Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
KOMATSU HD465-7,HD605-7 Rigid Dump Truck Service Repair Workshop Manual SEBM027616 – PDF DOWNLOAD
Original price was: $51.95.$32.95Current price is: $32.95.
KOMATSU HD465-7,HD605-7 Rigid Dump Truck Service Repair Workshop Manual
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU HD465-7,HD605-7 Rigid Dump Truck Service Repair Workshop Manual
FILE DETAILS:
KOMATSU HD465-7,HD605-7 Rigid Dump Truck Service Repair Workshop Manual
Pages:1371
Format: PDF
Language: English
Compatible: Win/Mac
KOMATSU HD465-7,HD605-7 RIGID DUMP TRUCK SERVICE REPAIR WORKSHOP MANUAL SEBM027616 – PDF DOWNLOAD:
DESCRIPTION:
KOMATSU HD465-7,HD605-7 Rigid Dump Truck Service Repair Workshop Manual
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.
TABLE OF CONTENTS:
KOMATSU HD465-7,HD605-7 Rigid Dump Truck Service Repair Workshop Manual
COVER
................................................................................................................................................................................................... 1
CONTENTS................................................................................................................................................................................................. 2
01 GENERAL............................................................................................................................................................................................... 29
SPECIFICATION DRAWINGS............................................................................................................................................................................... 30
SPECIFICATIONS....................................................................................................................................................................................... 31
WEIGHT TABLE......................................................................................................................................................................................... 37
FUEL,COOLANT AND LUBRICANTS.......................................................................................................................................................................... 38
10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD........................................................................................................................................................... 40
RADIATOR,TORQUE CONVERTER OIL COOLER,AFTER COOLER,WORK EQUIPMENT OIL COOLER,FUEL COOLER.............................................................................................................. 41
BRAKE OIL COOLER..................................................................................................................................................................................... 42
POWER TRAIN SKELETON................................................................................................................................................................................. 43
OUTPUT SHAFT......................................................................................................................................................................................... 44
DRIVE SHAFT.......................................................................................................................................................................................... 46
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING................................................................................................................................................... 47
TORQUE CONVERTER..................................................................................................................................................................................... 49
TRANSMISSION......................................................................................................................................................................................... 56
TRANSMISSION VALVE................................................................................................................................................................................... 65
ECMV................................................................................................................................................................................................. 66
AXLE................................................................................................................................................................................................. 76
DIFFERENTIAL......................................................................................................................................................................................... 78
FINAL DRIVE.......................................................................................................................................................................................... 80
WHEELS............................................................................................................................................................................................... 82
SUSPENSION........................................................................................................................................................................................... 83
SUSPENSION CYLINDER.................................................................................................................................................................................. 85
REAR AXLE SUPPORT.................................................................................................................................................................................... 91
STEERING COLUMN...................................................................................................................................................................................... 93
STEERING LINKAGE..................................................................................................................................................................................... 94
BRAKE PIPING......................................................................................................................................................................................... 97
BRAKE VALVE.......................................................................................................................................................................................... 101
EMERGENCY BRAKE VALVE................................................................................................................................................................................ 104
RELAY VALVE.......................................................................................................................................................................................... 105
FRONT BRAKE OFF VALVE................................................................................................................................................................................ 106
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.................................................................................................................................................................. 121
STEERING AND HOIST HYDRAULIC SYSTEM DIAGRAM.......................................................................................................................................................... 123
DUMP BODY CONTROL.................................................................................................................................................................................... 125
HYDRAULIC TANK....................................................................................................................................................................................... 126
STEERING CONTROL VALVE............................................................................................................................................................................... 127
CROSSOVER RELIEF VALVE............................................................................................................................................................................... 131
STEERING CYLINDER.................................................................................................................................................................................... 132
DEMAND VALVE......................................................................................................................................................................................... 133
HOIST VALVE.......................................................................................................................................................................................... 137
EPC VALVE............................................................................................................................................................................................ 143
HOIST CYLINDER....................................................................................................................................................................................... 144
HYDRAULIC PUMP....................................................................................................................................................................................... 145
AIR CONDITIONER...................................................................................................................................................................................... 149
MACHINE MONITOR SYSTEM............................................................................................................................................................................... 154
ENGINE CONTROL SYSTEM................................................................................................................................................................................ 169
AUTOMATIC SHIFT CONTROL SYSTEM....................................................................................................................................................................... 171
PAYLOAD METER Ⅱ(CARD TYPE)........................................................................................................................................................................... 184
AUTOMATIC EMERGENCY STEERING SYSTEM.................................................................................................................................................................. 216
AUTOMATIC SUSPENSION SYSTEM.......................................................................................................................................................................... 224
RETARDER CONTROL SYSTEM.............................................................................................................................................................................. 228
SENSORS,SWITCHES..................................................................................................................................................................................... 239
DUMP CONTROL LEVER................................................................................................................................................................................... 247
VHMS CONTROLLER...................................................................................................................................................................................... 251
BLOW-BY PRESSURE SENSOR.............................................................................................................................................................................. 251
ENGINE OIL PRESSURE SENSOR........................................................................................................................................................................... 252
EXHAUST TEMPERATURE SENSOR/AMP....................................................................................................................................................................... 253
AMBIENT TEMPERATURE SENSOR........................................................................................................................................................................... 253
COMMUNICATIONS (ORB・・・ORBCOMM) CONTROLLER/ANTENNA.................................................................................................................................................... 254
PAYLOAD METER (HAVING VHMS).......................................................................................................................................................................... 255
Auto greasing system................................................................................................................................................................................. 279
20 TESTING AND ADJUSTING................................................................................................................................................................................. 302
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS........................................................................................................................................................ 303
STANDARD VALUE TABLE FOR CHASSIS..................................................................................................................................................................... 304
TESTING AND ADJUSTING................................................................................................................................................................................ 316
TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING.................................................................................................................................................. 317
MEASURING ENGINE SPEED........................................................................................................................................................................... 321
ADJUSTING ENGINE SPEED SENSOR.................................................................................................................................................................... 323
MEASURING ENGINE OIL PRESSURE.................................................................................................................................................................... 324
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)................................................................................................................................................... 325
MEASURING EXHAUST TEMPERATURE.................................................................................................................................................................... 327
MEASURING BLOW-BY PRESSURE....................................................................................................................................................................... 329
TROUBLESHOOTING OF INJECTOR...................................................................................................................................................................... 330
MEASURING COMPRESSION PRESSURE................................................................................................................................................................... 331
HANDLING EQUIPMENT IN FUEL SYSTEM................................................................................................................................................................ 333
MEASURING FUEL PUMP OUTLET PORT PRESSURE......................................................................................................................................................... 333
MEASURING FUEL PUMP INLET PORT PRESSURE.......................................................................................................................................................... 335
VISUAL INSPECTION OF RETURN FUEL................................................................................................................................................................. 335
ADJUSTING INJECTOR SET LOAD...................................................................................................................................................................... 336
