Komatsu HD465-8E0 HD605-8E0 Articulated Dump Truck Shop Manual SEN06768-06 – PDF DOWNLOAD

Komatsu HD465-8E0 HD605-8E0 Articulated Dump Truck Shop Manual SEN06768-06 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HD465-8E0 HD605-8E0 Articulated Dump Truck Shop Manual SEN06768-06 – PDF DOWNLOAD

Language : English
Pages : 3290
Downloadable : Yes
File Type : PDF
Size: 78.1 MB

TABLE OF CONTENTS:

Komatsu HD465-8E0 HD605-8E0 Articulated Dump Truck Shop Manual SEN06768-06 – PDF DOWNLOAD

00 INDEX AND FOREWORD 00-1
ABBREVIATION LIST 00-22
FOREWORD, SAFETY, BASIC INFORMATION 00-25
HOW TO READ THE SHOP MANUAL 00-25
SAFETY NOTICE FOR OPERATION 00-27
PRECAUTIONS TO PREVENT FIRE 00-35
ACTIONS IF FIRE OCCURS 00-37
PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS 00-38
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION 00-39
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00-40
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS 00-43
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT 00-50
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 00-52
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 00-53
PRACTICAL USE OF KOMTRAX 00-54
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00-55
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 00-59
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 00-63
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 00-64
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 00-66
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 00-67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
00-69
HOW TO READ ELECTRICAL WIRE CODE 00-70
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00-74
STANDARD TIGHTENING TORQUE TABLE 00-77
CONVERSION TABLE 00-84
01 SPECIFICATION 01-1
CONTENTS 01-2
SPECIFICATIONS 01-3
SPECIFICATION DRAWING 01-3
SPECIFICATIONS 01-7
WEIGHT TABLE 01-17
FUEL, COOLANT, LUBRICANT 01-19
10 STRUCTURE AND FUNCTION 10-1
CONTENTS 10-2
NOx CONTROL SYSTEM 10-6
FUNCTION OF NOx CONTROL SYSTEM 10-6
BOOT-UP SYSTEM 10-9
BOOT UP SYSTEM DIAGRAM 10-9
BOOT UP SYSTEM DIAGRAM (For machines equipped with emergency engine stop switch) 10-10
SYSTEM OPERATING LAMP SYSTEM 10-12
BATTERY DISCONNECT SWITCH 10-13
ENGINE SHUTDOWN SECONDARY SWITCH 10-16
ENGINE SYSTEM 10-18
ENGINE SYSTEM DIAGRAM 10-18
ENGINE CONTROL SYSTEM 10-21
AUTOMATIC IDLE STOP SYSTEM 10-25
ENGINE SYSTEM 10-27
COOLING SYSTEM 10-48
COOLING SYSTEM DIAGRAM 10-48
RADIATOR FAN CONTROL SYSTEM 10-50
COOLING SYSTEM 10-52
CONTROL SYSTEM 10-66
CONTROL SYSTEM DIAGRAM 10-66
INDEX 00 INDEX AND FOREWORD
00-2 HD465-8E0, HD605-8E0
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH MOBILE COMMUNICATION TERMINAL)
10-68
RETARDER AND HOIST CONTROL SYSTEM 10-69
MACHINE MONITOR SYSTEM 10-71
REARVIEW MONITOR SYSTEM 10-73
KOMTRAX Plus SYSTEM 10-74
PAYLOAD METER SYSTEM 10-80
MACHINE LOCK-OUT SYSTEM 10-92
CONTROL SYSTEM 10-94
HYDRAULIC SYSTEM 10-160
HYDRAULIC SYSTEM DIAGRAM 10-160
HYDRAULIC SYSTEM 10-161
POWER TRAIN SYSTEM 10-182
POWER TRAIN DIAGRAM 10-182
TRANSMISSION CONTROL SYSTEM 10-184
GEAR SHIFT CONTROL SYSTEM 10-189
DIRECTION CONTROL SYSTEM 10-191
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 10-192
TRAVEL SPEED LIMITATION SYSTEM 10-194
POWER TRAIN SYSTEM 10-198
WORK EQUIPMENT SYSTEM 10-244
WORK EQUIPMENT CONTROL 10-244
HOIST CONTROL 10-245
WORK EQUIPMENT SYSTEM 10-247
STEERING SYSTEM 10-253
STEERING SYSTEM DIAGRAM 10-253
STEERING SYSTEM FUNCTION 10-254
STEERING COLUMN 10-255
STEERING LINKAGE 10-256
STEERING SYSTEM 10-257
BRAKE SYSTEM 10-275
BRAKE SYSTEM DIAGRAM 10-275
RETARDER CONTROL 10-277
ARSC SYSTEM 10-278
BRAKE SYSTEM 10-279
ABS 10-301
AUTO-GREASING SYSTEM 10-309
AUTO-GREASING SYSTEM DIAGRAM 10-309
AUTO-GREASING SYSTEM DIAGRAM 10-312
FUNCTION OF AUTO-GREASING SYSTEM 10-313
COMPONENT PARTS OF AUTO-GREASING SYSTEM 10-314
UNDERCARRIAGE AND FRAME 10-320
SUSPENSION 10-320
FRONT SUSPENSION 10-322
REAR SUSPENSION 10-324
SUSPENSION CYLINDER 10-326
WORK EQUIPMENT 10-328
STRUCTURE OF WORK EQUIPMENT 10-328
FUNCTION OF WORK EQUIPMENT 10-329
CAB RELATED PARTS 10-330
ROPS CAB 10-330
CAB MOUNT 10-331
20 STANDARD VALUE TABLE 20-1
CONTENTS 20-2
STANDARD VALUE TABLE FOR ENGINE 20-3
STANDARD VALUE TABLE FOR ENGINE:HD465-8E0 20-3
STANDARD VALUE TABLE FOR ENGINE:HD605-8E0 20-6
STANDARD VALUE TABLE FOR MACHINE 20-9
00 INDEX AND FOREWORD INDEX
HD465-8E0, HD605-8E0 00-3
STANDARD VALUE TABLE FOR MACHINE:HD465-8E0 20-9
STANDARD VALUE TABLE FOR MACHINE:HD605-8E0 20-27
MACHINE SETTING AND PROCEDURE TO MEASURE PERFORMANCE 20-45
30 TESTING AND ADJUSTING 30-1
CONTENTS 30-2
RELATED INFORMATION ON TESTING AND ADJUSTING 30-6
TOOLS TO TEST AND ADJUST 30-6
DIAGRAM FOR TEST AND ADJUST TOOLS 30-16
ENGINE AND COOLING SYSTEM 30-17
TEST ENGINE SPEED 30-17
TEST BOOST PRESSURE 30-19
TESTING EXHAUST GAS TEMPERATURE 30-23
TEST EXHAUST GAS COLOR 30-27
TEST AND ADJUST VALVE CLEARANCE 30-30
COMPRESSION TEST 30-33
BLOWBY PRESSURE TEST 30-37
TEST ENGINE OIL PRESSURE 30-40
EGR VALVE AND VGT OIL PRESSURE TEST 30-42
FUEL PRESSURE TEST 30-43
FUEL RETURN RATE AND LEAKAGE TEST 30-45
BLEEDING AIR FROM FUEL SYSTEM 30-49
FUEL CIRCUIT LEAK TEST 30-51
SUPPLY PUMP TEST 30-53
CYLINDER CUT-OUT MODE 30-56
NO-INJECTION CRANKING 30-57
CLEAN FUEL DOSER 30-58
PROGRAM INJECTOR TRIM CODE VALUE TO ENGINE CONTROLLER 30-61
PROGRAM ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 30-68
