Komatsu HD465-7R Dump Truck Shop Manual SEN06285-07 PDF  

Description

Komatsu HD465-7R Dump Truck Shop Manual SEN06285-07 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HD465-7R Dump Truck Shop Manual SEN06285-07 – PDF DOWNLOAD 

Language : English
Pages : 1714
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HD465-7R Dump Truck Shop Manual SEN06285-07 – PDF DOWNLOAD 

SERIAL NUMBERS 16132 and up

How to read the shop manual :
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

Komatsu HD465-7R Dump Truck Shop Manual SEN06285-07 – PDF DOWNLOAD 

SERIAL NUMBERS 16132 and up

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 21
Safety notice 22
How to read the shop manual 27
Explanation of terms for maintenance standard 29
Handling of electric equipment and hydraulic component 31
Handling of connectors newly used for engines 40
How to read electric wire code 43
Precautions when carrying out operation 46
Method of disassembling and connecting push-pull type coupler 49
Standard tightening torque table 52
Conversion table 56
01 Specification 63
Specification and technical data 63
Specification drawing 64
Specifications 65
Weight table 68
Fuel, coolant and lubricants 69
10 Structure, function and maintenance standard 73
Engine and cooling system 73
Radiator, torque converter oil cooler, after cooler, work equipment oil cooler, fuel cooler 74
Fuel system 76
Brake oil cooler 77
Output shaft 78
Power train, Part 1 81
Power train skeleton 82
Drive shaft 84
Torque converter and transmission hydraulic piping 86
Torque converter 88
Torque converter valve 95
Transmission 97
Transmission control valve 113
ECMV 114
Power train, Part 2 123
Axle 124
Differential 126
Final drive 127
Wheels 128
Steering system 131
Steering column 132
Steering linkage 133
Brake system 137
Brake piping 138
Brake valve 140
Secondary brake valve 143
Relay valve 144
Front brake off valve 145
Accumulator charge valve 146
Accumulator 150
Slack adjuster 151
Brake 153
Parking brake solenoid valve 157
Undercarriage and frame 159
Suspension 160
Suspension cylinder 162
Rear axle support 168
Hydraulic system 171
Steering and hoist hydraulic piping 172
Dump body control 174
Hydraulic tank 175
Steering valve 176
Crossover relief valve 180
Steering cylinder 181
Steering control valve 182
Hoist valve 188
EPC valve 194
Hoist cylinder 195
Hydraulic pump 196
Work equipment (Body) 201
Auto greasing system 202
Cab and its attachments 225
Air conditioner 226
Rear view monitor 232
Electrical system, Part 1 241
Machine monitor system 242
Electrical system, Part 2 303
Automatic shift control system 304
Transmission controller 308
External power supply heater 322
Automatic emergency steering system 324
Automatic suspension system 328
Retarder control system 331
Battery disconnect switch 342
Dump control lever 346
Electrical system, Part 3 351
Payload meter II (Card type) 352
Electrical system, Part 4 383
VHMS controller related 384
ASR system (If equipped) 408
Sensors, switches 415
Electrical system, Part 5 435
Mobile communication terminal 436
20 Standard value table 441
Standard service value table 441
Standard value table for engine 442
Standard value table for machine 444
30 Testing and adjusting 455
Testing and adjusting, Part 1 455
Tools for testing, adjusting, and troubleshooting 457
Sketch of special tool 460
Testing engine speed 461
Testing air supply pressure (boost pressure) 462
Testing exhaust temperature 463
Testing exhaust gas color 465
Adjustment of valve clearance 467
Testing of compression pressure 469
Testing blow-by pressure 472
Testing engine oil pressure 473
Handling of fuel system devices 474
Releasing residual pressure from fuel system 474
Testing of fuel pressure 475
Cylinder cut-out mode operation 476
No-injection cranking 476
Testing of fuel return rate and fuel leakage 477
Bleeding air from fuel circuit 479
Testing the fuel circuit for leakage 480
Replacing and adjusting of fan belt 481
Replacing and adjusting of alternator and air conditioner compressor belt 482
Testing and adjusting, Part 2 485
Testing torque converter stall speed 487
Testing power train oil pressure 488
Adjusting transmission speed sensor 495
Testing and adjusting brake oil pressure 496
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 499
Testing brake performance 507
Releasing remaining pressure in brake circuit 508
Bleeding air from brake circuit 509
