Komatsu HD465-7E0 Dump Truck Shop Manual SEN06732-00 PDF

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Komatsu HD465-7E0 Dump Truck Shop Manual SEN06732-00  – PDF DOWNLOAD

FILE DETAILS:

Komatsu HD465-7E0 Dump Truck Shop Manual SEN06732-00  – PDF DOWNLOAD

Language : English
Pages : 1684
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HD465-7E0 Dump Truck Shop Manual SEN06732-00  – PDF DOWNLOAD

• SERIAL NUMBERS     11497 and up

Cover . 1
00 Index and foreword . 3
Table of contents . 4
Foreword and general information 17
Safety notice . 17
How to read the shop manual . 22
Explanation of terms for maintenance standard . 24
Handling of electric equipment and hydraulic component 26
Handling of connectors newly used for engines . 35
How to read electric wire code 38
Precautions when carrying out operation . 41
Method of disassembling and connecting push-pull type coupler . 44
Standard tightening torque table 47
Conversion table 51
01 Specification 57
Contents 58
Specification and technical data 59
Specification drawing . 59
Specifications 60
Weight table 63
Fuel, coolant and lubricants 64
10 Structure, function and maintenance standard . 67
Cotents . 68
Engine and cooling system . 70
Radiator, torque converter oil cooler, after cooler, work equipment oil cooler, fuel cooler . 70
Fuel system . 72
Brake oil cooler 73
Output shaft 74
Power train . 76
Power train skeleton 76
Drive shaft . 78
Torque converter and transmission hydraulic piping 80
Brake cooling oil control valve (BCV) . 82
Torque converter 84
Torque converter valve 91
Transmission 93
Transmission control valve 109
ECMV 110
Axle 118
Differential 120
Final drive . 121
Wheels 122
Steering system . 124
Steering column . 124
Steering linkage 125
Brake system 128
Brake piping 128
Brake valve . 130
Secondary brake valve . 133
Relay valve . 134
Front brake off valve . 135
Accumulator charge valve 136
Accumulator . 140
Slack adjuster 141
Brake . 143
Parking brake solenoid valve 147
Undercarriage and frame . 148
Suspension 148
Suspension cylinder . 150
Rear axle support . 156
Hydraulic system 158
Steering and hoist hydraulic piping . 158
Dump body control . 160
Hydraulic tank 161
Steering valve 162
Crossover relief valve 166
Steering cylinder . 167
Steering control valve 168
Hoist valve . 174
Dump control valve (EPC valve) 180
Hoist cylinder 182
Hydraulic pump 183
Work equipment (Body) . 188
Auto greasing system 188
Cab and its attachments . 210
ROPS cab 210
Rear view monitor . 211
Electrical system . 216
Machine monitor system 216
Automatic shift control system 274
Transmission controller . 278
External power supply heater 292
Automatic emergency steering system . 293
Automatic suspension system . 296
Retarder control system . 299
Battery disconnector switch . 310
Dump control lever 314
Payload meter (Card type) . 318
VHMS controller related . 348
ASR system (If equipped) 372
Sensors, switches . 378
20 Standard value table . 397
Contents 398
Standard service value table 399
Standard value table for engine . 399
Standard value table for machine 401
30 Testing and adjusting 411
Contens . 412
Related information on testing and adjusting 414
Tools for testing, adjusting, and troubleshooting . 414
Sketch of special tool 420
Engine and cooling system . 421
Testing engine speed 421
Testing air supply pressure (boost pressure) 422
Testing exhaust temperature . 423
Testing exhaust gas color . 425
Adjustment of valve clearance . 427
Testing of compression pressure . 429
Testing blowby pressure . 432
Testing engine oil pressure . 433
Testing EGR valve and bypass valve drive oil pressure . 434
Handling of fuel system devices . 436
Releasing residual pressure from fuel system 436
Testing of fuel pressure 437
Reduced cylinder mode operation . 438
No-injection cranking . 438
Testing of fuel return rate and fuel leakage 439
Bleeding air from fuel circuit 441
Testing the fuel circuit for leakage 442
Replacement and adjustment of fan belt 443
Replacement and adjustment of alternator and air conditioner compressor belt 444
Power train . 445
Testing torque converter stall speed 445
Testing power train oil pressure 446
Adjusting transmission speed sensor . 453
Brake system 454
Testing and adjusting brake oil pressure 454
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas . 457
Testing brake performance . 465
Releasing remaining pressure in brake circuit . 466
Bleeding air from brake circuit . 467
Testing wear of front brake pad . 468
Testing wear of rear brake disc . 469
Method of releasing parking brake in an emergency . 470
Undercarriage and frame . 471
Testing and adjusting front suspension cylinder . 471
