MONITOR) (KR)............................................................................................ 895
[DASRKR] CAN COMMUNICATION・COMMUNICATION DEFECTIVE: ABNORMALITY IN OBJECTIVE COMPONENT (KR).................................................................................................. 898
[DB1SKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN RETARDER CONTROLLER AND MACHINE MONITOR) (KR)................................................................................................ 900
[DV00KB] SHORT CIRCUIT IN ALARM BUZZER OUTPUT・SHORT CIRCUIT (KB)............................................................................................................................. 903
MON-1 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR DOES NOT DISPLAY ANY ITEM........................................................................................................... 904
MON-2 WHEN STARTING SWITCH IS TURNED OFF AND MACHINE MONITOR DOES NOT OPERATE NORMALLY....................................................................................................... 905
MON-3 ALARM BUZZER DEFECTIVE................................................................................................................................................................. 907
a) ALARM BUZZER DOES NOT SOUND........................................................................................................................................................... 907
b) ALARM BUZZER DOES NOT STOP SOUNDING................................................................................................................................................... 908
MON-4 ITEMS DISPLAYED BY GAUGES, CAUTION LAMPS, AND CHARACTER DISPLAY OF MACHINE MONITOR ARE ABNORMAL........................................................................................ 909
a) ITEMS DISPLAYED BY GAUGES ARE DIFFERENT FROM MACHINE CONDITION........................................................................................................................ 909
b) ITEMS DISPLAYED BY CAUTION LAMPS ARE DIFFERENT FROM MACHINE CONDITION................................................................................................................. 910
c) CHARACTER DISPLAY DOES NOT DISPLAY ANY ITEM OR IT DISPLAYS ABNORMALLY................................................................................................................. 910
MON-5 OPERATION OF MACHINE MONITOR CANNOT BE CHECKED NORMALLY................................................................................................................................ 911
MON-6 DISPLAY OF CHARACTER DISPLAY CANNOT BE SELECTED NORMALLY............................................................................................................................... 912
a) MACHINE MONITOR MODE SELECT SWITCH 1 SYSTEM IS ABNORMAL............................................................................................................................... 912
b) MACHINE MONITOR MODE SELECT SWITCH 2 SYSTEM IS ABNORMAL............................................................................................................................... 914
MON-7 POWER MODE SELECT FUNCTION DOES NOT WORK NORMALLY...................................................................................................................................... 916
MON-8 SEAT BELT CAUTION LAMP DOES NOT OPERATE NORMALLY....................................................................................................................................... 917
a) LAMP LIGHTS UP WHILE SEAT BELT IS FASTENED............................................................................................................................................ 917
b) LAMP DOES NOT LIGHT UP WHILE SEAT BELT IS UNFASTENED.................................................................................................................................. 918
MON-9 TURN SIGNALS AND HAZARD LAMP DO NOT OPERATE NORMALLY................................................................................................................................... 919
a) WHEN TURN SIGNAL LEVER AND HAZARD LAMP SWITCH ARE OPERATED, ANY TURN SIGNAL LAMP DOES NOT FLASH....................................................................................... 919
b) WHEN TURN SIGNAL LEVER AND HAZARD LAMP SWITCH ARE OPERATED, THE TURN SIGNAL LAMPS DO NOT FLASH BUT LIGHT UP........................................................................... 920
c) WHEN TURN SIGNAL LEVER IS OPERATED, TURN SIGNAL LAMPS ON EITHER OR BOTH SIDES DO NOT FLASH (WHEN HAZARD LAMP SWITCH IS OPERATED, HOWEVER, TURN SIGNAL LAMPS FALSH MORMALLY)........... 921
d) WHEN HAZARD LAMP SWITCH IS TURNED ON, ANY TURN SIGNAL LAMP DOES NOT FLASH (WHEN TURN SIGNAL LEVER IS OPERATED, HOWEVER, TURN SIGNAL LAMPS FALSH MORMALLY)............................. 922
e) WHEN HAZARD LAMP SWITCH IS TURNED OFF, ANY TURN SIGNAL LAMPS CONTINUE FLASHING (WHEN TURN SIGNAL LEVER IS OPERATED, HOWEVER, TURN SIGNAL LAMPS FALSH NORMALLY)........................ 924
f) TURN SIGNAL PILOT LAMPS DO NOT FLASH NORMALLY (TURN SIGNAL LAMPS FLASH NORMALLY, HOWEVER)............................................................................................. 925
MON-10 NIGHT LIGHTING IS ABNORMAL............................................................................................................................................................ 927
a) WHEN LAMP SWITCH IS SET IN 1ST OR 2ND POSITION, ANY OF SMALL LAMP, NIGHT LAMP, AND HEAD LAMP DOES NOT LIGHT UP........................................................................ 927
b) WHEN LAMP SWITCH IS SET IN 1ST POSITION, SMALL LAMP AND NIGHT LAMP DO NOT LIGHT UP.................................................................................................... 928
c) WHEN LAMP SWITCH IS OFF, SMALL LAMP AND NIGHT LAMP LIGHT UP........................................................................................................................... 929
d) WHEN DIMMER SWITCH IS OPERATED, BRIGHTNESS OF NIGHT LIGHTING DOES NOT CHANGE.......................................................................................................... 930
e) HEAD LAMP "HI" BEAM DOES NOT LIGHT UP................................................................................................................................................. 931
f) HEAD LAMP "LO" BEAM DOES NOT LIGHT UP................................................................................................................................................. 932
g) HEAD LAMP CANNOT BE SET TO "HI" OR "LO"............................................................................................................................................... 933
h) WHEN HEAD LAMP IS SET TO "HI" BEAM, PILOT LAMP OF MACHINE MONITOR DOES NOT LIGHT UP................................................................................................... 934
MON-11 POWER WINDOW DOES NOT OPERATE NORMALLY................................................................................................................................................ 936
a) OPERATING LEFT SIDE DOES NOT.......................................................................................................................................................... 936
b) OPERATING RIGHT SIDE DOES NOT......................................................................................................................................................... 937
MON-12 DEFECTIVE AIR CONDITIONER............................................................................................................................................................. 939
a) AIR CONDITIONER DOES NOT OPERATE...................................................................................................................................................... 939
b) AIR DOES NOT COME OUT OR AIR FLOW CANNOT BE ADJUSTED.................................................................................................................................. 940
