Komatsu HD465-7E0 DUMP TRUCK Shop Manual SEN06732-04 PDF

Description

Komatsu HD465-7E0 DUMP TRUCK Shop Manual SEN06732-04  – PDF DOWNLOAD

FILE DETAILS:

Komatsu HD465-7E0 DUMP TRUCK Shop Manual SEN06732-04  – PDF DOWNLOAD

Language : English
Pages :1732
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HD465-7E0 DUMP TRUCK Shop Manual SEN06732-04  – PDF DOWNLOAD

HD465-7E0
Extreme Cold Area Specification (-40 degree C)
SERIAL NUMBERS 11497 and up

1. General precautions 

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

TABLE OF CONTENTS:

Komatsu HD465-7E0 DUMP TRUCK Shop Manual SEN06732-04  – PDF DOWNLOAD

HD465-7E0
Extreme Cold Area Specification (-40 degree C)
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
Mobile communication terminal (if equipped) 378
Sensors, switches 381
20 Standard value table 399
Contents 400
Standard service value table 401
Standard value table for engine 401
Standard value table for machine 403
30 Testing and adjusting 413
Contens 414
Related information on testing and adjusting 416
Tools for testing, adjusting, and troubleshooting 416
Sketch of special tool 422
Engine and cooling system 423
Testing engine speed 423
Testing air supply pressure (boost pressure) 424
Testing exhaust temperature 425
Testing exhaust gas color 427
Adjustment of valve clearance 429
Testing of compression pressure 431
Testing blowby pressure 434
Testing engine oil pressure 435
Testing EGR valve and bypass valve drive oil pressure 436
Handling of fuel system devices 438
Releasing residual pressure from fuel system 438
Testing of fuel pressure 439
Reduced cylinder mode operation 440
No-injection cranking 440
Testing of fuel return rate and fuel leakage 441
Bleeding air from fuel circuit 443
Testing the fuel circuit for leakage 444
Replacement and adjustment of fan belt 445
Replacement and adjustment of alternator and air conditioner compressor belt 446
Power train 447
Testing torque converter stall speed 447
Testing power train oil pressure 448
Adjusting transmission speed sensor 455
Brake system 456
Testing and adjusting brake oil pressure 456
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 459
Testing brake performance 467
Releasing remaining pressure in brake circuit 468
Bleeding air from brake circuit 469
Testing wear of front brake pad 470
Testing wear of rear brake disc 471
Method of releasing parking brake in an emergency 472
Undercarriage and frame 473
Testing and adjusting front suspension cylinder 473
Testing and adjusting rear suspension cylinder 477
Testing and adjusting front suspension cylinder (Automatic suspension specification) 481
Hydraulic system 482
Testing and adjusting hydraulic pressure in steering, hoist circuit 482
Testing and adjusting oil pressure in dump EPC circuit 485
Air bleeding from steering cylinder 486
Procedure for raising dump body in emergency 487
Procedure for lowering dump body in emergency 488
Adjusting body positioner sensor 489
Resetting method for dump body seating control 490
Adjustment of tilt lock lever of steering wheel 491
Handling of voltage circuit of engine controller 492
Adjusting transmission controller 492
Method for emergency escape at electrical system failure 493
Electrical system 497
Setting and adjusting of devices 497
Special functions of machine monitor (EMMS) 510
Request for opening ORBCOMM terminal 572
VHMS controller initial setting procedure 574
Using method of KOMTRAX functions of ORBCOMM terminal 594
Precautions for replacing VHMS controller 597
Pm Clinic check sheet 603
Initial setting of payload meter 607
Setting of payload meter built in VHMS 608
Setting of card-type payload meter (PLM-II) after installation or replacement 616
Setting of mobile communication terminal 622
40 Troubleshooting 633
Contents 634
General information on troubleshooting 642
Points to remember when performing troubleshooting 642
How to proceed in troubleshooting 644
Check before troubleshooting 646
Classification and procedures of troubleshooting 647
Information in troubleshooting table 651
Troubleshooting method for disconnecting wiring harness of pressure sensor system 653
Connection table for connector pin numbers 656
T-branch box and T-branch adapter table 692
Failure codes table 695
Fuse locations 706
Troubleshooting by failure code 711
Failure code [1500L0] (Dual engagement) 711
