Komatsu HD465-10E0 HD605-10E0 Shop Manual SEN06981-00

Data Size: 98.40 MB 
File Type: PDF 
Language: English 
Manufacturer: Komatsu 
Applicable Machine: Dump Truck 
Document: Shop Manual, Error Code, Electrical Schematic, Hydraulic Schematic 
Machine Model: Komatsu HD465-10E0 HD605-10E0 Dump Truck 
Serial Number: 63001 and up 
Book Number: SEN06981-00 
Page: 4072 Pages

List Contents:

00 Index and Foreword 
Foreword, Safety, Basic Information 
How to Read the Shop Manual 
Safety Notice for Operation 
Precautions to Prevent Fire 
Procedures If Fire Occurs 
Precautions for Disposing of Waste Materials 
Engine Technology to Conform Exhaust Gas Emission 
Precautions When You Handle Hydraulic Equipment 
Precautions When You Disconnect and Connect Pipings 
Precautions When You Handle Electrical Equipment 
Precautions When You Handle Fuel System Equipment 
Precautions When You Handle Intake System Equipment 
Practical Use of KOMTRAX 
Disconnect and Connect Push-Pull Type Coupler 
Precautions for Disconnection and Connection of Connectors 
How to Disconnect and Connect Deutsch Connector 
How to Disconnect and Connect Slide Lock Type Connector 
How to Disconnect and Connect Connector with Lock to Pull 
How to Disconnect and Connect Connector with Lock to Push 
How to Disconnect and Connect Connector with Housing to Rotate 
Standard Tightening Torque Table 
Conversion Table 
Abbreviation List 
01 Specifications 
Table of Contents 
Specifications 
Specification Drawing 
Specifications 
Weight Table 
Fuel, Coolant, Lubricant 
10 Structure and Function 
Table of Contents 
NOx Control System 
Function of NOx Control System 
Boot-up System 
Layout Drawing of Boot-up System 
System Operating Lamp System 
Battery Disconnect Switch 
Engine Shutdown Secondary Switch 
Engine System 
Layout Drawing of Engine System 
Engine Control System 
Engine Power Mode Selector System 
Automatic Idle Stop System 
Component Parts of Engine System 
Cooling System 
Layout Drawing of Cooling System 
Cooling Fan Control System 
Component Parts of Cooling System 
Control System 
Layout Drawing of Control System 
Layout Drawing of Control System (Machine with Mobile Communication Terminal) 
Retarder and Hoist Control System 
Machine Monitor System 
Rearview Monitor System 
KOMTRAX Plus System 
Payload Meter System 
Machine Lock-out System 
Component Parts of Control System 
Hydraulic System 
Layout Drawing of Hydraulic System 
Component Parts of Hydraulic System 
Power Train System 
Layout Drawing of Power Train System 
Transmission Control System 
Gear Shift Control System 
Direction Control System 
Komatsu Traction Control System (KTCS) 
Travel Speed Limitation System 
Component Parts of Power Train System 
Work Equipment System 
Work Equipment Control 
Hoist Control 
Component Parts of Work Equipment System 
Steering System 
Layout Drawing of Steering System 
Secondary Steering System 
Steering Column 
Steering Linkage 
Component Parts of Steering System 
Brake System 
Layout Drawing of Brake System 
Retarder Control 
ARSC System 
ABS 
Component Parts of Brake System 
KOWA Oil Sampling System 
Layout Drawing of KOWA Oil Sampling System 
Function of KOWA Oil Sampling System 
Undercarriage and Frame 
Suspension 
Front Suspension Cylinder 
Rear Suspension Cylinder 
Suspension Cylinder 
Automatic Suspension System 
Work Equipment 
Structure of Work Equipment 
Function of Work Equipment 
CAB Related Parts 
ROPS CAB 
CAB Mount 
20 Standard Value Table 
Table of Contents 
Standard Value Table for Engine 
Standard Value Table for Engine: HD465-10E0 
Standard Value Table for Engine: HD605-10E0 
Standard Value Table for Machine 
Standard Value Table for Machine: HD465-10E0 
Standard Value Table for Machine: HD605-10E0 
Machine Posture and Procedures to Measure Performance 
30 Testing and Adjusting 
Table of Contents 
Examine and Adjust Front Suspension Cylinder 
Examine and Adjust Front Suspension Cylinder (Machine with Automatic Suspension) 
