Komatsu HD465-7 HD605-7 Shop Manual SEBM027622 – PDF DOWNLOAD

HD465-7 7001 and up
HD605-7 7001 and up

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.

HD465-7 7001 and up
HD605-7 7001 and up

COVER 1
CONTENTS 2
01 GENERAL 23
SPECIFICATION DRAWINGS 24
SPECIFICATIONS 25
WEIGHT TABLE 31
FUEL,COOLANT AND LUBRICANTS 32
10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD 35
RADIATOR,TORQUE CONVERTER OIL COOLER,AFTER COOLER,WORK EQUIPMENT OIL COOLER,FUEL COOLER 37
BRAKE OIL COOLER 38
POWER TRAIN SKELETON 39
OUTPUT SHAFT 40
DRIVE SHAFT 42
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING 44
TORQUE CONVERTER 46
TRANSMISSION 54
TRANSMISSION VALVE 63
ECMV 64
AXLE 74
DIFFERENTIAL 76
FINAL DRIVE 78
WHEELS 80
SUSPENSION 82
SUSPENSION CYLINDER 84
REAR AXLE SUPPORT 90
STEERING COLUMN 92
STEERING LINKAGE 93
BRAKE PIPING 96
BRAKE VALVE 100
EMERGENCY BRAKE VALVE 103
RELAY VALVE 104
FRONT BRAKE OFF VALVE 105
ACCUMULATOR CHARGE VALVE 107
ACCUMULATOR 111
SLACK ADJUSTER 112
BRAKE 114
PROPORTIONAL REDUCING VALVE 119
PARKING BRAKE SOLENOID VALVE 120
STEERING AND HOIST HYDRAULIC PIPING 122
STEERING AND HOIST HYDRAULIC SYSTEM DIAGRAM 124
DUMP BODY CONTROL 126
HYDRAULIC TANK 127
STEERING CONTROL VALVE 128
CROSSOVER RELIEF VALVE 132
STEERING CYLINDER 133
DEMAND VALVE 134
HOIST VALVE 138
EPC VALVE 144
HOIST CYLINDER 145
HYDRAULIC PUMP 146
AIR CONDITIONER 150
MACHINE MONITOR SYSTEM 155
ENGINE CONTROL SYSTEM 170
AUTOMATIC SHIFT CONTROL SYSTEM 172
PAYLOAD METER Ⅱ(CARD TYPE) 187
AUTOMATIC EMERGENCY STEERING SYSTEM 220
AUTOMATIC SUSPENSION SYSTEM 228
RETARDER CONTROL SYSTEM 232
SENSORS,SWITCHES 244
DUMP CONTROL LEVER 252
VHMS CONTROLLER 256
BLOW-BY PRESSURE SENSOR 256
ENGINE OIL PRESSURE SENSOR 257
EXHAUST TEMPERATURE SENSOR/AMP 258
AMBIENT TEMPERATURE SENSOR 258
COMMUNICATIONS (ORB・・・ORBCOMM) CONTROLLER/ANTENNA 259
PAYLOAD METER (HAVING VHMS) 260
Auto greasing system 284
20 TESTING AND ADJUSTING 307
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 308
STANDARD VALUE TABLE FOR CHASSIS 309
TESTING AND ADJUSTING 321
TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING 322
MEASURING ENGINE SPEED 328
ADJUSTING ENGINE SPEED SENSOR 330
MEASURING ENGINE OIL PRESSURE 331
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 332
MEASURING EXHAUST TEMPERATURE 334
MEASURING BLOW-BY PRESSURE 336
TROUBLESHOOTING OF INJECTOR 337
MEASURING COMPRESSION PRESSURE 338
HANDLING EQUIPMENT IN FUEL SYSTEM 340
MEASURING FUEL PUMP OUTLET PORT PRESSURE 340
MEASURING FUEL PUMP INLET PORT PRESSURE 342
VISUAL INSPECTION OF RETURN FUEL 342
ADJUSTING INJECTOR SET LOAD 343
BLEEDING AIR FROM FUEL CIRCUIT 345
MEASURING EXHAUST COLOR 347
ADJUSTING VALVE CLEARANCE 348
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 349
TESTING AND ADJUSTING,AIR CONDITIONER COMPRESSOR BELT TENSION 350
MEASURING POWER TRAIN OIL PRESSURE 351
ADJUSTING TRANSMISSION SPEED SENSOR 358
INSPECTING BRAKE OIL PRESSURE 359
TESTING OF ACCUMULATORNITROGEN GAS PRESSUREAND PROCEDURE FORCHARGING ACCUMULATORWITH NITROGEN GAS 361
BLEEDING AIR FROM BRAKE CIRCUIT 369
TESTING WEAR OF FRONT BRAKE PAD 370
TESTING WEAR OF REAR BRAKE DISC 371
METHOD OF RELEASING PARKING BRAKE IN AN EMERGENCY 372
TESTING AND ADUSTING FRONT SUSPENSION CYLINDER 373
TESTING AND ADJUSTING INVERTED TYPE REAR SUSPENSION CYLINDER 377
TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER(MODE SELECTOR HYDRAULIC CYLNDER) 380
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING,HOIST CIRCUIT 381
TESTING AND ADJUSTING OIL PRESSURE IN DUMP EPC CIRCUIT 384
AIR BLEEDING FROM STEERING CYLINDER 385
PROCEDURE FOR RAISING DUMP BODY IN EMERGENCY 386
ADJUSTING BODY POSITIONER SENSOR 387
ADJUSTMENT OF TILT LOCKLEVER OF STEERING WHEEL 389
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM 390
ADJUSTING MACHINE MONITOR(EMMS) 394
ADJUSTING TRANSMISSION CONTROLLER 398
INITIAL SETTING OF PAYLOAD METER 399
SETTING OF CARD-TYPE PAYLOAD METER AFTER INSTALLATION OR REPLACEMENT 400
SPECIAL FUNCTIONS OF MACHINE MONITOR(EMMS) 409
BASIC PRECAUTIONS 464
OUTLINE 467
SETTING UP VHMS CONTROLLER 472
COLLECTION,TRANSMISSION OF DATA 474
INSPECTION AND MAINTENANCE 479
REPLACING PARTS 479
PROCEDURE FOR INITIAL SETUP OF VHMS 480
PROCEDURE FOR OPENING ORBCOMM SERVICE 483
PERFORMING PM-CLINIC USING MANUAL SNAPSHOT(=QUICK PM) 486
PM CLINIC SERVICE 491
TROUBLESHOOTING 495
POINTS TO REMEMBER WHEN TROUBLESHOOTING 496
SEQUENCE OF EVENTS IN TROUBLESHOOTING 497
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 498
CHECKS BEFORE TROUBLESHOOTING 506
CATEGORIES, PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS 509
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 516
T-ADAPTER TABLE 541
TYPES AND LOCATIONS OF CONNECTORS 544
CONNECTOR ARRANGEMENT LOCATION 560
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM(ENG MODE) 573
ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL 576
INFORMATION IN TROUBLESHOOTING TABLE 582
[C111KT] ABNORMALITY IN ENGINE CONTROLLER MEMORY 584
[C112LK] ABNORMALITY IN TIMING RAIL ACTUATOR 584
[C113KZ] ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM 585
[C115KZ] ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS 586