TEST TORQUE CONVERTER STALL SPEED 30-69
RADIATOR FAN SPEED TEST 30-71
POWER TRAIN 30-73
TEST POWER TRAIN OIL PRESSURE 30-73
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR 30-87
ADJUST TRANSMISSION INTERMEDIATE SPEED SENSOR 30-88
ADJUST TRANSMISSION OUTPUT SPEED SENSOR 30-89
CHECK AFTER ADJUSTMENT OF TRANSMISSION SPEED SENSORS 30-90
MOVE A MACHINE WITH ELECTRICAL SYSTEM PROBLEMS 30-91
STEERING SYSTEM 30-97
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 30-97
TEST SUPPLY PRESSURE OF ORBITROL VALVE 30-100
TEST STEERING CYLINDER PRESSURE 30-102
BLEED AIR FROM STEERING CYLINDER CIRCUIT 30-104
BRAKE SYSTEM 30-105
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 30-105
TEST WHEEL BRAKE OIL PRESSURE 30-106
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE 30-111
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR AND CHARGE NITROGEN GAS
30-114
TEST BRAKE PERFORMANCE 30-128
BLEED AIR FROM BRAKE CIRCUIT 30-131
TEST PARKING BRAKE OIL PRESSURE 30-143
RELEASE PARKING BRAKE MANUALLY 30-144
TEST THE AMOUNT OF FRONT BRAKE PAD WEAR 30-145
TEST THE QUANTITY OF REAR BRAKE DISC WEAR 30-147
HYDRAULIC SYSTEM 30-148
TEST AND ADJUST HOIST CIRCUIT OIL PRESSURE 30-148
TEST HOIST CYLINDER SUPPLY PRESSURE 30-150
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT 30-152
INDEX 00 INDEX AND FOREWORD
00-4 HD465-8E0, HD605-8E0
TEST RADIATOR FAN CIRCUIT OIL PRESSURE 30-154
TEST AND ADJUST FRONT SUSPENSION CYLINDER 30-156
TEST AND ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION)
30-161
TEST AND ADJUST REAR SUSPENSION CYLINDER 30-164
TEST KTCS CIRCUIT OIL PRESSURE (FOR MACHINE WITH KTCS) 30-170
WORK EQUIPMENT 30-172
TEST AND ADJUST DUMP BODY POSITIONER SENSOR 30-172
LOWER THE BODY MANUALLY 30-174
LIFT THE BODY MANUALLY 30-175
CAB RELATED PARTS 30-176
ADJUST STEERING WHEEL TILT LOCK LEVER 30-176
ADJUST RATTLING OPERATOR’S SEAT 30-178
ELECTRICAL SYSTEM 30-179
SET AND ADJUST EACH EQUIPMENT 30-179
SET AND OPERATE OF MACHINE MONITOR 30-183
PROCEDURE FOR STARTING UP KOMTRAX TERMINAL 30-320
STOP USE OF KOMTRAX TERMINAL 30-324
STOP USE OF KOMTRAX TERMINAL (MACHINE WITH MOBILE COMMUNICATION TERMINAL)
30-326
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER 30-328
SETTING DEFAULT OF WIRELESS LAN MODEM 30-331
DOWNLOAD KOMTRAX Plus CONTROLLER DATA 30-334
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED 30-338
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED 30-341
SETTING OF MOBILE COMMUNICATION TERMINAL 30-344
ADJUST REARVIEW CAMERA ANGLE 30-354
ADJUST OPTICAL AXIS OF HEAD LAMP 30-355
ENGINE CONTROLLER VOLTAGE CIRCUIT WORK 30-359
BATTERY DISCONNECT SWITCH 30-360
BATTERY DISCONNECT SWITCH (MACHINE WITH MOBILE COMMUNICATION TERMINAL) 30-362
TEST DIODES 30-364
Pm-CLINIC 30-365
Pm CLINIC SERVICE 30-365
PERFORMING QUICK Pm 30-385
40 TROUBLESHOOTING 40-1
CONTENTS 40-2
RELATED INFORMATION ON TROUBLESHOOTING 40-15
GENERAL TROUBLESHOOTING POINTS 40-15
TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEMS 40-16
SEQUENCE OF EVENTS IN TROUBLESHOOTING 40-24
CHECKS BEFORE TROUBLESHOOTING 40-26
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 40-28
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40-30
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 40-49
PROCEDURE FOR TESTING AND TROUBLESHOOTING 40-59
SYMPTOM AND TROUBLESHOOTING NUMBERS 40-61
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 40-64
CONNECTORS LIST AND LAYOUT 40-66
CONNECTOR CONTACT IDENTIFICATION 40-96
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 40-138
FUSE LOCATION TABLE 40-144
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 40-150
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 40-154
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 40-156
PREPARATION OF SHORT SOCKET ADAPTER (FOR FAILURE CODES [CA1883], [CB1883],
[CA3135] AND [CB3135]) 40-162
FAILURE CODES TABLE 40-164
00 INDEX AND FOREWORD INDEX
HD465-8E0, HD605-8E0 00-5
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 40-189
FAILURE CODE [1500L0] 40-189
FAILURE CODE [15B0NX] 40-190
FAILURE CODE [15F0KM] 40-192
FAILURE CODE [15F0MB] 40-193
FAILURE CODE [15F7KM] 40-194
FAILURE CODE [15G0MW] 40-195
FAILURE CODE [15G7KM] 40-197
FAILURE CODE [15H0MW] 40-198
FAILURE CODE [15J0MW] 40-200
FAILURE CODE [15K0MW] 40-202
FAILURE CODE [15L0MW] 40-204
FAILURE CODE [15M0MW] 40-206
FAILURE CODE [15N0MW] 40-208
FAILURE CODE [15SBL1] 40-210
FAILURE CODE [15SBMA] 40-213
FAILURE CODE [15SCL1] 40-215
FAILURE CODE [15SCMA] 40-218
FAILURE CODE [15SDL1] 40-220
FAILURE CODE [15SDMA] 40-223
FAILURE CODE [15SEL1] 40-225
FAILURE CODE [15SEMA] 40-228
FAILURE CODE [15SFL1] 40-230
FAILURE CODE [15SFMA] 40-233
FAILURE CODE [15SGL1] 40-235
FAILURE CODE [15SGMA] 40-238
FAILURE CODE [15SHL1] 40-240
FAILURE CODE [15SHMA] 40-243
FAILURE CODE [15SJMA] 40-245
FAILURE CODE [2C4MNX] 40-246
FAILURE CODE [2F00KM] 40-248
FAILURE CODE [2G42ZG] 40-251
FAILURE CODE [2G43ZG] 40-252
FAILURE CODE [6014NX] 40-253
FAILURE CODE [879AKA] 40-255
FAILURE CODE [879AKB] 40-256
FAILURE CODE [879BKA] 40-257
FAILURE CODE [879BKB] 40-258
FAILURE CODE [879CKA] 40-260
FAILURE CODE [879CKB] 40-261
FAILURE CODE [879EMC] 40-262
FAILURE CODE [879FMC] 40-263
FAILURE CODE [879GKX] 40-264
FAILURE CODE [989D00] 40-265
FAILURE CODE [989L00] 40-266
FAILURE CODE [989M00] 40-267
FAILURE CODE [989N00] 40-268
FAILURE CODE [989X00] 40-269