BLEEDING AIR FROM FUEL CIRCUIT................................................................................................................................................................... 338
MEASURING EXHAUST COLOR.......................................................................................................................................................................... 340
ADJUSTING VALVE CLEARANCE........................................................................................................................................................................ 341
TESTING AND ADJUSTING ALTERNATOR BELT TENSION.................................................................................................................................................... 342
TESTING AND ADJUSTING,AIR CONDITIONER COMPRESSOR BELT TENSION.................................................................................................................................... 343
MEASURING POWER TRAIN OIL PRESSURE............................................................................................................................................................... 344
ADJUSTING TRANSMISSION SPEED SENSOR.............................................................................................................................................................. 351
INSPECTING BRAKE OIL PRESSURE.................................................................................................................................................................... 352
BLEEDING AIR FROM BRAKE CIRCUIT.................................................................................................................................................................. 354
TESTING WEAR OF FRONT BRAKE PAD.................................................................................................................................................................. 355
TESTING WEAR OF REAR BRAKE DISC.................................................................................................................................................................. 356
METHOD OF RELEASING PARKING BRAKE IN AN EMERGENCY................................................................................................................................................ 357
TESTING AND ADUSTING FRONT SUSPENSION CYLINDER................................................................................................................................................... 358
TESTING AND ADJUSTING INVERTED TYPE REAR SUSPENSION CYLINDER..................................................................................................................................... 362
TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER(MODE SELECTOR HYDRAULIC CYLNDER)................................................................................................................. 365
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING,HOIST CIRCUIT............................................................................................................................... 366
TESTING AND ADJUSTING OIL PRESSURE IN DUMP EPC CIRCUIT........................................................................................................................................... 369
AIR BLEEDING FROM STEERING CYLINDER.............................................................................................................................................................. 370
PROCEDURE FOR RAISING DUMP BODY IN EMERGENCY..................................................................................................................................................... 371
ADJUSTING BODY POSITIONER SENSOR................................................................................................................................................................. 372
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM........................................................................................................................... 374
ADJUSTING MACHINE MONITOR(EMMS).................................................................................................................................................................. 378
ADJUSTING TRANSMISSION CONTROLLER................................................................................................................................................................ 382
INITIAL SETTING OF PAYLOAD METER................................................................................................................................................................. 383
SETTING OF CARD-TYPE PAYLOAD METER AFTER INSTALLATION OR REPLACEMENT............................................................................................................................. 384
SPECIAL FUNCTIONS OF MACHINE MONITOR(EMMS)....................................................................................................................................................... 392
BASIC PRECAUTIONS................................................................................................................................................................................ 444
OUTLINE.......................................................................................................................................................................................... 447
SETTING UP VHMS CONTROLLER ...................................................................................................................................................................... 452
COLLECTION,TRANSMISSION OF DATA.................................................................................................................................................................. 454
INSPECTION AND MAINTENANCE....................................................................................................................................................................... 459
REPLACING PARTS.................................................................................................................................................................................. 459
PROCEDURE FOR INITIAL SETUP OF VHMS.............................................................................................................................................................. 460
PROCEDURE FOR OPENING ORBCOMM SERVICE............................................................................................................................................................ 463
PERFORMING PM-CLINIC USING MANUAL SNAPSHOT(=QUICK PM)............................................................................................................................................ 466
PM CLINIC SERVICE................................................................................................................................................................................ 470
TROUBLESHOOTING...................................................................................................................................................................................... 473
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................................................................................................... 474
SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................................................................................................ 475
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE................................................................................................................................................. 476
CHECKS BEFORE TROUBLESHOOTING.................................................................................................................................................................... 484
CATEGORIES, PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS................................................................................................................................. 486
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....................................................................................................................................................... 492
T-ADAPTER TABLE.................................................................................................................................................................................. 516
TYPES AND LOCATIONS OF CONNECTORS................................................................................................................................................................ 519
CONNECTOR ARRANGEMENT LOCATION................................................................................................................................................................... 534
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM(ENG MODE)............................................................................................................................................ 546
ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL............................................................................................................................................. 548
INFORMATION IN TROUBLESHOOTING TABLE......................................................................................................................................................... 554
[C111KT] ABNORMALITY IN ENGINE CONTROLLER MEMORY............................................................................................................................................. 556
[C112LK] ABNORMALITY IN TIMING RAIL ACTUATOR................................................................................................................................................. 556
[C113KZ] ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM..................................................................................................................................... 557
[C115KZ] ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS........................................................................................................................................ 558
[C116KX] ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM......................................................................................................................... 560
[C117KX] ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM.......................................................................................................................... 561
[C118KX] ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM........................................................................................................................... 562
[C119KX] ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM............................................................................................................................ 563
[C121LC] ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEMS........................................................................................................................................ 563
[C122KX] ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR SYSTEM............................................................................................................................... 564
[C123KX] ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR SYSTEM................................................................................................................................ 565
[C131KX] ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM..................................................................................................................................... 566
[C132KX] ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM...................................................................................................................................... 568
[C135KX] ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM.......................................................................................................................... 569
[C141KX] ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM........................................................................................................................... 570
[C143ZG] LOWERING OF ENGINE OIL PRESSURE..................................................................................................................................................... 570
[C144KX] ABNORMALLY HIGH LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM................................................................................................................... 571
[C145KX] ABNORMALLY LOW LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM.................................................................................................................... 572
[C148KX] ABNORMALITY IN FM THROTTLE:OUT OF INPUT SIGNAL RANGE................................................................................................................................ 573
[C151NS] RISE OF ENGINE COOLANT TEMPERATURE.................................................................................................................................................. 574
[C153KX] ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM....................................................................................................................... 575
[C154KX] ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM........................................................................................................................ 576
[C221KX] ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM......................................................................................................................... 577
[C222KX] ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM.......................................................................................................................... 578
[C234NI] OVER-SPEED.......................................................................................................................................................................... 578
[C254KZ] ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE............................................................................................................................................. 579
[C259FS] ABNORMALITY IN FUEL SHUT-OFF VALVE.................................................................................................................................................. 580
[C261NS] ABNORMAL RISE OF FUEL TEMPERATURE................................................................................................................................................... 580
[C263KX] ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM............................................................................................................................. 581
[C265KX] ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM.............................................................................................................................. 582
[C316KZ] ABNORMAL CURRENT OF FUEL PUMP ACTUATOR.............................................................................................................................................. 583
[C318LK] ABNORMALITY IN FUEL PUMP ACTUATOR................................................................................................................................................... 584
[C346KT] ABNORMALITY IN POWER-DOWN UNIT OF ENGINE CONTROLLER................................................................................................................................. 585
[C423L6] ABNORMALITY IN IN-RANGE OF TIMING RAIL PRESSURE SENSOR SYSTEM....................................................................................................................... 587
[C431L4] ABNORMALITY IN IDLING VALIDATION SWITCH SYSTEM:※ SEE SEPARATE LIST(L4)(BOTH SIGNAL VOLTAGES OF 2 SYSTEMS ARE SENSED)................................................................ 589
[C432L5] ERROR IN IDLING VALIDATION PROCESS(※ SEE SEPARATE LIST(L5))......................................................................................................................... 591
[C441KK] ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM...................................................................................................................................... 593
[C442KG] ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGE SYSTEM..................................................................................................................................... 593
[C451KX] ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM........................................................................................................................... 594