Failure code [15B0NX] (Transmission oil filter: Clogging) 712
Failure code [15F0KM] (R → F shifting abuse 1: Mistake in operation) 714
Failure code [15F0MB] (R → F shifting abuse 2: Mistake in operation) 714
Failure code [15F7KM] (Forward clutch disk abuse: Mistake in operation or setting) 715
Failure code [15G0MW] (R clutch: Slipping) 716
Failure code [15G7KM] (Reverse clutch disk abuse: Mistake in operation or setting) 718
Failure code [15H0MW] (Hi clutch: Slipping) 720
Failure code [15J0MW] (Lo clutch: Slipping) 722
Failure code [15K0MW] (1st clutch: Slipping) 724
Failure code [15L0MW] (2nd clutch: Slipping) 726
Failure code [15M0MW] (3rd clutch: Slipping) 728
Failure code [15N0MW] (4th clutch: Slipping) 730
Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF) 732
Failure code [15SBMA] (R clutch solenoid: Malfunction) 734
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF) 735
Failure code [15SCMA] (Hi clutch solenoid: Malfunction) 738
Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF) 739
Failure code [15SDMA] (Lo clutch solenoid: Malfunction) 742
Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF) 743
Failure code [15SEMA] (1st clutch solenoid: Malfunction) 746
Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF 748
Failure code [15SFMA] 2nd clutch solenoid: Malfunction 751
Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF 752
Failure code [15SGMA] 3rd clutch solenoid: Malfunction 755
Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF 756
Failure code [15SHMA] 4th clutch solenoid: Malfunction 759
Failure code [15SJMA] Lockup clutch solenoid: Malfunction 760
Failure code [2C4MNX] Retarder cooling oil filter: Clogging 762
Failure code [2F00KM] Parking brake: Mistake in operation or setting 764
Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front) 767
Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear) 767
Failure code [6014NX] Hydraulic oil filter: Clogging 768
Failure code [989A00] Engine over run prevention command signal: Operating 770
Failure code [989D00] Rear section tipping over alarm: Alarm is activated 770
Failure code [A570NX] Engine oil filter: Clogging 771
Failure code [AA10NX] Air cleaner element: Clogging 772
Failure code [AB00MA] Alternator: Malfunction 774
Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure 776
Failure code [B@BAZK] Engine oil: Level too low 777
Failure code [B@BCNS] Engine: Overheat 778
Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level 780
Failure code [B@BFZK] Lowering of fuel level 782
Failure code [B@C7NS] Brake cooling oil: Overheating (Rear) 784
Failure code [B@CENS] Overheating of torque converter oil 786
Failure code [B@GAZK] Battery electrolyte level: Lowering of level 787
Failure code [B@JANS] Steering oil temperature: Overheat 788
Failure code [CA111] Abnormality in engine controller 790
Failure code [CA115] Engine Ne or Bkup speed sensor error 792
Failure code [CA122] Charge (boost) pressure sensor high error 794
Failure code [CA123] Charge (boost) pressure sensor low error 796
Failure code [CA131] Throttle sensor high error 798
Failure code [CA132] Throttle sensor low error 801
Failure code [CA135] Engine oil pressure sensor high error 804
Failure code [CA141] Engine oil pressure sensor low error 806
Failure code [CA144] Coolant temperature sensor high error 808
Failure code [CA145] Coolant temperature sensor low error 810
Failure code [CA153] Charge (boost) temperature sensor high error 812
Failure code [CA154] Charge (boost) temperature sensor low error 814
Failure code [CA187] Sensor power supply 2 low error 816
Failure code [CA212] Engine oil temperature sensor high error 818
Failure code [CA213] Engine oil temperature sensor low error 820
Failure code [CA221] Atmospheric pressure sensor high error 822
Failure code [CA222] Atmospheric pressure sensor low error 824
Failure code [CA227] Sensor power supply 2 high error 826
Failure code [CA234] Engine overspeed 827
Failure code [CA238] Ne speed sensor power supply error 828
Failure code [CA263] Fuel Temp Sensor High Error 830
Failure code [CA265] Fuel Temp Sensor Low Error 832
Failure code [CA271] PCV1 Short circuit 834
Failure code [CA272] PCV1 Disconnection 835
Failure code [CA273] PCV2 Short circuit 836
Failure code [CA274] PCV2 Disconnection 837
Failure code [CA322] Injector #1 open/short error 838
