Komatsu HD465-7, HD605-7 Dump Truck Service Repair Shop Manual (7001 and up) - SEBM027611

This Complete Service Repair Workshop Manual PDF Download for the Komatsu Dump Truck HD465-7 & HD605-7 (SN: 7001 and up) 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 HD465-7 Dump Truck
Serial Numbers : 7001 and up

Komatsu HD605-7 Dump Truck
Serial Numbers : 7001 and up


TABLE OF CONTENTS :

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


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM027611
Total Pages : 1190


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.

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COVER
CONTENTS
01 GENERAL
SPECIFICATION DRAWINGS
SPECIFICATIONS
WEIGHT TABLE
FUEL,COOLANT AND LUBRICANTS

10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD
RADIATOR,TORQUE CONVERTER OIL COOLER,AFTER COOLER,WORK EQUIPMENT OIL COOLER,FUEL COOLER
BRAKE OIL COOLER
POWER TRAIN SKELETON
OUTPUT SHAFT
DRIVE SHAFT
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING
TORQUE CONVERTER
TRANSMISSION
TRANSMISSION VALVE
ECMV
AXLE
DIFFERENTIAL
FINAL DRIVE
WHEELS
SUSPENSION
SUSPENSION CYLINDER
REAR AXLE SUPPORT
STEERING COLUMN
STEERING LINKAGE
BRAKE PIPING
BRAKE VALVE
EMERGENCY BRAKE VALVE
RELAY VALVE
FRONT BRAKE OFF VALVE
ACCUMULATOR CHARGE VALVE
ACCUMULATOR
SLACK ADJUSTER
BRAKE
PROPORTIONAL REDUCING VALVE
PARKING BRAKE SOLENOID VALVE
STEERING AND HOIST HYDRAULIC PIPING
STEERING AND HOIST HYDRAULIC SYSTEM DIAGRAM
DUMP BODY CONTROL
HYDRAULIC TANK
STEERING CONTROL VALVE
CROSSOVER RELIEF VALVE
STEERING CYLINDER
DEMAND VALVE
HOIST VALVE
EPC VALVE
HOIST CYLINDER
HYDRAULIC PUMP
AIR CONDITIONER
MACHINE MONITOR SYSTEM
ENGINE CONTROL SYSTEM
AUTOMATIC SHIFT CONTROL SYSTEM
PAYLOAD METER Ⅱ(CARD TYPE)
AUTOMATIC EMERGENCY STEERING SYSTEM
AUTOMATIC SUSPENSION SYSTEM
RETARDER CONTROL SYSTEM
SENSORS,SWITCHES
DUMP CONTROL LEVER
VHMS CONTROLLER
BLOW-BY PRESSURE SENSOR
ENGINE OIL PRESSURE SENSOR
EXHAUST TEMPERATURE SENSOR/AMP
AMBIENT TEMPERATURE SENSOR
COMMUNICATIONS (ORB・・・ORBCOMM) CONTROLLER/ANTENNA
PAYLOAD METER (HAVING VHMS)

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS
TESTING AND ADJUSTING
TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING
MEASURING ENGINE SPEED
ADJUSTING ENGINE SPEED SENSOR
MEASURING ENGINE OIL PRESSURE
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING EXHAUST TEMPERATURE
MEASURING BLOW-BY PRESSURE
TROUBLESHOOTING OF INJECTOR
MEASURING COMPRESSION PRESSURE
HANDLING EQUIPMENT IN FUEL SYSTEM
MEASURING FUEL PUMP OUTLET PORT PRESSURE
MEASURING FUEL PUMP INLET PORT PRESSURE
VISUAL INSPECTION OF RETURN FUEL
ADJUSTING INJECTOR SET LOAD
BLEEDING AIR FROM FUEL CIRCUIT
MEASURING EXHAUST COLOR
ADJUSTING VALVE CLEARANCE
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING,AIR CONDITIONER COMPRESSOR BELT TENSION
MEASURING POWER TRAIN OIL PRESSURE
ADJUSTING TRANSMISSION SPEED SENSOR
INSPECTING BRAKE OIL PRESSURE
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 ADUSTING FRONT SUSPENSION CYLINDER
TESTING AND ADJUSTING INVERTED TYPE REAR SUSPENSION CYLINDER
TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER(MODE SELECTOR HYDRAULIC CYLNDER)
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
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM
ADJUSTING MACHINE MONITOR(EMMS)
ADJUSTING TRANSMISSION CONTROLLER
INITIAL SETTING OF PAYLOAD METER
SETTING OF CARD-TYPE PAYLOAD METER AFTER INSTALLATION OR REPLACEMENT
SPECIAL FUNCTIONS OF MACHINE MONITOR(EMMS)
BASIC PRECAUTIONS
OUTLINE
SETTING UP VHMS CONTROLLER
COLLECTION,TRANSMISSION OF DATA
INSPECTION AND MAINTENANCE
REPLACING PARTS
PROCEDURE FOR INITIAL SETUP OF VHMS
PROCEDURE FOR OPENING ORBCOMM SERVICE
PERFORMING PM-CLINIC USING MANUAL SNAPSHOT(=QUICK PM)
PM CLINIC SERVICE
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
CATEGORIES, PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T-ADAPTER TABLE
TYPES AND LOCATIONS OF CONNECTORS
CONNECTOR ARRANGEMENT LOCATION
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM(ENG MODE)
ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL
INFORMATION IN TROUBLESHOOTING TABLE
[C111KT] ABNORMALITY IN ENGINE CONTROLLER MEMORY
[C112LK] ABNORMALITY IN TIMING RAIL ACTUATOR
[C113KZ] ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM
[C115KZ] ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS
[C116KX] ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM
[C117KX] ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM
[C118KX] ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM
[C119KX] ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM
[C121LC] ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEMS
[C122KX] ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR SYSTEM
[C123KX] ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR SYSTEM
[C131KX] ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM
[C132KX] ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM
[C135KX] ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM
[C141KX] ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM
[C143ZG] LOWERING OF ENGINE OIL PRESSURE
[C144KX] ABNORMALLY HIGH LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM
[C145KX] ABNORMALLY LOW LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM
[C148KX] ABNORMALITY IN FM THROTTLE:OUT OF INPUT SIGNAL RANGE
[C151NS] RISE OF ENGINE COOLANT TEMPERATURE
[C153KX] ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM
[C154KX] ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM
[C221KX] ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM
[C222KX] ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM
[C234NI] OVER-SPEED
[C254KZ] ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE
[C259FS] ABNORMALITY IN FUEL SHUT-OFF VALVE
[C261NS] ABNORMAL RISE OF FUEL TEMPERATURE
[C263KX] ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM
[C265KX] ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM
[C316KZ] ABNORMAL CURRENT OF FUEL PUMP ACTUATOR
[C318LK] ABNORMALITY IN FUEL PUMP ACTUATOR
[C346KT] ABNORMALITY IN POWER-DOWN UNIT OF ENGINE CONTROLLER
[C423L6] ABNORMALITY IN IN-RANGE OF TIMING RAIL PRESSURE SENSOR SYSTEM
[C431L4] ABNORMALITY IN IDLING VALIDATION SWITCH SYSTEM:※ SEE SEPARATE LIST(L4)(BOTH SIGNAL VOLTAGES OF 2 SYSTEMS ARE SENSED)
[C432L5] ERROR IN IDLING VALIDATION PROCESS(※ SEE SEPARATE LIST(L5))
[C441KK] ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM
[C442KG] ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGE SYSTEM
[C451KX] ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM
[C452KX] ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM
[C455KZ] ABNORMAL CURRENT OF FUEL RAIL ACTUATOR
[C467LK] ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL
[C468LK] ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL
[C514LK] ABNORMALITY IN FUEL RAIL ACTUATOR
[C551L4] ABNORMALITY IN IDLING VALIDATION SWITCH SYSTEM:※ SEE SEPARATE LIST(L4)(EITHER SIGNAL VOLTAGE OF 2 SYSTEMS IS NOT SENSED)
[C554L6] ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE SENSOR SYSTEM
ENG-1 ENGINE DOES NOT START
ENG-2 FAILURE IN PREHEATING
a) ENGINE IS NOT PREHEATED
b) PREHEATING IS ACTUATED EVEN UNDER NON-ACTUATION CONDITIONS FOR PREHEATING
ENG-3 AISS FUNCTION DOES NOT WORK NORMALLY
a) WHEN AISS SWITCH IS SET IN AUTO,LOW SPEED CONTROL IS SELECTED
b) WHEN AISS SWITCH IS SET IN LOW SPEED,AUTO CONTROL IS SELECTED
TROUBLESHOOTING FOR TRANSMISSION CONTROLLER SYSTEM (TM MODE)
ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL
INFORMATION IN TROUBLESHOOTING TABLE
TROUBLE CODE TABLE
[1380MW] LOCKUP CLUTCH・SLIP(MW)
[1500L0] DETECTION OF DOUBLE ENGAGEMENT・※ SEE SEPARATE LIST(L0)
[15B0NX] CLOGGING OF TRANSMISSION OIL FILTER・CLOGGING(NX)
[15E0KM] R→F GEAR SHIFT ABUSE 1・MISTAKE IN OPERATION OR SETTING (KM)
[15E7KM] R→F GEAR SHIFT ABUSE 2・MISTAKE IN OPERATION OR SETTING (KM)
[15G0MW] R CLUTCH・SLIP (MW)
[15H0MW] HI CLUTCH・SLIP (MW)
[15J0MW] LO CLUTCH・SLIP(MW)
[15K0MW] 1ST CLUTCH・SLIP(MW)
[15L0MW] 2ND CLUTCH・SLIP(MW)
[15M0MW] 3RD CLUTCH・SLIP(MW)
[15N0MW] 4TH CLUTCH・SLIP(MW)
[15SBL1] R CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1)
[15SBMA] R CLUTCH SOLENOID・※ MALFUNCTION(MA)