[C452KX] ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM............................................................................................................................ 595
[C455KZ] ABNORMAL CURRENT OF FUEL RAIL ACTUATOR.............................................................................................................................................. 596
[C467LK] ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL......................................................................................................................................... 597
[C468LK] ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL........................................................................................................................................... 597
[C514LK] ABNORMALITY IN FUEL RAIL ACTUATOR................................................................................................................................................... 598
[C551L4] ABNORMALITY IN IDLING VALIDATION SWITCH SYSTEM:※ SEE SEPARATE LIST(L4)(EITHER SIGNAL VOLTAGE OF 2 SYSTEMS IS NOT SENSED)............................................................ 599
[C554L6] ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE SENSOR SYSTEM......................................................................................................................... 601
ENG-1 ENGINE DOES NOT START.................................................................................................................................................................. 603
ENG-2 FAILURE IN PREHEATING.................................................................................................................................................................. 607
a) ENGINE IS NOT PREHEATED............................................................................................................................................................... 607
b) PREHEATING IS ACTUATED EVEN UNDER NON-ACTUATION CONDITIONS FOR PREHEATING............................................................................................................. 610
ENG-3 AISS FUNCTION DOES NOT WORK NORMALLY................................................................................................................................................... 612
a) WHEN AISS SWITCH IS SET IN AUTO,LOW SPEED CONTROL IS SELECTED......................................................................................................................... 612
b) WHEN AISS SWITCH IS SET IN LOW SPEED,AUTO CONTROL IS SELECTED......................................................................................................................... 613
TROUBLESHOOTING FOR TRANSMISSION CONTROLLER SYSTEM (TM MODE)..................................................................................................................................... 615
ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL.................................................................................................................................... 617
INFORMATION IN TROUBLESHOOTING TABLE......................................................................................................................................................... 618
TROUBLE CODE TABLE........................................................................................................................................................................... 619
[1380MW] LOCKUP CLUTCH・SLIP(MW) ............................................................................................................................................................. 620
[1500L0] DETECTION OF DOUBLE ENGAGEMENT・※ SEE SEPARATE LIST(L0).............................................................................................................................. 621
[15B0NX] CLOGGING OF TRANSMISSION OIL FILTER・CLOGGING(NX).................................................................................................................................... 622
[15E0KM] R→F GEAR SHIFT ABUSE 1・MISTAKE IN OPERATION OR SETTING (KM)......................................................................................................................... 623
[15E7KM] R→F GEAR SHIFT ABUSE 2・MISTAKE IN OPERATION OR SETTING (KM)......................................................................................................................... 623
[15G0MW] R CLUTCH・SLIP (MW).................................................................................................................................................................. 624
[15H0MW] HI CLUTCH・SLIP (MW)................................................................................................................................................................. 625
[15J0MW] LO CLUTCH・SLIP(MW).................................................................................................................................................................. 627
[15K0MW] 1ST CLUTCH・SLIP(MW)................................................................................................................................................................. 629
[15L0MW] 2ND CLUTCH・SLIP(MW)................................................................................................................................................................. 630
[15M0MW] 3RD CLUTCH・SLIP(MW)................................................................................................................................................................. 631
[15N0MW] 4TH CLUTCH・SLIP(MW)................................................................................................................................................................. 632
[15SBL1] R CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1)........................................................................................................................................... 633
[15SBMA] R CLUTCH SOLENOID・※ MALFUNCTION(MA)................................................................................................................................................. 634
[15SCL1] HI CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1).......................................................................................................................................... 635
[15SCMA] HI CLUTCH SOLENOID・MALFUNCTION(MA).................................................................................................................................................. 636
[15SDL1] LO CLUTCH SOLENOID・※ SEE SEPARATE LIST (L1)......................................................................................................................................... 637
[15SDMA] LO CLUTCH SOLENOID・MALFUNCTION(MA).................................................................................................................................................. 638
[15SEL1] 1ST CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1)......................................................................................................................................... 639
[15SEMA] 1ST CLUTCH SOLENOID・MALFUNCTION(MA)................................................................................................................................................. 640
[15SFL1] 2ND CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1)......................................................................................................................................... 641
[15SFMA] 2ND CLUTCH SOLENOID・MALFUNCTION(MA)................................................................................................................................................. 642
[15SGL1] 3RD CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1)......................................................................................................................................... 643
[15SGMA] 3RD CLUTCH SOLENOID・MALFUNCTION(MA)................................................................................................................................................. 644
[15SHL1] 4TH CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1)......................................................................................................................................... 645
[15SHMA] 4TH CLUTCH SOLENOID・MALFUNCTION(MA)................................................................................................................................................. 646
[15SJL1] LOCKUP CLUTCH SOLENOID・15SJ(L1)..................................................................................................................................................... 647
[15SJMA] LOCKUP CLUTCH SOLENOID・15SJ(MA)..................................................................................................................................................... 648
[2F00KM] PARKING BRAKE・MISTAKE IN OPERATION OR SETTING(KM)................................................................................................................................... 649
[989A00] ENGINE OVERRUN PREVENTION COMMAND SIGNAL・OPERATION(00).............................................................................................................................. 651
[989AKZ] ENGINE OVERRUN PREVENTION COMMAND SIGNAL・DISCONNECTION OR SHORT CIRCUIT(KZ)......................................................................................................... 652
[AA10NX] AIR CLEANER ELEMENT・CLOGGING(NX).................................................................................................................................................... 653
[AB00MA] ALTERNATOR・MALFUNCTION(MA).......................................................................................................................................................... 655
[B@CZK] LOWERING OF RADIATOR WATER:LOWERING OF LEVER (ZK).................................................................................................................................... 657
[D1B0KZ] TRANSMISSION CONTROLLER CUTOUT: DISCONNECTION OR SHORT CIRCUIT (KZ)................................................................................................................. 658
[D5ZMKZ] DISCONNECTION,GROUNDING FAULT,OR SHORT CIRCUIT IN ENGINE OUTPUT MODE COMMAND LINE・DISCONNECTION OR SHORT CIRCUIT(KZ)................................................................ 660
[DAQ0KK] TRANSMISSION CONTROLLER・LOWERING OF SOURCE/INPUT VOLTAGE(KK)........................................................................................................................ 661
[DAQ1KK] MAIN POWER LINE OF TRANSMISSION CONTROLLER・LOWERING OF SOURCE/INPUT VOLTAGE (KK).................................................................................................... 663
[DAQ2KK] TRANSMISSION CONTROLLER LOAD POWER LINE・LOWERING OF SOURCE/INPUT VOLTAGE(KK)........................................................................................................ 665
[DAQ3KK] DIRECT LINE OF TRANSMISSION CONTROLLER BATTERY・LOWERING OF SOURCE/INPUT VOLTAGE (KK)................................................................................................ 667
[DAQ9KM] TRANSMISSION CONTROLLER WIRING HARNESS・MISTAKE IN OPERATION OR SETTING(KM).......................................................................................................... 668
[DAQ9KQ] TRANSMISSION CONTROLLER WIRING HARNESS・DISAGREEMENT OF MODEL SELECTION SIGNALS(KQ).................................................................................................. 669
[DAQAKQ] TRANSMISSION CONTROLLER ROTARY SWITCH・DISAGREEMENT OF MODEL SELECTION SIGNALS(KQ)................................................................................................... 670
[DAQSMA] TRANSMISSION CONTROLLER・MALFUNCTION(MA)............................................................................................................................................. 670
[DDTGKA] LOCKUP CLUTCH FILL SWITCH:DISCONNECTION(KA)......................................................................................................................................... 671
[DDTHKA] HI CLUTCH FILL SWITCH:DISCONNECTION(KA)............................................................................................................................................. 672
[DDTJKA] LO CLUTCH FILL SWITCH:DISCONNECTION(KA)............................................................................................................................................. 673
[DDTKKA] 1ST CLUTCH FILL SWITCH:DISCONNECTION (KA)........................................................................................................................................... 674
[DDTLKA] 2ND CLUTCH FILL SWITCH:DISCONNECTION(KA)............................................................................................................................................ 675
[DDTMKA] 3RD CLUTCH FILL SWITCH:DISCONNECTION(KA)............................................................................................................................................ 676
[DDTNKA] R CLUTCH FILL SWITCH:DISCONNECTION(KA).............................................................................................................................................. 677
[DDTRKA] 4TH CLUTCH FILL SWITCH:DISCONNECTION(KA)............................................................................................................................................ 678
[DF10KA] SHIFT LEVER:DISCONNECTION(KA)....................................................................................................................................................... 679
[DF10KB] SHIFT LEVER:SHORT CIRCUIT(KB)....................................................................................................................................................... 683
[DGF1KX] TRANSMISSION VALVE OIL TEMPERATURE SENSOR:OUT OF INPUT SIGNAL RANGE(KX)............................................................................................................. 686
[DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR:OUT OF INPUTSIGNAL RANGE(KX)................................................................................................................ 688
[DHT5KX] TORQUE CONVERTER OIL PRESSURE SENSOR:OUT OF INPUT SIGNAL RANGE(KX).................................................................................................................. 689
[DHT5L6] TORQUE CONVERTER OIL PRESSURE SENSOR:※ SEE SEPARATE LIST(L6)........................................................................................................................ 691
[DJF1KA] FUEL LEVEL SENSOR:DISCONNECTION(KA)................................................................................................................................................. 692
[DK11KX] THROTTLE ANGLE SENSOR:OUT OF INPUT SIGNAL RANGE(KX)................................................................................................................................. 693
[DLE2KA] ENGINE SPEED SENSOR:DISCONNECTION(KA)............................................................................................................................................... 695
[DLE2LC] ENGINE SPEED SENSOR:※ SEE SEPARATE LIST(LC)......................................................................................................................................... 696
[DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR:DISCONNECTION(KA)............................................................................................................................. 697
[DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR:※ SEE SEPARATE LIST(LC)....................................................................................................................... 698
[DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR:DISCONNECTION(KA)...................................................................................................................... 699
[DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR:※ SEE SEPARATE LIST(LC)................................................................................................................ 700
[DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:DISCONNECTION(KA)............................................................................................................................ 701
[DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:※ SEE SEPARATE LIST(LC)...................................................................................................................... 702
[DXH1KA] DISCONNECTION IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID:DISCONNECTION(KA)......................................................................................................... 704