Examine and Adjust Rear Suspension Cylinder 
Examine Oil Pressure of KTCS Circuit 
Work Equipment 
Examine and Adjust Dump Body Positioner Sensor 
Lower Dump Body Manually 
Lift Dump Body Manually 
CAB Related Parts 
Adjust Tilt Lock Lever of Steering Wheel 
Adjust Play of Operator Seat 
Adjust Door Lock Link 
Electrical System 
Set and Adjust Each Equipment 
Set and Operate Machine Monitor 
How to Start Up KOMTRAX Terminal 
How to Stop Use of KOMTRAX Terminal 
How to Stop Use of KOMTRAX Terminal (Machine with Mobile Communication Terminal) 
Default Setting of KOMTRAX Plus Controller 
Default Setting of Wireless LAN Modem 
Download Data from KOMTRAX Plus Controller 
Adjust After Replacement of KOMTRAX Plus Controller 
Adjust After Replacement of Wireless LAN Modem 
Setting of Mobile Communication Terminal 
Adjust Rearview Camera Angle 
Adjust Optical Axis of Head Lamp 
Set Region of Bluetooth® Compatible Radio 
Handle Voltage Circuit of Engine Controller 
Handle Battery Disconnect Switch 
Battery Disconnect Switch (Machine with Mobile Communication Terminal) 
Examine Diodes 
Change Lighting Pattern of Seat Belt Reminder Lamp 
Pm Clinic 
Pm Clinic Service 
Quick Pm 
40 Troubleshooting 
Table of Contents 
Precautions Before Work 
Related Information for Troubleshooting 
Precautions for Troubleshooting 
Sequence of Events in Troubleshooting 
General Troubleshooting Points 
Troubleshooting Points for Aftertreatment System 
Inspection Before Troubleshooting 
Inspection Procedure Before Troubleshooting 
Test in Accordance with Testing Procedure 
Preparation for Troubleshooting of Electrical System 
Procedure for Troubleshooting 
Symptom and Troubleshooting Numbers 
Information Shown in Troubleshooting 
Connector List and Layout 
Connector List and Layout (Machine with ABS System) 
Connector List and Layout (Machine with Mobile Communication Terminal) 
Connector Contact Connection Table 
T-Branch Box and T-Branch Adapter Table 
Fuse Location Table 
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 
Prepare Troubleshoot Machine Monitor 
Procedure to Make Harness Checker on Machine Monitor LCD Unit 
Prepare of Short Circuit Electrical Connector (For Failure Codes [CA1883], [CB1883], [CA3135] and 
[CB3135]) 
Failure Code Table 
Troubleshooting by Failure Code (Display of Code) 
Failure Code [1500L0] 
Failure Code [15B0NX] 
Failure Code [15F0KM] 
Failure Code [15F0MB] 
Failure Code [15F7KM] 
Failure Code [15G0MW] 
Failure Code [15G7KM] 
Failure Code [15H0MW] 
Failure Code [15J0MW] 
Failure Code [15K0MW] 
Failure Code [15L0MW] 
Failure Code [15M0MW] 
Failure Code [15N0MW] 
Failure Code [15SBL1] 
Failure Code [15SBMA] 
Failure Code [15SCL1] 
Failure Code [15SCMA] 
Failure Code [15SDL1] 
Failure Code [15SDMA] 
Failure Code [15SEL1] 
Failure Code [15SEMA] 
Failure Code [15SFL1] 
Failure Code [15SFMA] 
Failure Code [15SGL1] 
Failure Code [15SGMA] 
Failure Code [15SHL1] 
Failure Code [15SHMA] 
Failure Code [15SJMA] 
Failure Code [2C4MNX] 
Failure Code [2F00KM] 
Failure Code [2G42ZG] 
Failure Code [2G43ZG] 
Failure Code [6014NX] 
Failure Code [879AKA] 
Failure Code [879AKB] 
Failure Code [879BKA] 
Failure Code [879BKB] 
Failure Code [879CKA] 
Failure Code [879CKB] 
Failure Code [879EMC] 
Failure Code [879FMC] 
Failure Code [879GKX] 
Failure Code [989D00] 
Failure Code [989L00] 
Failure Code [989M00] 
Failure Code [989N00] 
Failure Code [989X00] 
Failure Code [989Y00] 
Failure Code [989YR2] 
Failure Code [A1U0N3] 
Failure Code [A1U0N4] 
Failure Code [AA10NX] 
Failure Code [AB00KE] (Machine with 100A Alternator) 
Failure Code [AB00KE] (Machine with 140A Alternator) 
Failure Code [AB00KY] (Machine with 100A Alternator) 
Failure Code [AB00KY] (Machine with 140A Alternator) 
Failure Code [AQ00N3] 
Failure Code [AQ00N4] 
Failure Code [AQ10N3] 
Failure Code [AS00R2] 
Failure Code [AS00R3] 
Failure Code [AS00R4] 
Failure Code [AS00R6] 
Failure Code [B@BAZG] 
Failure Code [B@BAZK] 
Failure Code [B@BCNS] 