Testing wear of front brake pad 510
Testing wear of rear brake disc 511
Method of releasing parking brake in an emergency 512
Testing and adjusting front suspension cylinder 513
Testing and adjusting rear suspension cylinder 517
Testing and adjusting front suspension cylinder (Automatic suspension specification) 521
Testing and adjusting hydraulic pressure in steering, hoist circuit 522
Testing and adjusting oil pressure in dump EPC circuit 525
Air bleeding from steering cylinder 526
Procedure for raising dump body in emergency 527
Procedure for lowering dump body in emergency 528
Adjusting body positioner sensor 530
Resetting method for dump body seating control 531
Adjustment of tilt lock lever of steering wheel 532
Handling of voltage circuit of engine controller 533
Adjusting transmission controller 533
Method for emergency escape at electrical system failure 534
Testing and adjusting, Part 3 539
Setting and adjusting of devices 540
Special functions of machine monitor (EMMS) 553
Testing and adjusting, Part 4 577
Special functions of machine monitor (EMMS) 578
Testing and adjusting, Part 5 619
Request for opening ORBCOMM terminal 620
VHMS controller initial setting procedure 622
Using method of KOMTRAX functions of ORBCOMM terminal 642
Precautions for replacing VHMS controller 645
Pm Clinic check sheet 651
Initial setting of payload meter 654
Setting of payload meter built in VHMS 655
Setting of card-type payload meter (PLM-) after installation or replacement 663
Testing and adjusting, Part 6 671
Setting of mobile communication terminal 672
40 Troubleshooting 683
Failure code table and fuse locations 683
Failure codes table 684
Fuse locations 695
General information on troubleshooting 701
Points to remember when troubleshooting 702
Sequence of events in troubleshooting 703
Check before troubleshooting 704
Classification and procedures for troubleshooting 705
Contents of troubleshooting table 706
Troubleshooting method for disconnecting wiring harness of pressure sensor system 708
Connection table for connector pin numbers 711
T- branch box and T- branch adapter table 747
Troubleshooting by failure code, Part 1 751
Failure code [1500L0] Dual engagement 753
Failure code [15B0NX] Transmission oil filter: Clogging 754
Failure code [15F0KM] R → F shifting abuse 1: Mistake in operation 756
Failure code [15F0MB] R → F shifting abuse 2: Mistake in operation 756
Failure code [15F7KM] Forward clutch disk abuse: Mistake in operation or setting 757
Failure code [15G0MW] R clutch: Slipping 758
Failure code [15G7KM] Reverse clutch disk abuse: Mistake in operation or setting 760
Failure code [15H0MW] Hi clutch: Slipping 762
Failure code [15J0MW] Lo clutch: Slipping 764
Failure code [15K0MW] 1st clutch: Slipping 766
Failure code [15L0MW] 2nd clutch: Slipping 768
Failure code [15M0MW] 3rd clutch: Slipping 770
Failure code [15N0MW] 4th clutch: Slipping 772
Failure code [15SBL1] R clutch solenoid: Fill signal is ON when command current is OFF 774
Failure code [15SBMA] R clutch solenoid: Malfunction 776
Failure code [15SCL1] Hi clutch solenoid: Fill signal is ON when command current is OFF 777
Failure code [15SCMA] Hi clutch solenoid: Malfunction 780
Failure code [15SDL1] Lo clutch solenoid: Fill signal is ON when command current is OFF 781
Failure code [15SDMA] Lo clutch solenoid: Malfunction 784
Failure code [15SEL1] 1st clutch solenoid: Fill signal is ON when command current is OFF 785
Failure code [15SEMA] 1st clutch solenoid: Malfunction 788
Troubleshooting by failure code, Part 2 791
Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF 794
Failure code [15SFMA] 2nd clutch solenoid: Malfunction 797
Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF 798
Failure code [15SGMA] 3rd clutch solenoid: Malfunction 801
Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF 802
Failure code [15SHMA] 4th clutch solenoid: Malfunction 805
Failure code [15SJMA] Lockup clutch solenoid: Malfunction 806
Failure code [2C4MNX] Retarder cooling oil filter: Clogging 808
Failure code [2F00KM] Parking brake: Mistake in operation or setting 810
Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front) 813
Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear) 813
Failure code [6014NX] Hydraulic oil filter: Clogging 814
Failure code [989A00] Engine over run prevention command signal: Operating 816