[DXH1KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID:SHORT CIRCUIT (KB)........................................................................................................ 705
[DXH2KA] DISCONNECTION IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID:DISCONNECTION(KA)............................................................................................................. 706
[DXH2KB] SHORT CIRCUIT OF HI CLUTCH SOLENOID:SHORT CIRCUIT(KB)............................................................................................................................... 707
[DXH3KA] DISCONNECTION IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID:DISCONNECTION(KA)............................................................................................................. 709
[DXH3KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID:SHORT CIRCUIT(KB)............................................................................................................. 710
[DXH4KA] DISCONNECTION IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID:DISCONNECTION(KA)............................................................................................................ 712
[DXH4KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID:SHORT CIRCUIT(KB)............................................................................................................ 713
[DXH5KA] DISCONNECTION IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID:DISCONNECTION(KA)............................................................................................................ 714
[DXH5KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID:SHORT CIRCUIT(KB)............................................................................................................ 715
[DXH6KA] DISCONNECTION IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID:DISCONNECTION(KA)............................................................................................................ 716
[DXH6KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID:SHORT CIRCUIT(KB)............................................................................................................ 717
[DXH7KA] DISCONNECTION IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID:DISCONNECTION(KA).............................................................................................................. 718
[DXH7KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID:SHORT CIRCUIT(KB).............................................................................................................. 719
[DXHHKA] DISCONNECTION IN OUTPUT CIRCUIT OF 4TH CLUTCH SOLENOID:DISCONNECTION(KA)............................................................................................................ 720
[DXHHKB] SHORT CIRCUIT OF 4TH CLUTCH SOLENOID:SHORT CIRCUIT(KB).............................................................................................................................. 721
TM-1 FUEL LEVEL GAUGE DOES NOT OPERATE NORMALLY(IT ALWAYS INDICATES"FULL")................................................................................................................... 722
TM-2 ABNORMALITY IN BACKUP LAMP AND BACKUP BUZZER............................................................................................................................................ 723
a) WHEN THE SHIFT LEVER IS SET IN THE "R" POSITION,THE BACKUP LAMP AND BACKUP BUZZER ARE NOT TURNER ON................................................................................... 723
b) BACKUP LAMP IS NOT TURNED ON(BACKUP BUZZER IS NORMAL)................................................................................................................................. 724
c) BACKUP BUZZER IS NOT TURNED ON(BACKUP LAMP IS NORMAL)................................................................................................................................. 724
d) WHILE SHIFT LEVER IS NOT OPERATED,BACKUP LAMP AND BACKUP BUZZER ARE TURNED ON......................................................................................................... 725
TROUBLESHOOTING FOR RETARDER CONTROLLER SYSTEM(BK MODE).......................................................................................................................................... 727
ELECTRICAL SYSTEM DIAGRAM RELATED TO RETARDER CONTROL........................................................................................................................................ 729
INFORMATION IN TROUBLESHOOTING TABLE......................................................................................................................................................... 731
TROUBLE CODE TABLE........................................................................................................................................................................... 732
[2G42ZG] ACCUMULATOR(FRONT):LOWERING OF OIL PRESSURE(ZG)..................................................................................................................................... 733
[2G43ZG] ACCUMULATOR(REAR):LOWERING OF OIL PRESSURE(ZG)...................................................................................................................................... 733
[D1C0KZ] BRAKE CUTOUT RELAY:DISCONNECTION OR SHORT CIRCUIT(KZ)............................................................................................................................... 734
[D5ZNKZ] FAILURE OF FRONT BRAKE CUTOUT OUTPUT SYSTEM(DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT)(OPT):DISCONNECTION OR SHORT CIRCUIT(KZ).................................................... 736
[DB10KK] RETARDER CONTROLLER:LOWERING OF SOURCE/INPUT VOLTAGE(KK)............................................................................................................................ 738
[DB11KK] MAIN POWER LINE OF RETARDER CONTROLLER:LOWERING OF SOURCE/INPUT VOLTAGE(KK)......................................................................................................... 740
[DB12KK] RETARDER CONTROLLER LOAD POWER LINE:LOWERING OF SOURCE/INPUT VOLTAGE(KK)............................................................................................................ 742
[DB13KK] DIRECT LINE OF RETARDER CONTROLLER BATTERY:LOWERING OF SOURCE/INPUT VOLTAGE(KK)..................................................................................................... 744
[DB19KM] RETARDER CONTROLLER WIRING HARNESS:MISTAKE IN OPERATION OR SETTING(KM).............................................................................................................. 745
[DB1SKQ] WRONG INFORMATION ON MODEL SELECTION:DISAGREEMENT OF MODEL SELECTION SIGNALS(KQ).................................................................................................... 746
[DDD7KX] FAILURE IN TRAVEL SPEED SET SWITCH SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX)........................................................................................................ 747
[DDD8KA] ARSC SYSTEM SWITCH SYSTEM:DISCONNECTION(KA)......................................................................................................................................... 749
[DDD8KB] ARSC SYSTEM SWITCH SYSTEM:SHORT CIRCUIT(KB)......................................................................................................................................... 750
[dGR2L8] FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM:※ SEE SEPARATE LIST(L8)........................................................................................................... 751
[DGR2L8] BRAKE OIL TEMPERATURE SENSOR(REAR):※ SEE SEPARATE LIST(L8).......................................................................................................................... 752
[dHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR(FR) SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX)................................................................................................. 753
[DHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR(FR) SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX)................................................................................................. 755
[dHP5KX] FAILURE IN SUSPENSION PRESSURE SENSOR(FL) SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX)................................................................................................. 757
[DHP5KX] FAIURE IN SUSPENSION PRESSURE SENSOR (FL) SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX)................................................................................................. 759
[DHU2KX] ACCUMULATOR OIL PRESSURE SENSOR (FRONT):OUT OF INPUT SIGNAL RANGE (KX).............................................................................................................. 761
[DHU3KX] ACCUMULATOR OIL PRESSURE SENSOR (REAR):OUT OF INPUT SIGNAL RANGE (KX)............................................................................................................... 763
[dK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (OPT):OUT OF INPUT SIGNAL RANGE (KX).......................................................................................................... 765
[DK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (OPT):OUT OF INPUT SIGNAL RANGE (KX).......................................................................................................... 766
[DK51L5] RETARDER LEVER POTENTIOMETER:※ SEE SEPARATE LIST (L5)............................................................................................................................... 767
[DK52KX] DUMP LEVER POTENTIOMETER 1:OUT OF INPUT SIGNAL RANGE (KX)........................................................................................................................... 770
[DK53L8] DUMP LEVER POTENTIOMETER 2:※ SEE SEPARATE LIST (L8)................................................................................................................................. 772
[DK54KX] BODY POSITIONER SENSOR:OUT OF INPUT SIGNAL RANGE (KX)............................................................................................................................... 773
[DKD0L6] FAILURE IN STEERING SPEED SENSOR (OPT):※ SEE SEPARATE LIST (L6)..................................................................................................................... 775
[dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:DISCONNECTION (KA)........................................................................................................................... 777
[DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:DISCONNECTION (KA)........................................................................................................................... 778
[DW35KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 1 (OPT)(DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT):DISCONNECTION OR SHORT CIRCUIT (KZ)....................................... 779
[DW36KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 2 (OPT) (DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT):DISCONNECTION OR SHORT CIRCUIT (KZ)...................................... 780
[DW72KZ] FAILURE IN KICK-OUT SOLENOID OUTPUT SYSTEM (D_OUT3)(DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT):DISCONNECTION OR SHORT CIRCUIT (KZ)................................................ 781
[DW73KZ] FAILURE IN HOIST SELECT VALVE OUTPUT SYSTEM (D_OUT5)(DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT):DISCONNECTION OR SHORT CIRCUIT (KZ)............................................... 783
[DK11K4] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL:UNCONTROLLABLE (K4)..................................................................................................... 785
[DX11KA] DISCONNECTION IN OUTPUT CIRCUIT OF ELECTROMAGNETIC PROPORTIONAL PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2):DISCONNECTION (KA)................................................... 787
[DX11KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF ELECTROMAGNETIC PROPORTIONAL PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2):SHORT CIRCUIT (KB)................................................... 788
[DX11KY] GROUNDING FAULT IN OUTPUT CIRCUIT OF ELECTROMAGNETIC PROPORTIONAL PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2):SHORT CIRCUIT WITH POWER LINE (KY)................................. 789
[DX11MA] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL:MALFUNCTION (MA)........................................................................................................ 790
[DX13KA] DISCONNECTION IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):DISCONNECTION (KA)...................................................................................................... 791
[DX13KB] GROUNDING FAULT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):SHORT CIRCUIT (KB).................................................................................................... 792
[DX13KY] SHORT CIRCUIT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):SHORT CIRCUIT WITH POWER LINE (KY)...................................................................................... 793
BK-1 PARKING BRAKE DOES NOT OPERATE NORMALLY................................................................................................................................................. 795
a) WHEN THE PARKING BRAKE SWITCH IS SET IN THE OFF POSITION, THE PARKING BRAKE IS NOT RELEASED........................................................................................... 795
b) WHEN THE PARKING BRAKE SWITCH IS SET IN THE PARK POSITION, THE PARKING BRAKE DOES NOT WORK............................................................................................ 797
BK-2 RETARDER BRAKE OIL TEMPERATURE GAUGE DOES NOT OPERATE NORMALLY.......................................................................................................................... 799
BK-3 INCLINATION ALARM IS TURNED ON WHEN DUMP BODY IS RAISED (WHEN MACHINE IS NOT INCLINED MORE THAN 15°).................................................................................... 800
BK-4 TOUCH UP/DOWN AND CANCELLATION CANNOT BE PERFORMED...................................................................................................................................... 801
TROUBLESHOOTING FOR PAYLOAD METER SYSTEM (CARD TYPE) (LC MODE)................................................................................................................................... 803
ELECTRICAL SYSTEM DIAGRAM RELATED TO PAYLOAD METER........................................................................................................................................... 804
SERVICE CODES OF PAYLOAD METER Ⅱ (CARD TYPE) AND CONTENTS OF SELF-DIAGNOSIS.................................................................................................................. 806
INFORMATION IN TROUBLESHOOTING TABLE......................................................................................................................................................... 809
TROUBLE CODE TABLE........................................................................................................................................................................... 810
LC-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM IS NOT DISPLAYED............................................................................................................................ 811
LC-2 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL PILOT LAMPS DO NOT LIGHT UP ........................................................................................................... 813
LC-3 EXTERNAL LAMPS LIGHT UP WHILE CONDITION FOR LIGHTING IS NOT SET......................................................................................................................... 816
LC-4 LIGHTING LEVEL OF EXTERNAL PILOT LAMPS IS ABNORMAL...................................................................................................................................... 818
LC-5 CYCLE DATA AND ENGINE ON/OFF DATA NOT RECORDED (CHARGE LEVEL SIGNAL SYSTEM: JUDGES THAT ENGINE IS STOPPED).............................................................................. 820
LC-6 CALIBRATION CANNOT BE PERFORMED AND DISPLAYED CLOCK DOES NOT CONFORM TO CONDITION (SHIFT LEVER "N" POSITION SIGNAL SYSTEM).............................................................. 821
LC-7 DISPLAYED LOGIC IS ABNORMAL............................................................................................................................................................. 823
a) WHEN LOADED DUMP TRUCK STARTS TRAVELING, "O" IS KEPT DISPLAYED........................................................................................................................ 823
b) AFTER LOADED DUMP TRUCK STARTS TRAVELING, DISPLAY OF ODOMETER DOES NOT INCREASE....................................................................................................... 823