Failure Code [B@BCQA] 
Failure Code [B@BCZK] 
Failure Code [B@C7NS] 
Failure Code [B@CENS] 
Failure Code [B@JANS] 
Failure Code [CA115] 
Failure Code [CA122] 
Failure Code [CA123] 
Failure Code [CA131] 
Failure Code [CA132] 
Failure Code [CA135] 
Failure Code [CA141] 
Failure Code [CA144] 
Failure Code [CA145] 
Failure Code [CA153] 
Failure Code [CA154] 
Failure Code [CA187] 
Failure Code [CA212] 
Failure Code [CA213] 
Failure Code [CA221] 
Failure Code [CA222] 
Failure Code [CA227] 
Failure Code [CA234] 
Failure Code [CA238] 
Failure Code [CA239] 
Failure Code [CA271] 
Failure Code [CA272] 
Failure Code [CA273] 
Failure Code [CA274] 
Failure Code [CA322] 
Failure Code [CA323] 
Failure Code [CA324] 
Failure Code [CA325] 
Failure Code [CA331] 
Failure Code [CA332] 
Failure Code [CA343] 
Failure Code [CA351] 
Failure Code [CA352] 
Failure Code [CA356] 
Failure Code [CA357] 
Failure Code [CA386] 
Failure Code [CA431] 
Failure Code [CA432] 
Failure Code [CA441] 
Failure Code [CA442] 
Failure Code [CA449] 
Failure Code [CA451] 
Failure Code [CA452] 
Failure Code [CA515] 
Failure Code [CA516] 
Failure Code [CA553] 
Failure Code [CA555] 
Failure Code [CA556] 
Failure Code [CA559] 
Failure Code [CA595] 
Failure Code [CA687] 
Failure Code [CA689] 
Failure Code [CA691] 
Failure Code [CA692] 
Failure Code [CA697] 
Failure Code [CA698] 
Failure Code [CA731] 
Failure Code [CA778] 
Failure Code [CA1117] 
Failure Code [CA1135] 
Failure Code [CA1257] 
Failure Code [CA1664] 
Failure Code [CA1691] 
Failure Code [CA1695] 
Failure Code [CA1696] 
Failure Code [CA1843] 
Failure Code [CA1844] 
Failure Code [CA1879] 
Failure Code [CA1881] 
Failure Code [CA1883] 
Failure Code [CA1921] 
Failure Code [CA1922] 
Failure Code [CA1923] 
Failure Code [CA1924] 
Failure Code [CA1925] 
Failure Code [CA1927] 
Failure Code [CA1928] 
Failure Code [CA1942] 
Failure Code [CA1963] 
Failure Code [CA1977] 
Failure Code [CA1993] 
Failure Code [CA2185] 
Failure Code [CA2186] 
Failure Code [CA2249] 
Failure Code [CA2265] 
Failure Code [CA2266] 
Failure Code [CA2271] 
Failure Code [CA2272] 
Failure Code [CA2349] 
Failure Code [CA2353] 
Failure Code [CA2357] 
Failure Code [CA2381] 
Failure Code [CA2382] 
Failure Code [CA2383] 
Failure Code [CA2386] 
Failure Code [CA2387] 
Failure Code [CA2555] 
Failure Code [CA2556] 
Failure Code [CB1117] 
Failure Code [CB1257] 
Failure Code [CB1664] 
Failure Code [CB1691] 
Failure Code [CB1695] 
Failure Code [CB1696] 
Failure Code [CB1879] 
Failure Code [CB1881] 
Failure Code [CB1883] 
Failure Code [CB1921] 
Failure Code [CB1922] 
Failure Code [CB1923] 
Failure Code [CB1924] 
Failure Code [CB1925] 
Failure Code [CB1927] 
Failure Code [CB1928] 
Failure Code [CB1963] 
Failure Code [CB1977] 
Failure Code [CB1993] 
Failure Code [CB2265] 
Failure Code [CB2266] 
Failure Code [CB2637] 
Failure Code [CB2639] 
Failure Code [CB2732] 
Failure Code [CB2733] 
Failure Code [CB2741] 
Failure Code [CB2777] 
Failure Code [CB2878] 
Failure Code [CB2881] 
Failure Code [CB3133] 
Failure Code [CB3134] 
Failure Code [CB3135] 
Failure Code [CB3167] 
Failure Code [CB3251] 
Failure Code [CB3253] 
Failure Code [CB3254] 
Failure Code [CB3255] 
Failure Code [CB3256] 
Failure Code [CB3311] 
Failure Code [CB3312] 
Failure Code [CB3313] 
Failure Code [CB3314] 
Failure Code [CB3315] 
Failure Code [CB3316] 
Failure Code [CB3317] 
Failure Code [CB3318] 
Failure Code [CB3319] 
Failure Code [CB3321] 
Failure Code [CB3322] 
Failure Code [CB4151] 
Failure Code [CB4158] 
Failure Code [CB4161] 
Failure Code [CB4162] 
Failure Code [CB4163] 
Failure Code [CB4259] 
Failure Code [CB4952] 
Failure Code [CB5383] 
Failure Code [D101KA] 
Failure Code [D101KB] 
Failure Code [D101KY] 
Failure Code [D131KA] 
Failure Code [D131KB] 
Failure Code [D131KY] 
Failure Code [D150KB] 
Failure Code [D150KZ] 
Failure Code [D164KY] 
Failure Code [D19HKZ] 
Failure Code [D19JKZ] 
Failure Code [D19QKZ] 
Failure Code [D1EHKA] 
Failure Code [D1EHKB] 