Failure code [CA323] Injector #5 open/short error 840
Failure code [CA324] Injector #3 open/short error 842
Failure code [CA325] Injector #6 open/short error 844
Failure code [CA331] Injector #2 open/short error 846
Failure code [CA332] Injector #4 open/short error 848
Failure code [CA342] Calibration code inconsistency 850
Failure code [CA351] Injectors drive circuit error 851
Failure code [CA352] Sens Supply 1 Volt Low Error 852
Failure code [CA386] Sensor power supply 1 high error 854
Failure code [CA431] Idle validation switch error 855
Failure code [CA432] Idle validation action error 858
Failure code [CA441] Battery voltage low error 861
Failure code [CA442] Battery voltage high error 862
Failure code [CA449] Common rail pressure high error 2 863
Failure code [CA451] Rail Press Sensor High Error 864
Failure code [CA452] Rail Press Sensor Low Error 866
Failure code [CA553] Common rail pressure high error 1 868
Failure code [CA554] Common rail pressure sensor in range error 869
Failure code [CA559] Supply pump pressure very low error 1 870
Failure code [CA689] Engine Ne speed sensor error 874
Failure code [CA731] Engine Bkup speed sensor phase error 876
Failure code [CA757] All continuous data lost error 877
Failure code [CA778] Engine Bkup speed sensor error 878
Failure code [CA1228] EGR valve servo error 1 880
Failure code [CA1625] EGR valve servo error 2 881
Failure code [CA1626] (Bypass valve solenoid current high error) 882
Failure code [CA1627] (Bypass valve solenoid current low error) 884
Failure code [CA1628] Bypass Valve Servo Error 1 886
Failure code [CA1629] Bypass Valve Servo Error 2 887
Failure code [CA1631] (Bypass valve lift sensor high error) 888
Failure code [CA1632] (Bypass valve lift sensor low error) 890
Failure code [CA1633] KOMNET datalink timeout error 892
Failure code [CA2185] Throttle sensor supply voltage high error 894
Failure code [CA2186] Throttle sensor power supply low error 896
Failure code [CA2249] Supply pump pressure very low error 2 898
Failure code [CA2271] EGR valve lift sensor high error 900
Failure code [CA2272] EGR valve lift sensor low error 902
Failure code [CA2351] EGR valve solenoid operation short circuit 904
Failure code [CA2352] EGR valve solenoid operation disconnect 906
Failure code [CA2555] Intake air heater relay open circuit error 908
Failure code [CA2556] Intake air heater relay short circuit error 910
Failure code [D19HKB] Stop lamp relay output system: Short circuit 912
Failure code [D5ZKKZ] Front brake cut-off solenoid valve: Disconnection, short circuit or short circuit to power supply line 914
Failure code [DAF9KM] Wrong connection of connector 916
Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication 917
Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of power supply voltage 918
Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller 920
Failure code [DAQ2KK] Transmission controller solenoid power supply: Power supply voltage too low 922
Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection 924
Failure code [DAQRKR] Abnormality in CAN communication (Transmission) 925
Failure code [DAQRMA] Transmission controller option setting: Malfunction 930
Failure code [DAQV00] Neutral coast caution 930
Failure code [DAQW00] Neutral over speed caution 931
Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller 931
Failure code [DB12KK] Retarder controller solenoid power supply: Power supply system trouble 932
Failure code [DB13KK] Retarder controller battery direct power supply: Power supply voltage too low 934
Failure code [DB19KQ] Disagreement of model selection (Retarder controller) 936
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled 937
Failure code [DB1RMA] Disagreement of option setting (Retarder controller) 941
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled 942
Failure code [DBB0KK] or VHMS_LED display: “n9” → “01” 948
Failure code [DBB0KQ] or VHMS_LED display: “nF” → “11” 950
Failure code [DBB3KK] or VHMS_LED display: “n9” → “05” 952
Failure code [DBB5KP] or VHMS_LED display: “n9” → “04” 954
Failure code [DBB6KP] or VHMS_LED display: “n9” → “02” 956
Failure code [DBB7KP] or VHMS_LED display: “n9” → “03” 958
Failure code [DBBQKR] or VHMS_LED display: “n8” → “02” 959
Failure code [DBBRKR] Abnormality in CAN communication (VHMS) 959
Failure code [DBC2KK] ABS controller solenoid power supply: Power supply system trouble 960