c) WHEN TRAVEL SPEED EXCEEDS LIMIT SPEED, "SP:SP" DOES NOT GO OFF........................................................................................................................ 823
d) INTEGRATED PAY LOAD IS NOT DIAPLAYED.................................................................................................................................................. 824
e) DISPLAYED AND SAVED PAY LOAD IS NOT CORRECT........................................................................................................................................... 825
LC-8 PAYLOAD METER KEEPS DISPLAYING "b:FL" (BODY "FLOAT" SIGNAL SYSTEM: DUMP LEVER IS NOT IN "FLOAT" POSITION WHILE TRUCK IS NOT DUMPING).................................................... 826
LC-9 PAYLOAD METER DISPLAYS "F:09" (LOWERING OF INTERNAL BACKUP BATTERY VOLTAGE)............................................................................................................. 828
LC-10 PAYLOAD METER DISPLAYS "□:FULL" (DATA SAVING MEMORY IS FULL)........................................................................................................................... 828
LC-11 PAYLOAD METER DISPLAYS "F-20":FAILURE IN POWER SOURCE OF SUSPENSION PRESSURE SENSOR AND CLINOMETER SYSTEM.............................................................................. 829
LC-12 PAYLOAD METER DISPLAYS "F-21"-"F-24":DISCONNECTION OR GROUNDING FAULT IN SUSPENSION SENSOR SIGNAL SYSTEM............................................................................... 831
LC-13 PAYLOAD METER DISPLAYS "F-25"-"F-28":SHORT CIRCUIT WITH POWER SOURCE IN SUSPENSION SENSOR SIGNAL SYSTEM................................................................................ 834
LC-14 PAYLOAD METER DISPLAYS "F-CAL" (NEGLIGENCE OF CALIBRATION OR INTERNAL DAMAGE OF PAYLOAD METER)......................................................................................... 836
LC-15 PAYLOAD METER DISPLAYS "F:43"-"F:45" (SHORT CIRCUIT WITH POWER SOURCE IN EXTERNAL PILOT LAMP RELAY SYSTEM)............................................................................. 837
LC-16 PAYLOAD METER DISPLAYS "L-bad" (CYCLE DATA WERE SAVED WHILE TRUCK BODY WAS PITCHING)................................................................................................... 839
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.......................................... 841
LC-18 PAYLOAD METER DISPLAYS"F-31":GROUNDING FAULT OR DISCONNECTION IN CLINOMETER SENSOR SIGNAL SYSTEM....................................................................................... 842
LC-19 PAYLOAD METER DISPLAYS "F-32":SHORT CIRCUIT WITH POWER SOURCE IN CLINOMETER SENSOR SIGNAL SYSTEM....................................................................................... 844
LC-20 PAYLOAD METER DISPLAYS "F:18" (DISCONNECTION IN CHARGE LEVEL SIGNAL SYSTEM)............................................................................................................ 846
TROUBLESHOOTING FOR MONITOR SYSTE (MON MODE)..................................................................................................................................................... 847
ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR................................................................................................................................................. 849
INFORMATION IN TROUBLESHOOTING TABLE......................................................................................................................................................... 850
TROUBLE CODE TABLE........................................................................................................................................................................... 851
[B@C7NS] REAR BRAKE OIL:OVERHEATING (NS)..................................................................................................................................................... 852
[B@CENS] TORQUE CONVERTER:OVERHEATING (NS)................................................................................................................................................... 852
[DAF0KM] MONITOR PANEL:MISTAKE IN OPERATION OR SETTING (KM).................................................................................................................................. 853
[DAF9KM] MONITOR PANEL:MISTAKE IN OPERATION OR SETTING (KM).................................................................................................................................. 856
[DAFSKQ] MONITOR PANEL:DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ).......................................................................................................................... 857
[DAQSKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN TRANSMISSION CONTROLLER AND MACHINE MONITOR) (KR)............................................................................................ 858
[DASRKR] CAN COMMUNICATION・COMMUNICATION DEFECTIVE: ABNORMALITY IN OBJECTIVE COMPONENT (KR).................................................................................................. 861
[DB1SKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN RETARDER CONTROLLER AND MACHINE MONITOR) (KR)................................................................................................ 863
[DV00KB] SHORT CIRCUIT IN ALARM BUZZER OUTPUT・SHORT CIRCUIT (KB)............................................................................................................................. 866
MON-1 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR DOES NOT DISPLAY ANY ITEM........................................................................................................... 867
MON-2 WHEN STARTING SWITCH IS TURNED OFF AND MACHINE MONITOR DOES NOT OPERATE NORMALLY....................................................................................................... 868
MON-3 ALARM BUZZER DEFECTIVE................................................................................................................................................................. 870
a) ALARM BUZZER DOES NOT SOUND........................................................................................................................................................... 870
b) ALARM BUZZER DOES NOT STOP SOUNDING................................................................................................................................................... 871
MON-4 ITEMS DISPLAYED BY GAUGES, CAUTION LAMPS, AND CHARACTER DISPLAY OF MACHINE MONITOR ARE ABNORMAL........................................................................................ 872
a) ITEMS DISPLAYED BY GAUGES ARE DIFFERENT FROM MACHINE CONDITION........................................................................................................................ 872
b) ITEMS DISPLAYED BY CAUTION LAMPS ARE DIFFERENT FROM MACHINE CONDITION................................................................................................................. 873
c) CHARACTER DISPLAY DOES NOT DISPLAY ANY ITEM OR IT DISPLAYS ABNORMALLY................................................................................................................. 873
MON-5 OPERATION OF MACHINE MONITOR CANNOT BE CHECKED NORMALLY................................................................................................................................ 874
MON-6 DISPLAY OF CHARACTER DISPLAY CANNOT BE SELECTED NORMALLY............................................................................................................................... 875
a) MACHINE MONITOR MODE SELECT SWITCH 1 SYSTEM IS ABNORMAL............................................................................................................................... 875
b) MACHINE MONITOR MODE SELECT SWITCH 2 SYSTEM IS ABNORMAL............................................................................................................................... 877
MON-7 POWER MODE SELECT FUNCTION DOES NOT WORK NORMALLY...................................................................................................................................... 879
MON-8 SEAT BELT CAUTION LAMP DOES NOT OPERATE NORMALLY....................................................................................................................................... 880
a) LAMP LIGHTS UP WHILE SEAT BELT IS FASTENED............................................................................................................................................ 880
b) LAMP DOES NOT LIGHT UP WHILE SEAT BELT IS UNFASTENED.................................................................................................................................. 881
MON-9 TURN SIGNALS AND HAZARD LAMP DO NOT OPERATE NORMALLY................................................................................................................................... 882
a) WHEN TURN SIGNAL LEVER AND HAZARD LAMP SWITCH ARE OPERATED, ANY TURN SIGNAL LAMP DOES NOT FLASH....................................................................................... 882
b) WHEN TURN SIGNAL LEVER AND HAZARD LAMP SWITCH ARE OPERATED, THE TURN SIGNAL LAMPS DO NOT FLASH BUT LIGHT UP........................................................................... 883
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)........... 884
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)............................. 885
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)........................ 887
f) TURN SIGNAL PILOT LAMPS DO NOT FLASH NORMALLY (TURN SIGNAL LAMPS FLASH NORMALLY, HOWEVER)............................................................................................. 888
MON-10 NIGHT LIGHTING IS ABNORMAL............................................................................................................................................................ 890
a) WHEN LAMP SWITCH IS SET IN 1ST OR 2ND POSITION, ANY OF SMALL LAMP, NIGHT LAMP, AND HEAD LAMP DOES NOT LIGHT UP........................................................................ 890
b) WHEN LAMP SWITCH IS SET IN 1ST POSITION, SMALL LAMP AND NIGHT LAMP DO NOT LIGHT UP.................................................................................................... 891
c) WHEN LAMP SWITCH IS OFF, SMALL LAMP AND NIGHT LAMP LIGHT UP........................................................................................................................... 892
d) WHEN DIMMER SWITCH IS OPERATED, BRIGHTNESS OF NIGHT LIGHTING DOES NOT CHANGE.......................................................................................................... 893
e) HEAD LAMP "HI" BEAM DOES NOT LIGHT UP................................................................................................................................................. 894
f) HEAD LAMP "LO" BEAM DOES NOT LIGHT UP................................................................................................................................................. 895
g) HEAD LAMP CANNOT BE SET TO "HI" OR "LO"............................................................................................................................................... 896
h) WHEN HEAD LAMP IS SET TO "HI" BEAM, PILOT LAMP OF MACHINE MONITOR DOES NOT LIGHT UP................................................................................................... 897
MON-11 POWER WINDOW DOES NOT OPERATE NORMALLY................................................................................................................................................ 899
a) OPERATING LEFT SIDE DOES NOT.......................................................................................................................................................... 899
b) OPERATING RIGHT SIDE DOES NOT......................................................................................................................................................... 900
MON-12 DEFECTIVE AIR CONDITIONER............................................................................................................................................................. 902
a) AIR CONDITIONER DOES NOT OPERATE...................................................................................................................................................... 902
b) AIR DOES NOT COME OUT OR AIR FLOW CANNOT BE ADJUSTED.................................................................................................................................. 903
c) AIR IS NOT COOLED OR TEMPERATURE CANNOT BE ADJUSTED (ELECTRIC SYSTM).................................................................................................................. 905
d) RECIRCULATED AIR AND FRESH AIR CANNOT BE SELECTED..................................................................................................................................... 907
e) AIR OUTLETS CANNOT BE SELECTED........................................................................................................................................................ 908
f) AIR IS NOT COOLED (MECHANICAL SYSTEM)................................................................................................................................................. 910
g) AIR IS NOT HEATED (DEFECTIVE HOT WATER CIRCUIT)....................................................................................................................................... 911
h) ABNORMAL SOUND COMES OUT.............................................................................................................................................................. 911
i) WATER LEAKS........................................................................................................................................................................... 912
TROUBLESHOOTING OF VHMS CONTROLLER SYSTEM (VHMS MODE)............................................................................................................................................ 913
ELECTRICAL SYSTEM DIAGRAM RELATED VHMS CONTROLLER............................................................................................................................................ 914
INFORMATION GIVEN IN TROUBLESHOOTING CHART................................................................................................................................................... 917
FAILURE TYPE CODE LIST....................................................................................................................................................................... 918
[A000N1] (OR VHMS_LED DISPLAYS [n201]) ENGINE OVERRUN........................................................................................................................................ 919
[DBB0KK] (OR VHMS_LED INDICATES "n901") ABNORMALITY IN SOURCE VOLTAGE........................................................................................................................ 920
[DBB5KP] (OR VHMS_LED INDICATES "n904") ABNORMALITY IN SENSOR POWER SOURCE (5V) SYSTEM....................................................................................................... 922
[DBB6KP] (OR VHMS_LED INDICATES "n902") ABNORMALITY IN SENSOR POWER SOURCE (24V) SYSTEM...................................................................................................... 924
[DBB7KP] (OR VHMS_LED INDICATES "n903") ABNORMALITY IN SENSOR POWER SOURCE (12V) SYSTEM...................................................................................................... 926
[DBBRKR] (OR VHMS_LED DISPLAYS [n801]) DEFECTIVE CAN COMMUNICATIONS: DEFECTIVE COMMUNICATIONS (KR) (BETWEEN ENGINE CONTROLLER AND VIHMS CONTROLLER).......................................... 928
[DBBSKR] (OR VHMS_LED DISPLAYS [n803]) DEFECTIVE S-NET COMMUNICATIONS: (KR).................................................................................................................. 930
[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}.... 932
[DGE1KY] (OR VHMS_LED DISPLAYS [n241]) SHORT CIRCUIT WITH POWER SOURCE IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KY).......................................................................... 933
[DGE5KX] (OR VHMS_LED DISPLAYS [n401]) FAILURE IN AMBIENT TEMPERATURE SENSOR SYSTEM:INPUT SIGNAL OUTSIDE RANGE (KX).......................................................................... 934
[DGT4KA] (OR VHMS_LED DISPLAYS [n312]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO.1,2,3 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)........................................... 935
[DGT4KB] (OR VHMS_LED DISPLAYS [n311]) SHORT CIRCUIT WITH POWER SOURCE IN NO.1,2,3 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)............................................................ 937