[15SCL1] HI CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1)
[15SCMA] HI CLUTCH SOLENOID・MALFUNCTION(MA)
[15SDL1] LO CLUTCH SOLENOID・※ SEE SEPARATE LIST (L1)
[15SDMA] LO CLUTCH SOLENOID・MALFUNCTION(MA)
[15SEL1] 1ST CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1)
[15SEMA] 1ST CLUTCH SOLENOID・MALFUNCTION(MA)
[15SFL1] 2ND CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1)
[15SFMA] 2ND CLUTCH SOLENOID・MALFUNCTION(MA)
[15SGL1] 3RD CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1)
[15SGMA] 3RD CLUTCH SOLENOID・MALFUNCTION(MA)
[15SHL1] 4TH CLUTCH SOLENOID・※ SEE SEPARATE LIST(L1)
[15SHMA] 4TH CLUTCH SOLENOID・MALFUNCTION(MA)
[15SJL1] LOCKUP CLUTCH SOLENOID・15SJ(L1)
[15SJMA] LOCKUP CLUTCH SOLENOID・15SJ(MA)
[2F00KM] PARKING BRAKE・MISTAKE IN OPERATION OR SETTING(KM)
[989A00] ENGINE OVERRUN PREVENTION COMMAND SIGNAL・OPERATION(00)
[989AKZ] ENGINE OVERRUN PREVENTION COMMAND SIGNAL・DISCONNECTION OR SHORT CIRCUIT(KZ)
[AA10NX] AIR CLEANER ELEMENT・CLOGGING(NX)
[AB00MA] ALTERNATOR・MALFUNCTION(MA)
[B@CZK] LOWERING OF RADIATOR WATER:LOWERING OF LEVER (ZK)
[D1B0KZ] TRANSMISSION CONTROLLER CUTOUT: DISCONNECTION OR SHORT CIRCUIT (KZ)
[D5ZMKZ] DISCONNECTION,GROUNDING FAULT,OR SHORT CIRCUIT IN ENGINE OUTPUT MODE COMMAND LINE・DISCONNECTION OR SHORT CIRCUIT(KZ)
[DAQ0KK] TRANSMISSION CONTROLLER・LOWERING OF SOURCE/INPUT VOLTAGE(KK)
[DAQ1KK] MAIN POWER LINE OF TRANSMISSION CONTROLLER・LOWERING OF SOURCE/INPUT VOLTAGE (KK)
[DAQ2KK] TRANSMISSION CONTROLLER LOAD POWER LINE・LOWERING OF SOURCE/INPUT VOLTAGE(KK)
[DAQ3KK] DIRECT LINE OF TRANSMISSION CONTROLLER BATTERY・LOWERING OF SOURCE/INPUT VOLTAGE (KK)
[DAQ9KM] TRANSMISSION CONTROLLER WIRING HARNESS・MISTAKE IN OPERATION OR SETTING(KM)
[DAQ9KQ] TRANSMISSION CONTROLLER WIRING HARNESS・DISAGREEMENT OF MODEL SELECTION SIGNALS(KQ)
[DAQAKQ] TRANSMISSION CONTROLLER ROTARY SWITCH・DISAGREEMENT OF MODEL SELECTION SIGNALS(KQ)
[DAQSMA] TRANSMISSION CONTROLLER・MALFUNCTION(MA)
[DDTGKA] LOCKUP CLUTCH FILL SWITCH:DISCONNECTION(KA)
[DDTHKA] HI CLUTCH FILL SWITCH:DISCONNECTION(KA)
[DDTJKA] LO CLUTCH FILL SWITCH:DISCONNECTION(KA)
[DDTKKA] 1ST CLUTCH FILL SWITCH:DISCONNECTION (KA)
[DDTLKA] 2ND CLUTCH FILL SWITCH:DISCONNECTION(KA)
[DDTMKA] 3RD CLUTCH FILL SWITCH:DISCONNECTION(KA)
[DDTNKA] R CLUTCH FILL SWITCH:DISCONNECTION(KA)
[DDTRKA] 4TH CLUTCH FILL SWITCH:DISCONNECTION(KA)
[DF10KA] SHIFT LEVER:DISCONNECTION(KA)
[DF10KB] SHIFT LEVER:SHORT CIRCUIT(KB)
[DGF1KX] TRANSMISSION VALVE OIL TEMPERATURE SENSOR:OUT OF INPUT SIGNAL RANGE(KX)
[DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR:OUT OF INPUTSIGNAL RANGE(KX)
[DHT5KX] TORQUE CONVERTER OIL PRESSURE SENSOR:OUT OF INPUT SIGNAL RANGE(KX)
[DHT5L6] TORQUE CONVERTER OIL PRESSURE SENSOR:※ SEE SEPARATE LIST(L6)
[DJF1KA] FUEL LEVEL SENSOR:DISCONNECTION(KA)
[DK11KX] THROTTLE ANGLE SENSOR:OUT OF INPUT SIGNAL RANGE(KX)
[DLE2KA] ENGINE SPEED SENSOR:DISCONNECTION(KA)
[DLE2LC] ENGINE SPEED SENSOR:※ SEE SEPARATE LIST(LC)
[DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR:DISCONNECTION(KA)
[DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR:※ SEE SEPARATE LIST(LC)
[DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR:DISCONNECTION(KA)
[DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR:※ SEE SEPARATE LIST(LC)
[DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:DISCONNECTION(KA)
[DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:※ SEE SEPARATE LIST(LC)
[DXH1KA] DISCONNECTION IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID:DISCONNECTION(KA)
[DXH1KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID:SHORT CIRCUIT (KB)
[DXH2KA] DISCONNECTION IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID:DISCONNECTION(KA)
[DXH2KB] SHORT CIRCUIT OF HI CLUTCH SOLENOID:SHORT CIRCUIT(KB)
[DXH3KA] DISCONNECTION IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID:DISCONNECTION(KA)
[DXH3KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID:SHORT CIRCUIT(KB)
[DXH4KA] DISCONNECTION IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID:DISCONNECTION(KA)
