Komatsu HD465-8,HD605-8 Dump Truck Shop Manual SEN06605-24 PDF

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Komatsu HD465-8,HD605-8 Dump Truck Shop Manual SEN06605-24  – PDF DOWNLOAD

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Komatsu HD465-8,HD605-8 Dump Truck Shop Manual SEN06605-24  – PDF DOWNLOAD

Language : English
Pages : 3512
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HD465-8,HD605-8 Dump Truck Shop Manual SEN06605-24  – PDF DOWNLOAD

SERIAL NUMBERS

• HD465-8 30001 and up
• HD605-8 30001 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 51
Precautions When You Handle Fuel System Equipment . 53
Precautions When You Handle Intake System Equipment . 54
Practical Use of KOMTRAX 55
Disconnect and Connect Push-Pull Type Coupler . 56
How to Disconnect and Connect Type 1 Push-Pull Type Coupler . 56
How to Disconnect and Connect Type 2 Push-Pull Type Coupler . 57
How to Disconnect and Connect Type 3 Push-Pull Type Coupler . 58
Precautions for Disconnection and Connection of Connectors 60
How to Disconnect and Connect Deutsch Connector . 64
How to Disconnect and Connect Slide Lock Type Connector . 65
How to Disconnect and Connect Connector with Lock to Pull . 67
How to Disconnect and Connect Connector with Lock to Push . 68
How to Disconnect and Connect Connector with Housing to Rotate 70
How to Read the Codes for Electric Cable 71
Explanation of Terms for Maintenance Standard . 75
Standard Tightening Torque Table 78
Conversion Table 85
01 Specifications . 91
Table of Contents . 92
Specifications 93
Specification Drawing . 93
Diagram Specification: HD465-8 93
Specification Drawing: HD605-8 95
Specifications 97
Specifications: HD465-8 . 97
Specifications: HD605-8 . 102
Weight Table 107
Weight Table: HD465-8 . 107
Weight Table: HD605-8 . 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
Boot-up System 116
Layout Drawing of Boot-up System 116
Layout Drawing of Boot-up System (Machine with Emergency Engine Stop Switch) 117
System Operating Lamp System 119
System Diagram of System Operating Lamp System 119
Function of Operation Lamp System . 119
Battery Disconnect Switch . 120
Layout Drawing of Battery Disconnect Switch . 120
Function of Battery Disconnect Switch . 120
Function of Battery Disconnect Switch (Machine with Mobile Communication Terminal) 121
Engine Shutdown Secondary Switch 123
Engine Secondary Shutdown Switch Diagram 123
Function of Engine Shutdown Secondary Switch 123
Operation of Engine Shutdown Secondary Switch . 124
Engine System . 125
Layout Drawing of Engine System . 125
Function of Engine System . 126
Engine Control System . 128
System Diagram of Engine Control 128
Engine Power Mode Selector System (Machine with Engine Power Mode Selector System) 132
Engine Power Mode Selector System Diagram . 132
Function of Engine Power Mode Selector System . 132
Operation of Engine Power Mode Selector System 132
Automatic Idle Stop System 133
Function of Automatic Idle Stop System 133
Component Parts of Engine System 135
Damper 135
VGT . 137
EGR System 141
EGR Valve . 144
EGR Cooler 146
KCCV System . 147
KCCV Ventilator . 149
CDR Valve . 151
KDPF 152
Cooling System 156
Layout Drawing of Cooling System 156
Specifications of Cooling System 157
Radiator Fan Control System . 158
Radiator Fan Control System Diagram . 158
Function of Radiator Fan Control System . 158
Component Parts of Cooling System . 160
Cooling Fan, Hoist Pump . 160
Cooling Fan Motor . 167
Control System 174
Layout Drawing of Control System 174
Layout Drawing of Control System (Machine with Mobile Communication Terminal) . 176
Retarder and Hoist Control System . 177
Retarder and Hoist Control System Diagram . 177
Machine Monitor System 179
System Diagram of Machine Monitor System 179
Function of Machine Monitor System 180
Rearview Monitor System . 181
System Diagram of Rearview Monitor System . 181
Function of Rearview Monitor System . 181
KOMTRAX Plus System . 182
System Diagram of KOMTRAX Plus System . 182
System Diagram of KOMTRAX Plus System (Machine with Mobile Communication Terminal) 184
Function of KOMTRAX Plus System . 185
Payload Meter System 188
Layout Drawing of Payload Meter System 188
Payload Meter System Diagram 189
Function of Payload Meter System 189
Measurement Principle of Loading Mass . 190
Machine Lock-out System . 200
Layout Drawing of Machine Lock-out System . 200
Function of Machine Lock-out System . 201
Operation of Machine Lock-out System 201
Drowsiness Detection System . 202
Layout Drawing of Drowsiness Detection System . 202
System Diagram of Drowsiness Detection System . 203
Function of Drowsiness Detection System . 205
Operation of Drowsiness Detection System 206
Component Parts of Control System . 207
Machine Monitor . 207
Switch Panel 228
Rearview Monitor 229
Rearview Camera . 231
KOMTRAX Terminal 232
KOMTRAX Plus Controller . 234
Communication Terminal 239
Wireless LAN Unit . 240
Transmission Controller . 241
Retarder and Hoist Controller . 245
Monitor Controller 250
Engine Controller . 255
ABS Controller 267
Translator Controller . 271
Drowsiness Detection Camera . 275
Driver Status Monitor . 276
Accelerator Pedal . 278
Gear Shift Lever 279
Retarder Control Lever 280
Fuel Feed Pump 281
Fuel Feed Pump Switch . 282
Hydraulic System 284
Layout Drawing of Hydraulic System 284
Component Parts of Hydraulic System . 285
Hydraulic Tank 285
Steering and Hoist Pump . 286
LS Valve 292
CO Valve 293
Power Train and Brake Cooling Duplex Pump . 296
Brake Cooling, Control Triple Pump 298
Hoist Valve . 300
Power Train System 306
Layout Drawing of Power Train System 306
Transmission Control System . 308
Transmission Control System Diagram . 308
Gear Shift Lever Positions and Automatic Gear Shift Range . 309
Gear Shift Control System . 314
Automatic Gear Shift Control of Gear Shift Control System . 314
Automatic Gear Shift Control of Gear Shift Control System (Machine with Engine Power Mode Selector System) 315
How to Shift in Each Shift Lever Position of Gear Shift Control System 316
Gear Shift Disabled Time Control of Gear Shift Control System . 317
Direction Control System 318
Rim Pull Limit Function for Overload Prevention of Direction Control System . 318
Function of Throttle Limit Function at F1 Start at D Position Setting of Direction Control System . 318
Komatsu Traction Control System (KTCS) 319
Komatsu Traction Control System (KTCS) System Diagram . 319
Function of Komatsu Traction Control System (KTCS) 319
Operation of Komatsu Traction Control System (KTCS) System Logic 320
Travel Speed Limitation System 321
System Diagram of Travel Speed Limitation System 321
Function of Travel Speed Limitation System 322
Operation of Travel Speed Limitation System . 322
Component Parts of Power Train System . 325
Drive Shaft . 325
Torque Converter and PTO 327
Lockup Clutch ECMV 331
Transmission 334
Transmission Control Valve 355
Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV 357
Axle 366
Differential 368
Final Drive . 370
Work Equipment System . 371
Work Equipment Control 371
Layout Drawing of Work Equipment Control 371
Function of Work Equipment Control 371
Hoist Control . 372
Hoist Control System Diagram 372
Function of Hoist Control . 372
Component Parts of Work Equipment System 375
Dump Lever 375
Hoist EPC Valve . 380
Steering System . 381
Layout Drawing of Steering System . 381
Function of Steering System . 382
Steering Column . 383
Structure of Steering Column 383
Steering Linkage 384