Failure code [989D00] Rear section tipping over alarm: Alarm is activated 816
Failure code [A570NX] Engine oil filter: Clogging 817
Failure code [AA10NX] Air cleaner element: Clogging 818
Failure code [AB00MA] Alternator: Malfunction 820
Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure 822
Failure code [B@BAZK] Engine oil: Level too low 823
Failure code [B@BCNS] Engine: Overheat 824
Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level 826
Failure code [B@BFZK] Lowering of fuel level 828
Failure code [B@C7NS] Brake cooling oil: Overheating (Rear) 830
Failure code [B@CENS] Overheating of torque converter oil 832
Failure code [B@GAZK] Battery electrolyte level: Lowering of level 833
Failure code [B@JANS] Steering oil temperature: Overheat 834
Troubleshooting by failure code, Part 3 837
Failure code [CA111] Abnormality in engine controller 840
Failure code [CA115] Engine Ne or Bkup speed sensor error 842
Failure code [CA122] Charge (boost) pressure sensor high error 844
Failure code [CA123] Charge (boost) pressure sensor low error 846
Failure code [CA131] Throttle sensor high error 848
Failure code [CA132] Throttle sensor low error 851
Failure code [CA135] Engine oil pressure sensor high error 854
Failure code [CA141] Engine oil pressure sensor low error 856
Failure code [CA144] Coolant temperature sensor high error 858
Failure code [CA145] Coolant temperature sensor low error 860
Failure code [CA153] Charge (boost) temperature sensor high error 862
Failure code [CA154] Charge (boost) temperature sensor low error 864
Failure code [CA187] Sensor power supply 2 low error 866
Failure code [CA212] Engine oil temperature sensor high error 868
Failure code [CA213] Engine oil temperature sensor low error 870
Failure code [CA221] Atmospheric pressure sensor high error 872
Failure code [CA222] Atmospheric pressure sensor low error 874
Failure code [CA227] Sensor power supply 2 high error 876
Failure code [CA234] Engine overspeed 877
Failure code [CA238] Ne speed sensor power supply error 878
Failure code [CA263] Fuel Temp Sensor High Error 880
Failure code [CA265] Fuel Temp Sensor Low Error 882
Failure code [CA271] PCV1 Short circuit 884
Failure code [CA272] PCV1 Disconnection 885
Failure code [CA273] PCV2 Short circuit 886
Failure code [CA274] PCV2 Disconnection 887
Failure code [CA322] Injector #1 open/short error 888
Failure code [CA323] Injector #5 open/short error 890
Failure code [CA324] Injector #3 open/short error 892
Failure code [CA325] Injector #6 open/short error 894
Failure code [CA331] Injector #2 open/short error 896
Failure code [CA332] Injector #4 open/short error 898
Failure code [CA342] Calibration code inconsistency 900
Failure code [CA351] Injectors drive circuit error 901
Failure code [CA352] Sensor power supply 1 low error 902
Failure code [CA386] Sensor power supply 1 high error 904
Troubleshooting by failure code, Part 4 907
Failure code [CA431] Idle validation switch error 909
Failure code [CA432] Idle validation action error 912
Failure code [CA441] Battery voltage low error 915
Failure code [CA442] Battery voltage high error 916
Failure code [CA449] Common rail pressure high error 2 917
Failure code [CA451] Rail Press Sensor High Error 918
Failure code [CA452] Rail Press Sensor Low Error 920
Failure code [CA553] Common rail pressure high error 1 922
Failure code [CA554] Common rail pressure sensor in range error 923
Failure code [CA559] Supply pump pressure very low error 1 924
Failure code [CA689] Engine Ne speed sensor error 928
Failure code [CA731] Engine Bkup speed sensor phase error 930
Failure code [CA757] All continuous data lost error 931
Failure code [CA778] Engine Bkup speed sensor error 932
Failure code [CA1633] KOMNET datalink timeout error 934
Failure code [CA2185] Throttle sensor power supply voltage high error 936
Failure code [CA2186] Throttle sensor power supply voltage low error 938
Failure code [CA2249] Supply pump pressure very low error 2 940
Failure code [CA2555] Intake air heater relay open circuit error 942
Failure code [CA2556] Intake air heater relay short circuit error 944
Troubleshooting by failure code, Part 5 947
Failure code [D19HKB] Stop lamp relay output system: Short circuit 949
Failure code [D5ZKKZ] Front brake cut-off solenoid valve: Disconnection, short circuit or short circuit to power supply line 950
Failure code [DAF9KM] Wrong connection of connector 952
Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication 953
Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of power supply voltage 954
Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller 956
Failure code [DAQ2KK] Transmission controller solenoid power supply: Power supply voltage too low 958
Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection 960
Failure code [DAQRKR] Abnormality in CAN communication (Transmission) 961
Failure code [DAQRMA] Transmission controller option setting: Malfunction 966
Failure code [DAQV00] Neutral coast caution 967
Failure code [DAQW00] Neutral over speed caution 968
Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller 969
Failure code [DB12KK] Retarder controller solenoid power supply: Power supply system trouble 970
Failure code [DB13KK] Retarder controller battery direct power supply: Power supply voltage too low 972
Failure code [DB19KQ] Disagreement of model selection (Retarder controller) 974
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled 975
Failure code [DB1RMA] Disagreement of option setting (Retarder controller) 979
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled 980
Failure code [DBB0KK] or VHMS_LED display: “n9” → “01” 986
Failure code [DBB0KQ] or VHMS_LED display: “nF” → “11” 988
Failure code [DBB3KK] or VHMS_LED display: “n9” → “05” 990
Failure code [DBB5KP] or VHMS_LED display: “n9” → “04” 992
Failure code [DBB6KP] or VHMS_LED display: “n9” → “02” 994
Failure code [DBB7KP] or VHMS_LED display: “n9” → “03” 996
Failure code [DBBQKR] or VHMS_LED display: “n8” → “02” 997
Failure code [DBBRKR] Abnormality in CAN communication (VHMS) 997
Failure code [DBC2KK] ABS controller solenoid power supply: Power supply system trouble 998
Failure code [DBC3KK] ABS controller battery direct power supply: Power supply voltage too low 1000
Failure code [DBC9KQ] Disagreement of model selection (ABS controller) 1002
Failure code [DBCRKR] Abnormality in CAN communication (ABS) 1003
Failure code [DBCRMA] Disagreement of option setting (ABS controller) 1007
Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range 1008
Failure code [DDD8KA] ARSC system switch system: Disconnection (If equipped) 1010
Failure code [DDD8KB] ARSC system switch system: Short circuit (If equipped) 1012
Failure code [DDD9KA] ABS system switch system: Disconnection 1014
Failure code [DDD9KB] ABS system switch system: Short circuit 1016
Failure code [DDDAKA] ASR system switch: Disconnection 1018
Failure code [DDDAKB] ASR system switch: Short circuit 1020
Failure code [DDP6L4] Service brake pressure switch trouble (Rear) 1022
Failure code [DDTHKA] Hi clutch fill switch: Disconnection 1024
Failure code [DDTJKA] Lo clutch fill switch: Disconnection 1026
Failure code [DDTKKA] 1st clutch fill switch: Disconnection 1028
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection 1030
Failure code [DDTMKA] (3rd clutch fill switch: Disconnection) 1032
Failure code [DDTNKA] R clutch fill switch: Disconnection 1034
Failure code [DDTPKA] 4th clutch fill switch: Disconnection 1036
Failure code [DF10KA] Gear shift lever: Disconnection 1038
Failure code [DF10KB] Gear shift lever: Short circuit 1041
Failure code [DGE5KX] or VHMS_LED display: “n4” → “01” 1046
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range 1048
Failure code [DGR2KZ] Retarder oil temperature sensor system trouble : Ground fault (Rear wheel) 1050
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range 1052
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range 1054
Troubleshooting by failure code, Part 6 1057
Failure code [DGT4KA] or VHMS_LED display: “n3” -> “12” Exhaust gastemperature sensor (F): Disconnection 1059
Failure code [DGT4KB] or VHMS_LED display: “n3” -> “11” Exhaust gastemperature sensor (F): Short circuit 1062
Failure code [DGT5KA] or VHMS_LED display: “n3” -> “22” Exhaust gastemperature sensor (R): Disconnection 1065
Failure code [DGT5KB] or VHMS_LED display: “n3” -> “21” Exhaust gastemperature sensor (R): Short circuit 1068
Failure code [DHE5KB] or VHMS_LED display: “n3” -> “32” Blow-bypressure sensor: Short circuit 1071
Failure code [DHE5KY] or VHMS_LED display: “n3” -> “31” Blow-by pressure sensor: Short circuit with power supply line 1074
Failure code [DHP4KY] or VHMS_LED display: “n5” -> “44” Short circuit in suspension pressure sensor system (Front right) 1076