Failure code [DBC3KK] ABS controller battery direct power supply: Power supply voltage too low 962
Failure code [DBC9KQ] Disagreement of model selection (ABS controller) 964
Failure code [DBCRKR] Abnormality in CAN communication (ABS) 965
Failure code [DBCRMA] Disagreement of option setting (ABS controller) 969
Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range 970
Failure code [DDD8KA] ARSC system switch system: Disconnection (If equipped) 972
Failure code [DDD8KB] ARSC system switch system: Short circuit (If equipped) 974
Failure code [DDD9KA] ABS system switch system: Disconnection 976
Failure code [DDD9KB] ABS system switch system: Short circuit 978
Failure code [DDDAKA] ASR system switch: Disconnection 980
Failure code [DDDAKB] ASR system switch: Short circuit 982
Failure code [DDP6L4] Service brake pressure switch trouble (Rear) 984
Failure code [DDTHKA] Hi clutch fill switch: Disconnection 986
Failure code [DDTJKA] Lo clutch fill switch: Disconnection 988
Failure code [DDTKKA] 1st clutch fill switch: Disconnection 990
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection 992
Failure code [DDTMKA] (3rd clutch fill switch: Disconnection) 994
Failure code [DDTNKA] R clutch fill switch: Disconnection 996
Failure code [DDTPKA] 4th clutch fill switch: Disconnection 998
Failure code [DF10KA] Gear shift lever: Disconnection1000
Failure code [DF10KB] Gear shift lever: Short circuit1003
Failure code [DGE5KX] or VHMS_LED display: “n4” → “01”1008
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range1010
Failure code [DGR2KZ] Retarder oil temperature sensor system trouble : Ground fault (Rear wheel)1012
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range1014
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range1016
Failure code [DGT4KA] or VHMS_LED display: “n3” → “12” Exhaust gas temperature sensor (F): Disconnection1019
Failure code [DGT4KB] or VHMS_LED display: “n3” → “11” Exhaust gas temperature sensor (F): Short circuit1022
Failure code [DGT5KA] or VHMS_LED display: “n3” → “22” Exhaust gas temperature sensor (R): Disconnection1025
Failure code [DGT5KB] or VHMS_LED display: “n3” → “21” Exhaust gas temperature sensor (R): Short circuit1028
Failure code [DHE5KB] or VHMS_LED display: “n3” → “32” Blow-by pressure sensor: Short circuit1031
Failure code [DHE5KY] or VHMS_LED display: “n3” → “31” Blow-by pressure sensor: Short circuit with power supply line1034
Failure code [DHP4KY] or VHMS_LED display: “n5” → “44” Short circuit in suspension pressure sensor system (Front right)1036
Failure code [DHP4KZ] or VHMS_LED display: “n5” → “43” Disconnection or ground fault in suspension pressure sensor system(Front right)1038
Failure code [DHP5KY] or VHMS_LED display: “n5” → “54” Short circuit in suspension pressure sensor system (Front left)1040
Failure code [DHP5KZ] or VHMS_LED display: “n5” → “53” Disconnection or ground fault in suspension pressure sensor system(Front left)1042
Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear)1044
Failure code [DHP6KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Right rear)1046
Failure code [DHP6KY] or VHMS_LED display: “n5” → “64” Suspension pressure sensor system: Short circuit (Right rear)1048
Failure code [DHP6KZ] or VHMS_LED display: “n5” → “63” Suspension pressure sensor system: Disconnection or ground fault (Right rear)1050
Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear)1052
Failure code [DHP7KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Left rear)1054
Failure code [DHP7KY] or VHMS_LED display: “n5” → “74” Suspension pressure sensor system: Short circuit (Left rear)1056
Failure code [DHP7KZ] or VHMS_LED display: “n5” → “73” Suspension pressure sensor system: Disconnection or ground fault (Left rear)1058
Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range1060
Failure code [DHT5L6] Torque converter oil pressure sensor: Disagreement of run and stop condition with signal1062
Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range1064
Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range1066
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right)1068
Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left)1070
Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Front right)1072
Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Front right)1074