Failure Code [D1EHKY] 
Failure Code [D1EMKA] 
Failure Code [D1EMKB] 
Failure Code [D1EMKY] 
Failure Code [D1FBKB] 
Failure Code [D5ZHL6] 
Failure Code [D5ZKKZ] 
Failure Code [D862KA] 
Failure Code [DAF0KT] 
Failure Code [DAF0MB] 
Failure Code [DAF0MC] 
Failure Code [DAF3KK] 
Failure Code [DAF8KB] 
Failure Code [DAFDKB] 
Failure Code [DAFGMC] 
Failure Code [DAFLKA] 
Failure Code [DAFLKB] 
Failure Code [DAFQKR] 
Failure Code [DAQ0KK] 
Failure Code [DAQ0KT] 
Failure Code [DAQ0MC] 
Failure Code [DAQ1KA] 
Failure Code [DAQ2KK] 
Failure Code [DAQ2KT] 
Failure Code [DAQ9KQ] 
Failure Code [DAQLKA] 
Failure Code [DAQLKB] 
Failure Code [DAQQKR] 
Failure Code [DAQRKR] 
Failure Code [DAQRMA] 
Failure Code [DAQV00] 
Failure Code [DAQW00] 
Failure Code [DAZ9KQ] 
Failure Code [DAZQKR] 
Failure Code [DB10KT] 
Failure Code [DB10MC] 
Failure Code [DB11KA] 
Failure Code [DB12KK] 
Failure Code [DB12KT] 
Failure Code [DB13KK] 
Failure Code [DB19KQ] 
Failure Code [DB1LKA] 
Failure Code [DB1LKB] 
Failure Code [DB1QKR] 
Failure Code [DB1QMA] 
Failure Code [DHP5KY] 
Failure Code [DHP5KZ] 
Failure Code [DHP6KA] 
Failure Code [DHP6KX] 
Failure Code [DHP6KY] 
Failure Code [DHP6KZ] 
Failure Code [DHP7KA] 
Failure Code [DHP7KX] 
Failure Code [DHP7KY] 
Failure Code [DHP7KZ] 
Failure Code [DHQ2KX] 
Failure Code [DHQ4KX] 
Failure Code [DHT5KX] 
Failure Code [DHT5L6] 
Failure Code [DHT8KX] 
Failure Code [DHT8ZG] 
Failure Code [DHU2KX] 
Failure Code [DHU3KX] 
Failure Code [DHU6KX] 
Failure Code [DHU7KX] 
Failure Code [DHU8KX] 
Failure Code [DHU9KX] 
Failure Code [DHUCKX] 
Failure Code [DHUDKX] 
Failure Code [DHUHKX] 
Failure Code [DHULKX] 
Failure Code [DHUMKX] 
Failure Code [DHUPKX] 
Failure Code [DHUTKX] 
Failure Code [DHY9KX] 
Failure Code [DJF1KA] 
Failure Code [DK30KX] 
Failure Code [DK51L5] 
Failure Code [DK52KX] 
Failure Code [DK53L8] 
Failure Code [DK54KX] 
Failure Code [DK60KX] 
Failure Code [DKD0L6] 
Failure Code [DKH0KX] 
Failure Code [DKH1KX] 
Failure Code [DLF1KA] 
Failure Code [DLF1LC] 
Failure Code [DLF2KA] 
Failure Code [DLF2LC] 
Failure Code [DLF6KA] 
Failure Code [DLF6L3] 
Failure Code [DLF7KA] 
Failure Code [DLF7L3] 
Failure Code [DLF8KA] 
Failure Code [DLF8L3] 
Failure Code [DLF8LC] 
Failure Code [DLF8MA] 
Failure Code [DLF9KA] 
Failure Code [DLF9L3] 
Failure Code [DLF9LC] 
Failure Code [DLF9MA] 
Failure Code [DLM3KA] 
Failure Code [DLM3LC] 
Failure Code [DLM3MB] 
Failure Code [DLT3KA] 
Failure Code [DLT3LC] 
Failure Code [DPQ1KR] 
Failure Code [DPQ2KR] 
Failure Code [DPQ3KR] 
Failure Code [DSJ0KR] 
Failure Code [DV00KB] 
Failure Code [DW2AKA] 
Failure Code [DW2AKB] 
Failure Code [DW2AKY] 
Failure Code [DW2AL1] 
Failure Code [DW2ALH] 
Failure Code [DW2BKA] 
Failure Code [DW2BKB] 
Failure Code [DW2BKY] 
Failure Code [DW2BL1] 
Failure Code [DW2BLH] 
Failure Code [DW35KZ] 
Failure Code [DW36KZ] 
Failure Code [DW4BK4] 
Failure Code [DW4BMA] 
Failure Code [DW72KZ] 
Failure Code [DW73KA] 
Failure Code [DW73KB] 
Failure Code [DW73KY] 
Failure Code [DW78KZ] 
Failure Code [DW7BKB] 
Failure Code [DW7BKY] 
Failure Code [DW7BKZ] 
Failure Code [DW7NKZ] 
Failure Code [DWD6KA] 
Failure Code [DWD6KB] 
Failure Code [DWD6KY] 
Failure Code [DWD6MA] 
Failure Code [DWD7K4] 
Failure Code [DWD7KA] 
Failure Code [DWD7KB] 
Failure Code [DWD7KY] 
Failure Code [DWD7MA] 
Failure Code [DWNDKZ] 
Failure Code [DWNDMA] 
Failure Code [DWNEKZ] 
Failure Code [DWNEMA] 
Failure Code [DWNMKZ] 
Failure Code [DX11K4] 
Failure Code [DX11KA] 
Failure Code [DX11KB] 
Failure Code [DX11KY] 
Failure Code [DX11MA] 
Failure Code [DX13KA] 
Failure Code [DX13KB] 
Failure Code [DX13KY] 
Failure Code [DX16KA] 
Failure Code [DX16KB] 
Failure Code [DX16KY] 
Failure Code [DX21KA] 
Failure Code [DX21KB] 
Failure Code [DX21KY] 
Failure Code [DX21MA] 
Failure Code [DX22KA] 
Failure Code [DX22KB] 
Failure Code [DX22KY] 
Failure Code [DX22MA] 
Failure Code [DX23KA] 
Failure Code [DX23KB] 
Failure Code [DX23KY] 
Failure Code [DX23MA] 
Failure Code [DX24KA] 