Testing and adjusting rear suspension cylinder 475
Testing and adjusting front suspension cylinder (Automatic suspension specification) 479
Hydraulic system 480
Testing and adjusting hydraulic pressure in steering, hoist circuit . 480
Testing and adjusting oil pressure in dump EPC circuit 483
Air bleeding from steering cylinder . 484
Procedure for raising dump body in emergency 485
Procedure for lowering dump body in emergency . 486
Adjusting body positioner sensor 487
Resetting method for dump body seating control 488
Adjustment of tilt lock lever of steering wheel . 489
Handling of voltage circuit of engine controller 490
Adjusting transmission controller . 490
Method for emergency escape at electrical system failure 491
Electrical system . 495
Setting and adjusting of devices 495
Special functions of machine monitor (EMMS) . 508
Request for opening ORBCOMM terminal 570
VHMS controller initial setting procedure . 572
Using method of KOMTRAX functions of ORBCOMM terminal . 592
Precautions for replacing VHMS controller . 595
Pm Clinic check sheet . 601
Initial setting of payload meter 605
Setting of payload meter built in VHMS 606
Setting of card-type payload meter (PLM-) after installation or replacement . 614
40 Troubleshooting 621
Contents 622
General information on troubleshooting 630
Points to remember when performing troubleshooting 630
How to proceed in troubleshooting . 632
Check before troubleshooting 634
Classification and procedures of troubleshooting 635
Information in troubleshooting table 639
Troubleshooting method for disconnecting wiring harness of pressure sensor system . 641
Connection table for connector pin numbers 644
T-branch box and T-branch adapter table . 680
Failure codes table . 683
Fuse locations 694
Troubleshooting by failure code . 699
Failure code [1500L0] (Dual engagement) . 699
Failure code [15B0NX] (Transmission oil filter: Clogging) . 700
Failure code [15F0KM] (R → F shifting abuse 1: Mistake in operation) 702
Failure code [15F0MB] (R o F shifting abuse 2: Mistake in operation) 702
Failure code [15F7KM] (Forward clutch disk abuse: Mistake in operation or setting) 703
Failure code [15G0MW] (R clutch: Slipping) 704
Failure code [15G7KM] (Reverse clutch disk abuse: Mistake in operation or setting) 706
Failure code [15H0MW] (Hi clutch: Slipping) . 708
Failure code [15J0MW] (Lo clutch: Slipping) . 710
Failure code [15K0MW] (1st clutch: Slipping) 712
Failure code [15L0MW] (2nd clutch: Slipping) 714
Failure code [15M0MW] (3rd clutch: Slipping) 716
Failure code [15N0MW] (4th clutch: Slipping) 718
Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF) 720
Failure code [15SBMA] (R clutch solenoid: Malfunction) 722
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF) . 723
Failure code [15SCMA] (Hi clutch solenoid: Malfunction) . 726
Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF) . 727
Failure code [15SDMA] (Lo clutch solenoid: Malfunction) . 730
Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF) 731
Failure code [15SEMA] (1st clutch solenoid: Malfunction) 734
Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF 736
Failure code [15SFMA] 2nd clutch solenoid: Malfunction 739
Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF 740
Failure code [15SGMA] 3rd clutch solenoid: Malfunction 743
Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF 744
Failure code [15SHMA] 4th clutch solenoid: Malfunction 747
Failure code [15SJMA] Lockup clutch solenoid: Malfunction . 748
Failure code [2C4MNX] Retarder cooling oil filter: Clogging . 750
Failure code [2F00KM] Parking brake: Mistake in operation or setting 752
Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front) . 755
Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear) 755
Failure code [6014NX] Hydraulic oil filter: Clogging 756
Failure code [989A00] Engine over run prevention command signal: Operating 758
Failure code [989D00] Rear section tipping over alarm: Alarm is activated . 758
Failure code [A570NX] Engine oil filter: Clogging . 759
Failure code [AA10NX] Air cleaner element: Clogging . 760
Failure code [AB00MA] Alternator: Malfunction . 762
Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure 764
Failure code [B@BAZK] Engine oil: Level too low . 765
Failure code [B@BCNS] Engine: Overheat 766
Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level . 768
Failure code [B@BFZK] Lowering of fuel level 770
Failure code [B@C7NS] Brake cooling oil: Overheating (Rear) . 772
Failure code [B@CENS] Overheating of torque converter oil . 774
Failure code [B@GAZK] Battery electrolyte level: Lowering of level 775
