Komatsu HD465-7R 15001 & Up, HD605-7R 16001 & Up SEN02283-01 (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 ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
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 SYSTEM, 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 SYSTEM, 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
EPC VALVE
HOIST CYLINDER
HYDRAULIC PUMP
CAB AND ITS ATTACHMENTS
AIR CONDITIONER
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
ELECTRICAL SYSTEM, PART 3
PAYLOAD METER Ⅱ(CARD TYPE)
ELECTRICAL SYSTEM, PART 4
VHMS CONTROLLER RELATED
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
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
HANDLING OF FUEL SYSTEM DEVICES
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM
TESTING OF FUEL PRESSURE
CYLINDER CUT-OUT MODE OPERATION
NO-INJECTION CRANKING
TESTING OF FUEL RETURN RATE AND FUEL LEAKAGE
BLEEDING AIR FROM FUEL CIRCUIT
TESTING THE FUEL CIRCUIT FOR LEAKAGE
REPLACING AND ADJUSTING OF FAN BELT
REPLACING AND ADJUSTING 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
ADJUSTING BODY POSITIONER SENSOR
HANDLING OF HIGH 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
VHMS CONTROLLER INITIAL SETTING PROCEDURE
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
FAILURE CODE TABLE AND FUSE LOCATIONS
FAILURE CODES TABLE
FUSE LOCATIONS
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-ADAPTER BOX AND T-ADAPTER TABLE
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] (2ND CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF)
FAILURE CODE [15SFMA] (2ND CLUTCH SOLENOID: MALFUNCTION)
FAILURE CODE [15SGL1] (3RD CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF)
FAILURE CODE [15SGMA] (3RD CLUTCH SOLENOID: MALFUNCTION)
FAILURE CODE [15SHL1] (4TH CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF)
FAILURE CODE [15SHMA] (4TH CLUTCH SOLENOID: MALFUNCTION)
FAILURE CODE [15SJMA] (LOCKUP CLUTCH SOLENOID: MALFUNCTION)
FAILURE CODE [2F00KM] (PARKING BRAKE: MISTAKE IN OPERATION OR SETTING)
FAILURE CODE [2G42ZG] (ACCUMULATOR: OIL PRESSURE REDUCTION (FRONT))
FAILURE CODE [2G43ZG] (ACCUMULATOR: OIL PRESSURE REDUCTION (REAR))
FAILURE CODE [989A00] (ENGINE OVER RUN PREVENTION COMMAND SIGNAL: OPERATING)
FAILURE CODE [989D00] (REAR SECTION TIPPING OVER ALARM: ALARM IS ACTIVATED)
FAILURE CODE [A570NX] (ENGINE OIL FILTER: CLOGGING)
FAILURE CODE [AA10NX] (AIR CLEANER ELEMENT: CLOGGING)
FAILURE CODE [AB00MA] (ALTERNATOR: MALFUNCTION)
FAILURE CODE [B@BAZG] (ABNORMAL LOWERING OF ENGINE OIL PRESSURE: LOWERING OF OIL PRESSURE)
FAILURE CODE [B@BAZK] (ENGINE OIL: LEVEL TOO LOW)
FAILURE CODE [B@BCNS] (ENGINE: OVERHEAT)
FAILURE CODE [B@BCZK] (LOWERING OF RADIATOR COOLANT: LOWERING OF LEVEL)
FAILURE CODE [B@BFZK] (LOWERING OF FUEL LEVEL)
FAILURE CODE [B@C7NS] (BRAKE COOLING OIL: OVERHEATING (REAR))
FAILURE CODE [B@CENS] (OVERHEATING OF TORQUE CONVERTER OIL)
FAILURE CODE [B@GAZK] (BATTERY ELECTROLYTE LEVEL: LOWERING OF LEVEL)
FAILURE CODE [B@JANS] (STEERING OIL TEMPERATURE: OVERHEAT)