c) AIR IS NOT COOLED OR TEMPERATURE CANNOT BE ADJUSTED (ELECTRIC SYSTM).................................................................................................................. 942
d) RECIRCULATED AIR AND FRESH AIR CANNOT BE SELECTED..................................................................................................................................... 944
e) AIR OUTLETS CANNOT BE SELECTED........................................................................................................................................................ 945
f) AIR IS NOT COOLED (MECHANICAL SYSTEM)................................................................................................................................................. 947
g) AIR IS NOT HEATED (DEFECTIVE HOT WATER CIRCUIT)....................................................................................................................................... 948
h) ABNORMAL SOUND COMES OUT.............................................................................................................................................................. 948
i) WATER LEAKS........................................................................................................................................................................... 949
TROUBLESHOOTING OF VHMS CONTROLLER SYSTEM (VHMS MODE)............................................................................................................................................ 951
ELECTRICAL SYSTEM DIAGRAM RELATED VHMS CONTROLLER............................................................................................................................................ 952
INFORMATION GIVEN IN TROUBLESHOOTING CHART................................................................................................................................................... 956
FAILURE TYPE CODE LIST....................................................................................................................................................................... 957
[A000N1] (OR VHMS_LED DISPLAYS [n201]) ENGINE OVERRUN........................................................................................................................................ 958
[DBB0KK] (OR VHMS_LED INDICATES "n901") ABNORMALITY IN SOURCE VOLTAGE........................................................................................................................ 959
[DBB5KP] (OR VHMS_LED INDICATES "n904") ABNORMALITY IN SENSOR POWER SOURCE (5V) SYSTEM....................................................................................................... 961
[DBB6KP] (OR VHMS_LED INDICATES "n902") ABNORMALITY IN SENSOR POWER SOURCE (24V) SYSTEM...................................................................................................... 963
[DBB7KP] (OR VHMS_LED INDICATES "n903") ABNORMALITY IN SENSOR POWER SOURCE (12V) SYSTEM...................................................................................................... 965
[DBBRKR] (OR VHMS_LED DISPLAYS [n801]) DEFECTIVE CAN COMMUNICATIONS: DEFECTIVE COMMUNICATIONS (KR) (BETWEEN ENGINE CONTROLLER AND VIHMS CONTROLLER).......................................... 967
[DBBSKR] (OR VHMS_LED DISPLAYS [n803]) DEFECTIVE S-NET COMMUNICATIONS: (KR).................................................................................................................. 969
[DGE1KB] (OR VHMS_LED DISPLAYS [n242]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KB) {30 MIN (AT 500 RPM OR ABOVE) AFTER STARTING ENGINE}.... 971
[DGE1KY] (OR VHMS_LED DISPLAYS [n241]) SHORT CIRCUIT WITH POWER SOURCE IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KY).......................................................................... 972
[DGE5KX] (OR VHMS_LED DISPLAYS [n401]) FAILURE IN AMBIENT TEMPERATURE SENSOR SYSTEM:INPUT SIGNAL OUTSIDE RANGE (KX).......................................................................... 973
[DGT4KA] (OR VHMS_LED DISPLAYS [n312]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO.1,2,3 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)........................................... 974
[DGT4KB] (OR VHMS_LED DISPLAYS [n311]) SHORT CIRCUIT WITH POWER SOURCE IN NO.1,2,3 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)............................................................ 976
[DGT5KA] (OR VHMS_LED DISPLAYS [n322]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO.4,5,6 (REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)............................................ 978
[DGT5KB] (OR VHMS_LED DISPLAYS [n321]) SHORT CIRCUIT WITH POWER SOURCE IN NO.4,5,6 (REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)............................................................. 980
[DHE5KB] (OR VHMS_LED DISPLAYS [n332]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KA)........................................................ 982
[DHE5KY] (OR VHMS_LED DISPLAYS [n331]) SHORT CIRCUIT WITH POWER SOURCE IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KY)......................................................................... 983
[DhP4KX] SUSPENSION PRESSURE SENSOR (FRONT RIGHT):OUT OF INPUT SIGNAL RANGE (KX)............................................................................................................. 984
[DhP5KX] SUSPENSION PRESSURE SENSOR (FRONT LEFT):OUT OF INPUT SIGNAL RANGE (KX).............................................................................................................. 986
[DhP6KX] SUSPENSION PRESSURE SENSOR (REAR RIGHT):OUT OF INPUT SIGNAL RANGE (KX).............................................................................................................. 988
[DhP7KX] SUSPENSION PRESSURE SENSOR (REAR LEFT):OUT OF INPUT SIGNAL RANGE (KX)............................................................................................................... 990
[DKH1KX] PITCH ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX).................................................................................................................................. 992
[F@BBZL] (OR VHMS_LED DISPLAYS [n338]) ENGINE BLOW-BY PRESSURE IS HIGH: (ZL)................................................................................................................. 994
[F@BYNR] (OR VHMS_LED DISPLAYS [n362]) NO.1,2,3 (FRONT) EXHAUST TEMPERATURE IS HIGH (2):(NR)................................................................................................. 995
[F@BYNS] (OR VHMS_LED DISPLAYS [n361]) NO.1,2,3 (FRONT) EXHAUST TEMPERATURE IS HIGH (1):(NS)................................................................................................. 996
[F@BZNR] (OR VHMS_LED DISPLAYS [n372]) NO.4,5,6 (REAR) EXHAUST TEMPERATURE IS HIGH (2):(NR).................................................................................................. 997
[F@BZNS] (OR VHMS_LED DISPLAYS [n371]) NO.4,5,6 (REAR) EXHAUST TEMPERATURE IS HIGH (1):(NS).................................................................................................. 998
VHMS-1 ABNORMALITY IN SATELLITE DATA COMMUNICATION........................................................................................................................................... 999
a) SATELLITE COMMUNICATION DATA ARE NOT TRANSMITTED...................................................................................................................................... 999
b) ABNORMALITY IN DOWNLOADING INTO PC OR SETTING OF PC...................................................................................................................................1002
VHMS-2 ABNORMALITY IN SAVING DATA IN VHMS CONTROLLER (DATA ARE NOT SAVED)....................................................................................................................1004