[C116KX] ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM 588
[C117KX] ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM 589
[C118KX] ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM 590
[C119KX] ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM 591
[C121LC] ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEMS 591
[C122KX] ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR SYSTEM 592
[C123KX] ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR SYSTEM 593
[C131KX] ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM 594
[C132KX] ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM 596
[C135KX] ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM 597
[C141KX] ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM 598
[C143ZG] LOWERING OF ENGINE OIL PRESSURE 598
[C144KX] ABNORMALLY HIGH LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM 599
[C145KX] ABNORMALLY LOW LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM 600
[C148KX] ABNORMALITY IN FM THROTTLE:OUT OF INPUT SIGNAL RANGE 601
[C151NS] RISE OF ENGINE COOLANT TEMPERATURE 602
[C153KX] ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM 603
[C154KX] ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM 604
[C221KX] ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM 605
[C222KX] ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM 606
[C234NI] OVER-SPEED 606
[C254KZ] ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE 607
[C259FS] ABNORMALITY IN FUEL SHUT-OFF VALVE 608
[C261NS] ABNORMAL RISE OF FUEL TEMPERATURE 608
[C263KX] ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM 609
[C265KX] ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM 610
[C316KZ] ABNORMAL CURRENT OF FUEL PUMP ACTUATOR 611
[C318LK] ABNORMALITY IN FUEL PUMP ACTUATOR 612
[C346KT] ABNORMALITY IN POWER-DOWN UNIT OF ENGINE CONTROLLER 613
[C423L6] ABNORMALITY IN IN-RANGE OF TIMING RAIL PRESSURE SENSOR SYSTEM 615
[C431L4] ABNORMALITY IN IDLING VALIDATION SWITCH SYSTEM:※ SEE SEPARATE LIST(L4)(BOTH SIGNAL VOLTAGES OF 2 SYSTEMS ARE SENSED) 617
[C432L5] ERROR IN IDLING VALIDATION PROCESS(※ SEE SEPARATE LIST(L5)) 619
[C441KK] ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM 621
[C442KG] ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGE SYSTEM 621
[C451KX] ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM 622
[C452KX] ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM 623
[C455KZ] ABNORMAL CURRENT OF FUEL RAIL ACTUATOR 624
[C467LK] ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL 625
[C468LK] ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL 625
[C514LK] ABNORMALITY IN FUEL RAIL ACTUATOR 626
[C551L4] ABNORMALITY IN IDLING VALIDATION SWITCH SYSTEM:※ SEE SEPARATE LIST(L4)(EITHER SIGNAL VOLTAGE OF 2 SYSTEMS IS NOT SENSED) 627
[C554L6] ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE SENSOR SYSTEM 629
ENG-1 ENGINE DOES NOT START 631
ENG-2 FAILURE IN PREHEATING 635
a) ENGINE IS NOT PREHEATED 635
b) PREHEATING IS ACTUATED EVEN UNDER NON-ACTUATION CONDITIONS FOR PREHEATING 638
ENG-3 AISS FUNCTION DOES NOT WORK NORMALLY 640
a) WHEN AISS SWITCH IS SET IN AUTO,LOW SPEED CONTROL IS SELECTED 640
b) WHEN AISS SWITCH IS SET IN LOW SPEED,AUTO CONTROL IS SELECTED 641
TROUBLESHOOTING FOR TRANSMISSION CONTROLLER SYSTEM (TM MODE) 643
ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL 645
INFORMATION IN TROUBLESHOOTING TABLE 646
TROUBLE CODE TABLE 647
[1380MW] LOCKUP CLUTCH・SLIP(MW) 648
[1500L0] DETECTION OF DOUBLE ENGAGEMENT・※ SEE SEPARATE LIST(L0) 649
[15B0NX] CLOGGING OF TRANSMISSION OIL FILTER・CLOGGING(NX) 650
[15E0KM] R→F GEAR SHIFT ABUSE 1・MISTAKE IN OPERATION OR SETTING (KM) 651
[15E7KM] R→F GEAR SHIFT ABUSE 2・MISTAKE IN OPERATION OR SETTING (KM) 651
[15G0MW] R CLUTCH・SLIP (MW) 652
[15H0MW] HI CLUTCH・SLIP (MW) 653
[15J0MW] LO CLUTCH・SLIP(MW) 655
[15K0MW] 1ST CLUTCH・SLIP(MW) 657
[15L0MW] 2ND CLUTCH・SLIP(MW) 658
[15M0MW] 3RD CLUTCH・SLIP(MW) 659
[15N0MW] 4TH CLUTCH・SLIP(MW) 660
[15SBL1] R CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1) 661
[15SBMA] R CLUTCH SOLENOID・※ MALFUNCTION(MA) 662
[15SCL1] HI CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1) 663
[15SCMA] HI CLUTCH SOLENOID・MALFUNCTION(MA) 664
[15SDL1] LO CLUTCH SOLENOID・※ SEE SEPARATE LIST (L1) 665
[15SDMA] LO CLUTCH SOLENOID・MALFUNCTION(MA) 666
[15SEL1] 1ST CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1) 667
[15SEMA] 1ST CLUTCH SOLENOID・MALFUNCTION(MA) 668
[15SFL1] 2ND CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1) 669
[15SFMA] 2ND CLUTCH SOLENOID・MALFUNCTION(MA) 670
[15SGL1] 3RD CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1) 671
[15SGMA] 3RD CLUTCH SOLENOID・MALFUNCTION(MA) 672
[15SHL1] 4TH CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1) 673
[15SHMA] 4TH CLUTCH SOLENOID・MALFUNCTION(MA) 674
[15SJL1] LOCKUP CLUTCH SOLENOID・15SJ(L1) 675
[15SJMA] LOCKUP CLUTCH SOLENOID・15SJ(MA) 676
[2F00KM] PARKING BRAKE・MISTAKE IN OPERATION OR SETTING(KM) 677
[989A00] ENGINE OVERRUN PREVENTION COMMAND SIGNAL・OPERATION(00) 679
[989AKZ] ENGINE OVERRUN PREVENTION COMMAND SIGNAL・DISCONNECTION OR SHORT CIRCUIT(KZ) 680