[DXH4KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID:SHORT CIRCUIT(KB)
[DXH5KA] DISCONNECTION IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID:DISCONNECTION(KA)
[DXH5KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID:SHORT CIRCUIT(KB)
[DXH6KA] DISCONNECTION IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID:DISCONNECTION(KA)
[DXH6KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID:SHORT CIRCUIT(KB)
[DXH7KA] DISCONNECTION IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID:DISCONNECTION(KA)
[DXH7KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID:SHORT CIRCUIT(KB)
[DXHHKA] DISCONNECTION IN OUTPUT CIRCUIT OF 4TH CLUTCH SOLENOID:DISCONNECTION(KA)
[DXHHKB] SHORT CIRCUIT OF 4TH CLUTCH SOLENOID:SHORT CIRCUIT(KB)
TM-1 FUEL LEVEL GAUGE DOES NOT OPERATE NORMALLY(IT ALWAYS INDICATES"FULL")
TM-2 ABNORMALITY IN BACKUP LAMP AND BACKUP BUZZER
a) WHEN THE SHIFT LEVER IS SET IN THE "R" POSITION,THE BACKUP LAMP AND BACKUP BUZZER ARE NOT TURNER ON
b) BACKUP LAMP IS NOT TURNED ON(BACKUP BUZZER IS NORMAL)
c) BACKUP BUZZER IS NOT TURNED ON(BACKUP LAMP IS NORMAL)
d) WHILE SHIFT LEVER IS NOT OPERATED,BACKUP LAMP AND BACKUP BUZZER ARE TURNED ON
TROUBLESHOOTING FOR RETARDER CONTROLLER SYSTEM(BK MODE)
ELECTRICAL SYSTEM DIAGRAM RELATED TO RETARDER CONTROL
INFORMATION IN TROUBLESHOOTING TABLE
TROUBLE CODE TABLE
[2G42ZG] ACCUMULATOR(FRONT):LOWERING OF OIL PRESSURE(ZG)
[2G43ZG] ACCUMULATOR(REAR):LOWERING OF OIL PRESSURE(ZG)
[D1C0KZ] BRAKE CUTOUT RELAY:DISCONNECTION OR SHORT CIRCUIT(KZ)
[D5ZNKZ] FAILURE OF FRONT BRAKE CUTOUT OUTPUT SYSTEM(DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT)(OPT):DISCONNECTION OR SHORT CIRCUIT(KZ)
[DB10KK] RETARDER CONTROLLER:LOWERING OF SOURCE/INPUT VOLTAGE(KK)
[DB11KK] MAIN POWER LINE OF RETARDER CONTROLLER:LOWERING OF SOURCE/INPUT VOLTAGE(KK)
[DB12KK] RETARDER CONTROLLER LOAD POWER LINE:LOWERING OF SOURCE/INPUT VOLTAGE(KK)
[DB13KK] DIRECT LINE OF RETARDER CONTROLLER BATTERY:LOWERING OF SOURCE/INPUT VOLTAGE(KK)
[DB19KM] RETARDER CONTROLLER WIRING HARNESS:MISTAKE IN OPERATION OR SETTING(KM)
[DB1SKQ] WRONG INFORMATION ON MODEL SELECTION:DISAGREEMENT OF MODEL SELECTION SIGNALS(KQ)
[DDD7KX] FAILURE IN TRAVEL SPEED SET SWITCH SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX)
[DDD8KA] ARSC SYSTEM SWITCH SYSTEM:DISCONNECTION(KA)
[DDD8KB] ARSC SYSTEM SWITCH SYSTEM:SHORT CIRCUIT(KB)
[dGR2L8] FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM:※ SEE SEPARATE LIST(L8)
[DGR2L8] BRAKE OIL TEMPERATURE SENSOR(REAR):※ SEE SEPARATE LIST(L8)
[dHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR(FR) SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX)
[DHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR(FR) SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX)
[dHP5KX] FAILURE IN SUSPENSION PRESSURE SENSOR(FL) SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX)
[DHP5KX] FAIURE IN SUSPENSION PRESSURE SENSOR (FL) SYSTEM(OPT):OUT OF INPUT SIGNAL RANGE(KX)
[DHU2KX] ACCUMULATOR OIL PRESSURE SENSOR (FRONT):OUT OF INPUT SIGNAL RANGE (KX)
[DHU3KX] ACCUMULATOR OIL PRESSURE SENSOR (REAR):OUT OF INPUT SIGNAL RANGE (KX)
[dK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (OPT):OUT OF INPUT SIGNAL RANGE (KX)
[DK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (OPT):OUT OF INPUT SIGNAL RANGE (KX)
[DK51L5] RETARDER LEVER POTENTIOMETER:※ SEE SEPARATE LIST (L5)
[DK52KX] DUMP LEVER POTENTIOMETER 1:OUT OF INPUT SIGNAL RANGE (KX)
[DK53L8] DUMP LEVER POTENTIOMETER 2:※ SEE SEPARATE LIST (L8)
[DK54KX] BODY POSITIONER SENSOR:OUT OF INPUT SIGNAL RANGE (KX)
[DKD0L6] FAILURE IN STEERING SPEED SENSOR (OPT):※ SEE SEPARATE LIST (L6)
[dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:DISCONNECTION (KA)
[DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:DISCONNECTION (KA)
[DW35KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 1 (OPT)(DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT):DISCONNECTION OR SHORT CIRCUIT (KZ)
[DW36KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 2 (OPT) (DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT):DISCONNECTION OR SHORT CIRCUIT (KZ)