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 OPEN/SHORT ERROR)
FAILURE CODE [CA323] (INJECTOR #5 OPEN/SHORT ERROR)
FAILURE CODE [CA324] (INJECTOR #3 OPEN/SHORT ERROR)
FAILURE CODE [CA325] (INJECTOR #6 OPEN/SHORT ERROR)
FAILURE CODE [CA331] (INJECTOR #2 OPEN/SHORT ERROR)
FAILURE CODE [CA332] (INJECTOR #4 OPEN/SHORT ERROR)
FAILURE CODE [CA342] (CALIBRATION CODE 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] (TROUBLE IN IDLE VALIDATION SWITCH)
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 PRESSURE VERY LOW ERROR)
FAILURE CODE [CA689] (ENGINE NE SPEED SENSOR ERROR)
FAILURE CODE [CA731] (ENGINE BKUP SPEED SENSOR PHASE ERROR)
FAILURE CODE [CA757] (ALL CONTINUOUS DATA LOST ERROR)
FAILURE CODE [CA778] (ENGINE BKUP SPEED SENSOR 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 PRESSURE VERY LOW ERROR 2)
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] (STOP LAMP RELAY OUTPUT SYSTEM: SHORT CIRCUIT)
FAILURE CODE [D5ZKKZ] (FRONT BRAKE CUT-OFF SOLENOID VALVE: DISCONNECTION, SHORT CIRCUIT OR SHORT CIRCUIT TO POWER SORCE LINE)
FAILURE CODE [DAF9KM] WRONG CONNECTION OF CONNECTOR
FAILURE CODE [DAFRKR] (ABNORMAL CAN COMMUNICATION (MACHINE MONITOR): ABNORMAL COMMUNICATION)
FAILURE CODE [DAQ0KK] (TRANSMISSION CONTROLLER DIRECT POWER SUPPLY: LOWERING OF SOURCE VOLTAGE)
FAILURE CODE [DAQ0KT] (TRANSMISSION CONTROLLER NONVOLATILE MEMORY: ABNORMALITY IN CONTROLLER)
FAILURE CODE [DAQ2KK] (TRANSMISSION CONTROLLER SOLENOID POWER SOURCE: POWER SOURCE VOLTAGE TOO LOW)
FAILURE CODE [DAQ9KQ] (TRANSMISSION CONTROLLER: DISAGREEMENT OF MODEL SELECTION)
FAILURE CODE [DAQRKR] (ABNORMALITY IN CAN COMMUNICATION (TRANSMISSION))
FAILURE CODE [DAQRMA] (TRANSMISSION CONTROLLER OPTION SETTING: MALFUNCTION)
FAILURE CODE [DB10KT] (RETARDER CONTROLLER NONVOLATILE MEMORY: ABNORMALITY IN CONTROLLER)
FAILURE CODE [DB12KK] (RETARDER CONTROLLER SOLENOID POWER SOURCE: POWER SOURCE SYSTEM TROUBLE)
FAILURE CODE [DB13KK] (RETARDER CONTROLLER BATTERY DIRECT POWER SOURCE: POWER SOURCE VOLTAGE TOO LOW)
FAILURE CODE [DB19KQ] DISAGREEMENT OF MODEL SELECTION (RETARDER CONTROLLER)
FAILURE CODE [DB1RKR] (CAN COMMUNICATION (RETARDER CONTROLLER): COMMUNICATION DISABLED)
FAILURE CODE [DB1RMA] DISAGREEMENT OF OPTION SETTING (RETARDER CONTROLLER)
FAILURE CODE [DB2RKR] (CAN COMMUNICATION (ENGINE CONTROLLER): COMMUNICATION DISABLED)
FAILURE CODE [DBBRKR] (ABNORMALITY IN CAN COMMUNICATION (VHMS))
FAILURE CODE [DBC2KK] (ABS CONTROLLER SOLENOID POWER SOURCE: POWER SOURCE SYSTEM TROUBLE)
FAILURE CODE [DBC3KK] (ABS CONTROLLER BATTERY DIRECT POWER SOURCE: POWER SOURCE VOLTAGE TOO LOW)
FAILURE CODE [DBC9KQ] DISAGREEMENT OF MODEL SELECTION (ABS CONTROLLER)
FAILURE CODE [DBCRKR] (ABNORMALITY IN CAN COMMUNICATION (ABS))
FAILURE CODE [DBCRMA] DISAGREEMENT OF OPTION SETTING (ABS CONTROLLER)
FAILURE CODE [DDD7KX] (TROUBLE IN TRAVEL SPEED SETTING SWITCH SYSTEM: OUT OF INPUT SIGNAL RANGE)
FAILURE CODE [DDD8KA] (ARSC SYSTEM SWITCH SYSTEM: DISCONNECTION) (IF EQUIPPED)