[DGT5KA] (OR VHMS_LED DISPLAYS [n322]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO.4,5,6 (REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)............................................ 939
[DGT5KB] (OR VHMS_LED DISPLAYS [n321]) SHORT CIRCUIT WITH POWER SOURCE IN NO.4,5,6 (REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)............................................................. 941
[DHE5KB] (OR VHMS_LED DISPLAYS [n332]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KA)........................................................ 943
[DHE5KY] (OR VHMS_LED DISPLAYS [n331]) SHORT CIRCUIT WITH POWER SOURCE IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KY)......................................................................... 944
[DhP4KX] SUSPENSION PRESSURE SENSOR (FRONT RIGHT):OUT OF INPUT SIGNAL RANGE (KX)............................................................................................................. 945
[DhP5KX] SUSPENSION PRESSURE SENSOR (FRONT LEFT):OUT OF INPUT SIGNAL RANGE (KX).............................................................................................................. 947
[DhP6KX] SUSPENSION PRESSURE SENSOR (REAR RIGHT):OUT OF INPUT SIGNAL RANGE (KX).............................................................................................................. 949
[DhP7KX] SUSPENSION PRESSURE SENSOR (REAR LEFT):OUT OF INPUT SIGNAL RANGE (KX)............................................................................................................... 951
[DKH1KX] PITCH ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX).................................................................................................................................. 953
[F@BBZL] (OR VHMS_LED DISPLAYS [n338]) ENGINE BLOW-BY PRESSURE IS HIGH: (ZL)................................................................................................................. 955
[F@BYNR] (OR VHMS_LED DISPLAYS [n362]) NO.1,2,3 (FRONT) EXHAUST TEMPERATURE IS HIGH (2):(NR)................................................................................................. 956
[F@BYNS] (OR VHMS_LED DISPLAYS [n361]) NO.1,2,3 (FRONT) EXHAUST TEMPERATURE IS HIGH (1):(NS)................................................................................................. 957
[F@BZNR] (OR VHMS_LED DISPLAYS [n372]) NO.4,5,6 (REAR) EXHAUST TEMPERATURE IS HIGH (2):(NR).................................................................................................. 958
[F@BZNS] (OR VHMS_LED DISPLAYS [n371]) NO.4,5,6 (REAR) EXHAUST TEMPERATURE IS HIGH (1):(NS).................................................................................................. 959
VHMS-1 ABNORMALITY IN SATELLITE DATA COMMUNICATION........................................................................................................................................... 960
a) SATELLITE COMMUNICATION DATA ARE NOT TRANSMITTED...................................................................................................................................... 960
b) ABNORMALITY IN DOWNLOADING INTO PC OR SETTING OF PC................................................................................................................................... 963
VHMS-2 ABNORMALITY IN SAVING DATA IN VHMS CONTROLLER (DATA ARE NOT SAVED).................................................................................................................... 965
VHMS-3 ENGINE BLOW-BY PRESSURE INDICATED BY MONITOR IS LOW (WHEN BLOW-BY PRESSURE MEASURED WITH MEASURING INSTRUMENT IS NORMAL).............................................................. 967
TROUBLESHOOTING OF ASR CONTROLLER SYSTEM (ASR MODE).............................................................................................................................................. 968
ELECTRICAL SYSTEM DIAGRAM RELATED ASR CONTROL................................................................................................................................................ 969
INFORMATION IN TROUBLESHOOTING TABLE......................................................................................................................................................... 970
TROUBLE CODE TABLE........................................................................................................................................................................... 971
[DDDAKA] ASR SYSTEM SWITCH SYSTEM:DISCONNECTION (KA)......................................................................................................................................... 972
[DDDAKB] ASR SYSTEM SWITCH SYSTEM:SHORT CIRCUIT (KB)......................................................................................................................................... 973
[DK30KX] STEERING ANGLE SENSOR:OUT OF INPUT SIGNAL RANGE (KX)................................................................................................................................ 974
[DLF8KA] WHEEL SPEED SENSOR (RR):DISCONNECTION (KA).......................................................................................................................................... 976
[DLF8LC] WHEEL SPEED SENSOR (RR):※ SEE SEPARATE LIST (LC).................................................................................................................................... 977
[DLF9KA] WHEEL SPEED SENSOR (RL):DISCONNECTION (KA).......................................................................................................................................... 978
[DLF9LC] WHEEL SPEED SENSOR (RL):※ SEE SEPARATE LIST (LC).................................................................................................................................... 979
[dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:※ SEE SEPARATE LIST (LC)..................................................................................................................... 980
[DWNBK4] SHUT-OFF SOLENOID VALVE:UNCONTROLLABLE (K4)......................................................................................................................................... 982
[DWNBKA] SHUT-OFF SOLENOID VALVE:DISCONNECTION (KA).......................................................................................................................................... 984
[DWNBKB] SHUT-OFF SOLENOID VALVE:SHORT CIRCUIT (KB).......................................................................................................................................... 985
[DWNBKY] SHUT-OFF SOLENOID VALVE:SHORT CIRCUIT WITH POWER SOURCE (KY)........................................................................................................................ 986
[DWNBMA] SHUT-OFF SOLENOID VALVE:MALFUNCTION (MA)............................................................................................................................................ 987
[DX17K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):UNCONTROLLABLE (K4)....................................................................................................... 988
[DX17KA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):DISCONNECTION (KA)........................................................................................................ 990
[DX17KB] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):SHORT CIRCUIT (KB)........................................................................................................ 991
[DX17KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):SHORT CIRCUIT WITH POWER SOURCE (KY)...................................................................................... 992
[DX17MA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):MALFUNCTION (MA).......................................................................................................... 993
[DX18K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):UNCONTROLLABLE (K4)........................................................................................................ 994
[DX18KA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):DISCONNECTION (KA)......................................................................................................... 996
[DX18KB] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):SHORT CIRCUIT (KB)......................................................................................................... 997
[DX18KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):SHORT CIRCUIT WITH POWER SOURCE (KY)....................................................................................... 998
[DX18MA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):MALFUNCTION (MA)........................................................................................................... 999
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE).....................................................................................................................................1000
H-1 MACHINE DOES NOT START...................................................................................................................................................................1001
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY(MACHINE JERKS)..........................................................................................................................................1003
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED(ENGINE STALLS).......................................................................................................................................1003
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING................................................................................................................................................1004
H-5 TRANSMISSION DOES NOT SHIFT UP ..........................................................................................................................................................1004
a. DOES NOT SHIFT UP.....................................................................................................................................................................1004
b. DOES NOT SHIFT UP.....................................................................................................................................................................1004
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING..............................................................................................................................................1005
a. ABNORMALITY AT ALL SPEED RANGES.......................................................................................................................................................1005
b. TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE..............................................................................................................................................1006
c. ABNORMALITY AT SPECIFIC SPEED RANGES..................................................................................................................................................1007
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR.....................................................................................................................................1009
H-8 TORQUE CONVERTAR OIL TEMPERATURE IS HIGH.................................................................................................................................................1011
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW.....................................................................................................................................................1012
H-10 FRONT BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE................................................................................................................................1013
H-11 REAR BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE.................................................................................................................................1014
H-12 STEERING WHEEL IS HEAVY.................................................................................................................................................................1015
H-13 STEERING WHEEL DOES NOT WORK............................................................................................................................................................1016
H-14 STEERING WHEEL VIBRATES.................................................................................................................................................................1016
H-15 HOIST CYLINDER LACKS LIFTING FORCE(LIFTING SPEED).......................................................................................................................................1017
H-16 HOIST CYLINDER DOES NOT WORK............................................................................................................................................................1018
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY..................................................................................................................................................1019
TROUBLESHOOTING OF ENGINE SYSTEM (S MODDE).......................................................................................................................................................1020
POINTS TO REMEMBER WHEN TROUBLESHOOTING......................................................................................................................................................1021
METHOD OF USING TROUBLESHOOTING CHARTS.......................................................................................................................................................1022
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)................................................................................................................................1025
S-2 ENGINE DOES NOT START....................................................................................................................................................................1027
a) ENGINE DOES NOT TURN..................................................................................................................................................................1027
b) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED)...............................................................................................................1028
c) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED).............................................................................................................1030
S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)......................................................................................................................................1032
S-4 ENGINE STOPS DURING OPERATIONS...........................................................................................................................................................1034
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING).................................................................................................................................................1036
S-6 ENGINE LACKS OUTPUT(OR LACKS POWER)......................................................................................................................................................1038
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)............................................................................................................................................1040
S-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE)...................................................................................................................................1042
S-9 OIL BECOMES CONTAMINATED QUICKLY.........................................................................................................................................................1043
S-10 FUEL CONSUMPTION IS EXCESSIVE...........................................................................................................................................................1044
S-11 OIL IS COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN......................................................................................................................1045
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)...............................................................................................................................1046
S-13 OIL LEVEL RISES.........................................................................................................................................................................1047