[AA10NX] AIR CLEANER ELEMENT・CLOGGING(NX) 681
[AB00MA] ALTERNATOR・MALFUNCTION(MA) 683
[B@CZK] LOWERING OF RADIATOR WATER:LOWERING OF LEVER (ZK) 685
[D1B0KZ] TRANSMISSION CONTROLLER CUTOUT: DISCONNECTION OR SHORT CIRCUIT (KZ) 686
[D5ZMKZ] DISCONNECTION,GROUNDING FAULT,OR SHORT CIRCUIT IN ENGINE OUTPUT MODE COMMAND LINE・DISCONNECTION OR SHORT CIRCUIT(KZ) 688
[DAQ0KK] TRANSMISSION CONTROLLER・LOWERING OF SOURCE/INPUT VOLTAGE(KK) 689
[DAQ1KK] MAIN POWER LINE OF TRANSMISSION CONTROLLER・LOWERING OF SOURCE/INPUT VOLTAGE (KK) 691
[DAQ2KK] TRANSMISSION CONTROLLER LOAD POWER LINE・LOWERING OF SOURCE/INPUT VOLTAGE(KK) 693
[DAQ3KK] DIRECT LINE OF TRANSMISSION CONTROLLER BATTERY・LOWERING OF SOURCE/INPUT VOLTAGE (KK) 695
[DAQ9KM] TRANSMISSION CONTROLLER WIRING HARNESS・MISTAKE IN OPERATION OR SETTING(KM) 696
[DAQ9KQ] TRANSMISSION CONTROLLER WIRING HARNESS・DISAGREEMENT OF MODEL SELECTION SIGNALS(KQ) 697
[DAQAKQ] TRANSMISSION CONTROLLER ROTARY SWITCH・DISAGREEMENT OF MODEL SELECTION SIGNALS(KQ) 698
[DAQSMA] TRANSMISSION CONTROLLER・MALFUNCTION(MA) 698
[DDTGKA] LOCKUP CLUTCH FILL SWITCH:DISCONNECTION(KA) 699
[DDTHKA] HI CLUTCH FILL SWITCH:DISCONNECTION(KA) 700
[DDTJKA] LO CLUTCH FILL SWITCH:DISCONNECTION(KA) 701
[DDTKKA] 1ST CLUTCH FILL SWITCH:DISCONNECTION (KA) 702
[DDTLKA] 2ND CLUTCH FILL SWITCH:DISCONNECTION(KA) 703
[DDTMKA] 3RD CLUTCH FILL SWITCH:DISCONNECTION(KA) 704
[DDTNKA] R CLUTCH FILL SWITCH:DISCONNECTION(KA) 705
[DDTRKA] 4TH CLUTCH FILL SWITCH:DISCONNECTION(KA) 706
[DF10KA] SHIFT LEVER:DISCONNECTION(KA) 707
[DF10KB] SHIFT LEVER:SHORT CIRCUIT(KB) 711
[DGF1KX] TRANSMISSION VALVE OIL TEMPERATURE SENSOR:OUT OF INPUT SIGNAL RANGE(KX) 714
[DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR:OUT OF INPUTSIGNAL RANGE(KX) 716
[DHT5KX] TORQUE CONVERTER OIL PRESSURE SENSOR:OUT OF INPUT SIGNAL RANGE(KX) 717
[DHT5L6] TORQUE CONVERTER OIL PRESSURE SENSOR:※ SEE SEPARATE LIST(L6) 719
[DJF1KA] FUEL LEVEL SENSOR:DISCONNECTION(KA) 720
[DK11KX] THROTTLE ANGLE SENSOR:OUT OF INPUT SIGNAL RANGE(KX) 721
[DLE2KA] ENGINE SPEED SENSOR:DISCONNECTION(KA) 723
[DLE2LC] ENGINE SPEED SENSOR:※ SEE SEPARATE LIST(LC) 724
[DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR:DISCONNECTION(KA) 725
[DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR:※ SEE SEPARATE LIST(LC) 726
[DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR:DISCONNECTION(KA) 727
[DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR:※ SEE SEPARATE LIST(LC) 728
[DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:DISCONNECTION(KA) 729
[DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:※ SEE SEPARATE LIST(LC) 730
[DXH1KA] DISCONNECTION IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID:DISCONNECTION(KA) 732
[DXH1KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID:SHORT CIRCUIT (KB) 733
[DXH2KA] DISCONNECTION IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID:DISCONNECTION(KA) 734
[DXH2KB] SHORT CIRCUIT OF HI CLUTCH SOLENOID:SHORT CIRCUIT(KB) 735
[DXH3KA] DISCONNECTION IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID:DISCONNECTION(KA) 737
[DXH3KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID:SHORT CIRCUIT(KB) 738
[DXH4KA] DISCONNECTION IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID:DISCONNECTION(KA) 740
[DXH4KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID:SHORT CIRCUIT(KB) 741
[DXH5KA] DISCONNECTION IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID:DISCONNECTION(KA) 742
[DXH5KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID:SHORT CIRCUIT(KB) 743
[DXH6KA] DISCONNECTION IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID:DISCONNECTION(KA) 744
[DXH6KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID:SHORT CIRCUIT(KB) 745
[DXH7KA] DISCONNECTION IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID:DISCONNECTION(KA) 746
[DXH7KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID:SHORT CIRCUIT(KB) 747
[DXHHKA] DISCONNECTION IN OUTPUT CIRCUIT OF 4TH CLUTCH SOLENOID:DISCONNECTION(KA) 748
[DXHHKB] SHORT CIRCUIT OF 4TH CLUTCH SOLENOID:SHORT CIRCUIT(KB) 749
TM-1 FUEL LEVEL GAUGE DOES NOT OPERATE NORMALLY(IT ALWAYS INDICATES”FULL”) 750
TM-2 ABNORMALITY IN BACKUP LAMP AND BACKUP BUZZER 751
a) WHEN THE SHIFT LEVER IS SET IN THE “R” POSITION,THE BACKUP LAMP AND BACKUP BUZZER ARE NOT TURNER ON 751
b) BACKUP LAMP IS NOT TURNED ON(BACKUP BUZZER IS NORMAL) 752
c) BACKUP BUZZER IS NOT TURNED ON(BACKUP LAMP IS NORMAL) 752
d) WHILE SHIFT LEVER IS NOT OPERATED,BACKUP LAMP AND BACKUP BUZZER ARE TURNED ON 753
TROUBLESHOOTING FOR RETARDER CONTROLLER SYSTEM(BK MODE) 755
ELECTRICAL SYSTEM DIAGRAM RELATED TO RETARDER CONTROL 758
INFORMATION IN TROUBLESHOOTING TABLE 760
TROUBLE CODE TABLE 761
[2G42ZG] ACCUMULATOR(FRONT):LOWERING OF OIL PRESSURE(ZG) 762
[2G43ZG] ACCUMULATOR(REAR):LOWERING OF OIL PRESSURE(ZG) 762
[D1C0KZ] BRAKE CUTOUT RELAY:DISCONNECTION OR SHORT CIRCUIT(KZ) 763
[D5ZNKZ] FAILURE OF FRONT BRAKE CUTOUT OUTPUT SYSTEM(DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT)(OPT):DISCONNECTION OR SHORT CIRCUIT(KZ) 765
[DB10KK] RETARDER CONTROLLER:LOWERING OF SOURCE/INPUT VOLTAGE(KK) 767