Failure Code [DX24KB] 
Failure Code [DX24KY] 
Failure Code [DX24MA] 
Failure Code [DX25MA] 
Failure Code [DX26MA] 
Failure Code [DX37K4] 
Failure Code [DX37KA] 
Failure Code [DX37KB] 
Failure Code [DX37KY] 
Failure Code [DX37MA] 
Failure Code [DX38K4] 
Failure Code [DX38KA] 
Failure Code [DX38KB] 
Failure Code [DX38KY] 
Failure Code [DX38MA] 
Failure Code [DXH1KA] 
Failure Code [DXH1KB] 
Failure Code [DXH1KY] 
Failure Code [DXH2KA] 
Failure Code [DXH2KB] 
Failure Code [DXH2KY] 
Failure Code [DXH3KA] 
Failure Code [DXH3KB] 
Failure Code [DXH3KY] 
Failure Code [DXH4KA] 
Failure Code [DXH4KB] 
Failure Code [DXH4KY] 
Failure Code [DXH5KA] 
Failure Code [DXH5KB] 
Failure Code [DXH5KY] 
Failure Code [DXH6KA] 
Failure Code [DXH6KB] 
Failure Code [DXH6KY] 
Failure Code [DXH7KA] 
Failure Code [DXH7KB] 
Failure Code [DXH7KY] 
Failure Code [DXHHKA] 
Failure Code [DXHHKB] 
Failure Code [DXHHKY] 
Failure Code [DY30MA] 
Failure Code [DY30MC] 
Failure Code [DY30ME] 
Failure Code [F@BYNR] 
Failure Code [F@BYNS] 
Troubleshooting of Electrical System (E-Mode) 
E-1 Engine Does Not Start (Engine Does Not Crank) (Machine with 100A Alternator) 
E-2 Engine Does Not Start (Engine Does Not Crank) (Machine with 140A Alternator) 
E-3 Manual Preheating System Does Not Operate 
E-4 Automatic Preheating System Does Not Operate 
E-5 While Preheating is in Operation, Preheating Pilot Lamp Does Not Come On 
E-6 LCD Unit, LED Unit, and Meter Unit on Machine Monitor Do Not Show Anything 
E-7 LCD Unit on Machine Monitor Shows Nothing 
E-8 Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers) 
E-9 LCD Screen on Machine Monitor Does Not Show Correctly 
E-10 Meter Unit Display on Machine Monitor is Abnormal 
E-11 Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal 
E-12 LED Unit Lamp on Machine Monitor is Abnormal 
E-13 Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate 
Correctly 
E-14 Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate 
E-15 Switch Panel Buzzer of Machine Monitor is Abnormal 
E-16 Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Correctly 
E-17 Rearview Monitor Does Not Come On or Backlight Flickers 
E-18 Rearview Monitor Images are Not Shown Clearly 
E-19 Rearview Monitor Brightness Cannot be Adjusted 
E-20 Night Mode Lamp of Rearview Monitor is Abnormal 
E-21 Air Cleaner Clogging Caution Lamp Does Not Come On 
E-22 Transmission Oil Filter Clogging Caution Lamp Does Not Come On 
E-23 Radiator Coolant Level Caution Lamp Does Not Come On 
E-24 Rear View Monitor is Not Shown in Conjunction with Revers When the Constant Display Setting 
is Disable 
E-25 Rear View Monitor Reference Line is Not Shown When the Reference Line Display Setting is 
Turned ON 
E-26 Fuel Gauge Does Not Show Normally 
E-27 Torque Converter Oil Temperature Gauge Does Not Rise or Torque Converter Oil Temperature 
Caution Lamp Does Not Come On 
E-28 Retarder Oil Temperature Gauge Does Not Rise or Retarder Oil Temperature Caution Lamp Does 
Not Come On 
E-29 Seatbelt Caution Lamp Does Not Show Normally 
E-30 Machine Monitor Cannot be Operated When Starting Switch is in OFF Position 
E-31 Alarm Buzzer Does Not Operate 
E-32 Alarm Buzzer Does Not Stop 
E-33 Engine Mode Selector Function Does Not Operate Correctly When Engine Power Mode Selector 
Switch is Operated 
E-34 AISS Function Does Not Operate Correctly 
E-35 Dump (Hoist) Control Lever Does Not Operate Correctly 
E-36 Fuel Feed Pump Does Not Operate or Stop Automatically 
E-37 Turn Signal Lamp and Hazard Lamp Do Not Operate Correctly 
E-38 Horn Does Not Sound 
E-39 Horn Does Not Stop 
E-40 Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On 
E-41 Clearance Lamp Does Not Come On 
E-42 Tail Lamp Does Not Come On 
E-43 Headlamp (Low Beam) Does Not Come On 
E-44 Headlamp (High Beam) Does Not Come On 
E-45 Headlamp (Low Beam) and (High Beam) Do Not Come On 
E-46 Dump Light Does Not Come On 
E-47 Passing Lamp Does Not Come On 
E-48 KOMTRAX System Does Not Operate Correctly 