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING).........................................................................................................................................1048
S-15 ABNORMAL NOISE IS MADE..................................................................................................................................................................1049
S-16 VIBRATION IS EXCESSIVE..................................................................................................................................................................1050
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)....................................................................................................................................................1051
ELECTRICAL SYSTEM DIAGRAM RELATED TO EMERGENCY STEERING CONTROL..............................................................................................................................1052
INFORMATION IN TROUBLESHOOTING TABLE.........................................................................................................................................................1053
E-1 EMERGENCY STEERING SYSTEM DOES NOT OPERATE...............................................................................................................................................1055
TROUBLESHOOTING OF ABS CONTROLLER SYSTEM (ABS MODE) (IF EQUIPPED)................................................................................................................................1058
ELECTRICAL SYSTEM DIAGRAM RELATED ABS CONTROL................................................................................................................................................1059
INFORMATION IN TROUBLESHOOTING TABLE.........................................................................................................................................................1061
[D1E5KZ] ABS CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ).................................................................................................................................1063
[DBC0KK] ABS CONTROLLER: SUPPLY VOLTAGE REDUCTION (KK)......................................................................................................................................1065
[DBC1KK] ABS CONTROLLER MAIN POWER LINE: SUPPLY VOLTAGE REDUCTION (KK)......................................................................................................................1066
[DBC2KK] ABS CONTROLLER LOAD POWER LINE: SUPPLY VOLTAGE REDUCTION (KK)......................................................................................................................1067
[DBC3KK] ABS CONTROLLER BATTERY DIRECT POWER SUPPLY: SUPPLY VOLTAGE REDUCTION (KK)..........................................................................................................1069
[DBC9KM] ABS CONTROLLER WIRE WIRING HARNESS: SETTING OPERATION ERROR (KM)...................................................................................................................1070
[DBCSKR] ABS CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR)...................................................................................................................1071
[DDD9KA] ABS SYSTEM SWITCH: DISCONNECTION (KA)..............................................................................................................................................1073
[DDD9KB] ABS SYSTEM SWITCH: SHORT CIRCUIT (KB)..............................................................................................................................................1074
[DHU6KX] ABS CONTROL VALVE PRESSURE SENSOR FRONT WHEEL RIGHT (FR): OUTSIDE INPUT SIGNAL RANGE (KX)..........................................................................................1075
[DHU7KX] ABS CONTROL VALVE PRESSURE SENSOR FRONT WHEEL LEFT (FL): OUTSIDE INPUT SIGNAL RANGE (KX)...........................................................................................1077
[DHU8KX] ABS CONTROL VALVE PRESSURE SENSOR REAR WHEEL RIGHT (RR): OUTSIDE INPUT SIGNAL RANGE (KX)...........................................................................................1079
[DHU9KX] ABS CONTROL VALVE PRESSURE SENSOR REAR WHEEL LEFT (RL): OUTSIDE INPUT SIGNAL RANGE (KX)............................................................................................1081
[DK11KX] ACCELERATOR SENSOR: OUTSIDE INPUT SIGNAL RANGE (KX)................................................................................................................................1083
[DLF6KA] WHEEL SPEED SENSOR FRONT WHEEL RIGHT (FR): DISCONNECTION (KA)......................................................................................................................1085
[DLF7KA] WHEEL SPEED SENSOR FRONT WHEEL LEFT (FL): DISCONNECTION (KA).......................................................................................................................1087
[DLF8KA] WHEEL SPEED SENSOR REAR WHEEL RIGHT (RR): DISCONNECTION (KA).......................................................................................................................1089
[DLF9KA] WHEEL SPEED SENSOR REAR WHEEL LEFT (RL): DISCONNECTION (KA)........................................................................................................................1091
[DWNDKZ] ABS CUT VALVE (F): DISCONNECTION OR SHORT CIRCUIT (KZ).............................................................................................................................1093
[DWNDMA] ABS CUT VALVE (F): MALFUNCTION (MA)................................................................................................................................................1095
[DWNEKZ] ABS CUT VALVE (R): DISCONNECTION OR SHORT CIRCUIT (KZ).............................................................................................................................1096
[DWNEMA] ABS CUT VALVE (R): MALFUNCTION (MA)................................................................................................................................................1098
[DX21KA] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): DISCONNECTION (KA).......................................................................................................................1099
[DX21KB] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): SHORT CIRCUIT (KB).......................................................................................................................1100
[DX21KY] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): SHORT-CIRCUITED TO POWER SUPPLY (KY).....................................................................................................1101
[DX21MA] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): MALFUNCTION (MA).........................................................................................................................1102
[DX22KA] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): DISCONNECTION (KA)........................................................................................................................1103
[DX22KB] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): SHORT CIRCUIT (KB)........................................................................................................................1104
[DX22KY] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): SHORT-CIRCUITED TO POWER SUPPLY (KY)......................................................................................................1105
[DX22MA] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): MALFUNCTION (MA)..........................................................................................................................1106
[DX23KA] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): DISCONNECTION (KA)........................................................................................................................1107
[DX23KB] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): SHORT CIRCUIT (KB)........................................................................................................................1108
[DX23KY] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): SHORT-CIRCUITED TO POWER SUPPLY (KY)......................................................................................................1109
[DX23MA] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): MALFUNCTION (MA)..........................................................................................................................1110
[DX24KA] ABS CONTROL VALVE REAR WHEEL LEFT (RL): DISCONNECTION (KA).........................................................................................................................1111
[DX24KB] ABS CONTROL VALVE REAR WHEEL LEFT (RL): SHORT CIRCUIT (KB).........................................................................................................................1112
[DX24KY] ABS CONTROL VALVE REAR WHEEL LEFT (RL): SHORT-CIRCUITED WITH POWER SUPPLY (KY).....................................................................................................1113
[DX24MA] ABS CONTROL VALVE REAR WHEEL LEFT (RL): MALFUNCTION (MA)...........................................................................................................................1114
[DX25MA] ABS CONTROL VALVE (FRONT WHEEL SYSTEM): MALFUNCTION (MA)...........................................................................................................................1115
[DX26MA] ABS CONTROL VALVE (REAR WHEEL SYSTEM): MALFUNCTION (MA)............................................................................................................................1116
30 DISASSEMBLY AND ASSEMBLY..............................................................................................................................................................................1117
METHOD OF USING MANUAL...............................................................................................................................................................................1119
PRECAUTIONS WHEN CARRYING OUT OPERATION..............................................................................................................................................................1120
SPECIAL TOOL LIST....................................................................................................................................................................................1122
FUEL INJECTION PUMP..................................................................................................................................................................................1126
REMOVAL AND INSTALLATION.........................................................................................................................................................................1126
RADIATOR.............................................................................................................................................................................................1127
REMOVAL AND INSTALLATION.........................................................................................................................................................................1127
ENGINE AND TORQUE CONVERTER AND TRANSMISSION OIL COOLER..............................................................................................................................................1129
REMOVAL AND INSTALLATION.........................................................................................................................................................................1129
ENGINE FRONT SEAL....................................................................................................................................................................................1130
REMOVAL AND INSTALLATION.........................................................................................................................................................................1130
OUTPUT SHAFT.........................................................................................................................................................................................1131
REMOVAL AND INSTALLATION.........................................................................................................................................................................1131
DISASSEMBLY......................................................................................................................................................................................1132
ASSEMBLY.........................................................................................................................................................................................1133
ENGINE REAR SEAL.....................................................................................................................................................................................1135
REMOVAL AND INSTALLATION.........................................................................................................................................................................1135
CYLINDER HEAD........................................................................................................................................................................................1137
REMOVAL..........................................................................................................................................................................................1137
INSTALLATION.....................................................................................................................................................................................1139
ENGINE...............................................................................................................................................................................................1142
REMOVAL..........................................................................................................................................................................................1142
INSTALLATION.....................................................................................................................................................................................1143
TORQUE CONVERTER AND TRANSMISSION....................................................................................................................................................................1145
REMOVAL..........................................................................................................................................................................................1145
INSTALLATION.....................................................................................................................................................................................1146
TRANSMISSION ASSEMBLY AND TORQUE CONVERTER...........................................................................................................................................................1148
SEPARATION AND COUPLING..........................................................................................................................................................................1148
TORQUE CONVERTER.....................................................................................................................................................................................1149
DISASSEMBLY......................................................................................................................................................................................1149
ASSEMBLY.........................................................................................................................................................................................1153
TRANSMISSION.........................................................................................................................................................................................1159
DISASSEMBLY......................................................................................................................................................................................1159
ASSEMBLY.........................................................................................................................................................................................1172
DIFFERENTIAL.........................................................................................................................................................................................1187
REMOVAL..........................................................................................................................................................................................1187