[DW72KZ] FAILURE IN KICK-OUT SOLENOID OUTPUT SYSTEM (D_OUT3)(DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT):DISCONNECTION OR SHORT CIRCUIT (KZ)
[DW73KZ] FAILURE IN HOIST SELECT VALVE OUTPUT SYSTEM (D_OUT5)(DISCONNECTION,GROUNDING FAULT,SHORT CIRCUIT):DISCONNECTION OR SHORT CIRCUIT (KZ)
[DK11K4] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL:UNCONTROLLABLE (K4)
[DX11KA] DISCONNECTION IN OUTPUT CIRCUIT OF ELECTROMAGNETIC PROPORTIONAL PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2):DISCONNECTION (KA)
[DX11KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF ELECTROMAGNETIC PROPORTIONAL PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2):SHORT CIRCUIT (KB)
[DX11KY] GROUNDING FAULT IN OUTPUT CIRCUIT OF ELECTROMAGNETIC PROPORTIONAL PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2):SHORT CIRCUIT WITH POWER LINE (KY)
[DX11MA] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL:MALFUNCTION (MA)
[DX13KA] DISCONNECTION IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):DISCONNECTION (KA)
[DX13KB] GROUNDING FAULT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):SHORT CIRCUIT (KB)
[DX13KY] SHORT CIRCUIT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):SHORT CIRCUIT WITH POWER LINE (KY)
BK-1 PARKING BRAKE DOES NOT OPERATE NORMALLY
a) WHEN THE PARKING BRAKE SWITCH IS SET IN THE OFF POSITION, THE PARKING BRAKE IS NOT RELEASED
b) WHEN THE PARKING BRAKE SWITCH IS SET IN THE PARK POSITION, THE PARKING BRAKE DOES NOT WORK
BK-2 RETARDER BRAKE OIL TEMPERATURE GAUGE DOES NOT OPERATE NORMALLY
BK-3 INCLINATION ALARM IS TURNED ON WHEN DUMP BODY IS RAISED (WHEN MACHINE IS NOT INCLINED MORE THAN 15°)
BK-4 TOUCH UP/DOWN AND CANCELLATION CANNOT BE PERFORMED
TROUBLESHOOTING FOR PAYLOAD METER SYSTEM (CARD TYPE) (LC MODE)
ELECTRICAL SYSTEM DIAGRAM RELATED TO PAYLOAD METER
SERVICE CODES OF PAYLOAD METER Ⅱ (CARD TYPE) AND CONTENTS OF SELF-DIAGNOSIS
INFORMATION IN TROUBLESHOOTING TABLE
TROUBLE CODE TABLE
LC-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM IS NOT DISPLAYED
LC-2 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL PILOT LAMPS DO NOT LIGHT UP
LC-3 EXTERNAL LAMPS LIGHT UP WHILE CONDITION FOR LIGHTING IS NOT SET
LC-4 LIGHTING LEVEL OF EXTERNAL PILOT LAMPS IS ABNORMAL
LC-5 CYCLE DATA AND ENGINE ON/OFF DATA NOT RECORDED (CHARGE LEVEL SIGNAL SYSTEM: JUDGES THAT ENGINE IS STOPPED)
LC-6 CALIBRATION CANNOT BE PERFORMED AND DISPLAYED CLOCK DOES NOT CONFORM TO CONDITION (SHIFT LEVER "N" POSITION SIGNAL SYSTEM)
LC-7 DISPLAYED LOGIC IS ABNORMAL
a) WHEN LOADED DUMP TRUCK STARTS TRAVELING, "O" IS KEPT DISPLAYED
b) AFTER LOADED DUMP TRUCK STARTS TRAVELING, DISPLAY OF ODOMETER DOES NOT INCREASE
c) WHEN TRAVEL SPEED EXCEEDS LIMIT SPEED, "SP:SP" DOES NOT GO OFF
d) INTEGRATED PAY LOAD IS NOT DIAPLAYED
e) DISPLAYED AND SAVED PAY LOAD IS NOT CORRECT
LC-8 PAYLOAD METER KEEPS DISPLAYING "b:FL" (BODY "FLOAT" SIGNAL SYSTEM: DUMP LEVER IS NOT IN "FLOAT" POSITION WHILE TRUCK IS NOT DUMPING)
LC-9 PAYLOAD METER DISPLAYS "F:09" (LOWERING OF INTERNAL BACKUP BATTERY VOLTAGE)
LC-10 PAYLOAD METER DISPLAYS "□:FULL" (DATA SAVING MEMORY IS FULL)
LC-11 PAYLOAD METER DISPLAYS "F-20":FAILURE IN POWER SOURCE OF SUSPENSION PRESSURE SENSOR AND CLINOMETER SYSTEM
LC-12 PAYLOAD METER DISPLAYS "F-21"-"F-24":DISCONNECTION OR GROUNDING FAULT IN SUSPENSION SENSOR SIGNAL SYSTEM
LC-13 PAYLOAD METER DISPLAYS "F-25"-"F-28":SHORT CIRCUIT WITH POWER SOURCE IN SUSPENSION SENSOR SIGNAL SYSTEM
LC-14 PAYLOAD METER DISPLAYS "F-CAL" (NEGLIGENCE OF CALIBRATION OR INTERNAL DAMAGE OF PAYLOAD METER)
LC-15 PAYLOAD METER DISPLAYS "F:43"-"F:45" (SHORT CIRCUIT WITH POWER SOURCE IN EXTERNAL PILOT LAMP RELAY SYSTEM)
LC-16 PAYLOAD METER DISPLAYS "L-bad" (CYCLE DATA WERE SAVED WHILE TRUCK BODY WAS PITCHING)
LC-17 EXTERNAL PILOT LAMP INDICATES FORECAST WHILE TRUCK IS NOT BEING LOADED OR CLOCK IS DISPLAYED WHILE TRUCK TRAVELS FOR 160 M AFTER IT IS LOADED
LC-18 PAYLOAD METER DISPLAYS"F-31":GROUNDING FAULT OR DISCONNECTION IN CLINOMETER SENSOR SIGNAL SYSTEM