Failure code [B@JANS] Steering oil temperature: Overheat 776
Failure code [CA111] Abnormality in engine controller . 778
Failure code [CA115] Engine Ne or Bkup speed sensor error . 780
Failure code [CA122] Charge (boost) pressure sensor high error 782
Failure code [CA123] Charge (boost) pressure sensor low error . 784
Failure code [CA131] Throttle sensor high error . 786
Failure code [CA132] Throttle sensor low error 789
Failure code [CA135] Engine oil pressure sensor high error 792
Failure code [CA141] Engine oil pressure sensor low error . 794
Failure code [CA144] Coolant temperature sensor high error 796
Failure code [CA145] Coolant temperature sensor low error . 798
Failure code [CA153] Charge (boost) temperature sensor high error . 800
Failure code [CA154] Charge (boost) temperature sensor low error 802
Failure code [CA187] Sensor power supply 2 low error 804
Failure code [CA212] Engine oil temperature sensor high error . 806
Failure code [CA213] Engine oil temperature sensor low error 808
Failure code [CA221] Atmospheric pressure sensor high error . 810
Failure code [CA222] Atmospheric pressure sensor low error 812
Failure code [CA227] Sensor power supply 2 high error . 814
Failure code [CA234] Engine overspeed . 815
Failure code [CA238] Ne speed sensor power supply error . 816
Failure code [CA263] Fuel Temp Sensor High Error 818
Failure code [CA265] Fuel Temp Sensor Low Error . 820
Failure code [CA271] PCV1 Short circuit . 822
Failure code [CA272] PCV1 Disconnection . 823
Failure code [CA273] PCV2 Short circuit . 824
Failure code [CA274] PCV2 Disconnection . 825
Failure code [CA322] Injector #1 open/short error . 826
Failure code [CA323] Injector #5 open/short error . 828
Failure code [CA324] Injector #3 open/short error . 830
Failure code [CA325] Injector #6 open/short error . 832
Failure code [CA331] Injector #2 open/short error . 834
Failure code [CA332] Injector #4 open/short error . 836
Failure code [CA342] Calibration code inconsistency . 838
Failure code [CA351] Injectors drive circuit error 839
Failure code [CA352] Sens Supply 1 Volt Low Error . 840
Failure code [CA386] Sensor power supply 1 high error . 842
Failure code [CA431] Idle validation switch error . 843
Failure code [CA432] Idle validation action error . 846
Failure code [CA441] Battery voltage low error 849
Failure code [CA442] Battery voltage high error . 850
Failure code [CA449] Common rail pressure high error 2 851
Failure code [CA451] Rail Press Sensor High Error . 852
Failure code [CA452] Rail Press Sensor Low Error 854
Failure code [CA553] Common rail pressure high error 1 856
Failure code [CA554] Common rail pressure sensor in range error . 857
Failure code [CA559] Supply pump pressure very low error 1 858
Failure code [CA689] Engine Ne speed sensor error . 862
Failure code [CA731] Engine Bkup speed sensor phase error . 864
Failure code [CA757] All continuous data lost error . 865
Failure code [CA778] Engine Bkup speed sensor error . 866
Failure code [CA1228] EGR valve servo error 1 . 868
Failure code [CA1625] EGR valve servo error 2 . 869
Failure code [CA1626] (Bypass valve solenoid current high error) 870
Failure code [CA1627] (Bypass valve solenoid current low error) . 872
Failure code [CA1628] Bypass Valve Servo Error 1 874
Failure code [CA1629] Bypass Valve Servo Error 2 875
Failure code [CA1631] (Bypass valve lift sensor high error) . 876
Failure code [CA1632] (Bypass valve lift sensor low error) 878
Failure code [CA1633] KOMNET datalink timeout error . 880
Failure code [CA2185] Throttle sensor supply voltage high error . 882
Failure code [CA2186] Throttle sensor power supply low error 884
Failure code [CA2249] Supply pump pressure very low error 2 . 886
Failure code [CA2271] EGR valve lift sensor high error 888
Failure code [CA2272] EGR valve lift sensor low error . 890
Failure code [CA2351] EGR valve solenoid operation short circuit 892
Failure code [CA2352] EGR valve solenoid operation disconnect . 894
Failure code [CA2555] Intake air heater relay open circuit error 896
Failure code [CA2556] Intake air heater relay short circuit error . 898
Failure code [D19HKB] Stop lamp relay output system: Short circuit 900
Failure code [D5ZKKZ] Front brake cut-off solenoid valve: Disconnection, short circuit or short circuit to power supply line 902
Failure code [DAF9KM] Wrong connection of connector . 904
Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication 905
Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of power supply voltage . 906
Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller . 908