VHMS-3 ENGINE BLOW-BY PRESSURE INDICATED BY MONITOR IS LOW (WHEN BLOW-BY PRESSURE MEASURED WITH MEASURING INSTRUMENT IS NORMAL)..............................................................1006
TROUBLESHOOTING OF ASR CONTROLLER SYSTEM (ASR MODE)..............................................................................................................................................1007
ELECTRICAL SYSTEM DIAGRAM RELATED ASR CONTROL................................................................................................................................................1008
INFORMATION IN TROUBLESHOOTING TABLE.........................................................................................................................................................1009
TROUBLE CODE TABLE...........................................................................................................................................................................1010
[DDDAKA] ASR SYSTEM SWITCH SYSTEM:DISCONNECTION (KA).........................................................................................................................................1011
[DDDAKB] ASR SYSTEM SWITCH SYSTEM:SHORT CIRCUIT (KB).........................................................................................................................................1012
[DK30KX] STEERING ANGLE SENSOR:OUT OF INPUT SIGNAL RANGE (KX)................................................................................................................................1013
[DLF8KA] WHEEL SPEED SENSOR (RR):DISCONNECTION (KA)..........................................................................................................................................1015
[DLF8LC] WHEEL SPEED SENSOR (RR):※ SEE SEPARATE LIST (LC)....................................................................................................................................1016
[DLF9KA] WHEEL SPEED SENSOR (RL):DISCONNECTION (KA)..........................................................................................................................................1017
[DLF9LC] WHEEL SPEED SENSOR (RL):※ SEE SEPARATE LIST (LC)....................................................................................................................................1018
[dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:※ SEE SEPARATE LIST (LC).....................................................................................................................1019
[DWNBK4] SHUT-OFF SOLENOID VALVE:UNCONTROLLABLE (K4).........................................................................................................................................1021
[DWNBKA] SHUT-OFF SOLENOID VALVE:DISCONNECTION (KA)..........................................................................................................................................1023
[DWNBKB] SHUT-OFF SOLENOID VALVE:SHORT CIRCUIT (KB)..........................................................................................................................................1024
[DWNBKY] SHUT-OFF SOLENOID VALVE:SHORT CIRCUIT WITH POWER SOURCE (KY)........................................................................................................................1025
[DWNBMA] SHUT-OFF SOLENOID VALVE:MALFUNCTION (MA)............................................................................................................................................1026
[DX17K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):UNCONTROLLABLE (K4).......................................................................................................1027
[DX17KA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):DISCONNECTION (KA)........................................................................................................1029
[DX17KB] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):SHORT CIRCUIT (KB)........................................................................................................1030
[DX17KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):SHORT CIRCUIT WITH POWER SOURCE (KY)......................................................................................1031
[DX17MA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):MALFUNCTION (MA)..........................................................................................................1032
[DX18K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):UNCONTROLLABLE (K4)........................................................................................................1033
[DX18KA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):DISCONNECTION (KA).........................................................................................................1035
[DX18KB] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):SHORT CIRCUIT (KB).........................................................................................................1036
[DX18KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):SHORT CIRCUIT WITH POWER SOURCE (KY).......................................................................................1037
[DX18MA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):MALFUNCTION (MA)...........................................................................................................1038
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE).....................................................................................................................................1039
H-1 MACHINE DOES NOT START...................................................................................................................................................................1040
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY(MACHINE JERKS)..........................................................................................................................................1042
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED(ENGINE STALLS).......................................................................................................................................1042
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING................................................................................................................................................1043
H-5 TRANSMISSION DOES NOT SHIFT UP ..........................................................................................................................................................1043
a. DOES NOT SHIFT UP.....................................................................................................................................................................1043
b. DOES NOT SHIFT UP.....................................................................................................................................................................1043
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING..............................................................................................................................................1044
a. ABNORMALITY AT ALL SPEED RANGES.......................................................................................................................................................1044
b. TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE..............................................................................................................................................1045
c. ABNORMALITY AT SPECIFIC SPEED RANGES..................................................................................................................................................1046
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR.....................................................................................................................................1048
H-8 TORQUE CONVERTAR OIL TEMPERATURE IS HIGH.................................................................................................................................................1050
