Komatsu HD465-8E0,HD605-8E0 Dump Truck Shop Manual SEN06768-13 PDF

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Komatsu HD465-8E0,HD605-8E0 Dump Truck Shop Manual SEN06768-13 –  PDF DOWNLOAD

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Komatsu HD465-8E0,HD605-8E0 Dump Truck Shop Manual SEN06768-13 –  PDF DOWNLOAD

Language : English
Pages : 3514
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HD465-8E0,HD605-8E0 Dump Truck Shop Manual SEN06768-13 –  PDF DOWNLOAD

SERIAL NUMBERS

• HD465-35001 and up
• HD605-35001 and up

Cover 1
00 Index and Foreword . 3
Index . 4
Abbreviation List . 24
Foreword, Safety, Basic Information . 27
How to Read the Shop Manual . 27
Safety Notice for Operation . 29
Precautions to Prevent Fire . 37
Procedures If Fire Occurs . 39
Precautions When You Dispose of Waste Materials . 40
Engine Technology to Conform Exhaust Gas Emission . 41
Precautions When You Handle Hydraulic Equipment . 42
Precautions When You Disconnect and Connect Pipings . 45
Precautions When You Handle Electrical Equipment 52
Precautions When You Handle Fuel System Equipment . 54
Precautions When You Handle Intake System Equipment . 55
Practical Use of KOMTRAX 56
Disconnect and Connect Push-Pull Type Coupler . 57
How to Disconnect and Connect Type 1 Push-Pull Type Coupler . 57
How to Disconnect and Connect Type 2 Push-Pull Type Coupler . 58
How to Disconnect and Connect Type 3 Push-Pull Type Coupler . 59
Precautions for Disconnection and Connection of Connectors 61
How to Disconnect and Connect Deutsch Connector . 65
How to Disconnect and Connect Slide Lock Type Connector . 66
How to Disconnect and Connect Connector with Lock to Pull . 68
How to Disconnect and Connect Connector with Lock to Push . 69
How to Disconnect and Connect Connector with Housing to Rotate 71
How to Read the Codes for Electric Cable 72
Explanation of Terms for Maintenance Standard . 76
Standard Tightening Torque Table 79
Conversion Table 86
01 Specifications . 91
Table of Contents . 92
Specifications 93
Specification Drawing . 93
Specification Drawing: HD465-8E0 93
Specification Drawing: HD605-8E0 95
Specifications 97
Specifications: HD465-8E0 . 97
Specifications: HD605-8E0 . 102
Weight Table 107
Weight Table: HD465-8E0 . 107
Weight Table: HD605-8E0 . 108
Fuel, Coolant, Lubricant 109
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 109
10 Structure and Function . 111
Table of Contents . 112
NOx Control System 116
Function of NOx Control System 116
Boot-up System 119
Layout Drawing of Boot-up System 119
Layout Drawing of Boot-up System (Machine with Emergency Engine Stop Switch) 120
System Operating Lamp System 122
System Diagram of System Operating Lamp System 122
Function of Operation Lamp System . 122
Battery Disconnect Switch . 123
Layout Drawing of Battery Disconnect Switch . 123
Function of Battery Disconnect Switch . 123
Function of Battery Disconnect Switch (Machine with Mobile Communication Terminal) 124
Engine Shutdown Secondary Switch 126
Engine Secondary Shutdown Switch Diagram 126
Function of Engine Shutdown Secondary Switch 126
Operation of Engine Shutdown Secondary Switch . 127
Engine System . 128
Layout Drawing of Engine System . 128
Function of Engine System . 129
Engine Control System . 131
System Diagram of Engine Control 131
Engine Power Mode Selector System (Machine with Engine Power Mode Selector System) 135
Engine Power Mode Selector System Diagram . 135
Function of Engine Power Mode Selector System . 135
Operation of Engine Power Mode Selector System 135
Automatic Idle Stop System 136
Function of Automatic Idle Stop System 136
Component Parts of Engine System 138
Damper 138
VGT . 140
EGR System 144
EGR Valve . 147
EGR Cooler 148
KCCV System . 150
KCCV Ventilator . 152
CDR Valve . 154
KDPF 155
Cooling System 159
Layout Drawing of Cooling System 159
Specifications of Cooling System 160
Radiator Fan Control System . 161
Radiator Fan Control System Diagram . 161
Function of Radiator Fan Control System . 161
Component Parts of Cooling System . 163
Cooling Fan, Hoist Pump . 163
Cooling Fan Motor . 170
Control System 177
Layout Drawing of Control System 177
Layout Drawing of Control System (Machine with Mobile Communication Terminal) . 179
Retarder and Hoist Control System . 180
Retarder and Hoist Control System Diagram . 180
Machine Monitor System 182
System Diagram of Machine Monitor System 182
Function of Machine Monitor System 183
Rearview Monitor System . 184
System Diagram of Rearview Monitor System . 184
Function of Rearview Monitor System . 184
KOMTRAX Plus System . 185
System Diagram of KOMTRAX Plus System . 185
System Diagram of KOMTRAX Plus System (Machine with Mobile Communication Terminal) 187
Function of KOMTRAX Plus System . 188
Payload Meter System 191
Layout Drawing of Payload Meter System 191
Payload Meter System Diagram 192
Function of Payload Meter System 192
Measurement Principle of Loading Mass . 193
Machine Lock-out System . 203
Layout Drawing of Machine Lock-out System . 203
Function of Machine Lock-out System . 204
Operation of Machine Lock-out System 204
Drowsiness Detection System . 205
Layout Drawing of Drowsiness Detection System . 205
System Diagram of Drowsiness Detection System . 206
Function of Drowsiness Detection System . 208
Operation of Drowsiness Detection System 209
Component Parts of Control System . 210
Machine Monitor . 210
Switch Panel 231
Rearview Monitor 232
Rearview Camera . 234
KOMTRAX Terminal 235
KOMTRAX Plus Controller . 237
Communication Terminal 242
Wireless LAN Unit . 243
Transmission Controller . 244
Retarder and Hoist Controller . 248
Monitor Controller 253
Engine Controller . 258
ABS Controller 270
Translator Controller . 274
Drowsiness Detection Camera . 278
Driver Status Monitor . 279
Accelerator Pedal . 281
Gear Shift Lever 282
Retarder Control Lever 283
Fuel Feed Pump 284
Fuel Feed Pump Switch . 285
Hydraulic System 287
Layout Drawing of Hydraulic System 287
Component Parts of Hydraulic System . 288
Hydraulic Tank 288
Steering and Hoist Pump . 289
LS Valve 295
CO Valve 296
Power Train and Brake Cooling Duplex Pump . 299
Brake Cooling, Control Triple Pump 301
Hoist Valve . 303
Power Train System 309
Layout Drawing of Power Train System 309
Transmission Control System . 311
Transmission Control System Diagram . 311
Gear Shift Lever Positions and Automatic Gear Shift Range . 312
Gear Shift Control System . 317
Automatic Gear Shift Control of Gear Shift Control System . 317
Automatic Gear Shift Control of Gear Shift Control System (Machine with Engine Power Mode Selector System) 318
How to Shift in Each Shift Lever Position of Gear Shift Control System 319
Gear Shift Disabled Time Control of Gear Shift Control System . 320
Direction Control System 321
Rim Pull Limit Function for Overload Prevention of Direction Control System . 321
Function of Throttle Limit Function at F1 Start at D Position Setting of Direction Control System . 321
Komatsu Traction Control System (KTCS) 322
Komatsu Traction Control System (KTCS) System Diagram . 322
Function of Komatsu Traction Control System (KTCS) 322
Operation of Komatsu Traction Control System (KTCS) System Logic 323
Travel Speed Limitation System 324
System Diagram of Travel Speed Limitation System 324
Function of Travel Speed Limitation System 325
Operation of Travel Speed Limitation System . 325
Component Parts of Power Train System . 328
Drive Shaft . 328
Torque Converter and PTO 330
Lockup Clutch ECMV 334
Transmission 337
Transmission Control Valve 358
Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV 360
Axle 369