Structure of Steering Linkage . 384
Component Parts of Steering System 385
Demand Valve 385
Steering Relief Valve . 391
Orbitrol Valve 393
Steering Pump Selector Solenoid Valve . 399
Cross over Relief Valve . 400
Secondary Steering Pump . 401
Secondary Steering Motor 402
Brake System 403
Layout Drawing of Brake System 403
Retarder Control 405
Retarder Control System Diagram . 405
Function of Retarder Control 405
ARSC System . 406
ARSC System Diagram . 406
Function of ARSC System . 406
Component Parts of Brake System . 407
Brake Charge Pump . 407
Parking Brake Solenoid Valve 408
Accumulator Charge Valve 409
Brake Circuit Accumulator . 413
Brake Valve . 414
Secondary Brake Valve . 418
Secondary Brake Relay Valve . 419
Proportional Pressure Reducing Valve 420
Slack Adjuster 421
Brake . 423
Parking Brake . 426
Brake Sub-Tank 428
ABS . 429
Layout Drawing of ABS . 429
ABS System Diagram 430
Function of ABS . 431
Operation of ABS 431
Component Parts of ABS 434
Auto-Greasing System 437
Layout Drawing of Auto-Greasing System 437
Auto-Greasing System Diagram 440
Function of Auto-Greasing System 441
Auto-Greasing System 442
Auto-Greasing Pump 442
Auto-Greasing Injector 444
Undercarriage and Frame . 448
Suspension 448
Structure of Suspension . 448
Function of Suspension 448
Front Suspension 450
Structure of Front Suspension . 450
Function of Front Suspension 451
Rear Suspension . 452
Structure of Rear Suspension 452
Function of Rear Suspension . 453
Suspension Cylinder . 454
Structure of Suspension Cylinder 454
Function of Suspension Cylinder . 454
Operation of Suspension Cylinder 454
Work Equipment 456
Structure of Work Equipment . 456
Function of Work Equipment 457
CAB Related Parts . 458
ROPS CAB 458
Structure of ROPS CAB . 458
Function of ROPS CAB 458
CAB Mount . 459
Structure of CAB Mount 459
Function of CAB Mount . 459
20 Standard Value Table . 461
Table of Contents . 462
Standard Value Table for Engine . 463
Standard Value Table for Engine: HD465-8 463
Standard Value Table for Engine: HD605-8 467
Standard Value Table for Machine 470
Standard Value Table for Machine: HD465-8 . 470
Standard Value Table for Machine: HD605-8 . 488
Machine Posture and Procedures to Measure Performance . 506
30 Testing and Adjusting 507
Table of Contents . 508
Precautions Before Work . 512
Related Information on Testing and Adjusting 513
Tools for Testing and Adjusting . 513
Sketch of Tools for Testing and Adjusting . 523
Engine and Cooling System . 524
Examine Engine Speed 524
How to Examine Engine Speed . 524
Examine Boost Pressure 526
How to Examine Boost Pressure on Machine Monitor 526
How to Examine Boost Pressure by Testing Tool . 527
Examine Exhaust Gas Temperature . 530
How to Test Exhaust Gas Temperature by the Machine Monitor 530
How to Examine Exhaust Temperature by Testing Tools . 532
Examine Exhaust Gas Color . 534
How to Examine Exhaust Gas Color with the Handy Smoke Checker . 534
How to Examine Exhaust Gas Color with Smoke Meter . 535
Examine Mass Air Flow and Temperature Sensor 537
How to Examine Mass Air Flow and Temperature Sensor . 537
Examine and Adjust Valve Clearance 540
How to Examine Valve Clearance 540
How to Adjust Valve Clearance . 541
Examine Compression Pressure 543
How to Examine Compression Pressure . 543
Examine Blowby Pressure . 547
How to Examine Blowby Pressure 547
Examine Engine Oil Pressure . 550
How to Examine Engine Oil Pressure on Machine Monitor . 550
How to Examine Engine Oil Pressure by Testing Tool 550
Examine EGR Valve and VGT Oil Pressure 552
How to Examine EGR Valve and VGT Oil Pressure . 552
Examine Fuel Pressure . 553
How to Examine Fuel Pressure 553
Examine Fuel Return Rate and Leakage 555
How to Examine Fuel Return Rate and Leakage . 556
Bleed Air from Fuel System 559
How to Bleed Air from Fuel System . 559
Examine Fuel Circuit for Leakage 561
How to Examine Fuel System for Leakage 561
Examine Supply Pump . 563
How to Examine Supply Pump 563
Handle Cylinder Cut-out Mode Operation 566
Handle No-Injection Cranking Operation 567
Clean Fuel Doser 568
How to Clean Fuel Doser . 568
Write Injector Compensation Value to Engine Controller 571
How to Write Injector Compensation Value 571
Write Correction for Ash in Soot Accumulation to Engine Controller 578
How to Write Correction for Ash in Soot Accumulation to Engine Controller . 578
Examine Torque Converter Stall Speed 579
How to Examine Torque Converter Stall Speed . 579
Examine Radiator Fan Speed 581
How to Examine Radiator Fan Speed . 581
Power Train . 583
Examine Power Train Oil Pressure 583
How to Examine Power Train Oil Pressure . 585
Adjust Transmission Input Shaft Speed Sensor 597
How to Adjust Transmission Input Shaft Speed Sensor . 597
Adjust Transmission Intermediate Shaft Speed Sensor . 598
How to Adjust Transmission Intermediate Shaft Speed Sensor 598
Adjust Transmission Output Shaft Speed Sensor . 599
How to Adjust Transmission Output Shaft Speed Sensor 599
Examine After You Adjust Transmission Speed Sensor 600
How to Examine After Adjustment of Transmission Speed Sensor 600
Move Machine Which Has a Trouble in Electrical System . 601
How to Move Machine Which Has a Trouble in Engine Control System 601
How to Move Machine Which Has a Trouble in Transmission Control System 602
Steering System . 607
Examine and Adjust Steering Circuit Oil Pressure 607
How to Examine Steering Circuit Oil Pressure with the Machine Monitor . 607
How to Examine Steering Circuit Pressure with Test Tools 607
How to Adjust Steering Circuit Oil Pressure . 609
Examine Supply Pressure of Orbitrol Valve . 610
How to Examine Supply Pressure of Orbitrol Valve 610
Examine Steering Cylinder Pressure 612
How to Examine Steering Cylinder Pressure . 612
Bleed Air from Steering Cylinder Circuit 614
How to Bleed Air from Steering Cylinder Circuit . 614
Brake System 615
Release Remained Pressure in Brake Accumulator Circuit 615
How to Release Remained Pressure in Brake Accumulator Circuit . 615
Examine Wheel Brake Oil Pressure 616
How to Examine Operating Pressure of Front Brake 616
How to Examine Operating Pressure of Rear Brake . 617
How to Examine Retarder Brake Actuation Pressure 618
How to Examine Retarder Brake Actuation Pressure (For Machine with KTCS) 619
Examine and Adjust Brake Accumulator Charge Pressure 621
How to Examine Brake Accumulator Charge Pressure on Machine Monitor . 621
How to Examine Brake Accumulator Charge Pressure by Testing Tool 621
How to Adjust Brake Accumulator Charge Pressure . 622
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Nitrogen Gas 624
How to Examine Nitrogen Gas Pressure in Brake Accumulator (Front) . 624
How to Examine Nitrogen Gas Pressure in Brake Accumulator (Rear Brake and Parking Brake) 628
How to Charge Accumulator Nitrogen Gas for Brake 632
How to Release Nitrogen Gas When You Discard Accumulator 637
Examine Brake Performance . 638
How to Examine Foot Brake Performance . 638
How to Examine Retarder Brake Performance . 638
How to Examine Parking Brake Performance 639
Bleed Air from Brake Circuit 641
How to Bleed Air from Front Brake Circuit . 641
How to Bleed Air from Front Brake Circuit (Machine with ABS) 642
How to Bleed Air from Rear Brake Circuit 643
How to Bleed Air from Rear Brake Circuit (For Machine with ABS/Without KTCS) 645
How to Bleed Air from Rear Brake Circuit (For Machine with KTCS) 646
How to Bleed Air from Rear Brake Circuit (For Machine with ABS/KTCS) 648
How to Bleed Air from Parking Brake Circuit . 651