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW.....................................................................................................................................................1051
H-10 FRONT BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE................................................................................................................................1052
H-11 REAR BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE.................................................................................................................................1053
H-12 STEERING WHEEL IS HEAVY.................................................................................................................................................................1054
H-13 STEERING WHEEL DOES NOT WORK............................................................................................................................................................1055
H-14 STEERING WHEEL VIBRATES.................................................................................................................................................................1055
H-15 HOIST CYLINDER LACKS LIFTING FORCE(LIFTING SPEED).......................................................................................................................................1056
H-16 HOIST CYLINDER DOES NOT WORK............................................................................................................................................................1057
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY..................................................................................................................................................1058
TROUBLESHOOTING OF ENGINE SYSTEM (S MODDE).......................................................................................................................................................1059
POINTS TO REMEMBER WHEN TROUBLESHOOTING......................................................................................................................................................1060
METHOD OF USING TROUBLESHOOTING CHARTS.......................................................................................................................................................1061
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)................................................................................................................................1064
S-2 ENGINE DOES NOT START....................................................................................................................................................................1067
a) ENGINE DOES NOT TURN..................................................................................................................................................................1067
b) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED)...............................................................................................................1068
c) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED).............................................................................................................1070
S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)......................................................................................................................................1072
S-4 ENGINE STOPS DURING OPERATIONS...........................................................................................................................................................1074
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING).................................................................................................................................................1076
S-6 ENGINE LACKS OUTPUT(OR LACKS POWER)......................................................................................................................................................1078
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)............................................................................................................................................1080
S-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE)...................................................................................................................................1083
S-9 OIL BECOMES CONTAMINATED QUICKLY.........................................................................................................................................................1084
S-10 FUEL CONSUMPTION IS EXCESSIVE...........................................................................................................................................................1085
S-11 OIL IS COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN......................................................................................................................1086
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)...............................................................................................................................1087
S-13 OIL LEVEL RISES.........................................................................................................................................................................1088
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING).........................................................................................................................................1089
S-15 ABNORMAL NOISE IS MADE..................................................................................................................................................................1090
S-16 VIBRATION IS EXCESSIVE..................................................................................................................................................................1091
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)....................................................................................................................................................1093
ELECTRICAL SYSTEM DIAGRAM RELATED TO EMERGENCY STEERING CONTROL..............................................................................................................................1094
INFORMATION IN TROUBLESHOOTING TABLE.........................................................................................................................................................1095
E-1 EMERGENCY STEERING SYSTEM DOES NOT OPERATE...............................................................................................................................................1097
TROUBLESHOOTING OF ABS CONTROLLER SYSTEM (ABS MODE) (IF EQUIPPED)................................................................................................................................1101
ELECTRICAL SYSTEM DIAGRAM RELATED ABS CONTROL................................................................................................................................................1102
INFORMATION IN TROUBLESHOOTING TABLE.........................................................................................................................................................1104
[D1E5KZ] ABS CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ).................................................................................................................................1106
[DBC0KK] ABS CONTROLLER: SUPPLY VOLTAGE REDUCTION (KK)......................................................................................................................................1108
[DBC1KK] ABS CONTROLLER MAIN POWER LINE: SUPPLY VOLTAGE REDUCTION (KK)......................................................................................................................1109