[DB11KK] MAIN POWER LINE OF RETARDER CONTROLLER:LOWERING OF SOURCE/INPUT VOLTAGE(KK) 769
[DB12KK] RETARDER CONTROLLER LOAD POWER LINE:LOWERING OF SOURCE/INPUT VOLTAGE(KK) 771
[DB13KK] DIRECT LINE OF RETARDER CONTROLLER BATTERY:LOWERING OF SOURCE/INPUT VOLTAGE(KK) 773
[DB19KM] RETARDER CONTROLLER WIRING HARNESS:MISTAKE IN OPERATION OR SETTING(KM) 774
[DB1SKQ] WRONG INFORMATION ON MODEL SELECTION:DISAGREEMENT OF MODEL SELECTION SIGNALS(KQ) 775
[DDD7KX] FAILURE IN TRAVEL SPEED SET SWITCH SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX) 776
[DDD8KA] ARSC SYSTEM SWITCH SYSTEM:DISCONNECTION(KA) 778
[DDD8KB] ARSC SYSTEM SWITCH SYSTEM:SHORT CIRCUIT(KB) 779
[dGR2L8] FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM:※ SEE SEPARATE LIST(L8) 780
[DGR2L8] BRAKE OIL TEMPERATURE SENSOR(REAR):※ SEE SEPARATE LIST(L8) 781
[dHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR(FR) SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX) 782
[DHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR(FR) SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX) 784
[dHP5KX] FAILURE IN SUSPENSION PRESSURE SENSOR(FL) SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX) 786
[DHP5KX] FAIURE IN SUSPENSION PRESSURE SENSOR (FL) SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX) 788
[DHU2KX] ACCUMULATOR OIL PRESSURE SENSOR (FRONT):OUT OF INPUT SIGNAL RANGE (KX) 790
[DHU3KX] ACCUMULATOR OIL PRESSURE SENSOR (REAR):OUT OF INPUT SIGNAL RANGE (KX) 792
[dK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (OPT):OUT OF INPUT SIGNAL RANGE (KX) 794
[DK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (OPT):OUT OF INPUT SIGNAL RANGE (KX) 795
[DK51L5] RETARDER LEVER POTENTIOMETER:※ SEE SEPARATE LIST (L5) 796
[DK52KX] DUMP LEVER POTENTIOMETER 1:OUT OF INPUT SIGNAL RANGE (KX) 799
[DK53L8] DUMP LEVER POTENTIOMETER 2:※ SEE SEPARATE LIST (L8) 801
[DK54KX] BODY POSITIONER SENSOR:OUT OF INPUT SIGNAL RANGE (KX) 802
[DKD0L6] FAILURE IN STEERING SPEED SENSOR (OPT):※ SEE SEPARATE LIST (L6) 804
[dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:DISCONNECTION (KA) 806
[DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:DISCONNECTION (KA) 807
[DW35KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 1 (OPT)(DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT):DISCONNECTION OR SHORT CIRCUIT (KZ) 808
[DW36KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 2 (OPT) (DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT):DISCONNECTION OR SHORT CIRCUIT (KZ) 809
[DW72KZ] FAILURE IN KICK-OUT SOLENOID OUTPUT SYSTEM (D_OUT3)(DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT):DISCONNECTION OR SHORT CIRCUIT (KZ) 810
[DW73KZ] FAILURE IN HOIST SELECT VALVE OUTPUT SYSTEM (D_OUT5)(DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT):DISCONNECTION OR SHORT CIRCUIT (KZ) 812
[DK11K4] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL:UNCONTROLLABLE (K4) 815
[DX11KA] DISCONNECTION IN OUTPUT CIRCUIT OF ELECTROMAGNETIC PROPORTIONAL PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2):DISCONNECTION (KA) 818
[DX11KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF ELECTROMAGNETIC PROPORTIONAL PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2):SHORT CIRCUIT (KB) 819
[DX11KY] GROUNDING FAULT IN OUTPUT CIRCUIT OF ELECTROMAGNETIC PROPORTIONAL PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2):SHORT CIRCUIT WITH POWER LINE (KY) 820
[DX11MA] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL:MALFUNCTION (MA) 821
[DX13KA] DISCONNECTION IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):DISCONNECTION (KA) 823
[DX13KB] GROUNDING FAULT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):SHORT CIRCUIT (KB) 824
[DX13KY] SHORT CIRCUIT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):SHORT CIRCUIT WITH POWER LINE (KY) 825
BK-1 PARKING BRAKE DOES NOT OPERATE NORMALLY 827
a) WHEN THE PARKING BRAKE SWITCH IS SET IN THE OFF POSITION, THE PARKING BRAKE IS NOT RELEASED 827
b) WHEN THE PARKING BRAKE SWITCH IS SET IN THE PARK POSITION, THE PARKING BRAKE DOES NOT WORK 829
BK-2 RETARDER BRAKE OIL TEMPERATURE GAUGE DOES NOT OPERATE NORMALLY 831
BK-3 INCLINATION ALARM IS TURNED ON WHEN DUMP BODY IS RAISED (WHEN MACHINE IS NOT INCLINED MORE THAN 15°) 832
BK-4 TOUCH UP/DOWN AND CANCELLATION CANNOT BE PERFORMED 833
TROUBLESHOOTING FOR PAYLOAD METER SYSTEM (CARD TYPE) (LC MODE) 835
ELECTRICAL SYSTEM DIAGRAM RELATED TO PAYLOAD METER 836
SERVICE CODES OF PAYLOAD METER Ⅱ (CARD TYPE) AND CONTENTS OF SELF-DIAGNOSIS 838
INFORMATION IN TROUBLESHOOTING TABLE 841
TROUBLE CODE TABLE 842
LC-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM IS NOT DISPLAYED 843
LC-2 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL PILOT LAMPS DO NOT LIGHT UP 845
LC-3 EXTERNAL LAMPS LIGHT UP WHILE CONDITION FOR LIGHTING IS NOT SET 848
LC-4 LIGHTING LEVEL OF EXTERNAL PILOT LAMPS IS ABNORMAL 850
LC-5 CYCLE DATA AND ENGINE ON/OFF DATA NOT RECORDED (CHARGE LEVEL SIGNAL SYSTEM: JUDGES THAT ENGINE IS STOPPED) 852
LC-6 CALIBRATION CANNOT BE PERFORMED AND DISPLAYED CLOCK DOES NOT CONFORM TO CONDITION (SHIFT LEVER “N” POSITION SIGNAL SYSTEM) 853