E-49 Data Download with Wireless LAN Does Not Operate 
E-50 Cannot Access to the Setting Screen of the Mobile Communication Terminal 
E-51 Cannot Log in to the Setting Screen of the Mobile Communication Terminal Because the Log in 
Password is Unknown 
E-52 KOMTRAX Plus Controller is Not Found 
E-53 KOMTRAX Plus Controller Does Not Become Active 
E-3 Manual Preheating System Does Not Operate 
E-4 Automatic Preheating System Does Not Operate 
E-5 While Preheating is in Operation, Preheating Pilot Lamp Does Not Come On 
E-6 LCD Unit, LED Unit, and Meter Unit on Machine Monitor Do Not Show Anything 
E-7 LCD Unit on Machine Monitor Shows Nothing 
E-8 Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers) 
E-9 LCD Screen on Machine Monitor Does Not Show Correctly 
E-10 Meter Unit Display on Machine Monitor is Abnormal 
E-11 Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal 
E-12 LED Unit Lamp on Machine Monitor is Abnormal 
E-13 Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate 
Correctly 
E-14 Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate 
E-15 Switch Panel Buzzer of Machine Monitor is Abnormal 
E-16 Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Correctly 
E-17 Rearview Monitor Does Not Come On or Backlight Flickers 
E-18 Rearview Monitor Images are Not Shown Clearly 
E-19 Rearview Monitor Brightness Cannot be Adjusted 
E-20 Night Mode Lamp of Rearview Monitor is Abnormal 
E-21 Air Cleaner Clogging Caution Lamp Does Not Come On 
E-22 Transmission Oil Filter Clogging Caution Lamp Does Not Come On 
E-23 Radiator Coolant Level Caution Lamp Does Not Come On 
E-24 Rear View Monitor is Not Shown in Conjunction with Revers When the Constant Display Setting 
is Disable 
E-25 Rear View Monitor Reference Line is Not Shown When the Reference Line Display Setting is 
Turned ON 
E-26 Fuel Gauge Does Not Show Normally 
E-27 Torque Converter Oil Temperature Gauge Does Not Rise or Torque Converter Oil Temperature 
Caution Lamp Does Not Come On 
E-28 Retarder Oil Temperature Gauge Does Not Rise or Retarder Oil Temperature Caution Lamp Does 
Not Come On 
E-29 Seatbelt Caution Lamp Does Not Show Normally 
E-30 Machine Monitor Cannot be Operated When Starting Switch is in OFF Position 
E-31 Alarm Buzzer Does Not Operate 
E-32 Alarm Buzzer Does Not Stop 
E-33 Engine Mode Selector Function Does Not Operate Correctly When Engine Power Mode Selector 
Switch is Operated 
E-34 AISS Function Does Not Operate Correctly 
E-35 Dump (Hoist) Control Lever Does Not Operate Correctly 
E-36 Fuel Feed Pump Does Not Operate or Stop Automatically 
E-37 Turn Signal Lamp and Hazard Lamp Do Not Operate Correctly 
E-38 Horn Does Not Sound 
E-39 Horn Does Not Stop 
E-40 Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On 
E-41 Clearance Lamp Does Not Come On 
E-42 Tail Lamp Does Not Come On 
E-43 Headlamp (Low Beam) Does Not Come On 
E-44 Headlamp (High Beam) Does Not Come On 
E-45 Headlamp (Low Beam) and (High Beam) Do Not Come On 
E-46 Dump Light Does Not Come On 
E-47 Passing Lamp Does Not Come On 
E-48 KOMTRAX System Does Not Operate Correctly 
E-49 Data Download with Wireless LAN Does Not Operate 
E-50 Cannot Access to the Setting Screen of the Mobile Communication Terminal 
E-51 Cannot Log in to the Setting Screen of the Mobile Communication Terminal Because the Log in 
Password is Unknown 
E-52 KOMTRAX Plus Controller is Not Found 
E-53 KOMTRAX Plus Controller Does Not Become Active 
E-54 Communication Failure Occurs Between Mobile Communication Terminal and KOMTRAX Plus 
Server 
Restrictions on Radio Reception 
E-55 Data is Not Sent to KOMTRAX Plus Server 
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 
Information Shown in Troubleshooting Table (H-Mode) 
Failure Mode and Cause Table 
H-1 Machine Does Not Start 
H-2 Machine Does Not Travel Smoothly (Machine Hunts) 
H-3 Lockup is Not Released 
H-4 Strong Shock is Made When You Start Machine or Shift Gears 
H-5 Shiftup Does Not Operate 
