Komatsu HD465-7E0, HD605-7E0 SEN01081-12 (Preview)
COVER
00 Index and foreword
Index
Composition of shop manual
Table of contents
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
01 Specification
Specification and technical data
Specification drawing
Specifications
Weight table
Fuel, coolant and lubricants
10 Structure, function and maintenance standard
Engine and cooling system
Radiator, torque converter oil cooler, after cooler, work equipment oil cooler, fuel cooler
Fuel system
Brake oil cooler
Output shaft
Power train, Part 1
Power train skeleton
Drive shaft
Torque converter and transmission hydraulic piping
Brake cooling oil control valve (BCV)
Torque converter
Torque converter valve
Transmission
Transmission control valve
ECMV
Power train, Part 2
Axle
Differential
Final drive
Wheels
Steering system
Steering column
Steering linkage
Brake system
Brake piping
Brake valve
Secondary brake valve
Relay valve
Front brake off valve
Accumulator charge valve
Accumulator
Slack adjuster
Brake
Parking brake solenoid valve
Undercarriage and frame
Suspension
Suspension cylinder
Rear axle support
Hydraulic system
Steering and hoist hydraulic piping
Dump body control
Hydraulic tank
Steering valve
Crossover relief valve
Steering cylinder
Steering control valve
Hoist valve
Dump control valve (EPC valve)
Hoist cylinder
Hydraulic pump
Work equipment (Body)
Auto greasing system
Cab and its attachments
ROPS cab
Air conditioner
Rear view monitor
Electrical system, Part 1
Machine monitor system
Electrical system, Part 2
Automatic shift control system
Transmission controller
Automatic emergency steering system
Automatic suspension system
Retarder control system
Battery disconnector switch
Dump control lever
Electrical system, Part 3
Payload meter II (Card type)
Electrical system, Part 4
VHMS controller related
ASR system (If equipped)
Sensors, switches
20 Standard value table
Standard service value table
Standard value table for engine
Standard value table for machine
30 Testing and adjusting
Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting
Sketch of special tool
Testing engine speed
Testing air supply pressure (boost pressure)
Testing exhaust temperature
Testing exhaust gas color
Adjustment of valve clearance
Testing of compression pressure
Testing blow-by pressure
Testing engine oil pressure
Testing EGR valve and bypass valve drive oil pressure
Handling of fuel system devices
Releasing residual pressure from fuel system
Testing of fuel pressure
Reduced cylinder mode operation
No-injection cranking
Testing of fuel return rate and fuel leakage
Bleeding air from fuel circuit
Testing the fuel circuit for leakage
Replacement and adjustment of fan belt
Replacement and adjustment of alternator and air conditioner compressor belt
Testing and adjusting, Part 2
Testing torque converter stall speed
Testing power train oil pressure
Adjusting transmission speed sensor
Testing and adjusting brake oil pressure
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas
Testing brake performance
Bleeding air from brake circuit
Testing wear of front brake pad
Testing wear of rear brake disc
Method of releasing parking brake in an emergency
Testing and adjusting front suspension cylinder
Testing and adjusting rear suspension cylinder
Testing and adjusting front suspension cylinder (Automatic suspension specification)
Testing and adjusting hydraulic pressure in steering, hoist circuit
Testing and adjusting oil pressure in dump EPC circuit
Air bleeding from steering cylinder
Procedure for raising dump body in emergency
Procedure for lowering dump body in emergency
Adjusting body positioner sensor
Handling of voltage circuit of engine controller
Adjusting transmission controller
Method for emergency escape at electrical system failure
Testing and adjusting, Part 3
Setting and adjusting of devices
Special functions of machine monitor (EMMS)
Testing and adjusting, Part 4
Special functions of machine monitor (EMMS)
Testing and adjusting, Part 5
Request for opening ORBCOMM terminal
VHMS controller initial setting procedure
Using method of KOMTRAX functions of ORBCOMM terminal
Precautions for replacing VHMS controller
Pm Clinic check sheet
Initial setting of payload meter
Setting of payload meter built in VHMS
