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KOMATSU HD465-10 HD605-10 DUMP TRUCK SHOP MANUAL SEN06976-02 – PDF DOWNLOAD
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KOMATSU HD465-10 HD605-10 DUMP TRUCK SHOP MANUAL SEN06976-02 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU HD465-10 HD605-10 DUMP TRUCK SHOP MANUAL SEN06976-02 – PDF DOWNLOAD
Language : English
Pages : 3112
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU HD465-10 HD605-10 DUMP TRUCK SHOP MANUAL SEN06976-02 – PDF DOWNLOAD
Cover.................................................................................................................................. 1 00 Index and Foreword............................................................................................................. 3 Index......................................................................................................................... 4 Foreword, Safety, Basic Information........................................................................................... 21 How to Read the Shop Manual............................................................................................... 21 Safety Notice for Operation............................................................................................... 23 Precautions to Prevent Fire............................................................................................... 31 Procedures If Fire Occurs................................................................................................. 33 Precautions for Disposing of Waste Materials.............................................................................. 34 Engine Technology to Conform Exhaust Gas Emission......................................................................... 35 Precautions When You Handle Hydraulic Equipment........................................................................... 36 Precautions When You Disconnect and Connect Pipings....................................................................... 39 Precautions When You Handle Electrical Equipment.......................................................................... 46 Precautions When You Handle Fuel System Equipment......................................................................... 48 Precautions When You Handle Intake System Equipment....................................................................... 49 Practical Use of KOMTRAX.................................................................................................. 50 Disconnect and Connect Push-Pull Type Coupler............................................................................. 51 How to Disconnect and Connect Type 1 Push-Pull Type Coupler........................................................... 51 How to Disconnect and Connect Type 2 Push-Pull Type Coupler........................................................... 52 How to Disconnect and Connect Type 3 Push-Pull Type Coupler........................................................... 53 Precautions for Disconnection and Connection of Connectors................................................................ 55 How to Disconnect and Connect Deutsch Connector........................................................................... 59 How to Disconnect and Connect Slide Lock Type Connector................................................................... 60 How to Disconnect and Connect Connector with Lock to Pull................................................................. 62 How to Disconnect and Connect Connector with Lock to Push................................................................. 63 How to Disconnect and Connect Connector with Housing to Rotate............................................................ 65 Standard Tightening Torque Table.......................................................................................... 66 Conversion Table.......................................................................................................... 73 Abbreviation List......................................................................................................... 78 01 Specifications................................................................................................................. 81 Table of Contents............................................................................................................. 82 Specifications................................................................................................................ 83 Specification Drawing..................................................................................................... 83 Specification Drawing: HD465-10....................................................................................... 83 Specification Drawing: HD605-10....................................................................................... 85 Specifications............................................................................................................ 87 Specifications: HD465-10.............................................................................................. 87 Specifications: HD605-10.............................................................................................. 92 Weight Table.............................................................................................................. 97 Weight Table: HD465-10................................................................................................ 97 Weight Table: HD605-10................................................................................................ 98 Fuel, Coolant, Lubricant.................................................................................................. 99 How to Use Fuel, Coolant and Lubricants by Ambient Temperature........................................................ 99 10 Structure and Function......................................................................................................... 101 Table of Contents............................................................................................................. 102 Boot-up System................................................................................................................ 106 Layout Drawing of Boot-up System.......................................................................................... 106 System Operating Lamp System.............................................................................................. 108 System Diagram of System Operating Lamp System........................................................................ 108 Function of Operation Lamp System..................................................................................... 108 Battery Disconnect Switch................................................................................................. 110 Layout Drawing of Battery Disconnect Switch........................................................................... 110 Function of Battery Disconnect Switch................................................................................. 110 Engine Shutdown Secondary Switch.......................................................................................... 112 Engine Secondary Shutdown Switch Diagram.............................................................................. 112 Function of Engine Shutdown Secondary Switch.......................................................................... 112 Operation of Engine Shutdown Secondary Switch......................................................................... 113 Engine System................................................................................................................. 114 Layout Drawing of Engine System........................................................................................... 114 Function of Engine System............................................................................................. 115 Engine Control System..................................................................................................... 116 System Diagram of Engine Control...................................................................................... 116 Engine Power Mode Selector System......................................................................................... 119 Engine Power Mode Selector System Diagram............................................................................. 119 Function of Engine Power Mode Selector System......................................................................... 119 Operation of Engine Power Mode Selector System........................................................................ 119 Automatic Idle Stop System................................................................................................ 120 Function of Automatic Idle Stop System................................................................................ 120 Component Parts of Engine System.......................................................................................... 122 Damper................................................................................................................ 122 VGT................................................................................................................... 124 EGR System............................................................................................................ 128 EGR Valve............................................................................................................. 131 EGR Cooler............................................................................................................ 133 Crankcase Ventilation System.......................................................................................... 134 Blow-By Gas Filter.................................................................................................... 135 KDPF.................................................................................................................. 137 Cooling System................................................................................................................ 141 Layout Drawing of Cooling System.......................................................................................... 141 Specifications of Cooling System...................................................................................... 142 Cooling Fan Control System................................................................................................ 143 Cooling Fan Control System Diagram.................................................................................... 143 Function of Cooling Fan Control System................................................................................ 143 Component Parts of Cooling System......................................................................................... 145 Cooling Fan Pump...................................................................................................... 145 Cooling Fan Motor..................................................................................................... 152 Control System................................................................................................................ 158 Layout Drawing of Control System.......................................................................................... 158 Layout Drawing of Control System (Machine with Mobile Communication Terminal)............................................. 160 Retarder and Hoist Control System......................................................................................... 161 Retarder and Hoist Control System Diagram............................................................................. 161 Machine Monitor System.................................................................................................... 163 System Diagram of Machine Monitor System.............................................................................. 163 Function of Machine Monitor System.................................................................................... 164 Rearview Monitor System................................................................................................... 165 System Diagram of Rearview Monitor System............................................................................. 165 Function of Rearview Monitor System................................................................................... 165 KOMTRAX Plus System....................................................................................................... 166 System Diagram of KOMTRAX Plus System................................................................................. 166 System Diagram of KOMTRAX Plus System (Machine with Mobile Communication Terminal).................................... 168 Function of KOMTRAX Plus System....................................................................................... 169 Payload Meter System...................................................................................................... 173 Layout Drawing of Payload Meter System................................................................................ 173 Payload Meter System Diagram.......................................................................................... 174 Function of Payload Meter System...................................................................................... 174 Measurement Principle of Loading Mass................................................................................. 176 Machine Lock-out System................................................................................................... 180 Layout Drawing of Machine Lock-out System............................................................................. 180 Function of Machine Lock-out System................................................................................... 180 Operation of Machine Lock-out System.................................................................................. 181 Component Parts of Control System......................................................................................... 182 Machine Monitor....................................................................................................... 182 Switch Panel.......................................................................................................... 205 Rearview Monitor...................................................................................................... 206 Rearview Camera....................................................................................................... 208 KOMTRAX Terminal...................................................................................................... 209 KOMTRAX Plus Controller............................................................................................... 211 Communication Terminal................................................................................................ 216 Wireless LAN Unit..................................................................................................... 217 Transmission Controller............................................................................................... 218 Retarder and Hoist Controller......................................................................................... 222 Monitor Controller.................................................................................................... 227 Engine Controller..................................................................................................... 232 Accelerator Pedal..................................................................................................... 244 Gear Shift Lever...................................................................................................... 245 Retarder Control Lever................................................................................................ 246 Fuel Feed Pump........................................................................................................ 247 Fuel Feed Pump Switch................................................................................................. 248 Hydraulic System.............................................................................................................. 250 Layout Drawing of Hydraulic System........................................................................................ 250 Component Parts of Hydraulic System....................................................................................... 251 Hydraulic Tank........................................................................................................ 251 Pump Assembly (Steering, Hoist)....................................................................................... 252 LS Valve.............................................................................................................. 258 CO Valve.............................................................................................................. 259 Pump Assembly (Power Train and Brake Cooling)......................................................................... 262 Pump Assembly (Brake Cooling and Control)............................................................................. 264 Hoist Valve........................................................................................................... 266 Power Train System............................................................................................................ 272 Layout Drawing of Power Train System...................................................................................... 272 Transmission Control System............................................................................................... 274 Transmission Control System Diagram................................................................................... 274 Gear Shift Lever Positions and Automatic Gear Shift Range............................................................. 275 Gear Shift Control System................................................................................................. 281 Automatic Gear Shift Control of Gear Shift Control System............................................................. 281 Shifting Procedure in Each Gear Shift Lever Positions of Gear Shift Control System.................................... 282 Gear Shift Disabled Time Control of Gear Shift Control System......................................................... 283 Direction Control System.................................................................................................. 284 Rim Pull Limit Function for Overload Prevention of Direction Control System........................................... 284 Function of Throttle Limit Function at F1 Start at D Position Setting of Direction Control System..................... 284 Komatsu Traction Control System (KTCS).................................................................................... 285 Komatsu Traction Control System (KTCS) System Diagram................................................................. 285 Function of Komatsu Traction Control System (KTCS).................................................................... 285 Operation of Komatsu Traction Control System (KTCS) System Logic...................................................... 286 Travel Speed Limitation System............................................................................................ 287 System Diagram of Travel Speed Limitation System...................................................................... 287 Function of Travel Speed Limitation System............................................................................ 288 Operation of Travel Speed Limitation System........................................................................... 288 Component Parts of Power Train System..................................................................................... 291 Drive Shaft........................................................................................................... 