FAILURE CODE [989Y00] 40-270
FAILURE CODE [A1U0N3] 40-271
FAILURE CODE [A1U0N4] 40-273
FAILURE CODE [AA10NX] 40-275
FAILURE CODE [AB00KE] 40-277
FAILURE CODE [AB00KY] 40-279
FAILURE CODE [AQ00N3] 40-280
FAILURE CODE [AQ00N4] 40-281
FAILURE CODE [AQ10N3] 40-282
FAILURE CODE [AS00R2] 40-283
INDEX 00 INDEX AND FOREWORD
00-6 HD465-8E0, HD605-8E0
FAILURE CODE [AS00R3] 40-284
FAILURE CODE [AS00R4] 40-285
FAILURE CODE [AS00R6] 40-286
FAILURE CODE [B@BAZG] 40-287
FAILURE CODE [B@BAZK] 40-288
FAILURE CODE [B@BCNS] 40-289
FAILURE CODE [B@BCQA] 40-290
FAILURE CODE [B@BCZK] 40-292
FAILURE CODE [B@C7NS] 40-294
FAILURE CODE [B@CENS] 40-296
FAILURE CODE [B@JANS] 40-297
FAILURE CODE [CA115] 40-298
FAILURE CODE [CA122] 40-302
FAILURE CODE [CA123] 40-304
FAILURE CODE [CA131] 40-306
FAILURE CODE [CA132] 40-308
FAILURE CODE [CA135] 40-310
FAILURE CODE [CA141] 40-312
FAILURE CODE [CA144] 40-314
FAILURE CODE [CA145] 40-316
FAILURE CODE [CA153] 40-318
FAILURE CODE [CA154] 40-320
FAILURE CODE [CA187] 40-322
FAILURE CODE [CA212] 40-324
FAILURE CODE [CA213] 40-326
FAILURE CODE [CA221] 40-328
FAILURE CODE [CA222] 40-330
FAILURE CODE [CA227] 40-332
FAILURE CODE [CA234] 40-334
FAILURE CODE [CA238] 40-335
FAILURE CODE [CA239] 40-337
FAILURE CODE [CA271] 40-339
FAILURE CODE [CA272] 40-341
FAILURE CODE [CA273] 40-342
FAILURE CODE [CA274] 40-344
FAILURE CODE [CA322] 40-345
FAILURE CODE [CA323] 40-347
FAILURE CODE [CA324] 40-349
FAILURE CODE [CA325] 40-351
FAILURE CODE [CA331] 40-353
FAILURE CODE [CA332] 40-355
FAILURE CODE [CA343] 40-357
FAILURE CODE [CA351] 40-360
FAILURE CODE [CA352] 40-363
FAILURE CODE [CA356] 40-365
FAILURE CODE [CA357] 40-367
FAILURE CODE [CA386] 40-369
FAILURE CODE [CA431] 40-371
FAILURE CODE [CA432] 40-374
FAILURE CODE [CA441] 40-377
FAILURE CODE [CA442] 40-380
FAILURE CODE [CA449] 40-383
FAILURE CODE [CA451] 40-384
FAILURE CODE [CA452] 40-386
FAILURE CODE [CA515] 40-388
FAILURE CODE [CA516] 40-390
FAILURE CODE [CA553] 40-392
FAILURE CODE [CA555] 40-393
00 INDEX AND FOREWORD INDEX
HD465-8E0, HD605-8E0 00-7
FAILURE CODE [CA556] 40-395
FAILURE CODE [CA559] 40-397
FAILURE CODE [CA595] 40-402
FAILURE CODE [CA687] 40-404
FAILURE CODE [CA689] 40-406
FAILURE CODE [CA691] 40-408
FAILURE CODE [CA692] 40-410
FAILURE CODE [CA697] 40-412
FAILURE CODE [CA698] 40-413
FAILURE CODE [CA731] 40-414
FAILURE CODE [CA778] 40-417
FAILURE CODE [CA1117] 40-420
FAILURE CODE [CA1135] 40-423
FAILURE CODE [CA1257] 40-426
FAILURE CODE [CA1664] 40-427
FAILURE CODE [CA1691] 40-429
FAILURE CODE [CA1695] 40-432
FAILURE CODE [CA1696] 40-434
FAILURE CODE [CA1843] 40-436
FAILURE CODE [CA1844] 40-438
FAILURE CODE [CA1879] 40-440
FAILURE CODE [CA1881] 40-442
FAILURE CODE [CA1883] 40-444
FAILURE CODE [CA1921] 40-447
FAILURE CODE [CA1922] 40-449
FAILURE CODE [CA1923] 40-452
FAILURE CODE [CA1924] 40-454
FAILURE CODE [CA1925] 40-457
FAILURE CODE [CA1927] 40-459
FAILURE CODE [CA1928] 40-461
FAILURE CODE [CA1942] 40-463
FAILURE CODE [CA1963] 40-465
FAILURE CODE [CA1977] 40-470
FAILURE CODE [CA1993] 40-472
FAILURE CODE [CA2185] 40-475
FAILURE CODE [CA2186] 40-477
FAILURE CODE [CA2249] 40-479
FAILURE CODE [CA2265] 40-485
FAILURE CODE [CA2266] 40-487
FAILURE CODE [CA2271] 40-489
FAILURE CODE [CA2272] 40-491
FAILURE CODE [CA2349] 40-493
FAILURE CODE [CA2353] 40-495
FAILURE CODE [CA2357] 40-497
FAILURE CODE [CA2381] 40-500
FAILURE CODE [CA2382] 40-502
FAILURE CODE [CA2383] 40-504
FAILURE CODE [CA2386] 40-506
FAILURE CODE [CA2387] 40-508
FAILURE CODE [CA2555] 40-511
FAILURE CODE [CA2556] 40-513
FAILURE CODE [CA2637] 40-515
FAILURE CODE [CA2639] 40-517
FAILURE CODE [CA2732] 40-519
FAILURE CODE [CA2733] 40-521
FAILURE CODE [CA2741] 40-523
FAILURE CODE [CA2765] 40-525
FAILURE CODE [CA2777] 40-526
INDEX 00 INDEX AND FOREWORD
00-8 HD465-8E0, HD605-8E0
FAILURE CODE [CA2878] 40-528
FAILURE CODE [CA2881] 40-531
FAILURE CODE [CA3133] 40-534
FAILURE CODE [CA3134] 40-536
FAILURE CODE [CA3135] 40-538
FAILURE CODE [CA3167] 40-541
FAILURE CODE [CA3251] 40-544
FAILURE CODE [CA3253] 40-546
FAILURE CODE [CA3254] 40-550
FAILURE CODE [CA3255] 40-553
FAILURE CODE [CA3256] 40-555
FAILURE CODE [CA3311] 40-557
FAILURE CODE [CA3312] 40-559
FAILURE CODE [CA3313] 40-561
FAILURE CODE [CA3314] 40-562
FAILURE CODE [CA3315] 40-563
FAILURE CODE [CA3316] 40-566
FAILURE CODE [CA3317] 40-567
FAILURE CODE [CA3318] 40-568
FAILURE CODE [CA3319] 40-571
FAILURE CODE [CA3321] 40-572
FAILURE CODE [CA3322] 40-573
FAILURE CODE [CA3419] 40-576
FAILURE CODE [CA3421] 40-578
FAILURE CODE [CA4151] 40-580
FAILURE CODE [CA4158] 40-583
FAILURE CODE [CA4161] 40-585
FAILURE CODE [CA4162] 40-587
FAILURE CODE [CA4163] 40-589
FAILURE CODE [CA4259] 40-591
FAILURE CODE [CA4952] 40-593
FAILURE CODE [CA5383] 40-596
FAILURE CODE [CB115] 40-597
FAILURE CODE [CB187] 40-601
FAILURE CODE [CB227] 40-602
FAILURE CODE [CB238] 40-603
FAILURE CODE [CB239] 40-605
FAILURE CODE [CB271] 40-607
FAILURE CODE [CB272] 40-609
FAILURE CODE [CB273] 40-610
FAILURE CODE [CB274] 40-612
FAILURE CODE [CB343] 40-613
FAILURE CODE [CB352] 40-616
FAILURE CODE [CB386] 40-618
FAILURE CODE [CB441] 40-620
FAILURE CODE [CB442] 40-623
FAILURE CODE [CB689] 40-626
FAILURE CODE [CB697] 40-628
FAILURE CODE [CB698] 40-629
FAILURE CODE [CB731] 40-630
FAILURE CODE [CB778] 40-634
FAILURE CODE [CB1117] 40-636
FAILURE CODE [CB1257] 40-639
FAILURE CODE [CB1664] 40-640
FAILURE CODE [CB1691] 40-642