Failure code [DAQ2KK] Transmission controller solenoid power supply: Power supply voltage too low . 910
Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection 912
Failure code [DAQRKR] Abnormality in CAN communication (Transmission) . 913
Failure code [DAQRMA] Transmission controller option setting: Malfunction . 918
Failure code [DAQV00] Neutral coast caution . 918
Failure code [DAQW00] Neutral over speed caution 919
Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller . 919
Failure code [DB12KK] Retarder controller solenoid power supply: Power supply system trouble 920
Failure code [DB13KK] Retarder controller battery direct power supply: Power supply voltage too low . 922
Failure code [DB19KQ] Disagreement of model selection (Retarder controller) . 924
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled . 925
Failure code [DB1RMA] Disagreement of option setting (Retarder controller) 929
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled . 930
Failure code [DBB0KK] or VHMS_LED display: “n9” → “01” 936
Failure code [DBB0KQ] or VHMS_LED display: “nF” → “11” 938
Failure code [DBB3KK] or VHMS_LED display: “n9” → “05” 940
Failure code [DBB5KP] or VHMS_LED display: “n9” → “04” 942
Failure code [DBB6KP] or VHMS_LED display: “n9” → “02” 944
Failure code [DBB7KP] or VHMS_LED display: “n9” → “03” 946
Failure code [DBBQKR] or VHMS_LED display: “n8” → “02” 947
Failure code [DBBRKR] Abnormality in CAN communication (VHMS) . 947
Failure code [DBC2KK] ABS controller solenoid power supply: Power supply system trouble . 948
Failure code [DBC3KK] ABS controller battery direct power supply: Power supply voltage too low 950
Failure code [DBC9KQ] Disagreement of model selection (ABS controller) 952
Failure code [DBCRKR] Abnormality in CAN communication (ABS) 953
Failure code [DBCRMA] Disagreement of option setting (ABS controller) . 957
Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range 958
Failure code [DDD8KA] ARSC system switch system: Disconnection (If equipped) 960
Failure code [DDD8KB] ARSC system switch system: Short circuit (If equipped) 962
Failure code [DDD9KA] ABS system switch system: Disconnection . 964
Failure code [DDD9KB] ABS system switch system: Short circuit . 966
Failure code [DDDAKA] ASR system switch: Disconnection 968
Failure code [DDDAKB] ASR system switch: Short circuit 970
Failure code [DDP6L4] Service brake pressure switch trouble (Rear) 972
Failure code [DDTHKA] Hi clutch fill switch: Disconnection 974
Failure code [DDTJKA] Lo clutch fill switch: Disconnection 976
Failure code [DDTKKA] 1st clutch fill switch: Disconnection . 978
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection . 980
Failure code [DDTMKA] (3rd clutch fill switch: Disconnection) . 982
Failure code [DDTNKA] R clutch fill switch: Disconnection . 984
Failure code [DDTPKA] 4th clutch fill switch: Disconnection . 986
Failure code [DF10KA] Gear shift lever: Disconnection . 988
Failure code [DF10KB] Gear shift lever: Short circuit . 991
Failure code [DGE5KX] or VHMS_LED display: “n4” → “01” 996
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range 998
Failure code [DGR2KZ] Retarder oil temperature sensor system trouble : Ground fault (Rear wheel) 1000
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range 1002
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range 1004
Failure code [DGT4KA] or VHMS_LED display: “n3” → “12” Exhaust gas temperature sensor (F): Disconnection 1007
Failure code [DGT4KB] or VHMS_LED display: “n3” → “11” Exhaust gas temperature sensor (F): Short circuit 1010
Failure code [DGT5KA] or VHMS_LED display: “n3” → “22” Exhaust gas temperature sensor (R): Disconnection 1013
Failure code [DGT5KB] or VHMS_LED display: “n3” → “21” Exhaust gas temperature sensor (R): Short circuit 1016
Failure code [DHE5KB] or VHMS_LED display: “n3” → “32” Blow-by pressure sensor: Short circuit .1019
Failure code [DHE5KY] or VHMS_LED display: “n3” → “31” Blow-by pressure sensor: Short circuit with power supply line 1022
Failure code [DHP4KY] or VHMS_LED display: “n5” → “44” Short circuit in suspension pressure sensor system (Front right) .1024
Failure code [DHP4KZ] or VHMS_LED display: “n5” → “43” Disconnection or ground fault in suspension pressure sensor system(Front right) 1026
Failure code [DHP5KY] or VHMS_LED display: “n5” → “54” Short circuit in suspension pressure sensor system (Front left) 1028
Failure code [DHP5KZ] or VHMS_LED display: “n5” → “53” Disconnection or ground fault in suspension pressure sensor system(Front left) .1030
Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear) .1032
Failure code [DHP6KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Right rear) 1034