FAILURE CODE [DDD8KB] (ARSC SYSTEM SWITCH SYSTEM: SHORT CIRCUIT) (IF EQUIPPED)
FAILURE CODE [DDD9KA] (ABS SYSTEM SWITCH SYSTEM: DISCONNECTION)
FAILURE CODE [DDD9KB] (ABS SYSTEM SWITCH SYSTEM: SHORT CIRCUIT)
FAILURE CODE [DDDAKA] (ASR SYSTEM SWITCH: DISCONNECTION)
FAILURE CODE [DDDAKB] (ASR SYSTEM SWITCH: SHORT CIRCUIT)
FAILURE CODE [DDP6L4] (SERVICE BRAKE PRESSURE SWITCH TROUBLE (REAR))
FAILURE CODE [DDTHKA] (HI CLUTCH FILL SWITCH: DISCONNECTION)
FAILURE CODE [DDTJKA] (LO CLUTCH FILL SWITCH: DISCONNECTION)
FAILURE CODE [DDTKKA] (1ST CLUTCH FILL SWITCH: DISCONNECTION)
FAILURE CODE [DDTLKA] (2ND CLUTCH FILL SWITCH: DISCONNECTION)
FAILURE CODE [DDTMKA] (3RD CLUTCH FILL SWITCH: DISCONNECTION)
FAILURE CODE [DDTNKA] (R CLUTCH FILL SWITCH: DISCONNECTION)
FAILURE CODE [DDTPKA] (4TH CLUTCH FILL SWITCH: DISCONNECTION)
FAILURE CODE [DF10KA] (GEAR SHIFT LEVER: DISCONNECTION)
FAILURE CODE [DF10KB] (GEAR SHIFT LEVER: SHORT CIRCUIT)
FAILURE CODE [DGF1KX] (TRANSMISSION OIL TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE)
FAILURE CODE [DGR2KZ] (RETARDER OIL TEMPERATURE SENSOR SYSTEM TROUBLE : GROUND FAULT (REAR WHEEL))
FAILURE CODE [DGR6KX] (STEERING OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE)
FAILURE CODE [DGT1KX] (TORQUE CONVERTER OIL TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE)
TROUBLESHOOTING BY FAILURE CODE, PART 6
FAILURE CODE [DHP6KA] (SUSPENSION PRESSURE SENSOR SYSTEM: DISCONNECTION RIGHT REAR)
FAILURE CODE [DHP6KX] (FAILURE IN SUSPENSION PRESSURE SENSOR SYSTEM TROUBLE: OUT OF INPUT SIGNAL RANGE (RIGHT REAR))
FAILURE CODE [DHP6KY] (SUSPENSION PRESSURE SENSOR SYSTEM: SHORT CIRCUIT (RIGHT REAR))
FAILURE CODE [DHP6KZ] (SUSPENSION PRESSURE SENSOR SYSTEM: DISCONNECTION OR GROUND FAULT (RIGHT REAR))
FAILURE CODE [DHP7KA] (SUSPENSION PRESSURE SENSOR SYSTEM: DISCONNECTION (LEFT REAR))
FAILURE CODE [DHP7KX] (FAILURE IN SUSPENSION PRESSURE SENSOR SYSTEM TROUBLE: OUT OF INPUT SIGNAL RANGE) (LEFT REAR)
FAILURE CODE [DHP7KY] (SUSPENSION PRESSURE SENSOR SYSTEM: SHORT CIRCUIT (LEFT REAR))
FAILURE CODE [DHP7KZ] (SUSPENSION PRESSURE SENSOR SYSTEM: DISCONNECTION OR GROUND FAULT (LEFT REAR))
FAILURE CODE [DHT5KX] (TORQUE CONVERTER OIL PRESSURE SENSOR: OUT OF INPUT SIGNAL RANGE)
FAILURE CODE [DHT5L6] (TORQUE CONVERTER OIL PRESSURE SENSOR: DISAGREEMENT OF RUN AND STOP CONDITION WITH SIGNAL)
FAILURE CODE [DHU2KX] (FRONT ACCUMULATOR OIL PRESSURE SENSOR: OUT OF INPUT SIGNAL RANGE)
FAILURE CODE [DHU3KX] (REAR ACCUMULATOR OIL PRESSURE SENSOR: OUT OF INPUT SIGNAL RANGE)
FAILURE CODE [DJF1KA] (FUEL LEVEL SENSOR: DISCONNECTION)
FAILURE CODE [DK30KX] (STEERING ANGLE POTENTIOMETER: TROUBLE (DISCONNECTION))
FAILURE CODE [DK51L5] (RETARDER LEVER POTENTIOMETER: POTENTIOMETER SIGNAL IS INCONSISTENT WITH SWICH SIGNAL)
FAILURE CODE [DK52KX] (FAILURE IN HOIST LEVER POTENTIOMETER 1: OUT OF INPUT SIGNAL RANGE)
FAILURE CODE [DK53L8] (FAILURE IN HOIST LEVER POTENTIOMETER 2: DISAGREEMENT OF ANALOG SIGNAL)
FAILURE CODE [DK54KX] (BODY POSITIONER SENSOR: OUT OF INPUT SIGNAL RANGE)
FAILURE CODE [DKD0L6] (FAILURE IN STEERING SPEED SENSOR)
FAILURE CODE [DKH0KX] (PITCH ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE)
FAILURE CODE [DKH1KX] (PITCH ANGLE SENSOR: ABNORMALITY (DISCONNECTION OR SHORT CIRCUIT))
FAILURE CODE [DLF1KA] (TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION)
FAILURE CODE [DLF1LC] (TRANSMISSION INPUT SHAFT SPEED SENSOR: DISAGREEMENT OF REVOLUTION SPEED SIGNAL)
FAILURE CODE [DLF2KA] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISCONNECTION)
FAILURE CODE [DLF2LC] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISAGREEMENT OF REVOLUTION SPEED SIGNAL)
TROUBLESHOOTING BY FAILURE CODE, PART 7
FAILURE CODE [DLF8KA] (WHEEL SPEED SENSOR: DISCONNECTION (RIGHT REAR))
FAILURE CODE [DLF8L3] (WHEEL SPEED SENSOR: DISCONNECTION (RIGHT REAR))
FAILURE CODE [DLF8LC] (WHEEL SPEED SENSOR: TROUBLE (RIGHT REAR))
FAILURE CODE [DLF8MA] (WHEEL SPEED SENSOR: DISCONNECTION (RIGHT REAR))
FAILURE CODE [DLF9KA] (WHEEL SPEED SENSOR: DISCONNECTION (LEFT REAR))
FAILURE CODE [DLF9L3] (WHEEL SPEED SENSOR: TROUBLE (LEFT REAR))
FAILURE CODE [DLF9LC] (WHEEL SPEED SENSOR: TROUBLE (LEFT REAR))
FAILURE CODE [DLF9MA] (WHEEL SPEED SENSOR: DISCONNECTION (LEFT REAR))
FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION)
FAILURE CODE [DLT3LC] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISAGREEMENT OF REVOLUTION SPEED SIGNAL)
FAILURE CODE [DLT4KA] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION)
FAILURE CODE [DLT4MA] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION)
FAILURE CODE [DV00KB] (BUZZER OUTPUT: SHORT CIRCUIT)
FAILURE CODE [DW2AKA] (MAIN PRESSURE VARIABLE VALVE OUTPUT: DISCONNECTION)
FAILURE CODE [DW2AKB] (MAIN PRESSURE VARIABLE VALVE OUTPUT CIRCUIT: GROUND FAULT)
FAILURE CODE [DW2AKY] (MAIN PRESSURE VARIABLE VALVE OUTPUT CIRCUIT: HOT SHORT)
FAILURE CODE [DW2AL1] (MAIN PRESSURE VARIABLE VALVE: DEFECTIVE RESET)
FAILURE CODE [DW2ALH] (MAIN PRESSURE VARIABLE VALVE: MALFUNCTION)
FAILURE CODE [DW35KZ] (FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 1: DISCONNECTION OR SHORT CIRCUIT)
FAILURE CODE [DW36KZ] (FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 2: DISCONNECTION OR SHORT CIRCUIT) (IF EQUIPPED)
FAILURE CODE [DW72KZ] (KICK-OUT SOLENOID OUTPUT SYSTEM TROUBLE: DISCONNECTION OR SHORT CIRCUIT)
FAILURE CODE [DW73KZ] (FAILURE IN HOIST SELECT VALVE OUTPUT SYSTEM: DISCONNECTION OR SHORT CIRCUIT)
FAILURE CODE [DW78KZ] (BRAKE COOLING VALVE (BCV) (REAR WHEEL) OUTPUT SYSTEM TROUBLE: DISCONNECTION OR SHORT CIRCUIT)
FAILURE CODE [DWNBK4] (ASR SHUT-OFF VALVE: TROUBLE (VALVE KEEPS OPERATING))
FAILURE CODE [DWNBKA] (ASR SHUT-OFF VALVE OUTPUT CIRCUIT: DISCONNECTION)
FAILURE CODE [DWNBKB] (ASR SHUT-OFF VALVE OUTPUT CIRCUIT: GROUND FAULT)
FAILURE CODE [DWNBKY] (ASR SHUT-OFF VALVE OUTPUT CIRCUIT: SHORT CIRCUIT)
FAILURE CODE [DWNBMA] (ASR SHUT-OFF VALVE: TROUBLE (VALVE DOES NOT OPERATE))
TROUBLESHOOTING BY FAILURE CODE, PART 8
FAILURE CODE [DX11K4] (REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: OUT OF CONTROL)