LC-19 PAYLOAD METER DISPLAYS "F-32":SHORT CIRCUIT WITH POWER SOURCE IN CLINOMETER SENSOR SIGNAL SYSTEM
LC-20 PAYLOAD METER DISPLAYS "F:18" (DISCONNECTION IN CHARGE LEVEL SIGNAL SYSTEM)
TROUBLESHOOTING FOR MONITOR SYSTE (MON MODE)
ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR
INFORMATION IN TROUBLESHOOTING TABLE
TROUBLE CODE TABLE
[B@C7NS] REAR BRAKE OIL:OVERHEATING (NS)
[B@CENS] TORQUE CONVERTER:OVERHEATING (NS)
[DAF0KM] MONITOR PANEL:MISTAKE IN OPERATION OR SETTING (KM)
[DAF9KM] MONITOR PANEL:MISTAKE IN OPERATION OR SETTING (KM)
[DAFSKQ] MONITOR PANEL:DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ)
[DAQSKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN TRANSMISSION CONTROLLER AND MACHINE MONITOR) (KR)
[DASRKR] CAN COMMUNICATION・COMMUNICATION DEFECTIVE: ABNORMALITY IN OBJECTIVE COMPONENT (KR)
[DB1SKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN RETARDER CONTROLLER AND MACHINE MONITOR) (KR)
[DV00KB] SHORT CIRCUIT IN ALARM BUZZER OUTPUT・SHORT CIRCUIT (KB)
MON-1 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR DOES NOT DISPLAY ANY ITEM
MON-2 WHEN STARTING SWITCH IS TURNED OFF AND MACHINE MONITOR DOES NOT OPERATE NORMALLY
MON-3 ALARM BUZZER DEFECTIVE
a) ALARM BUZZER DOES NOT SOUND
b) ALARM BUZZER DOES NOT STOP SOUNDING
MON-4 ITEMS DISPLAYED BY GAUGES, CAUTION LAMPS, AND CHARACTER DISPLAY OF MACHINE MONITOR ARE ABNORMAL
a) ITEMS DISPLAYED BY GAUGES ARE DIFFERENT FROM MACHINE CONDITION
b) ITEMS DISPLAYED BY CAUTION LAMPS ARE DIFFERENT FROM MACHINE CONDITION
c) CHARACTER DISPLAY DOES NOT DISPLAY ANY ITEM OR IT DISPLAYS ABNORMALLY
MON-5 OPERATION OF MACHINE MONITOR CANNOT BE CHECKED NORMALLY
MON-6 DISPLAY OF CHARACTER DISPLAY CANNOT BE SELECTED NORMALLY
a) MACHINE MONITOR MODE SELECT SWITCH 1 SYSTEM IS ABNORMAL
b) MACHINE MONITOR MODE SELECT SWITCH 2 SYSTEM IS ABNORMAL
MON-7 POWER MODE SELECT FUNCTION DOES NOT WORK NORMALLY
MON-8 SEAT BELT CAUTION LAMP DOES NOT OPERATE NORMALLY
a) LAMP LIGHTS UP WHILE SEAT BELT IS FASTENED
b) LAMP DOES NOT LIGHT UP WHILE SEAT BELT IS UNFASTENED
MON-9 TURN SIGNALS AND HAZARD LAMP DO NOT OPERATE NORMALLY
a) WHEN TURN SIGNAL LEVER AND HAZARD LAMP SWITCH ARE OPERATED, ANY TURN SIGNAL LAMP DOES NOT FLASH
b) WHEN TURN SIGNAL LEVER AND HAZARD LAMP SWITCH ARE OPERATED, THE TURN SIGNAL LAMPS DO NOT FLASH BUT LIGHT UP
c) WHEN TURN SIGNAL LEVER IS OPERATED, TURN SIGNAL LAMPS ON EITHER OR BOTH SIDES DO NOT FLASH (WHEN HAZARD LAMP SWITCH IS OPERATED, HOWEVER, TURN SIGNAL LAMPS FALSH MORMALLY)
d) WHEN HAZARD LAMP SWITCH IS TURNED ON, ANY TURN SIGNAL LAMP DOES NOT FLASH (WHEN TURN SIGNAL LEVER IS OPERATED, HOWEVER, TURN SIGNAL LAMPS FALSH MORMALLY)
e) WHEN HAZARD LAMP SWITCH IS TURNED OFF, ANY TURN SIGNAL LAMPS CONTINUE FLASHING (WHEN TURN SIGNAL LEVER IS OPERATED, HOWEVER, TURN SIGNAL LAMPS FALSH NORMALLY)
f) TURN SIGNAL PILOT LAMPS DO NOT FLASH NORMALLY (TURN SIGNAL LAMPS FLASH NORMALLY, HOWEVER)
MON-10 NIGHT LIGHTING IS ABNORMAL
a) WHEN LAMP SWITCH IS SET IN 1ST OR 2ND POSITION, ANY OF SMALL LAMP, NIGHT LAMP, AND HEAD LAMP DOES NOT LIGHT UP
b) WHEN LAMP SWITCH IS SET IN 1ST POSITION, SMALL LAMP AND NIGHT LAMP DO NOT LIGHT UP
c) WHEN LAMP SWITCH IS OFF, SMALL LAMP AND NIGHT LAMP LIGHT UP
d) WHEN DIMMER SWITCH IS OPERATED, BRIGHTNESS OF NIGHT LIGHTING DOES NOT CHANGE
e) HEAD LAMP "HI" BEAM DOES NOT LIGHT UP
f) HEAD LAMP "LO" BEAM DOES NOT LIGHT UP
g) HEAD LAMP CANNOT BE SET TO "HI" OR "LO"
h) WHEN HEAD LAMP IS SET TO "HI" BEAM, PILOT LAMP OF MACHINE MONITOR DOES NOT LIGHT UP
MON-11 POWER WINDOW DOES NOT OPERATE NORMALLY
a) OPERATING LEFT SIDE DOES NOT
b) OPERATING RIGHT SIDE DOES NOT
MON-12 DEFECTIVE AIR CONDITIONER
a) AIR CONDITIONER DOES NOT OPERATE
b) AIR DOES NOT COME OUT OR AIR FLOW CANNOT BE ADJUSTED
c) AIR IS NOT COOLED OR TEMPERATURE CANNOT BE ADJUSTED (ELECTRIC SYSTM)
d) RECIRCULATED AIR AND FRESH AIR CANNOT BE SELECTED
e) AIR OUTLETS CANNOT BE SELECTED
f) AIR IS NOT COOLED (MECHANICAL SYSTEM)
g) AIR IS NOT HEATED (DEFECTIVE HOT WATER CIRCUIT)
h) ABNORMAL SOUND COMES OUT
i) WATER LEAKS
TROUBLESHOOTING OF VHMS CONTROLLER SYSTEM (VHMS MODE)