291 Torque Converter and PTO.............................................................................................. 293 Lockup Clutch ECMV.................................................................................................... 297 Transmission.......................................................................................................... 300 Transmission Control Valve............................................................................................ 321 Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV............................................................ 323 Axle.................................................................................................................. 332 Differential.......................................................................................................... 334 Final Drive........................................................................................................... 336 Work Equipment System......................................................................................................... 337 Work Equipment Control.................................................................................................... 337 Layout Drawing of Work Equipment Control.............................................................................. 337 Function of Work Equipment Control.................................................................................... 337 Hoist Control............................................................................................................. 338 Hoist Control System Diagram.......................................................................................... 338 Function of Hoist Control............................................................................................. 338 Component Parts of Work Equipment System.................................................................................. 341 Dump Lever............................................................................................................ 341 Hoist EPC Valve....................................................................................................... 346 Steering System............................................................................................................... 347 Layout Drawing of Steering System......................................................................................... 347 Secondary Steering System................................................................................................. 348 Secondary Steering System Diagram..................................................................................... 348 Function of Secondary Steering System................................................................................. 348 Steering Column........................................................................................................... 349 Structure of Steering Column.......................................................................................... 349 Steering Linkage.......................................................................................................... 350 Structure of Steering Linkage......................................................................................... 350 Component Parts of Steering System........................................................................................ 351 Demand Valve.......................................................................................................... 351 Steering Relief Valve................................................................................................. 358 Orbitrol Valve........................................................................................................ 359 Solenoid Valve (Steering Pump Selector)............................................................................... 365 Cross over Relief Valve............................................................................................... 366 Secondary Steering Pump............................................................................................... 367 Secondary Steering Motor.............................................................................................. 368 Brake System.................................................................................................................. 369 Layout Drawing of Brake System............................................................................................ 369 Retarder Control.......................................................................................................... 371 Retarder Control System Diagram....................................................................................... 371 Function of Retarder Control.......................................................................................... 371 ARSC System............................................................................................................... 372 ARSC System Diagram................................................................................................... 372 Function of ARSC System............................................................................................... 372 Component Parts of Brake System........................................................................................... 373 Brake Charge Pump..................................................................................................... 373 Solenoid Valve (Parking Brake)........................................................................................ 374 Accumulator Charge Valve.............................................................................................. 375 Brake Circuit Accumulator............................................................................................. 381 Brake Valve........................................................................................................... 382 Secondary Brake Valve................................................................................................. 385 Secondary Brake Relay Valve........................................................................................... 386 Proportional Pressure Reducing Valve.................................................................................. 387 Slack Adjuster........................................................................................................ 388 Brake................................................................................................................. 390 Parking Brake......................................................................................................... 393 Brake Sub-Tank........................................................................................................ 395 KOWA Oil Sampling System...................................................................................................... 396 Layout Drawing of KOWA Oil Sampling System................................................................................ 396 Function of KOWA Oil Sampling System...................................................................................... 398 Undercarriage and Frame....................................................................................................... 399 Suspension................................................................................................................ 399 Structure of Suspension............................................................................................... 399 Function of Suspension................................................................................................ 399 Front Suspension.......................................................................................................... 401 Structure of Front Suspension......................................................................................... 401 Function of Front Suspension.......................................................................................... 402 Rear Suspension........................................................................................................... 403 Structure of Rear Suspension.......................................................................................... 403 Function of Rear Suspension........................................................................................... 404 Suspension Cylinder....................................................................................................... 405 Structure of Suspension Cylinder...................................................................................... 405 Function of Suspension Cylinder....................................................................................... 405 Operation of Suspension Cylinder...................................................................................... 405 Work Equipment................................................................................................................ 407 Structure of Work Equipment............................................................................................... 407 Function of Work Equipment................................................................................................ 408 CAB Related Parts............................................................................................................. 409 ROPS CAB.................................................................................................................. 409 Structure of ROPS CAB................................................................................................. 409 Function of ROPS CAB.................................................................................................. 409 CAB Mount................................................................................................................. 410 Structure of CAB Mount................................................................................................ 410 Function of CAB Mount................................................................................................. 410 20 Standard Value Table........................................................................................................... 411 Table of Contents............................................................................................................. 412 Standard Value Table for Engine............................................................................................... 413 Standard Value Table for Engine: HD465-10................................................................................. 413 Standard Value Table for Engine: HD605-10................................................................................. 416 Standard Value Table for Machine.............................................................................................. 419 Standard Value Table for Machine: HD465-10................................................................................ 419 Standard Value Table for Machine: HD605-10................................................................................ 438 Machine Posture and Procedures to Measure Performance..................................................................... 457 30 Testing and Adjusting.......................................................................................................... 459 Table of Contents............................................................................................................. 460 Precautions Before Work....................................................................................................... 464 Differences In Machine Monitor Symbols........................................................................................ 465 Related Information on Testing and Adjusting.................................................................................. 466 Tools for Testing and Adjusting........................................................................................... 466 Sketch of Tools for Testing and Adjusting................................................................................. 478 Engine and Cooling System..................................................................................................... 479 Examine Engine Speed...................................................................................................... 479 How to Examine Engine High Idle Speed................................................................................. 479 How to Examine Engine Low Idle Speed.................................................................................. 479 How to Examine Engine Speed at Torque Converter Stall................................................................. 480 Examine Boost Pressure.................................................................................................... 483 How to Examine Boost Pressure on Machine Monitor...................................................................... 483 How to Examine Boost Pressure by Testing Tool......................................................................... 484 Examine Exhaust Gas Temperature........................................................................................... 486 How to Test Exhaust Gas Temperature by the Machine Monitor............................................................ 486 How to Examine Exhaust Temperature by Testing Tools................................................................... 487 Examine Exhaust Gas Color................................................................................................. 490 How to Examine Exhaust Gas Color with Handy Smoke Checker............................................................. 490 How to Examine Exhaust Gas Color with Smoke Meter..................................................................... 492 Examine Mass Air Flow and Temperature Sensor.............................................................................. 495 How to Examine Mass Air Flow and Temperature Sensor................................................................... 495 Examine and Adjust Valve Clearance........................................................................................ 498 How to Examine Valve Clearance........................................................................................ 498 How to Adjust Valve Clearance......................................................................................... 499 Examine Compression Pressure.............................................................................................. 501 How to Examine Compression Pressure................................................................................... 501 Examine Blowby Pressure................................................................................................... 505 How to Examine Blowby Pressure........................................................................................ 505 Examine Engine Oil Pressure............................................................................................... 508 How to Examine Engine Oil Pressure on Machine Monitor................................................................. 508 How to Examine Engine Oil Pressure by Testing Tool.................................................................... 508 Examine EGR Valve and VGT Oil Pressure.................................................................................... 510 How to Examine EGR Valve and VGT Oil Pressure......................................................................... 510 Examine Fuel Pressure..................................................................................................... 512 How to Examine Fuel Pressure.......................................................................................... 512 Examine Fuel Return Rate and Leakage...................................................................................... 514 How to Examine Fuel Return Rate and Leakage........................................................................... 515 Bleed Air from Fuel System................................................................................................ 519 How to Bleed Air from Fuel System..................................................................................... 519 Examine Fuel Circuit for Leakage.......................................................................................... 521 How to Examine Fuel System for Leakage................................................................................ 521 Test Fuel Low Pressure Circuit Devices.................................................................................... 522 How to Examine Fuel Low Pressure Circuit Devices...................................................................... 522 Examine Supply Pump....................................................................................................... 526 How to Examine Supply Pump............................................................................................ 526 Handle Cylinder Cut-out Mode Operation.................................................................................... 529 Handle No-Injection Cranking Operation.................................................................................... 530 Examine KDPF and Muffler for Looseness and Damage......................................................................... 531 How to Examine KDPF and Muffler for Looseness and Damage.............................................................. 531 Examine Installation of Cylinder Head Cover and Manifolds................................................................. 532 How to Examine Installed Condition of Cylinder Head covers and Manifolds.............................................. 532 Examine Engine Piping for Damage and Looseness............................................................................ 533 How to Examine Engine Piping for Damage and Looseness................................................................. 533 Clean Fuel Doser.......................................................................................................... 534 How to Clean Fuel Doser............................................................................................... 534 Write Injector Compensation Value to Engine Controller.................................................................... 537 Write Injector Compensation Value..................................................................................... 537 Write Correction for Ash in Soot Accumulation to Engine Controller........................................................ 544 How to Write Correction for Ash in Soot Accumulation to Engine Controller............................................. 544 Examine Cooling Fan Speed................................................................................................. 545 How to Examine Cooling Fan Speed...................................................................................... 545 Power Train................................................................................................................... 546 Examine Power Train Oil Pressure.......................................................................................... 546 How to Examine Power Train Oil Pressure............................................................................... 549 Adjust Speed Sensor (Transmission)........................................................................................ 566 How to Adjust Speed Sensor (Transmission)............................................................................. 566 Examine After You Adjust Speed Sensor (Transmission)...................................................................... 568 How to Examine After You Adjust Speed Sensor (Transmission)........................................................... 568 Move Machine Which Has a Trouble in Electrical System..................................................................... 569 Move Machine Which Has a Trouble in Engine Control System............................................................. 569 How to Move Machine Which Has a Trouble in Transmission Control System................................................ 571 Steering System............................................................................................................... 