FAILURE CODE [CB1695] 40-645
FAILURE CODE [CB1696] 40-647
FAILURE CODE [CB1879] 40-649
00 INDEX AND FOREWORD INDEX
HD465-8E0, HD605-8E0 00-9
FAILURE CODE [CB1881] 40-651
FAILURE CODE [CB1883] 40-653
FAILURE CODE [CB1921] 40-656
FAILURE CODE [CB1922] 40-658
FAILURE CODE [CB1923] 40-661
FAILURE CODE [CB1924] 40-663
FAILURE CODE [CB1925] 40-666
FAILURE CODE [CB1927] 40-668
FAILURE CODE [CB1928] 40-670
FAILURE CODE [CB1963] 40-672
FAILURE CODE [CB1977] 40-677
FAILURE CODE [CB1993] 40-679
FAILURE CODE [CB2265] 40-682
FAILURE CODE [CB2266] 40-684
FAILURE CODE [CB2637] 40-686
FAILURE CODE [CB2639] 40-689
FAILURE CODE [CB2732] 40-691
FAILURE CODE [CB2733] 40-693
FAILURE CODE [CB2741] 40-695
FAILURE CODE [CB2777] 40-696
FAILURE CODE [CB2878] 40-698
FAILURE CODE [CB2881] 40-701
FAILURE CODE [CB3133] 40-704
FAILURE CODE [CB3134] 40-706
FAILURE CODE [CB3135] 40-708
FAILURE CODE [CB3167] 40-711
FAILURE CODE [CB3251] 40-714
FAILURE CODE [CB3253] 40-716
FAILURE CODE [CB3254] 40-720
FAILURE CODE [CB3255] 40-723
FAILURE CODE [CB3256] 40-725
FAILURE CODE [CB3311] 40-727
FAILURE CODE [CB3312] 40-729
FAILURE CODE [CB3313] 40-731
FAILURE CODE [CB3314] 40-732
FAILURE CODE [CB3315] 40-733
FAILURE CODE [CB3316] 40-736
FAILURE CODE [CB3317] 40-737
FAILURE CODE [CB3318] 40-738
FAILURE CODE [CB3319] 40-741
FAILURE CODE [CB3321] 40-742
FAILURE CODE [CB3322] 40-743
FAILURE CODE [CB4151] 40-746
FAILURE CODE [CB4158] 40-749
FAILURE CODE [CB4161] 40-750
FAILURE CODE [CB4162] 40-752
FAILURE CODE [CB4163] 40-754
FAILURE CODE [CB4259] 40-756
FAILURE CODE [CB4952] 40-758
FAILURE CODE [CB5383] 40-761
FAILURE CODE [D150KB] 40-762
FAILURE CODE [D150KZ] 40-764
FAILURE CODE [D164KY] 40-766
FAILURE CODE [D19HKZ] 40-767
FAILURE CODE [D19JKZ] 40-769
FAILURE CODE [D19QKZ] 40-771
FAILURE CODE [D1EHKA] 40-773
FAILURE CODE [D1EHKB] 40-775
INDEX 00 INDEX AND FOREWORD
00-10 HD465-8E0, HD605-8E0
FAILURE CODE [D1EHKY] 40-777
FAILURE CODE [D1EMKA] 40-778
FAILURE CODE [D1EMKB] 40-779
FAILURE CODE [D1EMKY] 40-780
FAILURE CODE [D1FBKB] 40-781
FAILURE CODE [D5ZHL6] 40-783
FAILURE CODE [D5ZKKZ] 40-785
FAILURE CODE [D862KA] 40-787
FAILURE CODE [DAF0KT] 40-788
FAILURE CODE [DAF0MB] 40-789
FAILURE CODE [DAF0MC] 40-790
FAILURE CODE [DAF3KK] 40-791
FAILURE CODE [DAF8KB] 40-793
FAILURE CODE [DAFDKB] 40-795
FAILURE CODE [DAFGMC] 40-797
FAILURE CODE [DAFLKA] 40-798
FAILURE CODE [DAFLKB] 40-801
FAILURE CODE [DAFQKR] 40-804
FAILURE CODE [DAQ0KK] 40-805
FAILURE CODE [DAQ0KT] 40-808
FAILURE CODE [DAQ0MC] 40-809
FAILURE CODE [DAQ1KA] 40-810
FAILURE CODE [DAQ2KK] 40-813
FAILURE CODE [DAQ9KQ] 40-816
FAILURE CODE [DAQLKA] 40-817
FAILURE CODE [DAQLKB] 40-820
FAILURE CODE [DAQQKR] 40-823
FAILURE CODE [DAQRKR] 40-824
FAILURE CODE [DAQRMA] 40-825
FAILURE CODE [DAQV00] 40-826
FAILURE CODE [DAQW00] 40-827
FAILURE CODE [DAZ9KQ] 40-828
FAILURE CODE [DAZQKR] 40-829
FAILURE CODE [DB10KT] 40-831
FAILURE CODE [DB10MC] 40-832
FAILURE CODE [DB11KA] 40-833
FAILURE CODE [DB11KA] (For machines equipped with emergency engine stop switch) 40-836
FAILURE CODE [DB12KK] 40-839
FAILURE CODE [DB13KK] 40-842
FAILURE CODE [DB19KQ] 40-845
FAILURE CODE [DB1LKA] 40-846
FAILURE CODE [DB1LKB] 40-849
FAILURE CODE [DB1QKR] 40-852
FAILURE CODE [DB1QMA] 40-853
FAILURE CODE [DB1RKR] 40-854
FAILURE CODE [DB2QKR] 40-855
FAILURE CODE [DB2QKR] 40-862
FAILURE CODE [DB2RKR] 40-870
FAILURE CODE [DB2RKR] 40-877
FAILURE CODE [DBC0KT] 40-885
FAILURE CODE [DBC0MC] 40-886
FAILURE CODE [DBC1KA] 40-887
FAILURE CODE [DBC2KK] 40-890
FAILURE CODE [DBC3KK] 40-892
FAILURE CODE [DBC9KQ] 40-895
FAILURE CODE [DBCLKA] 40-896
FAILURE CODE [DBCLKB] 40-898
FAILURE CODE [DBCQKR] 40-900
00 INDEX AND FOREWORD INDEX
HD465-8E0, HD605-8E0 00-11
FAILURE CODE [DBCQMA] 40-901
FAILURE CODE [DBCRKR] 40-902
FAILURE CODE [DBV0MC] 40-903
FAILURE CODE [DBV1KK] 40-904
FAILURE CODE [DBV6KB] 40-906
FAILURE CODE [DBV7KB] 40-908
FAILURE CODE [DBVLKA] 40-909
FAILURE CODE [DBVLKB] 40-912
FAILURE CODE [DBVQKR] 40-915
FAILURE CODE [DBVRKR] 40-916
FAILURE CODE [DBVVKR] 40-917
FAILURE CODE [DBVWKR] 40-918
FAILURE CODE [DDAAL6] 40-919
FAILURE CODE [DDAAL6] (For machines equipped with emergency engine stop switch) 40-921
FAILURE CODE [DDACL4] 40-924
FAILURE CODE [DDADKA] 40-926
FAILURE CODE [DDADKY] 40-928
FAILURE CODE [DDD7KX] 40-930
FAILURE CODE [DDP6L4] 40-932
FAILURE CODE [DDTHKA] 40-934
FAILURE CODE [DDTJKA] 40-936
FAILURE CODE [DDTKKA] 40-938
FAILURE CODE [DDTLKA] 40-940
FAILURE CODE [DDTMKA] 40-942
FAILURE CODE [DDTNKA] 40-944
FAILURE CODE [DDTPKA] 40-946
FAILURE CODE [DF10KA] 40-948
FAILURE CODE [DF10KB] 40-952
FAILURE CODE [DGE5KX] 40-957
FAILURE CODE [DGF1KX] 40-959
FAILURE CODE [DGR2KB] 40-961
FAILURE CODE [DGR6KB] 40-963
FAILURE CODE [DGR6L8] 40-964
FAILURE CODE [DGT1KX] 40-966
FAILURE CODE [DGT4KA] 40-968
FAILURE CODE [DGT4KB] 40-970
FAILURE CODE [DGT4KY] 40-972
FAILURE CODE [DHA4KA] 40-974
FAILURE CODE [DHAAMA] 40-976
FAILURE CODE [DHABMA] 40-977
FAILURE CODE [DHACMA] 40-978
FAILURE CODE [DHADMA] 40-979
FAILURE CODE [DHP4KY] 40-980
FAILURE CODE [DHP4KZ] 40-982
FAILURE CODE [DHP5KY] 40-984
FAILURE CODE [DHP5KZ] 40-986
FAILURE CODE [DHP6KA] 40-988
FAILURE CODE [DHP6KX] 40-990
FAILURE CODE [DHP6KY] 40-992
FAILURE CODE [DHP6KZ] 40-994
FAILURE CODE [DHP7KA] 40-996
FAILURE CODE [DHP7KX] 40-998
FAILURE CODE [DHP7KY] 40-1000
FAILURE CODE [DHP7KZ] 40-1002
FAILURE CODE [DHQ2KX] 40-1004
FAILURE CODE [DHQ4KX] 40-1006