ELECTRICAL SYSTEM DIAGRAM RELATED VHMS CONTROLLER
INFORMATION GIVEN IN TROUBLESHOOTING CHART
FAILURE TYPE CODE LIST
[A000N1] (OR VHMS_LED DISPLAYS [n201]) ENGINE OVERRUN
[DBB0KK] (OR VHMS_LED INDICATES "n901") ABNORMALITY IN SOURCE VOLTAGE
[DBB5KP] (OR VHMS_LED INDICATES "n904") ABNORMALITY IN SENSOR POWER SOURCE (5V) SYSTEM
[DBB6KP] (OR VHMS_LED INDICATES "n902") ABNORMALITY IN SENSOR POWER SOURCE (24V) SYSTEM
[DBB7KP] (OR VHMS_LED INDICATES "n903") ABNORMALITY IN SENSOR POWER SOURCE (12V) SYSTEM
[DBBRKR] (OR VHMS_LED DISPLAYS [n801]) DEFECTIVE CAN COMMUNICATIONS: DEFECTIVE COMMUNICATIONS (KR) (BETWEEN ENGINE CONTROLLER AND VIHMS CONTROLLER)
[DBBSKR] (OR VHMS_LED DISPLAYS [n803]) DEFECTIVE S-NET COMMUNICATIONS: (KR)
[DGE1KB] (OR VHMS_LED DISPLAYS [n242]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KB) {30 MIN (AT 500 RPM OR ABOVE) AFTER STARTING ENGINE}
[DGE1KY] (OR VHMS_LED DISPLAYS [n241]) SHORT CIRCUIT WITH POWER SOURCE IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KY)
[DGE5KX] (OR VHMS_LED DISPLAYS [n401]) FAILURE IN AMBIENT TEMPERATURE SENSOR SYSTEM:INPUT SIGNAL OUTSIDE RANGE (KX)
[DGT4KA] (OR VHMS_LED DISPLAYS [n312]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO.1,2,3 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)
[DGT4KB] (OR VHMS_LED DISPLAYS [n311]) SHORT CIRCUIT WITH POWER SOURCE IN NO.1,2,3 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)
[DGT5KA] (OR VHMS_LED DISPLAYS [n322]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO.4,5,6 (REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)
[DGT5KB] (OR VHMS_LED DISPLAYS [n321]) SHORT CIRCUIT WITH POWER SOURCE IN NO.4,5,6 (REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)
[DHE5KB] (OR VHMS_LED DISPLAYS [n332]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KA)
[DHE5KY] (OR VHMS_LED DISPLAYS [n331]) SHORT CIRCUIT WITH POWER SOURCE IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KY)
[DhP4KX] SUSPENSION PRESSURE SENSOR (FRONT RIGHT):OUT OF INPUT SIGNAL RANGE (KX)
[DhP5KX] SUSPENSION PRESSURE SENSOR (FRONT LEFT):OUT OF INPUT SIGNAL RANGE (KX)
[DhP6KX] SUSPENSION PRESSURE SENSOR (REAR RIGHT):OUT OF INPUT SIGNAL RANGE (KX)
[DhP7KX] SUSPENSION PRESSURE SENSOR (REAR LEFT):OUT OF INPUT SIGNAL RANGE (KX)
[DKH1KX] PITCH ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)
[F@BBZL] (OR VHMS_LED DISPLAYS [n338]) ENGINE BLOW-BY PRESSURE IS HIGH: (ZL)
[F@BYNR] (OR VHMS_LED DISPLAYS [n362]) NO.1,2,3 (FRONT) EXHAUST TEMPERATURE IS HIGH (2):(NR)
[F@BYNS] (OR VHMS_LED DISPLAYS [n361]) NO.1,2,3 (FRONT) EXHAUST TEMPERATURE IS HIGH (1):(NS)
[F@BZNR] (OR VHMS_LED DISPLAYS [n372]) NO.4,5,6 (REAR) EXHAUST TEMPERATURE IS HIGH (2):(NR)
[F@BZNS] (OR VHMS_LED DISPLAYS [n371]) NO.4,5,6 (REAR) EXHAUST TEMPERATURE IS HIGH (1):(NS)
VHMS-1 ABNORMALITY IN SATELLITE DATA COMMUNICATION
a) SATELLITE COMMUNICATION DATA ARE NOT TRANSMITTED
b) ABNORMALITY IN DOWNLOADING INTO PC OR SETTING OF PC
VHMS-2 ABNORMALITY IN SAVING DATA IN VHMS CONTROLLER (DATA ARE NOT SAVED)
VHMS-3 ENGINE BLOW-BY PRESSURE INDICATED BY MONITOR IS LOW (WHEN BLOW-BY PRESSURE MEASURED WITH MEASURING INSTRUMENT IS NORMAL)
TROUBLESHOOTING OF ASR CONTROLLER SYSTEM (ASR MODE)
ELECTRICAL SYSTEM DIAGRAM RELATED ASR CONTROL
INFORMATION IN TROUBLESHOOTING TABLE
TROUBLE CODE TABLE
[DDDAKA] ASR SYSTEM SWITCH SYSTEM:DISCONNECTION (KA)
[DDDAKB] ASR SYSTEM SWITCH SYSTEM:SHORT CIRCUIT (KB)
[DK30KX] STEERING ANGLE SENSOR:OUT OF INPUT SIGNAL RANGE (KX)
[DLF8KA] WHEEL SPEED SENSOR (RR):DISCONNECTION (KA)
[DLF8LC] WHEEL SPEED SENSOR (RR):※ SEE SEPARATE LIST (LC)
[DLF9KA] WHEEL SPEED SENSOR (RL):DISCONNECTION (KA)
[DLF9LC] WHEEL SPEED SENSOR (RL):※ SEE SEPARATE LIST (LC)
[dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:※ SEE SEPARATE LIST (LC)
[DWNBK4] SHUT-OFF SOLENOID VALVE:UNCONTROLLABLE (K4)
[DWNBKA] SHUT-OFF SOLENOID VALVE:DISCONNECTION (KA)
[DWNBKB] SHUT-OFF SOLENOID VALVE:SHORT CIRCUIT (KB)
[DWNBKY] SHUT-OFF SOLENOID VALVE:SHORT CIRCUIT WITH POWER SOURCE (KY)
[DWNBMA] SHUT-OFF SOLENOID VALVE:MALFUNCTION (MA)