576 Examine and Adjust Steering Circuit Oil Pressure.......................................................................... 576 How to Examine Steering Circuit Oil Pressure with the Machine Monitor................................................. 576 How to Examine Steering Circuit Pressure with Test Tools.............................................................. 577 How to Adjust Steering Circuit Oil Pressure........................................................................... 578 Examine Supply Pressure of Orbitrol Valve................................................................................. 580 How to Examine Supply Pressure of Orbitrol Valve...................................................................... 580 Examine Steering Cylinder Pressure........................................................................................ 583 How to Examine Steering Cylinder Pressure............................................................................. 583 Bleed Air from Steering Cylinder Circuit.................................................................................. 585 How to Bleed Air from Steering Cylinder Circuit....................................................................... 585 Brake System.................................................................................................................. 586 Release Remained Pressure in Brake Accumulator Circuit.................................................................... 586 How to Release Remained Pressure in Brake Accumulator Circuit......................................................... 586 Examine Wheel Brake Oil Pressure.......................................................................................... 587 How to Examine Operating Pressure of Front Brake...................................................................... 587 How to Examine Operating Pressure of Rear Brake....................................................................... 589 How to Examine Retarder Brake Operating Pressure...................................................................... 590 Examine and Adjust Brake Accumulator Charge Pressure...................................................................... 592 How to Examine Brake Accumulator Charge Pressure on Machine Monitor................................................... 592 How to Examine Brake Accumulator Charge Pressure by Testing Tool...................................................... 592 How to Adjust Brake Accumulator Charge Pressure....................................................................... 594 Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas......................................................... 595 How to Examine Nitrogen Gas Pressure in Brake Accumulator (Front)..................................................... 596 How to Examine Nitrogen Gas Pressure in Brake Accumulator (Rear Brake and Parking Brake).............................. 599 How to Charge Accumulator Nitrogen Gas for Brake...................................................................... 602 How to Release Nitrogen Gas When You Discard Accumulator.................................................................. 608 Examine Brake Performance................................................................................................. 609 How to Examine Foot Brake Performance................................................................................. 609 How to Examine Retarder Brake Performance............................................................................. 611 How to Examine Parking Brake Performance.............................................................................. 614 Examine Operating Pressure of Secondary Brake............................................................................. 618 How to Examine Operating Pressure of Secondary Brake.................................................................. 618 Bleed Air from Brake Circuit.............................................................................................. 619 How to Bleed Air from Front Brake Circuit............................................................................. 619 How to Bleed Air from Rear Brake Circuit.............................................................................. 620 How to Bleed Air from Parking Brake Circuit........................................................................... 622 Examine Parking Brake Oil Pressure........................................................................................ 624 How to Examine Parking Brake Oil Pressure............................................................................. 624 Release Parking Brake Manually............................................................................................ 626 How to Release Parking Brake Manually................................................................................. 626 Examine Front Brake Pad Wear Volume....................................................................................... 628 How to Visually Examine Front Brake Pad Wear Volume................................................................... 628 How to Examine Front Brake Pad Wear with Gauge Measure................................................................ 628 Examine Rear Brake Disc Wear Volume....................................................................................... 630 How to Visually Examine Rear Brake Disc Wear Volume................................................................... 630 Hydraulic System.............................................................................................................. 632 Examine and Adjust Hoist Circuit Oil Pressure............................................................................. 632 How to Examine Hoist Circuit Oil Pressure............................................................................. 632 How to Adjust Hoist Circuit Oil Pressure.............................................................................. 634 Examine Hoist Cylinder Source Pressure.................................................................................... 635 How to Examine Source Pressure of Hoist Cylinder...................................................................... 635 Examine Oil Pressure of Hoist EPC Valve Circuit........................................................................... 637 How to Examine Source Pressure of Hoist EPC Valve..................................................................... 637 How to Examine Outlet Pressure of Hoist EPC Valve..................................................................... 638 Examine Cooling Fan Circuit Oil Pressure.................................................................................. 640 How to Examine Cooling Fan Circuit Oil Pressure....................................................................... 640 Examine and Adjust Front Suspension Cylinder.............................................................................. 642 How to Examine Front Suspension Cylinder.............................................................................. 642 How to Adjust Front Suspension Cylinder............................................................................... 643 Examine and Adjust Rear Suspension Cylinder............................................................................... 647 How to Examine Rear Suspension Cylinder............................................................................... 647 How to Adjust Rear Suspension Cylinder................................................................................ 648 Examine Oil Pressure of KTCS Circuit...................................................................................... 653 How to Examine Oil Pressure of KTCS Circuit with Machine Monitor...................................................... 653 How to Examine the Oil Pressure of KTCS Circuit with Test Tools....................................................... 653 Work Equipment................................................................................................................ 656 Examine and Adjust Dump Body Positioner Sensor............................................................................ 656 How to Examine Dump Body Positioner Sensor............................................................................ 656 How to Adjust Dump Body Positioner Sensor............................................................................. 656 How to Calibrate After Adjustment of Dump Body Positioner Sensor...................................................... 657 Lower Dump Body Manually.................................................................................................. 658 How to Lower Dump Body Manually....................................................................................... 658 Lift Dump Body Manually................................................................................................... 659 How to Lift Dump Body Manually........................................................................................ 659 CAB Related Parts............................................................................................................. 660 Adjust Tilt Lock Lever of Steering Wheel.................................................................................. 660 How to Adjust Tilt Lock Lever of Steering Wheel....................................................................... 660 Adjust Play of Operator Seat.............................................................................................. 662 How to Adjust Play of Operator Seat................................................................................... 662 Adjust Door Lock Link..................................................................................................... 663 How to Adjust Door Lock Link.......................................................................................... 663 Electrical System............................................................................................................. 665 Set and Adjust Each Equipment............................................................................................. 665 Set and Operate Machine Monitor........................................................................................... 668 Operator Mode......................................................................................................... 672 Service Mode.......................................................................................................... 687 Abnormality Record Menu............................................................................................... 711 Default Setting Menu.................................................................................................. 727 Testing Menu.......................................................................................................... 749 Adjustment Menu....................................................................................................... 763 No-Injection Cranking Operation....................................................................................... 794 Set Payload Meter..................................................................................................... 797 Communication with External Device Specification of Payload Meter System.............................................. 825 KOMTRAX Settings Menu................................................................................................. 833 How to Show Service Message........................................................................................... 837 How to Operate Snap Shot Manually..................................................................................... 838 How to Start Up KOMTRAX Terminal.......................................................................................... 843 How to Stop Use of KOMTRAX Terminal....................................................................................... 848 How to Stop Use of KOMTRAX Terminal (Machine with Mobile Communication Terminal).......................................... 850 Default Setting of KOMTRAX Plus Controller................................................................................ 852 Default Setting of KOMTRAX Plus Controller............................................................................ 852 Default Setting of Wireless LAN Modem..................................................................................... 855 Default Setting of Wireless LAN Modem................................................................................. 855 How to Examine Wireless LAN Modem Communication....................................................................... 856 Download Data from KOMTRAX Plus Controller................................................................................ 857 How to Download Data from KOMTRAX Plus Controller..................................................................... 857 Download Data from Service Connector in CAB........................................................................... 857 How to Download Data Through the Service Connector Outside CAB (Ground Level Download Specification).................. 858 Adjust After Replacement of KOMTRAX Plus Controller....................................................................... 861 How to Adjust After Replacement of KOMTRAX Plus Controller............................................................ 861 Adjust After Replacement of Wireless LAN Modem............................................................................ 864 How to Adjust After Replacement of Wireless LAN Modem................................................................. 864 Setting of Mobile Communication Terminal.................................................................................. 867 How to Set Mobile Communication Terminal.............................................................................. 867 Adjust Rearview Camera Angle.............................................................................................. 877 How to Adjust Rearview Camera Angle................................................................................... 877 Adjust Optical Axis of Head Lamp.......................................................................................... 878 How to Adjust Optical Axis of Head Lamp............................................................................... 878 Set Region of Bluetooth(R) Compatible Radio............................................................................... 882 How to Set Region of Bluetooth(R) Compatible Radio.................................................................... 882 Handle Voltage Circuit of Engine Controller............................................................................... 884 Handle Battery Disconnect Switch.......................................................................................... 885 Battery Disconnect Switch (Machine with Mobile Communication Terminal).................................................... 887 Examine Diodes............................................................................................................ 889 How to Examine Diodes by Digital Tester............................................................................... 889 How to Examine Diodes by Analog Tester................................................................................ 889 Change Lighting Pattern of Seat Belt Reminder Lamp........................................................................ 890 How to Change Lighting Pattern of Seat Belt Reminder Lamp............................................................. 890 Pm Clinic..................................................................................................................... 891 Pm Clinic Service......................................................................................................... 891 Pm Clinic Check Sheet: HD465-10....................................................................................... 895 Pm Clinic Check Sheet: HD605-10....................................................................................... 902 Quick Pm.............................................................................................................. 909 40 Troubleshooting................................................................................................................ 915 Table of Contents............................................................................................................. 916 Precautions Before Work....................................................................................................... 929 Related Information for Troubleshooting....................................................................................... 930 Precautions for Troubleshooting........................................................................................... 930 Sequence of Events in Troubleshooting..................................................................................... 931 General Troubleshooting Points............................................................................................ 933 Troubleshooting Points for Aftertreatment System.......................................................................... 934 Inspection Before Troubleshooting......................................................................................... 940 Inspection Procedure Before Troubleshooting............................................................................... 942 Walk-Around Check..................................................................................................... 942 Test in Accordance with Testing Procedure................................................................................. 944 Examine Fuel Level.................................................................................................... 944 Examine for Impure Ingredient in Fuel................................................................................. 945 Examine Fuel Prefilter................................................................................................ 945 Examine Fuel Main Filter.............................................................................................. 947 Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type........................................................... 949 Examine Coolant Level (Sub-Tank)...................................................................................... 950 Examine Air Cleaner Clogging.......................................................................................... 951 Clean Outer Element................................................................................................... 952 Replace Element....................................................................................................... 955 Examine Hydraulic Oil Level........................................................................................... 956 Examine Hydraulic Oil Strainer........................................................................................ 956 Examine Hydraulic Oil Filter.......................................................................................... 957 Examine Oil Level in Transmission Case................................................................................ 958 Examine Oil Level in Differential Case................................................................................ 958 Examine Oil Level in Final Drive Case................................................................................. 958 Bleed Air from Fuel System............................................................................................ 959 Bleed Air from Hydraulic System....................................................................................... 959 How to Examine Electrical Components.................................................................................. 959 Preparation for Troubleshooting of Electrical System...................................................................... 965 Preparation for Troubleshooting of Machine Monitor.................................................................... 