H-6 Travel Speed in All Gear Speed is Low or Power is Low During Travel with Lockup Function 
H-7 Travel Speed is Low or Power is Low During Travel with Torque Converter 
H-8 Travel Speed is Low or Power is Low in Specified Gear Speed 
H-9 Time Lag is Large When You Start Machine or Shift Gears 
H-10 Torque Converter Oil Temperature is High 
H-11 Torque Converter Oil Pressure is Low 
H-12 Steering Wheel is Heavy to Operate 
H-13 Steering Wheel is Disabled 
H-14 Steering Wheel is Shaken 
H-15 Parking Brake Does Not Operate or is Weak 
H-16 Parking Brake is Not Released or Drags 
H-17 Front Brake Does Not Operate Sufficiently 
H-18 Rear Brake Does Not Operate Sufficiently 
H-19 Speed is Low When Dump Body is Raised 
H-20 Hydraulic Drift of Dump Body is Large 
H-21 Dump Body is Disabled 
H-22 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 
H-23 Unusual Noise is Heard from Around Fan 
Troubleshooting of Engine (S-Mode) 
Information Shown in Troubleshooting Table (S-Mode) 
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 
S-2 Engine Cranks but No Exhaust Smoke Comes Out 
S-3 Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 
S-4 Engine Startability is Unsatisfactory 
S-5 Engine Does Not Pick Up Smoothly 
S-6 Engine Stops During Operation 
S-7 Engine Does Not Rotate Smoothly 
S-8 Engine Lacks Output (or Lacks Power) 
S-9 KDPF Becomes Clogged in a Short Time 
S-10 Engine Oil Consumption is Excessive 
S-11 Engine Oil Becomes Dirty Quickly 
S-12 Fuel Consumption is Excessive 
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 
S-14 Engine Oil Pressure Drops 
S-15 Fuel Mixes Into Engine Oil 
S-16 Water Mixes Into Engine Oil (Milky) 
S-17 Coolant Temperature Increases Too High (Overheat) 
S-18 Unusual Noise is Heard 
S-19 Vibration is Excessive 
S-20 Air Cannot be Bled from Fuel Circuit 
S-21 Active Regeneration is Done Frequently 
S-22 Active Regeneration Continues Long 
S-23 White Smoke is Exhausted During Active Regeneration 
50 Disassembly and Assembly 
Table of Contents 
Precautions Before Work 
Disassemble and Assemble Hoist Cylinder Assembly 
Drain and Add Hydraulic Oil 
Work Equipment 
Remove and Install Dump Body Assembly 
CAB Related Parts 
Remove and Install Air Conditioner Unit Assembly 
Remove and Install Operator Seat Assembly 
Remove and Install Seat Belt 
Electrical System 
Remove and Install Engine Controller Assembly 
Remove and Install Retarder and Hoist Controller Assembly 
Remove and Install ABS Controller Assembly 
Remove and Install Transmission Controller Assembly 
Remove and Install Machine Monitor Assembly 
Remove and Install Monitor Controller Assembly 
Remove and Install Mass Air Flow and Temperature Sensor 
Remove and Install Blowby Gas Filter Crankcase Pressure Sensor 
Remove and Install KOMTRAX Plus Controller Assembly 
Remove and Install Mobile Communication Terminal 
Remove and Install DC-DC Converter 
Remove and Install Mobile Communication Terminal Wiring Harness 
Remove and Install KOMTRAX Terminal Assembly 
Remove and Install Wireless LAN Unit Assembly 
60 Maintenance Standard 
Table of Contents 
Explanation of Terms for Maintenance Standard 
Engine and Cooling System 
Maintenance Standard for Engine Mount 
Maintenance Standard for Damper 
Maintenance Standard for Cooling Fan Pump 
Maintenance Standard for Servo Valve for Cooling Fan Pump 
Maintenance Standard for Cooling Fan Motor 
Power Train 
Maintenance Standard for Drive Shaft 
Maintenance Standard for Torque Converter and Transmission Mount 
Maintenance Standard for Torque Converter and PTO 
Maintenance Standard for Torque Converter Valve 
Maintenance Standard for Transmission 
Maintenance Standard for Transmission Control Valve 
Maintenance Standard for H, L, 4th, 3rd, R, 2nd, and 1st ECMV 
Maintenance Standard for Lockup Clutch ECMV 
Maintenance Standard for Front Axle 
Maintenance Standard for Rear Axle 
Maintenance Standard for Differential 
Maintenance Standard for Final Drive 