Examine Parking Brake Oil Pressure 652
How to Examine Parking Brake Oil Pressure . 652
Release Parking Brake Manually 653
How to Release Parking Brake Manually . 653
Examine Front Brake Pad Wear Volume . 654
How to Visually Examine Front Brake Pad Wear Volume . 654
How to Examine Front Brake Pad Wear with Gauge Measure 654
Examine Rear Brake Disc Wear Volume . 656
How to Visually Examine Rear Brake Disc Wear Volume . 656
Hydraulic System 657
Examine and Adjust Hoist Circuit Oil Pressure . 657
How to Examine Hoist Circuit Oil Pressure . 657
How to Adjust Hoist Circuit Oil Pressure 658
Examine Hoist Cylinder Source Pressure 659
How to Examine Source Pressure of Hoist Cylinder 659
Examine Oil Pressure of Hoist EPC Valve Circuit . 661
How to Examine Source Pressure of Hoist EPC Valve . 661
How to Examine Outlet Pressure of Hoist EPC Valve . 662
Examine Radiator Fan Circuit Oil Pressure . 663
How to Examine Radiator Fan Circuit Oil Pressure 663
Examine and Adjust Front Suspension Cylinder 665
How to Examine Front Suspension Cylinder 665
How to Adjust Front Suspension Cylinder . 666
Examine and Adjust Front Suspension Cylinder (Automatic Suspension Specification) . 670
How to Examine Front Suspension Cylinder (Automatic Suspension Specification) . 670
How to Adjust Front Suspension Cylinder (Automatic Suspension Specification) 671
Examine and Adjust Rear Suspension Cylinder . 673
How to Examine Rear Suspension Cylinder . 674
How to Adjust Rear Suspension Cylinder 675
Examine KTCS Circuit Oil Pressure (For Machine with KTCS) . 679
How to Examine the Oil Pressure of KTCS Circuit with Test Tools . 679
How to Examine the Oil Pressure of KTCS Circuit with Test Tools . 679
Work Equipment 681
Examine and Adjust Dump Body Positioner Sensor 681
How to Examine Dump Body Positioner Sensor 681
How to Adjust Dump Body Positioner Sensor . 681
How to Calibrate After Adjustment of Dump Body Positioner Sensor 681
Lower Dump Body Manually 683
How to Lower Dump Body Manually . 683
Lift Dump Body Manually . 684
How to Lift Dump Body Manually 684
CAB Related Parts . 685
Adjust Tilt Lock Lever of Steering Wheel 685
How to Adjust Tilt Lock Lever of Steering Wheel . 685
Adjust Play of Operator Seat 687
How to Adjust Play of Operator Seat . 687
Electrical System . 688
Set and Adjust Each Equipment . 688
Set and Operate Machine Monitor . 692
Operator Mode . 696
Service Mode 709
Abnormality Record Menu . 736
Default Menu 750
Diagnostic Tests Menu . 766
Adjustment Menu . 778
No-Injection Cranking Operation . 804
Payload Meter Setting . 806
How to Operate Snap Shot Manually . 824
KOMTRAX Settings Menu . 828
How to Show Service Message . 830
How to Start Up KOMTRAX Terminal 832
How to Stop Use of KOMTRAX Terminal . 836
How to Stop Use of KOMTRAX Terminal (Machine with Mobile Communication Terminal) 838
Default Setting of KOMTRAX Plus Controller 840
How to do the Default Setting of KOMTRAX Plus Controller 840
Default Setting of Wireless LAN Modem . 843
Default Setting of Wireless LAN Modem . 843
How to Examine Wireless LAN Modem Communication . 844
Download KOMTRAX Plus Controller Data . 846
How to Download Data from KOMTRAX Plus Controller . 846
Adjust When KOMTRAX Plus Controller Is Replaced . 850
How to Adjust After Replacement of KOMTRAX Plus Controller 850
Adjust After Replacement of Wireless LAN Modem 853
How to Adjust After Replacement of Wireless LAN Modem . 853
Setting of Mobile Communication Terminal 856
How to Set Mobile Communication Terminal 856
Set Driver Status Monitor . 866
Preparation for Driver Status Monitor Setting . 866
How to Set Driver Status Monitor 873
How to Do Operation Check of Driver Status Monitor 875
How to Adjust Drowsiness Detection Camera Angle . 876
Adjust Rearview Camera Angle 877
How to Adjust Rearview Camera Angle . 877
Adjust Optical Axis of Head Lamp 878
How to Adjust Optical Axis of Head Lamp . 878
Handle Voltage Circuit of Engine Controller . 882
Handle Battery Disconnect Switch 883
Battery Disconnect Switch (Machine with Mobile Communication Terminal) 885
Examine Diodes 887
How to Examine Diodes by Digital Tester . 887
How to Examine Diodes by Analog Tester 887
Pm Clinic . 888
Pm Clinic Service . 888
Pm Clinic Check Sheet HD465-8 . 892
Pm Clinic Check Sheet HD605-8 . 900
Perform Quick Pm 908
How to Perform Quick Pm . 908
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 . 935
Checks Before Troubleshooting . 937
Inspection Procedure Before Troubleshooting . 939
Walk-Around Check . 939
Test in Accordance with Testing Procedure . 941
Examine Fuel Level and Type . 941
Examine for Impure Ingredient in Fuel . 941
Examine Fuel Prefilter 941
Examine Fuel Main Filter 943
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type . 945
Examine Coolant Level (Reservoir Tank) 946
Examine Clogging of Air Cleaner . 947
Clean Outer Element . 948
Replace Element . 950
Examine Hydraulic Oil Level . 951
Examine Hydraulic Oil Strainer 952
Examine Hydraulic Oil Filter 952
Examine Oil Level in Transmission Case 953
Examine Oil Level in Differential Case 953
Examine Oil Level in Final Drive Case . 954
Bleed Air from Fuel System 954
Bleed Air from Hydraulic System . 954
How to Examine Electric Equipment . 954
Preparation for Troubleshooting of Electrical System 960
Procedure for Troubleshooting . 970
Symptom and Troubleshooting Numbers . 972
Information Shown in Troubleshooting Table 975
Connector List and Layout . 977
Connector Contact Connection Table 1009
T-Branch Box and T-Branch Adapter Table .1056
Fuse Location Table .1062
Precautions When You Clean and Replace KDPF (KCSF and KDOC) .1068
Prepare Troubleshoot Machine Monitor 1072
Procedure to Make Harness Checker on Machine Monitor LCD Unit .1074
Prepare of Short Socket Adapter (For Failure Codes [CA1883], [CB1883], [CA3135] and [CB3135]) .1080
Failure Code Table 1082
Troubleshooting by Failure Code (Display of Code) .1108
Failure Code [1500L0] .1108
Failure Code [15B0NX] .1109
Failure Code [15F0KM] .1111
Failure Code [15F0MB] .1112
Failure Code [15F7KM] .1113
Failure Code [15G0MW] .1114
Failure Code [15G7KM] .1116
Failure Code [15H0MW] .1117
Failure Code [15J0MW] .1119
Failure Code [15K0MW] .1121
Failure Code [15L0MW] .1123
Failure Code [15M0MW] .1125
Failure Code [15N0MW] .1127
Failure Code [15SBL1] .1129
Failure Code [15SBMA] .1132
Failure Code [15SCL1] .1134
Failure Code [15SCMA] .1137
Failure Code [15SDL1] .1139
Failure Code [15SDMA] .1142
Failure Code [15SEL1] .1144
Failure Code [15SEMA] .1147
Failure Code [15SFL1] .1149
Failure Code [15SFMA] .1152
Failure Code [15SGL1] .1154
Failure Code [15SGMA] .1157
Failure Code [15SHL1] .1159
Failure Code [15SHMA] .1162
Failure Code [15SJMA] .1164
Failure Code [2C4MNX] .1165
Failure Code [2F00KM] .1167
Failure Code [2G42ZG] .1170
Failure Code [2G43ZG] .1171
Failure Code [6014NX] .1172
Failure Code [879AKA] .1174
Failure Code [879AKB] .1175
Failure Code [879BKA] .1176
Failure Code [879BKB] .1177
Failure Code [879CKA] .1179
Failure Code [879CKB] .1180
Failure Code [879EMC] .1181
Failure Code [879FMC] .1182
Failure Code [879GKX] .1183
Failure Code [989D00] .1184
Failure Code [989L00] .1185
Failure Code [989M00] .1186
Failure Code [989N00] .1187
Failure Code [989X00] .1188
Failure Code [989Y00] .1189
Failure Code [98A000] .1190
Failure Code [98A100] .1191
Failure Code [98A200] .1192
Failure Code [98A300] .1193
Failure Code [98A400] .1194
Failure Code [98A500] .1195
Failure Code [98A600] .1196
Failure Code [A1U0N3] .1197
Failure Code [A1U0N4] .1199
Failure Code [AA10NX] .1201
Failure Code [AB00KE] .1203
Failure Code [AB00KY] .1205
Failure Code [AQ00N3] .1206
Failure Code [AQ00N4] .1207
Failure Code [AQ10N3] .1208
Failure Code [B@BAZG] .1209
Failure Code [B@BAZK] .1210
Failure Code [B@BCNS] .1211
Failure Code [B@BCQA] .1212
Failure Code [B@BCZK] .1214
Failure Code [B@C7NS] .1216
Failure Code [B@CENS] .1218
Failure Code [B@JANS] .1219
Failure Code [CA115] 1220
Failure Code [CA122] 1224
Failure Code [CA123] 1226
Failure Code [CA131] 1228
Failure Code [CA132] 1230
Failure Code [CA135] 1232
Failure Code [CA141] 1234
Failure Code [CA144] 1236
Failure Code [CA145] 1238
Failure Code [CA153] 1240
Failure Code [CA154] 1242
Failure Code [CA187] 1244
Failure Code [CA212] 1246
Failure Code [CA213] 1248
Failure Code [CA221] 1250
Failure Code [CA222] 1252
Failure Code [CA227] 1254
Failure Code [CA234] 1256
Failure Code [CA238] 1257
Failure Code [CA239] 1259
Failure Code [CA271] 1261
Failure Code [CA272] 1263
Failure Code [CA273] 1264
Failure Code [CA274] 1266
Failure Code [CA322] 1267
Failure Code [CA323] 1269
Failure Code [CA324] 1271
Failure Code [CA325] 1273
Failure Code [CA331] 1275
Failure Code [CA332] 1277
Failure Code [CA343] 1279
Failure Code [CA351] 1282
Failure Code [CA352] 1285
Failure Code [CA356] 1287
Failure Code [CA357] 1289
Failure Code [CA386] 1291
Failure Code [CA431] 1293
Failure Code [CA432] 1296
Failure Code [CA441] 1299
Failure Code [CA442] 1302
Failure Code [CA449] 1305
Failure Code [CA451] 1306
Failure Code [CA452] 1308
Failure Code [CA515] 1310
Failure Code [CA516] 1312
Failure Code [CA553] 1314
Failure Code [CA555] 1315
Failure Code [CA556] 1317
Failure Code [CA559] 1319
Failure Code [CA595] 1325
Failure Code [CA687] 1327
Failure Code [CA689] 1329
Failure Code [CA691] 1331
Failure Code [CA692] 1333
Failure Code [CA697] 1335
Failure Code [CA698] 1336
Failure Code [CA731] 1337
Failure Code [CA778] 1340
Failure Code [CA1117] .1343
Failure Code [CA1135] .1346
Failure Code [CA1257] .1349
Failure Code [CA1664] .1350
Failure Code [CA1691] .1352
Failure Code [CA1695] .1355
Failure Code [CA1696] .1357
Failure Code [CA1843] .1359
Failure Code [CA1844] .1361
Failure Code [CA1879] .1363
Failure Code [CA1881] .1365
Failure Code [CA1883] .1367
Failure Code [CA1921] .1370
Failure Code [CA1922] .1372
Failure Code [CA1923] .1375
Failure Code [CA1924] .1377
Failure Code [CA1925] .1382
Failure Code [CA1927] .1386
Failure Code [CA1928] .1388
Failure Code [CA1942] .1390
Failure Code [CA1963] .1392
Failure Code [CA1977] .1400
Failure Code [CA1993] .1402
Failure Code [CA2185] .1405
Failure Code [CA2186] .1407
Failure Code [CA2249] .1409
Failure Code [CA2265] .1415
Failure Code [CA2266] .1417
Failure Code [CA2271] .1419
Failure Code [CA2272] .1421
Failure Code [CA2349] .1423
Failure Code [CA2353] .1425
Failure Code [CA2357] .1427
Failure Code [CA2381] .1430
Failure Code [CA2382] .1432
Failure Code [CA2383] .1434
Failure Code [CA2386] .1436
Failure Code [CA2387] .1438
Troubleshooting Flowchart .1442
Failure Code [CA2555] .1443
Failure Code [CA2556] .1445
Failure Code [CA2637] .1447
Failure Code [CA2639] .1449
Failure Code [CA2732] .1451
Failure Code [CA2733] .1453
Failure Code [CA2741] .1455
Failure Code [CA2765] .1459
Failure Code [CA2777] .1460
Failure Code [CA2878] .1462
Failure Code [CA2881] .1467
Failure Code [CA3133] .1473
Failure Code [CA3134] .1475
Failure Code [CA3135] .1477
Failure Code [CA3167] .1480
Failure Code [CA3251] .1485
Failure Code [CA3253] .1487
Failure Code [CA3254] .1491
Failure Code [CA3255] .1494
Failure Code [CA3256] .1496
Failure Code [CA3311] .1498
Failure Code [CA3312] .1500
Failure Code [CA3313] .1502
Failure Code [CA3314] .1503
Failure Code [CA3315] .1504
Failure Code [CA3316] .1507
Failure Code [CA3317] .1508
Failure Code [CA3318] .1509
Failure Code [CA3319] .1512
Failure Code [CA3321] .1513
Failure Code [CA3322] .1514
Failure Code [CA3419] .1517
Failure Code [CA3421] .1519
Failure Code [CA4151] .1521
Failure Code [CA4158] .1524
Failure Code [CA4161] .1526
Failure Code [CA4162] .1528
Failure Code [CA4163] .1530
Failure Code [CA4259] .1532
Failure Code [CA4952] .1534
Failure Code [CA5383] .1537
Failure Code [CB115] 1538
Failure Code [CB187] 1542
Failure Code [CB227] 1543
Failure Code [CB238] 1544
Failure Code [CB239] 1546
Failure Code [CB271] 1548
Failure Code [CB272] 1550
Failure Code [CB273] 1551
Failure Code [CB274] 1553
Failure Code [CB343] 1554
Failure Code [CB352] 1557
Failure Code [CB386] 1559
Failure Code [CB441] 1561
Failure Code [CB442] 1564
Failure Code [CB689] 1567
Failure Code [CB697] 1569
Failure Code [CB698] 1570
Failure Code [CB731] 1571
Failure Code [CB778] 1575
Failure Code [CB1117] .1577
Failure Code [CB1257] .1580
Failure Code [CB1664] .1581
Failure Code [CB1691] .1583
Failure Code [CB1695] .1586
Failure Code [CB1696] .1588
Failure Code [CB1879] .1590
Failure Code [CB1881] .1592
Failure Code [CB1883] .1594
Failure Code [CB1921] .1597
Failure Code [CB1922] .1599
Failure Code [CB1923] .1602
Failure Code [CB1924] .1604
Failure Code [CB1925] .1609
Failure Code [CB1927] .1613
Failure Code [CB1928] .1615
Failure Code [CB1963] .1617
Failure Code [CB1977] .1625
Failure Code [CB1993] .1627
Failure Code [CB2265] .1630
Failure Code [CB2266] .1632
Failure Code [CB2637] .1634
Failure Code [CB2639] .1637
Failure Code [CB2732] .1639
Failure Code [CB2733] .1641
Failure Code [CB2741] .1643
Failure Code [CB2777] .1647
Failure Code [CB2878] .1649
Failure Code [CB2881] .1654
Failure Code [CB3133] .1660
Failure Code [CB3134] .1662
Failure Code [CB3135] .1664
Failure Code [CB3167] .1667
Failure Code [CB3251] .1672
Failure Code [CB3253] .1674
Failure Code [CB3254] .1678
Failure Code [CB3255] .1681
Failure Code [CB3256] .1683
Failure Code [CB3311] .1685
Failure Code [CB3312] .1687
Failure Code [CB3313] .1689
Failure Code [CB3314] .1690
Failure Code [CB3315] .1691
Failure Code [CB3316] .1694
Failure Code [CB3317] .1695
Failure Code [CB3318] .1696
Failure Code [CB3319] .1699
Failure Code [CB3321] .1700
Failure Code [CB3322] .1701
Failure Code [CB4151] .1704
Failure Code [CB4158] .1707
Failure Code [CB4161] .1708
Failure Code [CB4162] .1710
Failure Code [CB4163] .1712
Failure Code [CB4259] .1714
Failure Code [CB4952] .1716
Failure Code [CB5383] .1719
Failure Code [D018KB] .1720
Failure Code [D018KY] .1722
Failure Code [D019KB] .1724
Failure Code [D019KY] .1726
Failure Code [D150KB] .1728
Failure Code [D150KZ] .1730
Failure Code [D164KY] .1732
Failure Code [D19HKZ] .1733
Failure Code [D19JKZ] .1735
Failure Code [D19QKZ] .1737
Failure Code [D1EHKA] .1739
Failure Code [D1EHKB] .1741
Failure Code [D1EHKY] .1743
Failure Code [D1EMKA] .1744
Failure Code [D1EMKB] .1745
Failure Code [D1EMKY] .1746
Failure Code [D1FBKB] .1747
Failure Code [D5WNKZ] .1749
Failure Code [D5ZHL6] .1751
Failure Code [D5ZKKZ] .1753
Failure Code [D862KA] .1755
Failure Code [DAF0KT] .1756
Failure Code [DAF0MB] .1757
Failure Code [DAF0MC] .1758
Failure Code [DAF3KK] .1759
Failure Code [DAF8KB] .1761
Failure Code [DAFDKB] .1763
Failure Code [DAFGMC] .1765
Failure Code [DAFLKA] .1766
Failure Code [DAFLKB] .1769
Failure Code [DAFQKR] .1772
Failure Code [DAQ0KK] .1773
Failure Code [DAQ0KT] .1776
Failure Code [DAQ0MC] .1777
Failure Code [DAQ1KA] .1778
Failure Code [DAQ2KK] .1781
Failure Code [DAQ9KQ] .1784
Failure Code [DAQLKA] .1785
Failure Code [DAQLKB] .1788
Failure Code [DAQQKR] .1791
Failure Code [DAQRKR] .1792
Failure Code [DAQRMA] .1793
Failure Code [DAQV00] .1794
Failure Code [DAQW00] .1795
Failure Code [DAZ9KQ] .1796
Failure Code [DAZQKR] .1797
Failure Code [DB10KT] .1799
Failure Code [DB10MC] .1800
Failure Code [DB11KA] .1801
Failure Code [DB11KA] (Machine with Emergency Engine Stop Switch) .1804
Failure Code [DB12KK] .1807
Failure Code [DB13KK] .1810
Failure Code [DB19KQ] .1813
Failure Code [DB1LKA] .1814
Failure Code [DB1LKB] .1817
Failure Code [DB1QKR] .1820
Failure Code [DB1QMA] .1821
Failure Code [DB1RKR] .1822
Failure Code [DB2QKR] .1823
Failure Code [DB2QKR] .1830
Failure Code [DB2QKR] .1838
Failure Code [DB2RKR] .1845
Failure Code [DB2RKR] .1852
Failure Code [DB2RKR] .1860
Failure Code [DBC0KT] .1867
Failure Code [DBC0MC] .1868
Failure Code [DBC1KA] .1869
Failure Code [DBC2KK] .1872
Failure Code [DBC3KK] .1874
Failure Code [DBC9KQ] .1877
Failure Code [DBCLKA] .1878
Failure Code [DBCLKB] .1880
Failure Code [DBCQKR] .1882
Failure Code [DBCQMA] .1883
Failure Code [DBCRKR] .1884
Failure Code [DBV0MC] .1885
Failure Code [DBV1KK] .1886
Failure Code [DBV6KB] .1888
Failure Code [DBV7KB] .1890
Failure Code [DBVLKA] .1891
Failure Code [DBVLKB] .1894
Failure Code [DBVQKR] .1897
Failure Code [DBVRKR] .1898
Failure Code [DBVVKR] .1899
Failure Code [DBVWKR] .1900
Failure Code [DCR0MC] .1901
Failure Code [DCR2KK] .1902
Failure Code [DCR8L4] .1906
Failure Code [DCR9KQ] .1910
Failure Code [DCRLKA] .1912
Failure Code [DCRLKB] .1915
Failure Code [DCRQKR] .1917
Failure Code [DCRRKR] .1930
Failure Code [DDAAL6] .1942
Failure Code [DDAAL6] (For Machines to Which Emergency Engine Stop Switch is Installed) .1944
Failure Code [DDACL4] .1947
Failure Code [DDADKA] .1949
Failure Code [DDADKY] .1951
Failure Code [DDD7KX] .1953
Failure Code [DDP6L4] .1955
Failure Code [DDTHKA] .1957
Failure Code [DDTJKA] .1959
Failure Code [DDTKKA] .1961
Failure Code [DDTLKA] .1963
Failure Code [DDTMKA] .1965
Failure Code [DDTNKA] .1967
Failure Code [DDTPKA] .1969
Failure Code [DF10KA] .1971
Failure Code [DF10KB] .1975
Failure Code [DGE5KX] .1980
Failure Code [DGF1KX] .1982
Failure Code [DGR2KB] .1984
Failure Code [DGR6KB] .1986
Failure Code [DGR6L8] .1987
Failure Code [DGT1KX] .1989
Failure Code [DGT4KA] .1991
Failure Code [DGT4KB] .1993
Failure Code [DGT4KY] .1995
Failure Code [DHA4KA] .1997
Failure Code [DHAAMA] .1999
Failure Code [DHABMA] .2000
Failure Code [DHACMA] .2001
Failure Code [DHADMA] .2002
Failure Code [DHP4KY] .2003
Failure Code [DHP4KZ] .2005
Failure Code [DHP5KY] .2007
Failure Code [DHP5KZ] .2009
Failure Code [DHP6KA] .2011
Failure Code [DHP6KX] .2013
Failure Code [DHP6KY] .2015
Failure Code [DHP6KZ] .2017
Failure Code [DHP7KA] .2019
Failure Code [DHP7KX] .2021
Failure Code [DHP7KY] .2023
Failure Code [DHP7KZ] .2025
Failure Code [DHQ2KX] .2027
Failure Code [DHQ4KX] .2029
Failure Code [DHT5KX] .2031
Failure Code [DHT5L6] .2033
Failure Code [DHT8KX] .2035
Failure Code [DHT8ZG] .2037
Failure Code [DHU2KX] .2039
Failure Code [DHU3KX] .2041
Failure Code [DHU6KX] .2043
Failure Code [DHU7KX] .2045
Failure Code [DHU8KX] .2047
Failure Code [DHU9KX] .2049
Failure Code [DHUCKX] .2051
Failure Code [DHUDKX] .2054
Failure Code [DHUHKX] .2056
Failure Code [DHULKX] .2058
Failure Code [DHUMKX] .2061
Failure Code [DHUPKX] .2064
Failure Code [DHUTKX] .2066
Failure Code [DHY9KX] .2068
Failure Code [DJF1KA] .2070
Failure Code [DK30KX] .2072
Failure Code [DK51L5] .2074
Failure Code [DK52KX] .2077
Failure Code [DK53L8] .2079
Failure Code [DK54KX] .2081
Failure Code [DK60KX] .2083
Failure Code [DKD0L6] .2085
Failure Code [DKH0KX] .2087
Failure Code [DKH1KX] .2089
Failure Code [DLF1KA] .2091
Failure Code [DLF1LC] .2092
Failure Code [DLF2KA] .2094
Failure Code [DLF2LC] .2096
Failure Code [DLF6KA] .2098
Failure Code [DLF6L3] .2099
Failure Code [DLF7KA] .2101
Failure Code [DLF7L3] .2102
Failure Code [DLF8KA] .2104
Failure Code [DLF8L3] .2105
Failure Code [DLF8LC] .2106
Failure Code [DLF8MA] .2108
Failure Code [DLF9KA] .2109
Failure Code [DLF9L3] .2110
Failure Code [DLF9LC] .2111
Failure Code [DLF9MA] .2113
Failure Code [DLM3KA] .2114
Failure Code [DLM3LC] .2115
Failure Code [DLM3MB] .2117
Failure Code [DLT3KA] .2118
Failure Code [DLT3LC] .2119
Failure Code [DPQ1KR] .2121
Failure Code [DPQ2KR] .2124
Failure Code [DPQ3KR] .2127
Failure Code [DR81KR] .2131
Failure Code [DR81MA] .2141
Failure Code [DSJ0KR] .2142
Failure Code [DV00KB] .2143
Failure Code [DV03KB] .2145
Failure Code [DV03KY] .2148
Failure Code [DW2AKA] .2150
Failure Code [DW2AKB] .2151
Failure Code [DW2AKY] .2153
Failure Code [DW2AL1] .2154
Failure Code [DW2ALH] .2155
Failure Code [DW2BKA] .2156
Failure Code [DW2BKB] .2157
Failure Code [DW2BKY] .2158
Failure Code [DW2BL1] .2159
Failure Code [DW2BLH] .2160
Failure Code [DW35KZ] .2161
Failure Code [DW36KZ] .2163
Failure Code [DW4BK4] .2165
Failure Code [DW4BMA] .2169
Failure Code [DW72KZ] .2173
Failure Code [DW73KA] .2175
Failure Code [DW73KB] .2177
Failure Code [DW73KY] .2179
Failure Code [DW78KZ] .2180
Failure Code [DW7BKB] .2182
Failure Code [DW7BKY] .2184
Failure Code [DW7BKZ] .2185
Failure Code [DW7NKZ] .2187
Failure Code [DWD6KA] .2189
Failure Code [DWD6KB] .2191
Failure Code [DWD6KY] .2193
Failure Code [DWD6MA] .2194
Failure Code [DWD7K4] .2196
Failure Code [DWD7KA] .2197
Failure Code [DWD7KB] .2199
Failure Code [DWD7KY] .2201
Failure Code [DWD7MA] .2202
Failure Code [DWNDKZ] .2203
Failure Code [DWNDMA] .2205
Failure Code [DWNEKZ] .2207
Failure Code [DWNEMA] .2209
Failure Code [DWNMKZ] .2211
Failure Code [DX11K4] .2213
Failure Code [DX11KA] .2215
Failure Code [DX11KB] .2217
Failure Code [DX11KY] .2219
Failure Code [DX11MA] .2220
Failure Code [DX13KA] .2222
Failure Code [DX13KB] .2224
Failure Code [DX13KY] .2226
Failure Code [DX16KA] .2227
Failure Code [DX16KB] .2228
Failure Code [DX16KY] .2230
Failure Code [DX21KA] .2231
Failure Code [DX21KB] .2232
Failure Code [DX21KY] .2234
Failure Code [DX21MA] .2235
Failure Code [DX22KA] .2237
Failure Code [DX22KB] .2238
Failure Code [DX22KY] .2240
Failure Code [DX22MA] .2241
Failure Code [DX23KA] .2243
Failure Code [DX23KB] .2244
Failure Code [DX23KY] .2246
Failure Code [DX23MA] .2247
Failure Code [DX24KA] .2249
Failure Code [DX24KB] .2250
Failure Code [DX24KY] .2252
Failure Code [DX24MA] .2253
Failure Code [DX25MA] .2255
Failure Code [DX26MA] .2256
Failure Code [DX37K4] .2257
Failure Code [DX37KA] .2259
Failure Code [DX37KB] .2260
Failure Code [DX37KY] .2262
Failure Code [DX37MA] .2263
Failure Code [DX38K4] .2265
Failure Code [DX38KA] .2267
Failure Code [DX38KB] .2268
Failure Code [DX38KY] .2270
Failure Code [DX38MA] .2271
Failure Code [DXH1KA] .2273
Failure Code [DXH1KB] .2275
Failure Code [DXH1KY] .2277
Failure Code [DXH2KA] .2278
Failure Code [DXH2KB] .2280
Failure Code [DXH2KY] .2282
Failure Code [DXH3KA] .2285
Failure Code [DXH3KB] .2287
Failure Code [DXH3KY] .2289
Failure Code [DXH4KA] .2292
Failure Code [DXH4KB] .2294
Failure Code [DXH4KY] .2296
Failure Code [DXH5KA] .2299
Failure Code [DXH5KB] .2301
Failure Code [DXH5KY] .2303
Failure Code [DXH6KA] .2306
Failure Code [DXH6KB] .2308
Failure Code [DXH6KY] .2310
Failure Code [DXH7KA] .2313
Failure Code [DXH7KB] .2315
Failure Code [DXH7KY] .2317
Failure Code [DXHHKA] .2319
Failure Code [DXHHKB] .2321
Failure Code [DXHHKY] .2323
Failure Code [DY30MA] .2325
Failure Code [DY30MC] .2327
Failure Code [DY30ME] .2330
Failure Code [F@BYNR] .2332
Failure Code [F@BYNS] .2333
Troubleshooting of Electrical System (E-Mode) .2334
Engine Does Not Start (Engine Does Not Crank) .2334
Manual Preheating System Does Not Operate .2342
Automatic Preheating System Does Not Operate 2345
While Preheating is in Operation, Preheating Monitor Does Not Come On .2347
The LCD Unit, LED Unit, and Meter Unit of the Machine Monitor Show Nothing 2349
All of LCD Unit, LED Unit, and Meter Unit on Machine Monitor Show Nothing (For Machines to Which Emergency Engine Stop Switch is Installed) .2352
LCD Unit on Machine Monitor Shows Nothing .2355
Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers) .2357
LCD Screen on Machine Monitor Does Not Show Correctly .2359
Meter Unit Display on Machine Monitor is Abnormal .2361
Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal 2364
LED Unit Lamp on Machine Monitor is Abnormal 2367
Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly .2369
Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate 2371
Switch Panel Buzzer of Machine Monitor is Abnormal 2373
Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Normally 2375
Rearview Monitor Does Not Come On or Backlight Flickers .2376
Rearview Monitor Images are Not Shown Clearly .2380
Rearview Monitor Brightness Cannot be Adjusted 2384
Night Mode Lamp of Rearview Monitor is Abnormal .2388
Rearview Monitor Does Not Display Images While REVERSE Linked Display Function is Enabled .2390
Guide Line on Rearview Monitor is Not Shown While Guide Line is Set .2393
Fuel Gauge Does Not Show Normally .2395
Seatbelt Caution Lamp Does Not Show Normally 2397
Machine Monitor Cannot be Operated When Starting Switch is in OFF Position 2399
Alarm Buzzer Does Not Operate .2400
Alarm Buzzer Does Not Stop 2402
Engine Power Mode Selector Function Does Not Operate Correctly When Engine Power Mode Selector Switch is Operated (Machine with Engine Power Mode Selector System) 2404
AISS Function Does Not Operate Correctly 2408
Hoist Lever Does Not Operate Correctly 2410
Fuel Feed Pump Does Not Operate or Stop Automatically .2412
Turn Signal Lamp and Winker Lamp (Hazard Lamp) Do Not Operate Correctly .2417
Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On 2421
Clearance Lamp Does Not Come On .2424
Tail Lamp Does Not Come On 2427
Headlamp (Low Beam) Does Not Come On 2430
Headlamp (High Beam) Does Not Come On .2432
Headlamp (Low Beam) and (High Beam) Do Not Come On 2434
Passing Lamp Does Not Come On .2436
KOMTRAX System Does Not Operate Correctly .2438
Data Download with Wireless LAN Does Not Operate 2440
Cannot Access to the Setting Screen of the Mobile Communication Terminal 2441
Cannot Log in to the Setting Screen of the Mobile Communication Terminal Because the Log in Password is Unknown .2448
KOMTRAX Plus Controller is Not Found 2450
KOMTRAX Plus Controller Does Not Become Active 2452
Communication Failure Occurs Between Mobile Communication Terminal and KOMTRAX Plus Server 2453
Restrictions on Radio Reception .2455
Data is Not Sent to KOMTRAX Plus Server .2456
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) .2458
Information Shown in Troubleshooting Table (H-Mode) .2458
Failure Mode and Cause Table 2459
Machine Does Not Start 2469
Machine Does Not Travel Smoothly (Machine Hunts) 2472
Lockup is Not Released 2473
Strong Shock is Made When You Start Machine or Shift Gears 2474
Shiftup Does Not Operate 2476
Travel Speed in All Gear Speed is Low or Power is Low During Travel with Lockup Function 2479
Travel Speed is Low or Power is Low During Travel with Torque Converter .2480
Travel Speed is Low or Power is Low in Specified Gear Speed .2481
Time Lag is Large When You Start Machine or Shift Gears .2483
Torque Converter Oil Temperature is High 2486
Torque Converter Oil Pressure is Low 2487
Steering Wheel is Heavy to Operate 2488
Steering Wheel is Disabled 2489
Steering Wheel is Shaken 2490
Front Brake Does Not Operate Sufficiently .2491
Rear Brake Does Not Operate Sufficiently 2492
Speed is Low When Dump Body is Raised .2493
Hydraulic Drift of Dump Body is Large .2495
Dump Body is Disabled .2496
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) .2497
Unusual Noise is Heard from Around Fan 2498
Troubleshooting of Engine (S-Mode) 2499
Information Shown in Troubleshooting Table (S-Mode) .2499
Engine Does Not Crank When Starting Switch is Turned to Start Position 2500
Engine Cranks but No Exhaust Smoke Comes Out 2501
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) .2502
Engine Startability is Unsatisfactory .2503
Engine Does Not Pick Up Smoothly 2505
Engine Stops During Operation .2507
Engine Does Not Rotate Smoothly .2509
Engine Lacks Output (or Lacks Power) 2510
KDPF Becomes Clogged in a Short Time 2512
Engine Oil Consumption is Excessive .2514
Engine Oil Becomes Dirty Quickly 2515
Fuel Consumption is Excessive .2516
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) .2517
Engine Oil Pressure Drops .2518
Fuel Mixes Into Engine Oil 2520
Water Mixes Into Engine Oil (Milky) .2521
Coolant Temperature Increases Too High (Overheat) .2522
Unusual Noise is Heard 2523
Vibration is Excessive 2524
Air Cannot be Bled from Fuel Circuit 2525
Active Regeneration is Done Frequently 2526
Active Regeneration Continues Long 2527
White Smoke is Exhausted During Active Regeneration .2528
50 Disassembly and Assembly .2529
Table of Contents .2530
Precautions Before Work .2534
Related Information on Disassembly and Assembly .2535
How to Read This Manual .2535
Coating Materials List 2537
Special Tool List .2542
Sketches of Special Tools .2550
Engine and Cooling System .2553
Remove and Install Supply Pump Assembly .2553
How to Remove Supply Pump Assembly 2554
How to Install Supply Pump Assembly .2565
Remove and Install Injector Assembly 2581
How to Remove Injector Assembly .2583
How to Install Injector Assembly 2604
Remove and Install Fuel Doser Assembly 2634
How to Remove Fuel Doser Assembly .2635
How to Install Fuel Doser Assembly 2636
Remove and Install Cylinder Head Assembly .2639
How to Remove Cylinder Head Assembly 2641
How to Install Cylinder Head Assembly .2686
Remove and Install EGR Valve Assembly .2748
How to Remove EGR Valve Assembly 2749
How to Install EGR Valve Assembly .2751
Remove and Install EGR Cooler Assembly 2754
How to Remove EGR Cooler Assembly .2755
How to Install EGR Cooler Assembly 2764
Remove and Install Starter Assembly .2774
How to Remove Starting Motor Assembly .2774
How to Install Starting Motor Assembly 2775
Remove and Install Alternator Belt 2777
How to Remove Alternator Belt .2777
How to Install Alternator Belt 2778
Remove and Install Cooler Assembly 2780
How to Remove Cooling Assembly 2781
How to Install Cooling Assembly .2796
Remove and Install Radiator Core 2810
How to Remove Radiator Core .2811
How to Install Radiator Core 2817
Remove and Install Cooling Fan and Fan Motor Assembly .2824
How to Remove Cooling Fan and Fan Motor Assembly 2825
How to Install Cooling Fan and Fan Motor Assembly .2827
Remove and Install Aftercooler Assembly .2830
How to Remove Aftercooler Assembly 2831
How to Install Aftercooler Assembly .2837
Remove and Install Engine Assembly 2844
How to Remove Engine Assembly .2846
How to Install Engine Assembly 2859
Remove and Install Engine Front Oil Seal 2872
How to Remove Engine Front Oil Seal .2872
How to Install Engine Front Oil Seal 2874
Remove and Install Engine Rear Oil Seal .2876
How to Remove Engine Rear Oil Seal 2876
How to Install Engine Rear Oil Seal .2877
Remove and Install Damper Assembly 2882
How to Remove Damper Assembly .2883
How to Install Damper Assembly 2888
Disassemble and Assemble Damper Assembly 2897
How to Disassemble Damper Assembly 2898
How to Assemble Damper Assembly .2899
Remove and Install KDPF Assembly (with Bracket) .2902
How to Remove KDPF Assembly .2903
How to Install KDPF Assembly 2907
Remove and Install KDPF Assembly (Without Bracket) 2913
How to Remove KDPF Assembly .2914
How to Install KDPF Assembly 2920
Disassemble and Assemble KDPF Assembly 2928
How to Disassemble KDPF Assembly 2929
How to Assemble KDPF Assembly .2934
Remove and Install KCCV Assembly 2941
How to Remove KCCV Assembly .2942
How to Install KCCV Assembly 2944
Remove and Install Air Cleaner Assembly .2947
How to Remove Air Cleaner Assembly 2947
How to Install Air Cleaner Assembly .2948
Remove and Install Air Conditioner Compressor Assembly 2950
How to Remove Air Conditioner Compressor Assembly .2950
How to Install Air Conditioner Compressor Assembly 2951
Power Train .2953
Remove and Install Torque Converter and Transmission Assembly .2953
How to Remove Torque Converter and Transmission Assembly 2954
How to Install Torque Converter and Transmission Assembly .2959
Disconnect and Connect Torque Converter and Transmission Assembly .2964
How to Disconnect Torque Converter and Transmission Assembly 2965
How to Connect Torque Converter and Transmission Assembly .2973
Disassemble and Assemble Torque Converter Assembly 2991
How to Disassemble Torque Converter Assembly 2992
How to Assemble Torque Converter Assembly .2998
Disassemble and Assemble Transmission Assembly 3009
How to Disassemble Transmission Assembly 3011
How to Assemble Transmission Assembly .3030
Remove and Install Differential Assembly 3058
How to Remove Differential Assembly .3059
How to Install Differential Assembly 3062
Disassemble and Assemble Differential Assembly 3065
How to Disassemble Differential Assembly 3066
How to Assemble Differential Assembly .3072
Remove and Install Front Brake Caliper Pad 3082
How to Remove Front Brake Caliper Pad .3082
How to Install Front Brake Caliper Pad 3083
Remove and Install Front Brake Caliper Assembly .3084
How to Remove Front Brake Caliper Assembly 3084
How to Install Front Brake Caliper Assembly .3085
Disassemble and Assemble of Front Brake Caliper Assembly 3086
How to Disassemble Front Brake Caliper Assembly .3086
How to Assemble Front Brake Caliper Assembly 3086
Remove and Install Final Drive and Rear Brake Assembly 3089
How to Remove Final Drive and Rear Brake Assembly .3090
How to Install Final Drive and Rear Brake Assembly 3093
Remove and Install Final Drive, Rear Brake and Parking Brake Assembly .3097
How to Remove Final Drive, Rear Brake and Parking Brake Assembly 3097
How to Install Final Drive, Rear Brake and Parking Brake Assembly .3100
Disassemble and Assemble of Final Drive, Rear Brake and Parking Brake Assembly 3104
How to Disassemble Final Drive, Rear Brake and Parking Brake Assembly .3105
How to Assemble Final Drive, Rear Brake and Parking Brake Assembly 3110
Remove and Install Final Drive Carrier Assembly .3118
How to Remove Final Drive Carrier Assembly 3118
How to Install Final Drive Carrier Assembly .3120
Disassemble and Assemble Final Drive Carrier Assembly .3122
How to Disassemble Final Drive Carrier Assembly .3122
How to Assemble Final Drive Carrier Assembly 3122
Steering System .3123
Disassemble and Assemble Steering Cylinder Assembly .3123
How to Disassemble Steering Cylinder Assembly .3124
How to Assemble Steering Cylinder Assembly 3125
Undercarriage and Frame .3128
Remove and Install Front Wheel Assembly .3128
How to Remove Front Wheel Assembly 3128
How to Install Front Wheel Assembly .3129
Remove and Install Rear Wheel Assembly 3131
How to Remove Rear Wheel Assembly .3131
How to Install Rear Wheel Assembly 3133
Remove and Install Front Suspension Cylinder Assembly .3135
How to Remove Front Suspension Cylinder Assembly 3135
How to Install Front Suspension Cylinder Assembly .3136
Disassemble and Assemble Front Suspension Cylinder Assembly (Cylinder with Buffer Ring) .3139
How to Disassemble Front Suspension Cylinder Assembly .3139
How to Assemble Front Suspension Cylinder Assembly 3141
Remove and Install Rear Suspension Cylinder Assembly 3145
How to Remove Rear Suspension Cylinder Assembly .3145
How to Install Rear Suspension Cylinder Assembly 3146
Disassemble and Assemble Rear Suspension Cylinder Assembly (Cylinder with Buffer Ring) 3147
How to Disassemble Rear Suspension Cylinder Assembly 3148
How to Assemble Rear Suspension Cylinder Assembly .3149
Disassemble and Assemble of Front Wheel Hub Assembly 3153
How to Disassemble Front Wheel Hub Assembly .3153
How to Assemble Front Wheel Hub Assembly 3155
Hydraulic System 3159
Disassemble and Assemble Hoist Cylinder Assembly 3159
How to Disassemble Hoist Cylinder Assembly 3160
How to Assemble Hoist Cylinder Assembly .3162
Work Equipment 3168
Remove and Install Dump Body Assembly .3168
How to Remove Body Assembly .3168
How to Install Body Assembly 3169
CAB Related Parts .3172
Remove and Install Air Conditioner Unit Assembly 3172
How to Remove Air Conditioner Unit Assembly .3173
How to Install Air Conditioner Unit Assembly 3180
Remove and Install Operator Seat Assembly .3188
How to Remove Operator Seat Assembly 3188
How to Install Operator Seat Assembly .3190
How to Remove and Install Seat Belt .3193
How to Remove Seat Belt .3193
How to Install Seatbelt .3194
Electrical System .3196
Remove and Install Engine Controller Assembly .3196
How to Remove Engine Controller Assembly 3196
How to Install Engine Controller Assembly .3198
Remove and Install Retarder and Hoist Controller Assembly .3201
How to Remove Retarder and Hoist Controller Assembly 3201
How to Install Retarder and Hoist Controller Assembly .3202
Remove and Install ABS Controller Assembly 3204
How to Remove ABS Controller Assembly .3204
How to Install ABS Controller Assembly 3205
Remove and Install Transmission Controller Assembly .3206
How to Remove Transmission Controller Assembly 3206
How to Install Transmission Controller Assembly .3207
Remove and Install Machine Monitor Assembly .3208
How to Remove Machine Monitor Assembly 3209
How to Install Machine Monitor Assembly .3211
Remove and Install Monitor Controller Assembly 3214
How to Remove Monitor Controller Assembly .3214
How to Install Monitor Controller Assembly 3215
Remove and Install Mass Air Flow and Temperature Sensor .3216
How to Remove Mass Air Flow and Temperature Sensor 3216
How to Install Mass Air Flow and Temperature Sensor .3217
Remove and Install KCCV Crankcase Pressure Sensor .3219
How to Remove KCCV Crankcase Pressure Sensor 3219
How to Install KCCV Crankcase Pressure Sensor .3220
Remove And Install KOMTRAX Plus Controller Assembly .3222
How to Remove KOMTRAX Plus Controller Assembly 3222
How to Install KOMTRAX Plus Controller Assembly .3223
Remove and Install Mobile Communication Terminal 3225
How to Remove Mobile Communication Terminal .3225
How to Install Mobile Communication Terminal 3226
Remove and Install DC-DC Converter 3228
How to Remove DC-DC Converter .3228
How to Install DC-DC Converter 3229
Remove and Install Mobile Communication Terminal Wiring Harness .3230
How to Remove Mobile Communication Terminal Wiring Harness 3230
How to Install Mobile Communication Terminal Wiring Harness .3235
Remove and Install KOMTRAX Terminal Assembly 3241
How to Remove KOMTRAX Terminal Assembly .3241
How to Install KOMTRAX Terminal Assembly 3243
Remove and Install Wireless LAN Unit Assembly .3244
How to Remove Wireless LAN Unit Assembly 3244
How to Install Wireless LAN Unit Assembly .3245
Remove and Install Driver Status Monitor 3248
How to Remove Driver Status Monitor .3248
How to Install Driver Status Monitor 3249
Remove and Install Translator Controller 3251
How to Remove Translator Controller .3251
How to Install Translator Controller 3252
Remove and Install Drowsiness Detection Camera 3254
How to Remove Drowsiness Detection Camera .3254
How to Install Drowsiness Detection Camera 3255
Remove and Install Drowsiness Alarm Buzzer 3257
How to Remove Drowsiness Alarm Buzzer .3257
How to Install Drowsiness Alarm Buzzer 3258
Remove and Install Drowsiness Detection Wiring Harness 3260
How to Remove Drowsiness Detection Wiring Harness .3260
How to Install Drowsiness Detection Wiring Harness 3270
60 Maintenance Standard .3283
Table of Contents .3284
Engine and Cooling System .3285
Maintenance Standard for Engine Mount .3285
Maintenance Standard for Damper .3286
Maintenance Standard for Cooling Fan Pump .3288
Maintenance Standard for Servo Valve for Cooling Fan Pump .3290
Maintenance Standard for Cooling Fan Motor 3291
Power Train .3293
Maintenance Standard for Drive Shaft 3293
Maintenance Standard for Torque Converter and Transmission Mount 3294
Maintenance Standard for Torque Converter and PTO .3295
Maintenance Standard for Torque Converter Valve .3299
Maintenance Standard for Transmission .3301
Maintenance Standard for Transmission Control Valve .3307
Maintenance Standard for H, L, 4th, 3rd, R, 2nd, and 1st ECMV .3308
Maintenance Standard for Lockup Clutch ECMV .3309
Maintenance Standard for Front Axle .3310
Maintenance Standard for Rear Axle 3311
Maintenance Standard for Differential .3312
Maintenance Standard for Final Drive 3313
Steering System .3314
Maintenance Standard for Steering Column 3314
Maintenance Standard for Steering Linkage .3315
Maintenance Standard for Demand Valve .3318
Maintenance Standard for Steering Cylinder 3321
Brake System 3322
Maintenance Standard for Slack Adjuster .3322
Maintenance Standard for Front Brake 3323
Maintenance Standard for Rear Brake .3324
Undercarriage and Frame .3326
Maintenance Standard for Front Suspension Cylinder 3326
Maintenance Standard for Rear Suspension Cylinder .3329
Hydraulic System 3331
Maintenance Standard for Steering and Hoist Pump 3331
Maintenance Standard for Servo Valve for Steering and Hoist Pump 3332
Maintenance Standard for Power Train and Brake Cooling Duplex Pump 3334
Maintenance Standard for Brake Cooling, Control Triple Pump .3335
Maintenance Standard for Hoist Valve 3337
Work Equipment 3339
Maintenance Standard for Hoist Cylinder .3339
CAB Related Parts .3340
Maintenance Standard for CAB Mount 3340
80 Others .3341
Table of Contents .3342
Precautions Before Work .3344
Air Conditioner System 3345
Precautions for Refrigerant .3345
Air Conditioner Component .3346
Specifications of Air Conditioner .3348
Structure and Function of Refrigeration Cycle .3349
Outline of Refrigeration Cycle 3350
Component Parts of Air Conditioner System .3352
Air Conditioner Unit 3352
Configuration Diagram of Air Conditioner Unit .3352
Function of Air Conditioner Unit 3353
Component Parts of Air Conditioner Unit .3356
Function of Evaporator as Air Conditioner Unit Component 3357
Function of Heater Core as Air Conditioner Unit Component .3357
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component .3357
Function of Servo Motor as Air Conditioner Unit Component .3357
Structure of Expansion Valve as Air Conditioner Unit Component 3358
Function of Expansion Valve as Air Conditioner Unit Component .3358
Operate Expansion Valve as Air Conditioner Unit Component .3358
Function of Dual Pressure Switch 3359
Air Conditioner Controller 3360
Structure of Air Conditioner Controller .3360
Compressor 3361
Structure of Compressor .3361
Specifications of Compressor 3361
Function of Compressor 3361
Condenser .3362
Structure of Condenser 3362
Specifications of Condenser .3362
Function of Condenser .3362
Air Conditioner Related Sensors .3364
Structure of Outside Temperature Sensor .3364
Function of Outside Air Temperature Sensor 3364
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner .3365
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 3368
System Diagram of Air Conditioner .3370
Input and Output Signals of Air Conditioner Controller 3371
Function of Air Conditioner Controller 3372
Locations of Air Conditioner Parts and Layout of Connectors .3373
Examine Air Leakage (Duct) 3376
How to Examine Air Leakage (Duct) .3376
Examine Air Conditioner with Self-Diagnosis Function 3379
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor .3380
Examine Vent (Mode) Changeover 3382
How to Examine Vent (Mode) Changeover .3382
Examine Fresh/Recirc Air Changeover .3383
How to Examine Fresh/Recirc Air Changeover 3383
Examine Refrigerant (Dual) Pressure Switch 3384
How to Examine Refrigerant (Dual) Pressure Switch .3384
Examine Relay .3385
How to Examine Relay 3385
Air Conditioner Troubleshooting Chart 1 .3387
Air Conditioner Troubleshooting Chart 2 .3388
Information Shown in Troubleshooting Table 3391
Failure Code [879AKA] .3393
Failure Code [879AKB] .3394
Failure Code [879BKA] .3395
Failure Code [879BKB] .3396
Failure Code [879CKA] .3398
Failure Code [879CKB] .3399
Failure Code [879EMC] .3400
Failure Code [879FMC] .3401
Failure Code [879GKX] .3402
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 3403
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) .3405
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3408
Troubleshooting for Fresh/Recirc Air Changeover .3410
Troubleshooting by Gauge Pressure .3412
Connect Service Tool 3414
How to Connect Service Tool .3414
Precautions for Disconnection and Connection of Air Conditioner Piping 3416
Handle Compressor Oil .3418
How to Replace Desiccant 3420
90 Circuit Diagrams .3423
Table of Contents .3424
Abbreviation List .3425
Hydraulic Circuit Diagram .3431
Symbols Used in Hydraulic Circuit Diagram .3431
Hydraulic Circuit Diagram (1/3) .3435
Hydraulic Circuit Diagram (2/3) .3437
Hydraulic Circuit Diagram (3/3) .3439
Power Train Hydraulic Circuit Diagram .3441
Electrical Circuit Diagram 3443
Symbols Used in Electric Circuit Diagram 3443
Electrical Circuit Diagram of Inside of CAB (1/11) 3447
Electrical Circuit Diagram of Inside of CAB (2/11) 3449
Electrical Circuit Diagram of Inside of CAB (3/11) 3451
Electrical Circuit Diagram of Inside of CAB (4/11) 3453
Electrical Circuit Diagram of Inside of CAB (5/11) 3455
Electrical Circuit Diagram of Inside of CAB (6/11) 3457
Electrical Circuit Diagram of Inside of CAB (7/11) 3459
Electrical Circuit Diagram of Inside of CAB (8/11) 3461
Electrical Circuit Diagram of Inside of CAB (9/11) 3463
Electrical Circuit Diagram of Inside of CAB (10/11) .3465
Electrical Circuit Diagram of Inside of CAB (11/11) .3467
External CAB Electrical Diagram (1/8) .3469
External CAB Electrical Diagram (2/8) .3471
External CAB Electrical Diagram (3/8) .3473
External CAB Electrical Diagram (4/8) .3475
External CAB Electrical Diagram (5/8) .3477
External CAB Electrical Diagram (6/8) .3479
External CAB Electrical Diagram (7/8) .3481
External CAB Electrical Diagram (8/8) .3483
Electrical Circuit Diagram of Engine (1/2) 3485
Electrical Circuit Diagram of Engine (2/2) 3487
Electrical Circuit Diagram (Drowsiness Detection System (DDS)) 3489
Index 3491

DESCRIPTION:

Komatsu HD465-8,HD605-8 Dump Truck Shop Manual SEN06605-24  – PDF DOWNLOAD

SERIAL NUMBERS

• HD465-8 30001 and up
• HD605-8 30001 and up

G.B 28/12/24