965 Preparation for Troubleshooting of Transmission Controller............................................................ 965 Preparation for Troubleshooting of Retarder and Hoist Controller...................................................... 965 Preparation for Troubleshooting of Monitor Controller................................................................. 966 Preparation for Troubleshooting of KOMTRAX Terminal................................................................... 968 Preparation for Troubleshooting of KOMTRAX Plus Controller............................................................ 968 Preparation for Troubleshooting of Engine Controller.................................................................. 969 How to Disconnect and Connect Connector with a Special Lock........................................................... 970 Procedure for Troubleshooting............................................................................................. 974 Symptom and Troubleshooting Numbers....................................................................................... 977 Information Shown in Troubleshooting...................................................................................... 981 Connector List and Layout................................................................................................. 984 Connector Layout 1....................................................................................................1001 Connector Layout 2....................................................................................................1003 Connector Layout 3....................................................................................................1005 Connector Layout 4....................................................................................................1007 Connector Layout 5....................................................................................................1008 Connector Layout 6....................................................................................................1009 Connector List and Layout (Machine with Mobile Communication Terminal)....................................................1010 Connector Layout (Machine with Mobile Communication Terminal).........................................................1011 Connector Contact Connection Table........................................................................................1012 T-Branch Box and T-Branch Adapter Table...................................................................................1059 Fuse Location Table.......................................................................................................1065 Precautions When You Clean and Replace KDPF (KCSF and KDOC)...............................................................1071 Prepare Troubleshoot Machine Monitor......................................................................................1075 Procedure to Make Harness Checker on Machine Monitor LCD Unit.............................................................1077 Prepare of Short Circuit Electrical Connector (For Failure Codes [CA1883], [CB1883], [CA3135] and [CB3135])...............1082 Failure Code Table........................................................................................................1084 Troubleshooting by Failure Code (Display of Code).............................................................................1108 Failure Code [1500L0].....................................................................................................1108 Failure Code [15B0NX].....................................................................................................1109 Failure Code [15F0KM].....................................................................................................1113 Failure Code [15F0MB].....................................................................................................1114 Failure Code [15F7KM].....................................................................................................1115 Failure Code [15G0MW].....................................................................................................1116 Failure Code [15G7KM].....................................................................................................1118 Failure Code [15H0MW].....................................................................................................1119 Failure Code [15J0MW].....................................................................................................1121 Failure Code [15K0MW].....................................................................................................1123 Failure Code [15L0MW].....................................................................................................1125 Failure Code [15M0MW].....................................................................................................1127 Failure Code [15N0MW].....................................................................................................1129 Failure Code [15SBL1].....................................................................................................1131 Failure Code [15SBMA].....................................................................................................1134 Failure Code [15SCL1].....................................................................................................1136 Failure Code [15SCMA].....................................................................................................1139 Failure Code [15SDL1].....................................................................................................1141 Failure Code [15SDMA].....................................................................................................1144 Failure Code [15SEL1].....................................................................................................1146 Failure Code [15SEMA].....................................................................................................1149 Failure Code [15SFL1].....................................................................................................1151 Failure Code [15SFMA].....................................................................................................1154 Failure Code [15SGL1].....................................................................................................1156 Failure Code [15SGMA].....................................................................................................1159 Failure Code [15SHL1].....................................................................................................1161 Failure Code [15SHMA].....................................................................................................1164 Failure Code [15SJMA].....................................................................................................1166 Failure Code [2C4MNX].....................................................................................................1168 Failure Code [2F00KM].....................................................................................................1171 Failure Code [2G42ZG].....................................................................................................1175 Failure Code [2G43ZG].....................................................................................................1177 Failure Code [6014NX].....................................................................................................1179 Failure Code [879AKA].....................................................................................................1181 Failure Code [879AKB].....................................................................................................1182 Failure Code [879BKA].....................................................................................................1183 Failure Code [879BKB].....................................................................................................1186 Failure Code [879CKA].....................................................................................................1189 Failure Code [879CKB].....................................................................................................1190 Failure Code [879EMC].....................................................................................................1191 Failure Code [879FMC].....................................................................................................1192 Failure Code [879GKX].....................................................................................................1193 Failure Code [989D00].....................................................................................................1196 Failure Code [989L00].....................................................................................................1198 Failure Code [989M00].....................................................................................................1199 Failure Code [989N00].....................................................................................................1200 Failure Code [989X00].....................................................................................................1201 Failure Code [989Y00].....................................................................................................1202 Failure Code [989YR2].....................................................................................................1204 Failure Code [A1U0N3].....................................................................................................1206 Failure Code [A1U0N4].....................................................................................................1208 Failure Code [AA10NX].....................................................................................................1210 Failure Code [AB00KE].....................................................................................................1213 Failure Code [AB00KY].....................................................................................................1217 Failure Code [AQ00N3].....................................................................................................1219 Failure Code [AQ00N4].....................................................................................................1220 Failure Code [AQ10N3].....................................................................................................1221 Failure Code [B@BAZG].....................................................................................................1222 Failure Code [B@BAZK].....................................................................................................1223 Failure Code [B@BCNS].....................................................................................................1226 Failure Code [B@BCQA].....................................................................................................1227 Failure Code [B@BCZK].....................................................................................................1230 Failure Code [B@C7NS].....................................................................................................1233 Failure Code [B@CENS].....................................................................................................1236 Failure Code [B@JANS].....................................................................................................1239 Failure Code [CA115]......................................................................................................1242 Failure Code [CA122]......................................................................................................1246 Failure Code [CA123]......................................................................................................1248 Failure Code [CA131]......................................................................................................1250 Failure Code [CA132]......................................................................................................1252 Failure Code [CA135]......................................................................................................1254 Failure Code [CA141]......................................................................................................1256 Failure Code [CA144]......................................................................................................1258 Failure Code [CA145]......................................................................................................1260 Failure Code [CA153]......................................................................................................1262 Failure Code [CA154]......................................................................................................1264 Failure Code [CA187]......................................................................................................1266 Failure Code [CA212]......................................................................................................1268 Failure Code [CA213]......................................................................................................1270 Failure Code [CA221]......................................................................................................1272 Failure Code [CA222]......................................................................................................1274 Failure Code [CA227]......................................................................................................1276 Failure Code [CA234]......................................................................................................1278 Failure Code [CA238]......................................................................................................1279 Failure Code [CA239]......................................................................................................1281 Failure Code [CA271]......................................................................................................1283 Failure Code [CA272]......................................................................................................1285 Failure Code [CA273]......................................................................................................1286 Failure Code [CA274]......................................................................................................1288 Failure Code [CA322]......................................................................................................1289 Failure Code [CA323]......................................................................................................1291 Failure Code [CA324]......................................................................................................1293 Failure Code [CA325]......................................................................................................1295 Failure Code [CA331]......................................................................................................1297 Failure Code [CA332]......................................................................................................1299 Failure Code [CA343]......................................................................................................1301 Failure Code [CA351]......................................................................................................1304 Failure Code [CA352]......................................................................................................1307 Failure Code [CA356]......................................................................................................1309 Failure Code [CA357]......................................................................................................1311 Failure Code [CA386]......................................................................................................1313 Failure Code [CA431]......................................................................................................1315 Failure Code [CA432]......................................................................................................1318 Failure Code [CA441]......................................................................................................1321 Failure Code [CA442]......................................................................................................1324 Failure Code [CA449]......................................................................................................1327 Failure Code [CA451]......................................................................................................1328 Failure Code [CA452]......................................................................................................1330 Failure Code [CA515]......................................................................................................1332 Failure Code [CA516]......................................................................................................1334 Failure Code [CA553]......................................................................................................1336 Failure Code [CA555]......................................................................................................1337 Failure Code [CA556]......................................................................................................1339 Failure Code [CA559]......................................................................................................1341 Failure Code [CA595]......................................................................................................1344 Failure Code [CA687]......................................................................................................1346 Failure Code [CA689]......................................................................................................1348 Failure Code [CA691]......................................................................................................1350 Failure Code [CA692]......................................................................................................1352 Failure Code [CA697]......................................................................................................1354 Failure Code [CA698]......................................................................................................1355 Failure Code [CA731]......................................................................................................1356 Failure Code [CA778]......................................................................................................1359 Failure Code [CA1117].....................................................................................................1362 Failure Code [CA1135].....................................................................................................1365 Failure Code [CA1257].....................................................................................................1368 Failure Code [CA1664].....................................................................................................1369 Failure Code [CA1691].....................................................................................................1371 Failure Code [CA1695].....................................................................................................1374 Failure Code [CA1696].....................................................................................................1376 Failure Code [CA1843].....................................................................................................1378 Failure Code [CA1844].....................................................................................................1380 Failure Code [CA1879].....................................................................................................1382 Failure Code [CA1881].....................................................................................................1384 Failure Code [CA1883].....................................................................................................1386 Failure Code [CA1921].....................................................................................................1389 Failure Code [CA1922].....................................................................................................1391 Failure Code [CA1923].....................................................................................................1394 Failure Code [CA1924].....................................................................................................1396 Failure Code [CA1925].....................................................................................................1401 Failure Code [CA1927].....................................................................................................1405 Failure Code [CA1928].....................................................................................................1407 Failure Code [CA1942].....................................................................................................1409 Failure Code [CA1963].....................................................................................................1411 Failure Code [CA1977].....................................................................................................1419 Failure Code [CA1993].....................................................................................................1421 Failure Code [CA2185].....................................................................................................1424 Failure Code [CA2186].....................................................................................................1426 Failure Code [CA2249].....................................................................................................1428 Failure Code [CA2265].....................................................................................................1431 Failure Code [CA2266].....................................................................................................1433 Failure Code [CA2271].....................................................................................................1435 Failure Code [CA2272].....................................................................................................1437 Failure Code [CA2349].....................................................................................................1439 Failure Code [CA2353].....................................................................................................1441 Failure Code [CA2357].....................................................................................................1443 Failure Code [CA2381].....................................................................................................1446 Failure Code [CA2382].....................................................................................................1448 Failure Code [CA2383].....................................................................................................1450 Failure Code [CA2386].....................................................................................................1452 Failure Code [CA2387].....................................................................................................1454 Troubleshooting Flowchart.................................................................................................1458 Failure Code [CA2555].....................................................................................................1459 Failure Code [CA2556].....................................................................................................1461 Failure Code [CA2637].....................................................................................................1463 Failure Code [CA2639].....................................................................................................1465 Failure Code [CA2732].....................................................................................................1467 Failure Code [CA2733].....................................................................................................1469 Failure Code [CA2741].....................................................................................................1471 Failure Code [CA2765].....................................................................................................1475 Failure Code [CA2777].....................................................................................................1476 Failure Code [CA2878].....................................................................................................1478 Failure Code [CA2881].....................................................................................................1483 Failure Code [CA3133].....................................................................................................1489 Failure Code [CA3134].....................................................................................................1491 Failure Code [CA3135].....................................................................................................1493 Failure Code [CA3167].....................................................................................................1496 Failure Code [CA3251].....................................................................................................1501 Failure Code [CA3253].....................................................................................................1503 Failure Code [CA3254].....................................................................................................1507 Failure Code [CA3255].....................................................................................................1510 Failure Code [CA3256].....................................................................................................1512 Failure Code [CA3311].....................................................................................................1514 Failure Code [CA3312].....................................................................................................1516 Failure Code [CA3313].....................................................................................................1518 Failure Code [CA3314].....................................................................................................1519 Failure Code [CA3315].....................................................................................................1520 Failure Code [CA3316].....................................................................................................1523 Failure Code [CA3317].....................................................................................................1524 Failure Code [CA3318].....................................................................................................1525 Failure Code [CA3319].....................................................................................................1528 Failure Code [CA3321].....................................................................................................1529 Failure Code [CA3322].....................................................................................................1530 Failure Code [CA3419].....................................................................................................1533 Failure Code [CA3421].....................................................................................................1535 Failure Code [CA4151].....................................................................................................1537 Failure Code [CA4158].....................................................................................................1540 Failure Code [CA4161].....................................................................................................1542 Failure Code [CA4162].....................................................................................................1544 Failure Code [CA4163].....................................................................................................1546 Failure Code [CA4259].....................................................................................................1548 Failure Code [CA4952].....................................................................................................1550 Failure Code [CA5383].....................................................................................................1553 Failure Code [CB115]......................................................................................................1554 Failure Code [CB187]......................................................................................................1558 Failure Code [CB227]......................................................................................................1559 Failure Code [CB238]......................................................................................................1560 Failure Code [CB239]......................................................................................................1562 Failure Code [CB271]......................................................................................................1564 Failure Code [CB272]......................................................................................................1566 Failure Code [CB273]......................................................................................................1567 Failure Code [CB274]......................................................................................................1569 Failure Code [CB343]......................................................................................................1570 Failure Code [CB352]......................................................................................................1573 Failure Code [CB386]......................................................................................................1575 Failure Code [CB441]......................................................................................................1577 Failure Code [CB442]......................................................................................................1580 Failure Code [CB689]......................................................................................................1583 Failure Code [CB697]......................................................................................................1585 Failure Code [CB698]......................................................................................................1586 Failure Code [CB731]......................................................................................................1587 Failure Code [CB778]......................................................................................................1591 Failure Code [CB1117].....................................................................................................1593 Failure Code [CB1257].....................................................................................................1596 Failure Code [CB1664].....................................................................................................1597 Failure Code [CB1691].....................................................................................................1599 Failure Code [CB1695].....................................................................................................1602 Failure Code [CB1696].....................................................................................................1604 Failure Code [CB1879].....................................................................................................1606 Failure Code [CB1881].....................................................................................................1608 Failure Code [CB1883].....................................................................................................1610 Failure Code [CB1921].....................................................................................................1613 Failure Code [CB1922].....................................................................................................1615 Failure Code [CB1923].....................................................................................................1618 Failure Code [CB1924].....................................................................................................1620 Failure Code [CB1925].....................................................................................................1625 Failure Code [CB1927].....................................................................................................1629 Failure Code [CB1928].....................................................................................................1631 Failure Code [CB1963].....................................................................................................1633 Failure Code [CB1977].....................................................................................................1641 Failure Code [CB1993].....................................................................................................1643 Failure Code [CB2265].....................................................................................................1646 Failure Code [CB2266].....................................................................................................1648 Failure Code [CB2637].....................................................................................................1650 Failure Code [CB2639].....................................................................................................1653 Failure Code [CB2732].....................................................................................................1655 Failure Code [CB2733].....................................................................................................1657 Failure Code [CB2741].....................................................................................................1659 Failure Code [CB2777].....................................................................................................1663 Failure Code [CB2878].....................................................................................................1665 Failure Code [CB2881].....................................................................................................1670 Failure Code [CB3133].....................................................................................................1676 Failure Code [CB3134].....................................................................................................1678 Failure Code [CB3135].....................................................................................................1680 Failure Code [CB3167].....................................................................................................1683 Failure Code [CB3251].....................................................................................................1688 Failure Code [CB3253].....................................................................................................1690 Failure Code [CB3254].....................................................................................................1694 Failure Code [CB3255].....................................................................................................1697 Failure Code [CB3256].....................................................................................................1699 Failure Code [CB3311].....................................................................................................1701 Failure Code [CB3312].....................................................................................................1703 Failure Code [CB3313].....................................................................................................1705 Failure Code [CB3314].....................................................................................................1706 Failure Code [CB3315].....................................................................................................1707 Failure Code [CB3316].....................................................................................................1710 Failure Code [CB3317].....................................................................................................1711 Failure Code [CB3318].....................................................................................................1712 Failure Code [CB3319].....................................................................................................1715 Failure Code [CB3321].....................................................................................................1716 Failure Code [CB3322].....................................................................................................1717 Failure Code [CB4151].....................................................................................................1720 Failure Code [CB4158].....................................................................................................1723 Failure Code [CB4161].....................................................................................................1724 Failure Code [CB4162].....................................................................................................1726 Failure Code [CB4163].....................................................................................................1728 Failure Code [CB4259].....................................................................................................1730 Failure Code [CB4952].....................................................................................................1732 Failure Code [CB5383].....................................................................................................1735 Failure Code [D101KA].....................................................................................................1736 Failure Code [D101KB].....................................................................................................1739 Failure Code [D101KY].....................................................................................................1742 Failure Code [D131KA].....................................................................................................1745 Failure Code [D131KB].....................................................................................................1748 Failure Code [D131KY].....................................................................................................1751 Failure Code [D150KB].....................................................................................................1754 Failure Code [D150KZ].....................................................................................................1757 Failure Code [D164KY].....................................................................................................1760 Failure Code [D19HKZ].....................................................................................................1763 Failure Code [D19JKZ].....................................................................................................1766 Failure Code [D19QKZ].....................................................................................................1769 Failure Code [D1EHKA].....................................................................................................1772 Failure Code [D1EHKB].....................................................................................................1775 Failure Code [D1EHKY].....................................................................................................1778 Failure Code [D1EMKA].....................................................................................................1780 Failure Code [D1EMKB].....................................................................................................1782 Failure Code [D1EMKY].....................................................................................................1785 Failure Code [D1FBKB].....................................................................................................1787 Failure Code [D5ZHL6].....................................................................................................1790 Failure Code [D5ZKKZ].....................................................................................................1793 Failure Code [D862KA].....................................................................................................1796 Failure Code [DAF0KT].....................................................................................................1799 Failure Code [DAF0MB].....................................................................................................1800 Failure Code [DAF0MC].....................................................................................................1801 Failure Code [DAF3KK].....................................................................................................1802 Failure Code [DAF8KB].....................................................................................................1806 Failure Code [DAFDKB].....................................................................................................1809 Failure Code [DAFGMC].....................................................................................................1812 Failure Code [DAFLKA].....................................................................................................1813 Failure Code [DAFLKB].....................................................................................................1816 Failure Code [DAFQKR].....................................................................................................1818 Failure Code [DAQ0KK].....................................................................................................1830 Failure Code [DAQ0KT].....................................................................................................1833 Failure Code [DAQ0MC].....................................................................................................1835 Failure Code [DAQ1KA].....................................................................................................1836 Failure Code [DAQ2KK].....................................................................................................1839 Failure Code [DAQ2KT].....................................................................................................1843 Failure Code [DAQ9KQ].....................................................................................................1844 Failure Code [DAQLKA].....................................................................................................1846 Failure Code [DAQLKB].....................................................................................................1850 Failure Code [DAQQKR].....................................................................................................1853 Failure Code [DAQRKR].....................................................................................................1866 Failure Code [DAQRMA].....................................................................................................1879 Failure Code [DAQV00].....................................................................................................1881 Failure Code [DAQW00].....................................................................................................1882 Failure Code [DAZ9KQ].....................................................................................................1883 Failure Code [DAZQKR].....................................................................................................1885 Failure Code [DB10KT].....................................................................................................1897 Failure Code [DB10MC].....................................................................................................1898 Failure Code [DB11KA].....................................................................................................1899 Failure Code [DB12KK].....................................................................................................1902 Failure Code [DB12KT].....................................................................................................1906 Failure Code [DB13KK].....................................................................................................1907 Failure Code [DB19KQ].....................................................................................................1911 Failure Code [DB1LKA].....................................................................................................1913 Failure Code [DB1LKB].....................................................................................................1917 Failure Code [DB1QKR].....................................................................................................1920 Failure Code [DB1QMA].....................................................................................................1933 Failure Code [DB1RKR].....................................................................................................1935 Failure Code [DB2QKR].....................................................................................................1948 Failure Code [DB2RKR].....................................................................................................1964 Failure Code [DBV0MC].....................................................................................................1978 Failure Code [DBV1KK].....................................................................................................1979 Failure Code [DBV6KB].....................................................................................................1982 Failure Code [DBV7KB].....................................................................................................1986 Failure Code [DBVLKA].....................................................................................................1989 Failure Code [DBVLKB].....................................................................................................1992 Failure Code [DBVQKR].....................................................................................................1995 Failure Code [DBVRKR].....................................................................................................2006 Failure Code [DBVRMA].....................................................................................................2018 Failure Code [DBVVKR].....................................................................................................2020 Failure Code [DBVWKR].....................................................................................................2022 Failure Code [DDA7LD].....................................................................................................2024 Failure Code [DDAAL6].....................................................................................................2027 Failure Code [DDACL4].....................................................................................................2031 Failure Code [DDADKA].....................................................................................................2036 Failure Code [DDADKY].....................................................................................................2039 Failure Code [DDD7KX].....................................................................................................2041 Failure Code [DDTHKA].....................................................................................................2045 Failure Code [DDTJKA].....................................................................................................2048 Failure Code [DDTKKA].....................................................................................................2051 Failure Code [DDTLKA].....................................................................................................2054 Failure Code [DDTMKA].....................................................................................................2057 Failure Code [DDTNKA].....................................................................................................2060 Failure Code [DDTPKA].....................................................................................................2063 Failure Code [DF10KA].....................................................................................................2066 Failure Code [DF10KB].....................................................................................................2072 Failure Code [DGE5KX].....................................................................................................2077 Failure Code [DGF1KX].....................................................................................................2081 Failure Code [DGR2KB].....................................................................................................2085 Failure Code [DGR6KB].....................................................................................................2088 Failure Code [DGR6L8].....................................................................................................2091 Failure Code [DGR8KX].....................................................................................................2094 Failure Code [DGT1KX].....................................................................................................2098 Failure Code [DGT4KA].....................................................................................................2102 Failure Code [DGT4KY].....................................................................................................2107 Failure Code [DHA4KA].....................................................................................................2111 Failure Code [DHAAMA].....................................................................................................2114 Failure Code [DHABMA].....................................................................................................2115 Failure Code [DHACMA].....................................................................................................2116 Failure Code [DHADMA].....................................................................................................2117 Failure Code [DHP4KY].....................................................................................................2118 Failure Code [DHP4KZ].....................................................................................................2121 Failure Code [DHP5KY].....................................................................................................2124 Failure Code [DHP5KZ].....................................................................................................2127 Failure Code [DHP6KA].....................................................................................................2130 Failure Code [DHP6KX].....................................................................................................2134 Failure Code [DHP6KY].....................................................................................................2138 Failure Code [DHP6KZ].....................................................................................................2141 Failure Code [DHP7KA].....................................................................................................2144 Failure Code [DHP7KX].....................................................................................................2148 Failure Code [DHP7KY].....................................................................................................2152 Failure Code [DHP7KZ].....................................................................................................2155 Failure Code [DHQ2KX].....................................................................................................2158 Failure Code [DHQ4KX].....................................................................................................2162 Failure Code [DHT5KX].....................................................................................................2166 Failure Code [DHT5L6].....................................................................................................2169 Failure Code [DHT8KX].....................................................................................................2171 Failure Code [DHT8ZG].....................................................................................................2175 Failure Code [DHU2KX].....................................................................................................2177 Failure Code [DHU3KX].....................................................................................................2181 Failure Code [DHUCKX].....................................................................................................2185 Failure Code [DHUDKX].....................................................................................................2189 Failure Code [DHUHKX].....................................................................................................2193 Failure Code [DHULKX].....................................................................................................2197 Failure Code [DHUMKX].....................................................................................................2201 Failure Code [DHUPKX].....................................................................................................2205 Failure Code [DHY9KX].....................................................................................................2209 Failure Code [DJF1KA].....................................................................................................2212 Failure Code [DK30KX].....................................................................................................2215 Failure Code [DK51L5].....................................................................................................2219 Failure Code [DK52KX].....................................................................................................2225 Failure Code [DK53L8].....................................................................................................2230 Failure Code [DK54KX].....................................................................................................2233 Failure Code [DK60KX].....................................................................................................2237 Failure Code [DKH0KX].....................................................................................................2240 Failure Code [DKH1KX].....................................................................................................2244 Failure Code [DLF1KA].....................................................................................................2248 Failure Code [DLF1LC].....................................................................................................2251 Failure Code [DLF2KA].....................................................................................................2255 Failure Code [DLF2LC].....................................................................................................2258 Failure Code [DLF8KA].....................................................................................................2262 Failure Code [DLF8LC].....................................................................................................2265 Failure Code [DLF9KA].....................................................................................................2268 Failure Code [DLF9LC].....................................................................................................2271 Failure Code [DLM3KA].....................................................................................................2274 Failure Code [DLM3LC].....................................................................................................2276 Failure Code [DLM3MB].....................................................................................................2279 Failure Code [DLT3KA].....................................................................................................2281 Failure Code [DLT3LC].....................................................................................................2283 Failure Code [DPQ1KR].....................................................................................................2286 Failure Code [DPQ2KR].....................................................................................................2292 Failure Code [DPQ3KR].....................................................................................................2298 Failure Code [DSJ0KR].....................................................................................................2304 Failure Code [DV00KB].....................................................................................................2314 Failure Code [DW2AKA].....................................................................................................2317 Failure Code [DW2AKB].....................................................................................................2320 Failure Code [DW2AKY].....................................................................................................2323 Failure Code [DW2AL1].....................................................................................................2325 Failure Code [DW2ALH].....................................................................................................2328 Failure Code [DW2BKA].....................................................................................................2331 Failure Code [DW2BKB].....................................................................................................2334 Failure Code [DW2BKY].....................................................................................................2337 Failure Code [DW2BL1].....................................................................................................2339 Failure Code [DW2BLH].....................................................................................................2342 Failure Code [DW4BK4].....................................................................................................2345 Failure Code [DW4BMA].....................................................................................................2349 Failure Code [DW72KZ].....................................................................................................2353 Failure Code [DW73KA].....................................................................................................2356 Failure Code [DW73KB].....................................................................................................2358 Failure Code [DW73KY].....................................................................................................2361 Failure Code [DW78KZ].....................................................................................................2363 Failure Code [DW7BKB].....................................................................................................2367 Failure Code [DW7BKY].....................................................................................................2370 Failure Code [DW7BKZ].....................................................................................................2372 Failure Code [DW7NKZ].....................................................................................................2374 Failure Code [DWD6KA].....................................................................................................2377 Failure Code [DWD6KB].....................................................................................................2379 Failure Code [DWD6KY].....................................................................................................2382 Failure Code [DWD6MA].....................................................................................................2384 Failure Code [DWD7K4].....................................................................................................2388 