Steering System 
Maintenance Standard for Steering Column 
Maintenance Standard for Steering Linkage 
Maintenance Standard for Demand Valve 
Maintenance Standard for Steering Cylinder 
Brake System 
Maintenance Standard for Slack Adjuster 
Maintenance Standard for Front Brake 
Maintenance Standard for Rear Brake 
Undercarriage and Frame 
Maintenance Standard for Front Suspension Cylinder 
Maintenance Standard for Rear Suspension Cylinder 
Hydraulic System 
Maintenance Standard for Pump Assembly (Steering, Hoist) 
Maintenance Standard for Servo Valve of Pump Assembly (Steering, Hoist) 
Maintenance Standard of Pump Assembly (Power Train and Brake Cooling) 
Maintenance Standard of Pump Assembly (Brake Cooling and Control) 
Maintenance Standard for Hoist Valve 
Work Equipment 
Maintenance Standard for Hoist Cylinder 
CAB Related Parts 
Maintenance Standard for CAB Mount 
80 Others 
Table of Contents 
Precautions Before Work 
Air Conditioner System 
Precautions for Refrigerant 
Layout Drawing of Air Conditioner System 
Specifications of Air Conditioner 
Structure of Refrigeration Cycle 
Function of Refrigeration Cycle 
Component Parts of Air Conditioner System 
Component Parts of Air Conditioner Unit 
Air Conditioner Controller 
Compressor 
Condenser 
Receiver Drier 
Air Conditioner Related Sensors 
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 
System Diagram of Air Conditioner 
Locations of Air Conditioner Parts and Layout of Connectors 
Examine Air Leakage (Duct) 
Examine Air Conditioner with Self-Diagnosis Function 
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 
Examine Vent (Mode) Changeover 
Examine Fresh/Recirc Air Changeover 
Examine Refrigerant (Triple) Pressure Switch 
Examine Relay 
Air Conditioner Troubleshooting Chart 1 
Air Conditioner Troubleshooting Chart 2 
Information Shown in Troubleshooting Table 
Troubleshooting by Failure Code (Display of Code) 
Troubleshooting of Air Conditioner System (A-Mode) 
Troubleshooting by Gauge Pressure 
Connect Service Tool 
Precautions for Disconnection and Connection of Air Conditioner Piping 
Handle Compressor Oil 
90 Circuit Diagrams 
Table of Contents 
How to Read the Codes for Electric Cable 
Hydraulic Circuit Diagram 
Symbols Used in Hydraulic Circuit Diagram 
Hydraulic Circuit Diagram (1/3) 
Hydraulic Circuit Diagram (2/3) 
Hydraulic Circuit Diagram (3/3) 
Power Train Hydraulic Circuit Diagram 
Hydraulic Circuit Diagram of Steering, Hoist, Fan Control (at Reverse 1st, Right Turn, Brake Operation) 
Hydraulic Circuit Diagram of Steering, Hoist, Fan Control (at Hoist Raise, Forward 2nd Operation) 
Hydraulic Circuit Diagram of Brake Cooling (at Reverse 1st, Right Turn, Brake Operation) 
Hydraulic Circuit Diagram of Brake Cooling (at Retarder Brake Operation) 
Hydraulic Circuit Diagram of Power Train (at Reverse 1st + Right Turn + Brake Operation) 
Hydraulic Circuit Diagram of Power Train (at Hoist Raise + Forward 2nd Operation) 
Electrical Circuit Diagram 
Symbols Used in Electric Circuit Diagram 
Electrical Circuit Diagram of Inside of CAB (1/10) 
Electrical Circuit Diagram of Inside of CAB (2/10) 
Electrical Circuit Diagram of Inside of CAB (3/10) 
Electrical Circuit Diagram of Inside of CAB (4/10) 
Electrical Circuit Diagram of Inside of CAB (5/10) 
Electrical Circuit Diagram of Inside of CAB (6/10) 
Electrical Circuit Diagram of Inside of CAB (7/10) 
Electrical Circuit Diagram of Inside of CAB (8/10) 
Electrical Circuit Diagram of Inside of CAB (9/10) 
Electrical Circuit Diagram of Inside of CAB (10/10) 
Electrical Circuit Diagram of Machine (1/7) 
Electrical Circuit Diagram of Machine (2/7) 
Electrical Circuit Diagram of Machine (3/7) 
Electrical Circuit Diagram of Machine (4/7) 
Electrical Circuit Diagram of Machine (5/7) 
Electrical Circuit Diagram of Machine (6/7) 
Electrical Circuit Diagram of Machine (7/7) 
Electrical Circuit Diagram of Engine (1/2) 
Electrical Circuit Diagram of Engine (2/2) 
Index