Failure code [DHP4KZ] or VHMS_LED display: “n5” -> “43” Disconnectionor ground fault in suspension pressure sensor system(Front right)1 1078
Failure code [DHP5KY] or VHMS_LED display: “n5” -> “54” Short circuit in suspension pressure sensor system (Front left) 1080
Failure code [DHP5KZ] or VHMS_LED display: “n5” -> “53” Disconnectionor ground fault in suspension pressure sensor system(Front left) 1082
Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear) 1084
Failure code [DHP6KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Right rear) 1085
Failure code [DHP6KY] or VHMS_LED display: “n5” -> “64” Suspensionpressure sensor system: Short circuit (Right rear) 1088
Failure code [DHP6KZ] or VHMS_LED display: “n5” -> “63” Suspension pressure sensor system: Disconnection or ground fault (Right rear) 1090
Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear) 1092
Failure code [DHP7KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Left rear) 1094
Failure code [DHP7KY] or VHMS_LED display: “n5” -> “74” Suspension pressure sensor system: Short circuit (Left rear) 1096
Failure code [DHP7KZ] or VHMS_LED display: “n5” -> “73” Suspension pressure sensor system: Disconnection or ground fault (Left rear) 1098
Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range 1100
Failure code [DHT5L6] Torque converter oil pressure sensor: Disagreement of run and stop condition with signal 1102
Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range 1104
Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range 1106
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right) 1108
Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left) 1110
Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Front right) 1112
Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Front right) 1114
Failure code [DJF1KA] Fuel level sensor: Disconnection 1116
Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection) 1118
Failure code [DK51L5] Retarder lever potentiometer: Potentiometer signal is inconsistent with swich signal 1119
Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range 1122
Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal 1124
Failure code [DK54KX] Body positioner sensor: Out of input signal range 1126
Failure code [DKD0L6] Failure in steering speed sensor 1128
Failure code [DKH0KX] Clinometer sensor signal out of range 1130
Failure code [DKH1KX] or VHMS_LED display: “n4″->”33” Abnormality in clinometer sensor 1132
Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection 1134
Failure code [DLF1LC] Transmission input shaft speed sensor: Disagreement of revolution speed signal 1136
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection 1138
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal 1140
Troubleshooting by failure code, Part 7 1143
Failure code [DLF8KA] (Wheel speed sensor: Disconnection (Right rear)) 1146
Failure code [DLF8L3] (Wheel speed sensor: Disconnection (Right rear)) 1148
Failure code [DLF8LC] (Wheel speed sensor: Trouble (Right rear)) 1150
Failure code [DLF8MA] (Wheel speed sensor: Disconnection (Right rear)) 1151
Failure code [DLF9KA] (Wheel speed sensor: Disconnection (Left rear)) 1152
Failure code [DLF9L3] (Wheel speed sensor: Trouble (Left rear)) 1154
Failure code [DLF9LC] (Wheel speed sensor: Trouble (Left rear)) 1156
Failure code [DLF9MA] (Wheel speed sensor: Disconnection (Left rear)) 1157
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) 1158
Failure code [DLT3LC] (Transmission output shaft speed sensor: Disagreement of revolution speed signal) 1160
Failure code [DLT4KA] (Transmission output shaft speed sensor: Disconnection) 1162
Failure code [DLT4MA] (Transmission output shaft speed sensor: Malfunction) 1164
Failure code [DV00KB] (Buzzer output: Short circuit) 1166
Failure code [DW2AKA] (Main pressure variable valve output: Disconnection) 1168
Failure code [DW2AKB] (Main pressure variable valve output circuit: Ground fault) 1170
Failure code [DW2AKY] (Main pressure variable valve output circuit: Hot short) 1172
Failure code [DW2AL1] (Main pressure variable valve: Defective reset) 1174
Failure code [DW2ALH] (Main pressure variable valve: Malfunction) 1176
Failure code [DW35KZ] (Failure in output system of auto suspension solenoid 1: Disconnection or short circuit) 1178
Failure code [DW36KZ] (Failure in output system of auto suspension solenoid 2: Disconnection or short circuit) (If equipped) 1180