FAILURE CODE [DHT5KX] 40-1008
FAILURE CODE [DHT5L6] 40-1010
INDEX 00 INDEX AND FOREWORD
00-12 HD465-8E0, HD605-8E0
FAILURE CODE [DHT8KX] 40-1012
FAILURE CODE [DHT8ZG] 40-1014
FAILURE CODE [DHU2KX] 40-1016
FAILURE CODE [DHU3KX] 40-1018
FAILURE CODE [DHU6KX] 40-1020
FAILURE CODE [DHU7KX] 40-1022
FAILURE CODE [DHU8KX] 40-1024
FAILURE CODE [DHU9KX] 40-1026
FAILURE CODE [DHUCKX] 40-1028
FAILURE CODE [DHUDKX] 40-1031
FAILURE CODE [DHUHKX] 40-1033
FAILURE CODE [DHULKX] 40-1035
FAILURE CODE [DHUMKX] 40-1038
FAILURE CODE [DHUPKX] 40-1041
FAILURE CODE [DHUTKX] 40-1043
FAILURE CODE [DHY9KX] 40-1045
FAILURE CODE [DJF1KA] 40-1047
FAILURE CODE [DK30KX] 40-1049
FAILURE CODE [DK51L5] 40-1051
FAILURE CODE [DK52KX] 40-1054
FAILURE CODE [DK53L8] 40-1056
FAILURE CODE [DK54KX] 40-1058
FAILURE CODE [DK60KX] 40-1060
FAILURE CODE [DKD0L6] 40-1062
FAILURE CODE [DKH0KX] 40-1064
FAILURE CODE [DKH1KX] 40-1066
FAILURE CODE [DLF1KA] 40-1068
FAILURE CODE [DLF1LC] 40-1069
FAILURE CODE [DLF2KA] 40-1071
FAILURE CODE [DLF2LC] 40-1073
FAILURE CODE [DLF6KA] 40-1075
FAILURE CODE [DLF6L3] 40-1076
FAILURE CODE [DLF7KA] 40-1078
FAILURE CODE [DLF7L3] 40-1079
FAILURE CODE [DLF8KA] 40-1081
FAILURE CODE [DLF8L3] 40-1082
FAILURE CODE [DLF8LC] 40-1083
FAILURE CODE [DLF8MA] 40-1085
FAILURE CODE [DLF9KA] 40-1086
FAILURE CODE [DLF9L3] 40-1087
FAILURE CODE [DLF9LC] 40-1088
FAILURE CODE [DLF9MA] 40-1090
FAILURE CODE [DLM3KA] 40-1091
FAILURE CODE [DLM3LC] 40-1092
FAILURE CODE [DLM3MB] 40-1094
FAILURE CODE [DLT3KA] 40-1095
FAILURE CODE [DLT3LC] 40-1096
FAILURE CODE [DPQ1KR] 40-1098
FAILURE CODE [DPQ2KR] 40-1101
FAILURE CODE [DPQ3KR] 40-1104
FAILURE CODE [DSJ0KR] 40-1108
FAILURE CODE [DV00KB] 40-1109
FAILURE CODE [DW2AKA] 40-1111
FAILURE CODE [DW2AKB] 40-1112
FAILURE CODE [DW2AKY] 40-1114
FAILURE CODE [DW2AL1] 40-1115
FAILURE CODE [DW2ALH] 40-1116
FAILURE CODE [DW2BKA] 40-1117
00 INDEX AND FOREWORD INDEX
HD465-8E0, HD605-8E0 00-13
FAILURE CODE [DW2BKB] 40-1118
FAILURE CODE [DW2BKY] 40-1119
FAILURE CODE [DW2BL1] 40-1120
FAILURE CODE [DW2BLH] 40-1121
FAILURE CODE [DW35KZ] 40-1122
FAILURE CODE [DW36KZ] 40-1124
FAILURE CODE [DW4BK4] 40-1126
FAILURE CODE [DW4BMA] 40-1130
FAILURE CODE [DW72KZ] 40-1134
FAILURE CODE [DW73KA] 40-1136
FAILURE CODE [DW73KB] 40-1138
FAILURE CODE [DW73KY] 40-1140
FAILURE CODE [DW78KZ] 40-1141
FAILURE CODE [DW7BKB] 40-1143
FAILURE CODE [DW7BKY] 40-1145
FAILURE CODE [DW7BKZ] 40-1146
FAILURE CODE [DW7NKZ] 40-1148
FAILURE CODE [DWD6KA] 40-1150
FAILURE CODE [DWD6KB] 40-1152
FAILURE CODE [DWD6KY] 40-1154
FAILURE CODE [DWD6MA] 40-1155
FAILURE CODE [DWD7K4] 40-1157
FAILURE CODE [DWD7KA] 40-1158
FAILURE CODE [DWD7KB] 40-1160
FAILURE CODE [DWD7KY] 40-1162
FAILURE CODE [DWD7MA] 40-1163
FAILURE CODE [DWNDKZ] 40-1164
FAILURE CODE [DWNDMA] 40-1166
FAILURE CODE [DWNEKZ] 40-1168
FAILURE CODE [DWNEMA] 40-1170
FAILURE CODE [DWNMKZ] 40-1172
FAILURE CODE [DX11K4] 40-1174
FAILURE CODE [DX11KA] 40-1176
FAILURE CODE [DX11KB] 40-1178
FAILURE CODE [DX11KY] 40-1180
FAILURE CODE [DX11MA] 40-1181
FAILURE CODE [DX13KA] 40-1183
FAILURE CODE [DX13KB] 40-1185
FAILURE CODE [DX13KY] 40-1187
FAILURE CODE [DX16KA] 40-1188
FAILURE CODE [DX16KB] 40-1189
FAILURE CODE [DX16KY] 40-1191
FAILURE CODE [DX21KA] 40-1192
FAILURE CODE [DX21KB] 40-1193
FAILURE CODE [DX21KY] 40-1195
FAILURE CODE [DX21MA] 40-1196
FAILURE CODE [DX22KA] 40-1198
FAILURE CODE [DX22KB] 40-1199
FAILURE CODE [DX22KY] 40-1201
FAILURE CODE [DX22MA] 40-1202
FAILURE CODE [DX23KA] 40-1204
FAILURE CODE [DX23KB] 40-1205
FAILURE CODE [DX23KY] 40-1207
FAILURE CODE [DX23MA] 40-1208
FAILURE CODE [DX24KA] 40-1210
FAILURE CODE [DX24KB] 40-1211
FAILURE CODE [DX24KY] 40-1213
FAILURE CODE [DX24MA] 40-1214
INDEX 00 INDEX AND FOREWORD
00-14 HD465-8E0, HD605-8E0
FAILURE CODE [DX25MA] 40-1216
FAILURE CODE [DX26MA] 40-1217
FAILURE CODE [DX37K4] 40-1218
FAILURE CODE [DX37KA] 40-1220
FAILURE CODE [DX37KB] 40-1221
FAILURE CODE [DX37KY] 40-1223
FAILURE CODE [DX37MA] 40-1224
FAILURE CODE [DX38K4] 40-1226
FAILURE CODE [DX38KA] 40-1228
FAILURE CODE [DX38KB] 40-1229
FAILURE CODE [DX38KY] 40-1231
FAILURE CODE [DX38MA] 40-1232
FAILURE CODE [DXH1KA] 40-1234
FAILURE CODE [DXH1KB] 40-1236
FAILURE CODE [DXH1KY] 40-1238
FAILURE CODE [DXH2KA] 40-1239
FAILURE CODE [DXH2KB] 40-1241
FAILURE CODE [DXH2KY] 40-1243
FAILURE CODE [DXH3KA] 40-1246
FAILURE CODE [DXH3KB] 40-1248
FAILURE CODE [DXH3KY] 40-1250
FAILURE CODE [DXH4KA] 40-1253
FAILURE CODE [DXH4KB] 40-1255
FAILURE CODE [DXH4KY] 40-1257
FAILURE CODE [DXH5KA] 40-1260
FAILURE CODE [DXH5KB] 40-1262
FAILURE CODE [DXH5KY] 40-1264
FAILURE CODE [DXH6KA] 40-1267
FAILURE CODE [DXH6KB] 40-1269
FAILURE CODE [DXH6KY] 40-1271
FAILURE CODE [DXH7KA] 40-1274
FAILURE CODE [DXH7KB] 40-1276
FAILURE CODE [DXH7KY] 40-1278
FAILURE CODE [DXHHKA] 40-1280
FAILURE CODE [DXHHKB] 40-1282
FAILURE CODE [DXHHKY] 40-1284
FAILURE CODE [DY30MA] 40-1286
FAILURE CODE [DY30MC] 40-1288
FAILURE CODE [DY30ME] 40-1291
FAILURE CODE [F@BYNR] 40-1293
FAILURE CODE [F@BYNS] 40-1294
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 40-1295
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40-1295
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 40-1303
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 40-1306
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 40-1308
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING
40-1310