[DBC2KK] ABS CONTROLLER LOAD POWER LINE: SUPPLY VOLTAGE REDUCTION (KK)......................................................................................................................1110
[DBC3KK] ABS CONTROLLER BATTERY DIRECT POWER SUPPLY: SUPPLY VOLTAGE REDUCTION (KK)..........................................................................................................1112
[DBC9KM] ABS CONTROLLER WIRE WIRING HARNESS: SETTING OPERATION ERROR (KM)...................................................................................................................1113
[DBCSKR] ABS CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR)...................................................................................................................1114
[DDD9KA] ABS SYSTEM SWITCH: DISCONNECTION (KA)..............................................................................................................................................1117
[DDD9KB] ABS SYSTEM SWITCH: SHORT CIRCUIT (KB)..............................................................................................................................................1118
[DHU6KX] ABS CONTROL VALVE PRESSURE SENSOR FRONT WHEEL RIGHT (FR): OUTSIDE INPUT SIGNAL RANGE (KX)..........................................................................................1120
[DHU7KX] ABS CONTROL VALVE PRESSURE SENSOR FRONT WHEEL LEFT (FL): OUTSIDE INPUT SIGNAL RANGE (KX)...........................................................................................1122
[DHU8KX] ABS CONTROL VALVE PRESSURE SENSOR REAR WHEEL RIGHT (RR): OUTSIDE INPUT SIGNAL RANGE (KX)...........................................................................................1124
[DHU9KX] ABS CONTROL VALVE PRESSURE SENSOR REAR WHEEL LEFT (RL): OUTSIDE INPUT SIGNAL RANGE (KX)............................................................................................1126
[DK11KX] ACCELERATOR SENSOR: OUTSIDE INPUT SIGNAL RANGE (KX)................................................................................................................................1128
[DLF6KA] WHEEL SPEED SENSOR FRONT WHEEL RIGHT (FR): DISCONNECTION (KA)......................................................................................................................1130
[DLF7KA] WHEEL SPEED SENSOR FRONT WHEEL LEFT (FL): DISCONNECTION (KA).......................................................................................................................1132
[DLF8KA] WHEEL SPEED SENSOR REAR WHEEL RIGHT (RR): DISCONNECTION (KA).......................................................................................................................1134
[DLF9KA] WHEEL SPEED SENSOR REAR WHEEL LEFT (RL): DISCONNECTION (KA)........................................................................................................................1136
[DWNDKZ] ABS CUT VALVE (F): DISCONNECTION OR SHORT CIRCUIT (KZ).............................................................................................................................1138
[DWNDMA] ABS CUT VALVE (F): MALFUNCTION (MA)................................................................................................................................................1140
[DWNEKZ] ABS CUT VALVE (R): DISCONNECTION OR SHORT CIRCUIT (KZ).............................................................................................................................1142
[DWNEMA] ABS CUT VALVE (R): MALFUNCTION (MA)................................................................................................................................................1144
[DX21KA] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): DISCONNECTION (KA).......................................................................................................................1145
[DX21KB] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): SHORT CIRCUIT (KB).......................................................................................................................1146
[DX21KY] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): SHORT-CIRCUITED TO POWER SUPPLY (KY).....................................................................................................1147
[DX21MA] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): MALFUNCTION (MA).........................................................................................................................1148
[DX22KA] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): DISCONNECTION (KA)........................................................................................................................1149
[DX22KB] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): SHORT CIRCUIT (KB)........................................................................................................................1150
[DX22KY] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): SHORT-CIRCUITED TO POWER SUPPLY (KY)......................................................................................................1151
[DX22MA] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): MALFUNCTION (MA)..........................................................................................................................1152
[DX23KA] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): DISCONNECTION (KA)........................................................................................................................1153
[DX23KB] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): SHORT CIRCUIT (KB)........................................................................................................................1154
[DX23KY] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): SHORT-CIRCUITED TO POWER SUPPLY (KY)......................................................................................................1155
[DX23MA] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): MALFUNCTION (MA)..........................................................................................................................1156
[DX24KA] ABS CONTROL VALVE REAR WHEEL LEFT (RL): DISCONNECTION (KA).........................................................................................................................1157
[DX24KB] ABS CONTROL VALVE REAR WHEEL LEFT (RL): SHORT CIRCUIT (KB).........................................................................................................................1158
[DX24KY] ABS CONTROL VALVE REAR WHEEL LEFT (RL): SHORT-CIRCUITED WITH POWER SUPPLY (KY).....................................................................................................1159
[DX24MA] ABS CONTROL VALVE REAR WHEEL LEFT (RL): MALFUNCTION (MA)...........................................................................................................................1160
[DX25MA] ABS CONTROL VALVE (FRONT WHEEL SYSTEM): MALFUNCTION (MA)...........................................................................................................................1161
[DX26MA] ABS CONTROL VALVE (REAR WHEEL SYSTEM): MALFUNCTION (MA)............................................................................................................................1162
30 DISASSEMBLY AND ASSEMBLY..............................................................................................................................................................................1163
METHOD OF USING MANUAL...............................................................................................................................................................................1165
PRECAUTIONS WHEN CARRYING OUT OPERATION..............................................................................................................................................................1166
COATING MATERIALS LIST...............................................................................................................................................................................1168