Failure Code [DWD7KA].....................................................................................................2391 Failure Code [DWD7KB].....................................................................................................2393 Failure Code [DWD7KY].....................................................................................................2396 Failure Code [DWD7MA].....................................................................................................2398 Failure Code [DWNMKZ].....................................................................................................2401 Failure Code [DX11K4].....................................................................................................2404 Failure Code [DX11KA].....................................................................................................2407 Failure Code [DX11KB].....................................................................................................2410 Failure Code [DX11KY].....................................................................................................2413 Failure Code [DX11MA].....................................................................................................2416 Failure Code [DX13KA].....................................................................................................2419 Failure Code [DX13KB].....................................................................................................2421 Failure Code [DX13KY].....................................................................................................2424 Failure Code [DX16KA].....................................................................................................2426 Failure Code [DX16KB].....................................................................................................2428 Failure Code [DX16KY].....................................................................................................2431 Failure Code [DX37K4].....................................................................................................2433 Failure Code [DX37KA].....................................................................................................2436 Failure Code [DX37KB].....................................................................................................2439 Failure Code [DX37KY].....................................................................................................2442 Failure Code [DX37MA].....................................................................................................2444 Failure Code [DX38K4].....................................................................................................2447 Failure Code [DX38KA].....................................................................................................2450 Failure Code [DX38KB].....................................................................................................2453 Failure Code [DX38KY].....................................................................................................2456 Failure Code [DX38MA].....................................................................................................2458 Failure Code [DXH1KA].....................................................................................................2461 Failure Code [DXH1KB].....................................................................................................2464 Failure Code [DXH1KY].....................................................................................................2467 Failure Code [DXH2KA].....................................................................................................2469 Failure Code [DXH2KB].....................................................................................................2472 Failure Code [DXH2KY].....................................................................................................2475 Failure Code [DXH3KA].....................................................................................................2477 Failure Code [DXH3KB].....................................................................................................2480 Failure Code [DXH3KY].....................................................................................................2483 Failure Code [DXH4KA].....................................................................................................2485 Failure Code [DXH4KB].....................................................................................................2488 Failure Code [DXH4KY].....................................................................................................2491 Failure Code [DXH5KA].....................................................................................................2493 Failure Code [DXH5KB].....................................................................................................2496 Failure Code [DXH5KY].....................................................................................................2499 Failure Code [DXH6KA].....................................................................................................2501 Failure Code [DXH6KB].....................................................................................................2504 Failure Code [DXH6KY].....................................................................................................2507 Failure Code [DXH7KA].....................................................................................................2509 Failure Code [DXH7KB].....................................................................................................2512 Failure Code [DXH7KY].....................................................................................................2515 Failure Code [DXHHKA].....................................................................................................2517 Failure Code [DXHHKB].....................................................................................................2520 Failure Code [DXHHKY].....................................................................................................2523 Failure Code [DY30MA].....................................................................................................2525 Failure Code [DY30MC].....................................................................................................2529 Failure Code [DY30ME].....................................................................................................2536 Failure Code [F@BYNR].....................................................................................................2539 Failure Code [F@BYNS].....................................................................................................2541 Troubleshooting of Electrical System (E-Mode).................................................................................2543 Engine Does Not Start (Engine Does Not Crank).............................................................................2543 Manual Preheating System Does Not Operate.................................................................................2554 Automatic Preheating System Does Not Operate..............................................................................2559 While Preheating is in Operation, Preheating Pilot Lamp Does Not Come On..................................................2563 LCD Unit, LED Unit, and Meter Unit on Machine Monitor Do Not Show Anything................................................2565 LCD Unit on Machine Monitor Shows Nothing.................................................................................2575 Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers).....................................2578 LCD Screen on Machine Monitor Does Not Show Correctly.....................................................................2581 Meter Unit Display on Machine Monitor is Abnormal.........................................................................2584 Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal..............................................................2589 LED Unit Lamp on Machine Monitor is Abnormal..............................................................................2593 Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly.......................2597 Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate................................................2602 Switch Panel Buzzer of Machine Monitor is Abnormal........................................................................2607 Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Correctly.........................................2612 Rearview Monitor Does Not Come On or Backlight Flickers...................................................................2613 Rearview Monitor Images are Not Shown Clearly.............................................................................2618 Rearview Monitor Brightness Cannot be Adjusted............................................................................2624 Night Mode Lamp of Rearview Monitor is Abnormal...........................................................................2630 Air Cleaner Clogging Caution Lamp Does Not Come On........................................................................2634 Transmission Oil Filter Clogging Caution Lamp Does Not Come On............................................................2637 Radiator Coolant Level Caution Lamp Does Not Come On......................................................................2641 Rear View Monitor is Not Shown in Conjunction with Revers When the Constant Display Setting is Disable....................2644 Rear View Monitor Reference Line is Not Shown When the Reference Line Display Setting is Turned ON........................2647 Fuel Gauge Does Not Show Normally.........................................................................................2649 Torque Converter Oil Temperature Gauge Does Not Rise or Torque Converter Oil Temperature Caution Lamp Does Not Come On....2652 Retarder Oil Temperature Gauge Does Not Rise or Retarder Oil Temperature Caution Lamp Does Not Come On....................2655 Seatbelt Caution Lamp Does Not Show Normally..............................................................................2658 Machine Monitor Cannot be Operated When Starting Switch is in OFF Position................................................2662 Alarm Buzzer Does Not Operate.............................................................................................2666 Alarm Buzzer Does Not Stop................................................................................................2668 Engine Mode Selector Function Does Not Operate Correctly When Engine Power Mode Selector Switch is Operated...............2673 AISS Function Does Not Operate Correctly..................................................................................2677 Dump (Hoist) Control Lever Does Not Operate Correctly.....................................................................2681 Fuel Feed Pump Does Not Operate or Stop Automatically.....................................................................2684 Turn Signal Lamp and Hazard Lamp Do Not Operate Correctly.................................................................2693 Horn Does Not Sound.......................................................................................................2701 Horn Does Not Stop........................................................................................................2705 Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On....................................................................2708 Clearance Lamp Does Not Come On...........................................................................................2713 Tail Lamp Does Not Come On................................................................................................2716 Headlamp (Low Beam) Does Not Come On......................................................................................2719 Headlamp (High Beam) Does Not Come On.....................................................................................2723 Headlamp (Low Beam) and (High Beam) Do Not Come On........................................................................2727 Dump Light Does Not Come On...............................................................................................2730 Passing Lamp Does Not Come On.............................................................................................2733 KOMTRAX System Does Not Operate Correctly.................................................................................2736 Data Download with Wireless LAN Does Not Operate..........................................................................2738 Cannot Access to the Setting Screen of the Mobile Communication Terminal..................................................2739 Cannot Log in to the Setting Screen of the Mobile Communication Terminal Because the Log in Password is Unknown...........2745 KOMTRAX Plus Controller is Not Found......................................................................................2747 KOMTRAX Plus Controller Does Not Become Active............................................................................2749 Communication Failure Occurs Between Mobile Communication Terminal and KOMTRAX Plus Server................................2750 Restrictions on Radio Reception...........................................................................................2753 Data is Not Sent to KOMTRAX Plus Server...................................................................................2754 Troubleshooting for Hydraulic and Mechanical Systems (H Mode).................................................................2756 Information Shown in Troubleshooting Table (H-Mode).......................................................................2756 Failure Mode and Cause Table..............................................................................................2757 Machine Does Not Start....................................................................................................2761 Table of Clutch to be Used............................................................................................2768 Machine Does Not Travel Smoothly (Machine Hunts)..........................................................................2769 Table of Clutch to be Used............................................................................................2773 Lockup is Not Released....................................................................................................2774 Strong Shock is Made When You Start Machine or Shift Gears................................................................2775 Table of Clutch to be Used............................................................................................2777 Shiftup Does Not Operate..................................................................................................2778 Table of Clutch to be Used............................................................................................2782 Travel Speed in All Gear Speed is Low or Power is Low During Travel with Lockup Function..................................2783 Travel Speed is Low or Power is Low During Travel with Torque Converter...................................................2787 Travel Speed is Low or Power is Low in Specified Gear Speed...............................................................2791 Table of Clutch to be Used............................................................................................2793 Time Lag is Large When You Start Machine or Shift Gears...................................................................2795 Table of Clutch to be Used............................................................................................2799 Torque Converter Oil Temperature is High..................................................................................2800 Torque Converter Oil Pressure is Low......................................................................................2804 Steering Wheel is Heavy to Operate........................................................................................2808 Steering Wheel is Disabled................................................................................................2812 Steering Wheel is Shaken..................................................................................................2815 Parking Brake Does Not Operate or is Weak.................................................................................2817 Parking Brake is Not Released or Drags....................................................................................2818 Front Brake Does Not Operate Sufficiently.................................................................................2820 Rear Brake Does Not Operate Sufficiently..................................................................................2823 Speed is Low When Dump Body is Raised.....................................................................................2826 Hydraulic Drift of Dump Body is Large.....................................................................................2831 Dump Body is Disabled.....................................................................................................2832 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)...............................................................2836 Unusual Noise is Heard from Around Fan....................................................................................2840 Troubleshooting of Engine (S-Mode)............................................................................................2841 Information Shown in Troubleshooting Table (S-Mode).......................................................................2841 Engine Does Not Crank When Starting Switch is Turned to Start Position....................................................2842 Engine Cranks but No Exhaust Smoke Comes Out..............................................................................2843 Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)...................................2844 Engine Startability is Unsatisfactory.....................................................................................2845 Engine Does Not Pick Up Smoothly..........................................................................................2847 Engine Stops During Operation.............................................................................................2849 Engine Does Not Rotate Smoothly...........................................................................................2851 Engine Lacks Output (or Lacks Power)......................................................................................2852 KDPF Becomes Clogged in a Short Time......................................................................................2854 Engine Oil Consumption is Excessive.......................................................................................2856 Engine Oil Becomes Dirty Quickly..........................................................................................2857 Fuel Consumption is Excessive.............................................................................................2858 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down).....................................................2859 Engine Oil Pressure Drops.................................................................................................2860 Fuel Mixes Into Engine Oil................................................................................................2862 Water Mixes Into Engine Oil (Milky).......................................................................................2863 Coolant Temperature Increases Too High (Overheat).........................................................................2864 Unusual Noise is Heard....................................................................................................2865 Vibration is Excessive....................................................................................................2866 