Failure code [DHP6KY] or VHMS_LED display: “n5” → “64” Suspension pressure sensor system: Short circuit (Right rear) 1036
Failure code [DHP6KZ] or VHMS_LED display: “n5” → “63” Suspension pressure sensor system: Disconnection or ground fault (Right rear) 1038
Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear) 1040
Failure code [DHP7KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Left rear) .1042
Failure code [DHP7KY] or VHMS_LED display: “n5” → “74” Suspension pressure sensor system: Short circuit (Left rear) .1044
Failure code [DHP7KZ] or VHMS_LED display: “n5” → “73” Suspension pressure sensor system: Disconnection or ground fault (Left rear) .1046
Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range .1048
Failure code [DHT5L6] Torque converter oil pressure sensor: Disagreement of run and stop condition with signal 1050
Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range 1052
Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range .1054
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right) 1056
Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left) .1058
Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Front right) 1060
Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Front right) 1062
Failure code [DHUTKX] Trouble in ABS cut valve pressure sensor 1064
Failure code [DJF1KA] Fuel level sensor: Disconnection 1066
Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection) .1068
Failure code [DK51L5] Retarder lever potentiometer: Potentiometer signal is inconsistent with swich signal 1069
Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range .1072
Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal .1074
Failure code [DK54KX] Body positioner sensor: Out of input signal range .1076
Failure code [DKD0L6] Failure in steering speed sensor 1078
Failure code [DKH0KX] Clinometer sensor signal out of range .1080
Failure code [DKH1KX] or VHMS_LED display: “n4″→”33” Abnormality in clinometer sensor .1082
Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection 1084
Failure code [DLF1LC] Transmission input shaft speed sensor: Disagreement of revolution speed signal 1086
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection .1088
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal .1090
Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right) .1092
Failure code [DLF6L3] Trouble in wheel speed sensor (Front right) .1093
Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left) 1094
Failure code [DLF7L3] Trouble in wheel speed sensor (Front left) 1095
Failure code [DLF8KA] Disconnection in wheel speed sensor (Right rear) 1096
Failure code [DLF8L3] Trouble in wheel speed sensor (Right rear) 1098
Failure code [DLF8LC] Trouble in wheel speed sensor system (Right rear) .1100
Failure code [DLF8MA] Disconnection in wheel speed sensor (Right rear) 1101
Failure code [DLF9KA] Disconnection in wheel speed sensor (Left rear) .1102
Failure code [DLF9L3] Trouble in wheel speed sensor (Left rear) .1104
Failure code [DLF9LC] Trouble in wheel speed sensor system (Left rear) 1106
Failure code [DLF9MA] Disconnection in wheel speed sensor (Left rear) .1107
Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system 1108
Failure code [DLT3LC] Trouble in transmission output shaft speed sensor .1110
Failure code [DLT4KA] Disconnection in transmission output shaft speed sensor .1112
Failure code [DLT4MA] Disconnection in transmission output shaft speed sensor .1114
Failure code [DV00KB] Short circuit in buzzer output 1116
Failure code [DW2AKA] Disconnection in main pressure variable valve output 1118
Failure code [DW2AKB] Ground fault in main pressure variable valve output circuit .1120
Failure code [DW2AKY] Hot short in main pressure variable valve output circuit 1122
Failure code [DW2AL1] Defective reset of main pressure variable valve .1124
Failure code [DW2ALH] Malfunction of main pressure variable valve .1126
Failure code [DW35KZ] Trouble in output system of auto suspension solenoid 1 (Disconnection or short circuit) .1128
Failure code [DW36KZ] Trouble in output system of auto suspension solenoid 2 (Disconnection or short circuit) .1130
Failure code [DW72KZ] Trouble in kick-out solenoid output system (Disconnection or short circuit) .1132
Failure code [DW73KZ] Trouble in hoist select valve output system (Disconnection or short circuit) 1134
Failure code [DW78KZ] Trouble in brake cooling valve (BCV) (rear wheel) output system (Disconnection or short circuit) 1136
Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps operating) .1138