SPECIAL TOOL LIST....................................................................................................................................................................................1171
SKETCH OF SPECIAL TOOL...............................................................................................................................................................................1175
FUEL INJECTION PUMP..................................................................................................................................................................................1178
REMOVAL AND INSTALLATION.........................................................................................................................................................................1178
RADIATOR.............................................................................................................................................................................................1179
REMOVAL AND INSTALLATION.........................................................................................................................................................................1179
ENGINE AND TORQUE CONVERTER AND TRANSMISSION OIL COOLER..............................................................................................................................................1181
REMOVAL AND INSTALLATION.........................................................................................................................................................................1181
ENGINE FRONT SEAL....................................................................................................................................................................................1182
REMOVAL AND INSTALLATION.........................................................................................................................................................................1182
OUTPUT SHAFT.........................................................................................................................................................................................1183
REMOVAL AND INSTALLATION.........................................................................................................................................................................1183
DISASSEMBLY......................................................................................................................................................................................1184
ASSEMBLY.........................................................................................................................................................................................1185
ENGINE REAR SEAL.....................................................................................................................................................................................1187
REMOVAL AND INSTALLATION.........................................................................................................................................................................1187
CYLINDER HEAD........................................................................................................................................................................................1189
REMOVAL..........................................................................................................................................................................................1189
INSTALLATION.....................................................................................................................................................................................1191
ENGINE...............................................................................................................................................................................................1194
REMOVAL..........................................................................................................................................................................................1194
INSTALLATION.....................................................................................................................................................................................1195
TORQUE CONVERTER AND TRANSMISSION....................................................................................................................................................................1197
REMOVAL..........................................................................................................................................................................................1197
INSTALLATION.....................................................................................................................................................................................1198
TRANSMISSION ASSEMBLY AND TORQUE CONVERTER...........................................................................................................................................................1200
SEPARATION AND COUPLING..........................................................................................................................................................................1200
TORQUE CONVERTER.....................................................................................................................................................................................1201
DISASSEMBLY......................................................................................................................................................................................1201
ASSEMBLY.........................................................................................................................................................................................1205
TRANSMISSION.........................................................................................................................................................................................1211
DISASSEMBLY......................................................................................................................................................................................1211
ASSEMBLY.........................................................................................................................................................................................1224
DIFFERENTIAL.........................................................................................................................................................................................1239
REMOVAL..........................................................................................................................................................................................1239
INSTALLATION.....................................................................................................................................................................................1240
DISASSEMBLY......................................................................................................................................................................................1241
ASSEMBLY.........................................................................................................................................................................................1245
FRONT WHEEL .........................................................................................................................................................................................1253
REMOVAL AND INSTALLATION.........................................................................................................................................................................1253
REAR WHEEL...........................................................................................................................................................................................1254