Air Cannot be Bled from Fuel Circuit......................................................................................2867 Active Regeneration is Done Frequently....................................................................................2868 Active Regeneration Continues Long........................................................................................2872 White Smoke is Exhausted During Active Regeneration.......................................................................2873 60 Maintenance Standard...........................................................................................................2875 Table of Contents.............................................................................................................2876 Explanation of Terms for Maintenance Standard.................................................................................2877 Engine and Cooling System.....................................................................................................2879 Maintenance Standard for Engine Mount.....................................................................................2879 Maintenance Standard for Damper...........................................................................................2880 Maintenance Standard for Cooling Fan Pump.................................................................................2882 Maintenance Standard for Servo Valve for Cooling Fan Pump.................................................................2884 Maintenance Standard for Cooling Fan Motor................................................................................2885 Power Train...................................................................................................................2887 Maintenance Standard for Drive Shaft......................................................................................2887 Maintenance Standard for Torque Converter and Transmission Mount..........................................................2888 Maintenance Standard for Torque Converter and PTO.........................................................................2889 Maintenance Standard for Torque Converter Valve...........................................................................2893 Maintenance Standard for Transmission.....................................................................................2895 Maintenance Standard for Transmission Control Valve.......................................................................2901 Maintenance Standard for H, L, 4th, 3rd, R, 2nd, and 1st ECMV.............................................................2902 Maintenance Standard for Lockup Clutch ECMV...............................................................................2903 Maintenance Standard for Front Axle.......................................................................................2904 Maintenance Standard for Rear Axle........................................................................................2905 Maintenance Standard for Differential.....................................................................................2906 Maintenance Standard for Final Drive......................................................................................2907 Steering System...............................................................................................................2908 Maintenance Standard for Steering Column..................................................................................2908 Maintenance Standard for Steering Linkage.................................................................................2909 Maintenance Standard for Demand Valve.....................................................................................2912 Maintenance Standard for Steering Cylinder................................................................................2915 Brake System..................................................................................................................2916 Maintenance Standard for Slack Adjuster...................................................................................2916 Maintenance Standard for Front Brake......................................................................................2917 Maintenance Standard for Rear Brake.......................................................................................2918 Undercarriage and Frame.......................................................................................................2920 Maintenance Standard for Front Suspension Cylinder........................................................................2920 Maintenance Standard for Rear Suspension Cylinder.........................................................................2923 Hydraulic System..............................................................................................................2925 Maintenance Standard for Pump Assembly (Steering, Hoist)..................................................................2925 Maintenance Standard for Servo Valve of Pump Assembly (Steering, Hoist)...................................................2926 Maintenance Standard of Pump Assembly (Power Train and Brake Cooling).....................................................2928 Maintenance Standard of Pump Assembly (Brake Cooling and Control).........................................................2929 Maintenance Standard for Hoist Valve......................................................................................2931 Work Equipment................................................................................................................2933 Maintenance Standard for Hoist Cylinder...................................................................................2933 CAB Related Parts.............................................................................................................2934 Maintenance Standard for CAB Mount........................................................................................2934 80 Others.........................................................................................................................2935 Table of Contents.............................................................................................................2936 Precautions Before Work.......................................................................................................2938 Air Conditioner System........................................................................................................2939 Precautions for Refrigerant...............................................................................................2939 Layout Drawing of Air Conditioner System..................................................................................2940 Specifications of Air Conditioner.........................................................................................2942 Structure of Refrigeration Cycle..........................................................................................2943 Function of Refrigeration Cycle...........................................................................................2944 Component Parts of Air Conditioner System.................................................................................2946 Air Conditioner Unit..................................................................................................2946 Component Parts of Air Conditioner Unit...................................................................................2949 Function of Evaporator................................................................................................2949 Function of Heater Core...............................................................................................2949 Function of Evaporator Temperature Sensor.............................................................................2949 Function of Servomotor................................................................................................2949 Structure of Expansion Valve..........................................................................................2950 Function of Expansion Valve...........................................................................................2950 Operation of Expansion Valve..........................................................................................2950 Function of Triple Pressure Switch....................................................................................2951 Air Conditioner Controller................................................................................................2953 Structure of Air Conditioner Controller...............................................................................2953 Compressor................................................................................................................2954 Structure of Compressor...............................................................................................2954 Specifications of Compressor..........................................................................................2954 Function of Compressor................................................................................................2954 Condenser.................................................................................................................2955 Structure of Condenser................................................................................................2955 Specifications of Condenser...........................................................................................2955 Function of Condenser.................................................................................................2955 Receiver Drier............................................................................................................2957 Structure of Receiver Dryer...........................................................................................2957 Specifications of Receiver Dryer......................................................................................2957 Function of Receiver Dryer............................................................................................2957 Air Conditioner Related Sensors...........................................................................................2958 Structure of Outside Temperature Sensor...............................................................................2958 Function of Outside Air Temperature Sensor............................................................................2958 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner...............................................2959 Circuit Diagram and Configuration of Connector Pins of Air Conditioner....................................................2962 System Diagram of Air Conditioner.........................................................................................2964 Input and Output Signals of Air Conditioner Controller................................................................2965 Locations of Air Conditioner Parts and Layout of Connectors...............................................................2967 Examine Air Leakage (Duct)................................................................................................2971 How to Examine Air Leakage (Duct).....................................................................................2971 Examine Air Conditioner with Self-Diagnosis Function......................................................................2974 Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor...................................2975 Examine Vent (Mode) Changeover............................................................................................2977 How to Examine Vent (Mode) Changeover.................................................................................2977 Examine Fresh/Recirc Air Changeover.......................................................................................2978 How to Examine Fresh/Recirc Air Changeover............................................................................2978 Examine Refrigerant (Triple) Pressure Switch..............................................................................2979 How to Examine Refrigerant (Triple) Pressure Switch...................................................................2979 Examine Relay.............................................................................................................2981 How to Examine Relay..................................................................................................2981 Air Conditioner Troubleshooting Chart 1...................................................................................2983 Air Conditioner Troubleshooting Chart 2...................................................................................2985 Information Shown in Troubleshooting Table................................................................................2988 Troubleshooting by Failure Code (Display of Code).........................................................................2990 Failure Code [879AKA].................................................................................................2990 Failure Code [879AKB].................................................................................................2991 Failure Code [879BKA].................................................................................................2992 Failure Code [879BKB].................................................................................................2995 Failure Code [879CKA].................................................................................................2998 Failure Code [879CKB].................................................................................................2999 Failure Code [879EMC].................................................................................................3000 Failure Code [879FMC].................................................................................................3001 Failure Code [879GKX].................................................................................................3002 Troubleshooting of Air Conditioner System (A-Mode)........................................................................3005 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)............................................3005 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled).............................................3007 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)....................................3010 Troubleshooting for Fresh/Recirc Air Changeover.......................................................................3012 Troubleshooting by Gauge Pressure.........................................................................................3014 Connect Service Tool......................................................................................................3017 How to Connect Service Tool...........................................................................................3017 Precautions for Disconnection and Connection of Air Conditioner Piping....................................................3019 Handle Compressor Oil.....................................................................................................3021 90 Circuit Diagrams...............................................................................................................3023 Table of Contents.............................................................................................................3024 How to Read the Codes for Electric Cable......................................................................................3025 Hydraulic Circuit Diagram.....................................................................................................3029 Symbols Used in Hydraulic Circuit Diagram.................................................................................3029 Hydraulic Circuit Diagram (1/3)...........................................................................................3033 Hydraulic Circuit Diagram (2/3)...........................................................................................3035 Hydraulic Circuit Diagram (3/3)...........................................................................................3037 Power Train Hydraulic Circuit Diagram.....................................................................................3039 Hydraulic Circuit Diagram of Steering, Hoist, Fan Control (at Reverse 1st, Right Turn, Brake Operation)...................3041 Hydraulic Circuit Diagram of Steering, Hoist, Fan Control (at Hoist Raise, Forward 2nd Operation).........................3043 Hydraulic Circuit Diagram of Brake Cooling (at Reverse 1st, Right Turn, Brake Operation)..................................3045 Hydraulic Circuit Diagram of Brake Cooling (at Retarder Brake Operation)..................................................3047 Hydraulic Circuit Diagram of Power Train (at Reverse 1st + Right Turn + Brake Operation)..................................3049 Hydraulic Circuit Diagram of Power Train (at Hoist Raise + Forward 2nd Operation).........................................3051 Electrical Circuit Diagram....................................................................................................3053 Symbols Used in Electric Circuit Diagram..................................................................................3053 Electrical Circuit Diagram of Inside of CAB (1/10)........................................................................3057 Electrical Circuit Diagram of Inside of CAB (2/10)........................................................................3059 Electrical Circuit Diagram of Inside of CAB (3/10)........................................................................3061 Electrical Circuit Diagram of Inside of CAB (4/10)........................................................................3063 Electrical Circuit Diagram of Inside of CAB (5/10)........................................................................3065 Electrical Circuit Diagram of Inside of CAB (6/10)........................................................................3067 Electrical Circuit Diagram of Inside of CAB (7/10)........................................................................3069 Electrical Circuit Diagram of Inside of CAB (8/10)........................................................................3071 Electrical Circuit Diagram of Inside of CAB (9/10)........................................................................3073 Electrical Circuit Diagram of Inside of CAB (10/10).......................................................................3075 Electrical Circuit Diagram of Machine (1/7)...............................................................................3077 Electrical Circuit Diagram of Machine (2/7)...............................................................................3079 Electrical Circuit Diagram of Machine (3/7)...............................................................................3081 Electrical Circuit Diagram of Machine (4/7)...............................................................................3083 Electrical Circuit Diagram of Machine (5/7)...............................................................................3085 Electrical Circuit Diagram of Machine (6/7)...............................................................................3087 Electrical Circuit Diagram of Machine (7/7)...............................................................................3089 Electrical Circuit Diagram of Engine (1/2)................................................................................3091 Electrical Circuit Diagram of Engine (2/2)................................................................................3093 Index..............................................................................................................................3095
DESCRIPTION:
KOMATSU HD465-10 HD605-10 DUMP TRUCK SHOP MANUAL SEN06976-02 – PDF DOWNLOAD
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
50 Disassembly and Assembly
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
S.S 28/12/24