E-6 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING
(For machines equipped with emergency engine stop switch) 40-1313
E-7 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING 40-1316
E-8 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT
OR FLICKERS) 40-1318
E-9 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY 40-1320
E-10 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 40-1322
E-11 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 40-1325
E-12 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 40-1329
00 INDEX AND FOREWORD INDEX
HD465-8E0, HD605-8E0 00-15
E-13 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR
SWITCH DOES NOT OPERATE PROPERLY 40-1331
E-14 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION
40-1333
E-15 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 40-1335
E-16 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED
PROPERLY 40-1337
E-17 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 40-1338
E-18 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 40-1342
E-19 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 40-1346
E-20 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL 40-1350
E-21 REARVIEW MONITOR DOES NOT DISPLAY IMAGES WHILE REVERSE LINKED DISPLAY
FUNCTION IS ENABLED 40-1352
E-22 GUIDE LINE ON REARVIEW MONITOR IS NOT DISPLAYED WHILE GUIDE LINE IS SET
40-1355
E-23 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 40-1357
E-24 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL 40-1359
E-25 MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION
40-1361
E-26 ALARM BUZZER DOES NOT SOUND 40-1362
E-27 ALARM BUZZER DOES NOT STOP SOUNDING 40-1364
E-28 AISS FUNCTION DOES NOT OPERATE PROPERLY 40-1366
E-29 HOIST LEVER DOES NOT OPERATE PROPERLY 40-1368
E-30 FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY 40-1370
E-31 TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY
40-1373
E-32 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 40-1377
E-33 SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP 40-1380
E-34 TAIL LAMP DOES NOT LIGHT UP 40-1383
E-35 (LOW BEAM) HEAD LAMP DOES NOT LIGHT UP 40-1386
E-36 (HIGH BEAM) HEAD LAMP DOES NOT LIGHT UP 40-1388
E-37 NEITHER (LOW BEAM) NOR (HIGH BEAM) HEAD LAMPS LIGHTS UP 40-1390
E-38 HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED 40-1392
E-39 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 40-1394
E-40 DATA DOWNLOADING BY USING WIRELESS LAN CAN NOT BE PERFORMED 40-1396
E-41 CANNOT ACCESS TO THE SETTING SCREEN OF THE MOBILE COMMUNICATION TERMINAL
40-1397
E-42 CANNOT LOG IN TO THE SETTING SCREEN OF THE MOBILE COMMUNICATION TERMINAL
BECAUSE THE LOG IN PASSWORD IS UNKNOWN 40-1404
E-43 KOMTRAX Plus CONTROLLER IS NOT DETECTED 40-1406
E-44 KOMTRAX Plus CONTROLLER DOES NOT BECOME ACTIVE 40-1408
E-45 COMMUNICATION BETWEEN MOBILE COMMUNICATION TERMINAL AND KOMTRAX Plus
SERVER FAILS 40-1409
E-46 DATA IS NOT SENT TO KOMTRAX Plus SERVER 40-1412
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 40-1414
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 40-1414
FAILURE MODE AND CAUSE TABLE 40-1415
H-1 MACHINE DOES NOT START 40-1425
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS) 40-1428
H-3 LOCKUP IS NOT RELEASED 40-1429
H-4 ABNORMALLY LARGE SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING
40-1430
H-5 GEAR IS NOT SHIFTED UP 40-1432
H-6 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE
AT ALL GEAR SPEEDS 40-1435
H-7 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER
DRIVE MODE 40-1436
INDEX 00 INDEX AND FOREWORD
00-16 HD465-8E0, HD605-8E0
H-8 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT SOME GEAR SPEED
40-1437
H-9 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED 40-1439
H-10 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH 40-1442
H-11 OIL PRESSURE OF TORQUE CONVERTER IS LOW 40-1443
H-12 STEERING WHEEL IS HEAVY TO OPERATE 40-1444
H-13 STEERING WHEEL CANNOT BE OPERATED 40-1445
H-14 STEERING WHEEL WAGGLES 40-1446
H-15 FRONT BRAKE DOES NOT WORK ENOUGH 40-1447
H-16 REAR BRAKE DOES NOT WORK ENOUGH 40-1448
H-17 DUMP BODY RISING SPEED IS LOW 40-1449
H-18 HYDRAULIC DRIFT OF DUMP BODY IS LARGE 40-1451
H-19 DUMP BODY DOES NOT MOVE 40-1452
H-20 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 40-1453
H-21 UNUSUAL NOISE IS HEARD FROM AROUND FAN 40-1454
TROUBLESHOOTING OF ENGINE (S-MODE) 40-1455
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 40-1455
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION
40-1456
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 40-1457
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING:ENGINE CRANKS
BUT DOES NOT START) 40-1458
S-4 ENGINE STARTABILITY IS POOR 40-1459
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 40-1461
S-6 ENGINE STOPS DURING OPERATION 40-1463
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 40-1465
S-8 ENGINE LACKS POWER 40-1466
S-9 KDPF GETS CLOGGED IN A SHORT TIME 40-1468
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 40-1470
S-11 OIL BECOMES CONTAMINATED QUICKLY 40-1471
S-12 FUEL CONSUMPTION IS EXCESSIVE 40-1472
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)
40-1473
S-14 OIL PRESSURE DROPS 40-1474
S-15 FUEL MIXES INTO ENGINE OIL 40-1476
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 40-1477
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 40-1478