LC-7 DISPLAYED LOGIC IS ABNORMAL 855
a) WHEN LOADED DUMP TRUCK STARTS TRAVELING, “O” IS KEPT DISPLAYED 855
b) AFTER LOADED DUMP TRUCK STARTS TRAVELING, DISPLAY OF ODOMETER DOES NOT INCREASE 855
c) WHEN TRAVEL SPEED EXCEEDS LIMIT SPEED, “SP:SP” DOES NOT GO OFF 855
d) INTEGRATED PAY LOAD IS NOT DIAPLAYED 856
e) DISPLAYED AND SAVED PAY LOAD IS NOT CORRECT 857
LC-8 PAYLOAD METER KEEPS DISPLAYING “b:FL” (BODY “FLOAT” SIGNAL SYSTEM: DUMP LEVER IS NOT IN “FLOAT” POSITION WHILE TRUCK IS NOT DUMPING) 858
LC-9 PAYLOAD METER DISPLAYS “F:09” (LOWERING OF INTERNAL BACKUP BATTERY VOLTAGE) 860
LC-10 PAYLOAD METER DISPLAYS “□:FULL” (DATA SAVING MEMORY IS FULL) 860
LC-11 PAYLOAD METER DISPLAYS “F-20”:FAILURE IN POWER SOURCE OF SUSPENSION PRESSURE SENSOR AND CLINOMETER SYSTEM 861
LC-12 PAYLOAD METER DISPLAYS “F-21”-“F-24”:DISCONNECTION OR GROUNDING FAULT IN SUSPENSION SENSOR SIGNAL SYSTEM 863
LC-13 PAYLOAD METER DISPLAYS “F-25”-“F-28”:SHORT CIRCUIT WITH POWER SOURCE IN SUSPENSION SENSOR SIGNAL SYSTEM 866
LC-14 PAYLOAD METER DISPLAYS “F-CAL” (NEGLIGENCE OF CALIBRATION OR INTERNAL DAMAGE OF PAYLOAD METER) 868
LC-15 PAYLOAD METER DISPLAYS “F:43”-“F:45” (SHORT CIRCUIT WITH POWER SOURCE IN EXTERNAL PILOT LAMP RELAY SYSTEM) 869
LC-16 PAYLOAD METER DISPLAYS “L-bad” (CYCLE DATA WERE SAVED WHILE TRUCK BODY WAS PITCHING) 871
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 873
LC-18 PAYLOAD METER DISPLAYS”F-31″:GROUNDING FAULT OR DISCONNECTION IN CLINOMETER SENSOR SIGNAL SYSTEM 874
LC-19 PAYLOAD METER DISPLAYS “F-32”:SHORT CIRCUIT WITH POWER SOURCE IN CLINOMETER SENSOR SIGNAL SYSTEM 876
LC-20 PAYLOAD METER DISPLAYS “F:18” (DISCONNECTION IN CHARGE LEVEL SIGNAL SYSTEM) 878
TROUBLESHOOTING FOR MONITOR SYSTE (MON MODE) 879
ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR 882
INFORMATION IN TROUBLESHOOTING TABLE 883
TROUBLE CODE TABLE 884
[B@C7NS] REAR BRAKE OIL:OVERHEATING (NS) 885
[B@CENS] TORQUE CONVERTER:OVERHEATING (NS) 885
[DAF0KM] MONITOR PANEL:MISTAKE IN OPERATION OR SETTING (KM) 886
[DAF9KM] MONITOR PANEL:MISTAKE IN OPERATION OR SETTING (KM) 889
[DAFSKQ] MONITOR PANEL:DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ) 890
[DAQSKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN TRANSMISSION CONTROLLER AND MACHINE MONITOR) (KR) 891
[DASRKR] CAN COMMUNICATION・COMMUNICATION DEFECTIVE: ABNORMALITY IN OBJECTIVE COMPONENT (KR) 894
[DB1SKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN RETARDER CONTROLLER AND MACHINE MONITOR) (KR) 896
[DV00KB] SHORT CIRCUIT IN ALARM BUZZER OUTPUT・SHORT CIRCUIT (KB) 899
MON-1 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR DOES NOT DISPLAY ANY ITEM 900
MON-2 WHEN STARTING SWITCH IS TURNED OFF AND MACHINE MONITOR DOES NOT OPERATE NORMALLY 901
MON-3 ALARM BUZZER DEFECTIVE 903
a) ALARM BUZZER DOES NOT SOUND 903
b) ALARM BUZZER DOES NOT STOP SOUNDING 904
MON-4 ITEMS DISPLAYED BY GAUGES, CAUTION LAMPS, AND CHARACTER DISPLAY OF MACHINE MONITOR ARE ABNORMAL 905
a) ITEMS DISPLAYED BY GAUGES ARE DIFFERENT FROM MACHINE CONDITION 905
b) ITEMS DISPLAYED BY CAUTION LAMPS ARE DIFFERENT FROM MACHINE CONDITION 906
c) CHARACTER DISPLAY DOES NOT DISPLAY ANY ITEM OR IT DISPLAYS ABNORMALLY 906
MON-5 OPERATION OF MACHINE MONITOR CANNOT BE CHECKED NORMALLY 907
MON-6 DISPLAY OF CHARACTER DISPLAY CANNOT BE SELECTED NORMALLY 908
a) MACHINE MONITOR MODE SELECT SWITCH 1 SYSTEM IS ABNORMAL 908
b) MACHINE MONITOR MODE SELECT SWITCH 2 SYSTEM IS ABNORMAL 910
MON-7 POWER MODE SELECT FUNCTION DOES NOT WORK NORMALLY 912
MON-8 SEAT BELT CAUTION LAMP DOES NOT OPERATE NORMALLY 913
a) LAMP LIGHTS UP WHILE SEAT BELT IS FASTENED 913
b) LAMP DOES NOT LIGHT UP WHILE SEAT BELT IS UNFASTENED 914
MON-9 TURN SIGNALS AND HAZARD LAMP DO NOT OPERATE NORMALLY 915
a) WHEN TURN SIGNAL LEVER AND HAZARD LAMP SWITCH ARE OPERATED, ANY TURN SIGNAL LAMP DOES NOT FLASH 915
b) WHEN TURN SIGNAL LEVER AND HAZARD LAMP SWITCH ARE OPERATED, THE TURN SIGNAL LAMPS DO NOT FLASH BUT LIGHT UP 916
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) 917
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) 918
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) 920
f) TURN SIGNAL PILOT LAMPS DO NOT FLASH NORMALLY (TURN SIGNAL LAMPS FLASH NORMALLY, HOWEVER) 921
MON-10 NIGHT LIGHTING IS ABNORMAL 923
a) WHEN LAMP SWITCH IS SET IN 1ST OR 2ND POSITION, ANY OF SMALL LAMP, NIGHT LAMP, AND HEAD LAMP DOES NOT LIGHT UP 923
b) WHEN LAMP SWITCH IS SET IN 1ST POSITION, SMALL LAMP AND NIGHT LAMP DO NOT LIGHT UP 924
c) WHEN LAMP SWITCH IS OFF, SMALL LAMP AND NIGHT LAMP LIGHT UP 925
d) WHEN DIMMER SWITCH IS OPERATED, BRIGHTNESS OF NIGHT LIGHTING DOES NOT CHANGE 926
e) HEAD LAMP “HI” BEAM DOES NOT LIGHT UP 927
f) HEAD LAMP “LO” BEAM DOES NOT LIGHT UP 928
g) HEAD LAMP CANNOT BE SET TO “HI” OR “LO” 929
h) WHEN HEAD LAMP IS SET TO “HI” BEAM, PILOT LAMP OF MACHINE MONITOR DOES NOT LIGHT UP 930
MON-11 POWER WINDOW DOES NOT OPERATE NORMALLY 932
a) OPERATING LEFT SIDE DOES NOT 932
b) OPERATING RIGHT SIDE DOES NOT 933
MON-12 DEFECTIVE AIR CONDITIONER 935
a) AIR CONDITIONER DOES NOT OPERATE 935
b) AIR DOES NOT COME OUT OR AIR FLOW CANNOT BE ADJUSTED 936