Differential 371
Final Drive . 373
Work Equipment System . 374
Work Equipment Control 374
Layout Drawing of Work Equipment Control 374
Function of Work Equipment Control 374
Hoist Control . 375
Hoist Control System Diagram 375
Function of Hoist Control . 375
Component Parts of Work Equipment System 378
Dump Lever 378
Hoist EPC Valve . 383
Steering System . 384
Layout Drawing of Steering System . 384
Function of Steering System . 385
Steering Column . 386
Structure of Steering Column 386
Steering Linkage 387
Structure of Steering Linkage . 387
Component Parts of Steering System 388
Demand Valve 388
Steering Relief Valve . 394
Orbitrol Valve 396
Steering Pump Selector Solenoid Valve . 402
Cross over Relief Valve . 403
Secondary Steering Pump . 404
Secondary Steering Motor 405
Brake System 406
Layout Drawing of Brake System 406
Retarder Control 408
Retarder Control System Diagram . 408
Function of Retarder Control 408
ARSC System . 409
ARSC System Diagram . 409
Function of ARSC System . 409
Component Parts of Brake System . 410
Brake Charge Pump . 410
Parking Brake Solenoid Valve 411
Accumulator Charge Valve 412
Brake Circuit Accumulator . 416
Brake Valve . 417
Secondary Brake Valve . 421
Secondary Brake Relay Valve . 422
Proportional Pressure Reducing Valve 423
Slack Adjuster 424
Brake . 426
Parking Brake . 429
Brake Sub-Tank 431
ABS . 432
Layout Drawing of ABS . 432
ABS System Diagram 433
Function of ABS . 434
Operation of ABS 434
Component Parts of ABS 437
Auto-Greasing System 440
Layout Drawing of Auto-Greasing System 440
Auto-Greasing System Diagram 443
Function of Auto-Greasing System 444
Auto-Greasing System 445
Auto-Greasing Pump 445
Auto-Greasing Injector 447
Undercarriage and Frame . 451
Suspension 451
Structure of Suspension . 451
Function of Suspension 451
Front Suspension 453
Structure of Front Suspension . 453
Function of Front Suspension 454
Rear Suspension . 455
Structure of Rear Suspension 455
Function of Rear Suspension . 456
Suspension Cylinder . 457
Structure of Suspension Cylinder 457
Function of Suspension Cylinder . 457
Operation of Suspension Cylinder 457
Work Equipment 459
Structure of Work Equipment . 459
Function of Work Equipment 460
CAB Related Parts . 461
ROPS CAB 461
Structure of ROPS CAB . 461
Function of ROPS CAB 461
CAB Mount . 462
Structure of CAB Mount 462
Function of CAB Mount . 462
20 Standard Value Table . 463
Table of Contents . 464
Standard Value Table for Engine . 465
Standard Value Table for Engine: HD465-8E0 465
Standard Value Table for Engine: HD605-8E0 468
Standard Value Table for Machine 471
Standard Value Table for Machine: HD465-8E0 . 471
Standard Value Table for Machine: HD605-8E0 . 489
Machine Posture and Procedures to Measure Performance . 507
30 Testing and Adjusting 509
Table of Contents . 510
Precautions Before Work . 514
Related Information on Testing and Adjusting 515
Tools for Testing and Adjusting . 515
Sketch of Tools for Testing and Adjusting . 525
Engine and Cooling System . 526
Examine Engine Speed 526
How to Examine Engine Speed . 526
Examine Boost Pressure 528
How to Examine Boost Pressure on Machine Monitor 528
How to Examine Boost Pressure by Testing Tool . 529
Examine Exhaust Gas Temperature . 532
How to Test Exhaust Gas Temperature by the Machine Monitor 532
How to Examine Exhaust Temperature by Testing Tools . 534
Examine Exhaust Gas Color . 536
How to Examine Exhaust Gas Color with the Handy Smoke Checker . 536
How to Examine Exhaust Gas Color with Smoke Meter . 537
Examine Mass Air Flow and Temperature Sensor 539
How to Examine Mass Air Flow and Temperature Sensor . 539
Examine and Adjust Valve Clearance 542
How to Examine Valve Clearance 542
How to Adjust Valve Clearance . 543
Examine Compression Pressure 545
How to Examine Compression Pressure . 545
Examine Blowby Pressure . 549
How to Examine Blowby Pressure 549
Examine Engine Oil Pressure . 552
How to Examine Engine Oil Pressure on Machine Monitor . 552
How to Examine Engine Oil Pressure by Testing Tool 552
Examine EGR Valve and VGT Oil Pressure 554
How to Examine EGR Valve and VGT Oil Pressure . 554
Examine Fuel Pressure . 555
How to Examine Fuel Pressure 555
Examine Fuel Return Rate and Leakage 557
How to Examine Fuel Return Rate and Leakage . 558
Bleed Air from Fuel System 561
How to Bleed Air from Fuel System . 561
Examine Fuel Circuit for Leakage 563
How to Examine Fuel System for Leakage 563
Examine Supply Pump . 565
How to Examine Supply Pump 565
Handle Cylinder Cut-out Mode Operation 568
Handle No-Injection Cranking Operation 569
Clean Fuel Doser 570
How to Clean Fuel Doser . 570
Write Injector Compensation Value to Engine Controller 573
How to Write Injector Compensation Value 573
Write Correction for Ash in Soot Accumulation to Engine Controller 580
How to Write Correction for Ash in Soot Accumulation to Engine Controller . 580
Examine Torque Converter Stall Speed 581
How to Examine Torque Converter Stall Speed . 581
Examine Radiator Fan Speed 583
How to Examine Radiator Fan Speed . 583
Power Train . 585
Examine Power Train Oil Pressure 585
How to Examine Power Train Oil Pressure . 587
Adjust Transmission Input Shaft Speed Sensor 599
How to Adjust Transmission Input Shaft Speed Sensor . 599
Adjust Transmission Intermediate Shaft Speed Sensor . 600
How to Adjust Transmission Intermediate Shaft Speed Sensor 600
Adjust Transmission Output Shaft Speed Sensor . 601
How to Adjust Transmission Output Shaft Speed Sensor 601
Examine After You Adjust Transmission Speed Sensor 602
How to Examine After Adjustment of Transmission Speed Sensor 602
Move Machine Which Has a Trouble in Electrical System . 603
How to Move Machine Which Has a Trouble in Engine Control System 603
How to Move Machine Which Has a Trouble in Transmission Control System 604
Steering System . 609
Examine and Adjust Steering Circuit Oil Pressure 609
How to Examine Steering Circuit Oil Pressure with the Machine Monitor . 609
How to Examine Steering Circuit Pressure with Test Tools 609
How to Adjust Steering Circuit Oil Pressure . 611
Examine Supply Pressure of Orbitrol Valve . 612
How to Examine Supply Pressure of Orbitrol Valve 612
Examine Steering Cylinder Pressure 614
How to Examine Steering Cylinder Pressure . 614
Bleed Air from Steering Cylinder Circuit 616
How to Bleed Air from Steering Cylinder Circuit . 616
Brake System 617
Release Remained Pressure in Brake Accumulator Circuit 617
How to Release Remained Pressure in Brake Accumulator Circuit . 617
Examine Wheel Brake Oil Pressure 618
How to Examine Operating Pressure of Front Brake 618
How to Examine Operating Pressure of Rear Brake . 619
How to Examine Retarder Brake Actuation Pressure 620
How to Examine Retarder Brake Actuation Pressure (For Machine with KTCS) 621
Examine and Adjust Brake Accumulator Charge Pressure 623
How to Examine Brake Accumulator Charge Pressure on Machine Monitor . 623
How to Examine Brake Accumulator Charge Pressure by Testing Tool 623
How to Adjust Brake Accumulator Charge Pressure . 624
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Nitrogen Gas 626
How to Examine Nitrogen Gas Pressure in Brake Accumulator (Front) . 626
How to Examine Nitrogen Gas Pressure in Brake Accumulator (Rear Brake and Parking Brake) 630
How to Charge Accumulator Nitrogen Gas for Brake 634
How to Release Nitrogen Gas When You Discard Accumulator 639
Examine Brake Performance . 640
How to Examine Foot Brake Performance . 640
How to Examine Retarder Brake Performance . 640
How to Examine Parking Brake Performance 641
Bleed Air from Brake Circuit 643
How to Bleed Air from Front Brake Circuit . 643