S-18 UNUSUAL NOISE IS HEARD 40-1479
S-19 VIBRATION IS EXCESSIVE 40-1480
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 40-1481
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 40-1482
S-22 ACTIVE REGENERATION TAKES TIME 40-1483
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 40-1484
50 DISASSEMBLY AND ASSEMBLY 50-1
CONTENTS 50-2
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 50-6
HOW TO READ THIS MANUAL 50-6
COATING MATERIALS LIST 50-8
SPECIAL TOOLS LIST 50-12
SKETCHES OF SPECIAL TOOLS 50-20
ENGINE AND COOLING SYSTEM 50-23
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 50-23
REMOVE AND INSTALL INJECTOR ASSEMBLY 50-51
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 50-104
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 50-109
REMOVE AND INSTALL EGR VALVE ASSEMBLY 50-218
REMOVE AND INSTALL EGR COOLER ASSEMBLY 50-224
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 50-244
00 INDEX AND FOREWORD INDEX
HD465-8E0, HD605-8E0 00-17
REMOVE AND INSTALL ALTERNATOR BELT 50-247
REMOVE AND INSTALL COOLER ASSEMBLY 50-250
REMOVE AND INSTALL RADIATOR 50-280
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 50-294
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 50-300
REMOVE AND INSTALL ENGINE ASSEMBLY 50-314
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 50-342
REMOVE AND INSTALL ENGINE REAR OIL SEAL 50-346
REMOVE AND INSTALL DAMPER ASSEMBLY 50-352
DISASSEMBLE AND ASSEMBLE OF DAMPER ASSEMBLY 50-361
REMOVE AND INSTALL KDPF ASSEMBLY (WITH BRACKET) 50-366
REMOVE AND INSTALL KDPF ASSEMBLY (WITHOUT BRACKET) 50-377
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 50-392
REMOVE AND INSTALL KCCV ASSEMBLY 50-405
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 50-411
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 50-414
POWER TRAIN 50-417
REMOVE AND INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 50-417
DISCONNECT AND CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 50-428
DISASSEMBLE AND ASSEMBLE OF TORQUE CONVERTER ASSEMBLY 50-455
DISASSEMBLE AND ASSEMBLE OF TRANSMISSION ASSEMBLY 50-473
REMOVE AND INSTALL DIFFERENTIAL ASSEMBLY 50-522
DISASSEMBLE AND ASSEMBLE OF DIFFERENTIAL ASSEMBLY 50-529
REMOVE AND INSTALL FRONT BRAKE CALIPER PAD 50-546
REMOVE AND INSTALL FRONT BRAKE CALIPER ASSEMBLY 50-548
DISASSEMBLE AND ASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY 50-550
REMOVE AND INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY 50-553
REMOVE AND INSTALL FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY 50-561
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY
50-568
REMOVE AND INSTALL FINAL DRIVE CARRIER ASSEMBLY 50-582
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE CARRIER ASSEMBLY 50-586
STEERING SYSTEM 50-587
DISASSEMBLE AND ASSEMBLE OF STEERING CYLINDER ASSEMBLY 50-587
UNDERCARRIAGE AND FRAME 50-592
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY 50-592
REMOVE AND INSTALL REAR WHEEL ASSEMBLY 50-595
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY 50-599
DISASSEMBLE AND ASSEMBLE OF FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER
WITH BUFFERRING) 50-603
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY 50-609
DISASSEMBLE AND ASSEMBLE OF REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER
WITH BUFFERRING) 50-611
DISASSEMBLE AND ASSEMBLE OF FRONT WHEEL HUB ASSEMBLY 50-617
HYDRAULIC SYSTEM 50-623
DISASSEMBLE AND ASSEMBLE OF HOIST CYLINDER ASSEMBLY 50-623
WORK EQUIPMENT 50-632
REMOVE AND INSTALL DUMP BODY ASSEMBLY 50-632
CAB RELATED PARTS 50-636
REMOVE AND INSTALL AIR CONDITIONER ASSEMBLY 50-636
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY 50-652
REMOVE AND INSTALL SEATBELT 50-657
ELECTRICAL SYSTEM 50-660
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 50-660
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY 50-665
REMOVE AND INSTALL ABS CONTROLLER ASSEMBLY 50-668
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY 50-670
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 50-672
INDEX 00 INDEX AND FOREWORD
00-18 HD465-8E0, HD605-8E0
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY 50-678
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 50-680
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 50-683
REMOVE AND INSTALL KOMTRAX PLUS CONTROLLER ASSEMBLY 50-686
REMOVE AND INSTALL MOBILE COMMUNICATION TERMINAL 50-689
REMOVE AND INSTALL DC-DC CONVERTER 50-692
REMOVE AND INSTALL MOBILE COMMUNICATION TERMINAL WIRING HARNESS 50-694
REMOVE AND INSTALL KOMTRAX CONTROLLER ASSEMBLY 50-705
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY 50-708
60 MAINTENANCE STANDARD 60-1
CONTENTS 60-2
ENGINE AND COOLING SYSTEM 60-3
MAINTENANCE STANDARD FOR ENGINE MOUNT 60-3
MAINTENANCE STANDARD FOR OUTPUT SHAFT 60-4
MAINTENANCE STANDARD FOR COOLING FAN PUMP 60-6
MAINTENANCE STANDARD FOR SERVO VALVE FOR COOLING FAN PUMP 60-8
MAINTENANCE STANDARD FOR COOLING FAN MOTOR 60-9
POWER TRAIN 60-11
MAINTENANCE STANDARD FOR DRIVE SHAFT 60-11
MAINTENANCE STANDARD FOR TORQUE CONVERTER AND TRANSMISSION MOUNT 60-12
MAINTENANCE STANDARD FOR TORQUE CONVERTER AND PTO 60-13
MAINTENANCE STANDARD FOR TORQUE CONVERTER VALVE 60-17
MAINTENANCE STANDARD FOR TRANSMISSION 60-19
MAINTENANCE STANDARD FOR TRANSMISSION CONTROL VALVE 60-25
MAINTENANCE STANDARD FOR H, L, 4TH, 3RD, R, 2ND, and 1ST ECMV 60-26
MAINTENANCE STANDARD FOR LOCKUP CLUTCH ECMV 60-27