c) AIR IS NOT COOLED OR TEMPERATURE CANNOT BE ADJUSTED (ELECTRIC SYSTM) 938
d) RECIRCULATED AIR AND FRESH AIR CANNOT BE SELECTED 940
e) AIR OUTLETS CANNOT BE SELECTED 941
f) AIR IS NOT COOLED (MECHANICAL SYSTEM) 943
g) AIR IS NOT HEATED (DEFECTIVE HOT WATER CIRCUIT) 944
h) ABNORMAL SOUND COMES OUT 944
i) WATER LEAKS 945
TROUBLESHOOTING OF VHMS CONTROLLER SYSTEM (VHMS MODE) 947
ELECTRICAL SYSTEM DIAGRAM RELATED VHMS CONTROLLER 948
INFORMATION GIVEN IN TROUBLESHOOTING CHART 952
FAILURE TYPE CODE LIST 953
[A000N1] (OR VHMS_LED DISPLAYS [n201]) ENGINE OVERRUN 954
[DBB0KK] (OR VHMS_LED INDICATES “n901”) ABNORMALITY IN SOURCE VOLTAGE 955
[DBB5KP] (OR VHMS_LED INDICATES “n904”) ABNORMALITY IN SENSOR POWER SOURCE (5V) SYSTEM 957
[DBB6KP] (OR VHMS_LED INDICATES “n902”) ABNORMALITY IN SENSOR POWER SOURCE (24V) SYSTEM 959
[DBB7KP] (OR VHMS_LED INDICATES “n903”) ABNORMALITY IN SENSOR POWER SOURCE (12V) SYSTEM 961
[DBBRKR] (OR VHMS_LED DISPLAYS [n801]) DEFECTIVE CAN COMMUNICATIONS: DEFECTIVE COMMUNICATIONS (KR) (BETWEEN ENGINE CONTROLLER AND VIHMS CONTROLLER) 963
[DBBSKR] (OR VHMS_LED DISPLAYS [n803]) DEFECTIVE S-NET COMMUNICATIONS: (KR) 965
[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} 967
[DGE1KY] (OR VHMS_LED DISPLAYS [n241]) SHORT CIRCUIT WITH POWER SOURCE IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KY) 968
[DGE5KX] (OR VHMS_LED DISPLAYS [n401]) FAILURE IN AMBIENT TEMPERATURE SENSOR SYSTEM:INPUT SIGNAL OUTSIDE RANGE (KX) 969
[DGT4KA] (OR VHMS_LED DISPLAYS [n312]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO1,2,3 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA) 970
[DGT4KB] (OR VHMS_LED DISPLAYS [n311]) SHORT CIRCUIT WITH POWER SOURCE IN NO1,2,3 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KB) 972
[DGT5KA] (OR VHMS_LED DISPLAYS [n322]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO4,5,6 (REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KA) 974
[DGT5KB] (OR VHMS_LED DISPLAYS [n321]) SHORT CIRCUIT WITH POWER SOURCE IN NO4,5,6 (REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KB) 976
[DHE5KB] (OR VHMS_LED DISPLAYS [n332]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KA) 978
[DHE5KY] (OR VHMS_LED DISPLAYS [n331]) SHORT CIRCUIT WITH POWER SOURCE IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KY) 979
[DhP4KX] SUSPENSION PRESSURE SENSOR (FRONT RIGHT):OUT OF INPUT SIGNAL RANGE (KX) 980
[DhP5KX] SUSPENSION PRESSURE SENSOR (FRONT LEFT):OUT OF INPUT SIGNAL RANGE (KX) 982
[DhP6KX] SUSPENSION PRESSURE SENSOR (REAR RIGHT):OUT OF INPUT SIGNAL RANGE (KX) 984
[DhP7KX] SUSPENSION PRESSURE SENSOR (REAR LEFT):OUT OF INPUT SIGNAL RANGE (KX) 986
[DKH1KX] PITCH ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX) 988
[F@BBZL] (OR VHMS_LED DISPLAYS [n338]) ENGINE BLOW-BY PRESSURE IS HIGH: (ZL) 990
[F@BYNR] (OR VHMS_LED DISPLAYS [n362]) NO1,2,3 (FRONT) EXHAUST TEMPERATURE IS HIGH (2):(NR) 991
[F@BYNS] (OR VHMS_LED DISPLAYS [n361]) NO1,2,3 (FRONT) EXHAUST TEMPERATURE IS HIGH (1):(NS) 992
[F@BZNR] (OR VHMS_LED DISPLAYS [n372]) NO4,5,6 (REAR) EXHAUST TEMPERATURE IS HIGH (2):(NR) 993
[F@BZNS] (OR VHMS_LED DISPLAYS [n371]) NO4,5,6 (REAR) EXHAUST TEMPERATURE IS HIGH (1):(NS) 994
VHMS-1 ABNORMALITY IN SATELLITE DATA COMMUNICATION 995
a) SATELLITE COMMUNICATION DATA ARE NOT TRANSMITTED 995
b) ABNORMALITY IN DOWNLOADING INTO PC OR SETTING OF PC 998
VHMS-2 ABNORMALITY IN SAVING DATA IN VHMS CONTROLLER (DATA ARE NOT SAVED)1000
VHMS-3 ENGINE BLOW-BY PRESSURE INDICATED BY MONITOR IS LOW (WHEN BLOW-BY PRESSURE MEASURED WITH MEASURING INSTRUMENT IS NORMAL)1002
TROUBLESHOOTING OF ASR CONTROLLER SYSTEM (ASR MODE)1003
ELECTRICAL SYSTEM DIAGRAM RELATED ASR CONTROL1004
INFORMATION IN TROUBLESHOOTING TABLE1005
TROUBLE CODE TABLE1006
[DDDAKA] ASR SYSTEM SWITCH SYSTEM:DISCONNECTION (KA)1007
[DDDAKB] ASR SYSTEM SWITCH SYSTEM:SHORT CIRCUIT (KB)1008
[DK30KX] STEERING ANGLE SENSOR:OUT OF INPUT SIGNAL RANGE (KX)1009
[DLF8KA] WHEEL SPEED SENSOR (RR):DISCONNECTION (KA)1011
[DLF8LC] WHEEL SPEED SENSOR (RR):※ SEE SEPARATE LIST (LC)1012
[DLF9KA] WHEEL SPEED SENSOR (RL):DISCONNECTION (KA)1013
[DLF9LC] WHEEL SPEED SENSOR (RL):※ SEE SEPARATE LIST (LC)1014
[dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:※ SEE SEPARATE LIST (LC)1015
[DWNBK4] SHUT-OFF SOLENOID VALVE:UNCONTROLLABLE (K4)1017
[DWNBKA] SHUT-OFF SOLENOID VALVE:DISCONNECTION (KA)1019
[DWNBKB] SHUT-OFF SOLENOID VALVE:SHORT CIRCUIT (KB)1020
[DWNBKY] SHUT-OFF SOLENOID VALVE:SHORT CIRCUIT WITH POWER SOURCE (KY)1021
[DWNBMA] SHUT-OFF SOLENOID VALVE:MALFUNCTION (MA)1022
[DX17K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):UNCONTROLLABLE (K4)1023
[DX17KA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):DISCONNECTION (KA)1025
[DX17KB] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):SHORT CIRCUIT (KB)1026
[DX17KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):SHORT CIRCUIT WITH POWER SOURCE (KY)1027
[DX17MA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):MALFUNCTION (MA)1028
[DX18K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):UNCONTROLLABLE (K4)1029