Failure code [DWNBKA] Disconnection in ASR shut-off valve output circuit 1140
Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit .1142
Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit 1144
Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate) 1145
Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system .1146
Failure code [DWNDMA] Defective ABS cut-off valve (Front) .1148
Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system 1150
Failure code [DWNEMA] Defective ABS cut-off valve (Rear) 1152
Failure code [DX11K4] Trouble in rear brake proportional pressure reducing solenoid valve (Valve keeps operating) .1154
Failure code [DX11KA] Disconnection in rear brake proportional pressure reducing solenoid valve output circuit 1156
Failure code [DX11KB] Short circuit in rear brake proportional pressure reducing solenoid valve .1157
Failure code [DX11KY] Short circuit in rear wheel proportional pressure reducing solenoid valve output circuit 1158
Failure code [DX11MA] Trouble in rear wheel proportional pressure reducing solenoid valve (Valve does not operate) 1159
Failure code [DX13KA] Disconnection in hoist EPC valve output circuit .1160
Failure code [DX13KB] Short circuit in hoist EPC valve output circuit .1162
Failure code [DX13KY] Short circuit in hoist EPC valve output circuit .1164
Failure code [DX17K4] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve keeps operating) 1166
Failure code [DX17KA] Disconnection in ASR proportional pressure reducing solenoid valve (right) output circuit .1168
Failure code [DX17KB] Ground fault in ASR proportional pressure reducing solenoid valve (right) output circuit 1170
Failure code [DX17KY] Short circuit in ASR proportional pressure reducing solenoid valve (right) output circuit .1172
Failure code [DX17MA] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve does not operate) .1172
Failure code [DX18K4] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve keeps operating) .1174
Failure code [DX18KA] Disconnection in ASR proportional pressure reducing solenoid valve (left) output circuit 1176
Failure code [DX18KB] Ground fault in ASR proportional pressure reducing solenoid valve (left) output circuit .1178
Failure code [DX18KY] Short circuit in ASR proportional pressure reducing solenoid valve (left) output circuit 1180
Failure code [DX18MA] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve does not operate) 1180
Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right) .1181
Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right) 1182
Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right) .1183
Failure code [DX21MA] Defective ABS control valve (Front right) .1184
Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left) 1185
Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left) .1186
Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left) 1187
Failure code [DX22MA] Defective ABS control valve (Front left) 1188
Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right) 1189
Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right) .1190
Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right) 1191
Failure code [DX23MA] Defective ABS control valve (Rear right) 1192
Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left) .1193
Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left) 1194
Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left) .1195
Failure code [DX24MA] Defective ABS control valve (Rear left) .1196
Failure code [DX25MA] Defective ABS front wheel system control valve 1197
Failure code [DX26MA] Defective ABS rear wheel system control valve .1197
Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection 1198
Failure code [DXH1KB] Lockup clutch solenoid output circuit: Short circuit 1200
Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power supply line .1202
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection 1204
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit 1206
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power supply line .1208
Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection 1212
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit 1214
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power supply line .1216
Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection .1220
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit .1222
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power supply line 1224
Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection .1228
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit .1230
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power supply line 1232
Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection .1236
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit .1238
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power supply line 1240
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection .1244
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit .1246
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power supply line 1248
Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection .1250
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit .1252
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power supply line 1254
Failure code [F@BBZL] or VHMS_LED display: “n3″→”38” Blow-by pressure: High error .1257
Failure code [F@BYNR] or VHMS_LED display: “n3″→”62” Exhaust gas temperature (F): Abnormal heat .1258
Failure code [F@BYNS] or VHMS_LED display: “n3″→”61” Exhaust gas temperature (F): Overheat 1260
Failure code [F@BZNR] or VHMS_LED display: “n3″→”72” Exhaust gas temperature (R): Abnormal heat .1262
Failure code [F@BZNS] or VHMS_LED display: “n3″→”71” Exhaust gas temperature (R): Overheat 1264
Troubleshooting of electrical system (E-mode) .1267
Before troubleshooting of electric system .1267
Contents of troubleshooting table .1268
E-1 Engine does not start .1269
E-2 Automatic preheating does not operate .1272
E-3 Machine monitor does not display all, when starting switch is turned ON .1276
E-4 Machine monitor does not operate when starting switch is OFF 1278
E-5 Alarm buzzer does not sound .1280
E-6 Alarm buzzer does not stop sounding .1282
E-7 Gauges of machine monitor, caution lamps or character display section do not display properly .1284
E-8 A selection of the display in character display section cannot be changed .1285
E-9 Power mode pilot lamp does not light up normally 1288
E-10 AISS function does not operate properly 1289
E-11 Seat belt caution lamp does not display properly .1290
E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly 1291
E-13 Night illumination (lighting) does not work properly .1294
E-14 Emergency steering does not operate 1306
E-15 Hoist lever does not operate normally 1312
E-16 Electric priming pump does not operate or does not stop automatically 1314
Troubleshooting of hydraulic and mechanical system (H-mode) .1317
Contents of troubleshooting table .1317
H-1 Machine does not start 1318
H-2 Machine does not travel smoothly (hunting) 1320
H-3 Lockup cannot be cancelled 1320
H-4 Excessive shock when starting or shifting excessive .1321
H-5 Transmission does not shift up 1322
H-6 Machine lacks power or speed when traveling .1324
H-7 Time lag is excessive when starting or shifting gear 1328
H-8 Torque converter oil temperature is high 1330
H-9 Torque converter oil pressure is low 1331
H-10 Front brake is ineffective .1332
H-11 Rear brake is ineffective 1333
H-12 Steering wheel is heavy 1334
H-13 Steering wheel does not work .1335
H-14 Steering wheel vibrates 1336
H-15 Dump body lifting speed is slow 1337
H-16 Dump body does not work 1338
H-17 Excessive hydraulic drift of dump body .1339
Troubleshooting of engine (S-mode) 1340
Method of using troubleshooting chart .1340
S-1 Starting performance of engine is poor 1344
S-2 Engine does not start .1346
S-3 Engine does not pick up smoothly 1350
S-4 Engine stops during operation .1351
S-5 Engine does not rotate smoothly .1352
S-6 Engine lack output (or lacks power) .1353
S-7 Exhaust gas is black (incomplete combustion) 1354
S-8 Oil consumption is excessive (or exhaust gas is blue) .1356
S-9 Oil becomes dirty quickly .1357
S-10 Fuel consumption is excessive 1358
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 1359
S-12 Oil pressure drops .1360
S-13 Oil level rises (Entry of coolant or fuel) .1362
S-14 Coolant temperature becomes too high (Overheating) .1364
S-15 Abnormal noise is made .1365
S-16 Vibration is excessive .1366
S-17 Air cannot be bled from fuel circuit .1368
50 Disassembly and assembly .1371
Contents 1372
General information on disassembly and assembly .1374
How to read this manual .1374
Coating materials list 1376
Special tool list .1379
Sketches of special tools .1383
Engine and cooling system .1389
Removal and installation of fuel supply pump assembly .1389
Removal and installation of fuel injector assembly 1392
Removal and installation of cylinder head assembly 1396
Removal and installation of engine front seal .1408
Removal and installation of engine rear seal 1411
Removal and installation of engine assembly .1415
Removal and installation of radiator assembly .1422
Removal and installation of output shaft assembly .1426
Disassembly and assembly of output shaft assembly .1427
Removal and installation of brake and power train oil cooler assembly .1430
Power train .1432
Removal and installation of torque converter and transmission assembly 1432
Separation and coupling of transmission assembly and torque converter assembly 1435
Disassembly and assembly of torque converter and control valve assembly .1444
Disassembly and assembly of torque converter assembly .1446
Disassembly and assembly of transmission assembly .1459
Removal and installation of transmission control valve assembly (ECMV assembly) .1492
Disassembly and assembly of transmission control valve assembly (ECMV assembly) .1493
Removal and installation of differential assembly .1497
Disassembly and assembly of differential assembly .1499
Removal and installation of final drive carrier assembly 1511
Disassembly and assembly of final drive carrier assembly 1512
Disassembly and assembly of front wheel hub assembly 1513
Steering system .1518
Disassembly and assembly of steering cylinder assembly 1518
Brake system 1521
Removal and installation of front brake caliper pads 1521
Removal and installation of front brake calipers assembly .1522
Disassembly and assembly of front brake calipers assembly .1523
Removal and installation of final drive and rear brake assembly .1525
Removal and installation of final drive, rear brake, and parking brake assembly .1528
Disassembly and assembly of final drive, rear brake, and parking brake assembly .1529
Undercarriage and frame .1540
Removal and installation of front wheel assembly 1540
Removal and installation of rear wheel assembly .1541
Removal and installation of front suspension cylinder assembly 1543
Disassembly and assembly of front suspension cylinder assembly (Cylinder with buffer ring) 1545
Removal and installation of rear suspension cylinder assembly .1548
Disassembly and assembly of rear suspension cylinder assembly (Cylinder with buffer ring) .1549
Hydraulic system 1552
Disassembly and assembly of hoist cylinder assembly .1552
Body 1556
Removal and installation of body assembly .1556
Cab and its attachments .1559
Disassembly and assembly of operator’s seat assembly 1559
Removal and installation of air conditioner unit assembly .1568
Electrical system .1571
Removal and installation of engine controller assembly 1571
Removal and installation of transmission controller assembly 1572
Removal and installation of retarder controller assembly 1573
80 Appendix .1575
Contents 1576
Air conditioner .1577
Precautions for refrigerant .1577
Air conditioner .1578
Configuration and function of refrigeration cycle .1579
Outline of refrigeration cycle 1580
Air conditioner unit 1582
Compressor 1589
Condenser .1590
Reciver dryer .1591
Air conditioner control panel .1592
Troubleshooting procedure .1594
Circuit diagram and arrangement of connector pins .1596
System diagram 1598
Details of air conditioner unit .1599
Inspection by self-diagnosis function .1600
Testing temperature control system 1601
Testing vent (mode) changeover 1602
Testing FRESH/RECIRC air changeover .1604
Check evaporator temperature sensor .1606
Testing relays 1607
Troubleshooting chart 1 .1608
Troubleshooting chart 2 .1609
Information in troubleshooting table 1611
Troubleshooting for power supply system (Air conditioner does not operate) 1612
Troubleshooting for compressor and refrigerant system (Air is not cooled) .1615
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1619
Troubleshooting for temperature control .1622
Troubleshooting for vent (mode) changeover 1624
Troubleshooting for FRESH/RECIRC air changeover .1626
Troubleshooting with gauge pressure .1629
Connection of service tool 1631
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit .1632
Handling of compressor oil 1634
90 Diagrams and drawings 1637
Contents 1638
Hydraulic diagrams and drawings .1639
Symbols used in hydraulic circuit diagrams 1639
Power train hydraulic circuit diagram .1641
Steering and hoist hydraulic circuit diagram 1643
Brake hydraulic circuit diagram .1645
Electrical diagrams and drawings 1649
Symbols used in electric circuit diagrams .1649
Electrical circuit diagram inside cab .1653
Electrical circuit diagram outside cab 1659
Electrical circuit diagram for VHMS .1665
Electrical circuit diagram for ASR (If equipped) 1667
Air conditioner electrical circuit diagram 1669
Electrical circuit diagram of external power supply heater 1671
Connectors table and arrangement drawing .1673
Index .1675

DESCRIPTION:

Komatsu HD465-7E0 Dump Truck Shop Manual SEN06732-00  – PDF DOWNLOAD

• SERIAL NUMBERS     11497 and up

G.B 27/12/24