FAILURE CODE [DX11KA] (REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE OUTPUT CIRCUIT: DISCONNECTION)
FAILURE CODE [DX11KB] (REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: SHORT CIRCUIT)
FAILURE CODE [DX11KY] (REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: SHORT CIRCUIT TO POWER SOURCE LINE)
FAILURE CODE [DX11MA] (REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: MALFUNCTION)
FAILURE CODE [DX13KA] (OUTPUT CIRCUIT OF HOIST EPC VALVE: DISCONNECTION)
FAILURE CODE [DX13KB] (OUTPUT CIRCUIT OF HOIST EPC VALVE: SHORT CIRCUIT)
FAILURE CODE [DX13KY] (OUTPUT CIRCUIT OF HOIST EPC VALVE: SHORT CIRCUIT WITH POWER SOURCE LINE)
FAILURE CODE [DX17K4] (ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (RIGHT): TROUBLE (VALVE KEEPS OPERATING))
FAILURE CODE [DX17KA] (ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (RIGHT) OUTPUT CIRCUIT: DISCONNECTION)
FAILURE CODE [DX17KB] (ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (RIGHT) OUTPUT CIRCUIT: GROUND FAULT)
FAILURE CODE [DX17KY] (ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (RIGHT) OUTPUT CIRCUIT: SHORT CIRCUIT)
FAILURE CODE [DX17MA] (ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (RIGHT): TROUBLE (VALVE DOES NOT OPERATE))
FAILURE CODE [DX18K4] (ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (LEFT): TROUBLE (VALVE KEEPS OPERATING))
FAILURE CODE [DX18KA] (ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (LEFT) OUTPUT CIRCUIT: DISCONNECTION)
FAILURE CODE [DX18KB] (ASR PROPORTIONAL PRESSURE EDUCING SOLENOID VALVE (LEFT) OUTPUT CIRCUIT: GROUND FAULT)
FAILURE CODE [DX18KY] (ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (LEFT) OUTPUT CIRCUIT: SHORT CIRCUIT)
FAILURE CODE [DX18MA] (ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (LEFT): TROUBLE (VALVE DOES NOT OPERATE))
TROUBLESHOOTING BY FAILURE CODE, PART 9
FAILURE CODE [DXH1KA] (LOCKUP CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION)
FAILURE CODE [DXH1KB] (LOCKUP 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)
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 GAUGES OF MACHINE MONITOR, CAUTION LAMPS OR CHARACTER DISPLAY SECTION DO NOT DISPLAY PROPERLY
E-7 A SELECTION OF THE DISPLAY IN CHARACTER DISPLAY SECTION CANNOT BE CHANGED
E-8 POWER MODE SELECTING FUNCTION DOES NOT OPERATE PROPERLY
E-9 AISS FUNCTION DOES NOT OPERATE PROPERLY
E-10 SEAT BELT CAUTION LAMP DOES NOT DISPLAY PROPERLY
E-11 TURN SIGNAL LAMP OR TURNING LAMP (HAZARD LAMP) DO NOT WORK PROPERLY
E-12 NIGHT ILLUMINATION (LIGHTING) DOES NOT WORK PROPERLY
E-13 EMERGENCY STEERING DOES NOT OPERATE
E-14 HOIST LEVER DOES NOT OPERATE NORMALLY
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
90 DIAGRAMS AND DRAWINGS
HYDRAULIC CIRCUIT DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM
BRAKE HYDRAULIC CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (1/2)
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (2/2)
CONNECTORS TABLE AND ARRANGEMENT DRAWING
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