[DX18KA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):DISCONNECTION (KA)1031
[DX18KB] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):SHORT CIRCUIT (KB)1032
[DX18KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):SHORT CIRCUIT WITH POWER SOURCE (KY)1033
[DX18MA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):MALFUNCTION (MA)1034
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)1035
H-1 MACHINE DOES NOT START1036
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY(MACHINE JERKS)1038
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED(ENGINE STALLS)1038
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING1039
H-5 TRANSMISSION DOES NOT SHIFT UP 1039
a DOES NOT SHIFT UP1039
b DOES NOT SHIFT UP1039
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING1040
a ABNORMALITY AT ALL SPEED RANGES1040
b TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE1041
c ABNORMALITY AT SPECIFIC SPEED RANGES1042
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR1044
H-8 TORQUE CONVERTAR OIL TEMPERATURE IS HIGH1046
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW1047
H-10 FRONT BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE1048
H-11 REAR BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE1049
H-12 STEERING WHEEL IS HEAVY1050
H-13 STEERING WHEEL DOES NOT WORK1051
H-14 STEERING WHEEL VIBRATES1051
H-15 HOIST CYLINDER LACKS LIFTING FORCE(LIFTING SPEED)1052
H-16 HOIST CYLINDER DOES NOT WORK1053
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY1054
TROUBLESHOOTING OF ENGINE SYSTEM (S MODDE)1055
POINTS TO REMEMBER WHEN TROUBLESHOOTING1056
METHOD OF USING TROUBLESHOOTING CHARTS1057
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)1060
S-2 ENGINE DOES NOT START1063
a) ENGINE DOES NOT TURN1063
b) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED)1064
c) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED)1066
S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)1068
S-4 ENGINE STOPS DURING OPERATIONS1070
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)1072
S-6 ENGINE LACKS OUTPUT(OR LACKS POWER)1074
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)1076
S-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE)1079
S-9 OIL BECOMES CONTAMINATED QUICKLY1080
S-10 FUEL CONSUMPTION IS EXCESSIVE1081
S-11 OIL IS COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN1082
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)1083
S-13 OIL LEVEL RISES1084
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)1085
S-15 ABNORMAL NOISE IS MADE1086
S-16 VIBRATION IS EXCESSIVE1087
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1089
ELECTRICAL SYSTEM DIAGRAM RELATED TO EMERGENCY STEERING CONTROL1090
INFORMATION IN TROUBLESHOOTING TABLE1091
E-1 EMERGENCY STEERING SYSTEM DOES NOT OPERATE1093
TROUBLESHOOTING OF ABS CONTROLLER SYSTEM (ABS MODE) (IF EQUIPPED)1097
ELECTRICAL SYSTEM DIAGRAM RELATED ABS CONTROL1098
INFORMATION IN TROUBLESHOOTING TABLE1100
[D1E5KZ] ABS CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ)1102
[DBC0KK] ABS CONTROLLER: SUPPLY VOLTAGE REDUCTION (KK)1104
[DBC1KK] ABS CONTROLLER MAIN POWER LINE: SUPPLY VOLTAGE REDUCTION (KK)1105
[DBC2KK] ABS CONTROLLER LOAD POWER LINE: SUPPLY VOLTAGE REDUCTION (KK)1106
[DBC3KK] ABS CONTROLLER BATTERY DIRECT POWER SUPPLY: SUPPLY VOLTAGE REDUCTION (KK)1108
[DBC9KM] ABS CONTROLLER WIRE WIRING HARNESS: SETTING OPERATION ERROR (KM)1109
[DBCSKR] ABS CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR)1110
[DDD9KA] ABS SYSTEM SWITCH: DISCONNECTION (KA)1113
[DDD9KB] ABS SYSTEM SWITCH: SHORT CIRCUIT (KB)1114
[DHU6KX] ABS CONTROL VALVE PRESSURE SENSOR FRONT WHEEL RIGHT (FR): OUTSIDE INPUT SIGNAL RANGE (KX)1116
[DHU7KX] ABS CONTROL VALVE PRESSURE SENSOR FRONT WHEEL LEFT (FL): OUTSIDE INPUT SIGNAL RANGE (KX)1118
[DHU8KX] ABS CONTROL VALVE PRESSURE SENSOR REAR WHEEL RIGHT (RR): OUTSIDE INPUT SIGNAL RANGE (KX)1120
[DHU9KX] ABS CONTROL VALVE PRESSURE SENSOR REAR WHEEL LEFT (RL): OUTSIDE INPUT SIGNAL RANGE (KX)1122
[DK11KX] ACCELERATOR SENSOR: OUTSIDE INPUT SIGNAL RANGE (KX)1124
[DLF6KA] WHEEL SPEED SENSOR FRONT WHEEL RIGHT (FR): DISCONNECTION (KA)1126
[DLF7KA] WHEEL SPEED SENSOR FRONT WHEEL LEFT (FL): DISCONNECTION (KA)1128
[DLF8KA] WHEEL SPEED SENSOR REAR WHEEL RIGHT (RR): DISCONNECTION (KA)1130
[DLF9KA] WHEEL SPEED SENSOR REAR WHEEL LEFT (RL): DISCONNECTION (KA)1132
[DWNDKZ] ABS CUT VALVE (F): DISCONNECTION OR SHORT CIRCUIT (KZ)1134
[DWNDMA] ABS CUT VALVE (F): MALFUNCTION (MA)1136
[DWNEKZ] ABS CUT VALVE (R): DISCONNECTION OR SHORT CIRCUIT (KZ)1138
[DWNEMA] ABS CUT VALVE (R): MALFUNCTION (MA)1140
[DX21KA] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): DISCONNECTION (KA)1141
[DX21KB] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): SHORT CIRCUIT (KB)1142
[DX21KY] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): SHORT-CIRCUITED TO POWER SUPPLY (KY)1143
[DX21MA] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): MALFUNCTION (MA)1144
[DX22KA] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): DISCONNECTION (KA)1145
[DX22KB] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): SHORT CIRCUIT (KB)1146