Failure code [DHUTKX] Trouble in ABS cut valve pressure sensor1076
Failure code [DJF1KA] Fuel level sensor: Disconnection1078
Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection)1080
Failure code [DK51L5] Retarder lever potentiometer: Potentiometer signal is inconsistent with swich signal1081
Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range1084
Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal1086
Failure code [DK54KX] Body positioner sensor: Out of input signal range1088
Failure code [DKD0L6] Failure in steering speed sensor1090
Failure code [DKH0KX] Clinometer sensor signal out of range1092
Failure code [DKH1KX] or VHMS_LED display: “n4″→”33” Abnormality in clinometer sensor1094
Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection1096
Failure code [DLF1LC] Transmission input shaft speed sensor: Disagreement of revolution speed signal1098
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection1100
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal1102
Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right)1104
Failure code [DLF6L3] Trouble in wheel speed sensor (Front right)1105
Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left)1106
Failure code [DLF7L3] Trouble in wheel speed sensor (Front left)1107
Failure code [DLF8KA] Disconnection in wheel speed sensor (Right rear)1108
Failure code [DLF8L3] Trouble in wheel speed sensor (Right rear)1110
Failure code [DLF8LC] Trouble in wheel speed sensor system (Right rear)1112
Failure code [DLF8MA] Disconnection in wheel speed sensor (Right rear)1113
Failure code [DLF9KA] Disconnection in wheel speed sensor (Left rear)1114
Failure code [DLF9L3] Trouble in wheel speed sensor (Left rear)1116
Failure code [DLF9LC] Trouble in wheel speed sensor system (Left rear)1118
Failure code [DLF9MA] Disconnection in wheel speed sensor (Left rear)1119
Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system1120
Failure code [DLT3LC] Trouble in transmission output shaft speed sensor1122
Failure code [DLT4KA] Disconnection in transmission output shaft speed sensor1124
Failure code [DLT4MA] Disconnection in transmission output shaft speed sensor1126
Failure code [DV00KB] Short circuit in buzzer output1128
Failure code [DW2AKA] Disconnection in main pressure variable valve output1130
Failure code [DW2AKB] Ground fault in main pressure variable valve output circuit1132
Failure code [DW2AKY] Hot short in main pressure variable valve output circuit1134
Failure code [DW2AL1] Defective reset of main pressure variable valve1136
Failure code [DW2ALH] Malfunction of main pressure variable valve1138
Failure code [DW35KZ] Trouble in output system of auto suspension solenoid 1 (Disconnection or short circuit)1140
Failure code [DW36KZ] Trouble in output system of auto suspension solenoid 2 (Disconnection or short circuit)1142
Failure code [DW72KZ] Trouble in kick-out solenoid output system (Disconnection or short circuit)1144
Failure code [DW73KZ] Trouble in hoist select valve output system (Disconnection or short circuit)1146
Failure code [DW78KZ] Trouble in brake cooling valve (BCV) (rear wheel) output system (Disconnection or short circuit)1148
Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps operating)1150
Failure code [DWNBKA] Disconnection in ASR shut-off valve output circuit1152
Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit1154
Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit1156
Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate)1157
Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system1158
Failure code [DWNDMA] Defective ABS cut-off valve (Front)1160
Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system1162
Failure code [DWNEMA] Defective ABS cut-off valve (Rear)1164
Failure code [DX11K4] Trouble in rear brake proportional pressure reducing solenoid valve (Valve keeps operating)1166
Failure code [DX11KA] Disconnection in rear brake proportional pressure reducing solenoid valve output circuit1168
Failure code [DX11KB] Short circuit in rear brake proportional pressure reducing solenoid valve1169
Failure code [DX11KY] Short circuit in rear wheel proportional pressure reducing solenoid valve output circuit1170
Failure code [DX11MA] Trouble in rear wheel proportional pressure reducing solenoid valve (Valve does not operate)1171