Failure code [DW72KZ] (Kick-out solenoid output system trouble: Disconnection or short circuit) 1182
Failure code [DW73KZ] (Failure in hoist select valve output system: Disconnection or short circuit) 1184
Failure code [DW78KZ] (Brake cooling valve (BCV) (rear wheel) output system trouble: Disconnection or short circuit) 1186
Failure code [DWNBK4] (ASR shut-off valve: Trouble (Valve keeps operating)) 1188
Failure code [DWNBKA] (ASR shut-off valve output circuit: Disconnection) 1190
Failure code [DWNBKB] (ASR shut-off valve output circuit: Ground fault) 1192
Failure code [DWNBKY] (ASR shut-off valve output circuit: Short circuit) 1194
Failure code [DWNBMA] (ASR shut-off valve: Trouble (Valve does not operate)) 1195
Troubleshooting by failure code, Part 8 1197
Failure code [DX11K4] Rear brake proportional pressure reducing solenoid valve: Out of control 1200
Failure code [DX11KA] Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection 1202
Failure code [DX11KB] Rear brake proportional pressure reducing solenoid valve: Short circuit 1204
Failure code [DX11KY] Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line 1205
Failure code [DX11MA] Rear brake proportional pressure reducing solenoid valve: Malfunction 1206
Failure code [DX13KA] Output circuit of hoist EPC valve: Disconnection 1208
Failure code [DX13KB] Output circuit of hoist EPC valve: Short circuit 1210
Failure code [DX13KY] Output circuit of hoist EPC valve: Short circuit with power source line 1212
Failure code [DX17K4] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve keeps operating) 1214
Failure code [DX17KA] ASR proportional pressure reducing solenoid valve (right) output circuit: Disconnection 1216
Failure code [DX17KB] ASR proportional pressure reducing solenoid valve (right) output circuit: Ground fault 1218
Failure code [DX17KY] ASR proportional pressure reducing solenoid valve (right) output circuit: Short circuit 1220
Failure code [DX17MA] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve does not operate) 1221
Failure code [DX18K4] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve keeps operating) 1222
Failure code [DX18KA] ASR proportional pressure reducing solenoid valve (left) output circuit: Disconnection 1224
Failure code [DX18KB] ASR proportional pressure reducing solenoid valve (left) output circuit: Ground fault 1226
Failure code [DX18KY] ASR proportional pressure reducing solenoid valve (left) output circuit: Short circuit 1228
Failure code [DX18MA] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve does not operate) 1229
Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right) 1230
Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right) 1231
Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right) 1232
Failure code [DX21MA] Defective ABS control valve (Front right) 1234
Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left) 1236
Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left) 1237
Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left) 1238
Failure code [DX22MA] Defective ABS control valve (Front left) 1240
Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right) 1242
Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right) 1243
Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right) 1244
Failure code [DX23MA] Defective ABS control valve (Rear right) 1246
Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left) 1248
Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left) 1249
Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left) 1250
Failure code [DX24MA] Defective ABS control valve (Rear left) 1252
Failure code [DX25MA] Defective ABS front wheel system control valve 1254
Failure code [DX26MA] Defective ABS rear wheel system control valve 1254
Troubleshooting by failure code, Part 9 1257
Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection 1260
Failure code [DXH1KB] Lockup clutch solenoid output circuit: Short circuit 1262
Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power supply line 1264
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection 1266
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit 1268
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power supply line 1270
Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection 1274
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit 1276
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power supply line 1278
Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection 1282
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit 1284
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power supply line 1286
Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection 1290
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit 1292
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power supply line 1294
Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection 1298
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit 1300
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power supply line 1302
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection 1306
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit 1308
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power supply line 1310
Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection 1312
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit 1314
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power supply line 1316
Failure code [F@BBZL] or VHMS_LED display: “n3″->”38” Blow-by pressure: High error 1319
Failure code [F@BYNR] or VHMS_LED display: “n3″->”62” Exhaust gast emperature (F): Abnormal heat 1320
Failure code [F@BYNS] or VHMS_LED display: “n3″->”61” Exhaust gas temperature (F): Overheat 1322
Failure code [F@BZNR] or VHMS_LED display: “n3″->”72” Exhaust gas temperature (R): Abnormal heat 1324
Failure code [F@BZNS] or VHMS_LED display: “n3″->”71” Exhaust gas temperature (R): Overheat 1326
Troubleshooting of electrical system (E-mode) 1329
Before troubleshooting of electric system 1331
Contents of troubleshooting table 1332
E-1 Engine does not start 1333
E-2 Automatic preheating does not operate 1336
E-3 Machine monitor does not display all, when starting switch is turned ON 1340
E-4 Machine monitor does not operate when starting switch is OFF 1342
E-5 Alarm buzzer does not sound 1344
E-6 Alarm buzzer does not stop sounding 1346
E-7 Gauges of machine monitor, caution lamps or character display section do not display properly 1348
E-8 A selection of the display in character display section cannot be changed 1349
E-9 Power mode selecting function does not operate properly 1352
E-10 AISS function does not operate properly 1353
E-11 Seat belt caution lamp does not display properly 1354
E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly 1355
E-13 Night illumination (lighting) does not work properly 1358
E-14 Emergency steering does not operate 1370
E-15 Hoist lever does not operate normally 1375
E-16 Electric priming pump does not operate or does not stop automatically 1377
E-17 Cannot access to the setting screen of the mobile communication terminal 1379
E-18 Cannot log in to the setting screen of the mobile communication terminal because the log in password is unknown 1384
E-19 VHMS controller is not detected 1386
E-20 VHMS controller does not become active 1387
E-21 Communication between mobile communication terminal and KOMTRAX Plus server fails 1388
E-22 Data is not sent to KOMTRAX Plus server 1391
Troubleshooting of hydraulic and mechanical system (H-mode) 1395
Contents of troubleshooting table 1397
H-1 Machine does not start 1398
H-2 Machine does not travel smoothly (hunting) 1400
H-2 Machine does not travel smoothly (hunting) 1400
H-3 Lockup cannot be cancelled 1400
H-4 Excessive shock when starting or shifting excessive 1401
H-5 Transmission does not shift up 1402
H-6 Machine lacks power or speed when traveling 1404
H-7 Time lag is excessive when starting or shifting gear 1408
H-8 Torque converter oil temperature is high 1410
H-9 Torque converter oil pressure is low 1411
H-10 Front brake is ineffective 1412
H-11 Rear brake is ineffective 1413
H-12 Steering wheel is heavy 1414
H-13 Steering wheel does not work 1415
H-14 Steering wheel vibrates 1416
H-15 Dump body lifting speed is slow 1417
H-16 Dump body does not work 1418
H-17 Excessive hydraulic drift of dump body 1419
Troubleshooting of engine (S-mode) 1421
Method of using troubleshooting chart 1424
S-1 Starting performance of engine is poor 1428
S-2 Engine does not start 1429
S-3 Engine does not pick up smoothly 1432
S-4 Engine stops during operation 1433
S-5 Engine does not rotate smoothly 1434
S-6 Engine lack output (or lacks power) 1435
S-7 Exhaust gas is black (incomplete combustion) 1436
S-8 Oil consumption is excessive (or exhaust gas is blue) 1438