REMOVAL..........................................................................................................................................................................................1254
INSTALLATION.....................................................................................................................................................................................1255
FRONT BRAKE CALIPER PADS.............................................................................................................................................................................1256
REMOVAL AND INSTALLATION.........................................................................................................................................................................1256
FRONT BRAKE CALIPERS.................................................................................................................................................................................1257
REMOVAL AND INSTALLATION.........................................................................................................................................................................1257
DISASSEMBLY AND ASSEMBLY.........................................................................................................................................................................1258
FRONT WHEEL HUB......................................................................................................................................................................................1260
DISASSEMBLY......................................................................................................................................................................................1260
ASSEMBLY.........................................................................................................................................................................................1261
FINAL DRIVE CARRIER..................................................................................................................................................................................1265
REMOVAL AND INSTALLATION.........................................................................................................................................................................1265
DISASSEMBLY AND ASSEMBLY.........................................................................................................................................................................1266
FINAL DRIVE AND REAR BRAKE...........................................................................................................................................................................1267
REMOVAL..........................................................................................................................................................................................1267
INSTALLATION.....................................................................................................................................................................................1269
FINAL DRIVE,REAR BRAKE,AND PARKING BRAKE.............................................................................................................................................................1271
REMOVAL AND INSTALLATION.........................................................................................................................................................................1271
DISASSEMBLY......................................................................................................................................................................................1272
ASSEMBLY.........................................................................................................................................................................................1277
FRONT SUSPENSION CYLINDER............................................................................................................................................................................1283
REMOVAL..........................................................................................................................................................................................1283
INSTALLATION.....................................................................................................................................................................................1284
DISASSEMBLY......................................................................................................................................................................................1285
ASSEMBLY.........................................................................................................................................................................................1286
REAR SUSPENSION CYLINDER.............................................................................................................................................................................1292
REMOVAL AND INSTALLATION.........................................................................................................................................................................1292
DISASSEMBLY......................................................................................................................................................................................1293
ASSEMBLY.........................................................................................................................................................................................1294
RETARDER COOLING PUMP................................................................................................................................................................................1300
REMOVAL AND INSTALLATION.........................................................................................................................................................................1300
STEERING,HOIST,AND HOIST CONTROL PUMP................................................................................................................................................................1301
REMOVAL AND INSTALLATION.........................................................................................................................................................................1301
TORQUE CONVERTER,TRANSMISSION AND RETARDER COOLING,AND BRAKE PUMP....................................................................................................................................1302
REMOVAL AND INSTALLATION.........................................................................................................................................................................1302
STEERING VALVE.......................................................................................................................................................................................1303
REMOVAL AND INSTALLATION.........................................................................................................................................................................1303
DISASSEMBLY......................................................................................................................................................................................1304
ASSEMBLY.........................................................................................................................................................................................1307
DEMAND VALVE.........................................................................................................................................................................................1314