INSTALLATION.....................................................................................................................................................................................1188
DISASSEMBLY......................................................................................................................................................................................1189
ASSEMBLY.........................................................................................................................................................................................1193
FRONT WHEEL .........................................................................................................................................................................................1201
REMOVAL AND INSTALLATION.........................................................................................................................................................................1201
REAR WHEEL...........................................................................................................................................................................................1202
REMOVAL..........................................................................................................................................................................................1202
INSTALLATION.....................................................................................................................................................................................1203
FRONT BRAKE CALIPER PADS.............................................................................................................................................................................1204
REMOVAL AND INSTALLATION.........................................................................................................................................................................1204
FRONT BRAKE CALIPERS.................................................................................................................................................................................1205
REMOVAL AND INSTALLATION.........................................................................................................................................................................1205
DISASSEMBLY AND ASSEMBLY.........................................................................................................................................................................1206
FRONT WHEEL HUB......................................................................................................................................................................................1208
DISASSEMBLY......................................................................................................................................................................................1208
ASSEMBLY.........................................................................................................................................................................................1209
FINAL DRIVE CARRIER..................................................................................................................................................................................1211
REMOVAL AND INSTALLATION.........................................................................................................................................................................1211
DISASSEMBLY AND ASSEMBLY.........................................................................................................................................................................1212
FINAL DRIVE AND REAR BRAKE...........................................................................................................................................................................1213
REMOVAL..........................................................................................................................................................................................1213
INSTALLATION.....................................................................................................................................................................................1215
FINAL DRIVE,REAR BRAKE,AND PARKING BRAKE.............................................................................................................................................................1216
REMOVAL AND INSTALLATION.........................................................................................................................................................................1216
DISASSEMBLY......................................................................................................................................................................................1217
ASSEMBLY.........................................................................................................................................................................................1222
FRONT SUSPENSION CYLINDER............................................................................................................................................................................1228
REMOVAL..........................................................................................................................................................................................1228
INSTALLATION.....................................................................................................................................................................................1229
DISASSEMBLY......................................................................................................................................................................................1230
ASSEMBLY.........................................................................................................................................................................................1231
REAR SUSPENSION CYLINDER.............................................................................................................................................................................1236
REMOVAL AND INSTALLATION.........................................................................................................................................................................1236
DISASSEMBLY......................................................................................................................................................................................1237
ASSEMBLY.........................................................................................................................................................................................1238
RETARDER COOLING PUMP................................................................................................................................................................................1243
REMOVAL AND INSTALLATION.........................................................................................................................................................................1243
STEERING,HOIST,AND HOIST CONTROL PUMP................................................................................................................................................................1244
REMOVAL AND INSTALLATION.........................................................................................................................................................................1244
TORQUE CONVERTER,TRANSMISSION AND RETARDER COOLING,AND BRAKE PUMP....................................................................................................................................1245
REMOVAL AND INSTALLATION.........................................................................................................................................................................1245
STEERING VALVE.......................................................................................................................................................................................1246
REMOVAL AND INSTALLATION.........................................................................................................................................................................1246
DISASSEMBLY......................................................................................................................................................................................1247
ASSEMBLY.........................................................................................................................................................................................1250
DEMAND VALVE.........................................................................................................................................................................................1257
REMOVAL AND INSTALLATION.........................................................................................................................................................................1257
HOIST VALVE..........................................................................................................................................................................................1258
REMOVAL AND INSTALLATION.........................................................................................................................................................................1258
STEERING CYLINDER....................................................................................................................................................................................1259
DISASSEMBLY......................................................................................................................................................................................1259
ASSEMBLY.........................................................................................................................................................................................1260
HOIST CYLINDER.......................................................................................................................................................................................1262
DISASSEMBLY......................................................................................................................................................................................1262
ASSEMBLY.........................................................................................................................................................................................1263
DUMP BODY............................................................................................................................................................................................1266
REMOVAL..........................................................................................................................................................................................1266
INSTALLATION.....................................................................................................................................................................................1267
OPERATOR'S SEAT......................................................................................................................................................................................1269
DISASSEMBLY......................................................................................................................................................................................1269
ASSEMBLY.........................................................................................................................................................................................1274
90 OTHERS................................................................................................................................................................................................1348
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM................................................................................................................................................................1349
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM.........................................................................................................................................................1350
BRAKE HYDRAULIC CIRCUIT DIAGRAM......................................................................................................................................................................1351
ELECTRICAL CIRCUIT DIAGRAM (1/6).....................................................................................................................................................................1352
ELECTRICAL CIRCUIT DIAGRAM (2/6).....................................................................................................................................................................1353
ELECTRICAL CIRCUIT DIAGRAM (3/6).....................................................................................................................................................................1354
ELECTRICAL CIRCUIT DIAGRAM (4/6).....................................................................................................................................................................1355
ELECTRICAL CIRCUIT DIAGRAM (5/6) HD465-7 SERIAL NO. 7001 － 7693, HD605-7 SERIAL NO. 7001 － 7256......................................................................................................1356
ELECTRICAL CIRCUIT DIAGRAM (5/6) HD465-7 SERIAL NO. 7694 － 7714......................................................................................................................................1357
ELECTRICAL CIRCUIT DIAGRAM (5/6) HD465-7 SERIAL NO. 7715 － , HD605-7 SERIAL NO. 7257 －...............................................................................................................1358
ELECTRICAL CIRCUIT DIAGRAM (6/6) HD465-7 SERIAL NO. 7001 － 7693, HD605-7 SERIAL NO. 7001 － 7256......................................................................................................1359
ELECTRICAL CIRCUIT DIAGRAM (6/6) HD465-7 SERIAL NO. 7694 － 7714......................................................................................................................................1360
ELECTRICAL CIRCUIT DIAGRAM (6/6) HD465-7 SERIAL NO. 7715 － , HD605-7 SERIAL NO. 7257 －...............................................................................................................1361
ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL............................................................................................................................................1362
ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR.........................................................................................................................................................1363
ELECTRICAL CIRCUIT DIAGRMAM (A1 SIZE) (1/2)..........................................................................................................................................................1364
ELECTRICAL CIRCUIT DIAGRMAM (A1 SIZE) (2/2)..........................................................................................................................................................1365
ELECTRICAL SYSTEM DIAGRAM RELATED TO ABS CONTROLLER..................................................................................................................................................1366
ELECTRICAL CIRCUIT DIAGRAM RELATED TO ABS............................................................................................................................................................1367
ELECTRICAL CIRCUIT DIAGRAM FOR AUTO GREASING SYSTEM..................................................................................................................................................1368
EXTERNAL POWER SUPPLY HEATER.........................................................................................................................................................................1369
CONNECTORS TABLE (A1 SIZE)...........................................................................................................................................................................1370
ARRANGEMENT DRAWING (A1 SIZE)........................................................................................................................................................................1371
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