MAINTENANCE STANDARD FOR FRONT AXLE 60-28
MAINTENANCE STANDARD FOR REAR AXLE 60-29
MAINTENANCE STANDARD FOR DIFFERENTIAL 60-30
MAINTENANCE STANDARD FOR FINAL DRIVE 60-31
STEERING SYSTEM 60-32
MAINTENANCE STANDARD FOR STEERING COLUMN 60-32
MAINTENANCE STANDARD FOR STEERING LINKAGE 60-33
MAINTENANCE STANDARD FOR DEMAND VALVE 60-36
MAINTENANCE STANDARD FOR STEERING CYLINDER 60-39
BRAKE SYSTEM 60-40
MAINTENANCE STANDARD FOR SLACK ADJUSTER 60-40
MAINTENANCE STANDARD FOR FRONT BRAKE 60-41
MAINTENANCE STANDARD FOR REAR BRAKE 60-42
UNDERCARRIAGE AND FRAME 60-44
MAINTENANCE STANDARD FOR FRONT SUSPENSION CYLINDER 60-44
MAINTENANCE STANDARD FOR REAR SUSPENSION CYLINDER 60-47
HYDRAULIC SYSTEM 60-49
MAINTENANCE STANDARD FOR STEERING AND HOIST PUMP 60-49
MAINTENANCE STANDARD FOR SERVO VALVE FOR STEERING AND HOIST PUMP 60-50
MAINTENANCE STANDARD FOR POWER TRAIN AND BRAKE COOLING DUPLEX PUMP 60-52
MAINTENANCE STANDARD FOR BRAKE COOLING, CONTROL TRIPLE PUMP 60-53
MAINTENANCE STANDARD FOR HOIST VALVE 60-55
WORK EQUIPMENT 60-57
MAINTENANCE STANDARD FOR HOIST CYLINDER 60-57
CAB RELATED PARTS 60-58
MAINTENANCE STANDARD FOR CAB MOUNT 60-58
80 OTHERS 80-1
CONTENTS 80-2
AIR CONDITIONER SYSTEM 80-4
PRECAUTIONS FOR REFRIGERANT 80-4
AIR CONDITIONER COMPONENT 80-5
SPECIFICATIONS OF AIR CONDITIONER 80-7
00 INDEX AND FOREWORD INDEX
HD465-8E0, HD605-8E0 00-19
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 80-8
OUTLINE OF REFRIGERATION CYCLE 80-9
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 80-11
AIR CONDITIONER UNIT 80-11
COMPONENT PARTS OF AIR CONDITIONER UNIT 80-15
AIR CONDITIONER CONTROLLER 80-19
COMPRESSOR 80-20
CONDENSER 80-21
AIR CONDITIONER RELATED SENSORS 80-23
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER
80-24
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 80-27
AIR CONDITIONER SYSTEM DIAGRAM 80-29
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 80-30
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS
80-32
TESTING AIR LEAKAGE (DUCT) 80-35
METHOD FOR TESTING AIR LEAKAGE (DUCT) 80-35
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 80-38
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE
OF THE MACHINE MONITOR 80-39
TEST VENT (MODE) CHANGEOVER 80-41
METHOD FOR TESTING VENT (MODE) CHANGEOVER 80-41
TESTING FRESH/RECIRC AIR CHANGEOVER 80-42
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 80-42
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 80-43
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 80-43
TEST RELAYS 80-44
METHOD FOR TESTING RELAYS 80-44
AIR CONDITIONER TROUBLESHOOTING CHART 1 80-46
AIR CONDITIONER TROUBLESHOOTING CHART 2 80-47
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 80-50
FAILURE CODE [879AKA] 80-52
FAILURE CODE [879AKB] 80-53
FAILURE CODE [879BKA] 80-54
FAILURE CODE [879BKB] 80-55
FAILURE CODE [879CKA] 80-57
FAILURE CODE [879CKB] 80-58
FAILURE CODE [879EMC] 80-59
FAILURE CODE [879FMC] 80-60
FAILURE CODE [879GKX] 80-61
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)
80-62
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)
80-64
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS
ABNORMAL) 80-67
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 80-69
TROUBLESHOOTING USING GAUGE PRESSURE 80-71
CONNECTION OF SERVICE TOOL 80-73
METHOD FOR CONNECTING SERVICE TOOL 80-73
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER
PIPINGS 80-75
HANDLE COMPRESSOR OIL 80-77
METHOD FOR REPLACING DESICCANT 80-79
90 CIRCUIT DIAGRAMS 90-1
CONTENTS 90-2
HYDRAULIC CIRCUIT DIAGRAM 90-3
INDEX 00 INDEX AND FOREWORD
00-20 HD465-8E0, HD605-8E0
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 90-3
HYDRAULIC CIRCUIT DIAGRAM (1/3) 90-7
HYDRAULIC CIRCUIT DIAGRAM (2/3) 90-9
HYDRAULIC CIRCUIT DIAGRAM (3/3) 90-11
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 90-13
ELECTRICAL CIRCUIT DIAGRAM 90-15
SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM 90-15
INTERNAL CAB ELECTRICAL DIAGRAM (1/11) 90-19
INTERNAL CAB ELECTRICAL DIAGRAM (2/11) 90-21
INTERNAL CAB ELECTRICAL DIAGRAM (3/11) 90-23
INTERNAL CAB ELECTRICAL DIAGRAM (4/11) 90-25
INTERNAL CAB ELECTRICAL DIAGRAM (5/11) 90-27
INTERNAL CAB ELECTRICAL DIAGRAM (6/11) 90-29
INTERNAL CAB ELECTRICAL DIAGRAM (7/11) 90-31
INTERNAL CAB ELECTRICAL DIAGRAM (8/11) 90-33
INTERNAL CAB ELECTRICAL DIAGRAM (9/11) 90-35
INTERNAL CAB ELECTRICAL DIAGRAM (10/11) 90-37
INTERNAL CAB ELECTRICAL DIAGRAM (11/11) 90-39
EXTERNAL CAB ELECTRICAL DIAGRAM (1/8) 90-41
EXTERNAL CAB ELECTRICAL DIAGRAM (2/8) 90-43
EXTERNAL CAB ELECTRICAL DIAGRAM (3/8) 90-45
EXTERNAL CAB ELECTRICAL DIAGRAM (4/8) 90-47
EXTERNAL CAB ELECTRICAL DIAGRAM (5/8) 90-49
EXTERNAL CAB ELECTRICAL DIAGRAM (6/8) 90-51
EXTERNAL CAB ELECTRICAL DIAGRAM (7/8) 90-53
EXTERNAL CAB ELECTRICAL DIAGRAM (8/8) 90-55
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE (1/2) 90-57
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE (2/2) 90-59
INDEX 1

DESCRIPTION:

Komatsu HD465-8E0 HD605-8E0 Articulated Dump Truck Shop Manual SEN06768-06 – PDF DOWNLOAD

SERIAL NUMBERS

HD465-35001 and up
HD605-35001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
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 SPECIFICATIONS
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 THE OTHER INFORMATION
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.

IMAGES PREVIEW OF THE MANUAL: