Komatsu HD465-5, HD605-5 Dump Truck Service Repair Shop Manual - SEBM015202

This Complete Service Repair Workshop Manual PDF Download for the HD465-5 & HD605-5 Komatsu Dump Truck has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu Dump Truck HD465-5
Serial Numbers : 4626 and up

Komatsu Dump Truck HD605-5
Serial Numbers : 1013 and up


TABLE OF CONTENTS :

01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD
90 OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM015202
Total Pages : 994


This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

More Info : https://www.sitelux.com

-

CONTENTS
01 GENERAL
GENERAL ASSEMBLY DRAWING
SPECIFICATIONS
WEIGHT TABLE
LIST OF LUBRICANT AND WATER

10 STRUCTURE AND FUNCTION
RADIATOR, TORQUE CONVERTER, OIL COOLER, AFTER COOLER, WORK EQUIPMENT OIL COOLER
BRAKE OIL COOLER
POWER TRAIN SKELETON
OUTPUT SHAFT
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT SCHEMATICS
TORQUE CONVERTER
LOCKUP SOLENOID VALVE
TRANSMISSION
TRANSMISSION VALVE
ECMV
LUBRICATION RELIEF VALVE
FRONT AXLE
REAR AXLE
DIFFERENTIAL
FINAL DRIVE
FRONT BRAKE
REAR BRAKE
PARKING BRAKE
WHEELS
AXLE SUPPORT
STEERING SYSTEM
STEERING WHEEL
STEERING LINKAGE
SUSPENSION SYSTEM
SUSPENSION CYLINDER
AIR PIPING
AIR CIRCUIT DIAGRAM
AIR GOVERNOR
SAFETY VALVE
CHECK VALVE
DOUBLE CHECK VALVE
AUTO DRAIN VALVE
HAND BRAKE VALVE
BRAKE VALVE
REDUCING VALVE
EMERGENCY BRAKE CONTROL VALVE
PARKING BRAKE CONTROL VALVE
RELAY VALVE
PARKING BRAKE RELAY VALVE
QUICK-RELEASE VALVE
PARKING BRAKE CHAMBER
FRONT BRAKE CHAMBER
REAR BRAKE CHAMBER
SLACK ADJUSTER
HYDRAULIC PIPING
HYDRAULIC CIRCUIT DIAGRAM
DUMP BODY CONTROL
HYDRAULIC TANK AND BRAKE COOLING OIL TANK
BRAKE COOLING OIL CONTROL VALVE (BCV)
STEERING CONTROL VALVE
DEMAND VALVE
CROSS-OVER RELIEF VALVE
HOIST VALVE
STEERING CYLINDER
HOIST CYLINDER
ELECTRICAL CIRCUIT DIAGRAM
STOP LAMP SWITCH
EXHAUST BRAKE SWITCH
FRONT BRAKE CUT-OFF VALVE
OVERRUN PREVENTION VALVE
EXHAUST BRAKE VALVE
HORN VALVE
PARKING BRAKE SWITCH
AIR CONDITIONER
PIPING DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
REFRIGERANT CIRCUIT DIAGRAM
UNIT
RECEIVER DRYER
CONDENSER
COMPRESSOR
ENGINE CONTROL SYSTEM
SYSTEM DRAWING
AISS
FUEL INJECTION PUMP ELECTRONIC GOVERNOR
HYDRAULIC CIRCUIT DIAGRAM
ENGINE CONTROLLER
SENSORS, SWITCHES
ELECTRICAL CIRCUIT DIAGRAM
APS
EXHAUST BRAKE
SYSTEM DIAGRAM
SYSTEM CIRCUIT DIAGRAM
AUTOMATIC RETARD SPEED CONTROL SYSTEM
SYSTEM DRAWING
STRUCTURE OF SYSTEM
ELECTRICAL CIRCUIT DIAGRAM
AIR CIRCUIT DIAGRAM
AUTOMATIC RETARD SPEED CONTROL
AUTOMATIC RETARD SPEED CONTROLLER
AUTOMATIC SHIFT CONTROL SYSTEM
SYSTEM DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
TRANSMISSION CONTROLLER
CONNECTOR SIGNALS
SELF-DIAGNOSTIC FUNCTION
SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES
AUTOMATIC GEAR SHIFTING LINE GRAPH
SHIFT LEVER SWITCH
SENSORS, SWITCHES
ENGINE SPEED SENSOR
TRANSMISSION SPEED SENSOR
TRANSMISSION OIL TEMPERATURE SENSOR
FILL SWITCH
ACCELERATOR SENSOR
SHIFT LIMIT SWITCH
MODE SELECTOR SWITCH
AUTOMATIC EMERGENCY STEERING SYSTEM
SYSTEM DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
FLOW SWITCH
RELAY TIMER
AUTOMATIC SUSPENSION SYSTEM
STRUCTURE OF SYSTEM
SYSTEM CIRCUIT DIAGRAM
AUTOMATIC SUSPENSION MODE SELECTION CONTROL
SUSPENSION CONTROLLER
SENSORS, SWITCHES
STEERING ANGLE SENSOR
PRESSURE SENSOR
SELF-DIAGNOSTIC FUNCTION
PAYLOAD METER (Printer type)
STRUCTURE OF SYSTEM
ELECTRICAL CIRCUIT DIAGRAM
PRINCIPLE OF CALCULATION
FEATURES OF EQUIPMENT
1. Pay load meter
2. Pressure sensor
3. Clinometer
4. Lamp drive relay
SELF-DIAGNOSTIC FUNCTION
PAYLOAD METER II (Card type)
STRUCTURE OF SYSTEM
ELECTRICAL CIRCUIT DIAGRAM
PRINCIPLE OF MEASUREMENT
FEATURES OF EACH DEVICE
1. Payload meter II
LEFT FACE
2. Pressure sensor
3. Clinometer
4. Lamp drive relay
5. Self-diagnostic function
MACHINE MONITOR SYSTEM
SYSTEM DRAWING
MONITOR PANEL DIAGRAM
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS
SELF-DIAGNOSTIC FUNCTION WHEN STARTING SWITCH IS OPERATED
TRAVEL SPEED COMPENSATION ROTARY SWITCH
SENSORS, SWITCHES
ENGINE OIL PRESSURE
FUEL LEVEL SENSOR
ENGINE WATER TEMPERATURE SENSOR
RETARDER OIL TEMPERATURE SENSOR
TORQUE CONVERTER OIL TEMPERATURE SENSOR
AIR PRESSURE SENSOR
RADIATOR WATER LEVEL SENSOR
TRANSMISSION OIL FILTER SENSOR
STEERING OIL TEMPERATURE SENSOR
BRAKE STROKE SENSOR
BODY SEATED SWITCH
TILT SWITCH

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY
ADJUSTING FUEL INJECTION TIMING
BLEEDING AIR FROM FUEL-INJECTION PUMP
ADJUSTING ENGINE STOP MOTOR CABLE
ADJUSTING ACCELERATOR PEDAL
ADJUSTING ENGINE, TRANSMISSION SPEED SENSORS
TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE
TESTING ECMV OIL PRESSURE
TESTING TORQUE CONVERTER STALL SPEED
TESTING BRAKE PRESSURE
BLEEDING AIR FROM BRAKE CIRCUIT
TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE
TESTING WEAR OF FRONT BRAKE PAD
TESTING WEAR OF REAR BRAKE DISC
TESTING AND ADJUSTING SUSPENSION CYLINDER
TESTING AND ADJUSTING AIR PRESSURE IN AIR CIRCUIT
ADJUSTING HOIST LEVER LINKAGE
ADJUSTING BODY POSITIONER
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT
AIR BLEEDING FROM STEERING CYLINDER
ADJUSTING ELECTRONIC MONITOR
ADJUSTING Q [FUEL INJECTION AMOUNT] WHEN REPLACING ENGINE CONTROLLER
SETTING ROTARY SWITCH
METHOD OF DELETING DATA FROM ENGINE CONTROLLER, TRANSMISSION CONTROLLER MEMORY
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
CONNECTOR PIN ALLOCATION CHART
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM ) OF ELECTRICAL SYSTEM
MONITOR PANEL USER CODES AND SERVICE MODE FUNCTION
SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS
TABLE OF SERVICE CODES AND USER CODES
METHOD OF USING JUDGMENT TABLE
METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ELECTRONIC COVERNOR SPECIFICATION G MODE)
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROB- LEMS ON MACHINE
JUDGMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS
G-1 [0.0] [OFF] or C010 Abnormality in power source
G-2 C011 Abnormality in controller
G-3 C012 Abnormality in rack sensor system
G-4 C014 Abnormality in governor solenoid system
G-5 C016 Abnormality in governor cut relay system
G-6 C018 Abnormality in rack sensor power source system
G-7 C019 Abnormality in governor servo system bank
G-8 C01b Abnormality in engine speed sensor system A
G-9 C01C Abnormality in engine speed sensor system B
G-10 C01d Abnormality in pre-stroke solenoid system
G-11 C021 Mistaken connection of connector
G-12 C022 Engine overrun
G-13 C023 Engine overheating
G-14 C024 Drop in engine oil pressure
G-15 C031 Abnormality in acceleration sensor system
G-16 C034 Abnormality in engine water temperature
G-17 C036 Abnormality in engine oil pressure sensor
G-18 C055 Abnormality in network
G-19 C056 Abnormality in solenoid power source
G-20 C058 Abnormality in backup power source system
G-21 C059 Abnormality in backup power source system
G-22 C0C2 Defective model selection data
G-23 C0C4 Abnormality in acceleration sensor system
G-24 C0C5 Abnormality in idling validation
G-25 Engine does not start
G-26 Defective actuation of APS
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
METHOD OF USING TROUBLESHOOTING CHART
S-1 Starting performance is poor (Starting always takes time)
S-2 Engine does not start
a) Engine turns but no exhaust smoke comes out
b) Exhaust smoke comes out but engine does not start (fuel is being injected)
S-3 Engine does not pick up smoothly (Follow-up is poor)
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly (Hunting)
S-6 Engine lacks output (or lacks power)
S-7 Exhaust smoke is black (Incomplete combustion)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in cooling water, or water spurts back, or water level goes down
S-12 Oil pressure caution lamp lights up (drop in oil pressure)
S-13 Oil level rises
S-14 Water temperature becomes too high (Overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE)
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLE- SHOOTING OF TRANSMISSION CONTROLLER SYSTEM
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PAR%
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM
A-1 Abnormality in power source system
a) [OFF] Controller self-diagnostic display LED does not light up
b001 b) Drop in voltage of controller power source is displayed
b0dA c) Drop in voltage of battery direct power source is displayed
b0db d) Drop in voltage of main power source is displayed
b002 e) Abnormality in transmission cut relay power source is displayed
A-2 b003 Abnormality in neutral safety system is displayed
A-3 b005 Double engagement for clutch is displayed
A-4 b006 Abnormality in transmission [cut relay] system displayed
A-5 b008 Abnormality in rear brake solenoid system is displayed
A-6 b009 Abnormality in exhaust brake solenoid system is displayed
A-7 b0C4 a) Short circuit with ground in BCV rear solenoid is displayed
b0C6 b) Short circuit in BCV rear solenoid is displayed
b0C8 c) Disconnection in BCV rear solenoid is displayed
A-8 b010 or b060 Abnormality in speed sensor system
b010 or b060 a) Disconnection in engine speed sensor [B] system is displayed or Failure of engine speed sensor is displayed
b011 or b061 b) Disconnection in input shaft speed sensor system is displayed or Failure of input shaft speed sensor is displaye
b012 or b062 c) Disconnection in intermediate shaft speed sensor system is displayed or Failure of intermediate shaft speed sens
b013 or b063 d) Disconnection in travel speed sensor (transmission output shaft speed sensor) system is displayed or Failure of
A-9 b022 or b023 Speed sensor system, clutch slipping
b022 or b023 a) Input shaft speed sensor or H, L clutch system is displayed
b024 - b028 b) Travel speed sensor system or speed clutch (1, 2, 3, 4, R) system is displayed
A-10 b014 Abnormality in model selection (wiring harness) is displayed
b014 a) Abnormality in model selection (wiring harness) is displayed
b0A1 b) Abnormality in model selection (rotary switch) is displayed
A-11 b007 Abnormality in shift lever system
b007 a) Abnormality in shift lever system
b015 b) Shift lever position signal input for 2 or more systems is displayed
b016 c) Shift lever position signal is not input
A-12 b017 Abnormality in accelerator signal is displayed
A-13 b019 Abnormality in transmission oil temperature sensor is displayed
A-14 b032 - b038 Abnormality in pressure control valve system
b032 - b038 a) Fill signal (clutch ON) is displayed regardless of command
b042 - b048 b) Fill signal is not input and clutch slipping is displayed
b-1) Inspecting fill signal system
b042 - b043 b-2) Inspecting transmission input shaft speed signal system, H, L clutch system (check clutch slip)
b044 - b048 b-3) Inspecting transmission output shaft speed signal system, 1-4, R clutch system (check clutch slip)
A-15 b052 - b058 When fill signal is not input (flow detector valve system)
A-16 b071 - b078 Short circuit in pressure valve solenoid system is displayed
b091 - b098 Disconnection in pressure control valve solenoid system is displayed
A-17 b0A2 Abnormality in sensor system
b0A2 a) Abnormality in torque converter oil temperature sensor system is displayed
b0A3 b) Abnormality in fuel level sensor system is displayed
b0A3 c) Abnormality in air pressure sensor system is displayed
b0A4 d) Abnormality in retarder brake oil temperature sensor system is displayed
A-18 b0d1 Warning display
b0d1 a) Transmission filter clogged warning displayed
b0d5 b) Tilt warning is displayed
b0d6 c) Drop in radiator water level warning is displayed
b0d7 d) Battery charge warning is displayed
b0E5 e) Steering oil temperature overheat warning is displayed
b0F6 f) Rear brake oil pressure warning is displayed
A-19 b0C1 Abnormality in connector connection is displayed
A-20 b0d2 a) Torque converter oil temperature overheat warning is displayed
b0E9 b) Air pressure drop warning is displayed
b0F3 c) Retarder brake oil temperature overheat warning is displayed
b0d8 d) Engine overrun actuated is displayed
b0d9 e) Engine overshoot actuated is displayed
TROUBLESHOOTING OF SUSPENSION CONTROLLER SYSTEM (SP MODE)
JUDGMENT TABLE FOR SUSPENSION CONTROLLER, SUSPENSION RELATED PARTS
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE
ELECTRICAL CIRCUIT DIAGRAM OF SUSPENSION CONTROLLER SYSTEM
SP-1 d001 Abnormality in power source is displayed
SP-2 d011 Abnormality in pressure sensor [right] system is displayed
SP-3 d012 Abnormality in pressure sensor [left] system is displayed
SP-4 d015 Abnormality in travel speed sensor system is displayed
SP-5 d016 Abnormality in steering sensor system is displayed
SP-6 d0C2 Defective model selection data is displayed
SP-7 d021 Abnormality in solenoid [I] system is displayed
SP-8 d022 Abnormality in solenoid [2] system is displayed
SP-9 d023 Abnormality in solenoid [3] system is displayed
SP-10 d0C1 Disconnection in network is displayed
SP-11 d0C3 Defective travel speed compensation data is displayed
TROUBLESHOOTING OF PAYLOAD METER (PRINTER TYPE) SYSTEM (LP MODE)
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER (PRINTER TYPE)
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER (PRINTER TYPE) SYSTEM
LP-1 No display appears when starting switch is turned ON
LP-2 Calibration demand (CAL flashes) is shown continuously after starting switch is turned ON
LP-3 Calibration cannot be carried out
LP-4 After starting switch is turned ON, all external display lamps do not light up
LP-5 Condition does not exist for lamps to light up, but external display lamps light up
LP-6 Level of lighting up of external display lamps is not correct
LP-7 Abnormality in display logic
LP-8 E01 - E04 is displayed
LP-9 E11 - E14 is displayed
LP-10 E21 - E28 is displayed by sensor check
LP-11 E31 is displayed
LP-12 E32 is displayed
LP-13 E41 is displayed
LP-14 E42 is displayed
LP-15 Printer does not print anything (blank paper comes out)
LP-16 Printer prints only "NO DATA”
LP-17 Printer does not print out when PRT switch is pressed
LP-18 “PAPE” flashes
LP-19 Time is wrong
LP-20 E33 is displayed
TROUBLESHOOTING OF PAYLOAD METER II (CARD TYPE) SYSTEM (LC MODE)
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER II (CARD TYPE)
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER II (CARD TYPE) SYSTEM
LC-1 No display appears when starting switch is turned ON
LC-2 After starting switch is turned ON, all external display lamps do not light up
LC-3 Condition does not exist for lamps to light up, but external display lamps light up
LC-4 Level of lighting up of external display lamps is not correct
LC-5 Cycle data is not recorded, ON/OFF data is not recorded: Battery charge signal system: Engine not started is detected
LC-6 Calibration cannot be carried out, time display does not match conditions Shift lever N position signal system
LC-7 Abnormality in display logic
LC-8 b-FL remains displayed and does not change Body FLOAT relay system: When not dumping and when dump lever is not at FLOAT position
LC-9 F-09 is displayed: Drop in voltage of back-up battery built into payload meter
LC-10 FULL display appears
LC-11 F-20 is displayed Sensor power source voltage system
LC-12 F-21 - F-24 is displayed: Disconnection, short circuit with ground in suspension pressure sensor system
LC-13 F-25 - F-28 is displayed: Short circuit in suspension pressure sensor system power source *
LC-14 F.CAL is displayed: Calibration not carried out, damaged data inside payload meter
LC-15 F-41 - F-45 is displayed: Short circuit in external display lamp system power source
LC-16 L-bad is displayed: Cycle data saved when machine was swaying
LC-17 Machine is not loading but external display lamps give load estimate display. After loading, display switches to time disp
LC-18 F-31 is displayed: Disconnection, short circuit with ground in clinometer system
LC-19 F-32 is displayed: Short circuit with clinometer system power source
LC-20 F-18 is displayed: Disconnection in battery charge signal
TROUBLESHOOTING OF ARSC [AUTOMATIC RETARDER SPEED CONTROLLER] SYSTEM (R MODE)
OUTLINE
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM
R-1 0.1 (Abnormality in power source voltage) is displayed
R-2 1.0 (Disconnection in engine speed sensor system) is displayed
R-3 1.3 (Disconnection in transmission output shaft speed sensor system) is displayed
R-4 1.5 (Failure in retarder oil temperature sensor system) is displayed
R-5 1.7 (Failure in accelerator signal system) is displayed
R-6 1.8 (Failure in suspension pressure sensor “left” system) is displayed
R-7 1.9 (Failure in suspension pressure sensor “right” system) is displayed
R-8 4.2 (Disconnection in exhaust brake selector signal system) is displayed
R-9 4.3 (Disconnection in ARSC caution lamp system) is displayed
R-10 4.4 (Disconnection in READY lamp system) is displayed
R-11 4.5 (Disconnection in panel caution and buzzer system) is displayed
R-12 5.2 (Short circuit with ground in exhaust brake selector signal output system) is displayed
R-13 5.3 (Short circuit with ground in ARSC caution lamp system) is displayed
R-14 5.4 (Short circuit with ground in READY output circuit system) is displayed
R-15 5.5 (Short circuit with ground in panel caution lamp and buzzer output system) is displayed
R-16 6.0 (Failure in engine speed system) is displayed
R-17 7.0 (Disconnection in travel speed display UP output system) is displayed
R-18 7.1 (Disconnection in travel speed display DOWN output system) is displayed
R-19 7.2 (Disconnection in travel speed display CLEAR output system) is displayed
R-20 7.3 (Short circuit with ground in travel speed display UP output system) is displayed
R-21 7.4 (Short circuit with ground in travel speed display DOWN output system) is displayed
R-22 7.5 (Short circuit with ground in travel speed display CLEAR output system) is displayed
R-23 8.1 (Short circuit with ground in pressure control valve system) is displayed
R-24 8.3 (Disconnection in pressure control valve system) is displayed
R-25 8.5 (Failure in pressure control valve (pressure control valve remains open) is displayed
R-26 8.7 (Failure in pressure control valve (pressure control valve does not open) is displayed
R-27 8.9 (Short circuit with ground in pressure switch valve system) is displayed
R-28 9.0 (Disconnection in pressure switch valve system) is displayed
R-29 9.1 (Failure in pressure switch valve system (remains open)) is displayed
R-30 9.2 (Failure in pressure switch valve system (does not open)) is displayed
R-31 9.3 (Disconnection in system switch system) is displayed
R-32 9.4 (Short circuit with ground in system switch system) is displayed
R-33 9.5 (Disconnection, short circuit with ground in travel speed set- ting switch system) is displayed
R-101 Set speed cannot be set
R-102 Failure code is always cleared (controller display window always shows ‘I- -” or failure code cannot be cleared
R-103 Effect of retarder is too strong when machine is empty, or too weak when machine is loaded (does not judge loaded/unloaded
R-104 Abnormality appears in other controller
R-105 When traveling downhill, even when set speed is exceeded, no control is carried out
R-106 Monitor lamp (buzzer) stays on (or off)
R-107 READY lamp does not light up (or stays lighted up)
R-108 Exhaust brake is actuated when exhaust brake switch is OFF; or exhaust brake is not actuated when exhaust brake switch is ON
R-109 There is difference between travel speed rod value and actual machine value
R-110 Retarder lamp does not light up, or stays lighted up
R-111 Travel speed display always gives display (or does not give any display)
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
H-1 Machine does not start
H-2 Machine does not travel smoothly (machine jerks)
H-3 Lock-up clutch cannot be disengaged (engine stalls)
H-4 Excessive shock when starting or shifting
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, or effective only on one side
H-11 Rear brake is ineffective, or effective only on one side
H-12 Steering wheel is heavy
H-13 Steering wheel does not work
H-14 Steering wheel vibrates
H-15 Hoist cylinder lacks lifting force (lifting speed)
H-16 Hoist cylinder does not work
H-17 Excessive hydraulic drift of dump body
H-18 Air pressure does not rise (Low-pressure buzzer does not stop. Air gauge does not rise to green range.)
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (P MODE)
METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MONITOR PANEL AND CONTROLLERS
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM
P-1 Check pattern for wiring harnesses between modules
P-2 Nothing on monitor panel works
P-3 LH, RH module and fuel gauge do not work
P-4 LH, RH module and fuel gauge do not work
P-5 RH module does not work
P-6 LH module does not work
P-7 Travel calculator does not work
P-8 Service meter display does not work correctly
P-9 Central warning lamp does not work, or monitor panel detects failure code (monitor panel display) [A002]
P-10 Central warning lamp stays lighted up
P-11 Alarm buzzer does not work, or monitor panel detects [A003]
P-12 Alarm buzzer continues to sound
P-13 All data from shift controller (speedometer, tachometer, shift indicator, etc.) are abnormal (nothing is displayed, or does
P-14 Suspension mode, power/economy mode displays are abnormal (nothing is displayed, or display does not change), or monitor pa
P-15 Gauge displays are abnormal (nothing is displayed, or display does not change)
P-16 Cooling water level drop caution lamp does not work, or monitor panel detects service code [A001]
P-17 Cooling water level drop caution lamp stays lighted up
P-18 Emergency steering pilot lamp does not work, or monitor panel detects service code [A001]
P-19 Emergency steering pilot lamp stays lighted up
P-20 Engine oil pressure drop caution lamp does not work, or monitor panel detects service code [A001]
P-21 Engine oil pressure drop caution lamp stays lighted up
P-22 Exhaust brake pilot lamp does not work, or monitor panel detects service code [A001]
P-23 Exhaust brake pilot lamp stays lighted up
P-24 Charging circuit abnormality caution lamp does not work, or monitor panel detects service code [A001]
P-25 Charging circuit abnormality caution lamp stays lighted up
P-26 Transmission filter clogging caution lamp does not work, or monitor panel detects service code [A001]
P-27 Transmission filter clogging caution lamp stays lighted up
P-28 Brake stroke caution lamp does not work, or monitor panel detects [A001]
P-29 Brake stroke caution lamp stays lighted up
P-30 Preheating switch pilot lamp does not work, or monitor panel detects [A001]
P-31 Preheating switch pilot lamp stays lighted up
P-32 Tit warning lamp does not work, or monitor panel detects [A001]
P-33 Tilt warning lamp stays lighted up
P-34 Body FLOAT (except FLOAT) pilot lamp does not work, or monitor panel [A001]
P-35 Body FLOAT (except FLOAT) pilot lamp stays lighted up
P-36 Rear brake pilot lamp does not work, or monitor panel detects service [A001]
P-37 Rear brake pilot lamp stays lighted up
P-38 Parking brake pilot lamp does not work, or monitor panel detects [A001]
P-39 Parking brake pilot lamp stays lighted up
P-40 Maintenance caution lamp does not work, or monitor panel detects [A001]
P-41 Maintenance caution lamp stays lighted up
P-42 Steering oil temperature caution lamp does not work, or monitor panel [A001]
P-43 Steering oil temperature caution lamp stays lighted up
P-44 Differential lock pilot lamp does not work, or monitor panel detects service code [A001]
P-45 Differential lock pilot lamp stays lighted up
P-46 High beam display does not light up
P-47 Turn signal lamp (right) does not light up
P-48 Turn signal lamp (left) does not light up
P-49 Lamp check switch does not work
P-50 AISS switch does not work
P-51 Exhaust brake switch does not work
P-52 Mode change switch (1) does not work
P-53 Mode change switch (2) does not work
P-54 KPH/MPH speedometer unit selector does not work
P-55 Defective operation of all switch inputs
P-56 Monitor panel detects service or codes [A014] or [A019]
P-57 Monitor panel detects service code [A015]
P-58 Monitor panel detects service code [A011]
P-59 Monitor panel detects service code [A012]
P-60 Monitor panel detects service code [A000]

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
STARTING MOTOR
REMOVAL AND INSTALLATION
ALTERNATOR
REMOVAL AND INSTALLATION
ENGINE OIL COOLER
REMOVAL AND INSTALLATION
AIR CONDITIONER COMPRESSOR
REMOVAL AND INSTALLATION
FUEL INJECTION PUMP
REMOVAL
INSTALLATION
AIR COMPRESSOR
REMOVAL AND INSTALLATION
AIR CONDITIONER CONDENSER
REMOVAL AND INSTALLATION
WATER PUMP
REMOVAL AND INSTALLATION
AFTERCOOLER CORE
REMOVAL AND INSTALLATION
EXHAUST BRAKE CYLINDER
REMOVAL AND INSTALLATION
TURBOCHARGER
REMOVAL AND INSTALLATION
NOZZLE HOLDER
REMOVAL AND INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
ENGINE
REMOVAL
INSTALLATION
ENGINE FRONT SEAL
REMOVAL
INSTALLATION
ENGINE REAR SEAL
REMOVAL AND INSTALLATION
RADIATOR, TORQUE CONVERTER OIL COOLER
REMOVAL
INSTALLATION
BRAKE OIL COOLER
REMOVAL AND INSTALLATION
OUTPUT SHAFT
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
TORQUE CONVERTER, TRANSMISSION
REMOVAL
INSTALLATION
PROCEDURE FOR CENTERING THE ENGINE ASSEMBLY AND TORQUE CONVERTER, TRANSMISSION ASSEMBLY
TORQUE CONVERTER, CONTROL VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER AND TRANSMISSION
DISCONNECTION
CONNECTION
TORQUE CONVERTER, PTO
DISASSEMBLY
ASSEMBLY
TRANSMISSION
DISASSEMBLY
ASSEMBLY
TRANSMISSION CONTROL VALVE (ECMV ASSEMBLY)
REMOVAL AND INSTALLATION
ECMV
DISASSEMBLY AND ASSEMBLY
DIFFERENTIAL
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
FRONT WHEEL
REMOVAL AND INSTALLATION
REAR WHEEL
REMOVAL
INSTALLATION
FRONT BRAKE CALIPER PAD
REMOVAL AND INSTALLATION
FRONT BRAKE CALIPER
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
FRONT WHEEL HUB
DISASSEMBLY
ASSEMBLY
FINAL DRIVE CARRIER
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
DISASSEMBLY
ASSEMBLY
REAR BRAKE
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
PARKING BRAKE PAD
REMOVAL AND INSTALLATION
PARKING BRAKE CALIPER
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
FRONT SUSPENSION CYLINDER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
VARIABLE DAMPING SELECTOR VALVE
DISASSEMBLY
ASSEMBLY
REAR SUSPENSION CYLINDER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
AIR GOVERNOR
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
BRAKE VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
PARKING BRAKE CHAMBER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
FRONT BRAKE CHAMBER
REMOVAL AND INSTALLAITON
DISASSEMBLY
ASSEMBLY
REAR BRAKE CHAMBER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
SLACK ADJUSTER
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
TRANSMISSION LUBRICATION, RETARDER BRAKE PUMP
REMOVAL AND INSTALLATION
BRAKE COOLING PUMP
REMOVAL AND INSTALLATION
HOIST, STEERING PUMP
REMOVAL AND INSTALLATION
EMERGENCY STEERING MOTOR PUMP
REMOVAL AND INSTALLATION
BRAKE CONTROL VALVE
REMOVAL AND INSTALLATION
STEERING VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
DEMAND VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
RELIEF VALVE
DISASSEMBLY AND ASSEMBLY
HOIST VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
STEERING CYLINDER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
HOIST CYLINDER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
BODY
REMOVAL
INSTALLATION
TRANSMISSION CONTROLLER
REMOVAL AND INSTALLATION
SUSPENSION CONTROLLER
REMOVAL AND INSTALLATION

40 MAINTENANCE STANDARD
OUTPUT SHAFT
TORQUE CONVERTER VALVE
TORQUE CONVERTER
TRANSMISSION
ECMV
FRONT AXLE
REAR AXLE SUPPORT
DIFFERENTIAL
FINAL DRIVE
FRONT BRAKE
REAR BRAKE
PARKING BRAKE
STEERING LINKAGE
FRONT SUSPENSION CYLINDER
REAR SUSPENSION CYLINDER
PARKING BRAKE CHAMBER
SLACK ADJUSTER
HYDRAULIC PUMP (For steering, work equipment, brake cooling)
DEMAND VALVE
CROSS-OVER RELIEF VALVE
HOIST VALVE
STEERING CYLINDER
HOIST CYLINDER

90 OTHER
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (1/3)
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (2/3)
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (3/3)
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (1/2)
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (2/2)
ENGINE CONTROL SYSTEM
ELECTRICAL CIRCUIT DIAGRAM
AUTOMATIC RETARD SPEED CONTROL SYSTEM
ELECTRICAL CIRCUIT DIAGRAM
AUTOMATIC SHIFT CONTROL SYSTEM
ELECTRICAL CIRCUIT DIAGRAM
AUTOMATIC SUSPENSION SYSTEM
SYSTEM CIRCUIT DIAGRAM (1/2)
SYSTEM CIRCUIT DIAGRAM (2/2)
PAYLOAD METER (Printer Type)
ELECTRICAL CIRCUIT DIAGRAM
PAYLOAD METER II (Card Type)
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM

-