Failure code [DX13KA] Disconnection in hoist EPC valve output circuit1172
Failure code [DX13KB] Short circuit in hoist EPC valve output circuit1174
Failure code [DX13KY] Short circuit in hoist EPC valve output circuit1176
Failure code [DX17K4] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve keeps operating)1178
Failure code [DX17KA] Disconnection in ASR proportional pressure reducing solenoid valve (right) output circuit1180
Failure code [DX17KB] Ground fault in ASR proportional pressure reducing solenoid valve (right) output circuit1182
Failure code [DX17KY] Short circuit in ASR proportional pressure reducing solenoid valve (right) output circuit1184
Failure code [DX17MA] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve does not operate)1185
Failure code [DX18K4] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve keeps operating)1186
Failure code [DX18KA] Disconnection in ASR proportional pressure reducing solenoid valve (left) output circuit1188
Failure code [DX18KB] Ground fault in ASR proportional pressure reducing solenoid valve (left) output circuit1190
Failure code [DX18KY] Short circuit in ASR proportional pressure reducing solenoid valve (left) output circuit1192
Failure code [DX18MA] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve does not operate)1193
Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right)1194
Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right)1195
Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right)1196
Failure code [DX21MA] Defective ABS control valve (Front right)1197
Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left)1198
Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left)1199
Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left)1200
Failure code [DX22MA] Defective ABS control valve (Front left)1201
Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right)1202
Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right)1203
Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right)1204
Failure code [DX23MA] Defective ABS control valve (Rear right)1205
Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left)1206
Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left)1207
Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left)1208
Failure code [DX24MA] Defective ABS control valve (Rear left)1209
Failure code [DX25MA] Defective ABS front wheel system control valve1210
Failure code [DX26MA] Defective ABS rear wheel system control valve1210
Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection1212
Failure code [DXH1KB] Lockup clutch solenoid output circuit: Short circuit1214
Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power supply line1216
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection1218
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit1220
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power supply line1222
Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection1226
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit1228
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power supply line1230
Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection1234
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit1236
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power supply line1238
Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection1242
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit1244
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power supply line1246
Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection1250
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit1252
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power supply line1254
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection1258
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit1260
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power supply line1262
Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection1264
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit1266
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power supply line1268
Failure code [F@BBZL] or VHMS_LED display: “n3″→”38” Blow-by pressure: High error1271
Failure code [F@BYNR] or VHMS_LED display: “n3″→”62” Exhaust gas temperature (F): Abnormal heat1272
Failure code [F@BYNS] or VHMS_LED display: “n3″→”61” Exhaust gas temperature (F): Overheat1274
Failure code [F@BZNR] or VHMS_LED display: “n3″→”72” Exhaust gas temperature (R): Abnormal heat1276
Failure code [F@BZNS] or VHMS_LED display: “n3″→”71” Exhaust gas temperature (R): Overheat1278
Troubleshooting of electrical system (E-mode)1281
Before troubleshooting of electric system1281
Contents of troubleshooting table1282
E-1 Engine does not start1283
E-2 Automatic preheating does not operate1286
E-3 Machine monitor does not display all, when starting switch is turned ON1290
E-4 Machine monitor does not operate when starting switch is OFF1292
E-5 Alarm buzzer does not sound1294
E-6 Alarm buzzer does not stop sounding1296
E-7 Gauges of machine monitor, caution lamps or character display section do not display properly1298
E-8 A selection of the display in character display section cannot be changed1299
E-9 Power mode pilot lamp does not light up normally1302
E-10 AISS function does not operate properly1303
E-11 Seat belt caution lamp does not display properly1304
E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly1305
E-13 Night illumination (lighting) does not work properly1308
E-14 Emergency steering does not operate1320
E-15 Hoist lever does not operate normally1326
E-16 Electric priming pump does not operate or does not stop automatically1328
E-17 Cannot access to the setting screen of the mobile communication terminal1330
E-18 Cannot log in to the setting screen of the mobile communication terminal because the log in password is unknown1335
E-19 VHMS controller is not detected1337
E-20 VHMS controller does not become active1338
E-21 Communication between mobile communication terminal and KOMTRAX Plus server fails1339
E-22 Data is not sent to KOMTRAX Plus server1342
Troubleshooting of hydraulic and mechanical system (H-mode)1345
Contents of troubleshooting table1345
H-1 Machine does not start1346
H-2 Machine does not travel smoothly (hunting)1348
H-3 Lockup cannot be cancelled1348
H-4 Excessive shock when starting or shifting excessive1349
H-5 Transmission does not shift up1350
H-6 Machine lacks power or speed when traveling1352
H-7 Time lag is excessive when starting or shifting gear1356
H-8 Torque converter oil temperature is high1358
H-9 Torque converter oil pressure is low1359
H-10 Front brake is ineffective1360
H-11 Rear brake is ineffective1361
H-12 Steering wheel is heavy1362
H-13 Steering wheel does not work1363
H-14 Steering wheel vibrates1364
H-15 Dump body lifting speed is slow1365
H-16 Dump body does not work1366
H-17 Excessive hydraulic drift of dump body1367
Troubleshooting of engine (S-mode)1368
Method of using troubleshooting chart1368
S-1 Starting performance of engine is poor1372
S-2 Engine does not start1374
S-3 Engine does not pick up smoothly1378
S-4 Engine stops during operation1379
S-5 Engine does not rotate smoothly1380
S-6 Engine lack output (or lacks power)1381
S-7 Exhaust gas is black (incomplete combustion)1382
S-8 Oil consumption is excessive (or exhaust gas is blue)1384
S-9 Oil becomes dirty quickly1385
S-10 Fuel consumption is excessive1386
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1387
S-12 Oil pressure drops1388
S-13 Oil level rises (Entry of coolant or fuel)1390
S-14 Coolant temperature becomes too high (Overheating)1392
S-15 Abnormal noise is made1393
S-16 Vibration is excessive1394
S-17 Air cannot be bled from fuel circuit1396
50 Disassembly and assembly1399
Contents1400
General information on disassembly and assembly1402
How to read this manual1402
Coating materials list1404
Special tool list1407
Sketches of special tools1411
Engine and cooling system1417
Removal and installation of fuel supply pump assembly1417
Removal and installation of fuel injector assembly1420
Removal and installation of cylinder head assembly1424
Removal and installation of engine front seal1439
Removal and installation of engine rear seal1442
Removal and installation of engine assembly1446
Removal and installation of radiator assembly1453
Removal and installation of damper assembly1457
Disassembly and assembly of damper assembly1458
Removal and installation of brake and power train oil cooler assembly1461
Power train1463
Removal and installation of torque converter and transmission assembly1463
Separation and coupling of transmission assembly and torque converter assembly1466
Disassembly and assembly of torque converter and control valve assembly1475