S-9 Oil becomes dirty quickly 1439
S-10 Fuel consumption is excessive 1440
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 1441
S-12 Oil pressure drops 1442
S-13 Oil level rises (Entry of coolant or fuel) 1443
S-14 Coolant temperature becomes too high (Overheating) 1444
S-15 Abnormal noise is made 1445
S-16 Vibration is excessive 1446
50 Disassembly and assembly 1449
General information on disassembly and assembly 1449
How to read this manual 1450
Coating materials list 1452
Special tool list 1455
Sketches of special tools 1459
Engine and cooling system 1467
Removal and installation of engine assembly 1468
Removal and installation of radiator assembly 1475
Removal and installation of damper assembly 1479
Disassembly and assembly of damper assembly 1480
Removal and installation of fuel supply pump assembly 1483
Removal and installation of fuel injector assembly 1486
Removal and installation of brake and power train oil cooler assembly 1490
Power train, Part 1 1493
Removal and installation of torque converter and transmission assembly 1494
Separation and coupling of transmission assembly and torque converter assembly 1497
Disassembly and assembly of torque converter and control valve assembly 1506
Disassembly and assembly of torque converter assembly 1508
Disassembly and assembly of transmission assembly 1521
Removal and installation of transmission control valve assembly (ECMV assembly) 1554
Disassembly and assembly of transmission control valve assembly (ECMV assembly) 1555
Power train, Part 2 1561
Removal and installation of differential assembly 1562
Disassembly and assembly of differential assembly 1564
Removal and installation of final drive carrier assembly 1576
Disassembly and assembly of final drive carrier assembly 1577
Disassembly and assembly of front wheel hub assembly 1578
Steering system 1585
Disassembly and assembly of steering cylinder assembly 1586
Brake system 1591
Removal and installation of front brake caliper pads 1592
Removal and installation of front brake calipers assembly 1593
Disassembly and assembly of front brake calipers assembly 1594
Removal and installation of final drive and rear brake assembly 1596
Removal and installation of final drive, rear brake, and parking brake assembly 1599
Disassembly and assembly of final drive, rear brake, and parking brake assembly 1600
Undercarriage and frame 1613
Removal and installation of front wheel assembly 1614
Removal and installation of rear wheel assembly 1615
Removal and installation of front suspension cylinder assembly 1617
Disassembly and assembly of front suspension cylinder assembly (Cylinder with buffer ring) 1619
Removal and installation of rear suspension cylinder assembly 1622
Disassembly and assembly of rear suspension cylinder assembly (Cylinder with buffer ring) 1623
Hydraulic system 1627
Disassembly and assembly of hoist cylinder assembly 1628
Body 1633
Removal and installation of body assembly 1634
Cab and its attachments 1639
Disassembly and assembly of operator’s seat assembly 1640
Removal and installation of air conditioner unit assembly 1649
Electrical system, Part 1 1653
Removal and installation of engine controller assembly 1654
Removal and installation of transmission controller assembly 1655
Removal and installation of retarder controller assembly 1656
Electrical system, Part 2 1659
Removal and installation of mobile communication terminal 1660
Removal and installation of DC/DC converter 1662
Removal and installation of mobile communication terminal harness 1664
90 Diagrams and drawings 1675
Hydraulic diagrams and drawings 1675
Power train hydraulic circuit diagram 1676
Steering and hoist hydraulic circuit diagram 1677
Brake hydraulic circuit diagram 1681
Electrical diagrams and drawings 1687
Electrical circuit diagram inside cab (1/3) 1689
Electrical circuit diagram inside cab (2/3) 1691
Electrical circuit diagram inside cab (3/3) 1693
Electrical circuit diagram outside cab (1/3) 1695
Electrical circuit diagram outside cab (2/3) 1697
Electrical circuit diagram outside cab (3/3) 1699
Electrical circuit diagram for VHMS 1701
Electrical circuit diagram for ASR (If equipped) 1703
Air conditioner electrical circuit diagram 1705
Electrical circuit diagram of mobile communication terminal (if equipped) 1707
Connectors table and arrangement drawing 1709

IMAGES PREVIEW OF THE MANUAL:

S.V  17/12/24