REMOVAL AND INSTALLATION.........................................................................................................................................................................1314
HOIST VALVE..........................................................................................................................................................................................1315
REMOVAL AND INSTALLATION.........................................................................................................................................................................1315
STEERING CYLINDER....................................................................................................................................................................................1316
DISASSEMBLY......................................................................................................................................................................................1316
ASSEMBLY.........................................................................................................................................................................................1317
HOIST CYLINDER.......................................................................................................................................................................................1319
DISASSEMBLY......................................................................................................................................................................................1319
ASSEMBLY.........................................................................................................................................................................................1320
DUMP BODY............................................................................................................................................................................................1323
REMOVAL..........................................................................................................................................................................................1323
INSTALLATION.....................................................................................................................................................................................1324
OPERATOR'S SEAT......................................................................................................................................................................................1326
DISASSEMBLY......................................................................................................................................................................................1326
ASSEMBLY.........................................................................................................................................................................................1331
90 OTHERS................................................................................................................................................................................................1405
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM................................................................................................................................................................1406
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM.........................................................................................................................................................1407
BRAKE HYDRAULIC CIRCUIT DIAGRAM......................................................................................................................................................................1409
ELECTRICAL CIRCUIT DIAGRAM (1/6).....................................................................................................................................................................1411
ELECTRICAL CIRCUIT DIAGRAM (2/6).....................................................................................................................................................................1413
ELECTRICAL CIRCUIT DIAGRAM (3/6).....................................................................................................................................................................1415
ELECTRICAL CIRCUIT DIAGRAM (4/6).....................................................................................................................................................................1417
ELECTRICAL CIRCUIT DIAGRAM (5/6) HD465-7 SERIAL NO. 7001 － 7693, HD605-7 SERIAL NO. 7001 － 7256......................................................................................................1419
ELECTRICAL CIRCUIT DIAGRAM (5/6) HD465-7 SERIAL NO. 7694 － 7714......................................................................................................................................1421
ELECTRICAL CIRCUIT DIAGRAM (5/6) HD465-7 SERIAL NO. 7715 － , HD605-7 SERIAL NO. 7257 －...............................................................................................................1423
ELECTRICAL CIRCUIT DIAGRAM (6/6) HD465-7 SERIAL NO. 7001 － 7693, HD605-7 SERIAL NO. 7001 － 7256......................................................................................................1425
ELECTRICAL CIRCUIT DIAGRAM (6/6) HD465-7 SERIAL NO. 7694 － 7714......................................................................................................................................1427
ELECTRICAL CIRCUIT DIAGRAM (6/6) HD465-7 SERIAL NO. 7715 － , HD605-7 SERIAL NO. 7257 －...............................................................................................................1429
ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL............................................................................................................................................1431
ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR.........................................................................................................................................................1433
ELECTRICAL CIRCUIT DIAGRMAM (A1 SIZE) (1/2)..........................................................................................................................................................1435
ELECTRICAL CIRCUIT DIAGRMAM (A1 SIZE) (2/2)..........................................................................................................................................................1437
ELECTRICAL SYSTEM DIAGRAM RELATED TO ABS CONTROLLER..................................................................................................................................................1439
ELECTRICAL CIRCUIT DIAGRAM RELATED TO ABS............................................................................................................................................................1441
ELECTRICAL CIRCUIT DIAGRAM FOR AUTO GREASING SYSTEM..................................................................................................................................................1443
EXTERNAL POWER SUPPLY HEATER.........................................................................................................................................................................1444
CONNECTORS TABLE (A1 SIZE)...........................................................................................................................................................................1445
ARRANGEMENT DRAWING (A1 SIZE)........................................................................................................................................................................1447DESCRIPTION:
KOMATSU HD465-7 HD605-7 SHOP MANUAL SEBM027618 – PDF DOWNLOAD
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This 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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
S.S 26/12/24