Disassembly and assembly of torque converter assembly1477
Disassembly and assembly of transmission assembly1490
Disassembly and assembly of transmission assembly1515
Removal and installation of transmission control valve assembly (ECMV assembly)1523
Disassembly and assembly of transmission control valve assembly (ECMV assembly)1524
Removal and installation of differential assembly1528
Disassembly and assembly of differential assembly1530
Removal and installation of final drive carrier assembly1542
Disassembly and assembly of final drive carrier assembly1543
Disassembly and assembly of front wheel hub assembly1544
Steering system1549
Disassembly and assembly of steering cylinder assembly1549
Brake system1552
Removal and installation of front brake caliper pads1552
Removal and installation of front brake calipers assembly1553
Disassembly and assembly of front brake calipers assembly1554
Removal and installation of final drive and rear brake assembly1556
Removal and installation of final drive, rear brake, and parking brake assembly1559
Disassembly and assembly of final drive, rear brake, and parking brake assembly1560
Undercarriage and frame1571
Removal and installation of front wheel assembly1571
Removal and installation of rear wheel assembly1572
Removal and installation of front suspension cylinder assembly1574
Disassembly and assembly of front suspension cylinder assembly (Cylinder with buffer ring)1576
Removal and installation of rear suspension cylinder assembly1579
Disassembly and assembly of rear suspension cylinder assembly (Cylinder with buffer ring)1580
Hydraulic system1583
Disassembly and assembly of hoist cylinder assembly1583
Body1587
Removal and installation of body assembly1587
Cab and its attachments1590
Disassembly and assembly of operator’s seat assembly1590
Removal and installation of air conditioner unit assembly1599
Electrical system1602
Removal and installation of engine controller assembly1602
Removal and installation of transmission controller assembly1603
Removal and installation of retarder controller assembly1604
Removal and installation of mobile communication terminal1605
Removal and installation of DC/DC converter1607
Removal and installation of mobile communication terminal harness1609
80 Appendix1619
Contents1620
Air conditioner1621
Precautions for refrigerant1621
Air conditioner1622
Configuration and function of refrigeration cycle1623
Outline of refrigeration cycle1624
Air conditioner unit1626
Compressor1633
Condenser1634
Reciver dryer1635
Air conditioner control panel1636
Troubleshooting procedure1638
Circuit diagram and arrangement of connector pins1640
System diagram1642
Details of air conditioner unit1643
Inspection by self-diagnosis function1644
Testing temperature control system1645
Testing vent (mode) changeover1646
Testing FRESH/RECIRC air changeover1648
Check evaporator temperature sensor1650
Testing relays1651
Troubleshooting chart 11652
Troubleshooting chart 21653
Information in troubleshooting table1655
Troubleshooting for power supply system (Air conditioner does not operate)1656
Troubleshooting for compressor and refrigerant system (Air is not cooled)1659
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)1663
Troubleshooting for temperature control1666
Troubleshooting for vent (mode) changeover1668
Troubleshooting for FRESH/RECIRC air changeover1670
Troubleshooting with gauge pressure1673
Connection of service tool1675
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit1676
Handling of compressor oil1678
90 Diagrams and drawings1681
Contents1682
Hydraulic diagrams and drawings1683
Symbols used in hydraulic circuit diagrams1683
Power train hydraulic circuit diagram1685
Steering and hoist hydraulic circuit diagram1687
Brake hydraulic circuit diagram1689
Electrical diagrams and drawings1693
Symbols used in electric circuit diagrams1693
Electrical circuit diagram inside cab 1697
Electrical circuit diagram outside cab1703
Electrical circuit diagram for VHMS1709
Electrical circuit diagram for ASR (If equipped)1711
Air conditioner electrical circuit diagram1713
Electrical circuit diagram of external power supply heater1715
Electrical circuit diagram of mobile communication terminal (if equipped)1717
Connectors table and arrangement drawing1719
Index1723

IMAGES PREVIEW OF THE MANUAL:

S.M 28/12/24