How to Bleed Air from Front Brake Circuit (Machine with ABS) 644
How to Bleed Air from Rear Brake Circuit 645
How to Bleed Air from Rear Brake Circuit (For Machine with ABS/Without KTCS) 647
How to Bleed Air from Rear Brake Circuit (For Machine with KTCS) 648
How to Bleed Air from Rear Brake Circuit (For Machine with ABS/KTCS) 650
How to Bleed Air from Parking Brake Circuit . 653
Examine Parking Brake Oil Pressure 654
How to Examine Parking Brake Oil Pressure . 654
Release Parking Brake Manually 655
How to Release Parking Brake Manually . 655
Examine Front Brake Pad Wear Volume . 656
How to Visually Examine Front Brake Pad Wear Volume . 656
How to Examine Front Brake Pad Wear with Gauge Measure 656
Examine Rear Brake Disc Wear Volume . 658
How to Visually Examine Rear Brake Disc Wear Volume . 658
Hydraulic System 659
Examine and Adjust Hoist Circuit Oil Pressure . 659
How to Examine Hoist Circuit Oil Pressure . 659
How to Adjust Hoist Circuit Oil Pressure 660
Examine Hoist Cylinder Source Pressure 661
How to Examine Source Pressure of Hoist Cylinder 661
Examine Oil Pressure of Hoist EPC Valve Circuit . 663
How to Examine Source Pressure of Hoist EPC Valve . 663
How to Examine Outlet Pressure of Hoist EPC Valve . 664
Examine Radiator Fan Circuit Oil Pressure . 665
How to Examine Radiator Fan Circuit Oil Pressure 665
Examine and Adjust Front Suspension Cylinder 667
How to Examine Front Suspension Cylinder 667
How to Adjust Front Suspension Cylinder . 668
Examine and Adjust Front Suspension Cylinder (Automatic Suspension Specification) . 672
How to Examine Front Suspension Cylinder (Automatic Suspension Specification) . 672
How to Adjust Front Suspension Cylinder (Automatic Suspension Specification) 673
Examine and Adjust Rear Suspension Cylinder . 675
How to Examine Rear Suspension Cylinder . 676
How to Adjust Rear Suspension Cylinder 677
Examine KTCS Circuit Oil Pressure (For Machine with KTCS) . 681
How to Examine the Oil Pressure of KTCS Circuit with Test Tools . 681
How to Examine the Oil Pressure of KTCS Circuit with Test Tools . 681
Work Equipment 683
Examine and Adjust Dump Body Positioner Sensor 683
How to Examine Dump Body Positioner Sensor 683
How to Adjust Dump Body Positioner Sensor . 683
How to Calibrate After Adjustment of Dump Body Positioner Sensor 683
Lower Dump Body Manually 685
How to Lower Dump Body Manually . 685
Lift Dump Body Manually . 686
How to Lift Dump Body Manually 686
CAB Related Parts . 687
Adjust Tilt Lock Lever of Steering Wheel 687
How to Adjust Tilt Lock Lever of Steering Wheel . 687
Adjust Play of Operator Seat 689
How to Adjust Play of Operator Seat . 689
Electrical System . 690
Set and Adjust Each Equipment . 690
Set and Operate Machine Monitor . 694
Operator Mode . 698
Service Mode 711
Abnormality Record Menu . 738
Default Menu 752
Diagnostic Tests Menu . 767
Adjustment Menu . 779
No-Injection Cranking Operation . 805
Payload Meter Setting . 807
How to Operate Snap Shot Manually . 825
KOMTRAX Settings Menu . 829
How to Show Service Message . 831
How to Start Up KOMTRAX Terminal 833
How to Stop Use of KOMTRAX Terminal . 837
How to Stop Use of KOMTRAX Terminal (Machine with Mobile Communication Terminal) 839
Default Setting of KOMTRAX Plus Controller 841
How to do the Default Setting of KOMTRAX Plus Controller 841
Default Setting of Wireless LAN Modem . 844
Default Setting of Wireless LAN Modem . 844
How to Examine Wireless LAN Modem Communication . 845
Download KOMTRAX Plus Controller Data . 847
How to Download Data from KOMTRAX Plus Controller . 847
Adjust When KOMTRAX Plus Controller Is Replaced . 851
How to Adjust After Replacement of KOMTRAX Plus Controller 851
Adjust After Replacement of Wireless LAN Modem 854
How to Adjust After Replacement of Wireless LAN Modem . 854
Setting of Mobile Communication Terminal 857
How to Set Mobile Communication Terminal 857
Set Driver Status Monitor . 867
Preparation for Driver Status Monitor Setting . 867
How to Set Driver Status Monitor 874
How to Do Operation Check of Driver Status Monitor 876
How to Adjust Drowsiness Detection Camera Angle . 877
Adjust Rearview Camera Angle 878
How to Adjust Rearview Camera Angle . 878
Adjust Optical Axis of Head Lamp 879
How to Adjust Optical Axis of Head Lamp . 879
Handle Voltage Circuit of Engine Controller . 883
Handle Battery Disconnect Switch 884
Battery Disconnect Switch (Machine with Mobile Communication Terminal) 886
Examine Diodes 888
How to Examine Diodes by Digital Tester . 888
How to Examine Diodes by Analog Tester 888
Pm Clinic . 889
Pm Clinic Service . 889
Pm Clinic Check Sheet: HD465-8E0 893
Pm Clinic Check Sheet: HD605-8E0 901
Perform Quick Pm 909
How to Perform Quick Pm . 909
40 Troubleshooting 913
Table of Contents . 914
Precautions Before Work . 927
Related Information to Troubleshooting 928
General Troubleshooting Points 928
Troubleshooting Points for Aftertreatment System 929
Sequence of Events in Troubleshooting . 937
Checks Before Troubleshooting . 939
Inspection Procedure Before Troubleshooting . 941
Walk-Around Check . 941
Test in Accordance with Testing Procedure . 943
Examine Fuel Level and Type . 943
Examine for Impure Ingredient in Fuel . 943
Examine Fuel Prefilter 943
Examine Fuel Main Filter 945
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type . 947
Examine Coolant Level (Reservoir Tank) 948
Examine Clogging of Air Cleaner . 949
Clean Outer Element . 950
Replace Element . 952
Examine Hydraulic Oil Level . 953
Examine Hydraulic Oil Strainer 954
Examine Hydraulic Oil Filter 954
Examine Oil Level in Transmission Case 955
Examine Oil Level in Differential Case 955
Examine Oil Level in Final Drive Case . 956
Bleed Air from Fuel System 956
Bleed Air from Hydraulic System . 956
How to Examine Electric Equipment . 956
Preparation for Troubleshooting of Electrical System 962
Procedure for Troubleshooting . 972
Symptom and Troubleshooting Numbers . 974
Information Shown in Troubleshooting Table 977
Connector List and Layout . 979
Connector Contact Connection Table 1011
T-Branch Box and T-Branch Adapter Table .1058
Fuse Location Table .1064
Precautions When You Clean and Replace KDPF (KCSF and KDOC) .1070
Prepare Troubleshoot Machine Monitor 1074
Procedure to Make Harness Checker on Machine Monitor LCD Unit .1076
Prepare of Short Socket Adapter (For Failure Codes [CA1883], [CB1883], [CA3135] and [CB3135]) .1082
Failure Code Table 1084
Troubleshooting by Failure Code (Display of Code) .1111
Failure Code [1500L0] .1111
Failure Code [15B0NX] .1112
Failure Code [15F0KM] .1114
Failure Code [15F0MB] .1115
Failure Code [15F7KM] .1116
Failure Code [15G0MW] .1117
Failure Code [15G7KM] .1119
Failure Code [15H0MW] .1120
Failure Code [15J0MW] .1122
Failure Code [15K0MW] .1124
Failure Code [15L0MW] .1126
Failure Code [15M0MW] .1128
Failure Code [15N0MW] .1130
Failure Code [15SBL1] .1132
Failure Code [15SBMA] .1135
Failure Code [15SCL1] .1137
Failure Code [15SCMA] .1140
Failure Code [15SDL1] .1142
Failure Code [15SDMA] .1145
Failure Code [15SEL1] .1147
Failure Code [15SEMA] .1150
Failure Code [15SFL1] .1152
Failure Code [15SFMA] .1155
Failure Code [15SGL1] .1157
Failure Code [15SGMA] .1160
Failure Code [15SHL1] .1162
Failure Code [15SHMA] .1165
Failure Code [15SJMA] .1167
Failure Code [2C4MNX] .1168
Failure Code [2F00KM] .1170
Failure Code [2G42ZG] .1173
Failure Code [2G43ZG] .1174
Failure Code [6014NX] .1175
Failure Code [879AKA] .1177
Failure Code [879AKB] .1178
Failure Code [879BKA] .1179
Failure Code [879BKB] .1180
Failure Code [879CKA] .1182
Failure Code [879CKB] .1183
Failure Code [879EMC] .1184
Failure Code [879FMC] .1185
Failure Code [879GKX] .1186
Failure Code [989D00] .1187
Failure Code [989L00] .1188
Failure Code [989M00] .1189
Failure Code [989N00] .1190
Failure Code [989X00] .1191
Failure Code [989Y00] .1192
Failure Code [98A000] .1193
Failure Code [98A100] .1194
Failure Code [98A200] .1195
Failure Code [98A300] .1196
Failure Code [98A400] .1197
Failure Code [98A500] .1198
Failure Code [98A600] .1199
Failure Code [A1U0N3] .1200
Failure Code [A1U0N4] .1202
Failure Code [AA10NX] .1204
Failure Code [AB00KE] .1206
Failure Code [AB00KY] .1208
Failure Code [AQ00N3] .1209
Failure Code [AQ00N4] .1210
Failure Code [AQ10N3] .1211
Failure Code [AS00R2] .1212
Failure Code [AS00R3] .1213
Failure Code [AS00R4] .1214
Failure Code [AS00R6] .1215
Failure Code [B@BAZG] .1216
Failure Code [B@BAZK] .1217
Failure Code [B@BCNS] .1218
Failure Code [B@BCQA] .1219
Failure Code [B@BCZK] .1221
Failure Code [B@C7NS] .1223
Failure Code [B@CENS] .1225
Failure Code [B@JANS] .1226
Failure Code [CA115] 1227
Failure Code [CA122] 1231
Failure Code [CA123] 1233
Failure Code [CA131] 1235
Failure Code [CA132] 1237
Failure Code [CA135] 1239
Failure Code [CA141] 1241
Failure Code [CA144] 1243
Failure Code [CA145] 1245
Failure Code [CA153] 1247
Failure Code [CA154] 1249
Failure Code [CA187] 1251
Failure Code [CA212] 1253
Failure Code [CA213] 1255
Failure Code [CA221] 1257
Failure Code [CA222] 1259
Failure Code [CA227] 1261
Failure Code [CA234] 1263
Failure Code [CA238] 1264
Failure Code [CA239] 1266
Failure Code [CA271] 1268
Failure Code [CA272] 1270
Failure Code [CA273] 1271
Failure Code [CA274] 1273
Failure Code [CA322] 1274
Failure Code [CA323] 1276
Failure Code [CA324] 1278
Failure Code [CA325] 1280
Failure Code [CA331] 1282
Failure Code [CA332] 1284
Failure Code [CA343] 1286
Failure Code [CA351] 1289
Failure Code [CA352] 1292
Failure Code [CA356] 1294
Failure Code [CA357] 1296
Failure Code [CA386] 1298
Failure Code [CA431] 1300
Failure Code [CA432] 1303
Failure Code [CA441] 1306
Failure Code [CA442] 1309
Failure Code [CA449] 1312
Failure Code [CA451] 1313
Failure Code [CA452] 1315
Failure Code [CA515] 1317
Failure Code [CA516] 1319
Failure Code [CA553] 1321
Failure Code [CA555] 1322
Failure Code [CA556] 1324
Failure Code [CA559] 1326
Failure Code [CA595] 1332
Failure Code [CA687] 1334
Failure Code [CA689] 1336
Failure Code [CA691] 1338
Failure Code [CA692] 1340
Failure Code [CA697] 1342
Failure Code [CA698] 1343
Failure Code [CA731] 1344
Failure Code [CA778] 1347
Failure Code [CA1117] .1350
Failure Code [CA1135] .1353
Failure Code [CA1257] .1356
Failure Code [CA1664] .1357
Failure Code [CA1691] .1359
Failure Code [CA1695] .1362
Failure Code [CA1696] .1364
Failure Code [CA1843] .1366
Failure Code [CA1844] .1368
Failure Code [CA1879] .1370
Failure Code [CA1881] .1372
Failure Code [CA1883] .1374
Failure Code [CA1921] .1377
Failure Code [CA1922] .1379
Failure Code [CA1923] .1382
Failure Code [CA1924] .1384
Failure Code [CA1925] .1389
Failure Code [CA1927] .1393
Failure Code [CA1928] .1395
Failure Code [CA1942] .1397
Failure Code [CA1963] .1399
Failure Code [CA1977] .1407
Failure Code [CA1993] .1409
Failure Code [CA2185] .1412
Failure Code [CA2186] .1414
Failure Code [CA2249] .1416
Failure Code [CA2265] .1422
Failure Code [CA2266] .1424
Failure Code [CA2271] .1426
Failure Code [CA2272] .1428
Failure Code [CA2349] .1430
Failure Code [CA2353] .1432
Failure Code [CA2357] .1434
Failure Code [CA2381] .1437
Failure Code [CA2382] .1439
Failure Code [CA2383] .1441
Failure Code [CA2386] .1443
Failure Code [CA2387] .1445
Troubleshooting Flowchart .1449
Failure Code [CA2555] .1450
Failure Code [CA2556] .1452
Failure Code [CA2637] .1454
Failure Code [CA2639] .1456
Failure Code [CA2732] .1458
Failure Code [CA2733] .1460
Failure Code [CA2741] .1462
Failure Code [CA2765] .1466
Failure Code [CA2777] .1467
Failure Code [CA2878] .1469
Failure Code [CA2881] .1474
Failure Code [CA3133] .1480
Failure Code [CA3134] .1482
Failure Code [CA3135] .1484
Failure Code [CA3167] .1487
Failure Code [CA3251] .1492
Failure Code [CA3253] .1494
Failure Code [CA3254] .1498
Failure Code [CA3255] .1501
Failure Code [CA3256] .1503
Failure Code [CA3311] .1505
Failure Code [CA3312] .1507
Failure Code [CA3313] .1509
Failure Code [CA3314] .1510
Failure Code [CA3315] .1511
Failure Code [CA3316] .1514
Failure Code [CA3317] .1515
Failure Code [CA3318] .1516
Failure Code [CA3319] .1519
Failure Code [CA3321] .1520
Failure Code [CA3322] .1521
Failure Code [CA3419] .1524
Failure Code [CA3421] .1526
Failure Code [CA4151] .1528
Failure Code [CA4158] .1531
Failure Code [CA4161] .1533
Failure Code [CA4162] .1535
Failure Code [CA4163] .1537
Failure Code [CA4259] .1539
Failure Code [CA4952] .1541
Failure Code [CA5383] .1544
Failure Code [CB115] 1545
Failure Code [CB187] 1549
Failure Code [CB227] 1550
Failure Code [CB238] 1551
Failure Code [CB239] 1553
Failure Code [CB271] 1555
Failure Code [CB272] 1557
Failure Code [CB273] 1558
Failure Code [CB274] 1560
Failure Code [CB343] 1561
Failure Code [CB352] 1564
Failure Code [CB386] 1566
Failure Code [CB441] 1568
Failure Code [CB442] 1571
Failure Code [CB689] 1574
Failure Code [CB697] 1576
Failure Code [CB698] 1577
Failure Code [CB731] 1578
Failure Code [CB778] 1582
Failure Code [CB1117] .1584
Failure Code [CB1257] .1587
Failure Code [CB1664] .1588
Failure Code [CB1691] .1590
Failure Code [CB1695] .1593
Failure Code [CB1696] .1595
Failure Code [CB1879] .1597
Failure Code [CB1881] .1599
Failure Code [CB1883] .1601
Failure Code [CB1921] .1604
Failure Code [CB1922] .1606
Failure Code [CB1923] .1609
Failure Code [CB1924] .1611
Failure Code [CB1925] .1616
Failure Code [CB1927] .1620
Failure Code [CB1928] .1622
Failure Code [CB1963] .1624
Failure Code [CB1977] .1632
Failure Code [CB1993] .1634
Failure Code [CB2265] .1637
Failure Code [CB2266] .1639
Failure Code [CB2637] .1641
Failure Code [CB2639] .1644
Failure Code [CB2732] .1646
Failure Code [CB2733] .1648
Failure Code [CB2741] .1650
Failure Code [CB2777] .1654
Failure Code [CB2878] .1656
Failure Code [CB2881] .1661
Failure Code [CB3133] .1667
Failure Code [CB3134] .1669
Failure Code [CB3135] .1671
Failure Code [CB3167] .1674
Failure Code [CB3251] .1679
Failure Code [CB3253] .1681
Failure Code [CB3254] .1685
Failure Code [CB3255] .1688
Failure Code [CB3256] .1690
Failure Code [CB3311] .1692
Failure Code [CB3312] .1694
Failure Code [CB3313] .1696
Failure Code [CB3314] .1697
Failure Code [CB3315] .1698
Failure Code [CB3316] .1701
Failure Code [CB3317] .1702
Failure Code [CB3318] .1703
Failure Code [CB3319] .1706
Failure Code [CB3321] .1707
Failure Code [CB3322] .1708
Failure Code [CB4151] .1711
Failure Code [CB4158] .1714
Failure Code [CB4161] .1715
Failure Code [CB4162] .1717
Failure Code [CB4163] .1719
Failure Code [CB4259] .1721
Failure Code [CB4952] .1723
Failure Code [CB5383] .1726
Failure Code [D018KB] .1727
Failure Code [D018KY] .1729
Failure Code [D019KB] .1731
Failure Code [D019KY] .1733
Failure Code [D150KB] .1735
Failure Code [D150KZ] .1737
Failure Code [D164KY] .1739
Failure Code [D19HKZ] .1740
Failure Code [D19JKZ] .1742
Failure Code [D19QKZ] .1744
Failure Code [D1EHKA] .1746
Failure Code [D1EHKB] .1748
Failure Code [D1EHKY] .1750
Failure Code [D1EMKA] .1751
Failure Code [D1EMKB] .1752
Failure Code [D1EMKY] .1753
Failure Code [D1FBKB] .1754
Failure Code [D5WNKZ] .1756
Failure Code [D5ZHL6] .1758
Failure Code [D5ZKKZ] .1760
Failure Code [D862KA] .1762
Failure Code [DAF0KT] .1763
Failure Code [DAF0MB] .1764
Failure Code [DAF0MC] .1765
Failure Code [DAF3KK] .1766
Failure Code [DAF8KB] .1768
Failure Code [DAFDKB] .1770
Failure Code [DAFGMC] .1772
Failure Code [DAFLKA] .1773
Failure Code [DAFLKB] .1776
Failure Code [DAFQKR] .1779
Failure Code [DAQ0KK] .1780
Failure Code [DAQ0KT] .1783
Failure Code [DAQ0MC] .1784
Failure Code [DAQ1KA] .1785
Failure Code [DAQ2KK] .1788
Failure Code [DAQ9KQ] .1791
Failure Code [DAQLKA] .1792
Failure Code [DAQLKB] .1795
Failure Code [DAQQKR] .1798
Failure Code [DAQRKR] .1799
Failure Code [DAQRMA] .1800
Failure Code [DAQV00] .1801
Failure Code [DAQW00] .1802
Failure Code [DAZ9KQ] .1803
Failure Code [DAZQKR] .1804
Failure Code [DB10KT] .1806
Failure Code [DB10MC] .1807
Failure Code [DB11KA] .1808
Failure Code [DB11KA] (Machine with Emergency Engine Stop Switch) .1811
Failure Code [DB12KK] .1814
Failure Code [DB13KK] .1817
Failure Code [DB19KQ] .1820
Failure Code [DB1LKA] .1821
Failure Code [DB1LKB] .1824
Failure Code [DB1QKR] .1827
Failure Code [DB1QMA] .1828
Failure Code [DB1RKR] .1829
Failure Code [DB2QKR] .1830
Failure Code [DB2QKR] .1837
Failure Code [DB2QKR] .1845
Failure Code [DB2RKR] .1852
Failure Code [DB2RKR] .1859
Failure Code [DB2RKR] .1867
Failure Code [DBC0KT] .1874
Failure Code [DBC0MC] .1875
Failure Code [DBC1KA] .1876
Failure Code [DBC2KK] .1879
Failure Code [DBC3KK] .1881
Failure Code [DBC9KQ] .1884
Failure Code [DBCLKA] .1885
Failure Code [DBCLKB] .1887
Failure Code [DBCQKR] .1889
Failure Code [DBCQMA] .1890
Failure Code [DBCRKR] .1891
Failure Code [DBV0MC] .1892
Failure Code [DBV1KK] .1893
Failure Code [DBV6KB] .1895
Failure Code [DBV7KB] .1897
Failure Code [DBVLKA] .1898
Failure Code [DBVLKB] .1901
Failure Code [DBVQKR] .1904
Failure Code [DBVRKR] .1905
Failure Code [DBVVKR] .1906
Failure Code [DBVWKR] .1907
Failure Code [DCR0MC] .1908
Failure Code [DCR2KK] .1909
Failure Code [DCR8L4] .1913
Failure Code [DCR9KQ] .1917
Failure Code [DCRLKA] .1919
Failure Code [DCRLKB] .1922
Failure Code [DCRQKR] .1924
Failure Code [DCRRKR] .1937
Failure Code [DDAAL6] .1949
Failure Code [DDAAL6] (For Machines to Which Emergency Engine Stop Switch is Installed) .1951
Failure Code [DDACL4] .1954
Failure Code [DDADKA] .1956
Failure Code [DDADKY] .1958
Failure Code [DDD7KX] .1960
Failure Code [DDP6L4] .1962
Failure Code [DDTHKA] .1964
Failure Code [DDTJKA] .1966
Failure Code [DDTKKA] .1968
Failure Code [DDTLKA] .1970
Failure Code [DDTMKA] .1972
Failure Code [DDTNKA] .1974
Failure Code [DDTPKA] .1976
Failure Code [DF10KA] .1978
Failure Code [DF10KB] .1982
Failure Code [DGE5KX] .1987
Failure Code [DGF1KX] .1989
Failure Code [DGR2KB] .1991
Failure Code [DGR6KB] .1993
Failure Code [DGR6L8] .1994
Failure Code [DGT1KX] .1996
Failure Code [DGT4KA] .1998
Failure Code [DGT4KB] .2000
Failure Code [DGT4KY] .2002
Failure Code [DHA4KA] .2004
Failure Code [DHAAMA] .2006
Failure Code [DHABMA] .2007
Failure Code [DHACMA] .2008
Failure Code [DHADMA] .2009
Failure Code [DHP4KY] .2010
Failure Code [DHP4KZ] .2012
Failure Code [DHP5KY] .2014
Failure Code [DHP5KZ] .2016
Failure Code [DHP6KA] .2018
Failure Code [DHP6KX] .2020
Failure Code [DHP6KY] .2022
Failure Code [DHP6KZ] .2024
Failure Code [DHP7KA] .2026
Failure Code [DHP7KX] .2028
Failure Code [DHP7KY] .2030
Failure Code [DHP7KZ] .2032
Failure Code [DHQ2KX] .2034
Failure Code [DHQ4KX] .2036
Failure Code [DHT5KX] .2038
Failure Code [DHT5L6] .2040
Failure Code [DHT8KX] .2042
Failure Code [DHT8ZG] .2044
Failure Code [DHU2KX] .2046
Failure Code [DHU3KX] .2048
Failure Code [DHU6KX] .2050
Failure Code [DHU7KX] .2052
Failure Code [DHU8KX] .2054
Failure Code [DHU9KX] .2056
Failure Code [DHUCKX] .2058
Failure Code [DHUDKX] .2061
Failure Code [DHUHKX] .2063
Failure Code [DHULKX] .2065
Failure Code [DHUMKX] .2068
Failure Code [DHUPKX] .2071
Failure Code [DHUTKX] .2073
Failure Code [DHY9KX] .2075
Failure Code [DJF1KA] .2077
Failure Code [DK30KX] .2079
Failure Code [DK51L5] .2081
Failure Code [DK52KX] .2084
Failure Code [DK53L8] .2086
Failure Code [DK54KX] .2088
Failure Code [DK60KX] .2090
Failure Code [DKD0L6] .2092
Failure Code [DKH0KX] .2094
Failure Code [DKH1KX] .2096
Failure Code [DLF1KA] .2098
Failure Code [DLF1LC] .2099
Failure Code [DLF2KA] .2101
Failure Code [DLF2LC] .2103
Failure Code [DLF6KA] .2105
Failure Code [DLF6L3] .2106
Failure Code [DLF7KA] .2108
Failure Code [DLF7L3] .2109
Failure Code [DLF8KA] .2111
Failure Code [DLF8L3] .2112
Failure Code [DLF8LC] .2113
Failure Code [DLF8MA] .2115
Failure Code [DLF9KA] .2116
Failure Code [DLF9L3] .2117
Failure Code [DLF9LC] .2118
Failure Code [DLF9MA] .2120
Failure Code [DLM3KA] .2121
Failure Code [DLM3LC] .2122
Failure Code [DLM3MB] .2124
Failure Code [DLT3KA] .2125
Failure Code [DLT3LC] .2126
Failure Code [DPQ1KR] .2128
Failure Code [DPQ2KR] .2131
Failure Code [DPQ3KR] .2134
Failure Code [DR81KR] .2138
Failure Code [DR81MA] .2148
Failure Code [DSJ0KR] .2149
Failure Code [DV00KB] .2150
Failure Code [DV03KB] .2152
Failure Code [DV03KY] .2155
Failure Code [DW2AKA] .2157
Failure Code [DW2AKB] .2158
Failure Code [DW2AKY] .2160
Failure Code [DW2AL1] .2161
Failure Code [DW2ALH] .2162
Failure Code [DW2BKA] .2163
Failure Code [DW2BKB] .2164
Failure Code [DW2BKY] .2165
Failure Code [DW2BL1] .2166
Failure Code [DW2BLH] .2167
Failure Code [DW35KZ] .2168
Failure Code [DW36KZ] .2170
Failure Code [DW4BK4] .2172
Failure Code [DW4BMA] .2176
Failure Code [DW72KZ] .2180
Failure Code [DW73KA] .2182
Failure Code [DW73KB] .2184
Failure Code [DW73KY] .2186
Failure Code [DW78KZ] .2187
Failure Code [DW7BKB] .2189
Failure Code [DW7BKY] .2191
Failure Code [DW7BKZ] .2192
Failure Code [DW7NKZ] .2194
Failure Code [DWD6KA] .2196
Failure Code [DWD6KB] .2198
Failure Code [DWD6KY] .2200
Failure Code [DWD6MA] .2201
Failure Code [DWD7K4] .2203
Failure Code [DWD7KA] .2204
Failure Code [DWD7KB] .2206
Failure Code [DWD7KY] .2208
Failure Code [DWD7MA] .2209
Failure Code [DWNDKZ] .2210
Failure Code [DWNDMA] .2212
Failure Code [DWNEKZ] .2214
Failure Code [DWNEMA] .2216
Failure Code [DWNMKZ] .2218
Failure Code [DX11K4] .2220
Failure Code [DX11KA] .2222
Failure Code [DX11KB] .2224
Failure Code [DX11KY] .2226
Failure Code [DX11MA] .2227
Failure Code [DX13KA] .2229
Failure Code [DX13KB] .2231
Failure Code [DX13KY] .2233
Failure Code [DX16KA] .2234
Failure Code [DX16KB] .2235
Failure Code [DX16KY] .2237
Failure Code [DX21KA] .2238
Failure Code [DX21KB] .2239
Failure Code [DX21KY] .2241
Failure Code [DX21MA] .2242
Failure Code [DX22KA] .2244
Failure Code [DX22KB] .2245
Failure Code [DX22KY] .2247
Failure Code [DX22MA] .2248
Failure Code [DX23KA] .2250
Failure Code [DX23KB] .2251
Failure Code [DX23KY] .2253
Failure Code [DX23MA] .2254
Failure Code [DX24KA] .2256
Failure Code [DX24KB] .2257
Failure Code [DX24KY] .2259
Failure Code [DX24MA] .2260
Failure Code [DX25MA] .2262
Failure Code [DX26MA] .2263
Failure Code [DX37K4] .2264
Failure Code [DX37KA] .2266
Failure Code [DX37KB] .2267
Failure Code [DX37KY] .2269
Failure Code [DX37MA] .2270
Failure Code [DX38K4] .2272
Failure Code [DX38KA] .2274
Failure Code [DX38KB] .2275
Failure Code [DX38KY] .2277
Failure Code [DX38MA] .2278
Failure Code [DXH1KA] .2280
Failure Code [DXH1KB] .2282
Failure Code [DXH1KY] .2284
Failure Code [DXH2KA] .2285
Failure Code [DXH2KB] .2287
Failure Code [DXH2KY] .2289
Failure Code [DXH3KA] .2292
Failure Code [DXH3KB] .2294
Failure Code [DXH3KY] .2296
Failure Code [DXH4KA] .2299
Failure Code [DXH4KB] .2301
Failure Code [DXH4KY] .2303
Failure Code [DXH5KA] .2306
Failure Code [DXH5KB] .2308
Failure Code [DXH5KY] .2310
Failure Code [DXH6KA] .2313
Failure Code [DXH6KB] .2315
Failure Code [DXH6KY] .2317
Failure Code [DXH7KA] .2320
Failure Code [DXH7KB] .2322
Failure Code [DXH7KY] .2324
Failure Code [DXHHKA] .2326
Failure Code [DXHHKB] .2328
Failure Code [DXHHKY] .2330
Failure Code [DY30MA] .2332
Failure Code [DY30MC] .2334
Failure Code [DY30ME] .2337
Failure Code [F@BYNR] .2339
Failure Code [F@BYNS] .2340
Troubleshooting of Electrical System (E-Mode) .2341
Engine Does Not Start (Engine Does Not Crank) .2341
Manual Preheating System Does Not Operate .2349
Automatic Preheating System Does Not Operate 2352
While Preheating is in Operation, Preheating Monitor Does Not Come On .2354
The LCD Unit, LED Unit, and Meter Unit of the Machine Monitor Show Nothing 2356
All of LCD Unit, LED Unit, and Meter Unit on Machine Monitor Show Nothing (For Machines to Which Emergency Engine Stop Switch is Installed) .2359
LCD Unit on Machine Monitor Shows Nothing .2362
Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers) .2364
LCD Screen on Machine Monitor Does Not Show Correctly .2366
Meter Unit Display on Machine Monitor is Abnormal .2368
Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal 2371
LED Unit Lamp on Machine Monitor is Abnormal 2374
Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly .2376
Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate 2378
Switch Panel Buzzer of Machine Monitor is Abnormal 2380
Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Normally 2382
Rearview Monitor Does Not Come On or Backlight Flickers .2383
Rearview Monitor Images are Not Shown Clearly .2387
Rearview Monitor Brightness Cannot be Adjusted 2391
Night Mode Lamp of Rearview Monitor is Abnormal .2395
Rearview Monitor Does Not Display Images While REVERSE Linked Display Function is Enabled .2397
Guide Line on Rearview Monitor is Not Shown While Guide Line is Set .2400
Fuel Gauge Does Not Show Normally .2402
Seatbelt Caution Lamp Does Not Show Normally 2404
Machine Monitor Cannot be Operated When Starting Switch is in OFF Position 2406
Alarm Buzzer Does Not Operate .2407
Alarm Buzzer Does Not Stop 2409
Engine Power Mode Selector Function Does Not Operate Correctly When Engine Power Mode Selector Switch is Operated (Machine with Engine Power Mode Selector System) 2411
AISS Function Does Not Operate Correctly 2415
Hoist Lever Does Not Operate Correctly 2417
Fuel Feed Pump Does Not Operate or Stop Automatically .2419
Turn Signal Lamp and Winker Lamp (Hazard Lamp) Do Not Operate Correctly .2424
Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On 2428
Clearance Lamp Does Not Come On .2431
Tail Lamp Does Not Come On 2434
Headlamp (Low Beam) Does Not Come On 2437
Headlamp (High Beam) Does Not Come On .2439
Headlamp (Low Beam) and (High Beam) Do Not Come On 2441
Passing Lamp Does Not Come On .2443
KOMTRAX System Does Not Operate Correctly .2445
Data Download with Wireless LAN Does Not Operate 2447
Cannot Access to the Setting Screen of the Mobile Communication Terminal 2448
Cannot Log in to the Setting Screen of the Mobile Communication Terminal Because the Log in Password is Unknown .2455
KOMTRAX Plus Controller is Not Found 2457
KOMTRAX Plus Controller Does Not Become Active 2459
Communication Failure Occurs Between Mobile Communication Terminal and KOMTRAX Plus Server 2460
Restrictions on Radio Reception .2462
Data is Not Sent to KOMTRAX Plus Server .2463
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) .2465
Information Shown in Troubleshooting Table (H-Mode) .2465
Failure Mode and Cause Table 2466
Machine Does Not Start 2476
Machine Does Not Travel Smoothly (Machine Hunts) 2479
Lockup is Not Released 2480
Strong Shock is Made When You Start Machine or Shift Gears 2481
Shiftup Does Not Operate 2483
Travel Speed in All Gear Speed is Low or Power is Low During Travel with Lockup Function 2486
Travel Speed is Low or Power is Low During Travel with Torque Converter .2487
Travel Speed is Low or Power is Low in Specified Gear Speed .2488
Time Lag is Large When You Start Machine or Shift Gears .2490
Torque Converter Oil Temperature is High 2493
Torque Converter Oil Pressure is Low 2494
Steering Wheel is Heavy to Operate 2495
Steering Wheel is Disabled 2496
Steering Wheel is Shaken 2497
Front Brake Does Not Operate Sufficiently .2498
Rear Brake Does Not Operate Sufficiently 2499
Speed is Low When Dump Body is Raised .2500
Hydraulic Drift of Dump Body is Large .2502
Dump Body is Disabled .2503
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) .2504
Unusual Noise is Heard from Around Fan 2505
Troubleshooting of Engine (S-Mode) 2506
Information Shown in Troubleshooting Table (S-Mode) .2506
Engine Does Not Crank When Starting Switch is Turned to Start Position 2507
Engine Cranks but No Exhaust Smoke Comes Out 2508
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) .2509
Engine Startability is Unsatisfactory .2510
Engine Does Not Pick Up Smoothly 2512
Engine Stops During Operation .2514
Engine Does Not Rotate Smoothly .2516
Engine Lacks Output (or Lacks Power) 2517
KDPF Becomes Clogged in a Short Time 2519
Engine Oil Consumption is Excessive .2521
Engine Oil Becomes Dirty Quickly 2522
Fuel Consumption is Excessive .2523
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) .2524
Engine Oil Pressure Drops .2525
Fuel Mixes Into Engine Oil 2527
Water Mixes Into Engine Oil (Milky) .2528
Coolant Temperature Increases Too High (Overheat) .2529
Unusual Noise is Heard 2530
Vibration is Excessive 2531
Air Cannot be Bled from Fuel Circuit 2532
Active Regeneration is Done Frequently 2533
Active Regeneration Continues Long 2534
White Smoke is Exhausted During Active Regeneration .2535
50 Disassembly and Assembly .2537
Table of Contents .2538
Precautions Before Work .2542
Related Information on Disassembly and Assembly .2543
How to Read This Manual .2543
Coating Materials List 2545
Special Tool List .2550
Sketches of Special Tools .2558
Engine and Cooling System .2561
Remove and Install Supply Pump Assembly .2561
How to Remove Supply Pump Assembly 2562
How to Install Supply Pump Assembly .2573
Remove and Install Injector Assembly 2589
How to Remove Injector Assembly .2591
How to Install Injector Assembly 2612
Remove and Install Fuel Doser Assembly 2642
How to Remove Fuel Doser Assembly .2643
How to Install Fuel Doser Assembly 2644
Remove and Install Cylinder Head Assembly .2647
How to Remove Cylinder Head Assembly 2649
How to Install Cylinder Head Assembly .2694
Remove and Install EGR Valve Assembly .2756
How to Remove EGR Valve Assembly 2757
How to Install EGR Valve Assembly .2759
Remove and Install EGR Cooler Assembly 2762
How to Remove EGR Cooler Assembly .2763
How to Install EGR Cooler Assembly 2772
Remove and Install Starter Assembly .2782
How to Remove Starting Motor Assembly .2782
How to Install Starting Motor Assembly 2783
Remove and Install Alternator Belt 2785
How to Remove Alternator Belt .2785
How to Install Alternator Belt 2786
Remove and Install Cooler Assembly 2788
How to Remove Cooling Assembly 2789
How to Install Cooling Assembly .2804
Remove and Install Radiator Core 2818
How to Remove Radiator Core .2819
How to Install Radiator Core 2825
Remove and Install Cooling Fan and Fan Motor Assembly .2832
How to Remove Cooling Fan and Fan Motor Assembly 2833
How to Install Cooling Fan and Fan Motor Assembly .2835
Remove and Install Aftercooler Assembly .2838
How to Remove Aftercooler Assembly 2839
How to Install Aftercooler Assembly .2845
Remove and Install Engine Assembly 2852
How to Remove Engine Assembly .2854
How to Install Engine Assembly 2867
Remove and Install Engine Front Oil Seal 2880
How to Remove Engine Front Oil Seal .2880
How to Install Engine Front Oil Seal 2882
Remove and Install Engine Rear Oil Seal .2884
How to Remove Engine Rear Oil Seal 2884
How to Install Engine Rear Oil Seal .2885
Remove and Install Damper Assembly 2890
How to Remove Damper Assembly .2891
How to Install Damper Assembly 2896
Disassemble and Assemble Damper Assembly 2905
How to Disassemble Damper Assembly 2906
How to Assemble Damper Assembly .2907
Remove and Install KDPF Assembly (with Bracket) .2910
How to Remove KDPF Assembly .2911
How to Install KDPF Assembly 2915
Remove and Install KDPF Assembly (Without Bracket) 2921
How to Remove KDPF Assembly .2922
How to Install KDPF Assembly 2928
Disassemble and Assemble KDPF Assembly 2936
How to Disassemble KDPF Assembly 2937
How to Assemble KDPF Assembly .2942
Remove and Install KCCV Assembly 2949
How to Remove KCCV Assembly .2950
How to Install KCCV Assembly 2952
Remove and Install Air Cleaner Assembly .2955
How to Remove Air Cleaner Assembly 2955
How to Install Air Cleaner Assembly .2956
Remove and Install Air Conditioner Compressor Assembly 2958
How to Remove Air Conditioner Compressor Assembly .2958
How to Install Air Conditioner Compressor Assembly 2959
Power Train .2961
Remove and Install Torque Converter and Transmission Assembly .2961
How to Remove Torque Converter and Transmission Assembly 2962
How to Install Torque Converter and Transmission Assembly .2967
Disconnect and Connect Torque Converter and Transmission Assembly .2972
How to Disconnect Torque Converter and Transmission Assembly 2973
How to Connect Torque Converter and Transmission Assembly .2981
Disassemble and Assemble Torque Converter Assembly 2999
How to Disassemble Torque Converter Assembly 3000
How to Assemble Torque Converter Assembly .3006
Disassemble and Assemble Transmission Assembly 3017
How to Disassemble Transmission Assembly 3019
How to Assemble Transmission Assembly .3038
Remove and Install Differential Assembly 3066
How to Remove Differential Assembly .3067
How to Install Differential Assembly 3070
Disassemble and Assemble Differential Assembly 3073
How to Disassemble Differential Assembly 3074
How to Assemble Differential Assembly .3080
Remove and Install Front Brake Caliper Pad 3090
How to Remove Front Brake Caliper Pad .3090
How to Install Front Brake Caliper Pad 3091
Remove and Install Front Brake Caliper Assembly .3092
How to Remove Front Brake Caliper Assembly 3092
How to Install Front Brake Caliper Assembly .3093
Disassemble and Assemble of Front Brake Caliper Assembly 3094
How to Disassemble Front Brake Caliper Assembly .3094
How to Assemble Front Brake Caliper Assembly 3094
Remove and Install Final Drive and Rear Brake Assembly 3097
How to Remove Final Drive and Rear Brake Assembly .3098
How to Install Final Drive and Rear Brake Assembly 3101
Remove and Install Final Drive, Rear Brake and Parking Brake Assembly .3105
How to Remove Final Drive, Rear Brake and Parking Brake Assembly 3105
How to Install Final Drive, Rear Brake and Parking Brake Assembly .3108
Disassemble and Assemble of Final Drive, Rear Brake and Parking Brake Assembly 3112
How to Disassemble Final Drive, Rear Brake and Parking Brake Assembly .3113
How to Assemble Final Drive, Rear Brake and Parking Brake Assembly 3118
Remove and Install Final Drive Carrier Assembly .3126
How to Remove Final Drive Carrier Assembly 3126
How to Install Final Drive Carrier Assembly .3128
Disassemble and Assemble Final Drive Carrier Assembly .3130
How to Disassemble Final Drive Carrier Assembly .3130
How to Assemble Final Drive Carrier Assembly 3130
Steering System .3131
Disassemble and Assemble Steering Cylinder Assembly .3131
How to Disassemble Steering Cylinder Assembly .3132
How to Assemble Steering Cylinder Assembly 3133
Undercarriage and Frame .3136
Remove and Install Front Wheel Assembly .3136
How to Remove Front Wheel Assembly 3136
How to Install Front Wheel Assembly .3137
Remove and Install Rear Wheel Assembly 3139
How to Remove Rear Wheel Assembly .3139
How to Install Rear Wheel Assembly 3141
Remove and Install Front Suspension Cylinder Assembly .3143
How to Remove Front Suspension Cylinder Assembly 3143
How to Install Front Suspension Cylinder Assembly .3144
Disassemble and Assemble Front Suspension Cylinder Assembly (Cylinder with Buffer Ring) .3147
How to Disassemble Front Suspension Cylinder Assembly .3147
How to Assemble Front Suspension Cylinder Assembly 3149
Remove and Install Rear Suspension Cylinder Assembly 3153
How to Remove Rear Suspension Cylinder Assembly .3153
How to Install Rear Suspension Cylinder Assembly 3154
Disassemble and Assemble Rear Suspension Cylinder Assembly (Cylinder with Buffer Ring) 3155
How to Disassemble Rear Suspension Cylinder Assembly 3156
How to Assemble Rear Suspension Cylinder Assembly .3157
Disassemble and Assemble of Front Wheel Hub Assembly 3161
How to Disassemble Front Wheel Hub Assembly .3161
How to Assemble Front Wheel Hub Assembly 3163
Hydraulic System 3167
Disassemble and Assemble Hoist Cylinder Assembly 3167
How to Disassemble Hoist Cylinder Assembly 3168
How to Assemble Hoist Cylinder Assembly .3170
Work Equipment 3176
Remove and Install Dump Body Assembly .3176
How to Remove Body Assembly .3176
How to Install Body Assembly 3177
CAB Related Parts .3180
Remove and Install Air Conditioner Unit Assembly 3180
How to Remove Air Conditioner Unit Assembly .3181
How to Install Air Conditioner Unit Assembly 3188
Remove and Install Operator Seat Assembly .3196
How to Remove Operator Seat Assembly 3196
How to Install Operator Seat Assembly .3198
How to Remove and Install Seat Belt .3201
How to Remove Seat Belt .3201
How to Install Seatbelt .3202
Electrical System .3204
Remove and Install Engine Controller Assembly .3204
How to Remove Engine Controller Assembly 3204
How to Install Engine Controller Assembly .3206
Remove and Install Retarder and Hoist Controller Assembly .3209
How to Remove Retarder and Hoist Controller Assembly 3209
How to Install Retarder and Hoist Controller Assembly .3210
Remove and Install ABS Controller Assembly 3212
How to Remove ABS Controller Assembly .3212
How to Install ABS Controller Assembly 3213
Remove and Install Transmission Controller Assembly .3214
How to Remove Transmission Controller Assembly 3214
How to Install Transmission Controller Assembly .3215
Remove and Install Machine Monitor Assembly .3216
How to Remove Machine Monitor Assembly 3217
How to Install Machine Monitor Assembly .3219
Remove and Install Monitor Controller Assembly 3222
How to Remove Monitor Controller Assembly .3222
How to Install Monitor Controller Assembly 3223
Remove and Install Mass Air Flow and Temperature Sensor .3224
How to Remove Mass Air Flow and Temperature Sensor 3224
How to Install Mass Air Flow and Temperature Sensor .3225
Remove and Install KCCV Crankcase Pressure Sensor .3227
How to Remove KCCV Crankcase Pressure Sensor 3227
How to Install KCCV Crankcase Pressure Sensor .3228
Remove And Install KOMTRAX Plus Controller Assembly .3230
How to Remove KOMTRAX Plus Controller Assembly 3230
How to Install KOMTRAX Plus Controller Assembly .3231
Remove and Install Mobile Communication Terminal 3233
How to Remove Mobile Communication Terminal .3233
How to Install Mobile Communication Terminal 3234
Remove and Install DC-DC Converter 3236
How to Remove DC-DC Converter .3236
How to Install DC-DC Converter 3237
Remove and Install Mobile Communication Terminal Wiring Harness .3238
How to Remove Mobile Communication Terminal Wiring Harness 3238
How to Install Mobile Communication Terminal Wiring Harness .3243
Remove and Install KOMTRAX Terminal Assembly 3249
How to Remove KOMTRAX Terminal Assembly .3249
How to Install KOMTRAX Terminal Assembly 3251
Remove and Install Wireless LAN Unit Assembly .3252
How to Remove Wireless LAN Unit Assembly 3252
How to Install Wireless LAN Unit Assembly .3253
Remove and Install Driver Status Monitor 3256
How to Remove Driver Status Monitor .3256
How to Install Driver Status Monitor 3257
Remove and Install Translator Controller 3259
How to Remove Translator Controller .3259
How to Install Translator Controller 3260
Remove and Install Drowsiness Detection Camera 3262
How to Remove Drowsiness Detection Camera .3262
How to Install Drowsiness Detection Camera 3263
Remove and Install Drowsiness Alarm Buzzer 3265
How to Remove Drowsiness Alarm Buzzer .3265
How to Install Drowsiness Alarm Buzzer 3266
Remove and Install Drowsiness Detection Wiring Harness 3268
How to Remove Drowsiness Detection Wiring Harness .3268
How to Install Drowsiness Detection Wiring Harness 3278
60 Maintenance Standard .3291
Table of Contents .3292
Engine and Cooling System .3293
Maintenance Standard for Engine Mount .3293
Maintenance Standard for Damper .3294
Maintenance Standard for Cooling Fan Pump .3296
Maintenance Standard for Servo Valve for Cooling Fan Pump .3298
Maintenance Standard for Cooling Fan Motor 3299
Power Train .3301
Maintenance Standard for Drive Shaft 3301
Maintenance Standard for Torque Converter and Transmission Mount 3302
Maintenance Standard for Torque Converter and PTO .3303
Maintenance Standard for Torque Converter Valve .3307
Maintenance Standard for Transmission .3309
Maintenance Standard for Transmission Control Valve .3315
Maintenance Standard for H, L, 4th, 3rd, R, 2nd, and 1st ECMV .3316
Maintenance Standard for Lockup Clutch ECMV .3317
Maintenance Standard for Front Axle .3318
Maintenance Standard for Rear Axle 3319
Maintenance Standard for Differential .3320
Maintenance Standard for Final Drive 3321
Steering System .3322
Maintenance Standard for Steering Column 3322
Maintenance Standard for Steering Linkage .3323
Maintenance Standard for Demand Valve .3326
Maintenance Standard for Steering Cylinder 3329
Brake System 3330
Maintenance Standard for Slack Adjuster .3330
Maintenance Standard for Front Brake 3331
Maintenance Standard for Rear Brake .3332
Undercarriage and Frame .3334
Maintenance Standard for Front Suspension Cylinder 3334
Maintenance Standard for Rear Suspension Cylinder .3337
Hydraulic System 3339
Maintenance Standard for Steering and Hoist Pump 3339
Maintenance Standard for Servo Valve for Steering and Hoist Pump 3340
Maintenance Standard for Power Train and Brake Cooling Duplex Pump 3342
Maintenance Standard for Brake Cooling, Control Triple Pump .3343
Maintenance Standard for Hoist Valve 3345
Work Equipment 3347
Maintenance Standard for Hoist Cylinder .3347
CAB Related Parts .3348
Maintenance Standard for CAB Mount 3348
80 Others .3349
Table of Contents .3350
Precautions Before Work .3352
Air Conditioner System 3353
Precautions for Refrigerant .3353
Air Conditioner Component .3354
Specifications of Air Conditioner .3356
Structure and Function of Refrigeration Cycle .3357
Outline of Refrigeration Cycle 3358
Component Parts of Air Conditioner System .3360
Air Conditioner Unit 3360
Configuration Diagram of Air Conditioner Unit .3360
Function of Air Conditioner Unit 3361
Component Parts of Air Conditioner Unit .3364
Function of Evaporator as Air Conditioner Unit Component 3365
Function of Heater Core as Air Conditioner Unit Component .3365
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component .3365
Function of Servo Motor as Air Conditioner Unit Component .3365
Structure of Expansion Valve as Air Conditioner Unit Component 3366
Function of Expansion Valve as Air Conditioner Unit Component .3366
Operate Expansion Valve as Air Conditioner Unit Component .3366
Function of Dual Pressure Switch 3367
Air Conditioner Controller 3368
Structure of Air Conditioner Controller .3368
Compressor 3369
Structure of Compressor .3369
Specifications of Compressor 3369
Function of Compressor 3369
Condenser .3370
Structure of Condenser 3370
Specifications of Condenser .3370
Function of Condenser .3370
Air Conditioner Related Sensors .3372
Structure of Outside Temperature Sensor .3372
Function of Outside Air Temperature Sensor 3372
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner .3373
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 3376
System Diagram of Air Conditioner .3378
Input and Output Signals of Air Conditioner Controller 3379
Function of Air Conditioner Controller 3380
Locations of Air Conditioner Parts and Layout of Connectors .3381
Examine Air Leakage (Duct) 3384
How to Examine Air Leakage (Duct) .3384
Examine Air Conditioner with Self-Diagnosis Function 3387
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor .3388
Examine Vent (Mode) Changeover 3390
How to Examine Vent (Mode) Changeover .3390
Examine Fresh/Recirc Air Changeover .3391
How to Examine Fresh/Recirc Air Changeover 3391
Examine Refrigerant (Dual) Pressure Switch 3392
How to Examine Refrigerant (Dual) Pressure Switch .3392
Examine Relay .3393
How to Examine Relay 3393
Air Conditioner Troubleshooting Chart 1 .3395
Air Conditioner Troubleshooting Chart 2 .3396
Information Shown in Troubleshooting Table 3399
Failure Code [879AKA] .3401
Failure Code [879AKB] .3402
Failure Code [879BKA] .3403
Failure Code [879BKB] .3404
Failure Code [879CKA] .3406
Failure Code [879CKB] .3407
Failure Code [879EMC] .3408
Failure Code [879FMC] .3409
Failure Code [879GKX] .3410
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 3411
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) .3413
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3416
Troubleshooting for Fresh/Recirc Air Changeover .3418
Troubleshooting by Gauge Pressure .3420
Connect Service Tool 3422
How to Connect Service Tool .3422
Precautions for Disconnection and Connection of Air Conditioner Piping 3424
Handle Compressor Oil .3426
How to Replace Desiccant 3428
90 Circuit Diagrams .3431
Table of Contents .3432
Hydraulic Circuit Diagram .3433
Symbols Used in Hydraulic Circuit Diagram .3433
Hydraulic Circuit Diagram (1/3) .3437
Hydraulic Circuit Diagram (2/3) .3439
Hydraulic Circuit Diagram (3/3) .3441
Power Train Hydraulic Circuit Diagram .3443
Electrical Circuit Diagram 3445
Symbols Used in Electric Circuit Diagram 3445
Electrical Circuit Diagram of Inside of CAB (1/11) 3449
Electrical Circuit Diagram of Inside of CAB (2/11) 3451
Electrical Circuit Diagram of Inside of CAB (3/11) 3453
Electrical Circuit Diagram of Inside of CAB (4/11) 3455
Electrical Circuit Diagram of Inside of CAB (5/11) 3457
Electrical Circuit Diagram of Inside of CAB (6/11) 3459
Electrical Circuit Diagram of Inside of CAB (7/11) 3461
Electrical Circuit Diagram of Inside of CAB (8/11) 3463
Electrical Circuit Diagram of Inside of CAB (9/11) 3465
Electrical Circuit Diagram of Inside of CAB (10/11) .3467
Electrical Circuit Diagram of Inside of CAB (11/11) .3469
External CAB Electrical Diagram (1/8) .3471
External CAB Electrical Diagram (2/8) .3473
External CAB Electrical Diagram (3/8) .3475
External CAB Electrical Diagram (4/8) .3477
External CAB Electrical Diagram (5/8) .3479
External CAB Electrical Diagram (6/8) .3481
External CAB Electrical Diagram (7/8) .3483
External CAB Electrical Diagram (8/8) .3485
Electrical Circuit Diagram of Engine (1/2) 3487
Electrical Circuit Diagram of Engine (2/2) 3489
Electrical Circuit Diagram (Drowsiness Detection System (DDS)) 3491
Index 3493

DESCRIPTION:

Komatsu HD465-8E0,HD605-8E0 Dump Truck Shop Manual SEN06768-13 –  PDF DOWNLOAD

SERIAL NUMBERS

• HD465-35001 and up
• HD605-35001 and up

G.B 28/12/24