Setting of card-type payload meter (PLM-II) after installation or replacement
40 Troubleshooting
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Check before troubleshooting
Classification and procedures for troubleshooting
Contents of troubleshooting table
Connection table for connector pin numbers
T-branch box and T-branch adapter table
Failure code table and fuse locations
Failure codes table
Fuse locations
Troubleshooting by failure code, Part 1
Failure code [1500L0] (Dual engagement)
Failure code [15B0NX] (Transmission oil filter: Clogging)
Failure code [15F0KM] (R → F shifting abuse 1: Mistake in operation)
Failure code [15F0MB] (R → F shifting abuse 2: Mistake in operation)
Failure code [15F7KM] (Forward clutch disk abuse: Mistake in operation or setting)
Failure code [15G0MW] (R clutch: Slipping)
Failure code [15G7KM] (Reverse clutch disk abuse: Mistake in operation or setting)
Failure code [15H0MW] (Hi clutch: Slipping)
Failure code [15J0MW] ( Lo clutch: Slipping)
Failure code [15K0MW] (1st clutch: Slipping)
Failure code [15L0MW] (2nd clutch: Slipping)
Failure code [15M0MW] (3rd clutch: Slipping)
Failure code [15N0MW] (4th clutch: Slipping)
Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF)
Failure code [15SBMA] (R clutch solenoid: Malfunction)
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF)
Failure code [15SCMA] (Hi clutch solenoid: Malfunction)
Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF)
Failure code [15SDMA] (Lo clutch solenoid: Malfunction)
Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF)
Failure code [15SEMA] (1st clutch solenoid: Malfunction)
Troubleshooting by failure code, Part 2
Failure code [15SFL1] Trouble I in 2nd clutch pressure control valve (Fill signal is ON though command current is OFF)
Failure code [15SFMA] Trouble II in 2nd clutch pressure control valve (Though command is holding pressure, 2nd clutch fill switch is OFF, and slipping detected)
Failure code [15SGL1] Trouble I in 3rd clutch pressure control valve (Fill signal is ON though command current is OFF)
Failure code [15SGMA] Trouble II in 3rd clutch pressure control valve (Though command is holding pressure, 3rd clutch fill switch is OFF, and slipping detected)
Failure code [15SHL1] Trouble I in 4th clutch pressure control valve (Fill signal is ON though command current is OFF)
Failure code [15SHMA] Trouble II in 4th clutch pressure control valve (Though command is holding pressure, 4th clutch fill switch is OFF, and slipping detected)
Failure code [15SJMA] Trouble II in lockup clutch pressure control valve (Though lockup command is holding pressure, slipping is detected)
Failure code [2C4MNX] Retarder cooling oil filter: Clogging
Failure code [2F00KM] Parking brake: Dragging
Failure code [2G42ZG] Lowering of accumulator oil pressure (Front)
Failure code [2G43ZG] Lowering of accumulator oil pressure (Rear)
Failure code [6014NX] Hydraulic oil filter: Clogging
Failure code [989A00] Operation of engine overrun prevention device (Note: Information is obtained from transmission controller and failure code is displayed on monitor panel)
Failure code [989D00] Inclination alarm (Raising body while machine is inclined) (Note: Information is obtained from transmission controller and failure code is displayed on monitor panel)
Failure code [A570NX] Engine oil filter: Clogging
Failure code [AA10NX] Air cleaner: Clogging
Failure code [AB00MA] Trouble in battery charge circuit (No R-terminal signal from alternator)
Failure code [B@BAZG] Lowering of engine oil pressure
Failure code [B@BAZK] Lowering of engine oil
Failure code [B@BCNS] Engine overheat
Failure code [B@BCZK] Coolant level low alarm
Failure code [B@BFZK] Lowering of fuel level
Failure code [B@C7NS] Overheating of brake cooling oil (Rear)
Failure code [B@CENS] Overheating of torque converter oil
Failure code [B@GAZK] Lowering of battery electrolyte level
Failure code [B@JANS] Overheating of steering oil
Troubleshooting by failure code, Part 3
Failure code [CA111] Abnormality in engine controller
Failure code [CA115] Engine Ne or Bkup speed sensor error
Failure code [CA122] Charge pressure sensor high error
Failure code [CA123] Charge pressure sensor low error
Failure code [CA131] Throttle sensor high error
Failure code [CA132] Throttle sensor low error
Failure code [CA135] Engine oil pressure sensor high error
Failure code [CA141] Engine oil pressure sensor low error
Failure code [CA144] Coolant temperature sensor high error
Failure code [CA145] Coolant temperature sensor low error
Failure code [CA153] Charge temperature sensor high error
Failure code [CA154] Charge temperature sensor low error
Failure code [CA187] Sensor power supply 2 low error
Failure code [CA212] Engine oil temperature sensor high error
Failure code [CA213] Engine oil temperature sensor low error
Failure code [CA221] Atmospheric pressure sensor high error
Failure code [CA222] Atmospheric pressure sensor low error
Failure code [CA227] Sensor power supply 2 high error
Failure code [CA234] Engine overspeed
Failure code [CA238] Ne speed sensor power supply error
Failure code [CA263] Fuel temperature sensor high error
Failure code [CA265] Fuel temperature sensor low error
Failure code [CA271] PCV1 short circuit
Failure code [CA272] PCV1 disconnection
Failure code [CA273] PCV2 short circuit
Failure code [CA274] PCV2 disconnection
Failure code [CA322] Injector #1 system disconnection or short circuit
Failure code [CA323] Injector #5 system disconnection or short circuit
Failure code [CA324] Injector #3 system disconnection or short circuit
Failure code [CA325] Injector #6 system disconnection or short circuit
Failure code [CA331] Injector #2 system disconnection or short circuit
Failure code [CA332] Injector #4 system disconnection or short circuit
Failure code [CA342] Engine controller data inconsistency
Failure code [CA351] Injectors drive circuit error
Failure code [CA352] Sensor power supply 1 low error
Failure code [CA386] Sensor power supply 1 high error
Troubleshooting by failure code, Part 4
Failure code [CA431] Idle validation switch error
Failure code [CA432] Idle validation action error
Failure code [CA441] Battery voltage low error
Failure code [CA442] Battery voltage high error
Failure code [CA449] Common rail pressure high error 2
Failure code [CA451] Common rail pressure sensor high error
Failure code [CA452] Common rail pressure sensor low error
Failure code [CA553] Common rail pressure high error 1
Failure code [CA554] Common rail pressure sensor: In-range error
Failure code [CA559] Supply pump no-pressure feed error 1
Failure code [CA689] Engine Ne speed sensor error
Failure code [CA731] Engine Bkup speed sensor phase error
Failure code [CA757] All engine controller data lost error
Failure code [CA778] Engine Bkup speed sensor error
Failure code [CA1228] EGR valve servo error 1
Failure code [CA1625] EGR valve servo error 2
Failure code [CA1626] Short circuit in bypass valve solenoid drive system
Failure code [CA1627] Disconnection in bypass valve solenoid drive system
Failure code [CA1628] Bypass valve servo error 1
Failure code [CA1629] Bypass valve servo error 2
Failure code [CA1631] Bypass valve lift sensor high error
Failure code [CA1632] Bypass valve lift sensor low error
Failure code [CA1633] KOMNET (datalink timeout) error
Failure code [CA2185] Throttle sensor supply voltage high error
Failure code [CA2186] Throttle sensor power supply low error
Failure code [CA2249] Supply pump no-pressure feed error 2
Failure code [CA2271] EGR valve lift sensor high error
Failure code [CA2272] EGR valve lift sensor low error
Failure code [CA2351] Short circuit in EGR valve solenoid drive system
Failure code [CA2352] Disconnection in EGR valve solenoid drive system
Failure code [CA2555] Intake heater relay voltage low error
Failure code [CA2556] Intake heater relay voltage high error
Troubleshooting by failure code, Part 5
Failure code [D19HKB] Short circuit in stop lamp relay output system
Failure code [D5ZKKZ] Trouble in front brake cut valve system (Disconnection or short circuit)
Failure code [DAF9KM] Wrong connection of connector
Failure code [DAFRKR] Abnormal CAN communication (machine monitor)
Failure code [DAQ0KK] Lowering of power supply voltage in transmission controller direct power supply
Failure code [DAQ0KT] Abnormality in transmission controller nonvolatile memory
Failure code [DAQ2KK] Transmission controller solenoid power supply voltage low error
Failure code [DAQ9KQ] Disagreement of model selection signal (Transmission controller)
Failure code [DAQRKR] Abnormality in CAN communication (Transmission controller)
Failure code [DAQRMA] Disagreement of option setting (Transmission controller)
Failure code [DB10KT] Abnormality in retarder controller nonvolatile memory
Failure code [DB12KK] Trouble in retarder controller solenoid power supply system
Failure code [DB13KK] Retarder controller battery direct power supply voltage low error
Failure code [DB19KQ] Disagreement of model selection (Retarder controller)
Failure code [DB1RKR] Abnormality in CAN communication (Retarder controller)
Failure code [DB1RMA] Disagreement of option setting (Retarder controller)
Failure code [DB2RKR] Abnormality in CAN communication (Engine controller)
Failure code [DBB0KK] (or VHMS_LED display: “n9” → “01”) VHMS controller: Low source voltage (input)
Failure code [DBB0KQ] (or VHMS_LED display: “nF” → “11”) (VHMS controller: Disagreement of model selection signals)
Failure code [DBB3KK] (or VHMS_LED display: “n9” → “05”) VHMS controller battery power supply: Low source voltage (input)
Failure code [DBB5KP] (or VHMS_LED display: “n9” → “04”) (VHMS controller 5 V power supply output: Low output voltage)
Failure code [DBB6KP] (or VHMS_LED display: “n9” → “02”) (VHMS controller 24 V power supply output: Low output voltage)
Failure code [DBB7KP] (or VHMS_LED display: “n9” → “03”) (VHMS controller 12 V power supply output: Low output voltage)
Failure code [DBBQKR] (or VHMS_LED display: “n8” → “02”) VHMS controller CAN communication: Defective communication (Abnormality in target component system)
Failure code [DBBRKR] Abnormality in CAN communication (VHMS)
Failure code [DBC2KK] Trouble in ABS controller solenoid power supply system
Failure code [DBC3KK] ABS controller battery direct power supply voltage low error
Failure code [DBC9KQ] Disagreement of model selection (ABS controller)
Failure code [DBCRKR] Abnormality in CAN communication (ABS controller)
Failure code [DBCRMA] Disagreement of option setting (ABS controller)
Failure code [DDD7KX] Trouble in travel speed setting switch system (If equipped) (When ARSC is set and ARSC system switch is ON)
Failure code [DDD8KA] Disconnection in ARSC system switch (If equipped) (When ARSC is set and ARSC system switch is ON)
Failure code [DDD8KB] Short circuit in ARSC system switch (If equipped) (When ARSC is set and ARSC system switch is ON)
Failure code [DDD9KA] Disconnection in ABS system switch (When ABS is set and ABS system switch is ON)
Failure code [DDD9KB] Short circuit in ABS system switch (When ABS is set and ABS system switch is ON)
Failure code [DDDAKA] Disconnection in ASR system switch
Failure code [DDDAKB] Short circuit in ASR system switch
Failure code [DDP6L4] Trouble in service brake pressure switch (Rear)
Failure code [DDTHKA] Trouble in Hi clutch fill switch (Command is holding pressure, fill switch is OFF, and slip is not sensed)
Failure code [DDTJKA] Trouble in Lo clutch fill switch (Command is holding pressure, fill switch is OFF, and slip is not sensed)
Failure code [DDTKKA] Trouble in 1st clutch fill switch (Command is holding pressure, fill switch is OFF, and slip is not sensed)
Failure code [DDTLKA] Trouble in 2nd clutch fill switch (Command is holding pressure, fill switch is OFF, and slip is not sensed)
Failure code [DDTMKA] Trouble in 3rd clutch fill switch (Command is holding pressure, fill switch is OFF, and slip is not sensed)
Failure code [DDTNKA] Trouble in R clutch fill switch (Command is holding pressure, fill switch is OFF, and slip is not sensed)
Failure code [DDTPKA] Trouble in 4th clutch fill switch (Command is holding pressure, fill switch is OFF, and slip is not sensed)
Failure code [DF10KA] Gear shift lever signal non-input
Failure code [DF10KB] Gear shift lever signal multi-input
Failure code [DGE5KX] (or VHMS_LED display: “n4” → “01”) (Atmospheric temperature sensor: Out of input signal range)
Failure code [DGF1KX] Transmission oil temperature sensor input signal out of range
Failure code [DGR2KZ] Trouble in retarder oil temperature sensor rear wheel system (Ground fault)
Failure code [DGR6KX] Steering oil temperature sensor input signal out of range
Failure code [DGT1KX] Torque converter oil temperature sensor input signal out of range
Troubleshooting by failure code, Part 6
Failure code [DGT4KA] (or VHMS_LED display: “n3” → “12”) (Exhaust gas temperature sensor (F): Disconnection)
Failure code [DGT4KB] (or VHMS_LED display: “n3” → “11”) (Exhaust gas temperature sensor (F): Short circuit)
Failure code [DGT5KA] (or VHMS_LED display: “n3” → “22”) (Exhaust gas temperature sensor (R): Disconnection)
Failure code [DGT5KB] (or VHMS_LED display: “n3” → “21”) (Exhaust gas temperature sensor (R): Short circuit)
Failure code [DHE5KB] (or VHMS_LED display: “n3” → “32”) (Blow-by pressure sensor: Short circuit)
Failure code [DHE5KY] (or VHMS_LED display: “n3” → “31”) (Blow-by pressure sensor: Short circuit with power supply line)
Failure code [DHP4KY] (or VHMS_LED display: “n5” → “44”) Short circuit in suspension pressure sensor system (Front right)
Failure code [DHP4KZ] (or VHMS_LED display: “n5” → “43”) Disconnection or ground fault in suspension pressure sensor system (Front right)
Failure code [DHP5KY] (or VHMS_LED display: “n5” → “54”) Short circuit in suspension pressure sensor system (Front left)
Failure code [DHP5KZ] (or VHMS_LED display: “n5” → “53”) Disconnection or ground fault in suspension pressure sensor system (Front left)
Failure code [DHP6KA] Trouble in suspension pressure sensor system (Right rear)
Failure code [DHP6KX] Trouble in suspension pressure sensor system (Right rear)
Failure code [DHP6KY] (or VHMS_LED display: “n5” → “64”) Short circuit in suspension pressure sensor system (Right rear)
Failure code [DHP6KZ] (or VHMS_LED display: “n5” → “63”) Disconnection or ground fault in suspension pressure sensor system (Right rear)
Failure code [DHP7KA] Trouble in suspension pressure sensor system (Left rear)
Failure code [DHP7KX] Trouble in suspension pressure sensor system (Left rear)
Failure code [DHP7KY] (or VHMS_LED display: “n5” → “74”) Short circuit in suspension pressure sensor system (Left rear)
Failure code [DHP7KZ] (or VHMS_LED display: “n5” → “73”) Disconnection or ground fault in suspension pressure sensor system (Left rear)
Failure code [DHT5KX] Disconnection, ground fault in torque converter inlet oil pressure sensor
Failure code [DHT5L6] Trouble in torque converter oil pressure sensor
Failure code [DHU2KX] Trouble in front accumulator oil pressure sensor
Failure code [DHU3KX] Trouble in rear accumulator oil pressure sensor
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right)
Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left)
Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Rear right)
Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Rear left)
Failure code [DJF1KA] Disconnection in fuel level sensor
Failure code [DK30KX] Trouble in steering angle potentiometer
Failure code [DK51L5] Trouble in manual retarder potentiometer and retarder swich signal
Failure code [DK52KX] Trouble 1 in hoist lever potentiometer sensor
Failure code [DK53L8] Trouble 2 in hoist lever potentiometer sensor
Failure code [DK54KX] Trouble in body positioner sensor
Failure code [DKD0L6] Trouble in steering speed sensor
Failure code [DKH0KX] Clinometer sensor signal out of range
Failure code [DKH1KX] (or VHMS_LED display: “n4” → “33”) Abnormality in clinometer sensor
Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system
Failure code [DLF1LC] Trouble in transmission input shaft speed sensor
Failure code [DLF2KA] Disconnection in transmission intermediate shaft speed sensor system
Failure code [DLF2LC] Trouble in transmission intermediate shaft speed sensor
Troubleshooting by failure code, Part 7
Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right)
Failure code [DLF6L3] Trouble in wheel speed sensor (Front right)
Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left)
Failure code [DLF7L3] Trouble in wheel speed sensor (Front left)
Failure code [DLF8KA] Disconnection in wheel speed sensor (Right rear)
Failure code [DLF8L3] Trouble in wheel speed sensor (Right rear)
Failure code [DLF8LC] Trouble in wheel speed sensor system (Right rear)
Failure code [DLF8MA] Disconnection in wheel speed sensor (Right rear)
Failure code [DLF9KA] Disconnection in wheel speed sensor (Left rear)
Failure code [DLF9L3] Trouble in wheel speed sensor (Left rear)
Failure code [DLF9LC] Trouble in wheel speed sensor system (Left rear)
Failure code [DLF9MA] Disconnection in wheel speed sensor (Left rear)
Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system
Failure code [DLT3LC] Trouble in transmission output shaft speed sensor
Failure code [DLT4KA] Disconnection in transmission output shaft speed sensor
Failure code [DLT4MA] Disconnection in transmission output shaft speed sensor
Failure code [DV00KB] Short circuit in buzzer output
Failure code [DW2AKA] Disconnection in main pressure variable valve output
Failure code [DW2AKB] Ground fault in main pressure variable valve output circuit
Failure code [DW2AKY] Hot short in main pressure variable valve output circuit
Failure code [DW2AL1] Defective reset of main pressure variable valve
Failure code [DW2ALH] Malfunction of main pressure variable valve
Failure code [DW35KZ] Trouble in output system of auto suspension solenoid 1 (Disconnection or short circuit)
Failure code [DW36KZ] Trouble in output system of auto suspension solenoid 2 (Disconnection or short circuit)
Failure code [DW72KZ] Trouble in kick-out solenoid output system (Disconnection or short circuit)
Failure code [DW73KZ] Trouble in hoist select valve output system (Disconnection or short circuit)
Failure code [DW78KZ] Trouble in brake cooling valve (BCV) (rear wheel) output system (Disconnection or short circuit)
Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps operating)
Failure code [DWNBKA] Disconnection in ASR shut-off valve output circuit
Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit
Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit
Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate)
Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system
Failure code [DWNDMA] Defective ABS cut-off valve (Front)
Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system
Failure code [DWNEMA] Defective ABS cut-off valve (Rear)
Troubleshooting by failure code, Part 8
Failure code [DX11K4] Trouble in rear brake proportional pressure reducing solenoid valve (Valve keeps operating)
Failure code [DX11KA] Disconnection in rear brake proportional pressure reducing solenoid valve output circuit
Failure code [DX11KB] Short circuit in rear brake proportional pressure reducing solenoid valve
Failure code [DX11KY] Short circuit in rear wheel proportional pressure reducing solenoid valve output circuit
Failure code [DX11MA] Trouble in rear wheel proportional pressure reducing solenoid valve (Valve does not operate)
Failure code [DX13KA] Disconnection in hoist EPC valve output circuit
Failure code [DX13KB] Short circuit in hoist EPC valve output circuit
Failure code [DX13KY] Short circuit in hoist EPC valve output circuit
Failure code [DX17K4] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve keeps operating)
Failure code [DX17KA] Disconnection in ASR proportional pressure reducing solenoid valve (right) output circuit
Failure code [DX17KB] Ground fault in ASR proportional pressure reducing solenoid valve (right) output circuit
Failure code [DX17KY] Short circuit in ASR proportional pressure reducing solenoid valve (right) output circuit
Failure code [DX17MA] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve does not operate)
Failure code [DX18K4] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve keeps operating)
Failure code [DX18KA] Disconnection in ASR proportional pressure reducing solenoid valve (left) output circuit
Failure code [DX18KB] Ground fault in ASR proportional pressure reducing solenoid valve (left) output circuit
Failure code [DX18KY] Short circuit in ASR proportional pressure reducing solenoid valve (left) output circuit
Failure code [DX18MA] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve does not operate)
Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right)
Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right)
Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right)
Failure code [DX21MA] Defective ABS control valve (Front right)
Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left)
Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left)
Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left)
Failure code [DX22MA] Defective ABS control valve (Front left)
Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right)
Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right)
Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right)
Failure code [DX23MA] Defective ABS control valve (Rear right)
Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left)
Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left)
Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left)
Failure code [DX24MA] Defective ABS control valve (Rear left)
Failure code [DX25MA] Defective ABS front wheel system control valve
Failure code [DX26MA] Defective ABS rear wheel system control valve
Troubleshooting by failure code, Part 9
Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection)
Failure code [DXH1KB] (Lock-up clutch solenoid output circuit: Short circuit)
Failure code [DXH1KY] (Lockup clutch solenoid output circuit: Short circuit to power source line)
Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection)
Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit)
Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line)
Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection)
Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit)
Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line)
Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection)
Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit)
Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit to power source line)
Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection)
Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit)
Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit in power source line)
Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection)
Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit)
Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit to power source line)
Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection)
Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit)
Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line)
Failure code [DXHHKA] (4th clutch solenoid output circuit: Disconnection)
Failure code [DXHHKB] (4th clutch solenoid output circuit: Short circuit)
Failure code [DXHHKY] (4th clutch solenoid output circuit: Short circuit to power source line)
Failure code [F@BBZL] (or VHMS_LED display: “n3” → “38”) (Blow-by pressure: High error)
Failure code [F@BYNR] (or VHMS_LED display: “n3” → “62”) (Exhaust gas temperature (F): Abnormal heat)
Failure code [F@BYNS] (or VHMS_LED display: “n3” → “61”) (Exhaust gas temperature (F): Overheat)
Failure code [F@BZNR] (or VHMS_LED display: “n3” → “72”) (Exhaust gas temperature (R): abnormal heat)
Failure code [F@BZNS] (or VHMS_LED display “n3” → “71”) (Exhaust gas temperature (R): Overheat)
Troubleshooting of electrical system (E-mode)
Before troubleshooting of electric system
Contents of troubleshooting table
E-1 Engine does not start
E-2 Automatic preheating does not operate
E-3 Machine monitor does not display all, when starting switch is turned ON
E-4 Machine monitor does not operate when starting switch is OFF
E-5 Alarm buzzer does not sound
E-6 Alarm buzzer does not stop sounding
E-7 Gauges of machine monitor, caution lamps or character display section do not display properly
E-8 A selection of the display in character display section cannot be changed
E-9 Power mode selecting function does not operate properly
E-10 AISS function does not operate properly
E-11 Seat belt caution lamp does not display properly
E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly
E-13 Night illumination (lighting) does not work properly
E-14 Emergency steering does not operate
E-15 Hoist lever does not operate normally
E-16 Electric priming pump does not operate or does not stop automatically
Troubleshooting of hydraulic and mechanical system (H-mode)
Contents of troubleshooting table
H-1 Machine does not start
H-2 Machine does not travel smoothly (hunting)
H-3 Lockup cannot be cancelled
H-4 Excessive shock when starting or shifting excessive
H-5 Transmission does not shift up
H-6 Machine lacks power or speed when traveling
H-7 Time lag is excessive when starting or shifting gear
H-8 Torque converter oil temperature is high
H-9 Torque converter oil pressure is low
H-10 Front brake is ineffective
H-11 Rear brake is ineffective
H-12 Steering wheel is heavy
H-13 Steering wheel does not work
H-14 Steering wheel vibrates
H-15 Dump body lifting speed is slow
H-16 Dump body does not work
H-17 Excessive hydraulic drift of dump body
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
S-1 Starting performance of engine is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operation
S-5 Engine does not rotate smoothly
S-6 Engine lack output (or lacks power)
S-7 Exhaust gas is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust gas is blue)
S-9 Oil becomes dirty quickly
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (Entry of coolant or fuel)
S-14 Coolant temperature becomes too high (Overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
S-17 Air cannot be bled from fuel circuit
50 Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tool list
Sketches of special tools
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of cylinder head assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Removal and installation of engine assembly
Removal and installation of radiator assembly
Removal and installation of output shaft assembly
Disassembly and assembly of output shaft assembly
Removal and installation of brake and power train oil cooler assembly
Power train, Part 1
Removal and installation of torque converter and transmission assembly
Separation and coupling of transmission assembly and torque converter assembly
Disassembly and assembly of transmission assembly and torque converter assembly
Disassembly and assembly of torque converter assembly
Disassembly and assembly of transmission assembly
Removal and installation of transmission control valve assembly (ECMV assembly)
Disassembly and assembly of transmission control valve assembly (ECMV assembly)
Power train, Part 2
Removal and installation of differential assembly
Disassembly and assembly of differential assembly
Removal and installation of final drive carrier assembly
Disassembly and assembly of final drive carrier assembly
Disassembly and assembly of front wheel hub assembly
Steering system
Disassembly and assembly of steering cylinder assembly
Brake system
Removal and installation of front brake caliper pads
Removal and installation of front brake calipers assembly
Disassembly and assembly of front brake calipers assembly
Removal and installation of final drive and rear brake assembly
Removal and installation of final drive, rear brake, and parking brake assembly
Disassembly and assembly of final drive, rear brake, and parking brake assembly
Undercarriage and frame
Removal and installation of front wheel assembly
Removal and installation of rear wheel assembly
Removal and installation of front suspension cylinder assembly
Disassembly and assembly of front suspension cylinder assembly (Cylinder with buffer ring)
Removal and installation of rear suspension cylinder assembly
Disassembly and assembly of rear suspension cylinder assembly (Cylinder with buffer ring)
Hydraulic system
Disassembly and assembly of hoist cylinder assembly
Body
Removal and installation of body assembly
Cab and its attachments
Disassembly and assembly of operator’s seat assembly
Removal and installation of air conditioner unit assembly
Electrical system
Removal and installation of engine controller assembly
Removal and installation of transmission controller assembly
Removal and installation of retarder controller assembly
90 Diagrams and drawings
Hydraulic diagrams and drawings
Power train hydraulic circuit diagram
Steering and hoist hydraulic circuit diagram
Brake hydraulic circuit diagram
Electrical diagrams and drawings
Electrical circuit diagram inside cab (1/3)
Electrical circuit diagram inside cab (2/3)
Electrical circuit diagram inside cab (3/3)
Electrical circuit diagram outside cab (1/3)
Electrical circuit diagram outside cab (2/3)
Electrical circuit diagram outside cab (3/3)
Electrical circuit diagram for VHMS
Electrical circuit diagram for ASR (If equipped)
Air conditioner electrical circuit diagram
Electrical circuit diagram for auto greasing (If equipped)
Connectors table and arrangement drawing
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