[DX22KY] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): SHORT-CIRCUITED TO POWER SUPPLY (KY)1147
[DX22MA] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): MALFUNCTION (MA)1148
[DX23KA] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): DISCONNECTION (KA)1149
[DX23KB] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): SHORT CIRCUIT (KB)1150
[DX23KY] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): SHORT-CIRCUITED TO POWER SUPPLY (KY)1151
[DX23MA] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): MALFUNCTION (MA)1152
[DX24KA] ABS CONTROL VALVE REAR WHEEL LEFT (RL): DISCONNECTION (KA)1153
[DX24KB] ABS CONTROL VALVE REAR WHEEL LEFT (RL): SHORT CIRCUIT (KB)1154
[DX24KY] ABS CONTROL VALVE REAR WHEEL LEFT (RL): SHORT-CIRCUITED WITH POWER SUPPLY (KY)1155
[DX24MA] ABS CONTROL VALVE REAR WHEEL LEFT (RL): MALFUNCTION (MA)1156
[DX25MA] ABS CONTROL VALVE (FRONT WHEEL SYSTEM): MALFUNCTION (MA)1157
[DX26MA] ABS CONTROL VALVE (REAR WHEEL SYSTEM): MALFUNCTION (MA)1158
30 DISASSEMBLY AND ASSEMBLY1159
METHOD OF USING MANUAL1161
PRECAUTIONS WHEN CARRYING OUT OPERATION1162
COATING MATERIALS LIST1164
SPECIAL TOOL LIST1167
SKETCH OF SPECIAL TOOL1171
FUEL INJECTION PUMP1174
REMOVAL AND INSTALLATION1174
RADIATOR1175
REMOVAL AND INSTALLATION1175
ENGINE AND TORQUE CONVERTER AND TRANSMISSION OIL COOLER1177
REMOVAL AND INSTALLATION1177
ENGINE FRONT SEAL1178
REMOVAL AND INSTALLATION1178
OUTPUT SHAFT1179
REMOVAL AND INSTALLATION1179
DISASSEMBLY1180
ASSEMBLY1181
ENGINE REAR SEAL1183
REMOVAL AND INSTALLATION1183
CYLINDER HEAD1185
REMOVAL1185
INSTALLATION1187
ENGINE1190
REMOVAL1190
INSTALLATION1191
TORQUE CONVERTER AND TRANSMISSION1193
REMOVAL1193
INSTALLATION1194
TRANSMISSION ASSEMBLY AND TORQUE CONVERTER1196
SEPARATION AND COUPLING1196
TORQUE CONVERTER1197
DISASSEMBLY1197
ASSEMBLY1201
TRANSMISSION1207
DISASSEMBLY1207
ASSEMBLY1220
DIFFERENTIAL1235
REMOVAL1235
INSTALLATION1236
DISASSEMBLY1237
ASSEMBLY1241
FRONT WHEEL 1249
REMOVAL AND INSTALLATION1249
REAR WHEEL1250
REMOVAL1250
INSTALLATION1251
FRONT BRAKE CALIPER PADS1252
REMOVAL AND INSTALLATION1252
FRONT BRAKE CALIPERS1253
REMOVAL AND INSTALLATION1253
DISASSEMBLY AND ASSEMBLY1254
FRONT WHEEL HUB1256
DISASSEMBLY1256
ASSEMBLY1257
FINAL DRIVE CARRIER1261
REMOVAL AND INSTALLATION1261
DISASSEMBLY AND ASSEMBLY1262
FINAL DRIVE AND REAR BRAKE1263
REMOVAL1263
INSTALLATION1265
FINAL DRIVE,REAR BRAKE,AND PARKING BRAKE1267
REMOVAL AND INSTALLATION1267
DISASSEMBLY1268
ASSEMBLY1273
FRONT SUSPENSION CYLINDER1279
REMOVAL1279
INSTALLATION1280
DISASSEMBLY1281
ASSEMBLY1282
REAR SUSPENSION CYLINDER1288
REMOVAL AND INSTALLATION1288
DISASSEMBLY1289
ASSEMBLY1290
RETARDER COOLING PUMP1296
REMOVAL AND INSTALLATION1296
STEERING,HOIST,AND HOIST CONTROL PUMP1297
REMOVAL AND INSTALLATION1297
TORQUE CONVERTER,TRANSMISSION AND RETARDER COOLING,AND BRAKE PUMP1298
REMOVAL AND INSTALLATION1298
STEERING VALVE1299
REMOVAL AND INSTALLATION1299
DISASSEMBLY1300
ASSEMBLY1303
DEMAND VALVE1310
REMOVAL AND INSTALLATION1310
HOIST VALVE1311
REMOVAL AND INSTALLATION1311
STEERING CYLINDER1312
DISASSEMBLY1312
ASSEMBLY1313
HOIST CYLINDER1315
DISASSEMBLY1315
ASSEMBLY1316
DUMP BODY1319
REMOVAL1319
INSTALLATION1320
OPERATOR’S SEAT1322
DISASSEMBLY1322
ASSEMBLY1327
90 OTHERS1401
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM1404
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM1405
BRAKE HYDRAULIC CIRCUIT DIAGRAM1407
ELECTRICAL CIRCUIT DIAGRAM (1/6) HD465-7 SERIAL NO 7001 － 7169, HD605-7 SERIAL NO 7001 － 70741409
ELECTRICAL CIRCUIT DIAGRAM (1/6) HD465-7 SERIAL NO 7170 － , HD605-7 SERIAL NO 7075 － 1411
ELECTRICAL CIRCUIT DIAGRAM (2/6) HD465-7 SERIAL NO 7001 － 7169, HD605-7 SERIAL NO 7001 － 70741413
ELECTRICAL CIRCUIT DIAGRAM (2/6) HD465-7 SERIAL NO 7170 － , HD605-7 SERIAL NO 7075 － 1415
ELECTRICAL CIRCUIT DIAGRAM (3/6) HD465-7 SERIAL NO 7001 － 7169, HD605-7 SERIAL NO 7001 － 70741417
ELECTRICAL CIRCUIT DIAGRAM (3/6) HD465-7 SERIAL NO 7170 － , HD605-7 SERIAL NO 7075 － 1419
ELECTRICAL CIRCUIT DIAGRAM (4/6) HD465-7 SERIAL NO 7001 － 7169, HD605-7 SERIAL NO 7001 － 70741421
ELECTRICAL CIRCUIT DIAGRAM (4/6) HD465-7 SERIAL NO 7170 － , HD605-7 SERIAL NO 7075 － 1423
ELECTRICAL CIRCUIT DIAGRAM (5/6) HD465-7 SERIAL NO 7001 － 7693, HD605-7 SERIAL NO 7001 － 72561425
ELECTRICAL CIRCUIT DIAGRAM (5/6) HD465-7 SERIAL NO 7694 － 77141427
ELECTRICAL CIRCUIT DIAGRAM (5/6) HD465-7 SERIAL NO 7715 － , HD605-7 SERIAL NO 7257 －1429
ELECTRICAL CIRCUIT DIAGRAM (6/6) HD465-7 SERIAL NO 7001 － 7693, HD605-7 SERIAL NO 7001 － 72561431
ELECTRICAL CIRCUIT DIAGRAM (6/6) HD465-7 SERIAL NO 7694 － 77141433
ELECTRICAL CIRCUIT DIAGRAM (6/6) HD465-7 SERIAL NO 7715 － , HD605-7 SERIAL NO 7257 －1435
ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL1437
ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR1439
ELECTRICAL CIRCUIT DIAGRMAM (A1 SIZE) (1/2)1441
ELECTRICAL CIRCUIT DIAGRMAM (A1 SIZE) (2/2)1443
ELECTRICAL SYSTEM DIAGRAM RELATED TO ABS CONTROLLER1445
ELECTRICAL CIRCUIT DIAGRAM RELATED TO ABS1447
ELECTRICAL CIRCUIT DIAGRAM FOR AUTO GREASING SYSTEM1449
EXTERNAL POWER SUPPLY HEATER1450
CONNECTORS TABLE (A1 SIZE)1451
ARRANGEMENT DRAWING (A1 SIZE)1453