[DX17K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):UNCONTROLLABLE (K4)
[DX17KA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):DISCONNECTION (KA)
[DX17KB] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):SHORT CIRCUIT (KB)
[DX17KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):SHORT CIRCUIT WITH POWER SOURCE (KY)
[DX17MA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):MALFUNCTION (MA)
[DX18K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):UNCONTROLLABLE (K4)
[DX18KA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):DISCONNECTION (KA)
[DX18KB] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):SHORT CIRCUIT (KB)
[DX18KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):SHORT CIRCUIT WITH POWER SOURCE (KY)
[DX18MA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):MALFUNCTION (MA)
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
a. DOES NOT SHIFT UP
b. DOES NOT SHIFT UP
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING
a. ABNORMALITY AT ALL SPEED RANGES
b. TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE
c. ABNORMALITY AT SPECIFIC SPEED RANGES
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR
H-8 TORQUE CONVERTAR 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
TROUBLESHOOTING OF ENGINE SYSTEM (S MODDE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
S-2 ENGINE DOES NOT START
a) ENGINE DOES NOT TURN
b) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED)
c) 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 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 ELECTRICAL SYSTEM (E-MODE)
ELECTRICAL SYSTEM DIAGRAM RELATED TO EMERGENCY STEERING CONTROL
INFORMATION IN TROUBLESHOOTING TABLE
E-1 EMERGENCY STEERING SYSTEM DOES NOT OPERATE

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
FUEL INJECTION PUMP
REMOVAL AND INSTALLATION
RADIATOR
REMOVAL AND INSTALLATION
ENGINE AND TORQUE CONVERTER AND TRANSMISSION OIL COOLER
REMOVAL AND INSTALLATION
ENGINE FRONT SEAL
REMOVAL AND INSTALLATION
OUTPUT SHAFT
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
ENGINE REAR SEAL
REMOVAL AND INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
ENGINE
REMOVAL
INSTALLATION
TORQUE CONVERTER AND TRANSMISSION
REMOVAL
INSTALLATION
TRANSMISSION ASSEMBLY AND TORQUE CONVERTER
SEPARATION AND COUPLING
TORQUE CONVERTER
DISASSEMBLY
ASSEMBLY
TRANSMISSION
DISASSEMBLY
ASSEMBLY
DIFFERENTIAL
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
FRONT WHEEL
REMOVAL AND INSTALLATION
REAR WHEEL
REMOVAL
INSTALLATION
FRONT BRAKE CALIPER PADS
REMOVAL AND INSTALLATION
FRONT BRAKE CALIPERS
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
FRONT WHEEL HUB
DISASSEMBLY
ASSEMBLY
FINAL DRIVE CARRIER
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE AND REAR BRAKE
REMOVAL
INSTALLATION
FINAL DRIVE,REAR BRAKE,AND PARKING BRAKE
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
FRONT SUSPENSION CYLINDER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
REAR SUSPENSION CYLINDER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
RETARDER COOLING PUMP
REMOVAL AND INSTALLATION
STEERING,HOIST,AND HOIST CONTROL PUMP
REMOVAL AND INSTALLATION
TORQUE CONVERTER,TRANSMISSION AND RETARDER COOLING,AND BRAKE PUMP
REMOVAL AND INSTALLATION
STEERING VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
DEMAND VALVE
REMOVAL AND INSTALLATION
HOIST VALVE
REMOVAL AND INSTALLATION
STEERING CYLINDER
DISASSEMBLY
ASSEMBLY
HOIST CYLINDER
DISASSEMBLY
ASSEMBLY
DUMP BODY
REMOVAL
INSTALLATION
OPERATOR'S SEAT
DISASSEMBLY
ASSEMBLY

90 OTHERS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM
BRAKE HYDRAULIC CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM (1/6)
ELECTRICAL CIRCUIT DIAGRAM (2/6)
ELECTRICAL CIRCUIT DIAGRAM (3/6)
ELECTRICAL CIRCUIT DIAGRAM (4/6)
ELECTRICAL CIRCUIT DIAGRAM (5/6)
ELECTRICAL CIRCUIT DIAGRAM (6/6)
ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR
ELECTRICAL CIRCUIT DIAGRMAM (A1 SIZE) (1/2)
ELECTRICAL CIRCUIT DIAGRMAM (A1 SIZE) (2/2)
CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE)

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